XT225N

4BE-AE3

SUPPLEMENTARY SERVICEMANUAL

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and new data for the XT225N. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual. XT225D/XT225DC SERVICE MANUAL: 4BE-28197-20 XT225H/XT225HC SUPPLEMENTARY SERVICE MANUAL: 4BE-AE1 XT225J SUPPLEMENTARY SERVICE MANUAL: 4BE-AE2

XT225N SUPPLEMENTARY SERVICE MANUAL 2000 by Yamaha Motor Co., Ltd. First edition, October 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

EAS00003

NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. 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. Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. Designs and specifications are subject to change without notice.
@ @@

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person checking or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer.

CAUTION:
NOTE:

EAS00007

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: 2nd title 2: This is a chapter with its symbol on the upper right of each page. This title appears on the upper of each page on the left of the chapter symbol. (For the chapter Periodic inspection and adjustment the 3rd title appears.) This is a final title.

3rd title 3:

MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections. A set of particularly important procedure 4 is placed between a line of asterisks * with each procedure preceded by q. IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol 5. q An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data or an alignment mark 7, the others being indicated by an alphabetical letter in a box 8. q A condition of a faulty component will precede an arrow symbol and the course of action required the symbol 9.
q

EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

EAS00008

SYMBOLS
The following symbols are not relevant to every vehicle. 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 8 Troubleshooting

GEN INFO
3

SPEC
4

CHK ADJ
5

ENG
6

CARB
7
+

CHAS
8

ELEC
9

TRBL SHTG
0

Symbols 9 to E indicate the following.

9 Filling fluid 0 Lubricant A Special tool B Tightening torque C Wear limit, clearance D Engine speed E Electrical data

B
T.

R.

Symbols F to K in the exploded diagrams indicate the types of lubricants and lubrication points.
M
F Engine oil G Gear oil H Molybdenum disulfide oil I Wheel bearing grease J Lithium soap base grease K Molybdenum disulfide grease

E
I
B

G
J
LS

K
M

Symbols L to M in the exploded diagrams indicate the following.

LT

New

L Apply locking agent (LOCTITE) M Replace the part

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 ...............................21 ENGINE ...........................................................................................................23 ENGINE ASSEMBLY AND ADJUSTMENT .............................................23 CLUTCH AND OIL PUMP....................................................................23 CYLINDER HEAD ................................................................................24 CAMSHAFT AND TIMING CHAIN .......................................................25 CHASSIS .........................................................................................................26 FRONT BRAKE........................................................................................26 ELECTRICAL ..................................................................................................27 CHECKING OF SWITCHES ....................................................................27 SWITCH CONNECTION AS SHOWN IN MANUAL.............................27 CHECKING SWITCH FOR TERMINAL CONNECTION ......................27 XT225N WIRING DIAGRAM

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (with oil and a full fuel tank) Dry (without oil and fuel) Maximum load (total of cargo, rider, passenger, and accessories) 4BEX 2,070 mm (81.5 in) 805 mm (31.7 in) 1,160 mm (45.7 in) 810 mm (31.9 in) 1,350 mm (53.1 in) 285 mm (11.2 in) 1,900 mm (74.8 in) 121 kg (267 lb) 108 kg (238 lb) 183 kg (404 lb) Standard ---------------------------------Limit

-1-

ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS

Item Engine Engine type Displacement Cylinder arrangement Bore stroke Compression ratio Engine idling speed Standard compression pressure (at sea level) Camshaft Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaft-cap clearance Intake camshaft lobe dimensions
C A

SPEC
Limit ----------------------

Standard Air-cooled, 4-stroke, SOHC 223 cm3 Forward inclined single cylinder 70 58 mm (2.76 2.28 in) 9.5 : 1 1,300 ~ 1,500 r/min 1,200 kPa (12.0 kgf/cm2, 174 psi) at 1,000 r/min Chain drive (left) 25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in) 24.960 ~ 24.980 mm (0.9827 ~ 0.9835 in) 0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in)

