Segment:
Dual-sport / Enduro motorcycle
Target Audience:
Riders seeking an accessible, lightweight, and reliable off-road capable motorcycle for trail riding, light commuting, and adventure touring.
Key Competitors:
Honda CRF250L (later models), Kawasaki KLX250S, Suzuki DR-Z250, older dual-sport models from various manufacturers.
Design Philosophy:
Simplicity, durability, off-road prowess with on-road usability.
Distinguishing Characteristics:
Lightweight chassis, long-travel suspension, user-friendly power delivery, reliability.
Countries Of Sale:
Global (Manual intended for models sold internationally, specific regional variations may exist not detailed in a general manual).
Estimated Page Count:
300-500 pages (Typical for a comprehensive service manual of this era and complexity, actual count varies by edition).
Type:
Service and Repair Workshop Manual
Language:
English (Primary language for downloaded manual is English, as implied by product description. Other languages may exist for regional markets).
Format:
Digital Download (PDF)
File Format:
PDF (Portable Document Format)
Print Quality:
High Resolution (Designed for clear viewing and printing of diagrams and text).
Binding Type:
Not Applicable (Digital download).
Paper Type:
Not Applicable (Digital download).
Searchability:
Searchable text within PDF for quick information retrieval.
Engine Mechanical:
Engine disassembly, inspection, assembly, top-end overhaul, bottom-end rebuild, valve clearance adjustment, piston and ring replacement, crankshaft and connecting rod inspection.
Fuel System:
Carburetor disassembly, cleaning, adjustment, jetting, fuel pump (if applicable, though typically gravity fed on this model), fuel tank, fuel lines, fuel filter replacement.
Ignition System:
CDI system, spark plug specifications, ignition timing, stator and pickup coil testing, ignition coil testing.
Cooling System:
Air-cooled engine (no liquid cooling system to detail).
Transmission Drivetrain:
Gearbox disassembly, inspection, assembly, clutch operation, clutch plate replacement, gear selection mechanism, output shaft and bearings, chain drive maintenance.
Suspension Front:
Telescopic front forks, fork oil change, seal replacement, spring inspection, damping characteristics, internal fork component inspection.
Suspension Rear:
Monoshock rear suspension, shock absorber inspection, linkage maintenance, bearing lubrication, spring pre-load adjustment.
Brakes Front:
Hydraulic disc brake system, caliper disassembly, piston seals, brake pad replacement, rotor inspection, master cylinder overhaul, brake fluid flush and bleed.
Brakes Rear:
Drum brake system, brake shoe inspection and replacement, brake cam lubrication, brake pedal adjustment.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), lighting system (headlight, taillight, signals), starter system (if electric start is present on certain models), fuse replacement, switchgear troubleshooting.
Frame Chassis:
Frame inspection for cracks and damage, steering head bearing maintenance, swingarm bearing lubrication, wheel bearing inspection and replacement, general chassis component tightening.
Bodywork Fittings:
Fender replacement, seat removal, fuel tank removal and installation, side cover attachment, handlebar and control lever adjustments.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain lubrication and adjustment, brake inspection, tire pressure checks, general lubrication points.
Troubleshooting:
Diagnostic flowcharts for common running issues, electrical system faults, starting problems, braking concerns.
Component Overhaul:
Detailed step-by-step instructions for rebuilding carburetors, fork assemblies, brake calipers, and transmission components.
Inspections:
Specific visual and functional checks for critical components like spokes, exhaust system, fasteners, and frame integrity.
Adjustments:
Valve clearance, carburetor idle and mixture, clutch lever free play, brake pedal free play, throttle cable free play, chain slack.
Diagnostic Capabilities:
Advanced diagnostic procedures for electrical systems, ignition timing verification, and fuel system performance analysis.
Rebuild Procedures:
Comprehensive rebuild instructions for major mechanical components including the engine, transmission, and suspension.
Torque Specifications:
Detailed torque values for all critical fasteners, critical for correct assembly and preventing damage.
Clearances Tolerances:
Precise specifications for valve clearances, piston-to-cylinder wall clearance, bearing tolerances, and other critical measurements.
Type:
4-stroke, SOHC, 2-valve, Air-cooled single-cylinder
Bore X Stroke:
Approx. 67.0 mm x 63.0 mm (Specific figures may vary slightly by year; manual will confirm).
Compression Ratio:
Approx. 9.5:1 (Check manual for exact figure).
Carburetion:
Mikuni VM Series carburetor (e.g., VM28 or similar, manual will specify exact model and jetting).
Horsepower:
Approx. 18-20 HP @ 7500 RPM (Estimated, manual will provide exact figures for specific years/regions).
Torque:
Approx. 1.9-2.0 kg-m (13.7-14.5 lb-ft) @ 6000 RPM (Estimated, manual will provide exact figures).
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approx. 11 Liters (2.9 US gallons) (Check manual for specific capacity).
Oil Change Interval:
Every 3,000-5,000 km (1,800-3,000 miles) or annually, whichever comes first. Consult manual for exact interval based on usage.
Oil Filter Replacement:
Recommended with every oil change or as per manual specifications.
Air Filter Cleaning:
Every 1,000-2,000 km (600-1,200 miles) or as needed, especially if riding in dusty conditions.
Valve Clearance Check:
Every 8,000-10,000 km (5,000-6,000 miles). Critical procedure detailed in the manual.
Chain Adjustment:
Check every 500 km (300 miles) and adjust as needed. Lubricate every 500 km (300 miles).
Engine Oil Type:
Yamaha Motorcycle Oil SAE 10W-40 or SAE 20W-40 (API SE, SF or SG type).
Engine Oil Capacity:
Approx. 1.6 Liters (1.7 US qt) without filter change; 1.8 Liters (1.9 US qt) with filter change. Refer to manual for exact capacity.
Fork Oil Type:
Yamaha Fork Oil G10 or equivalent SAE 10W fork oil.
Fork Oil Quantity:
Approx. 395 ml (0.42 US qt) per fork leg. Check manual for precise amount and level.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Carburetor Cleaning:
Can become clogged with debris over time, requiring cleaning and synchronization. Manual provides detailed procedure.
Fork Seal Leaks:
Front fork seals can wear and develop leaks, especially with hard off-road use. Manual covers replacement.
Chain And Sprockets:
Wear out over time due to chain tension and lubrication. Regular maintenance is key, replacement procedures are in the manual.
Exhaust Flange Gasket:
Can leak, requiring replacement. Manual guides through exhaust system removal and reinstallation.
Throttle Cable Adjustment:
Cable can stretch or seize, affecting throttle response. Manual details adjustment and replacement.
Yamaha Legacy:
Yamaha Motor Company, established in 1955, has a rich history in building high-performance motorcycles, from racing machines to versatile dual-sport models. Known for innovation and reliability.
Xt Serow Lineage:
The XT Serow line is known for its lightweight, agile, and go-anywhere capability. The XT225 specifically bridged the gap between smaller trail bikes and larger dual-sports, offering a user-friendly experience.
Manufacturing Locations:
Primarily manufactured in Japan (Asahi, Japan).
Key Updates During Coverage:
While the core design remained consistent, minor updates like carburetor jetting, graphics, and possibly minor electrical component revisions occurred throughout its production run from 1992 to 2007. The manual will detail these year-specific differences where significant.
