Yamaha XT225R(C) manual

PRINTED IN JAPAN 2002·5– 0.7 × 1(E) ! 5RK-28199-11 LIT-11626-16-22 OWNER’S MANUAL XT225R(C) PRINTED ON RECYCLED PAPER Y AMAHA MOTOR CO. , L TD.[...]

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EAU00002 INTRODUCTION Congratulations on your purchase of the Yamaha XT225/XT225C. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give y[...]

EAU00003 IMPORT ANT MANUAL INFORMA TION Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspe[...]

IMPORT ANT MANUAL INFORMA TION EW000000 w PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADE- QUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE [...]

XT225R(C) OWNER’S MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2002 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan. P/N LIT-11626-16-22 EAU04247 AFFIX DEALER LABEL HERE 5RK-9-11(US) 4/26/02 7:15 PM Page 4[...]

EAU00009 T ABLE OF CONTENTS SAFETY INFORMATION ...................................1-1 Safe riding .......................................................1-1 Protective apparel ...........................................1-3 Modifications ...................................................1-3 Loading and accessories ................................1-[...]

Removing and installing the cowling and panels ...........................................................6-7 Checking the spark plug ..................................6-8 Canister (for California only) ..........................6-10 Engine oil and oil filter element .....................6-10 Cleaning the air filter element ........................[...]

T ABLE OF CONTENTS CONSUMER INFORMATION ............................9-1 Identification numbers .....................................9-1 Key identification number ................................9-1 Vehicle identification number ..........................9-1 Model label ......................................................9-2 Reporting safety defec[...]

1-1 EAU00017 Q SAFETY INFORMA TION 1 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPER- TISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE- MENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: 1. OBTAIN THOROUGH INSTRUCTIONS FROM A CO[...]

1-2 Q SAFETY INFORMA TION 1 4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. a. Make sure that you are qualified and that you only lend your motorcycle to other qualified oper - ators. b. Know your skills and limits. Staying within your limi[...]

1-3 Q SAFETY INFORMA TION 1 Protective apparel The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. 1. Always wear an approved helmet. 2. Wear a face shield or goggles. Wind in your unprotected eyes could c[...]

1-4 Q SAFETY INFORMA TION 1 Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 183 kg (404 lb). When loading within this weight limit, keep the following in mind: 1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the [...]

1-5 Q SAFETY INFORMA TION 1 a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. b. Bulky or large accessories may seriousl[...]

1-6 Q SAFETY INFORMA TION 1 a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. c. Do not park the motorcycle near a flammable source (e.g., a kerosene heater,[...]

1-7 Q SAFETY INFORMA TION 1 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle. 1 4 23 5RK-9-11(US) 4/26/02 7:15 PM Page 14[...]

1-8 Q SAFETY INFORMA TION 1 q WARNING BEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER ’ S MANUAL AND ALL LABELS. ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye protection, and protective clothing. 5GK-2118K-00 1 2 EMISSION HOSE ROUTING CARB. FROM FUEL TANK CANISTER TO ATMOSPHERE 4YN-21686-00 3 California only 4 5RK-9-11(US) 4/26/02 7:16 PM Page 1[...]

2-1 EAU00026 DESCRIPTION 2 1. Headlight (page 6-36) 2. Fuel cock (page 3-7) 3. Air filter element (page 6-14) 4. Helmet holder (page 3-9) 5. Owner ’ s tool kit (page 6-1) 6. Shock absorber spring preload adjusting nut (page 3-10) 7. Shock absorber rebound damping adjusting dial (page 3-11) 8. Shift pedal (page 3-4) 12 5 7 6 8 3 4 Left view 5RK-9-[...]

2-2 DESCRIPTION 2 9. Battery (page 6-33) 10. Fuse (page 6-35) 11. Engine oil filter element (page 6-11) 12. Engine oil level check window (page 6-10) 13. Brake pedal (page 3-4, 6-23) 14. Spark arrester (page 6-16) 13 14 9 10 11 12 Right view 5RK-9-11(US) 4/26/02 7:16 PM Page 17[...]