-------------

Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions

C A

36.51 ~ 36.61 mm (1.437 ~ 1.441 in) 30.1 ~ 30.2 mm (1.185 ~ 1.189 in) 6.50 ~ 6.62 mm (0.256 ~ 0.261 in)

36.41 mm (1.43 in) 30.0 mm (1.18 in) ----

Measurement A Measurement B Measurement C

36.51 ~ 36.61 mm (1.437 ~ 1.441 in) 30.15 ~ 30.25 mm (1.187 ~ 1.191 in) 6.50 ~ 6.62 mm (0.256 ~ 0.261 in)

36.41 mm (1.43 in) 30.05 mm (1.18 in) ----

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ENGINE SPECIFICATIONS
Item Max. camshaft runout ---Standard

SPEC
Limit 0.03 mm (0.0012 in)

Timing chain Model/number of links Tensioning system Valve springs Inner springs Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt

Borg Warner 92RH/104 Automatic

-------

36.17 mm (1.42 in) 36.17 mm (1.42 in)

34.35 mm (1.35 in) 34.35 mm (1.35 in) -------------

30.5 mm (1.20 in) 30.5 mm (1.20 in) 75.0 ~ 91.7 N (7.50 ~ 9.17 kgf, 16.9 ~ 20.6 lb) 75.0 ~ 91.7 N (7.50 ~ 9.17 kgf, 16.9 ~ 20.6 lb)

Intake Exhaust Winding direction (top view) Intake Exhaust

-------

2.5 /1.6 mm (2.5 /0.063 in) 2.5 /1.6 mm (2.5 /0.063 in) -------

Counterclockwise Counterclockwise

-3-

ENGINE SPECIFICATIONS
Item Outer springs Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt Standard

SPEC
Limit

36.63 mm (1.44 in) 36.63 mm (1.44 in)

34.80 mm (1.37 in) 34.80 mm (1.37 in) -------------

32.0 mm (1.26 in) 32.0 mm (1.26 in) 128.5 ~ 157.9 N (12.9 ~ 15.8 kgf, 28.9 ~ 35.5 lb) 128.5 ~ 157.9 N (12.9 ~ 15.8 kgf, 28.9 ~ 35.5 lb)

Intake Exhaust Winding direction (top view) Intake Exhaust

-------

2.5 /1.6 mm (2.5 /0.063 in) 2.5 /1.6 mm (2.5 /0.063 in) -------

Clockwise Clockwise

Piston Piston-to-cylinder clearance Diameter D

0.15 mm (0.0059 in) 69.960 ~ 69.975 mm (2.7543 ~ 2.7549 in) ----

0.025 ~ 0.050 mm (0.001 ~ 0.002 in)

H D

Height H

5.0 mm (0.2 in)

----

-4-

ENGINE SPECIFICATIONS
Item Piston pin bore (in the piston) Diameter Offset Offset direction Piston pin Outside diameter Standard

SPEC
Limit

16.002 ~ 16.013 mm (0.6300 ~ 0.6304 in) 16.043 mm (0.6316 in) 0.5 mm (0.0197 in) ---Intake side ----

15.991 ~ 16.000 mm (0.6296 ~ 0.6299 in) 15.971 mm (0.6288 in) Piston-pin-to-piston-pin-bore clear- 0.002 ~ 0.022 mm 0.072 mm ance (0.000079 ~ 0.000866 in) (0.0028 in) Piston rings Top ring
B T

Ring type Dimensions (B T) End gap (installed) Ring side clearance 2nd ring
B T

Barrel 1.2 2.8 mm (0.05 0.11 in) 0.15 ~ 0.30 mm (0.006 ~ 0.011 in) 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in)

------0.55 mm (0.02 in) 0.12 mm (0.0047 in)

Ring type Dimensions (B T) End gap (installed) Ring side clearance Oil ring
B T

Taper 1.2 2.8 mm (0.05 0.11 in) 0.15 ~ 0.30 mm (0.006 ~ 0.011 in) 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in)

