Yamaha XT225-D-G Service Manual Download

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Page 391: ...XT225N XT225NC SUPPLEMENTARY SERVICEMANUAL LIT 11616 14 42 4BE 28197 22 ...

Page 392: ...he following manual XT225D XT225DC SERVICE MANUAL LIT 11616 07 99 4BE 28197 20 XT225H XT225HC SUPPLEMENTARY SERVICE MANUAL LIT 11616 10 05 4BE 28197 21 XT225N C SUPPLEMENTARY SERVICE MANUAL 2000 by Yamaha Motor Corporation U S A First edition October 2000 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibite...

Page 393: ... to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable NOTE ...

Page 394: ... an easy to read handy reference that contains comprehensive explanations of all disassembly repair assembly and inspections A set of particularly important procedure 4 is placed between a line of asterisks with each pro cedure preceded by IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol 5 An encircled numeral 6 indicates a part name and an encircled alp...

Page 395: ...al tool B Tightening torque C Wear limit clearance D Engine speed E Electrical data Symbols F to K in the exploded diagrams indicate the types of lubricants and lubrication points F Engine oil G Gear oil H Molybdenum disulfide oil I Wheel bearing grease J Lithium soap base grease K Molybdenum disulfide grease Symbols L to M in the exploded diagrams indicate the following L Apply locking agent LOCT...

Page 396: ...RQUES 12 CABLE ROUTING 13 PERIODIC INSPECTION AND ADJUSTMENT 21 ENGINE 21 THROTTLE CABLE FREE PLAY ADJUSTMENT 21 ENGINE 23 ENGINE ASSEMBLY AND ADJUSTMENT 23 CLUTCH AND OIL PUMP 23 CYLINDER HEAD 24 CAMSHAFT AND TIMING CHAIN 25 CHASSIS 26 FRONT BRAKE 26 ELECTRICAL 27 CHECKING OF SWITCHES 27 SWITCH CONNECTION AS SHOWN IN MANUAL 27 CHECKING SWITCH FOR TERMINAL CONNECTION 27 XT225N XT225NC WIRING DIAGR...

Page 397: ...m 31 7 in Overall height 1 160 mm 45 7 in Seat height 810 mm 31 9 in Wheelbase 1 350 mm 53 1 in Minimum ground clearance 285 mm 11 2 in Minimum turning radius 1 900 mm 74 8 in Weight Wet with oil and a full fuel tank 121 kg 267 lb Dry without oil and fuel 108 kg 238 lb Maximum load total of cargo rider passenger and accessories 183 kg 404 lb GENERAL SPECIFICATIONS ...

Page 398: ...inside diameter 25 000 25 021 mm 0 9843 0 9851 in Camshaft journal diameter 24 960 24 980 mm 0 9827 0 9835 in Camshaft journal to camshaft cap clearance 0 020 0 061 mm 0 0008 0 0024 in Intake camshaft lobe dimensions Measurement A 36 51 36 61 mm 1 437 1 441 in 36 41 mm 1 43 in Measurement B 30 1 30 2 mm 1 185 1 189 in 30 0 mm 1 18 in Measurement C 6 50 6 62 mm 0 256 0 261 in Exhaust camshaft lobe ...

Page 399: ... mm 1 42 in 34 35 mm 1 35 in Installed length valve closed Intake 30 5 mm 1 20 in Exhaust 30 5 mm 1 20 in Compressed spring force installed Intake 75 0 91 7 N 7 50 9 17 kgf 16 9 20 6 lb Exhaust 75 0 91 7 N 7 50 9 17 kgf 16 9 20 6 lb Spring tilt Intake 2 5 1 6 mm 2 5 0 063 in Exhaust 2 5 1 6 mm 2 5 0 063 in Winding direction top view Intake Counterclockwise Exhaust Counterclockwise Item Standard Li...

