Yamaha XT225-D-G Manuals

Manuals and User Guides for Yamaha XT225-D-G. We have 1 Yamaha XT225-D-G manual available for free PDF download: Service Manual

Yamaha XT225-D-G Service Manual (428 pages)

Brand: Yamaha | Category: Motorcycle | Size: 69.85 MB

Important Information
4
Notice
4
Exploded Diagram
5
Important Features
5
Manual Format
5
Illustrated Symbols
6
Contents
7
Engine Serial Number
8
General Information
8
Motorcycle Identification
8
Vehicle Identification Number
8
Specifications
9
Chassis
14
Lubrication Points and Lubricant Type
14
Cable Routing
15
Engine Assembly and Adjustment
19
Clutch and Oil Pump
19
Front Fork
20
Particularly Important Information
22
Index
25
Troubleshooting
32
All Replacement Parts
35
Bearings and Oil Seals
35
Gaskets, Oil Seals, and O-Rings
35
Lock Washers/Plates and Cotter Pins
35
Circlips
36
For Tune up
36
Special Tools
36
Crankcase
53
Lubrication Chart
53
Tightening Sequence
53
Ignition Coil
57
Electrical
57
C.D.I.
57
A.C. Generator
58
Definition of Units
60
General Torque Specifications
60
Lubrication Diagram
63
Maintenance Intervals Charts
71
Periodic Inspection and Adjustment
71
Periodic Maintenance/Emission Control System
71
General Maintenance/Lubrication
72
Seat, Fuel Tank and Cover
76
Valve Clearance Adjustment
80
Idling Speed Adjustment
83
Timing Chain Adjustment
83
Throttle Cable Free Play Adjustment
84
Standard Spark Plug
86
Spark Plug Inspection
86
Ignition Timing Check
87
Compression Pressure Measurement
88
Engine Oil Level Inspection
91
Engine Oil Replacement
92
Clutch Adjustment
97
Oil Pressure Inspection
97
Air Filter Cleaning
98
Crankcase Ventilation Hose Inspection
101
Fuel Line Inspection
101
Canister Inspection
102
Exhaust System Inspection
102
Front Brake Adjustment
103
Front Brake Fluid Level Inspection
104
Front Brake Pad Inspection
104
Air Bleeding
105
Rear Brake Adjustment
106
Rear Brake Light Switch Adjustment
107
Rear Brake Shoe Inspection
107
Drive Chain Slack Adjustment
108
Drive Chain Lubrication
110
Steering Head Adjustment
111
Front Fork Adjsutment
113
Front Fork Inspection
113
Rear Shock Absorber Adjustment
115
Rear Shock Absorber Settings
117
Recommended Combinations of the Front Fork
117
Tire Inspection
118
Tube Type Wheel
119
Front
120
Rear
120
Wheel Inspection
120
Cable Inspection and Lubrication
121
Spokes Inspection and Tightening
121
Lever and Pedal Lubrication
122
Rear Suspension Lubrication
122
Recommended Lubricant
122
Sidestand Lubrication
122
Battery Inspection
123
Charging Method
123
Battery Condition Checking Steps
125
Charging Method Using a Variable-Current Type Charger
127
Charging Method Using a Constant-Voltage Type Charger
128
Fuse Inspection
129
Blown Fuse
130
Headlight Beam Adjustment
131
Headlight Bulb Replacement
131
Engine Removal
133
Engine Overhaul
133
Engine Oil
133
Engine Guard
133
Battery Leads
134
Canister
134
Exhaust Pipe and Muffler
134
Crankcase Ventilation Hose and Carburetor
135
Horn, Cables and Leads
135
Cylinder Head, Cylinder and Piston
140
Engine Disassembly
140
TDC Alignment
141
Clutch, Oil Pump and Balancer Gear
147
Shift Shaft
150
Cylinder Head
157
Valve Seat
158
Cut Section
159
Lapping
160
Steam-To-Guide Problems
161
Valve and Valve Guide
161
Rocker Arm and Rocker Arm Shaft
165
Timing Chain, Sprocket, Chain Guide and Tensioner
166
Cylinder and Piston
167
Cylinder Bore
168
Piston Skirt
168
Piston Ring
169
Piston to Cylinder Clearance
169
Side Clearance
169
End Gap
170
Piston Pin
170
Big End Side Clearance
171
Crankshaft
171
Runout Limit
171
Primary Drive
172
Balancer Drive Gear and Balancer Gear
172
Crankshaft Reassembling Point
172
Clutch Plate
173
Clutch Plate Warpage
173
Clutch
173
Circumferential Play
174
Clutch Spring Free Length
174
Shift Fork Movement
175
Transmission and Shifter
175
Reassembling Point
176
Oil Pump and Strainer
177
Tip Clearance
177
