🏷️ Basic Information

Make:

Yamaha

Model:

XT250

Product Name:

Yamaha XT250 XT 250 1980-1984 Service Repair Workshop Manual

Model Codes:

XT250 (specific model codes may vary by market and year, but the manual covers the core XT250 platform for these years)

👋 Introduction

Target Audience:

Yamaha XT250 owners seeking to perform maintenance and repairs themselves, independent motorcycle repair shops.

Value Proposition:

Provides essential, manufacturer-authorized information to maintain and repair the Yamaha XT250, saving on dealership service costs and enabling self-sufficiency.

Essential Resource:

Indispensable guide for understanding and maintaining the specific XT250 models from 1980-1984.

📋 Manual Details

Years Covered:

1980, 1981, 1982, 1983, 1984

Estimated Pages:

400-600 (typical for a comprehensive service manual covering multiple years and systems)

Type:

Service Repair Workshop Manual

Language:

English

Format:

Digital (likely PDF, but physical copies may also exist)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul procedures, cylinder head, cylinder, piston, crankshaft, camshaft, valve timing, lubrication system.

Engine Fuel System:

Carburetor disassembly, cleaning, adjustment, jetting, fuel pump (if applicable), fuel lines.

Engine Ignition System:

Ignition timing, spark plugs, ignition coil, CDI unit, wiring diagrams.

Transmission:

Gearbox disassembly, inspection, repair, gear selection, clutch operation.

Clutch:

Clutch operation, adjustment, friction plates, pressure plates, clutch cable.

Chassis Frame:

Frame inspection, alignment, swingarm, bearings, steering head bearings.

Suspension Front:

Front fork disassembly, seal replacement, oil levels, spring rates, damping adjustments.

Brakes Front:

Brake caliper, master cylinder, brake pads, brake lines, bleeding procedure, rotor inspection.

Electrical System:

Wiring diagrams, battery, charging system (stator, rectifier/regulator), lighting, horn, starter motor, switches.

Wheels Tires:

Wheel balancing, spoke tension, bearing inspection, tire pressure, tire types.

Exhaust System:

Exhaust pipe and muffler inspection, gasket replacement, noise level specifications.

Bodywork:

Fairings, fenders, fuel tank removal and installation, seat, body panel repair.

Suspension Rear:

Rear shock absorber inspection, service, linkage systems (if applicable), adjustment.

Brakes Rear:

Brake drum, brake shoes, brake linkage, adjustment, inspection.

Routine Maintenance:

Oil changes, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement.

Troubleshooting:

Diagnostic flowcharts for common starting, running, and electrical issues.

Engine Rebuild:

Detailed step-by-step instructions for complete engine disassembly and reassembly.

Transmission Repair:

Gearbox overhaul, shift drum and forks, bearing replacement.

Electrical Diagnostics:

Testing of charging system components, ignition system, lighting circuits, and switches using multimeters.

Suspension Service:

Fork seal replacement, shock absorber servicing, bearing replacement.

Brake System Service:

Brake bleeding, pad/shoe replacement, caliper/drum maintenance.

Carburetor Tuning:

Idle speed adjustment, mixture screw settings, jetting for different conditions.

Depth:

Comprehensive (covers everything from basic maintenance to full engine and transmission overhauls).

Detail Level:

Detailed torque specifications, clearances, component measurements, and diagnostic procedures.

📊 Manual Specifications

File Type:

PDF (commonly provided for digital manuals)

Searchability:

Likely text-searchable, allowing quick access to specific information.

Print Readability:

High resolution for clear text and diagrams when printed.

Binding:

N/A (for digital format); If physical, would be wire-bound or perfect bound for durability.

Paper Quality:

N/A (for digital format); If physical, typically on durable, semi-gloss paper.