Page 400: ...ntake 128 5 157 9 N 12 9 15 8 kgf 28 9 35 5 lb Exhaust 128 5 157 9 N 12 9 15 8 kgf 28 9 35 5 lb Spring tilt Intake 2 5 1 6 mm 2 5 0 063 in Exhaust 2 5 1 6 mm 2 5 0 063 in Winding direction top view Intake Clockwise Exhaust Clockwise Piston Piston to cylinder clearance 0 025 0 050 mm 0 001 0 002 in 0 15 mm 0 0059 in Diameter D 69 960 69 975 mm 2 7543 2 7549 in Height H 5 0 mm 0 2 in Item Standard L...

Page 401: ... 30 mm 0 006 0 011 in 0 55 mm 0 02 in Ring side clearance 0 03 0 07 mm 0 0012 0 0028 in 0 12 mm 0 0047 in 2nd ring Ring type Taper Dimensions B T 1 2 2 8 mm 0 05 0 11 in End gap installed 0 15 0 30 mm 0 006 0 011 in 0 65 mm 0 025 in Ring side clearance 0 02 0 06 mm 0 0008 0 0024 in 0 12 mm 0 0047 in Oil ring Dimensions B T 2 5 2 8 mm 0 10 0 11 in End gap installed 0 3 0 9 mm 0 01 0 04 in Clutch Cl...

Page 402: ...ding limit 0 5 mm 0 02 in Carburetors Model manufacturer quantity BST34 MIKUNI 1 Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in ID mark 4BEV 30 4BEW 20 for California Main jet 125 Main air jet 1 0 Jet needle 5DL27 1 Needle jet 0 1 Pilot air jet 1 70 Pilot air jet 2 1 2 Pilot outlet 0 85 Pilot jet 40 Bypass 1 0 8 Valve seat size 2 0 Starter jet 1 65 Starter jet 2 0 ...

Page 403: ... pressure cold 0 90 kg 0 198 lb 150 kPa 1 5 kg cm2 21 8 psi 90 197 kg 198 434 lb 175 kPa 1 75 kg cm2 25 4 psi Min tire tread depth 1 0 mm 0 04 in Front brake Brake type Single disc brake Operation Right hand operation Brake lever free play at lever end 2 5 mm 0 08 0 20 in Recommended fluid DOT 4 Brake disc Diameter thickness 220 3 5 mm 8 66 0 14 in Min thickness 3 0 mm 0 12 in Max deflection 0 15 ...

Page 404: ... 13 9 06 in Optional spring available No Standard enclosed gas air pressure 2 000 kPa 20 kgf cm2 290 psi Fork oil Recommended oil Fork oil 10 W or equivalent Quantity each front fork leg 366 cm3 12 9 Imp oz 12 4 US oz Level from the top of the inner tube with the inner tube fully compressed and without the fork spring 140 mm 5 51 in Steering Steering bearing type Ball and taper roller bearing No s...

Page 405: ... 9 SPEC Drive chain Model manufacturer 428V2 DAIDO Link quantity 120 Drive chain slack 35 45 mm 1 38 1 77in Item Standard Limit CHASSIS SPECIFICATIONS ...

Page 406: ...nductor short circuit Model manufacturer SH629A 12 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier capacity 10 A Withstand voltage 200 V Battery Battery type GT6B 3 Battery voltage capacity 12 V 6 AH Specific gravity 1 320 Bulbs voltage wattage quantity Headlight 12 V 60 W 55 W 1 Tail brake light 12 V 8 W 27 W 1 Front turn signal light 12 V 27 W 8 W 2 Rear turn signal light 12 V 27 W 2 ...

Page 407: ... 1 Max amperage 1 5 A Performance 95 105 db 2 m Coil resistance 4 3 4 8 Ω Turn signal relay Relay type Full transistor Model manufacturer FE246BH DENSO Self cancelling device built in No Turn signal blinking frequency 75 95 cycles min Wattage 27 W 2 3 4 W Fuses amperage quantity Main fuse 20 A 1 Reserve fuse 20 A 1 Item Standard Limit ELECTRICAL SPECIFICATIONS ...

