Yamaha XT225-C Service Manual
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Yamaha XT225-C Service Manual

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  • Page 391 XT225N XT225NC SUPPLEMENTARY SERVICEMANUAL LIT-11616-14-42 4BE-28197-22...
  • Page 392 XT225D/XT225DC SERVICE MANUAL: LIT-11616-07-99 (4BE-28197-20) XT225H/XT225HC SUPPLEMENTARY SERVICE MANUAL: LIT-11616-10-05 (4BE-28197-21) XT225N(C) SUPPLEMENTARY SERVICE MANUAL © 2000 by Yamaha Motor Corporation, U.S.A. First edition, October 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.
  • Page 393 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 394 HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “SYMBOLS”) 1st title 1: This is a chapter with its symbol on the upper right of each page. 2nd title 2: This title appears on the upper of each page on the left of the chapter sym- bol.
  • Page 395 EAS00008 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Chassis 7 Electrical system CHAS CARB 8 Troubleshooting...
  • Page 396 CONTENTS SPECIFICATIONS .................... 1 GENERAL SPECIFICATIONS ..............1 ENGINE SPECIFICATIONS..............2 CHASSIS SPECIFICATIONS..............7 ELECTRICAL SPECIFICATIONS ............10 TIGHTENING TORQUES................ 12 ENGINE TIGHTENING TORQUES............. 12 CHASSIS TIGHTENING TORQUES........... 12 CABLE ROUTING ................... 13 PERIODIC INSPECTION AND ADJUSTMENT..........21 ENGINE....................21 THROTTLE CABLE FREE PLAY ADJUSTMENT.......
  • Page 397 SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 4BEV ---- 4BEW (For California) ---- Dimensions Overall length 2,070 mm (81.5 in) ---- Overall width 805 mm (31.7 in) ---- Overall height 1,160 mm (45.7 in) ---- Seat height 810 mm (31.9 in) ---- Wheelbase...
  • Page 398 SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Air-cooled, 4-stroke, SOHC ---- Displacement 223 cm ---- Cylinder arrangement Forward inclined single cylinder ---- Bore × stroke 70 × 58 mm (2.76 × 2.28 in) ---- Compression ratio 9.5 : 1 ---- Engine idling speed...
  • Page 399 SPEC ENGINE SPECIFICATIONS Item Standard Limit Max. camshaft runout ---- 0.03 mm (0.0012 in) Timing chain Model/number of links Borg Warner 92RH/104 ---- Tensioning system Automatic ---- Valve springs Inner springs Free length Intake 36.17 mm (1.42 in) 34.35 mm (1.35 in) Exhaust 36.17 mm (1.42 in)
  • Page 400 SPEC ENGINE SPECIFICATIONS Item Standard Limit Outer springs Free length Intake 36.63 mm (1.44 in) 34.80 mm (1.37 in) Exhaust 36.63 mm (1.44 in) 34.80 mm (1.37 in) Installed length (valve closed) Intake 32.0 mm (1.26 in) ---- Exhaust 32.0 mm (1.26 in) ---- Compressed spring force (installed) Intake...
  • Page 401 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston pin bore (in the piston) Diameter 16.002 ~ 16.013 mm (0.6300 ~ 0.6304 in) 16.043 mm (0.6316 in) Offset 0.5 mm (0.0197 in) ---- Offset direction Intake side ---- Piston pin Outside diameter 15.991 ~ 16.000 mm (0.6296 ~ 0.6299 in) 15.971 mm (0.6288 in) Piston-pin-to-piston-pin-bore clear-...
  • Page 402 SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch plates Thickness 1.5 ~ 1.7 mm (0.06 ~ 0.07 in) ---- Plate quantity ---- Max. warpage ---- 0.2 mm (0.008 in) Clutch springs Free length 37.3 mm (1.47 in) ---- Spring quantity ---- Minimum length ---- 35.3 mm...
