ServiceManual - RAWRATS.COM

1 3C5-28197-10XT250 XXT250 XCSERVICE MANUALLIT-11616-21-522008 EAS20050XT250 XXT250 XCSERVICE MANUAL 2008 by Yamaha Motor Corporation, edition, August 2007 All rights reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, is expressly in LIT-11616-21-52 EAS20070 NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealersand 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 vehiclesshould have a basic understanding of mechanics and the techniques to repair these types of and maintenance work attempted by anyone without this knowledge is likely to render the vehi-cle unsafe and unfit for model has been designed and manufactured to perform within certain specifications in regard toperformance and emissions.

2 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 youcontact a Yamaha dealer for any service information changes that apply to this model. This policy isintended to provide the customer with the most satisfaction from his vehicle and to conform to federalenvironmental quality 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 andwill appear in future editions of this manual where : This Service Manual contains information regarding periodic maintenance to the emission controlsystem.

3 Please read this material carefully. Designs and specifications are subject to change without MANUAL INFORMATIONP articularly important information is distinguished in this manual by 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 CAUTION indicates special precautions that must be taken to avoid damage to the NOTE provides key information to make procedures easier or :NOTE:EAS20090 HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic.

4 Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures are laidout with the individual steps in sequential order. The manual is divided into chapters and each chapter is divided into sections. The current section titleis 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 eachremoval and disassembly section 3 . Numbers are given in the order of the jobs in the exploded diagram.

5 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 ofparts, notes in jobs, etc 6 . Jobs requiring more information (such as special tools and technical data) are described sequentially 7 .72 CLUTCH5-31 Removing the clutchOrderJob/Parts to removeQ tyRemarks1 Clutch spring52 Pressure plate13 Adjusting screw14 Push plate15 Friction plate66 Clutch plate57 Clutch damper spring18 Clutch damper spring seat19 Primary drive gear nut110 Lock washer111 Claw washer112 Clutch boss nut113 Lock washer114 Clutch boss115 Thrust washer116 Clutch housing117 Ball118 Clutch push rod119 Primary drive gear1 For installation, reverse the removal Nm ( m kg, ft Ib) Nm ( m kg, 54 ft Ib) Nm ( m kg, 58 ft Ib)

6 12567812131516179101119181434(5)34561 CLUTCH5-33 EAS25070 REMOVING THE CLUTCH1. Straighten the lock washer Loosen:Primary drive gear nut 1 NOTE:Insert aluminum plate a between primary drivegear 2 and primary driven gear 3 , and loosenthe primary drive gear Loosen:Clutch boss nut 1 NOTE:While holding the clutch boss 1 with the univer-sal clutch holder 2 , loosen the clutch boss THE FRICTION PLATESThe following procedure applies to all of the fric-tion Check:Friction plateDamage/wear Replace the friction platesas a Measure.

7 Friction plate thicknessOut of specification Replace the frictionplates as a :Measure the friction plate at four THE CLUTCH PLATESThe following procedure applies to all of theclutch Check:Clutch plateDamage Replace the clutch plates as Measure:Clutch plate warpage(with a surface plate and thickness gauge 1 )Out of specification Replace the clutchplates as a THE CLUTCH SPRINGSThe following procedure applies to all of theclutch Check:Clutch springDamage Replace the clutch springs as Measure:Universal clutch holder90890-04086YM-91042213 Friction plate mm ( in)Wear mm ( in)Warpage mm ( in)EAS20100 SYMBOLSThe following symbols are used in this manualfor easier :The following symbols are not relevant to Serviceable with engine mounted2.

8 Filling fluid3. Lubricant4. Special tool5. Tightening torque6. Wear limit, clearance7. Engine speed8. Electrical data9. Engine oil10. Gear oil11. Molybdenum-disulfide oil12. Brake fluid13. Wheel-bearing grease14. Lithium-soap-based grease15. Molybdenum-disulfide grease16. Silicone grease17. Apply locking agent (LOCTITE )18. Replace the partGENERAL INFORMATION1 SPECIFICATIONS2 PERIODIC CHECKS ANDADJUSTMENTS3 CHASSIS4 ENGINE5 FUEL SYSTEM6 ELECTRICAL SYSTEM7 TROUBLESHOOTING8 EAS20110 TABLE OF CONTENTS123456789 GENERAL INFORMATIONIDENTIFICATION.

9 1-1 VEHICLE IDENTIFICATION 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 AND OIL THE CONNECTIONS ..1-4 SPECIAL TOOLS ..1-5 IDENTIFICATION1-1 EAS20130 IDENTIFICATIONEAS20140 VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the right side of the steering head LABELThe model label 1 is affixed to the frame. Thisinformation will be needed to order spare INFORMATION1-2 EAS20180 IMPORTANT INFORMATIONEAS20190 PREPARATION FOR REMOVAL AND DISASSEMBLY1.

10 Before removal and disassembly, remove alldirt, mud, dust and foreign Use only the proper tools and cleaning to SPECIAL TOOLS on page When disassembling, always keep matedparts together. This includes gears, cylin-ders, pistons and other parts that have been mated through normal wear. Mated partsmust always be reused or replaced as an During disassembly, clean all of the parts andplace them in trays in the order of disassem-bly. This will speed up assembly and allow forthe correct installation of all Keep all parts away from any source of PARTSUse only genuine Yamaha parts for all replace-ments.