2-3 DESCRIPTION 2 1. Clutch lever (page 3-3, 6-21) 2. Left handlebar switches (page 3-2) 3. Starter (choke) knob (page 3-8) 4. Speedometer unit (page 3-2) 5. Main switch/steering lock (page 3-1) 6. Right handlebar switches (page 3-3) 7. Brake lever (page 3-4, 6-22) 8. Throttle grip (page 6-17, 6-30) 9. Fuel tank cap (page 3-5) 12 45 6 7 8 9 3 Contr[...]

3-1 EAU00027 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00029 Main switch/steering lock The main switch/steering lock con- trols the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU00032 ON All electrical systems are supplied with power, and the headlight, meter lighting, taillight and posit[...]

3-2 EAU00056 Indicator lights EAU00063 High beam indicator light “ & ” This indicator light comes on when the high beam of the headlight is switched on. EAU00057 Turn signal indicator light “ 5 ” This indicator light flashes when the turn signal switch is pushed to the left or right. EAU00061 Neutral indicator light “ N ” This indic[...]

3-3 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00129 Horn switch “ * ” Press this switch to sound the horn. EAU00152 Clutch lever The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the han- dlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly [...]

3-4 EAU00157 Shift pedal The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 6-speed constant-mesh transmission equipped on this motorcycle. INSTRUMENT AND CONTROL FUNCTIONS 3 1 1. Shift pedal EAU00158 Brake lever The brake lever is located at the right handlebar [...]

3-5 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00177* Fuel tank cap To remove the fuel tank cap 1. Insert the key into the lock and turn it 1/3 turn counterclockwise. 2. Turn the fuel tank cap 1/3 turn counterclockwise and pull it off. b 1 a 1. Fuel tank cap a. Unlock. b. Open. EAU03753 Fuel Make sure that there is sufficient fuel in the tank. Fill the [...]

3-6 EAU00185 c C Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted sur- faces or plastic parts. INSTRUMENT AND CONTROL FUNCTIONS 3 EAU04265 ECA00104 c C Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and pis- ton rings, as[...]

3-7 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU03050 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running. FUEL FUEL 1 1. Arrow mark positioned over [...]

3-8 EAU04038 Starter (choke) knob “ 1 ” Starting a cold engine requires a rich- er air-fuel mixture, which is supplied by the starter (choke). Move the knob in direction a to turn on the starter (choke). Move the knob in direction b to turn off the starter (choke). INSTRUMENT AND CONTROL FUNCTIONS 3 1 a b 1. Starter (choke) knob “ 1 ” EAU02[...]

3-9 INSTRUMENT AND CONTROL FUNCTIONS 3 To install the seat 1. Insert the projection on the front of the seat into the seat holder as shown. 2. Place the seat in the original position, and then tighten the bolts. 3. Install the panels. NOTE: Make sure that the seat is properly secured before riding. 1 2 1. Projection 2. Seat holder EAU04848 Adjustin[...]

3-10 Spring preload 1. Loosen the locknut. 2. To increase the spring preload and thereby harden the suspen- sion, turn the adjusting nut in direction a . To decrease the spring preload and thereby soft- en the suspension, turn the adjusting nut in direction b . INSTRUMENT AND CONTROL FUNCTIONS 3 1 2 a b 1. Spring preload adjusting nut 2. Locknut NO[...]

3-11 INSTRUMENT AND CONTROL FUNCTIONS 3 Rebound damping force To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting dial in direction a . To decrease the rebound damping force and thereby soften the rebound damping, turn the adjusting dial in direction b . 1 a b 1. Rebound damping force adjusting dial EAU0[...]

3-12 EAU00330 Sidestand The sidestand is located on the left side of the frame. Raise the side- stand or lower it with your foot while holding the motorcycle upright. NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situ- ations. (See further down for an explanation of the igniti[...]