⚙️ Engine Specifications

Engine Type:

Four-stroke, air-cooled, SOHC, single-cylinder

Displacement:

249cc (approximately, exact may vary slightly by year/market)

Bore X Stroke:

Approx. 70.0 mm x 64.0 mm (typical for this era's XT250)

Compression Ratio:

Approx. 9.5:1 (typical)

Horsepower:

Around 20-22 HP @ 7,500 RPM (estimated, peak power figures often not directly published in manuals)

Torque:

Around 19-21 Nm @ 6,000 RPM (estimated)

Carburetor Type:

Mikuni VM series (e.g., VM34SS or similar) or Keihin (specific model depends on market/year).

Fuel Capacity:

Approx. 10-11 Liters (3.0-3.3 US gallons)

Fuel Type:

Unleaded gasoline, 90 octane or higher recommended.

🔧 Transmission

Type:

Constant mesh, 5-speed

Gear Ratios:

Specific ratios are detailed within the manual; typical urban/trail gearing.

Final Drive:

Chain drive

Clutch Type:

Wet, multiple-disc, cable-operated

Transmission Oil Type:

Yamaha brand gear oil or equivalent API service SE, SF type, SAE 20W-40 or 10W-30

📐 Dimensions

Length:

Approx. 2140 mm (84.3 in)

Width:

Approx. 825 mm (32.5 in)

Height:

Approx. 1170 mm (46.1 in)

Wheelbase:

Approx. 1360 mm (53.5 in)

Dry Weight:

Approx. 111 kg (244.7 lbs)

Wet Weight:

Approx. 123 kg (271.2 lbs) (with all fluids)

Max Load:

Typically around 150-180 kg including rider and luggage.

🛡️ Safety Features

Safety Standards:

Meets all applicable Japanese and relevant international safety standards for motorcycles of its era.

Braking System:

Front disc brake, rear drum brake providing adequate stopping power for its class.

Lighting:

Headlight, taillight, brake light, turn signals for visibility and signaling.

💡 Technology Features

Infotainment Features:

N/A (basic motorcycle of its era, no electronic infotainment features).

Electronic Aids:

N/A (no electronic rider aids such as ABS or traction control).

Connectivity Features:

N/A (mechanical systems only).

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-5,000 km (1,800-3,000 miles) or 6-12 months, refer to manual for exact mileage/time.

Valve Clearance Check:

Every 10,000-15,000 km (6,000-9,000 miles), critical for engine health.

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after riding in wet conditions.

Air Filter Cleaning:

Every 5,000-7,500 km (3,000-4,500 miles) or more frequently in dusty conditions.

Engine Oil Capacity:

Approx. 1.8 Liters (1.9 US qt) with filter change, 1.6 Liters (1.7 US qt) without filter change.

Engine Oil Viscosity:

SAE 20W-40 or SAE 10W-30, API Service SE, SF or SG category.

Fork Oil Type:

Yamaha Fork Oil G-10 or equivalent SAE 10W (refer to manual for specific grade and volume per fork leg).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (for front disc brake master cylinder).

Common Wear Items:

Clutch plates, valve stem seals, fork seals, swingarm and steering head bearings due to age and mileage.

Carburetor Issues:

Potential for gumming up if not run regularly, requiring cleaning and adjustment.

Electrical Connections:

Corrosion on electrical connectors can lead to intermittent issues over time; regular inspection and cleaning are beneficial.

📚 Vehicle History

Yamaha Legacy:

Yamaha has a long and successful history in motorcycles, known for innovation and performance across various segments, including dual-sport and off-road.

Xt Series:

The XT series is Yamaha's iconic dual-sport line, renowned for ruggedness, reliability, and versatility, dating back to the legendary XT500.

Manufacturing Origin:

Primarily manufactured in Japan.

Production Period:

The XT250 was produced for many years, with this manual specifically covering the first generation models from 1980 through 1984.

🏆 Awards & Recognition

Industry Reputation:

The XT series generally received positive reviews for its reliability, off-road capability, and ease of maintenance, establishing Yamaha as a strong competitor in the dual-sport market.