Page 408: ...ctor Screw M6 2 7 0 7 5 1 Exhaust pipe and muffler link Bolt M8 1 20 2 0 14 Crankcase 1 2 Bolt M6 7 10 1 0 7 2 Crankcase 1 2 Bolt M6 2 10 1 0 7 2 Crankcase 1 2 Bolt M6 2 10 1 0 7 2 Crankcase 1 2 Bolt M6 1 10 1 0 7 2 Crankcase cover 1 Bolt M6 6 10 1 0 7 2 Crankcase cover 1 Bolt M6 2 10 1 0 7 2 Ignition coil lead clamp Bolt M6 1 10 1 0 7 2 Crankcase cover 2 Bolt M6 2 10 1 0 7 2 Crankcase cover 3 Bol...

Page 409: ...h lead left 8 Clutch switch lead 9 Flasher light lead right 0 Indicator light box lead A Main switch lead B Speedometer cable C Speedometer lead D Flasher light lead left È Pass the starter cable to the front of the clutch cable and the throttle cable É Pass the throttle cable through the guide Ê Pass the brake hose through the guide CABLE ROUTING ...

Page 410: ... front brake switch lead and handlebar switch lead right between the handlebar crown and speedometer then through the head pipe guide left Ï Route the clutch switch lead between the handle crown and meter and through the head pipe guide left Ð Clamp the flasher light lead left speedometer lead main switch lead and handlebar switch lead left Ñ To headlight Ò Align the locating tape on the wireharne...

Page 411: ...e 4 Brake hose holder 5 Cable guide 6 Cable guide 7 Front brake switch lead 8 Handle switch lead right 9 Throttle cable 0 Starter cable A Clutch cable B Sidestand switch lead C Overflow hose D Horn lead E Cable holder F Rear brake switch lead CABLE ROUTING ...

Page 412: ...locking tie Ê Fasten the wireharness throttle cable clutch cable and starter cable with a plastic clamp Ë Fasten the wireharness with a plastic locking tie Ì Fasten the flasher light lead left and sidestand switch lead with a plastic locking tie Í Fasten the flasher light lead left with a plastic locking tie Î Fasten the sidestand switch lead with a metal clamp Ï Fasten the sidestand switch lead w...

Page 413: ...d with white paint with the clamp Ó Clamp the front brake hose Ô Fasten the front brake hose and speedometer cable with a plastic locking tie Õ Fasten the flywheel magneto lead pulser coil lead battery lead starter motor lead and rear brake switch leads with a plastic locking tie Ö Fasten the flywheel magneto lead pulser coil lead battery lead and starter motor lead with a metal clamp To engine CA...

Page 414: ...e 0 Canister for California only A Overflow hose for California only B CDI unit lead C Battery lead D Starter relay È Fasten the flasher light lead right and taillight lead with a plastic locking tie É Fasten the flywheel magneto lead pulser coil lead battery lead starter motor lead and wireharness with a plastic locking tie CABLE ROUTING ...

Page 415: ...ten the canister hose for California only and wireharness with a plastic clip Î Fasten the wireharness with a plastic clamp Ï Pass the canister hose through the guide for California only Ð Fasten the starter motor lead with a metal clamp Ñ Fasten the battery lead with a plastic clamp Ò Fasten the flasher light lead right and taillight lead with a locking tie CABLE ROUTING ...

Page 416: ...d switch lead È Fasten the flasher light lead right and taillight lead with a metal clamp É Fasten the taillight lead with a metal clamp Ê Fasten the flasher light lead left with a metal clamp Ë Fasten the relay lead flasher light lead left and sidestand switch lead with a plastic clip Ì Clamp the flywheel magneto lead CABLE ROUTING ...

Page 417: ...ng the throttle cable free play the engine idle speed should be adjusted 1 Check Throttle cable free play a Out of specification Adjust Throttle cable free play 3 5 mm 0 12 0 20 in a 2 Remove Side covers Seat Air scoops Fuel tank Refer to the SEAT FUEL TANK AND COVER section THROTTLE CABLE FREE PLAY ADJUSTMENT ...

