Yamaha XT225 XT225-C 1986-2007 Service Repair Factory Manual

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类型: Motorcycle

斯库: 57989

标签: 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Misc Motorcycle Motorcycles XT225 XT225-C Yamaha

产品多属性

Description

The Yamaha XT225 and XT225-C are versatile dual-sport motorcycles produced from 1986 through 2007. Renowned for their reliability and user-friendly design, these models are powered by a simple, air-cooled, 223cc four-stroke engine, making them ideal for a variety of riding conditions, from trail exploration to everyday commuting. The XT225 features capable front telescopic forks and a rear monoshock suspension, providing good ground clearance and off-road compliance, further enhanced by their lightweight construction and durable steel diamond frame. These motorcycles have earned a strong reputation for their value, durability, and low maintenance requirements within the dual-sport segment. This comprehensive service repair factory manual provides detailed information essential for the maintenance, troubleshooting, and repair of the Yamaha XT225 and XT225-C models from 1986 to 2007. It covers all major systems, including the engine, drivetrain, chassis, and electrical components, with in-depth procedures for scheduled maintenance, component replacement, and diagnostic troubleshooting. The manual includes critical technical specifications, torque values, fluid capacities, and detailed wiring diagrams, empowering owners and technicians to effectively maintain and repair the motorcycle, ensuring its longevity and optimal performance.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XT225 / XT225-C

Product Type:

Service Repair Factory Manual

Product Format:

PDF Download

Codes

Engine Code General:

4JG, 4PT (Common codes for this era, specific VIN decoding recommended)

Chassis Code General:

XT225, XT225-C

👋 Introduction

Market Position

Vehicle Segment:

Lightweight dual-sport motorcycle, popular for trail riding, commuting, and light adventure touring.

Target Audience:

Beginner to intermediate riders, those seeking an affordable and reliable off-road capable machine.

Competitive Analysis

Key Competitors:

Honda CRF230F (later years), Kawasaki KLR250, Suzuki DR200SE, older KTM 200/250 models.

Key Features

Engine Type:

Simple, air-cooled, 4-stroke, single-cylinder engine known for reliability and ease of maintenance.

Suspension Type:

Capable front telescopic forks and a rear monoshock suspension providing good ground clearance and off-road compliance.

Utility:

Versatile for both on-road and off-road use, making it a practical choice for varied riding conditions.

Manual Value Proposition

Manual Benefit:

Empowers owners to perform routine maintenance, diagnose issues, and carry out repairs themselves, saving on dealership costs and ensuring proper upkeep.

📋 Manual Details

Coverage Areas

Model Years Covered:

1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

Vehicle Type:

Dual-sport Motorcycle

Page Count

Estimated Page Count:

400-600 (Typical for comprehensive factory service manuals of this era, exact count may vary)

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Engine Systems:

Top end (cylinder head, valves, camshaft), Bottom end (crankcase, crankshaft, con-rod), Lubrication system (oil pump, oil passages), Cooling system (air-cooled design), Fuel system (carburetor, fuel lines, fuel tank), Ignition system (CDI, spark plug, wiring), Exhaust system (muffler, header pipe, catalytic converter if applicable)

Drivetrain Systems:

Clutch (operation, adjustment, replacement), Transmission (gearbox internal components, shifting mechanism), Drive chain and sprockets (maintenance, adjustment, replacement), Final drive (if applicable)

Chassis Systems:

Frame and sub-frame, Front suspension (telescopic forks, seals, oil change), Rear suspension (monoshock, swingarm, linkage, adjustment), Steering system (headstock bearings, steering stem), Braking system (front and rear brakes, master cylinders, calipers, pads, lines, fluid), Wheel assembly (hubs, spokes, rims, bearings), Electrical system (wiring diagrams, lighting, battery, charging system, starter motor, switches)

Bodywork And Accessories:

Body panels (fenders, side covers, fuel tank), Seat, Handlebars and controls, Footpegs, Luggage rack (if equipped)

Procedures Included

Maintenance Procedures:

Scheduled maintenance (oil changes, filter replacements, chain lubrication/adjustment), Tire pressure checks and adjustments, Brake adjustments, Clutch adjustments, Spark plug replacement, Air filter cleaning/replacement, Valve clearance checks and adjustments, Carburetor cleaning and synchronization, Suspension adjustments and maintenance, Battery maintenance, General inspection and cleaning

Repair Procedures:

Engine top-end rebuild (cylinder, piston, rings), Engine bottom-end overhaul (crankshaft, bearings), Carburetor overhaul and jetting, Transmission disassembly and reassembly, Clutch replacement, Fork seal replacement and fork oil service, Shock absorber rebuilding/replacement, Brake caliper overhaul, Wheel bearing replacement, Electrical component troubleshooting and replacement, Wiring harness repair

Troubleshooting Diagnostics:

Symptoms and causes of common problems, Diagnostic charts, Electrical system troubleshooting (using wiring diagrams), Engine performance troubleshooting, Fuel system issues, Clutch and transmission problems, Suspension and brake issues

Technical Depth

Diagnostic Tools:

Specification of required tools, torque wrenches, feeler gauges, multimeters, etc.

Specifications And Tolerances:

Detailed torque values, clearances, fluid capacities, and material specifications for all components.

Wiring Diagrams:

Comprehensive and detailed electrical wiring diagrams for all circuits and components.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, searchable text, printable pages.