3-13 INSTRUMENT AND CONTROL FUNCTIONS 3 With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “ # ” . 3. Turn the key to “ ON ” . 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle shoul[...]

4-1 EAU01114 PRE-OPERA TION CHECKS 4 The condition of a vehicle is the owner ’ s responsibility. Vital components can start to deteriorate quickly and unexpect- edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak- age or loss of tire air pressure could have serious consequences. [...]

4-2 PRE-OPERA TION CHECKS 4 Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. 6-17, 6-30 Control cables • Make sure that operation is smooth. • Lubricate if necessary. 6-29 – 6-30 Drive chain • Check chain slack. [...]

4-3 PRE-OPERA TION CHECKS 4 NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved. EWA00033 w If any item in the Pre-operation check list is not working properly, have it inspected and repaired befo[...]

5-1 EAU00372 OPERA TION AND IMPORT ANT RIDING POINTS 5 EAU00373 w 8 Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or func- tion that you do not thorough- ly understand. 8 Never start the engine or oper- ate it in a closed area for any length of time. Exhaust f[...]

5-2 OPERA TION AND IMPORT ANT RIDING POINTS 5 1. Turn the fuel cock lever to “ ON ” . 2. Turn the key to “ ON ” and make sure that the engine stop switch is set to “ # ” . 3. Shift the transmission into the neutral position. NOTE: When the transmission is in the neu- tral position, the neutral indicator light should be on, otherwise hav[...]

5-3 OPERA TION AND IMPORT ANT RIDING POINTS 5 EAU01258 Starting a warm engine Follow the same procedure as for starting a cold engine with the excep- tion that the starter (choke) is not required when the engine is warm. EC000048 c C 8 Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and[...]

5-4 OPERA TION AND IMPORT ANT RIDING POINTS 5 EAU02988 To start out and accelerate 1. Pull the clutch lever to disengage the clutch. 2. Shift the transmission into first gear. The neutral indicator light should go out. 3. Open the throttle gradually, and at the same time, release the clutch lever slowly. 4. At the recommended shift points shown in [...]

5-5 OPERA TION AND IMPORT ANT RIDING POINTS 5 EAU02989 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below. EAU01128 Engine break-in There is never a more important peri- od in the life of your engine than the period between 0 and 1,600 km (1,000 mi). For this reason, you should re[...]

5-6 OPERA TION AND IMPORT ANT RIDING POINTS 5 ECA00077 c C After 1,000 km (600 mi) of opera- tion, the engine oil must be changed, and the oil filter element and the oil strainer cleaned. 1,600 km (1,000 mi) and beyond The vehicle can now be operated normally. EC000049 c C If any engine trouble should occur during the engine break-in period, immedi[...]

6-1 EAU00462 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU01790 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condi- tion possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages. Maint[...]

6-2 PERIODIC MAINTENANCE AND MINOR REP AIR 6 NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you. EW000062 w Modifications not approved by Yamaha may cause loss of perfor- mance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting[...]

6-3 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00471 Periodic maintenance chart for the emission control system INITIAL ODOMETER READINGS NO. ITEM ROUTINE 600 mi 4,000 mi 7,000 mi 10,000 mi 13,000 mi (1,000 km) or (6,000 km) or (11,000 km) or (16,000 km) or (21,000 km) or 1 month 6 months 12 months 18 months 24 months 1 * Valve clearance 9 Check a[...]

6-4 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00472 General maintenance and lubrication chart INITIAL ODOMETER READINGS NO. ITEM ROUTINE TYPE 600 mi 4,000 mi 7,000 mi 10,000 mi 13,000 mi (1,000 km) or (6,000 km) or (11,000 km) or (16,000 km) or (21,000 km) or 1 month 6 months 12 months 18 months 24 months 1 Engine oil 9 Warm-up engine before See [...]