------0.65 mm (0.025 in) 0.12 mm (0.0047 in)

Dimensions (B T) End gap (installed) Clutch Clutch type Clutch release method Operation Friction plates Thickness Plate quantity

2.5 2.8 mm (0.10 0.11 in) 0.3 ~ 0.9 mm (0.01 ~ 0.04 in) Wet, multiple disc Inner push, cam push Left-hand operation 2.9 ~ 3.1 mm (0.11 ~ 0.12 in) 6

---------------2.8 mm (0.110 in) ----

-5-

ENGINE SPECIFICATIONS
Item Clutch plates Thickness Plate quantity Max. warpage Clutch springs Free length Spring quantity Minimum length Clutch housing thrust clearance Clutch housing radial clearance Push rod bending limit Carburetor Model (manufacturer) quantity Throttle cable free play (at the flange of the throttle grip) ID mark Main jet Main air jet Jet needle Needle jet Pilot air jet 1 Pilot air jet 2 Pilot outlet Pilot jet Bypass 1 Valve seat size Starter jet 1 Starter jet 2 Throttle valve size Fuel level (below from the float chamber mating surface) Standard 1.5 ~ 1.7 mm (0.06 ~ 0.07 in) 5 ----

SPEC
Limit ------0.2 mm (0.008 in) ------35.3 mm (1.39 in) ------0.5 mm (0.02 in) ----------------------------------------------------

37.3 mm (1.47 in) 4 ---0.010 ~ 0.044 mm (0.0004 ~ 0.0017 in) 0.10 ~ 0.35 mm (0.0039 ~ 0.0138 in) ----

BST34 (MIKUNI) 1 3 ~ 5 mm (0.12 ~ 0.20 in) 4BEV 30 #125 1.0 5DL27-1 0-1 #70 #1.2 0.85 #40 0.8 2.0 #65 0.8 #130 11.5 mm (0.45 in)

-6-

CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS

Item Front tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 90 ~ 183 kg (198 ~ 404 lb) Min. tire tread depth Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 90 ~ 197 kg (198 ~ 434 lb) Min. tire tread depth Front brake Brake type Operation Brake lever free play (at lever end) Recommended fluid Brake disc Diameter thickness Min. thickness Max. deflection Brake pad lining thickness Master cylinder inside diameter Caliper cylinder inside diameter Standard With tube 2.75-21-45P TW27 (BRIDGESTONE) C-6006 (CHENG SHIN) 125 kPa (1.25 kg/cm2, 18 psi) 150 kPa (1.5 kg/cm2, 22 psi) ----

SPEC
Limit ------------------1.0 mm (0.04 in) ------------------1.0 mm (0.04 in) ---------------3.0 mm (0.12 in) 0.15 mm (0.0059 in) 0.8 mm (0.03 in) -------

With tube 120/80-18-62P TW30 (BRIDGESTONE) C-6006 (CHENG SHIN) 150 kPa (1.5 kg/cm2, 21.8 psi) 175 kPa (1.75 kg/cm2, 25.4 psi) ----

Single-disc brake Right-hand operation 2 ~ 5 mm (0.08 ~ 0.20 in) DOT 4 220 3.5 mm (8.66 0.14 in) ------5.3 mm (0.21 in) 11 mm (0.43 in) 26.9 mm (1.06 in) and 22.2 mm (0.87 in)

