@ YAMAHA XT250/ NTea0 -*5 ~-OERVIGE MANUAL%7250/350 ‘SERVICE MANUAL (©1984 by Yamaha Motor Co.. Ltd. ‘st Edition, October 1984 All rights reserved. Any reprinting or unauthorized use without the written jon of Yamaha Motor Co., Lt. ts exprossly prohibitedNOTICE “This manual was weiten by the Vamahe Motor Company pimariy fr use by Yamaha desers and their qualified mechanics. isnot possible to put an enti mechanic's education into ene manual, 0 ts assumed that persons using this book to perform maintenance and repairs on Yamaha motor. ‘ysles have abate understanding of tha mechanical concepts and procedures inherent in motoreyls repair technology. Without such knowledge, attempted repairs or service to this model may ender ietunfit to use and/or unsafe, ‘Yamahe Motor Company, ids continually ving to improve all models manufacture by Yamahe. Modifications nd significant changes in specifications or procedure willbe forwarded to all Authorized Yamaha dealers and wil where applicable, pear in future editions of thie manual TECHNICAL PUBLICATIONS ‘SERVICE DIVISION MOTORCYCLE OPERATIONS YAMAHA MOTOR CO.,LTD HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION ‘This materia is distinguished by the folowing notation. NOTE: [A NOTE provides key information to mako procedures easier or claro. A CAUTION indicates special procedures that must be followed to avoid damage to tho motoreyel, |AWARNING incicats spacial procedures thet must be followed to avd injury to ' motoreycle operator or person inspecting or rpaiting the motorcycle MANUAL FORMAT Al ofthe procedures inthis manual are orgarized in a sequential, stop-by-stp format. The informa: ‘tion has been compiled to provide the mechanic with en eaay to ead, handy rferencs that containg comorahensive explanations of all isassombl. ropat. assembly and inspection operations. In ths revised format, the condition of fauity component will precede an arrow symbol and the course fof action requied wil flow the symbol, @¢., Bearings Prting/Damage--feplace EXPLODED DIAGRAM Each chapter provides expladed agrams before each dleassembly sation for aaa indenting cor rect dsassersly and assenbly procedures.o © & © o ® o ILLUSTRATED SYMBOLS (Refer to the illustration) Iustrated symbols @ to @) ate designed as ‘thumb tabs to indeate the chapter's number and content Pesto Inspection ond austen ceatng system Carbureton ) Chal retro Appondions tstrted symbols @) to B are used to iden- Ay the specications appearing in the text 3 ling id ae 3 Wear time, dosronee Engia spe ava strated symbols ( to @ in the exploded clagram indesta grade of lubricant and location of lubrication point. Aealyengia ol ‘Roo tolvadenum tie at ‘Abby wa boing grease ‘App ignightitium-soop bass grease ‘Rep molvadenum dui grease Appl ocing agent (LOCTITE® |INDEX oS GENERAL INFORMATION GEN PERIODIC INSPECTIONS AND ADJUSTMENTS NSP A) ENGINE OVERHAUL ENG CARBURETION eee carey. CHASSIS e ELECTRICAL eecTS an APPENDICES [ArexGEN INFO |9™S CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER IMPORTANT INFORMATION ‘ALL REPLACEMENT PARTS. GASKETS, OIL SEALS, AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS cRCUPS. SPECIAL TOOLS FOR TUNEUP FOR ENGINE SEAVICE FOR CHASSIS SERVICE FOR ELECTRICAL COMPONENTS.INFO 6%] motoRcycte IneNTIFICATION GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER “The frame serial number (Dis stamped into the right side ofthe steering head pine, ENGINE SERIAL NUMBER ‘Tho engine serial number (Di stamped int the Fat side ofthe engine unit production number. Starting Serial Number: XT250.....IEU-000101 (For Switzerland) XTa50.../s5V-000%01 XT360..|55V.016I01 (For Germany! Note; ‘Designs and specications ara subject t change without notice.os) IMPORTANT INFORMATION ‘ALL REPLACEMENT PARTS 1. We recommend to use Yarahe genuine parts {ora replacements, Use of and/or grease recommended by Yamaha for assembly and adjustment, GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seas, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, ol soa ins, aed Oings must be cleaned. 