Page 418: ...hten the locknut NOTE If the free play can not be adjusted here adjust it at the throttle grip side of the cable Final step Loosen the locknut 7 Turn the adjuster 8 in or out until the speci fied free play is obtained Tighten the locknut WARNING After adjusting the free play turn the han dlebar to right and left and make sure that the engine idling does not run faster Install the fuel tank seat an...

Page 419: ... boss 8 Thrust washer 9 Primary driven gear 0 Ball A Push rod 2 B Push lever C Primary drive gear D Oil pump gear cover E Oil pump driven gear F Oil pump G Gasket ENGINE ASSEMBLY AND ADJUSTMENT A FRICTION PLATE THICKNESS 2 90 3 10 mm 0 114 0 122 in LIMIT 2 8 mm 0 110 in B CLUTCH SPRING MINIMUM FREE LENGTH 35 3 mm 1 39 in C CLUTCH PLATE WARPAGE LIMIT 0 2 mm 0 008 in ...

Page 420: ...st 8 O ring 9 Cylinder head 0 Dowel pin A Grommet B Cylinder head gasket C Breather cover D O ring E O ring F Cylinder head side cover ENGINE ASSEMBLY AND ADJUSTMENT A SPARK PLUG TYPE DR8EA N G K X24ESR U DENSO B SPARK PLUG GAP 0 6 0 7 mm 0 02 0 03 in C CYLINDER HEAD WARPAGE LIMIT 0 03 mm 0 0012 in D TIGHTENING SEQUENCE ...

Page 421: ...ensioner 3 Gasket 4 Timing chain guide intake side 5 Camshaft 6 Pin 7 Cam sprocket 8 Timing chain 9 Timing chain guide exhaust side ENGINE ASSEMBLY AND ADJUSTMENT A SHAFT TO CAP CLEARANCE 0 020 0 061 mm 0 0008 0 0024 in B CAMSHAFT RUNOUT LIMIT 0 03 mm 0 0012 in ...

Page 422: ...5 Holder brake hose and meter cable 6 Brake hose 7 Brake caliper body 8 Rubber boot 9 Pad spring 0 Caliper bracket A Brake pads B Piston C Dust boot D Piston seal E Brake disc F Cable holder FRONT BRAKE A BRAKE FLUID TYPE DOT 4 B BRAKE PAD WEAR LIMIT 0 8 mm 0 03 in C BRAKE DISC WEAR LIMIT 3 0 mm 0 12 in ...

Page 423: ...es the switch positions and the top line indicates the colors of leads of connected with the terminals in the switch component indicates the terminals between which there is a continuity of electricity i e a closed circuit at the respective switch posi tions In this chart R and Br and B W and B are continuous with the ON switch position ON R Br B W B OFF LOCK CHECKING SWITCH FOR TERMINAL CONNECTIO...

Page 424: ... repair it NOTE If the coupler is clogged with mud or dust blow it off by compressed air 3 Use the connection chart to check the color combination for continuity a closed circuit In this example the continuity is as follows R and Br and B W and B are continu ous with the ON switch position Please note that there is no continuity an open circuit at all for the color combina tions other than the abo...

Page 425: ...e switch position ON 1 OFF 2 and LOCK 3 There must be continuity the tester indicat ing 0 at the ON switch position and there must be no continuity the tester indicating at OFF or LOCK There is something wrong between R and Br if there is no continuity at the ON posi tion or if there is some continuity either at the OFF or LOCK NOTE Check the switch for continuity several times 5 Next go on to che...

Page 426: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A ...

Page 427: ...1 CDI magneto 2 Neutral switch 3 Rectifier regulator 4 Battery lead 5 Battery 6 Battery lead 7 Starter relay 8 Starter motor 9 Main switch 0 Starting circuit cut off relay A Clutch switch B Start switch C Engine stop switch D Right handlebar switch E Diode F Sidestand switch G CDI unit H Neutral relay I Ignition coil J Meter light K Neutral indicator light L Turn signal indicator light M High beam...

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