1980-1984 Yamaha XT250 / XT250G/H/J/K/L Service & Repair Manual (P/N LIT-11616-XT-04)

• Covers 1980–1984 Yamaha XT250 motorcycles, including the California-compliant XT250LC variant and earlier XT250G/H/J/K sub-models
• Official Yamaha publication P/N LIT-11616-XT-04, 1st Edition June 1984
• Contains 83 detailed exploded-view assembly diagrams and 35 individual torque specification tables for critical chassis and engine components
• Features a fully searchable OCR text layer, allowing you to jump straight to specific tolerance data or routine repair information by keyword
• Acts as the master reference for the entire 1980–1984 production run by consolidating previous supplementary documentation into one 327-page volume

Factory Service Documentation

The Yamaha service manual documents factory procedures designed to streamline your daily workshop workflow. Coverage begins with general machine identification, including specific VIN and engine serial number prefix locations for both standard and California-spec units. Subsequent sections detail periodic inspection intervals for emissions-related components and essential lubrication schedules covering engine oil, air filtration, and drive chain maintenance. You will find specialized, descriptive guidance detailing the carburetor system. This includes specifications for coasting enricher operation, idle speed settings, and synchronization data for the primary and secondary carburetors. Before servicing these fuel systems or working with pressurized components, always observe the factory safety protocols and cautionary procedures outlined within these pages to prevent injury or equipment damage.

Engine and Chassis Specifications

Engine overhaul sections provide the necessary dimensional data for top-end components. This covers critical measurements like piston-to-cylinder tolerances, valve seat width limits, and cam-to-cap clearance values. Cylinder head bolt torque values are documented in a precise multi-stage sequence, with final-stage values reaching 40 Nm (29 ft lb) for M10 bolts. Diagnostic reference charts specify the Yamaha XT250 compression pressure at 1,079 kPa. In the cylinder head specification table, the intake valve clearance is listed at 0.08–0.12 mm. For suspension maintenance, the front fork oil capacity is strictly documented at 323 cm³ per tube. Having this level of structural reference material on hand takes the guesswork out of any mechanical repair job, ensuring technicians can quickly locate tolerance charts and electrical schematics.