-7-

CHASSIS SPECIFICATIONS
Item Rear brake Brake type Operation Brake pedal position Brake drum Inside diameter Lining thickness Shoe spring free length Front suspension Suspension type Front fork type Front fork travel Spring Free length Spring rate (K1) Spring stroke (K1) Spring rate (K2) Spring stroke (K2) Optional spring available Standard enclosed gas/air pressure Fork oil Recommended oil Quantity (each front fork leg) Level (from the top of the inner tube, with the inner tube fully compressed, and without the fork spring) Steering Steering bearing type No./size of steel balls (upper) Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Standard Leading, trailing - drum brake Right-foot operation 10 mm (0.39 in) 110 mm (4.33 in) 4 mm (0.16 in) 50.5 mm (1.99 in) Telescopic fork Coil spring/oil damper 225 mm (8.86 in) 594.7 mm (23.41 in) 3.4 N/mm (0.34 kgf/mm, 19.4 lb/in) 0 ~ 105 mm (0 ~ 4.13 in) 3.9 N/mm (0.39 kgf/mm, 22.27 lb/in) 105 ~ 230 mm (4.13 ~ 9.06 in) No 2,000 kPa (20 kgf/cm2, 290 psi) Fork oil 10 W or equivalent 366 cm3 (12.9 Imp oz, 12.4 US oz) 140 mm (5.51 in)

SPEC
Limit ---------111 mm (4.37 in) 1.5 mm (0.06 in) ------------582.8 mm (22.94 in) -------------------------------

Ball and taper roller bearing 19 pcs./0.1875 in Swingarm (link suspension) Coil spring, gas/oil damper 72 mm (2.83 in) 174 mm (6.85 in) 60.3 N/mm (6.03 kgf/mm, 344.3 lb/in) 0 ~ 87 mm (0 ~ 3.43 in) No

----------------------------

-8-

CHASSIS SPECIFICATIONS
Item Drive chain Model (manufacturer) Link quantity Drive chain slack Standard 428V2 (DAIDO) 120 35 ~ 45 mm (1.38 ~ 1.77in)

SPEC
Limit ----------

-9-

ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS

Item Ignition coil Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance CDI CDI magneto model (manufacturer) CDI unit model (manufacturer) Pickup coil resistance Source coil resistance Charging system System type Model (manufacturer) Nominal output Stator coil resistance Rectifier regulator Regulator type Model (manufacturer) No-load regulated voltage Rectifier capacity Withstand voltage Battery Battery type Battery voltage/capacity Specific gravity Bulbs (voltage/wattage quantity) Headlight Tail/brake light Front turn signal light Rear turn signal light Meter light Electric starting system System type Starter motor Model (manufacturer) Power output Brushes Overall length Spring force Armature coil resistance Commutator diameter Mica undercut 2JN (YAMAHA) 6 mm (0.24 in) 0.18 ~ 0.28 6.32 ~ 9.48 k 4JG1 (YAMAHA) 3GX (YAMAHA) 803.6 ~ 836.4 /R-W 600 ~ 900 /Br-G 472 ~ 708 /Y-G AC magneto 4JG1 (YAMAHA) 14 V/12.1 A at 5,000 r/min 0.48 ~ 0.72 Semiconductor, short circuit SH629A-12 (SHINDENGEN) 14.1 ~ 14.9 V 10 A 200 V GT6B-3 12 V/6 AH 1.320 12 V 60 W/55 W 1 12 V 8 W/27 W 1 12 V 27 W/8 W 2 12 V 27 W 2 12 V 3.4 W 1 Constant mesh 4JG (YAMAHA) 0.4 kW 10 mm (0.39 in) Standard

SPEC
Limit ----------------------------------------------------------------------------------------

3.5 mm (0.14 in) 5.52 ~ 8.28 N (552 ~ 828 gf, 19.9 ~ 29.8 oz) ---0.013 ~ 0.015 ---22 mm (0.87 in) 21 mm (0.83 in) 1.5 mm (0.06 in) ----

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ELECTRICAL SPECIFICATIONS
Item Starter relay Model (manufacturer) Amperage Coil resistance Horn Horn type Model (manufacturer) quantity Max. amperage Performance Coil resistance Turn signal relay Relay type Model (manufacturer) Self-cancelling device built-in Turn signal blinking frequency Wattage Fuses (amperage quantity) Main fuse Reserve fuse Standard MS5F-651 (JIDECO) 180 A 3.52 ~ 5.28 Plane GF-12 (NIKKO) 1 1.5 A 95 ~ 105 db/2 m 4.3 ~ 4.8 Full transistor FE246BH (DENSO) No 75 ~ 95 cycles/min. 27 W 2 + 3.4 W 20 A 1 20 A 1

