🏷️ Basic Information

Make:

Yamaha

Model:

XT 225

Product Name:

Yamaha XT 225 Service Repair Workshop Manual 1991-1999

Model Years Covered:

1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999

Chassis Codes:

Generally designated as 'XT225', specific internal Yamaha codes may vary by production year and region but often begin with '4JG' or similar sequences for dual-purpose models.

Engine Codes:

Typically a 223cc single-cylinder designation, specific engine internal codes are usually detailed within the manual.

👋 Introduction

Vehicle Segment:

Lightweight dual-sport motorcycle, popular for trail riding, off-road adventures, and general utility due to its balance of capability and ease of use.

Target Audience:

Beginner to intermediate riders, recreational users, those seeking a reliable and versatile off-road/on-road capable machine.

Competitors:

Competed with models like the Honda CRF230F, Kawasaki KLX250, Suzuki DR-Z250, and other similar displacement dual-sport/enduro bikes of the era.

Versatility:

Designed for both on-road and off-road use, making it a versatile choice for various riding environments.

Simplicity:

Known for its relatively simple mechanical design, making it user-friendly for maintenance and repairs.

Reliability:

Yamaha's reputation for building durable and reliable motorcycles is reflected in the XT 225.

📋 Manual Details

Coverage Scope:

All models and all repairs A-Z for the specified model years.

Technical Specificity:

Vehicle/model specific, not generic repair information.

Estimated Page Count:

Typically 300-500+ pages for a comprehensive service manual of this era and coverage scope. Exact count not provided, but reflects full dealer-level documentation.

Type:

Service Repair Workshop Manual

Intended User:

Technicians at local dealerships, DIY enthusiasts.

Language:

English (presumed based on product description and typical market distribution)

Format:

Digital (PDF is common for such products, though physical copies may also exist). Searchable text is standard for quality digital manuals.

📖 Manual Coverage

Engine:

Engine construction, disassembly, inspection, assembly, timing, valve adjustment, lubrication, cooling system.

Fuel System:

Carburetor(s) (including disassembly, cleaning, adjustment, synchronization), fuel pump, fuel tank, fuel lines.

Ignition System:

CDI unit, ignition coil, spark plug, wiring, timing inspection.

Transmission:

Clutch operation, transmission disassembly, inspection, assembly, gear shifting mechanisms, lubrication.

Chassis Suspension:

Front fork (dismount, assembly, seal replacement, oil levels), rear shock absorber, swingarm, bearings.

Brakes:

Front and rear brake systems (disc or drum depending on sub-model), hydraulic components, brake pad/shoe replacement, bleeding procedures.

Electrical System:

Wiring diagrams, battery, lighting (headlight, taillight, signals), starter motor, charging system (alternator/stator, regulator/rectifier), fuses, switches, instrumentation.

Frame Bodywork:

Frame inspection, removal and installation of body panels, seat, fuel tank, fenders, handlebars.

Wheels Tires:

Wheel removal and installation, spoke tensioning, tire mounting and balancing, bearing inspection.

Exhaust System:

Exhaust pipe and muffler inspection, removal, installation.

Maintenance:

Scheduled maintenance, oil changes, filter replacement, chain adjustment, lubrication points, bolt torque specifications.

Troubleshooting:

Diagnostic procedures for common and uncommon issues across all systems, symptom-based troubleshooting guides.

Repair:

Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly.

Rebuilds:

Detailed procedures for engine and transmission overhauls and component rebuilds.

Adjustments:

Carburetor adjustments, valve clearance adjustments, clutch and throttle cable adjustments, brake adjustments.

Diagnostic Tests:

Tests for electrical components, ignition system performance, fuel system delivery, and mechanical component integrity.

Depth:

Comprehensive, covering basic maintenance to full engine and transmission rebuilds, including electrical diagnostics and frame repair.

Diagnostic Level:

Advanced diagnostics and troubleshooting, suitable for identifying root causes of complex problems.

Diagrams Illustrations:

Includes detailed diagrams, exploded views, and illustrations for clear understanding of procedures and component identification.

📊 Manual Specifications

Digital Format:

Likely PDF, optimized for digital viewing and printing. May include bookmarking and search functionality.

Print Readability:

High resolution, ensuring clarity of text and diagrams when printed. Professional typesetting.

Physical Binding:

If a physical copy: Spiral-bound or perfect-bound for durability and ease of use in a workshop environment. If digital, no physical binding.

Physical Paper Quality:

If a physical copy: Durable, often glossy or semi-gloss paper to withstand workshop conditions. If digital, not applicable.