6-5 PERIODIC MAINTENANCE AND MINOR REP AIR 6 INITIAL ODOMETER READINGS NO. ITEM ROUTINE TYPE 600 mi 4,000 mi 7,000 mi 10,000 mi 13,000 mi (1,000 km) or (6,000 km) or (11,000 km) or (16,000 km) or (21,000 km) or 1 month 6 months 12 months 18 months 24 months Rear arm pivot shaft 9 Apply until new grease Lithium-soap based 8* and rear suspension show[...]

6-6 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03906 NOTE: From 16,000 mi (26,000 km) or 30 months, repeat the maintenance intervals starting from 4,000 mi (6,000 km) or 6 months. EAU03057 NOTE: 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 8 Hydraulic brake system 9 When disassembling the master c[...]

6-7 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03516 Removing and installing the cowling and panels The cowling and panels shown above need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the cowling or a panel needs to be removed and installed. 1 3 2 1. Cowling A 2. Panel A 3. Panel[...]

6-8 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00488 Panel B To remove the panel Remove the screw, and then pull the panel off as shown. To install the panel Place the panel in the original posi- tion, and then install the screw. 1 2 1. Panel B 2. Screw 2. Remove the spark plug as shown, with the spark plug wrench included in the owner ’ s tool [...]

6-9 PERIODIC MAINTENANCE AND MINOR REP AIR 6 To check the spark plug 1. Check that the porcelain insula- tor around the center electrode of the spark plug is a medium-to- light tan (the ideal color when the motorcycle is ridden normally). NOTE: If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to di[...]

6-10 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU01796 Canister (for California only) This model is equipped with a canis- ter to prevent the discharging of fuel vapor into the atmosphere. 8 Check each hose connection. 8 Check each hose and canister for cracks or damage. Replace if damaged. 8 Make sure the vent hose is not blocked. Clean it if nece[...]

6-11 PERIODIC MAINTENANCE AND MINOR REP AIR 6 3. Wait a few minutes until the oil settles, and then check the oil level through the check window located at the bottom right side of the engine guard. NOTE: The engine oil should be between the minimum and maximum level marks. 4. If the engine oil is below the min- imum level mark, add sufficient oil [...]

6-12 PERIODIC MAINTENANCE AND MINOR REP AIR 6 ECA00039 c C When removing the engine oil drain bolt, the O-ring, compression spring, and oil strainer will fall out. Take care not to lose these parts. Check the O-ring for damage and replace it if necessary. 5. Clean the engine oil strainer with solvent. NOTE: Skip steps 6 – 11 if the oil filter ele[...]

6-13 PERIODIC MAINTENANCE AND MINOR REP AIR 6 NOTE: Make sure that the O-ring is properly seated. 12. Install the engine oil strainer, compression spring, O-ring and engine oil drain bolt, and then tighten the drain bolt to the spec- ified torque. EC000071 c C Before installing the engine oil drain bolt, do not forget to install the O-ring, compres[...]

6-14 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU04221 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrica- tion chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. 1. Remove panel A. (See page 6-7 for removal a[...]

6-15 PERIODIC MAINTENANCE AND MINOR REP AIR 6 5. Clean the sponge material with solvent, and then squeeze the remaining solvent out. 6. Apply oil of the recommended type to the entire surface of the sponge material, and then squeeze the excess oil out. NOTE: The sponge material should be wet but not dripping. 12 3 4 EC000082 c C 8 8 Make sure that [...]

6-16 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU01549 Cleaning the spark arrester The spark arrester should be cleaned at the intervals specified in the Periodic maintenance and lubrication chart. EWA00007 w 8 Always let the exhaust system cool prior to touching exhaust components. 8 Do not start the engine when cleaning the exhaust system. NOTE: [...]