SPEC
Limit ----------------------------------------------

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TIGHTENING TORQUES TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES Part to be tightened Breather assembly Tensioner Air filter case Carburetor joint clamp Air filter case (front) Air filter case (rear) Exhaust pipe protector Muffler protector Exhaust pipe and muffler link Crankcase 1 & 2 Crankcase 1 & 2 Crankcase 1 & 2 Crankcase 1 & 2 Crankcase cover 1 Crankcase cover 1 Ignition coil lead clamp Crankcase cover 2 Crankcase cover 3 Crankcase cover 3 Crankcase cover 3 Starter clutch assembly CHASSIS TIGHTENING TORQUES Part to be tightened Shift pedal assembly Thread size M6 Part name Screw Bolt Bolt Screw Screw Bolt Screw Screw Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Thread Qty size M6 M6 M6 M4 M6 M6 M6 M6 M8 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M8 2 2 2 2 1 2 3 2 1 7 2 2 1 6 2 1 2 5 3 2 3

SPEC

Tightening torque Nm 10 7.5 10 2 7 7 7 7 20 10 10 10 10 10 10 10 10 10 10 10 30 mkgf 1.0 0.75 1.0 0.2 0.7 0.7 0.7 0.7 2.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 3.0 ftlb 7.2 5.4 7.2 1.4 5.1 5.1 5.1 5.1 14 7.2 7.2 7.2 7.2 7.2 7.2 7.2 7.2 7.2 7.2 7.2 22

Remarks

Tightening torque Nm 10 mkgf 1.0 ftlb 7.2

Remarks

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CABLE ROUTING CABLE ROUTING

1 Clutch cable 2 Brake hose 3 Throttle cable 4 Band 5 Front brake switch lead 6 Handlebar switch lead (right) 7 Handlebar switch lead (left) 8 Clutch switch lead 9 Flasher light lead (right)

SPEC

0 Indicator light box lead A Main switch lead B Speedometer cable C Speedometer lead D Flasher light lead (left) Pass the starter cable to the front of the clutch cable and the throttle cable. Pass the throttle cable through the guide. Pass the brake hose through the guide.

- 13 -

CABLE ROUTING
Align the end of the brake master cylinder holder with the punch mark in the handlebar. Align the slit of clutch lever holder with the punch mark on the handlebar. Align the end of the handlebar switch (left) with the punch mark on the handlebar. Route the front brake switch lead and handlebar switch lead (right) between the handlebar crown and speedometer, then through the head pipe guide (left).

SPEC

Route the clutch switch lead between the handlebar crown and speedometer and through the head pipe guide (left). Clamp the flasher light lead (left), speedometer lead, main switch lead and handlebar switch lead (left). To headlight. Align the locating tape on the wireharness with the headlight stay. Clamp the wireharness. 10

- 14 -

CABLE ROUTING
1 Speedometer cable 2 Cable holder 3 Brake hose 4 Brake hose holder 5 Cable guide 6 Cable guide 7 Front brake switch lead 8 Handle switch lead (right) 9 Throttle cable 0 Starter cable A Clutch cable B Sidestand switch lead C Overflow hose D Horn lead E Cable holder F Rear brake switch lead

SPEC

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CABLE ROUTING
Pass the handlebar switch lead (right), front brake switch lead, clutch switch lead, starter cable, throttle cable and clutch cable through the guide. Fasten the front brake switch lead, clutch switch lead and handlebar switch lead (right) with a plastic locking tie. Fasten the wireharness, throttle cable, clutch cable and starter cable with a plastic clamp. Fasten the wireharness with a plastic locking tie.

