2013 Yamaha XT250 / XT250D(C) Service & Repair Manual (P/N LIT-11616-26-08)

This Yamaha service manual covers the 2013 XT250 / XT250D(C), with its fuel-injected 249cc air-cooled SOHC four-stroke engine, in 1YB1 (U49) and 1YB2 (California) configurations. First edition, April 2012; P/N LIT-11616-26-08, with cover reference 1YB-28197-10.

Text search, bookmarks and wiring detail: The PDF has searchable text and embedded bookmarks for chapters and service sections. Small connector labels and wire-color codes on the detailed circuit diagrams are readable with zooming.

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

• Clutch and transmission: Wet multi-disc clutch repair, transmission disassembly, shift-drum and shift-fork inspection, and starter-clutch testing.

• Fuel injection: Fuel-pressure testing, throttle-body and injector inspection, ECU fault-code diagnosis, and sensor and actuator checks through the multi-function display.

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

• Electrical troubleshooting: Ignition, starting, charging, lighting and signaling circuit diagnosis, with component tests and starting-circuit cut-off checks.

• Service references: General, engine and chassis tightening-torque tables, maintenance and lubrication charts, fluid capacities, wear limits, and electrical test specifications.

Yamaha prepared this manual primarily for its dealers and qualified mechanics, with an understanding of mechanical principles and vehicle repair techniques assumed.

Engine and Drivetrain Repair

Cylinder-head work extends to valve-guide replacement, valve-seat lapping and camshaft and rocker-arm inspection. Cylinder and piston sections provide piston-to-cylinder clearance checks and piston-ring inspection criteria.

Clutch procedures address friction-plate wear, plate warpage, push rods and release-mechanism alignment. Transmission coverage includes gear ratios, shaft runout, gear engagement and shift-drum assembly inspection. Exploded assembly views and accompanying job instruction charts identify parts and their removal sequence.

The oil-pump and balancer-gear sections cover rotor clearance inspection and gear alignment. An Engine Oil Lubrication Chart and lubrication diagrams show the oil circuit, while crankshaft work identifies the YU-01135-B crankcase separator and dedicated installation tools.

Fuel Injection and California Equipment

Configuration differences: U49 and California specifications list different throttle-body types and identification marks. California-specific material covers the evaporative-emissions canister, rollover valve and hose routing, helping match the fuel-system layout before selecting parts.

Fuel-system procedures cover pump removal and installation, injector checks, and throttle-body inspection. Fuel-pressure testing specifies gauge YU-03153 and adapter YM-03186.

Air induction coverage explains the air cut-off valve and reed valve, with a system diagram and inspection procedures. Yamaha's safety precautions address residual pressure in fuel lines and hazards during ignition testing.

ECU Diagnostics and Electrical Fault Tracing

The multi-function display provides access to diagnostic mode, including sensor readings, actuator tests and malfunction-history retrieval and clearing. Fault-specific tables connect displayed codes with connector, harness and component checks, helping distinguish a wiring fault from a failed sensor.

Tests include ignition-coil and injector actuation, fuel-pump and headlight relay operation, and the FID (fast idle solenoid). Lean-angle-sensor voltage testing calls for the six-pin test harness YU-03209.

The Starting Circuit Cut-off System Operation diagram explains the clutch, neutral and sidestand interlocks. The Fuel Injection System Circuit Diagram maps the ECU connections; separate ignition and lighting diagrams accompany their troubleshooting charts. Cable-routing drawings show harness placement around the frame and handlebar.

Brakes, Suspension and Routine Service

Caliper and master-cylinder procedures cover internal inspection and reassembly. The brake sections warn that solvents can swell and distort piston seals and dust seals.

Front-fork work covers bushings, seals and fork-oil level. The disassembly notes warn that bottoming the inner tube can damage the oil flow stopper.

Steering-head and swingarm procedures include bearing and bushing checks. Rear-shock coverage addresses removal, inspection and preload adjustment, alongside Yamaha's warning against opening the nitrogen-charged unit.

Maintenance charts cover the air filter, spark arrester and fuel systems. Adjustment data address valve clearances, engine idle speed and spark-plug gap.

PDF Contents and Included Wiring Sheets

The single printable English-language file is a 340-page PDF: 338 pages of manual content, front matter, covers and blank pages, followed by two landscape wiring sheets, one black-and-white and one color. Both wiring sheets are included in the total.