2. Propety ola mating parts and bearings du ing reassembly. Apply grease to the ol sel lps. PINs pry tightaned, BEARINGS AND OIL SEALS inetaling. eAUTIO! Do not use compressed surfaces LOCK WASHERS/PLATES AND COTTER 1 Al lock washer/plates (and cotter pine must be replaced when they are removed Lock tas) shouldbe bent along the bot oF rt flats) afte the bot or nut has been pro: 1. Insta the besring(s} () and oll seals} @) With heir manufacturer's marks or numbers facing outward in othor words, the stamped letters must be on the side exposed to view) When instaling of sells), apply a light coating of lightweight ithium base grease to ‘the seal ip). Ol the bearings liberally when (opin the bear- Ings dry. This causes damage tothe bearingGEN INFO SPECIAL TOOLS cIRCLIPS: {Al circle should be inspected caretuly befor reassembly. Always replace piston pin clips after one use, Replace dstortd ccips. [When intaing a cirlip (D), make sure that the sharp-edgod corer @) is pastoned op posite tothe thust @) i eceves. Soo the ‘ectonal viw. @ shat ‘SPECIAL TOOLS ‘The proper special tools ae necessary for com: plete and accurate tune-up and assembly. Using the correct special too wil halp prevent damage ‘caused by the use of improper tools or improvis- ‘2d tochniquos. FOR TUNE UP 1. Inductive Tachometer PIN, 90880-08113, This 00! ode for detocting engine «pm. 2. Inducthe Timing Light PIN, soe90-09108 ‘Tie tool fs necessary for checking lgnton timing 3, Compression Gauge IN, S0880-08081 This gouge is used to mesture the enginesreciat roots | REY | oes “4. Fuel Level Gauge PIN, 90880-01312 This gauge is used to measure the fuel level in the float chamber FOR ENGINE SERVICE 1. Universal Clutch Holder PIN, 90890-04005 “Thistle used to hal the clutch when remo Ing or intaling the elutch boss locknut 2, Teppet Adjusting Too! IN. 90800-04106, This tools necessary to replace valve adjusting pads. 3. Valve Spring Compressor IN, 90600-04018 This tool's needed to remove and instal the vaive 4. Valve Guide Remover (6.5 mm) PIN, S0690-01122 ‘This too ie used to remove the valve guidesSPECIAL TOOLS INFO |6*) 16 5, Valve Guide Reamer (5.5 mem) PIN, 90800-01796 This too is used to rebore the new valve guide, 6. Valve Guide installer PN, 90890-04015 This tool is needed to instal the valve guides propery. 7. Valve Seat Cutter Set PIN, Yw.9089| This tool is needed to resurface the valve seat 8, Piston Pin Pll IN, 90e90-01208 “This tools used to remove the piston pin. 9. Plasigage? Set "Green" PIN, YU-38210 ‘This gauge is needed to measure the clearance for the connecting red bearingspeciat Toors | SEN | dt 10. Yamaha Bond No, 1215 IN, 90890-85505, ‘This sealant (bonds used for crankcase mating uraces, ete 11. Wrench Adapter B mm (0.3 in) P/N, 90800-06076 This tool t used to retighten the cylinder head s2cuting bal 12, Fiywheo! Pll PIN. soaso-ori89 @ 5 @ yhoo! Puller Attachment SS] PIN, 90680-07382 @ =) 6 ‘These tools ate used for femoving the flywheel Ce 12, Cankease: Separator j PIN, 90690-01135 “This tool is usd for removing the crankshaft from the crankcase "4. Universal Magnoto & Rotor Holder IN, 90860-01235 ‘This tools used when loosening oF tightering the fiywheo! magneto securing bot. 6SPECIAL TOOLS uw 15. Crankshaft Intaling Set Pot IN, soe80-01274 oO aot IN, 20800-01275 @ Adepter PIN, 90800-01383 @ ‘These tools are used when installing the crankshat. FOR CHASSIS SERVICE 1. TeHandle PIN, soeo0-o1305, oO Front Fore Cynder Holder 22 mm PIN, soaao-oT365, @ This tol i used to loosen and tighten the front fork eyinder holding bolt 2. Front Fork Seal Driver (weight) PIN, soeg0-o1367 @ ‘Adepter (38 mm) PIN, 9088001870 @ “These tol are used when instaling tho fork soa 3. Ring Nut Wrench