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

• Covers 1980-1984 Yamaha XT250 models through the XT250G base manual, the XT250J and XT250K/XT250KC supplements, and the later XT250L/XT250LC service section. Yamaha's index directs XT250H owners to the G-model manual.
• Documents engine removal and overhaul, including cylinder head and valve gear, cam timing, piston and cylinder, crankshaft and balancer, oil pump, wet clutch, kick starter, transmission inspection, and final assembly adjustments.
• Explains both fuel-system generations: the earlier Mikuni VM28SS carburetor and the L/LC TK Y22PV primary/secondary arrangement, with fuel-level checks, synchronization, coasting-enricher service, and crankcase-ventilation work.
• Covers wheel and drum-brake repair, rims and spokes, drive chain and sprockets, front-fork disassembly and seal replacement, steering-head service, swingarm inspection, and Monocross rear-suspension work.
• Provides CDI ignition and starting-circuit diagnosis, charging and regulator tests, lighting and signal checks, battery and circuit-breaker service, plus model-specific wiring and cable-routing diagrams.
• Supplied as a 327-page image-based scanned PDF under combined Yamaha publication LIT-11616-XT-04, 1st Edition June 1984, 2nd Printing January 1985: 4 pages of combined front matter; 166 pages for L/LC; 28 for K/KC; 23 for J; and 106 for the G base section. The scan does not contain a usable searchable OCR text layer.

Yamaha wrote this material for authorized dealers and qualified mechanics, and it assumes the reader already understands basic motorcycle repair practices. It is suited to experienced technicians or owners who can use the specified pullers, holders, measuring equipment, and electrical test instruments safely.

Factory identifiers printed on the included sections are LIT-11616-04-23 for L/LC, LIT-11616-03-58 and 20T-28197-10 for K/KC, LIT-11616-03-01 for J, and LIT-11616-01-91 for the G manual.

Know Which XT250 Section Applies

The manual does not treat every model year as mechanically identical. Yamaha's combined index specifies that H models use the XT250G manual with its early air-cooled SOHC engine, five-speed transmission, Mikuni carburetor, and 6-volt electrical system. The J supplement adds the sidestand/neutral starting-interlock circuit and revised specifications; the K/KC supplement adds its own identification, maintenance, specification, torque, and wiring data, including the California-only evaporative-emission system.

The XT250L and California-spec XT250LC are covered by a separate service section for the later DOHC four-valve engine, six-speed transmission, staged primary/secondary carburetors, 12-volt electrical system, air/oil front fork, and New Yamaha Monocross rear suspension. This separation matters because valve data, cylinder-head torques, carburetor settings, electrical tests, and fork capacities are not interchangeable between the early and late designs.

Factory identification data includes XT250G starting number 3Y1-000101 and XT250J 3Y1-120101. The K/KC section lists starting VINs JYA3Y100DA200101 and JYA20T00DA000101, while the L/LC section identifies model codes 42U and 43E with starting VINs JYA42U00EA000101 and JYA43E00EA000101.

Repair Depth and Technical Reference

Valve-train coverage goes beyond routine clearance checks. It includes valve-guide removal, installation and reaming, seat cutting, spring inspection, L/LC camshaft-to-cap clearance measurement with Plastigage, adjusting-pad selection, and cam-chain timing. Bottom-end work covers crankcase separation, crankshaft installation, bearing and oil-seal replacement, transmission shaft and gear inspection, shift-fork checks, and lubrication-circuit inspection.

Named service tools include the YU-01135 crankcase separator, YM-01189 flywheel puller, YU-90050 crankshaft installing set, YU-33210 Plastigauge set, YM-08010 fork-seal/guide-bush installer, and YU-33260/YU-33263 electrical testers. Reference sections supply component-specific torque tables, fluid capacities, wear limits, running clearances, carburetor adjustment data, and electrical resistance, voltage, and output specifications for the covered configuration.

Named visuals include the L/LC primary/secondary carburetor sectional view, L/LC and K/KC wiring diagrams, the J-model starting-circuit schematic, the California evaporative-control sectional view, and the swingarm assembly chart. Component-level exploded views and cable-routing drawings support the related engine, chassis, and electrical repair sections.

The G-based flywheel-puller body uses a left-hand thread, and Yamaha flags the magneto-base silicone O-ring as easily damaged; the right-side crankshaft oil seal also installs opposite the usual orientation. L/LC fork service warns against scoring the tube surface during seal removal and calls for a new seal at assembly. The gas-charged rear shock section must be followed as written: heat, cylinder damage, or disassembly of the pressurized unit can create a pressure hazard or leave the shock with poor damping.