6-17 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU01752 Adjusting the carburetor The carburetor is an important part of the engine and its emission control system, which requires very sophisti- cated adjustment. Therefore, carbu- retor adjustments should be left to Yamaha dealer, who has the neces- sary professional knowledge and experience. EAU0063[...]

6-18 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU04836 Tires To maximize the performance, dura- bility, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure The tire air pressure should be checked and, if necessary, adjusted before each ride. EW000082 w 8 The tire air pressure must be che[...]

6-19 PERIODIC MAINTENANCE AND MINOR REP AIR 6 8 Adjust the suspension and tire air pressure with regard to the load. 8 Check the tire condition and air pressure before each ride. Tire information This motorcycle is equipped with tube tires. EW000078 w 8 The front and rear tires should be of the same make and design, otherwise the handling character[...]

6-20 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00680 w 8 It is dangerous to ride with a worn-out tire. When a tire tread begins to show cross- wise lines, have a Yamaha dealer replace the tire immedi- ately. 8 The replacement of all wheel- and brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary profe[...]

6-21 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00691 Accessories and replacement parts w This motorcycle is not designed to pull a trailer or to be attached to a sidecar. The accessories or replacement parts you choose for your motorcycle should be designed specifically for this model, and they must be securely mounted to maintain the inherent st[...]

6-22 PERIODIC MAINTENANCE AND MINOR REP AIR 6 3. If the specified clutch lever free play could be obtained as described above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows. 4. Fully turn the adjusting bolt in direction a to loosen the clutch cable. 5. Loosen the locknut further down the clutch cable. 6. To in[...]

6-23 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00707 Adjusting the brake pedal position and free play EW000104 w It is advisable to have a Yamaha dealer make these adjustments. Brake pedal position The top of the brake pedal should be positioned approximately 10 mm (0.4 in) below the top of the footrest. Periodically check the brake pedal positio[...]

6-24 PERIODIC MAINTENANCE AND MINOR REP AIR 6 To increase the brake pedal free play, turn the adjusting nut at the brake rod in direction a . To decrease the brake pedal free play, turn the adjusting nut in direction b . a 1 b 1. Brake pedal free play adjusting nut EAU00713 Adjusting the rear brake light switch The rear brake light switch, which is[...]

6-25 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00720 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. EAU04502 Rear brake shoes The rear brake is provided with a wear indicator, which allows you to[...]

6-26 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03294 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads [...]

6-27 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03985 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic mainte- nance and lubrication chart. In addi- tion, have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the inter- vals li[...]

6-28 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU04369 To adjust the drive chain slack 1. Loosen the brake pedal free play adjusting nut. 2. Loosen the axle nut. 3. To tighten the drive chain, turn the adjusting plate on each side of the swingarm in direction a . To loosen the drive chain, turn the adjusting plate on each side of the swingarm in di[...]

6-29 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03006 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica- tion chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. EC000097 c C The drive[...]

6-30 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EW000111 w Damage to the outer housing of cables may result in internal rust- ing and cause interference with cable movement. Replace dam- aged cables as soon as possible to prevent unsafe conditions. EAU03370 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedal[...]

6-31 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. EAU04282 Lubricating the rear suspension The pivoting points of the rear sus- pension must be lubricated [...]

6-32 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU02939 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the peri- odic maintenance and lubrication chart. To check the condition EW000115 w Securely support the motorcycle so that there is no danger of it falling over. Check[...]

6-33 PERIODIC MAINTENANCE AND MINOR REP AIR 6 2. Hold the lower ends of the front fork legs and try to move them forward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering. EAU00800 Battery This motorcycle is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need[...]

6-34 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EW000116 w 8 Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any con- tact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. 9 EXTERNAL: Flush with plen- ty[...]

6-35 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EC000102 c C 8 Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. 8 To charge a sealed-type (MF) battery, a special (constant- voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a[...]

6-36 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU01528 Replacing the headlight bulb This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove cowling A. (See page 6-7 for cowling removal and installation procedures.) 3. Disconnect the headlight cou- pler, and then remove the head- li[...]