IN, sues0-o1268 @ PIN. YU-33975 ®@ “This tools wed to loosen and ighton te soe Ing tog nt FOR ELECTRICAL COMPONENTS 1. electro Tester PIN, 90880-03021 “Thisinstrumentis necessary for checking the l rion system componentsSPECIAL TOOLS GEN INFO |d™| 2, Pocket Testar P/N, 90880-03104 ‘This inseument is invaluable fr checking theelac- tical system,GEN INFO |O™S|CHAPTER 2. PERIODIC INSPECTIONS AND ADJUSTMENTS inTRopucTion PERIODIC MAINTENANCE/LUBRICATION INTERVALS ENGINE. VALVE CLEARANCE ADJUSTMENT DECOMPRESSION CABLE ADJUSTMENT SPARK PLUG. (CRANKCASE VENTILATION SYSTEM FUEL LINE INTAKE MANIFOLD EXHAUST SYSTEM... ILE SPEEC ENGINE OIL CLUTCH ADJUSTMENT. IGNITION TIMING CHECK COMPRESSION PRESSURE MEASUREMENT chassis FUEL COCK. A FILTER FRONT AND REAR BRAKE DRIVE CHAIN CABLE INSPECTION AND LUBRICATION BRAKE AND CHANGE PEDALS/BRAKE AND (CLUTCH LEVERS, CENTERSTAND AND SIDESTAND FRONT FORK OIL CHANGE FRONT FORK AND REAR SHOCK ABSORBER ‘ADJUSTMENT STEERING HEAD WHEEL BEARINGS TIRES AND SPOKE WHEELS. ELECTRICAL BATTERY HEADLIGHT CIRCUIT BREAKER 24 24 2a 27 27 28 28 29 29 29 29 213 244 215 20 27 218 218 220 22 298 229 231 231 20 23 234 236INSP INTRODUCTION/PERIODIC MAINTENANCE/ ADJ LUBRICATION PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all nformation necessary to perform racommended inspections ané adjustments, “These preventive maintenance procedures, i flowed, vl ensure more celiabe vehicle operation and 2 longer service life, The ned for costly overhaul work wil be great reduced. This information ap- plies to vehicles alwady inservice s well as new vehicles that are being prepared for sal. All service techaiclons shouldbe famiiar with this ene chepter. PERIODIC MAINTENANCE/LUBRICATION INTERVALS Una tm Te REMARKS BREAKIN |" 6,000 12,000 . 1,000 1600 | 000) or | a, 080) or Sinem | 12m 5 sok wr aecmmy | TOR-ORE TOF OE Vata Greek vos coerce Adit ecemany, | FB is o Gam cant hack cm aon, Act recs | —O 3 o out pg” [ EET. Cn rps 7 5 S Air Fito ‘[Clean. Replace if necassary.. o oO a pede open, Rak | a a 5 ‘heck hl hon ad vas por Ful ine! “cracks or damage. Raplace if necessary. ° ° Fue aier | hee eon, Replace ras 5 xg a epic (Wam engine bolas drain 3 o 3 Engine afew Rape. o[10r[~o Engine al eronet_| Gen, 3 3 © Brake" heck prin Tad taper Sos Wa ‘for disc brekel _| Correct if necessary. ° © Sum tak) _ | CME eon. Ac cry ° ° Gieh | hack pean, Aaa area 3 cy le eee ° ° hock war am ate for owes Rear arm pve apa ant (nite fore a ° ° ° Fear suspension sheck operation. Moderateh ack, FE | Chick epeation, Moran na ° ° Week Ghec lnch darae/noaote a Morspoe wioat_| ight Rene neocey | hee ergs sean for Whee! besines" | isscness/ damage. Replace if damaged 2 ‘heck besser fo verse Sting beorng” | Corot tracery. Mazes ence ° sry 2,000 6,06) or ma aINSP_ Uni: kr ni Tey ; Oa BREAKIN [S003 | 1200 re ae 0 | or | Sw Brent | 12 ments | Fron tomar | Chisk apart aga PASAT a necessary. ~ ° feat [Sean aT —t> Dinechan [seamen Aaa env so oo Fitings/Festaners | Ghack al chasis ftngs and fastens, ° oO ° Saeed ‘Check oporton. Repair necessary o o o one? fernese epstion Cones Pnacaaeh” | o fo {Is cornered at tase toms be serdced by » Yamane dealer * Raatum wight whol baring grease, (besrng type) NoTE: Brake fluid replacement 1. When clssssombling the master cylinder or caliper cylinder, replace the ui. Normally chack the brake/cluteh fi lel and acs tho fluid require. 