SPEC

Fasten the flasher light lead (left) and sidestand switch lead with a plastic locking tie. Fasten the flasher light lead (left) with a plastic locking tie. Fasten the sidestand switch lead with a metal clamp. Fasten the sidestand switch lead with a plastic locking tie. Guide (engine side)

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CABLE ROUTING
Fasten the handlebar switch lead, clutch switch lead, front brake switch lead, starter cable, clutch cable and throttle cable with a plastic locking tie. Align the portion of the front brake hose marked with white paint with the clamp. Clamp the front brake hose. Fasten the front brake hose and speedometer cable with a plastic locking tie.

SPEC

Fasten the flywheel magneto lead, pulser coil lead, battery lead (), starter motor lead and rear brake switch leads with a plastic locking tie. Fasten the flywheel magneto lead, pulser coil lead, battery lead () and starter motor lead with a metal clamp. To engine.

- 17 -

CABLE ROUTING
1 Starter motor lead 2 Battery lead () 3 Battery 4 Ground lead 5 Pulser lead 6 Flywheel magneto lead 7 Wireharness 8 Horn lead 9 Diode 0 Canister (for California only) A Overflow hose (for California only)

SPEC

B CDI unit lead C Battery lead (+) D Starter relay Fasten the flasher light lead (right) and taillight lead with a plastic locking tie. Fasten the flywheel magneto lead, pulser coil lead, battery lead (), starter motor lead and wireharness with a plastic locking tie.

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CABLE ROUTING
Align the white tape with the arrow mark. Fasten the clutch cable with a plastic locking tie. Pass the canister hose through the guide (for California only). Fasten the canister hose (for California only) and wireharness with a plastic clip. Fasten the wireharness with a plastic clamp. Pass the canister hose through the guide (for California only).

SPEC

Fasten the starter motor lead with a metal clamp. Fasten the battery lead (+) with a plastic clamp. Fasten the flasher light lead (right) and taillight lead with a locking tie.

- 19 -

CABLE ROUTING
1 Wireharness 2 Rectifier/regulator 3 Flasher light lead (right) 4 Tail/brake light lead 5 Flasher light lead (left) 6 Sidestand switch lead Fasten the flasher light lead (right) and taillight lead with a metal clamp. Fasten the taillight lead with a metal clamp.

SPEC

Fasten the flasher light lead (left) with a metal clamp. Fasten the relay lead, flasher light lead (left) and sidestand switch lead with a plastic clip. Clamp the flywheel magneto lead.

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THROTTLE CABLE FREE PLAY ADJUSTMENT

CHK ADJ

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: q Throttle cable free play a Out of specification Adjust.

Throttle cable free play: 3 ~ 5 mm (0.12 ~ 0.20 in)

2. Remove: q Side covers q Seat q Air scoops q Fuel tank Refer to the SEAT, FUEL TANK AND COVER section.

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THROTTLE CABLE FREE PLAY ADJUSTMENT

2 4 3 6 5 1

CHK ADJ

3. Adjust: q Throttle cable free play

*********************************
Adjustment steps: NOTE: When accelerating, throttle cable #1 1 is pulled and throttle cable #2 2 is pushed. First step: q Loosen the locknut 3 on throttle cable #2. q Turn the adjuster 4 in or out until all slack is removed from throttle cable #2. Second step: q Loosen the locknut 5 on throttle cable #1. q Turn the adjuster 6 in or out until the specified free play is obtained. Turning in Turning out
q

Free play is increased. Free play is decreased.

Tighten the locknut.

NOTE: If the free play can not be adjusted here, adjust it at the throttle grip side of the cable. Final step: q Loosen the locknut 7. q Turn the adjuster 8 in or out until the specified free play is obtained. Turning in Turning out
q

Free play is increased. Free play is decreased.

Tighten the locknut.

WARNING
After adjusting the free play, turn the handlebar to right and left, and make sure that the engine idling does not run faster.
q

Install the fuel tank, seat and the side covers. Bolts (fuel tank, air scoops, seat and side cover): 7 Nm (0.7 mkg, 5.1 ftlb)

*********************************

T.