6-37 PERIODIC MAINTENANCE AND MINOR REP AIR 6 4. Remove the headlight bulb hold- er by turning it counterclockwise, and then remove the defective bulb. EW000119 w Headlight bulbs get very hot. Therefore, keep flammable prod- ucts away from a lit headlight bulb, and do not touch the bulb until it has cooled down. 5. Place a new bulb into position, a[...]

6-38 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03497 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. 2 1 1. Lens 2. Screw EAU01623 Replacing the tail/brake light bulb 1. Remove the tail/brake light lens by removing the screws. 1 2 1. Lens 2. Screw ( × 2) 2. Remove the defective bulb by pushing it in[...]

6-39 PERIODIC MAINTENANCE AND MINOR REP AIR 6 2. Remove the defective bulb by pushing it in and turning it coun- terclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clock- wise until it stops. 4. Install the lens by installing the screws. EC000108 c C Do not overtighten the screws, otherwise the lens may break. 1 1. Bul[...]

6-40 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03781 Front wheel To remove the front wheel EW000122 w 8 It is advisable to have a Yamaha dealer service the wheel. 8 Securely support the motorcy- cle so that there is no danger of it falling over. 1. Remove the engine guard by removing the bolt. 2 1 1. Engine guard 2. Bolt ECA00048 c C Do not apply[...]

6-41 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03782 To install the front wheel 1. Install the speedometer gear unit into the wheel hub so that the projections mesh with the slots. 2. Lift the wheel up between the fork legs. 1 1. Speedometer gear unit 6. Connect the speedometer cable, and then install the speedometer cable holder by installing th[...]

6-42 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03766 Rear wheel To remove the rear wheel EW000122 w 8 It is advisable to have a Yamaha dealer service the wheel. 8 Securely support the motorcy- cle so that there is no danger of it falling over. 1. Remove the engine guard by removing the bolt. 2 1 1. Engine guard 2. Bolt 7. Push the wheel forward, [...]

6-43 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03767 To install the rear wheel 1. Insert the wheel axle from the left-hand side. NOTE: Make sure that the drive chain adjust- ing plates are installed with the punched sides facing to the outside and that the slot in the brake shoe plate fits over the retainer on the swingarm. 1 1. Retainer EW000103[...]

6-44 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU01008 T roubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting chart[...]

6-45 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU01397 T roubleshooting chart EW000125 w Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel 2. Compression 3. Ignition Operate the electric starter. There is compression. There is no compression. Check the ignition. Have a Yamaha dealer check the vehicle. Chec[...]

7-1 EAU03521 MOT ORCYCLE CARE AND ST ORAGE 7 Care While the open design of a motorcy- cle reveals the attractiveness of the technology, it also makes it more vul- nerable. Rust and corrosion can develop even if high-quality compo- nents are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appear- ance of a[...]

7-2 MOT ORCYCLE CARE AND ST ORAGE 7 8 Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abra- sive cleaning products, sol- vent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or elec- trolyte. 8 Do not use high-pressure washe[...]

7-3 MOT ORCYCLE CARE AND ST ORAGE 7 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Immediately dry the drive chain and lubricate it to prevent it from rusting. 3. Use a chrome polish to shine chrome, aluminum and stainless- steel parts, including the exhaust system. (Even the thermally induced discoloring of stainless[...]

7-4 MOT ORCYCLE CARE AND ST ORAGE 7 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, pro- tect it against dust with a porous cover. ECA00014 c C 8 Storing the motorcycle in a poorly ventilated room or cov- ering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust. 8 T[...]

7-5 MOT ORCYCLE CARE AND ST ORAGE 7 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to pre- vent the tires from becoming degraded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent m[...]

8-1 EAU01038 SPECIFICA TIONS 8 Specifications Model XT225R(C) 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 1,350 mm (53.1 in) Ground clearance 285 mm (11.2 in) Minimum turning radius 1,900 mm (74.8 in) Basic weight 121 kg (267 lb) (With oil and f[...]

