User Manuals: Yamaha XT250XC 2008 Off-road Motorcycle

Manuals and User Guides for Yamaha XT250XC 2008 Off-road Motorcycle. We have 1 Yamaha XT250XC 2008 Off-road Motorcycle manual available for free PDF download: Service Manual

Yamaha XT250XC 2008 Service Manual

Yamaha XT250XC 2008 Service Manual (282 pages)

Brand: Yamaha | Category: Motorcycle | Size: 10 MB

Table of Contents

Table of Contents

7
- General Information
  9
- Identification
  10
- Vehicle Identification Number
  10
- Model Label
  10
- Important Information
  11
- Preparation for Removal and Disassembly
  11
- Replacement Parts
  11
- Gaskets, Oil Seals and O-Rings
  11
- Lock Washers/Plates and Cotter Pins
  11
- Bearings and Oil Seals
  11
- Circlips
  12
- Checking the Connections
  13
- Special Tools
  14
Specifications

19
- General Specifications
  20
- Engine Specifications
  21
- Chassis Specifications
  28
- Electrical Specifications
  30
- Engine Tightening Torques
  32
- General Tightening Torque Specifications
  32
- Tightening Torques
  32
- Chassis Tightening Torques
  34
- Engine
  37
- Lubrication Points and Lubricant Types
  37
- Chassis
  38
- Engine Oil Lubrication Chart
  40
- Lubrication System Chart and Diagrams
  40
- Lubrication Diagrams
  42
- Cable Routing
  44
Periodic Checks and Adjustments

55
Chassis

83
- General Chassis
  85
- Front Wheel
  86
- Checking the Front Wheel
  88
- Disassembling the Front Wheel
  88
- Removing the Front Wheel
  88
- Adjusting the Front Wheel Static Balance
  89
- Assembling the Front Wheel
  89
- Installing the Front Wheel (Disc)
  90
- Rear Wheel
  92
- Checking and Replacing the Rear Wheel Sprocket
  94
- Checking the Rear Wheel
  94
- Disassembling the Rear Wheel
  94
- Removing the Rear Wheel (Disc)
  94
- Adjusting the Rear Wheel Static Balance
  95
- Assembling the Rear Wheel
  95
- Installing the Rear Wheel
  95
- Front Brake
  96
- Checking the Front Brake Disc
  101
- Introduction
  101
- Replacing the Front Brake Pads
  102
- Checking the Front Brake Caliper
  103
- Disassembling the Front Brake Caliper
  103
- Removing the Front Brake Caliper
  103
- Assembling the Front Brake Caliper
  104
- Installing the Front Brake Caliper
  104
- Checking the Front Brake Master Cylinder
  105
- Removing the Front Brake Master Cylinder
  105
- Assembling the Front Brake Master Cylinder
  106
- Installing the Front Brake Master Cylinder
  106
- Rear Brake
  108
- Checking the Rear Brake Disc
  113
- Introduction
  113
- Replacing the Rear Brake Pads
  113
- Disassembling the Rear Brake Caliper
  114
- Removing the Rear Brake Caliper
  114
- Assembling the Rear Brake Caliper
  115
- Checking the Rear Brake Caliper
  115
- Installing the Rear Brake Caliper
  115
- Removing the Rear Brake Master Cylinder
  116
- Assembling the Rear Brake Master Cylinder
  117
- Checking the Rear Brake Master Cylinder
  117
- Installing the Rear Brake Master Cylinder
  117
- Handlebar
  119
- Checking the Handlebar
  120
- Installing the Handlebar
  120
- Removing the Handlebars
  120
- Front Fork
  123
- Disassembling the Front Fork Legs
  126
- Removing the Front Fork Legs
  126
- Assembling the Front Fork Legs
  127
- Checking the Front Fork Legs
  127
- Installing the Front Fork Legs
  130
- Steering Head
  131
- Checking the Steering Head
  133
- Installing the Steering Head
  133
- Removing the Lower Bracket
  133
- Rear Shock Absorber Assembly
  135
- Checking the Connecting Arm and Relay Arm
  136
- Checking the Rear Shock Absorber Assembly
  136
- Disposing of a Rear Shock Absorber
  136
- Handling the Rear Shock Absorber
  136
- Installing the Relay Arm
  136
- Removing the Rear Shock Absorber Assembly
  136
- Installing the Rear Shock Absorber Assembly
  137
- Swingarm
  138
- Checking the Swingarm
  139
- Installing the Swingarm
  139
- Removing the Swingarm
  139
- Chain Drive
  141
- Checking the Drive Chain
  142
- Removing the Drive Chain
  142
- Checking the Drive Sprocket
  143
- Installing the Drive Chain
  143
Engine