Print Quality

Print Suitability:

Designed for clear printing of all diagrams, illustrations, and text.

Binding Type

Binding Method Original:

Likely a bound manual with a sturdy cover for workshop use.

Paper Type

Paper Type Original:

Durable paper stock suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 4-stroke, SOHC, 2-valve, single-cylinder

Displacement:

223cc

Bore X Stroke:

67.0 mm x 63.7 mm

Compression Ratio:

9.5:1 (Approximate, may vary slightly by year)

Performance

Horsepower:

Approximately 16-18 HP @ 7500 RPM (Varies by tuning and year)

Torque:

Approximately 17-19 Nm @ 6000 RPM (Varies by tuning and year)

Fuel System

Fuel Delivery:

Carburetor

Carburetor Model:

Mikuni VM34 (or similar 34mm Mikuni variant)

Fuel Type:

Unleaded Gasoline (Octane rating specified in manual)

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition)

🔧 Transmission

Standard

Transmission Type:

Constant-mesh 5-speed sequential

Optional

Transmission Options:

N/A (Standard 5-speed manual)

Features

Clutch Type:

Wet, multiple disc

Final Drive:

Chain drive

Gear Ratios:

Detailed in manual, typically: 1st: 2.833, 2nd: 1.750, 3rd: 1.333, 4th: 1.090, 5th: 0.916

📐 Dimensions

Exterior

Overall Length:

Approximately 2130 mm (83.9 in)

Overall Width:

Approximately 800 mm (31.5 in)

Overall Height:

Approximately 1155 mm (45.5 in)

Wheelbase:

Approximately 1370 mm (53.9 in)

Ground Clearance:

Approximately 265 mm (10.4 in)

Seat Height:

Approximately 845 mm (33.3 in)

Weights

Dry Weight:

Approximately 122 kg (269 lbs)

Wet Weight:

Approximately 128 kg (282 lbs)

Cargo

Fuel Tank Capacity:

Approximately 11 Liters (2.9 US gal)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles typically do not undergo standardized crash testing like cars.)

Active Features

Braking System:

Front: Disc brake, Rear: Drum brake (Later models may have rear disc)

Lighting:

Halogen headlight, LED tail light, incandescent turn signals.

Passive Features

Frame Construction:

Steel diamond frame for rigidity and durability.

Tires:

Dual-purpose tires suitable for both on-road and off-road use.

💡 Technology Features

Infotainment

Instrument Cluster:

Basic analog speedometer, odometer, and indicator lights (turn signals, high beam, neutral).

Driver Assistance

N/A (Anti-lock Braking System was not a standard feature on this model).

Connectivity

Bluetooth Usb:

N/A (This motorcycle predates common integration of Bluetooth and USB ports).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first (refer to manual for exact interval).

Oil Filter Replacement:

At every oil change, or as specified in the manual.

Chain Lubrication Adjustment:

Every 500-1,000 km (300-600 miles), or after riding in wet/dusty conditions.

Valve Clearance Check:

Every 10,000-15,000 km (6,000-9,000 miles) (critical maintenance item).

Fluid Specifications

Engine Oil Type:

Yamaha recommends Yamalube or equivalent SAE 10W-40 API SG or higher motorcycle oil. Check manual for exact viscosity and API rating.

Engine Oil Capacity:

Approx. 1.7 L (1.8 US qt) with filter change, 1.5 L (1.6 US qt) without filter change. (Verify in manual).

Brake Fluid Type:

DOT 3 or DOT 4 glycol-based brake fluid. (Verify in manual).

Fork Oil Type Capacity:

Yamaha Fork Oil (or equivalent) SAE 10W. Capacity: 497 cc (16.8 US oz) per fork leg. (Verify in manual).

Known Issues

Carburetor Issues:

Carburetors can be prone to clogging from fuel varnish if left sitting for long periods, requiring thorough cleaning and potentially re-jetting for optimal performance.

Electrical Connections:

As with any motorcycle of this age, electrical connections can corrode, leading to intermittent issues. Ensuring clean and secure connections is important.

Suspension Wear:

Fork seals and rear shock bushings can wear over time, leading to leaks and a loss of damping performance. Regular inspection is advised.

Cam Chain Tensioner:

Some models may develop noise from a worn cam chain tensioner. The manual will detail inspection and replacement procedures.

📚 Vehicle History

Brand Heritage

Yamaha Motors Corporation:

Founded in 1887, Yamaha has a long and distinguished history in musical instruments and, since the 1950s, in motorcycle manufacturing, known for innovation and performance.

Model Evolution

Xt Series Legacy:

The XT designation has a storied history for Yamaha, representing reliable and capable dual-sport motorcycles. The XT225 builds upon this legacy.

Xt225 Development:

Introduced as a successor to earlier XT models, the XT225 was designed to offer a more user-friendly, lighter, and more accessible dual-sport experience.

Production

Production Period:

1986-2007 (with minor updates over the years)

Manufacturing Location:

Primarily Japan, with some models potentially assembled in other Yamaha facilities globally.

Model Variants:

XT225 (standard), XT225-C (often referring to a specific market or version, details in manual).

🏆 Awards & Recognition

Recognitions

Market Reputation:

Widely recognized for its reliability, ease of use, and value for money in the dual-sport segment.

Ratings

Durability Ranking:

Consistently rated highly by riders for its long-term durability and low maintenance costs.

Certifications

Emissions Standards:

Meets relevant emissions standards for its production era. Specifics will be in the manual.