Yamaha XT225R Owner'S Manual Download Page 44

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6-2

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

If you do not have the tools or experi-
ence required for a particular job,
have a Yamaha dealer perform it for
you.

EW000062

Modifications not approved by
Yamaha may cause loss of perfor-
mance, excessive emissions, and
render the vehicle unsafe for use.
Consult a Yamaha dealer before
attempting any changes.

5RK-9-11(US) 4/26/02 7:16 PM Page 42

Summary of Contents for XT225R

Page 1: ...5RK 28199 11 LIT 11626 16 22 OWNER S MANUAL XT225R C...

Page 2: ......

Page 3: ...is motorcycle If you have any questions concerning the operation or maintenance of your motorcy cle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply wit...

Page 4: ...en to avoid damage to the motorcycle A NOTE provides key information to make procedures easier or clearer Q w cC NOTE NOTE 8 This manual should be considered a permanent part of this motorcycle and sh...

Page 5: ...EMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADE QUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPEC T...

Page 6: ...edition April 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 16 22...

Page 7: ...Fuel tank cap 3 5 Fuel 3 5 Fuel cock 3 7 Starter choke knob 3 8 Seat 3 8 Helmet holder 3 9 Adjusting the shock absorber assembly 3 9 Sidestand 3 12 Ignition circuit cut off system 3 12 PRE OPERATION C...

Page 8: ...ing the brake fluid 6 27 Drive chain slack 6 27 Lubricating the drive chain 6 29 Checking and lubricating the cables 6 29 Checking and lubricating the throttle grip and cable 6 30 Checking and lubrica...

Page 9: ...tification number 9 1 Vehicle identification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 6 Street and enduro motorcycle limited warrant...

Page 10: ...ARY BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failur...

Page 11: ...g wide on a turn due to EXCESSIVE SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic condi tions b A...

Page 12: ...ration They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 Passengers should also observe the precautions mentioned above Modifications Mod...

Page 13: ...ems including such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use o...

Page 14: ...ability therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric...

Page 15: ...ld catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock s are turned to ON or RES for vacuum type OFF for manual type If the motor...

Page 16: ...1 7 QSAFETY INFORMATION 1 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle 1 4 2 3 5RK 9 11 US 4 26 02 7 15 PM Page 14...

Page 17: ...EAD THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing 5GK 2118K 00 1 2 EMISSION HOSE ROUTING CARB FROM FUEL TANK CANISTER TO ATMOSPHERE...

Page 18: ...filter element page 6 14 4 Helmet holder page 3 9 5 Owner s tool kit page 6 1 6 Shock absorber spring preload adjusting nut page 3 10 7 Shock absorber rebound damping adjusting dial page 3 11 8 Shift...

Page 19: ...age 6 33 10 Fuse page 6 35 11 Engine oil filter element page 6 11 12 Engine oil level check window page 6 10 13 Brake pedal page 3 4 6 23 14 Spark arrester page 6 16 13 14 9 10 11 12 Right view 5RK 9...

Page 20: ...ter choke knob page 3 8 4 Speedometer unit page 3 2 5 Main switch steering lock page 3 1 6 Right handlebar switches page 3 3 7 Brake lever page 3 4 6 22 8 Throttle grip page 6 17 6 30 9 Fuel tank cap...

Page 21: ...can be started The key cannot be removed EAU00038 OFF All electrical systems are off The key can be removed ON OFF LOCK To unlock the steering Insert the key and turn it to OFF EW000017 w Never turn t...

Page 22: ...speed The odometer shows the total distance traveled The tripmeter shows the distance traveled since it was last set to zero with the reset knob The tripmeter can be used to estimate the distance tha...

Page 23: ...utch switch which is part of the igni tion circuit cut off system See page 3 12 for an explanation of the ignition circuit cut off system 1 1 Clutch lever EAU03890 Engine stop switch Set this switch t...

Page 24: ...this motorcycle INSTRUMENT AND CONTROL FUNCTIONS 3 1 1 Shift pedal EAU00158 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the han d...