R.

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ENGINE ASSEMBLY AND ADJUSTMENT

ENG

ENGINE
ENGINE ASSEMBLY AND ADJUSTMENT
CLUTCH AND OIL PUMP
1 Clutch spring 2 Pressure plate 3 Push plate 4 Push rod 1 5 Clutch plate 6 Friction plate 7 Clutch boss 8 Thrust washer 9 Primary driven gear 0 Ball A Push rod 2 B Push lever C Primary drive gear D Oil pump gear cover E Oil pump driven gear F Oil pump G Gasket

FRICTION PLATE THICKNESS: 2.90 ~ 3.10 mm (0.114 ~ 0.122 in) <LIMIT>: <2.8 mm (0.110 in)>

CLUTCH SPRING MINIMUM FREE LENGTH: 35.3 mm (1.39 in) CLUTCH PLATE WARPAGE LIMIT: 0.2 mm (0.008 in)

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ENGINE ASSEMBLY AND ADJUSTMENT

CYLINDER HEAD
1 Bolt 2 Washer 3 Spark plug 4 Tappet cover (intake) 5 O-ring 6 Bolt (oil check) 7 Tappet cover (exhaust) 8 O-ring 9 Cylinder head

ENG

0 Dowel pin A Grommet B Cylinder head gasket C Breather cover D O-ring E O-ring F Cylinder head side cover

A B C

SPARK PLUG TYPE: DR8EA (N.G.K.), X24ESR-U (DENSO) SPARK PLUG GAP: 0.6 ~ 0.7 mm (0.02 ~ 0.03 in) CYLINDER HEAD WARPAGE LIMIT: 0.03 mm (0.0012 in)

TIGHTENING SEQUENCE:

- 24 -

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)

ENG

A B

SHAFT-TO-CAP CLEARANCE: 0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in) CAMSHAFT RUNOUT LIMIT: 0.03 mm (0.0012 in)

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FRONT BRAKE

CHAS

CHASSIS
FRONT BRAKE
1 Master cylinder cap 2 Diaphragm 3 Master cylinder kit 4 Master cylinder 5 Holder (brake hose and meter cable) 6 Brake hose 7 Brake caliper body 8 Rubber boot BRAKE FLUID TYPE: DOT 4 BRAKE PAD WEAR LIMIT: 0.8 mm (0.03 in) BRAKE DISC WEAR LIMIT: 3.0 mm (0.12 in) 9 Pad spring 0 Caliper bracket A Brake pads B Piston C Dust boot D Piston seal E Brake disc F Cable holder

A B C

- 26 -

CHECKING OF SWITCHES

ELEC

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 the switches (e.g., main switch, handlebar switch, bracket switch, lighting switch etc.). The extreme left column indicates the switch positions and the top line indicates the colors of leads of connected with the terminals in the switch component. indicates the terminals between which there is a continuity of electricity; i.e., a closed circuit at the respective switch positions. In this chart: R and Br and B/W and B are continuous with the ON switch position.

R ON OFF LOCK

Br B/W B

CHECKING SWITCH FOR TERMINAL CONNECTION Before checking the switch, refer to the connection chart as shown above and check for the correct terminal connection (closed circuit) by the color combination. To explain how to check the switch, the main switch taken for example in the following.

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CHECKING OF SWITCHES

ELEC

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 coupler. 2. Inspect whether any lead is off the terminal inside the coupler. If it is, repair it. NOTE: If the coupler is clogged with mud or dust, blow it off by compressed air.

R ON OFF LOCK

Br B/W B

3. Use the connection chart to check the color combination for continuity (a closed circuit). In this example, the continuity is as follows. R and Br and B/W and B are continuous with the ON switch position. Please note that there is no continuity (an open circuit) at all for the color combinations other than the above. 4. Check the switch component for the continuity between R and Br.