⚙️ Engine Specifications

Engine Type:

4-stroke, SOHC, air-cooled, single-cylinder

Displacement:

223 cc (223cc)

Bore X Stroke:

Typically around 67.0 mm x 64.8 mm (check manual for exact specifications)

Compression Ratio:

Around 9.5:1 (check manual for exact specifications)

Horsepower:

Approximately 16-20 HP (at the crankshaft, varies by year and tuning)

Torque:

Approximately 13-15 lb-ft (at the crankshaft, varies by year and tuning)

Carburetor Type:

Mikuni constant-velocity (CV) carburetor, typically a 34mm size (e.g., VM34SS or similar). Specific model varies by year and market.

Fuel Type:

Unleaded gasoline, typically 87 octane (or equivalent).

Fuel Capacity:

Approximately 2.8 - 3.0 gallons (10.6 - 11.4 liters)

🔧 Transmission

Type:

5-speed manual transmission

Automatic Option:

No automatic transmission option was typically offered for the XT 225.

Clutch Type:

Wet, multi-plate clutch

Final Drive:

Chain drive

📐 Dimensions

Overall Length:

Approximately 85.2 inches (2165 mm)

Overall Width:

Approximately 33.1 inches (840 mm)

Overall Height:

Approximately 45.5 inches (1155 mm)

Wheelbase:

Approximately 54.9 inches (1395 mm)

Ground Clearance:

Approximately 10.2 inches (260 mm)

Seat Height:

Approximately 31.9 inches (810 mm)

Dry Weight:

Approximately 254 lbs (115 kg)

Wet Weight:

Approximately 278 lbs (126 kg) (with all fluids)

🛡️ Safety Features

Crash Safety Ratings:

Motorcycles are not typically subject to the same formalized crash safety ratings (like NHTSA or Euro NCAP) as automobiles. Safety is primarily rider-dependent and based on vehicle design and handling characteristics.

Braking System:

Front disc brake, rear drum brake (or front/rear disc on later/specific models). ABS was not common on this model during this period.

Lighting:

Headlight, taillight, brake light, turn signals for visibility.

Frame Construction:

Robust steel frame designed for durability and stability in varied terrain.

Ergonomics:

Upright riding position for rider comfort and control, essential for off-road riding.

💡 Technology Features

Infotainment System:

No integrated infotainment system. Relies on basic analog instrumentation.

ABS:

Anti-lock Braking System (ABS) was not a standard or common option on the XT 225 during this period.

Connectivity Features:

No electronic connectivity features such as Bluetooth or smartphone integration.

Dashboard Features:

Analog speedometer, odometer, and indicator lights (e.g., turn signal, neutral, high beam). Tachometer may be present on some variants.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000 miles (5,000 km) or 6 months. Check manual for specific recommendation.

Valve Clearance Check:

Recommended every 6,000 miles (10,000 km) or annually. Precise interval detailed in manual.

Chain Lubrication Adjustment:

Lubricate chain every 500-1000 miles (800-1600 km) and adjust tension as needed, typically with some slack specified.

Engine Oil Type:

Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher. Consult manual for exact specification and viscosity range based on climate.

Engine Oil Capacity:

Approximately 1.7 - 1.8 Liters (with oil filter change). Consult manual for precise capacity.

Fork Oil Type:

Yamaha Fork Oil (or equivalent) SAE 10W or 20W. Consult manual for specific weight and volume.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (for disc brake models).

Carburetor Performance:

Carburetors can be prone to gumming up if fuel sits for extended periods, requiring cleaning and adjustment. Jetting may need modification for altitude or aftermarket exhaust.

Electrical Connections:

Corrosion or loose connections in the wiring harness can lead to intermittent electrical issues, particularly in older models exposed to moisture.

Suspension Wear:

Fork seals and rear shock bushings can wear over time, leading to leaks and poor damping performance, requiring replacement.

Cam Chain Tensioner:

Some models may experience a noisy cam chain tensioner as it ages, which can be adjusted or replaced.

📚 Vehicle History

Yamaha Legacy:

Yamaha Motor Corporation is a Japanese manufacturer renowned for its extensive history in motorcycles, musical instruments, and power equipment, known for innovation and quality.

Xt Series Origin:

The XT designation has a long history within Yamaha, dating back to the early dual-purpose motorcycles like the XT500, establishing Yamaha's strong presence in the off-road and dual-sport segments.

Xt225 Development:

The XT 225 was developed as a more accessible and user-friendly dual-sport machine, building on the legacy of its larger displacement siblings, focusing on manageable power and weight.

Manufacturing Location:

Primarily manufactured in Japan and other Yamaha global facilities.

Production Run:

The XT 225 had a significant production run, with the 1991-1999 models being a well-established generation before updates and potential successor models.

🏆 Awards & Recognition

Industry Awards:

Specific industry awards for the XT 225 model are not widely documented as it was a pragmatic utility bike rather than a performance or luxury showcase. Its recognition comes from its widespread adoption and reliability.

Consumer Reviews:

Consistently received positive consumer reviews for its reliability, ease of use, off-road capability, and low running costs.

Emissions Compliance:

Compliant with emissions standards relevant to its production years in major markets (e.g., EPA in the US).