Page 25: ...tank otherwise it may overflow when the fuel warms up and expands 8 Avoid spilling fuel on the hot engine 1 2 1 Fuel level 2 Filler tube To install the fuel tank cap 1 Insert the fuel tank cap into t...

Page 26: ...ch octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance cost...

Page 27: ...mark positioned over OFF RES This indicates reserve If you run out of fuel while riding move the lever to this position Fill the tank at the first opportunity Be sure to set the lever back to ON afte...

Page 28: ...a to turn on the starter choke Move the knob in direction b to turn off the starter choke INSTRUMENT AND CONTROL FUNCTIONS 3 1 a b 1 Starter choke knob 1 EAU02949 Seat To remove the seat 1 Remove pan...

Page 29: ...y is equipped with a spring preload adjusting nut and a rebound damping force adjusting dial EC000015 cC Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings EAU00261 He...

Page 30: ...adjustment 8 The spring preload setting is determined by measuring dis tance A shown in the illustration The longer distance A is the higher the spring preload the shorter distance A is the lower the...

Page 31: ...not subject the shock absorber to an open flame or other high heat sources other wise it may explode due to excessive gas pressure 8 Do not deform or damage the gas cylinder in any way as this will re...

Page 32: ...in fulfilling the responsibility of rais ing the sidestand before starting off Therefore check this system regularly as described below and have a Yamaha dealer repair it if it does not function prop...

Page 33: ...p the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Pu...

Page 34: ...heck fuel level in fuel tank Refuel if necessary Check fuel line for leakage 3 5 3 6 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leak...

Page 35: ...ary 6 18 6 20 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 30 Brake and clutch levers Make sure that operation is smooth Lubricate lever piv...

Page 36: ...h an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved EWA00033 w If any item in the Pre operation check list is not working prop...

Page 37: ...the opera tor resulting in a possible loss of control EAU00376 cC 8 Make sure not to store person al items near the air cleaner intake otherwise air intake will be blocked and performance will suffer...

Page 38: ...ne more than 10 seconds on any one attempt 6 After starting the engine move the starter choke knob back halfway ECA00055 cC For maximum engine life always warm the engine up before starting off Never...

Page 39: ...ng Inadequate lubrication may damage the transmission 8 Always use the clutch while changing gears to avoid dam aging the engine transmis sion and drive train which are not designed to withstand the s...

Page 40: ...ansmission into the neutral position 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear NOTE Always shift gears at th...

Page 41: ...full throttle operation or any condition that might result in engine overheating must be avoided EAU04234 0 150 km 0 90 mi 8 Avoid prolonged operation above 1 3 throttle 8 After every hour of operati...

Page 42: ...should occur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU00457 Parking When parking stop the engine remove the key from the main switch and then turn the fu...

Page 43: ...ols provided in the owner s tool kit are intended to assist you in the performance of pre ventive maintenance and minor repairs However additional tools such as a torque wrench may be nec essary to pe...

Page 44: ...quired for a particular job have a Yamaha dealer perform it for you EW000062 w Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for...

Page 45: ...ths 3 Crankcase 9 Check breather hose for cracks or damage breather system 9 Replace if necessary 4 Fuel line 9 Check fuel hose for cracks or damage 9 Replace if necessary 9 Check for leakage 5 Exhaus...

Page 46: ...filter and strainer if damaged 9 Wet type filter elements 3 Air filter element must be washed and dampened with oil 9 Adjust free play 9 Check fluid leakage Front see NOTE page 6 6 4 Brake system 9 Co...

Page 47: ...pose grease 9 Check operation and free play Throttle grip 9 Adjust the throttle cable Lithium soap based 11 housing and free play if necessary grease all purpose cable 9 Lubricate the throttle grip gr...

Page 48: ...if you are riding in unusually wet or dusty areas 8 Hydraulic brake system 9 When disassembling the master cylinder or caliper cylinder always replace the brake fluid Check the brake fluid level regul...

Page 49: ...d and installed 1 3 2 1 Cowling A 2 Panel A 3 Panel B EAU00488 Panel A To remove the panel Remove the screw and then pull the panel off as shown To install the panel Place the panel in the original po...

