Product Name:
Yamaha XT225 1992-2007 Factory Service Repair Manual
Model Years Covered:
1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Engine Code:
4CS1 (varies slightly by year and market, but core engine architecture remains consistent)
Vehicle Segment:
Dual-sport, trail, light adventure motorcycle.
Target Audience:
Riders seeking an accessible, reliable, and versatile motorcycle for off-road exploration and light street use.
Competitors:
Honda CRF250L (later model), Kawasaki KLX250, Suzuki DR-Z400S (larger displacement but similar category).
Versatility:
Engineered for both on-road and off-road riding, offering a balanced package for various terrains.
Reliability:
Known for its robust engine and durable components, making it a dependable choice.
Accessibility:
User-friendly ergonomics and manageable power delivery make it suitable for novice riders and commuters.
Engine:
Complete overhaul, disassembly, inspection, assembly, tuning, and troubleshooting of the 223cc single-cylinder, SOHC, air-cooled engine.
Fuel System:
Carburetor (Mikuni BS34) inspection, cleaning, adjustment, rebuilding, and troubleshooting.
Ignition System:
CDI ignition system, spark plug specifications, coil testing, and troubleshooting.
Transmission:
6-speed transmission, clutch operation, disassembly, inspection, and reassembly.
Drivetrain:
Chain drive system inspection, adjustment, lubrication, and replacement. Rear swingarm and linkage service.
Suspension:
Front telescopic fork (including oil type and level, seal replacement, damper rod inspection) and rear monoshock absorber (pre-load adjustment, rebuild procedures if applicable).
Brakes:
Front disc brake system (caliper inspection, pad replacement, fluid flush, master cylinder service) and rear drum brake system (adjustment, shoe inspection, and replacement).
Electrical System:
Wiring diagrams, lighting system, battery maintenance, charging system (stator, regulator/rectifier), starter motor, and troubleshooting.
Cooling System:
Air-cooled system description and maintenance.
Frame And Bodywork:
Frame inspection, handlebar replacement, seat removal, fuel tank and fender removal/installation, and general body panel maintenance.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug inspection/replacement, air filter cleaning/replacement, brake adjustments, and lubrication points.
Troubleshooting Guides:
Diagnostic charts and procedures for common performance issues, starting problems, electrical faults, and braking system concerns.
Engine Rebuild:
Detailed steps for engine disassembly, piston and cylinder inspection, valve clearance adjustment, crankshaft and connecting rod checks, and complete engine reassembly.
Carburetor Rebuild:
Step-by-step instructions for dismantling, cleaning, inspecting, and reassembling the Mikuni BS34 carburetor, including jetting information.
Suspension Rebuild:
Front fork seal replacement, fork oil change and level adjustment, and rear shock absorber servicing.
Electrical Component Testing:
Procedures for testing the stator, regulator/rectifier, ignition coil, starter motor, and battery.
Wheel And Tire Service:
Tire pressure checks, wheel bearing inspection, and spoke tension adjustment (if applicable to spoke wheels).
Diagnostic Capabilities:
Comprehensive diagnostic information for identifying and resolving mechanical, electrical, and fuel system issues.
Repair Procedures:
Detailed, step-by-step repair instructions for virtually all components and systems on the motorcycle.
Overhaul Manuals:
Provides the necessary detail for complete engine and transmission overhauls.
Wiring Diagrams:
Clear and detailed electrical wiring diagrams for easy diagnosis and repair of electrical systems.
Oil Change Interval:
Every 3,000 km (1,864 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 1,000 km (621 miles) or 6 months.
Valve Clearance Check:
Every 6,000 km (3,728 miles) or 12 months.
Spark Plug Replacement:
Every 6,000 km (3,728 miles) or 12 months.
Engine Oil Type:
Yamalube 4 (or equivalent SAE 20W-40 API SE, SF, SG, SH or SJ)
Engine Oil Capacity:
1.50 L (1.59 US qt) without filter change; 1.70 L (1.80 US qt) with filter change.
Fork Oil Type:
Yamaha Suspension Oil 10W (or equivalent)
Fork Oil Level:
122 mm (4.80 in) from top of inner tube with spring removed and fork compressed.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Carburetor Gumming:
Carburetor jets can become clogged if the motorcycle sits for extended periods without fuel stabilizer, leading to starting issues or poor running. Regular use or proper storage is recommended.
Rear Shock Wear:
Over time, the rear shock absorber may lose damping ability. Rebuilding or replacement may be necessary for optimal performance.
Stator Reliability:
While generally reliable, some units may experience stator failure over a long service life, impacting charging system performance.
Chain And Sprockets:
Regular cleaning, lubrication, and adjustment are crucial for extending the life of the chain and sprockets due to its dual-sport nature.
Yamaha Offroad Legacy:
Yamaha has a long and storied history in off-road and dual-sport motorcycles, with models like the XT500 and TT series setting benchmarks.
Xt Lineage:
The XT225 is an evolution of Yamaha's popular XT dual-sport line, offering a smaller displacement option that remained largely consistent throughout its production run.
Manufacturing Location:
Primarily Japan, though some assembly may have occurred in other regions depending on the market.
Major Updates:
While the core design remained consistent, minor updates related to emissions, graphics, and some component suppliers may have occurred across the years.
