Category:
Dual-sport / Trail Motorcycle
Target Audience:
Enthusiasts seeking a capable, reliable, and relatively simple-to-maintain motorcycle for off-road trails and light street use.
Key Competitors:
Honda CRF230F, Kawasaki KLX250S, Suzuki DR-Z250.
Versatility:
Excellent balance between off-road capability and street-legal features.
Durability:
Known for its robust construction and reliability.
Simplicity:
Relatively uncomplicated mechanical design, making maintenance and repairs more accessible.
Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Type:
Service Repair Workshop Manual
Format:
Downloadable Digital File (Likely PDF)
Engine:
Complete engine overhaul, top-end rebuild (cylinder head, piston, rings), bottom-end rebuild (crankshaft, connecting rod, bearings), valve adjustment, timing chain inspection and replacement.
Fuel System:
Carburetor disassembly, cleaning, adjustment, and rebuilding; fuel tank maintenance; fuel petcock operation and service.
Ignition System:
Spark plug specifications and replacement, ignition coil testing, CDI unit troubleshooting, stator and rotor inspection.
Transmission And Drivetrain:
Clutch operation, adjustment, and replacement; transmission gear inspection and replacement; final drive chain adjustment and lubrication.
Suspension:
Front fork disassembly, oil change, seal replacement; rear shock absorber inspection and adjustment; linkage bearing maintenance.
Brakes:
Front and rear brake caliper maintenance, brake pad replacement, brake fluid flush and bleeding, brake hose inspection.
Electrical System:
Wiring diagrams, battery testing and maintenance, headlight and taillight bulb replacement, fuse box layout and troubleshooting, starter motor and charging system diagnostics.
Cooling System:
Air-cooled engine, therefore minimal cooling system coverage beyond general engine inspection.
Chassis And Bodywork:
Frame inspection, handlebar and control lever adjustment, seat removal and installation, fender and fairing maintenance.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug inspection/replacement, chain lubrication and adjustment, brake adjustment, tire pressure checks.
Troubleshooting:
Diagnostic procedures for common starting issues, engine performance problems, electrical faults, and transmission issues.
Repair And Rebuild:
Detailed step-by-step instructions for engine disassembly, component replacement, and reassembly; suspension overhauls; brake system repairs.
Torque Specifications:
Critical torque values for all fasteners and internal engine components for proper assembly and longevity.
Wiring Diagrams:
Comprehensive electrical system schematics for accurate diagnosis and repair.
Depth:
Comprehensive, covering everything from basic rider maintenance to full engine and chassis rebuilds.
File Type:
PDF (Portable Document Format) - Standard for downloadable manuals.
Searchable Text:
Likely features searchable text for quick access to information.
Printability:
Designed to be printable for users who prefer a physical copy.
Binding:
Not applicable (downloadable digital file).
Paper Quality:
Not applicable (downloadable digital file).
Engine Type:
4-stroke, SOHC, 2-valve, Air-cooled
Displacement:
223 cc (13.6 cubic inches)
Bore X Stroke:
67.0 mm x 63.5 mm
Horsepower:
Approx. 16-18 HP (Varies slightly by year and region)
Torque:
Approx. 14-16 Nm (Varies slightly by year and region)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Fuel Tank Capacity:
11.0 L (2.9 US gal)
Safety Features:
As a motorcycle, safety features are primarily rider-controlled and mechanical. Focus is on reliable braking and stable handling.
Lighting:
Headlight, taillight, brake light, turn signals for visibility.
Frame Construction:
Steel frame provides structural integrity.
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
Every 3,000 km (1,800 miles) or 6 months (if applicable, some models may have a screen).
Air Filter Cleaning:
Every 1,000 km (600 miles) or as needed in dusty conditions.
Valve Clearance Check:
Every 6,000 km (3,600 miles) or 12 months.
Spark Plug Replacement:
Every 10,000 km (6,000 miles).
Chain Lubrication:
Every 500 km (300 miles) and after washing or riding in rain.
Engine Oil:
Yamalube 4 (or equivalent) SAE 20W-40 API SE, SF or SG.
Engine Oil Capacity:
1.70 L (1.80 US qt) without filter change; 1.90 L (2.01 US qt) with filter change.
Brake Fluid:
DOT 4 Hydraulic Brake Fluid.
Carburetor Icing:
Can occur in very cold, humid conditions due to venturi effect; manual will likely detail proper vent routing or carb cleaner.
Clutch Wear:
Normal wear item, especially with aggressive riding; manual covers replacement procedures.
Fork Seal Leaks:
Common on older motorcycles, manual provides fork seal replacement instructions.
Heritage:
Yamaha has a long and storied history in motorcycle manufacturing, known for innovation and performance across various segments.
Xt Series Legacy:
The XT series has a lineage of reliable and capable dual-sport motorcycles, with the XT225 being a popular choice for its accessibility and ease of use.
Production Period:
The XT225 was produced from the early 1990s through the mid-2000s, with this manual covering a significant portion of its lifespan.