  • Page 403 SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Front tire Tire type With tube ---- Size 2.75-21-45P ---- Model (manufacturer) TW27 (BRIDGESTONE) ---- C-6006 (CHENG SHIN) ---- Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 125 kPa (1.25 kg/cm , 18 psi) ---- 90 ~ 183 kg (198 ~ 404 lb)
  • Page 404 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear brake Brake type Leading, trailing - drum brake ---- Operation Right-foot operation ---- Brake pedal position 10 mm (0.39 in) ---- Brake drum Inside diameter 110 mm (4.33 in) 111 mm (4.37 in) Lining thickness 4 mm (0.16 in) 1.5 mm...
  • Page 405 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Drive chain Model (manufacturer) 428V2 (DAIDO) ---- Link quantity ---- Drive chain slack 35 ~ 45 mm (1.38 ~ 1.77in) ---- - 9 -...
  • Page 406 SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit Ignition coil Model (manufacturer) 2JN (YAMAHA) ---- Minimum ignition spark gap 6 mm (0.24 in) ---- 0.18 ~ 0.28 Ω Primary coil resistance ---- Secondary coil resistance 6.32 ~ 9.48 kΩ ----...
  • Page 407 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Starter relay Model (manufacturer) MS5F-651 (JIDECO) ---- Amperage 180 A ---- 3.52 ~ 5.28 Ω Coil resistance ---- Horn Horn type Plane ---- Model (manufacturer) × quantity GF-12 (NIKKO) × 1 ---- Max. amperage 1.5 A ---- Performance...
  • Page 408 SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size m·kgf ft·lb Breather assembly Screw Tensioner Bolt 0.75 Air filter case Bolt Carburetor joint clamp Screw Air filter case (front) Screw Air filter case (rear) Bolt...
  • Page 409 SPEC CABLE ROUTING CABLE ROUTING 1 Clutch cable 0 Indicator light box lead 2 Brake hose A Main switch lead 3 Throttle cable B Speedometer cable 4 Band C Speedometer lead 5 Front brake switch lead D Flasher light lead (left) 6 Handlebar switch lead (right) È...
  • Page 410 SPEC CABLE ROUTING Ë Align the end of the brake master cylinder holder Ï Route the clutch switch lead between the handle with the punch mark in the handlebar. crown and meter and through the head pipe Ì Align the slit of clutch lever holder with the punch guide (left).
  • Page 411 SPEC CABLE ROUTING 1 Speedometer cable A Clutch cable 2 Cable holder B Sidestand switch lead 3 Brake hose C Overflow hose 4 Brake hose holder D Horn lead 5 Cable guide E Cable holder 6 Cable guide F Rear brake switch lead 7 Front brake switch lead 8 Handle switch lead (right) 9 Throttle cable...
  • Page 412 SPEC CABLE ROUTING È Pass the handlebar switch lead (right), front brake Ì Fasten the flasher light lead (left) and sidestand switch lead, clutch switch lead, starter cable, switch lead with a plastic locking tie. Í Fasten the flasher light lead (left) with a plastic throttle cable and clutch cable through the guide.
  • Page 413 SPEC CABLE ROUTING Ñ Fasten the handlebar switch lead, clutch switch Õ Fasten the flywheel magneto lead, pulser coil lead, front brake switch lead, starter cable, lead, battery lead (–), starter motor lead and rear clutch cable and throttle cable with a plastic lock- brake switch leads with a plastic locking tie.
  • Page 414 SPEC CABLE ROUTING 1 Starter motor lead A Overflow hose (for California only) 2 Battery lead (–) B CDI unit lead 3 Battery C Battery lead (+) 4 Ground lead D Starter relay 5 Pulser lead È Fasten the flasher light lead (right) and taillight 6 Flywheel magneto lead lead with a plastic locking tie.
  • Page 415 SPEC CABLE ROUTING Ê Align the white tape with the arrow mark. Ð Fasten the starter motor lead with a metal Ë Fasten the clutch cable with a plastic locking tie. clamp. Ì Pass the canister hose through the guide (for Ñ...
  • Page 416 SPEC CABLE ROUTING 1 Wireharness Ê Fasten the flasher light lead (left) with a metal 2 Rectifier/regulator clamp. 3 Flasher light lead (right) Ë Fasten the relay lead, flasher light lead (left) and 4 Tail/brake light lead sidestand switch lead with a plastic clip. 5 Flasher light lead (left) Ì...