Page 50: ...n the owner s tool kit 1 1 Spark plug wrench EAU01833 Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug t...

Page 51: ...when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 4 Install t...

Page 52: ...ngine oil and oil filter element The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter element cleaned at the intervals specified in the Genera...

Page 53: ...e correct level 2 3 1 1 Engine oil level check window 2 Maximum level mark 3 Minimum level mark 4 Remove the engine oil filler cap and drain bolt along with the O ring compression spring and engine oi...

Page 54: ...e oil filter element and O rings 9 Check the O rings for damage and replace them if necessary 10 Clean the oil filter element with solvent and then install it NOTE Check the oil filter element for dam...

Page 55: ...eign material enters the crankcase 14 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the ca...

Page 56: ...y if you are riding in unusually wet or dusty areas 1 Remove panel A See page 6 7 for removal and installation pro cedures 2 Remove the air filter case cover by removing the screws 2 1 1 Air filter ca...

Page 57: ...lter case 8 8 The engine should never be operated without the air filter element installed otherwise the piston and or cylinder may become excessively worn 8 Install the air filter case cover by insta...

Page 58: ...e sure to select a well ventilated area free of combustible materials to clean the spark arrester 2 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arre...

Page 59: ...valve clearance The valve clearance changes with use resulting in improper air fuel mix ture and or engine noise To prevent this from occurring the valve clear ance must be adjusted by a Yamaha dealer...

Page 60: ...erformance and safety character istics of your motorcycle you should keep the following precau tions in mind 8 NEVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle may result in tire da...

Page 61: ...inspection The tires must be checked before each ride If the tire shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha...

Page 62: ...g a tire since the tire sur face must first be broken in for it to develop its optimal charac teristics EAU00685 Spoke wheels To maximize the performance dura bility and safe operation of your motorcy...

Page 63: ...ies or replace ment parts may cause loss of handling stability and riding safe ty Since Yamaha cannot control the quality of accessories or parts EAU02996 Adjusting the clutch lever free play The clut...

Page 64: ...brake is working properly 8 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the...

Page 65: ...a a Brake pedal position Brake pedal free play The brake pedal free play should measure 20 30 mm 0 8 1 2 in as shown Periodically check the brake pedal free play and if necessary adjust it as follows...

Page 66: ...adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on ear lier turn the adjusting nut in direction a To mak...

Page 67: ...the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set 2 1 1 Wear i...

Page 68: ...As the brake pads wear it is nor mal for the brake fluid level to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause Observe these precautions...

Page 69: ...on into the neutral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain sla...

Page 70: ...g plate EW000103 w After adjusting the brake pedal free play check the operation of the brake light NOTE Make sure that both adjusting plates are in the same position for proper wheel alignment EC0000...

Page 71: ...drive chain with steam cleaners high pressure washers or inappropriate solvents 2 Wipe the drive chain dry EAU03297 Checking and lubricating the cables The operation of all control cables and the cond...

Page 72: ...t pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lubricated if necessary EAU04034 Checking and lubricating the throttle grip and c...

Page 73: ...c maintenance and lubrication chart 1 1 1 Grease nipple 5 EAU03165 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and...

Page 74: ...re the opera tion of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrica tion chart 1 Place a stand under the engine to raise the front wheel off...

Page 75: ...any maintenance There is no need to check the electrolyte or to add distilled water EC000101 cC Never attempt to remove the bat tery cell seals as this would per manently damage the battery EAU01144 C...

Page 76: ...e sufficient ventilation when charging it in an enclosed space To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the ba...

Page 77: ...ng than recommend ed to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fu...

Page 78: ...bulb burns out replace it as follows 1 Remove cowling A See page 6 7 for cowling removal and installation procedures 3 Disconnect the headlight cou pler and then remove the head light bulb cover 1 2 1...

Page 79: ...holder 8 Install the cowling 9 Have a Yamaha dealer adjust the headlight beam if necessary EC000105 cC Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transpa...

