2008 Yamaha XT250, XT250X, XT250XC OEM Service Manual (P/N LIT-11616-21-52)

This Yamaha service manual covers the 2008–2009 XT250X and XT250XC dual-sport models in the XT250 family, identified as 3C58 (U49) and 3C59 (CAL). Yamaha publication P/N LIT-11616-21-52, first edition August 2007.

• Engine repair: Engine removal, cylinder-head and piston service, valve-clearance adjustment, camshaft timing, crankcase separation, and crankshaft inspection.

• Clutch and transmission: Wet-clutch disassembly, friction-plate and spring checks, shift-fork inspection, and constant-mesh transmission disassembly and reassembly.

• Brakes and chassis: Hydraulic brake bleeding, caliper and master-cylinder service, front-fork rebuilding, steering-head bearing replacement, and swingarm inspection.

• Fuel and emissions: Teikei MV33 carburetor disassembly, float-height adjustment, fuel-cock inspection, air-induction checks, and California evaporative-emission maintenance.

• Electrical diagnosis: CDI ignition and starting-interlock troubleshooting, charging-system tests, starter-motor overhaul, and carburetor-heater fault tracing.

• Workshop references: Exploded assembly views, component torque tables, emission-control and general maintenance charts, lubrication charts and diagrams, cable-routing drawings, and full wiring diagrams.

Written primarily for Yamaha dealers and their qualified mechanics, this manual assumes a working knowledge of motorcycle maintenance and repair.

Engine, Clutch and Transmission Repair

Periodic checks for the air-cooled SOHC engine include compression testing and NGK DR7EA spark-plug inspection. The specifications section supplies oil-fill quantities and wear limits, with general, engine and chassis tightening-torque tables.

Internal engine work extends to valve-guide replacement, valve-seat lapping, piston-ring inspection, oil-pump checks and balancer-gear alignment. The Engine Oil Lubrication Chart and lubrication diagrams trace oil delivery through the engine and transmission.

Crankshaft procedures identify separator YU-01135-B and installation tooling; clutch service specifies universal holder YM-91042. Transmission instructions distinguish the marked shift forks and include gear-dog and shaft-runout checks.

Brake and Suspension Service

Wheel service includes bearing replacement and static balancing. Fork procedures cover seals and bushings, including a warning that bottoming the inner tube during disassembly can damage the oil-flow stopper.

Rear-shock coverage includes spring-preload adjustment, removal, inspection and assembly replacement. The gas-pressurized damper is not covered as an internal rebuild; Yamaha warns against opening it. Connecting-arm and relay-arm bearing work is documented separately.

Brake repair includes piston-seal and master-cylinder cup replacement, with cautions about solvents swelling and distorting caliper seals. Securely support the motorcycle during wheel, fork and steering work.

Carburetor and Emissions Systems

Carburetor inspection extends to the piston-valve diaphragm and coasting enricher, with separate checks for jets, the float and needle valve. The air-induction section explains the reed valve and vacuum-operated air cut-off valve.

Separate U49 and CAL carburetor identification marks and California canister/rollover-valve hose-routing illustrations distinguish the regional configurations.

Ignition, Starting and Charging Diagnosis

The Starting Circuit Cut-Off System Operation diagram explains the neutral, clutch and sidestand interlocks. Its accompanying tests help distinguish an interlock fault from a starter-motor problem before parts are replaced.

Ignition and carburetor-heating circuit diagrams support fault charts for loss of spark and heater failure. Component tests cover the stator coil, rectifier/regulator and thermo switch, with separate checks for lighting, signaling and speed-sensor faults.

The troubleshooting chapter also addresses clutch slip, shifting faults, overheating and unstable handling.

A Preview of Valve and Fork Adjustment Data

These valve and fork figures are a small selection of the adjustment data in the manual.

For the covered engine, cold valve clearance is 0.05–0.10 mm at the intake and 0.10–0.15 mm at the exhaust, measured at room temperature with the piston at compression TDC.

The fork section specifies an oil level of 125.0 mm below the top of the inner tube, with the fork upright, fully compressed and the spring removed.

PDF Navigation and Wiring Detail

Search, bookmarks and diagram labels: The manual text is searchable, with embedded bookmarks for all eight chapters, individual procedures and wiring sheets. Some graphical diagram identifiers are not searchable. Small wire-color codes and connector labels require enlargement for comfortable reading.

One printable 282-page PDF contains the 280-page manual, including its covers and blank pages, plus two appended large-format wiring sheets—one black-and-white and one color. Both additional sheets are already included in the total.