Yamaha XT250X Manuale utente

3C5-28197-10

XT250X

XT250XC

SERVICE MANUAL

LIT-11616-21-52

2008

EAS20050

XT250X

XT250XC

SERVICE MANUAL

First edition, August 2007

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

P/N LIT-11616-21-52

EAS20070

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-

ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles

should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-

cle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard to

performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-

cle will operate as designed. If there is any question about a service procedure, it is imperative that you

contact a Yamaha dealer for any service information changes that apply to this model. This policy is

intended to provide the customer with the most satisfaction from his vehicle and to conform to federal

environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and

will appear in future editions of this manual where applicable.

NOTE:

●This Service Manual contains information regarding periodic maintenance to the emission control

system. Please read this material carefully.

●Designs and specifications are subject to change without notice.

EAS20080

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the

vehicle operator, a bystander or a person checking or repairing the vehicle.

A CAUTION indicates special precautions that must be taken to avoid damage to the

vehicle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

EAS20090

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid

out with the individual steps in sequential order.

●The manual is divided into chapters and each chapter is divided into sections. The current section title

is shown at the top of each page “1”.

●Sub-section titles appear in smaller print than the section title “2”.

●To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section “3”.

●Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassem-

bly step “4”.

●Symbols indicate parts to be lubricated or replaced “5”.

Refer to “SYMBOLS”.

●A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc “6”.

●Jobs requiring more information (such as special tools and technical data) are described sequentially

“7”.

CLUTCH

5-31

Removing the clutch

Order Job/Parts to remove Q’ty Remarks

1 Clutch spring 5

2 Pressure plate 1

3 Adjusting screw 1

4 Push plate 1

5 Friction plate 6

6 Clutch plate 5

7 Clutch damper spring 1

8 Clutch damper spring seat 1

9 Primary drive gear nut 1

10 Lock washer 1

11 Claw washer 1

12 Clutch boss nut 1

13 Lock washer 1

14 Clutch boss 1

15 Thrust washer 1

16 Clutch housing 1

17 Ball 1

18 Clutch push rod 1

19 Primary drive gear 1

For installation, reverse the removal proce-

dure.

New

8 Nm (0.8 m •kg, 5.8 ft •Ib)

75 Nm (7.5 m •kg, 54 ft •Ib)

80 Nm (8.0 m •kg, 58 ft •Ib)

7812

16 17

910

(5)

CLUTCH

5-33

EAS25070

REMOVING THE CLUTCH

1. Straighten the lock washer tab.

2. Loosen:

Primary drive gear nut “1”

NOTE:

Insert aluminum plate “a” between primary drive

gear “2” and primary driven gear “3”, and loosen

the primary drive gear nut.

3. Loosen:

Clutch boss nut “1”

NOTE:

While holding the clutch boss “1” with the univer-

sal clutch holder “2”, loosen the clutch boss nut.

EAS25100

CHECKING THE FRICTION PLATES

The following procedure applies to all of the fric-

tion plates.

1. Check:

Friction plate

Damage/wear Replace the friction plates

as a set.

2. Measure:

Friction plate thickness

Out of specification Replace the friction

plates as a set.

NOTE:

Measure the friction plate at four places.

EAS25110

CHECKING THE CLUTCH PLATES

The following procedure applies to all of the

clutch plates.

1. Check:

Clutch plate

Damage Replace the clutch plates as a

set.

2. Measure:

Clutch plate warpage

(with a surface plate and thickness gauge “1”)

Out of specification Replace the clutch

plates as a set.

EAS25140

CHECKING THE CLUTCH SPRINGS

The following procedure applies to all of the

clutch springs.

1. Check:

Clutch spring

Damage Replace the clutch springs as a

set.

2. Measure:

Universal clutch holder

90890-04086

YM-91042

Friction plate thickness

2.70—2.90 mm (0.106—0.114 in)

Wear limit

2.60 mm (0.1024 in)

Warpage limit

0.20 mm (0.0079 in)

EAS20100

SYMBOLS

The following symbols are used in this manual

for easier understanding.

NOTE:

The following symbols are not relevant to every

vehicle.

BLS

9 10

11 12

13 14

15 16

17 18

LT New

1 2 3

4 5 6

7 8

1. Serviceable with engine mounted

2. Filling ﬂuid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10. Gear oil

11. Molybdenum-disulﬁde oil

12. Brake ﬂuid

13. Wheel-bearing grease

14. Lithium-soap-based grease

15. Molybdenum-disulﬁde grease

16. Silicone grease

17. Apply locking agent (LOCTITE®)

18. Replace the part

GENERAL INFORMATION 1

SPECIFICATIONS 2

PERIODIC CHECKS AND

ADJUSTMENTS 3

CHASSIS 4

ENGINE 5

FUEL SYSTEM 6

ELECTRICAL SYSTEM 7

TROUBLESHOOTING 8

EAS20110

TABLE OF CONTENTS

GENERAL INFORMATION

IDENTIFICATION ...........................................................................................1-1

VEHICLE IDENTIFICATION NUMBER....................................................1-1

MODEL LABEL ........................................................................................1-1

IMPORTANT INFORMATION ........................................................................1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY .........................1-2

REPLACEMENT PARTS .........................................................................1-2

GASKETS, OIL SEALS AND O-RINGS ...................................................1-2

LOCK WASHERS/PLATES AND COTTER PINS....................................1-2

BEARINGS AND OIL SEALS...................................................................1-2

CIRCLIPS.................................................................................................1-3

CHECKING THE CONNECTIONS.................................................................1-4

SPECIAL TOOLS...........................................................................................1-5

IDENTIFICATION

1-1

EAS20130

IDENTIFICATION

EAS20140

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped

into the right side of the steering head pipe.

EAS20150

MODEL LABEL

The model label “1” is affixed to the frame. This

information will be needed to order spare parts.

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