Page 80: ...lb 1 Remove the tail brake light lens by removing the screws 1 2 1 Lens 2 Screw 2 2 Remove the defective bulb by pushing it in and turning it coun terclockwise 3 Insert a new bulb into the socket push...

Page 81: ...wheel or under each side of the swingarm EAU01579 Supporting the motorcycle Since this model is not equipped with a centerstand follow these precau tions when removing the front and rear wheel or perf...

Page 82: ...r the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut 2 Remove the brake disc cover by removing the screws 3 Remove the speedometer cable holder by rem...

Page 83: ...ew 7 Install the brake disc cover by installing the screws 8 Install the engine guard by installing the bolt NOTE Make sure that there is enough space between the brake pads before inserting the brake...

Page 84: ...hain does not need to be disassembled in order to remove and install the wheel 8 Pull the wheel axle out and then remove the wheel 2 Remove the brake pedal free play adjusting nut and then dis connect...

Page 85: ...ll the engine guard by installing the bolt 2 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 28 for drive chain slack adjust ment procedures 3 Install t...

Page 86: ...lowing troubleshooting chart represents a quick and easy proce dure for checking these vital systems yourself However should your motorcycle require any repair take it to a Yamaha dealer whose skilled...

Page 87: ...ion Supply fuel The engine does not start Check the compression 4 Battery Wet Dry Wipe off with a dry cloth and correct the Have a Yamaha dealer check the vehicle Remove the spark the electrodes plug...

Page 88: ...s all electrical cou plers and connectors including the spark plug cap are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but...

Page 89: ...leave any marks If the windshield is scratched use a quality plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then ri...

Page 90: ...inor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry complete ly before storing or covering it EWA00001 w 8 Make sure that there is no oil or wax on the brakes or...

Page 91: ...rained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to prote...

Page 92: ...degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month...

Page 93: ...cation system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher cC In order to prevent clutch slippage since the engine oil also lubricates the clutch...

Page 94: ...ratio 3 318 Secondary reduction system Chain drive Secondary reduction ratio 3 000 Number of drive chain sprocket teeth rear front 45 15 Transmission type Constant mesh 6 speed Operation Left foot Ge...

Page 95: ...eel Size 21 1 60 Rear Type Spoke wheel Size 18 2 15 Brakes Front Type Single disc brake Operation Right hand Fluid DOT 4 Rear Type Drum brake Operation Right foot Suspension Front Type Telescopic fork...

Page 96: ...60 55W 1 Tail brake light 12V 8 27W 1 Front turn signal position light 12V 27 8W 2 Rear turn signal light 12V 27W 2 Meter lighting 12V 3 4W 1 Neutral indicator light 12V 3 4W 1 High beam indicator li...

Page 97: ...43 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to id...

Page 98: ...o the frame under the seat See page 3 8 for seat removal and installation pro cedures Record the information on this label in the space provided This information will be needed when ordering spare par...

Page 99: ...an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you yo...

Page 100: ...w vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been rem...

Page 101: ...9 5 CONSUMER INFORMATION 9 5RK 9 11 US 4 26 02 7 16 PM Page 99...

Page 102: ...the emissions warranty The chart below is printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Serv...

Page 103: ...00 km or 36 months 22 000 mi 36 000 km or 42 months 25 000 mi 41 000 km or 48 months 28 000 mi 46 000 km or 54 months 31 000 mi 51 000 km or 60 months Maintenance interval Date of service Mileage Serv...

Page 104: ...9 8 CONSUMER INFORMATION 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 5RK 9 11 US 4 26 02 7 16 PM Page 102...

Page 105: ...9 9 CONSUMER INFORMATION 9 5RK 9 11 US 4 26 02 7 16 PM Page 103...

Page 106: ...9 10 CONSUMER INFORMATION 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S 5RK 9 11 US 4 26 02 7 16 PM Page 104...

Page 107: ...9 11 9 5RK 9 11 US 4 26 02 7 16 PM Page 105...

Page 108: ...PRINTED IN JAPAN 2002 5 0 7 1 E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD...

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