  • Page 417 THROTTLE CABLE FREE PLAY ADJUSTMENT PERIODIC INSPECTION AND ADJUSTMENT ENGINE THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. 1. Check: Throttle cable free play a Out of specification → Adjust. Throttle cable free play: 3 ~ 5 mm (0.12 ~ 0.20 in) 2.
  • Page 418 THROTTLE CABLE FREE PLAY ADJUSTMENT 3. Adjust: Throttle cable free play ********************************* Adjustment steps: NOTE: When accelerating, throttle cable #1 1 is pulled and throttle cable #2 2 is pushed. First step: Loosen the locknut 3 on throttle cable #2. Turn the adjuster 4 in or out until all slack is removed from throttle cable #2.
  • Page 419 ENGINE ASSEMBLY AND ADJUSTMENT ENGINE ENGINE ASSEMBLY AND ADJUSTMENT CLUTCH AND OIL PUMP 1 Clutch spring 7 Clutch boss C Primary drive gear 2 Pressure plate 8 Thrust washer D Oil pump gear cover 3 Push plate 9 Primary driven gear E Oil pump driven gear 4 Push rod 1 0 Ball...
  • Page 420 ENGINE ASSEMBLY AND ADJUSTMENT CYLINDER HEAD 1 Bolt 0 Dowel pin 2 Washer A Grommet 3 Spark plug B Cylinder head gasket 4 Tappet cover (intake) C Breather cover 5 O-ring D O-ring 6 Bolt (oil check) E O-ring 7 Tappet cover (exhaust) F Cylinder head side cover 8 O-ring 9 Cylinder head...
  • Page 421 ENGINE ASSEMBLY AND ADJUSTMENT CAMSHAFT AND TIMING CHAIN 1 Gasket 2 Timing chain tensioner 3 Gasket 4 Timing chain guide (intake side) 5 Camshaft 6 Pin 7 Cam sprocket 8 Timing chain 9 Timing chain guide (exhaust side) SHAFT-TO-CAP CLEARANCE: 0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in) CAMSHAFT RUNOUT LIMIT:...
  • Page 422 CHAS FRONT BRAKE CHASSIS FRONT BRAKE 1 Master cylinder cap 9 Pad spring 2 Diaphragm 0 Caliper bracket 3 Master cylinder kit A Brake pads 4 Master cylinder B Piston 5 Holder (brake hose and meter cable) C Dust boot 6 Brake hose D Piston seal 7 Brake caliper body...
  • Page 423 – ELEC CHECKING OF SWITCHES ELECTRICAL CHECKING OF SWITCHES NOTE: This section is written based on a general model. Check the switches for the continuity between the terminal to determine correct connection. Read the following for switch inspection. SWITCH CONNECTION AS SHOWN IN MANUAL The manual contains a connection chart as shown left showing the terminal connections of...
  • Page 424 – ELEC CHECKING OF SWITCHES 1. Disconnect the main switch coupler from the wireharness. CAUTION: Never disconnect the main switch coupler by pulling the leads. Otherwise, leads may be pulled off the terminals inside the cou- pler. 2. Inspect whether any lead is off the termi- nal inside the coupler.
  • Page 425 – ELEC CHECKING OF SWITCHES ********************************* Checking steps: Turn the switch key to the “ON”, “OFF” and “LOCK” several times. Set the pocket tester selector to the “Ω × 1”. Connect the tester (+) lead to the “R” lead terminal in the coupler and the (–) lead to the “Br”...
  • Page 426 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
  • Page 427 XT225N/XT225NC WIRING DIAGRAM 1 CDI magneto 2 Neutral switch 3 Rectifier/regulator 4 Battery (+) lead G/L G/W 5 Battery 6 Battery (–) lead (GRAY) (GRAY) 7 Starter relay 8 Starter motor 9 Main switch 0 Starting circuit cut-off relay A Clutch switch W W W B Start switch C Engine stop switch...

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