8-2 SPECIFICA TIONS 8 Fuel Type UNLEADED GASOLINE ONLY Fuel tank capacity 8.8 L (1.94 lmp qt, 2.32 US qt) Reserve amount 2.0 L (0.44 lmp qt, 0.53 US qt) Carburetor Manufacturer MIKUNI Model × quantity BST34 × 1 Spark plug Manufacturer/model NGK/DR8EA or DENSO/X24ESR-U Gap 0.6 – 0.7 mm (0.02 – 0.03 in) Clutch type Wet, multiple-disc Transmissi[...]

8-3 SPECIFICA TIONS 8 Maximum load* 183 kg (404 lb) Tire air pressure (measured on cold tires) Up to 90 kg (198 lb) load* Front 125 kPa (1.25 kgf/cm 2 , 18 psi) Rear 150 kPa (1.50 kgf/cm 2 , 22 psi) 90 kg (198 lb) load – maximum load* Front 150 kPa (1.50 kgf/cm 2 , 22 psi) Rear 175 kPa (1.75 kgf/cm 2 , 25 psi) * Total weight of rider, passenger, [...]

8-4 SPECIFICA TIONS 8 Headlight type Quartz bulb (halogen) Bulb voltage, wattage × quantity Headlight 12V, 60/55W × 1 Tail/brake light 12V, 8/27W × 1 Front turn signal/ position light 12V, 27/8W × 2 Rear turn signal light 12V, 27W × 2 Meter lighting 12V, 3.4W × 1 Neutral indicator light 12V, 3.4W × 1 High beam indicator light 12V, 3.4W × 1 [...]

9-1 EAU01039 CONSUMER INFORMA TION 9 EAU02944 Identification numbers Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: 2. VEHICLE IDENT[...]

9-2 CONSUMER INFORMA TION 9 EAU01050 Model label The model label is affixed to the frame under the seat. (See page 3-8 for seat removal and installation pro- cedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer. 1 1. Model label 5RK-9-11(US) 4/26/02 7:16[...]

9-3 CONSUMER INFORMA TION 9 EAU01051 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should imme- diately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A. If NHTSA receives similar complaint[...]

9-4 CONSUMER INFORMA TION 9 EAU01053 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into a[...]

9-5 CONSUMER INFORMA TION 9 5RK-9-11(US) 4/26/02 7:16 PM Page 99[...]

9-6 CONSUMER INFORMA TION 9 EAU03052 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acce[...]

9-7 CONSUMER INFORMA TION 9 16,000 mi (26,000 km) or 30 months 19,000 mi (31,000 km) or 36 months 22,000 mi (36,000 km) or 42 months 25,000 mi (41,000 km) or 48 months 28,000 mi (46,000 km) or 54 months 31,000 mi (51,000 km) or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 5RK-9-11(US) 4/26/02 7:16[...]

9-8 CONSUMER INFORMA TION 9 EAU02918 Y AMAHA MOTOR CORPORA TION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED W ARRANTY 5RK-9-11(US) 4/26/02 7:16 PM Page 102[...]

9-9 CONSUMER INFORMA TION 9 5RK-9-11(US) 4/26/02 7:16 PM Page 103[...]

9-10 CONSUMER INFORMA TION 9 EAU01063 Y AMAHA EXTENDED SERVICE (Y .E.S.) 5RK-9-11(US) 4/26/02 7:16 PM Page 104[...]

9-11 9 5RK-9-11(US) 4/26/02 7:16 PM Page 105[...]

PRINTED IN JAPAN 2002·5– 0.7 × 1(E) ! 5RK-28199-11 LIT-11626-16-22 OWNER’S MANUAL XT225R(C) PRINTED ON RECYCLED PAPER Y AMAHA MOTOR CO. , L TD.[...]