Electric Starter Drive
178
Starter Clutch Operation
178
Bearing and Oil Seal
179
Circlip and Washer
180
Valves, Rocker Arm and Camshaft
181
Valve Clearance
181
Valve Spring Tilt Limit
181
Balancer and Transmission
189
Shifter
190
Balancer, Transmission and Shifter
191
Balancer Gear
199
Rotor and Starter Drives
207
Carburetion
227
Carburetor
227
Coasting Enrichter
228
Sectional View
228
SU Type Carburetor
228
Front Wheel
241
Front Brake
248
Brake Pad Replacement
249
Caliper Disassembly
252
Brake Disc Thickness
258
Maximum Deflection
258
Bolt
259
Retaining Bolt
260
Union Bolt
260
Recommended Brake Fluid
261
Master Cylinder Assembly
262
Screw
262
Rear Wheel
266
Rim Runout Limit
266
Tire Air Pressure
266
Tire Size
266
Steering Head and Handlebar
285
Handlebar
286
Steering Head
287
Rear Shock Absorber and Swingarm
299
Handling Notes
301
Notes on Disposal
301
Shock Absorber Disposal
301
Rear Shock Absorber
302
Swingarm
303
Shim Thickness
307
Drive Chain and Sprockets
312
Circuit Diagram
319
Electrical Components
321
Checking of Switches
323
Switch Connection as Shown in Manual
323
Checking Switch for Terminal Connection
324
Checking Bulb Condition
327
Checking of Bulbs
327
Kinds of Bulbs
327
Ignition System
329
Ignition Control Circuit Operation
331
Dynamic Spark Tester
332
If Ignition System Should Become Inoperative
332
Ignition System Troubleshooting
332
Pocket Tester
332
Ignition Spark Plug
333
Spark Plug
333
Ignition Coil Resistance
334
Spark Plug Cap Resistance
334
Main Switch
335
Engine Stop Switch
336
Neutral Switch
336
Neutral Relay
337
Sidestand Switch
337
Charge Coil Resistance
338
Pulser Coil Resistance
339
Wiring Connection
339
Electrical Starting System
341
Starter Motor Does Not Operate
344
Starter Motor
349
Charging System
357
Battery
359
Fuse
359
The Battery Is Not Charged
359
Charging Voltage
360
Stator Coil Resistance
360
Lighting System
363
Signal System
369
Horn Switch
373
Voltage
373
Horn
374
Brake Switch
375
Bulb and Bulb Socket
375
Starting Failure/Hard Starting
381
Poor Idle Speed Performance
383
Poor Medium and High Speed Performance
383
Faulty Gear Shifting
384
Hard Shifting
384
Jump out Gear
384
Shift Pedal Does Not Move
384
Clutch Dragging
385
Overheating
385
Faulty Brake
386
Front Fork Oil Leakage and Front Fork Malfunction
386
Poor Braking Effect
386
Instable Handling
387
Headlight Dark
388
Flasher Does Not Light
388
Bulb Burnt out
388
Flasher Winks Quicker
389
Flasher Winks Slower
389
Horn Is Inoperative
389
Important Manual Information
393
Symbols
395
Symbols F to K in the Exploded Diagrams
395
Symbols L to M in the Exploded Diagrams
395
Table of Contents
396
General Specifications
397
Engine Specifications
398
- Piston Pin Bore (in the Piston)
  401
- Clutch Plates
  402
- Clutch Springs
  402
- Carburetors
  402
Chassis Specifications
403
Electrical Specifications
406
- Engine Tightening Torques
  408
- Chassis Tightening Torques
  408
Cable Routing
409
Periodic Inspection and Adjustment

417
- Engine
  417
  - Throttle Cable Free Play Adjustment
    417
    
    First Step
    418
    
    Second Step
    418
    
    Final Step
    418
Engine

419
- Engine Assembly and Adjustment
  419
  - Clutch and Oil Pump
    419
  - Cylinder Head
    420
  - Camshaft and Timing Chain
    421
    
    Shaft-To-Cap Clearance
    421
    
    Camshaft Runout Limit
    421
Chassis

422
- Front Brake
  422
Electrical

423
- Checking of Switches
  423
  - Switch Connection as Shown in Manual
    423
  - Checking Switch for Terminal Connection
    423
Xt225N/Xt225Nc Wiring Diagram

427

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Yamaha XT225-D-G Manuals

Yamaha XT225-D-G Service Manual (428 pages)

Table of Contents

Periodic Inspection and Adjustment

Engine

Chassis

Electrical

Xt225N/Xt225Nc Wiring Diagram

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