2. Ontha inner parts of shemastr cylinder an caliper eyinder, replace the ol = 3. Replace the broke/clutch hoses every four years, or if cracked or damaged. Is overy two yrs,INSP. ‘ADJ VALVE CLEARANCE ADJUSTMENT ENGINE VALVE CLEARANCE ADJUSTMENT Removal 1. Remove: ‘Side covers Seat ‘Fue tank ‘Engin air coop (Ror to Engine Removal) 2, Disconnect ‘Spark plug cap 3. Remove. ‘Spark plug ‘Cylinder head cover (D 4. Remove Change pedsl Left crankcase cover Inspection and Adjustment 1. Measure ‘Valve clearance Nore; Be sure piston is at Top Dead Conter (TDC) on compeesson stroke when measuring clearence. Valve clearance measurement stops: Nore: valve clearance must be measured when the engine is coal to the touch, ‘Turn the crankshaft courttclocie ton the "T" mack) on the rotor with the trankcaee mark when the itn at TDC onthe compresn stoke. ‘ieasure the valve earance using @ Fear Gauge ©) ‘Record the measured amountif the earance 's income.INSP VALVE CLEARANCE ADJUSTMENT | ADJ Valve Clearance (cold Tnvake Valve Exhaust Valve 008-02 mm | 0.418-0.17 mm (@.003a005 my _| (0.005 8.07 ind 2. Adjust ‘Valve clesrance Valve clearance adjustment ‘Position the vale ter slots (intake and ex haust sid} facing eech other. * Depress tha vale liftar and insta the Tappet ‘Adjusting Too! (90890-04106) onto. the ‘ylnder hase. ‘Turn the camshaft uni the lobe of the Tap= pet Adjusting Too! () depresses the valve life. ‘Remove the pads @ trom the liter. Use a small secewdhver and a magnate tod for removal Note pad numbers, tollows: ‘of the motorcycle) Intake @): Carefully rotate CLOCKWISE. Exhaust: Carafully rotate COUNTER: clockwise, “Soloct ho proper vale susting pad fom the chart below: Fad Rei Pad at 25 increments, Bam ase npped in wo. 20- rin RoR” Sram | 6 mm ain (007m note; ‘Tho thickness ofeach pads is marked on the pad face that contacts the valeiter (not the ‘amINSP ADS QI] vai cisanance ADJUSTMENT ‘Round off the hunts igi ofthe original pad number tothe naarest 0.05 mm (0.02 fn increment. Hunareathe a Rounded valve or? 0 5 (WOT ROUNDED OFFI 2 70 EXAMPLE: Original pad number= 258 (2.58 mm) Rounded off dgit=260 NOTE: Pads can only be ssacted in 0.05 men (0.002 in) increments ‘Locate the “Installed Ped Number” on the chart, and thon find the measured valve ‘learee. The point whore these coordinates Intersect i the new pad number Note: Use the now pad number os a guide only a8 ‘the number must be verified Ped number verification stops ‘stall tho raw pad with the number down, ‘Remove the adjusting too. ‘Recheck the valve cesrance. ‘tf the clearance is incorec, repeat al ofthe clerone aghsment taps une rer 3. Assembly verso removal steps. Note the following assembly step: ‘install head cover Head Cover Bolt 10 Nem (1.0 mekg, 7.2 fb)vaave cucnance aosusraenr FESS INTAKE ESTA Fao NoMa oa | aa sa nz a i a a ene am 2h uo a me Sa 9 as i a 20| a | ma Sole sla zal as 2 26 esas Sala a 23 SS a a > sas zal e529 pe sole anla A ane get 8-8 2084 Wea PO WER tL i i i nz zz | sas 9 Beat | ase en loa ea) | [=a ne | a al saws 057s au | | ae | met 2 ‘gst [a eal 2)INSP. ADJ Q) DECOMPRESSION CABLE ADJUSTMENT/ SPARK PLUG DECOMPRESSION CABLE ADJUSTMENT Nove; DDecomp-cabe adustment must follow the valve Cloarance adjustment 1. Remove *Change pedal ‘Left crankcase cover Spark plug 2, Tur the crankshaft counterciocknise to align the “7 mark @ on the rotor with the ‘crankcase mare when the piston i st TOC fon the compression stoke 3, Loosen: sLocknut 4. Rotate ‘Adjuster Q “Turn it clockwise or counterlackwia unt proper decompression lever free pley is atsined 27 Decompras @: 2-3 mm (0.079~0.12 in} fan Laver Fri Play 5, Tighten “Locknut SPARK PLUG 1. Remove Spark plug 2. Inspect: eBiecrode Wear/DamageReplace. insulator color @) 3, Measure: Pig gap @ Out of specification--Regop. Use a Wire Gauge or Feolor Gouge,SPARK PLUG/CRANKCASE VENTILATION SYSTEM/ [INSP FUEL LINE [ADS ‘Spark Plug Gap: 0.7~0.8 mm (0.028~0.032 in} Clean the plug with a sperk plug cleaner if necassary. ‘Standard Spark Plug: DRZES (NGK) DABES (NGK) DRBES-L (NGK) Before insaling sparkplug, clean the gasket surface and plug surface 4. Tighten: Spark pogls) Spark Plug {17.5 Nim (1.75 m-kg, 12.5 felb) Note: Finger-ghten (the spark plots before tora lng @) to speciation CRANKCASE VENTILATION SYSTEM 1. Inspect: ‘*Crankcase ventiaton hose Cracks/Damage-*Replace. FUEL LINE 1. Inspect ‘Fuel hoses ‘Cracks /DamageReplece. 28