Table Of Contents - Yamaha XT225-C Service Manual

Table of Contents

Notice4
Important Information4
Manual Format5
Important Features5
Exploded Diagram5
Illustrated Symbols6
Contents7
General Information8
Motorcycle Identification8
Vehicle Identification Number8
Engine Serial Number8
Specifications9
Lubrication Points And Lubricant Type14
Chassis14
Cable Routing15
Engine Assembly And Adjustment19
Clutch And Oil Pump19
Front Fork20
Particularly Important Information22
Index25
Troubleshooting32
All Replacement Parts35
Gaskets, Oil Seals, And O-Rings35
Lock Washers/Plates And Cotter Pins35
Bearings And Oil Seals35
Special Tools36
Circlips36
For Tune Up36
Tightening Sequence53
Crankcase53
Lubrication Chart53
Electrical57
C.d.i.57
Ignition Coil57
A.c. Generator58
General Torque Specifications60
Definition Of Units60
Lubrication Diagram63
Periodic Inspection And Adjustment71
Maintenance Intervals Charts71
Periodic Maintenance/Emission Control System71
General Maintenance/Lubrication72
Seat, Fuel Tank And Cover76
Valve Clearance Adjustment80
Timing Chain Adjustment83
Idling Speed Adjustment83
Throttle Cable Free Play Adjustment84
Spark Plug Inspection86
Standard Spark Plug86
Ignition Timing Check87
Compression Pressure Measurement88
Engine Oil Level Inspection91
Engine Oil Replacement92
Oil Pressure Inspection97
Clutch Adjustment97
Air Filter Cleaning98
Fuel Line Inspection101
Crankcase Ventilation Hose Inspection101
Exhaust System Inspection102
Canister Inspection102
Front Brake Adjustment103
Front Brake Fluid Level Inspection104
Front Brake Pad Inspection104
Air Bleeding105
Rear Brake Adjustment106
Rear Brake Shoe Inspection107
Rear Brake Light Switch Adjustment107
Drive Chain Slack Adjustment108
Drive Chain Lubrication110
Steering Head Adjustment111
Front Fork Inspection113
Front Fork Adjsutment113
Rear Shock Absorber Adjustment115
Recommended Combinations Of The Front Fork117
Rear Shock Absorber Settings117
Tire Inspection118
Tube Type Wheel119
Wheel Inspection120
Front120
Rear120
Spokes Inspection And Tightening121
Cable Inspection And Lubrication121
Lever And Pedal Lubrication122
Sidestand Lubrication122
Rear Suspension Lubrication122
Recommended Lubricant122
Battery Inspection123
Charging Method123
Battery Condition Checking Steps125
Charging Method Using A Variable-Current Type Charger127
Charging Method Using A Constant-Voltage Type Charger128
Fuse Inspection129
Blown Fuse130
Headlight Beam Adjustment131
Headlight Bulb Replacement131
Engine Removal133
Engine Overhaul133
Engine Guard133
Engine Oil133
Battery Leads134
Canister134
Exhaust Pipe And Muffler134
Crankcase Ventilation Hose And Carburetor135
Horn, Cables And Leads135
Engine Disassembly140
Cylinder Head, Cylinder And Piston140
Tdc Alignment141
Clutch, Oil Pump And Balancer Gear147
Shift Shaft150
Cylinder Head157
Valve Seat158
Cut Section159
Lapping160
Valve And Valve Guide161
Steam-To-Guide Problems161
Rocker Arm And Rocker Arm Shaft165
Timing Chain, Sprocket, Chain Guide And Tensioner166
Cylinder And Piston167
Cylinder Bore168
Piston Skirt168
Piston To Cylinder Clearance169
Piston Ring169
Side Clearance169
End Gap170
Piston Pin170
Crankshaft171
Runout Limit171
Big End Side Clearance171
Balancer Drive Gear And Balancer Gear172
Crankshaft Reassembling Point172
Primary Drive172
Clutch173
Clutch Plate173
Clutch Plate Warpage173
Clutch Spring Free Length174
Circumferential Play174
Transmission And Shifter175
Shift Fork Movement175
Reassembling Point176
Oil Pump And Strainer177
Tip Clearance177
Electric Starter Drive178
Starter Clutch Operation178
Bearing And Oil Seal179
Circlip And Washer180
Valves, Rocker Arm And Camshaft181
Valve Spring Tilt Limit181
Valve Clearance181
Balancer And Transmission189
Shifter190
Balancer, Transmission And Shifter191
Balancer Gear199
Rotor And Starter Drives207
Carburetion227
Carburetor227
Sectional View228
Su Type Carburetor228
Coasting Enrichter228
Front Wheel241
Front Brake248
Brake Pad Replacement249
Caliper Disassembly252
Maximum Deflection258
Brake Disc Thickness258
Bolt259
Retaining Bolt260
Union Bolt260
Recommended Brake Fluid261
Master Cylinder Assembly262
Screw262
Rear Wheel266
Tire Air Pressure266
Tire Size266
Rim Runout Limit266
Steering Head And Handlebar285
Handlebar286
Steering Head287
Rear Shock Absorber And Swingarm299
Handling Notes301
Notes On Disposal301
Shock Absorber Disposal301
Rear Shock Absorber302
Swingarm303
Shim Thickness307
Drive Chain And Sprockets312
Circuit Diagram319
Electrical Components321
Checking Of Switches323
Switch Connection As Shown In Manual323
Checking Switch For Terminal Connection324
Checking Of Bulbs327
Kinds Of Bulbs327
Checking Bulb Condition327
Ignition System329
Ignition Control Circuit Operation331
Ignition System Troubleshooting332
If Ignition System Should Become Inoperative332
Dynamic Spark Tester332
Pocket Tester332
Spark Plug333
Ignition Spark Plug333
Spark Plug Cap Resistance334
Ignition Coil Resistance334
Main Switch335
Engine Stop Switch336
Neutral Switch336
Sidestand Switch337
Neutral Relay337
Charge Coil Resistance338
Pulser Coil Resistance339
Wiring Connection339
Electrical Starting System341
Starter Motor Does Not Operate344
Starter Motor349
Charging System357
The Battery Is Not Charged359
Fuse359
Battery359
Charging Voltage360
Stator Coil Resistance360
Lighting System363
Signal System369
Horn Switch373
Voltage373
Horn374
Bulb And Bulb Socket375
Brake Switch375
Starting Failure/Hard Starting381
Poor Idle Speed Performance383
Poor Medium And High Speed Performance383
Faulty Gear Shifting384
Hard Shifting384
Shift Pedal Does Not Move384
Jump Out Gear384
Clutch Dragging385
Overheating385
Faulty Brake386
Poor Braking Effect386
Front Fork Oil Leakage And Front Fork Malfunction386
Instable Handling387
Headlight Dark388
Bulb Burnt Out388
Flasher Does Not Light388
Flasher Winks Slower389
Flasher Winks Quicker389
Horn Is Inoperative389
Important Manual Information393
Symbols395
Symbols F To K In The Exploded Diagrams395
Symbols L To M In The Exploded Diagrams395
Table Of Contents396
General Specifications397
Engine Specifications398
Piston Pin Bore (In The Piston)401
Clutch Plates402
Clutch Springs402
Carburetors402
Chassis Specifications403
Electrical Specifications406
Engine Tightening Torques408
Chassis Tightening Torques408
Engine417
First Step418
Second Step418
Final Step418
Camshaft And Timing Chain421
Shaft-To-Cap Clearance421
Camshaft Runout Limit421
Xt225N/Xt225Nc Wiring Diagram427