R Br

B/W B

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CHECKING OF SWITCHES

ELEC

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Checking steps: q Turn the switch key to the ON, OFF and LOCK several times. q Set the pocket tester selector to the 1. q Connect the tester (+) lead to the R lead terminal in the coupler and the () lead to the Br lead terminal. NOTE: Use thin probes for checking the continuity. Otherwise, the probes may contact other terminals inside the coupler.
q

Check the continuity between R and Br at the switch position ON 1, OFF 2 and LOCK 3. There must be continuity (the tester indicating 0) at the ON switch position, and there must be no continuity (the tester indicating ) at OFF or LOCK. There is something wrong between R and Br if there is no continuity at the ON position or if there is some continuity either at the OFF or LOCK.

NOTE: Check the switch for continuity several times.

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5. Next go on to checking of the continuity between B/W and B at the respective switch position, as in the same manner mentioned above. 6. If there is something wrong with any one of the combinations, replace the switch component.

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XT225N WIRING DIAGRAM

Sb

W/L W/R O L/Y B O L/Y B

G Br

G/L G/W B/R (GRAY) G/W G/L B/R W/R W/L

(GRAY) G Y Br R Sb W W W Sb W

O B

W W W

W W W

G
B/W

2
R L/Y B/W
ON

L/Y

9
B/W B R Br B L/B L/Y Br R

B
OFF START

C
OFF RUN R/W R/W L/W B B/W B R/W B/W

W W W R R W R W W

R R

OFF LOCK

(BLACK)

3
B

D
B/W R/W B/W B

7
B B B

R L/W R/W (BLACK) L/W R/W Br

L/B

B
B

B
B Br L/W Sb L/W B/Y L/W Sb Br L/W L/B Br

6
B

H
L/B B/W Sb

Sb B/W Br L/W

E
L/W B/Y B/Y L/W

A
L/B

B B

B/Y L/B

F
B B (BLUE) B/W Br L/W B/W

J
B Br

Br

Br

Br

L B

Br B

R
P Br

V
P

Br/W Br

S
Br/W Br/W

O
Br Sb Y G/Y Br Br/W Ch Dg

1 CDI magneto 2 Neutral switch 3 Rectifier/regulator 4 Battery (+) lead 5 Battery 6 Battery () lead 7 Starter relay 8 Starter motor 9 Main switch 0 Starting circuit cut-off relay A Clutch switch B Start switch C Engine stop switch D Right handlebar switch E Diode F Sidestand switch G CDI unit H Neutral relay I Ignition coil J Meter light K Neutral indicator light L Turn signal indicator light M High beam indicator light N Meter assembly O Rear brake switch P Tail/brake light lead Q Tail/brake light R Front brake switch S Turn signal relay T Front turn signal/position light U Rear turn signal V Horn W TURN switch X LIGHTS (Dimmer) switch Y HORN switch Z Left handlebar switch [ Headlight

Br Y

B B

K L
B Sb Dg Ch Br Y Sb B Br Br/W B Br

(BLACK) (BLACK)

Br

Br Ch P Br/W B Dg (RED)

Ch Y/R Br/W P Dg B (RED)

Y
OFF ON

X
HIGH LOW

W
L N R

N
Y Y

M
B Ch Dg

Z
B B Y G B

B B

Y G Y G

[
B Dg Ch Ch L Dg Y L

U
B

P
B Y L B Y L

COLOR CODE
B ............black Br ...........brown Ch ..........chocolate Dg ..........dark green G ............green L.............blue O ........... orange P............ pink R............ red Sb.......... sky blue W........... white Y............ yellow B/R.........black/red B/W........black/white B/Y.........black/yellow Br/W.......brown/white G/L.........green/blue B/W........green/white G/Y........ green/yellow L/B ........ blue/black L/W ....... blue/white L/Y ........ blue/yellow R/W ....... red/white W/L ....... white/blue W/R ....... white/red Y/R ........ yellow/red