1980-1984 Yamaha XT250 printed Motorcycle Service Manual

Description

This 1980-1984 Yamaha XT250 Motorcycle Service Manual is a printed reproduction of the original, out of print manual. This manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1980-1984 Yamaha XT250 motorcycles. Includes everything you need to know to service your machine. Features wiring diagrams and cable routing guide. This is the same manual used by factory authorized Yamaha dealers.

Includes bonus supplement that covers up to 1984 XT250 motorcycles.

1980 Yamaha XT250G
1981 Yamaha XT250H
1982 Yamaha XT250J
1983 Yamaha XT250K
1984 Yamaha XT250L

Table of Contents

CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
Vehicle Identification Number
Engine Serial Number
SPECIAL TOOLS
For Tune-up
For Engine Service
For Chassis Service
For Electrical Components

CHAPTER 2
PERIODIC INSPECTIONS
AND ADJUSTMENTS
INTRODUCTION
MAINTENANCE INTERVALS CHARTS
PERIODIC MAINTENANCE EMISSION
CONTROL SYSTEM
PERIODIC MAINTENANCE/LUBRICATION
ENGINE
Cylinder Head Retightening
Valve Clearance Adjustment
Decompression System
Spark Plug
Crankcase Ventilation System
Exhaust System
Idle Speed
Engine Oil
Clutch Adjustment
Checking Ignition Timing
Compression Pressure Measurement
CHASSIS
Air Filter
Front and Rear Brake
Cable Inspection and Lubrication
Brake and Change Pedals/Brake and Clutch
Levers/Sidestand
Drive Chain
Front Fork Oil Change
Front Fork and Rear Shock Absorber Adjustment
Steering Head Adjustment
Wheel Bearings
Fuel Cock
Tires and Wheels
ELECTRICAL
Battery
Circuit Breaker
Headlight

CHAPTER 3
ENGINE OVERHAUL
ENGINE REMOVAL
Preparation for Removal
Seat and Fuel Tank
Battery
Exhaust Pipe and Muffler
Left Crankcase Cover and Chain Drive Sprocket
Footrests and Cables
Carburetor and Leads
Engine Removal
ENGINE DISASSEMBLY
Cylinder Head Cover, Cylinder Head,
and Cylinder
Piston Pin and Piston
Kick Crank
Crankcase Cover (Right)
Clutch Assembly and Drive Gears
Kick Axle, Idle Gears, and Oil Pump
Change Shaft Assembly
Clutch Push Lever
Primary Drive and Balancer Driven Gears
Flywheel
Crankcase
Crankshaft Balancer Shaft and Transmission
INSPECTION AND REPAIR
Cylinder Head Cover
Cylinder Head
Valves Valve Guides Valve Seats
and Valve Springs
Camshafts, Cam Chains, and Cam Sprockets
Cylinder
Piston and Piston Rings
Crankshaft and Connecting Rod
Oil Pump
Primary Drive
Clutch
Transmission
Kick Starter
Bearings and Oil Seals
Installation
ENGINE ASSEMBLY AND ADJUSTMENT
Important Information
Left-Side Crankcase
Flywheel
Primary Drive Gear and Balancer Drive Gears
Oil Pump
Shifter
Kick Starter and Idle Gears
Clutch
Crankcase Cover (Right) and Oil Filter
Piston and Cylinder
Cylinder Head and Cam Sprockets
Cylinder Head Cover
Mounting the Engine

CHAPTER 4 CARBURETION
CARBURETOR
Sectional View
Specifications
Disassembly
Inspection
Assembly
Adjustment
COASTING ENRICHER
Operation of Enricher
Maintenance
AIR CLEANER AND CRANKCASE
VENTILATION SYSTEM

CHAPTER 5 CHASSIS
FRONT WHEEL
Removal
Checking Brake Shoe Wear
Brake Drum
Brake Shoe Plate
Front Axle Inspection
Replacing Wheel Bearings
Front Wheel Inspection
Installing Front Wheel
REAR WHEEL
Removal
Checking Brake Shoe Wear
Brake Drum
Brake Shoe Plate
Rear Axle Inspection
Replacing Wheel Bearings
Rear Wheel Inspection
Installing Rear Wheel
RIMS AND SPOKES
Checking for Loose Spokes
Checking Rim “Run-Out”
TIRES AND TUBES
Removal
Installation
DRIVE CHAIN AND SPROCKETS
Drive Sprocket
Driven Sprocket
Chain Inspection
Drive Chain Lubrication
FRONT FORK
Removal and Disassembly
Inspection
Assembly
STEERING HEAD
Adjustment
Removal
Inspection
Assembly
SWINGARM
Free Play Inspection
Removal
Inspection and Lubrication
Assembly
SWINGARM ASSEMBLY CHART
REAR SHOCK ABSORBER
Removal
Inspection
Installation and Adjustment
CABLES AND FITTINGS
Cable Maintenance
Throttle Maintenance
Lubrication of Levers, Pedals, etc

CHAPTER 6 ELECTRICAL
XT250L/XT250LC WIRING DIAGRAM
CHARGING SYSTEM
AC GENERATOR AND VOLTAGE REGULATOR
Inspection
Battery Inspection
Charging Coil Inspection
Circuit Breaker
IGNITION AND STARTING SYSTEM
Description
Ignition Timing
Troubleshooting
Ignition Spark Gap Check
Ignition Coil Resistance Check
Spark Plug
Pickup Coil Resistance Check
Charge Coil Resistance Check
STARTING CIRCUIT OPERATION
Ignition Control Unit
Sidestand Switch
LIGHTING SYSTEM
Lighting Tests’and Checks
Lighting Coil Resistance Check
Lighting Voltage Check
SIGNAL SYSTEM
Signal System Tests and Checks
Switches
Battery

CHAPTER 7 APPENDICES
SPECIFICATIONS
CONSUMER INFORMATION
GENERAL TORQUE SPECIFICATIONS
DEFINITION OF UNITS
CONVERSION TABLES
EXPLODED DIAGRAMS
CYLINDER HEAD AND CAMSHAFTS
CLUTCH
TRANSMISSION
STEERING HEAD
FRONT FORK
FRONT WHEEL
REAR WHEEL
SWINGARM
ELECTRICAL COMPONENTS
LUBRICATION DIAGRAMS
CABLE ROUTING
XT250L/XT250LC WIRING DIAGRAM