145
- Engine Removal
  147
- Installing the Engine
  150
- Installing the Shift Pedal
  150
- Cylinder Head
  152
- Removing the Cylinder Head
  154
- Checking the Camshaft Sprocket and Timing Chain Guide (Exhaust System Side)
  155
- Checking the Cylinder Head
  155
- Checking the Tappet Covers and Camshaft Sprocket Cover
  155
- Checking the Timing Chain Tensioner
  156
- Installing the Cylinder Head
  156
- Camshaft
  159
- Checking the Camshaft
  160
- Removing the Rocker Arms and Camshaft
  160
- Checking the Rocker Arms and Rocker Arm Shafts
  161
- Installing the Camshaft and Rocker Arms
  161
- Checking the Valves and Valve Guides
  164
- Removing the Valves
  164
- Valves and Valve Springs
  164
- Checking the Valve Seats
  166
- Checking the Valve Springs
  167
- Installing the Valves
  169
- Cylinder and Piston
  171
- Checking the Cylinder and Piston
  172
- Removing the Piston
  172
- Checking the Piston Rings
  173
- Checking the Piston Pin
  174
- Installing the Piston and Cylinder
  174
- Clutch
  176
- Checking the Clutch Plates
  179
- Checking the Clutch Springs
  179
- Checking the Friction Plates
  179
- Removing the Clutch
  179
- Checking the Clutch Boss
  180
- Checking the Clutch Housing
  180
- Checking the Clutch Push Rods
  180
- Checking the Pressure Plate
  180
- Checking the Primary Drive Gear
  180
- Checking the Primary Driven Gear
  180
- Installing the Clutch
  180
- Oil Pump and Balancer Gear
  184
- Checking the Oil Pump
  186
- Checking the Oil Strainer
  186
- Removing the Balancer Gear
  186
- Assembling the Oil Pump
  187
- Install the Oil Pump and Balancer Gear
  187
- Shift Shaft
  189
- Checking the Shift Shaft
  190
- Checking the Stopper Lever
  190
- Installing the Shift Shaft
  190
- Generator and Starter Clutch
  191
- Checking the Starter Clutch
  193
- Removing the Generator
  193
- Removing the Starter Clutch
  193
- Installing the Generator
  194
- Installing the Starter Clutch
  194
- Electric Starter
  196
- Checking the Starter Motor
  198
- Assembling the Starter Motor
  199
- Crankcase
  200
- Assembling the Crankcase
  202
- Checking the Bearing and Oil Seal
  202
- Checking the Crankcase
  202
- Checking the Timing Chain, Crankshaft Sprocket, Timing Chain Guide (Intake Side)
  202
- Disassembling the Crankcase
  202
- Checking the Crankshaft and Connecting Rod
  205
- Crankshaft Assembly
  205
- Installing the Crankshaft Assembly
  205
- Removing the Crankshaft Assembly
  205
- Transmission
  207
- Checking the Shift Drum Assembly
  209
- Checking the Shift Forks
  209
- Checking the Transmission
  209
- Installing the Shift Forks and Shift Drum Assembly
  210
Fuel System

211
- Checking the Fuel Cock
  213
- Fuel Tank
  213
- Carburetor
  214
- Checking the Carburetor
  217
- Assembling the Carburetor
  218
- Installing the Carburetor
  219
- Air Induction System
  220
- Checking the Air Induction System
  223
Electrical System

225
- Circuit Diagram
  226
- Ignition System
  226
- Troubleshooting
  228
- Circuit Diagram
  230
- Electric Starting System
  230
- Starting Circuit Cut-Off System Operation
  232
- Troubleshooting
  234
- Charging System
  236
- Circuit Diagram
  236
- Troubleshooting
  238
- Circuit Diagram
  240
- Lighting System
  240
- Troubleshooting
  242
- Circuit Diagram
  244
- Signaling System
  244
- Troubleshooting
  246
- Carburetor Heating System
  250
- Circuit Diagram
  250
- Troubleshooting
  252
- Electrical Components
  254
- Checking the Switches
  258
- Checking the Bulbs and Bulb Sockets
  261
- Checking and Charging the Battery
  262
- Checking the Fuse
  262
- Checking the Relays
  265
- Checking the Turn Signal Relay
  266
- Checking the Diode
  267
- Checking the Spark Plug Cap
  267
- Checking the Ignition Coil
  268
- Checking the Pickup Coil
  269
- Checking the Stator Coil
  269
- Checking the Horn
  270
- Checking the Rectifier/Regulator
  270
- Checking the Speed Sensor
  271
- Checking the Thermo Switch
  271
- Checking the Carburetor Warmer
  272
Troubleshooting

273
- General Information
  274
- Incorrect Engine Idling Speed
  274
- Starting Failures
  274
- Faulty Clutch
  275
- Faulty Gear Shifting
  275
- Jumps out of Gear
  275
- Poor Medium-And-High-Speed Performance
  275
- Shift Pedal Does Not Move
  275
- Faulty Front Fork Legs
  276
- Faulty Lighting or Signaling System
  276
- Overheating
  276
- Poor Braking Performance
  276
- Unstable Handling
  276

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