XT225N 4BE-AE3

SUPPLEMENTARYSERVICEMANUAL

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and new data forthe XT225N. For complete information on service procedures, it is necessary to use this Supple-mentary Service Manual together with the following manual.

XT225D/XT225DC SERVICE MANUAL: 4BE-28197-20XT225H/XT225HC SUPPLEMENTARY SERVICE MANUAL: 4BE-AE1

XT225J SUPPLEMENTARY SERVICE MANUAL: 4BE-AE2

XT225NSUPPLEMENTARY SERVICE MANUAL

2000 by Yamaha Motor Co., Ltd.First edition, October 2000

All rights reserved.Any reproduction or unauthorized use

without the written permission ofYamaha Motor Co., Ltd.is expressly prohibited.

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NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic inone manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamahavehicles should have a basic understanding of mechanics and the techniques to repair these typesof vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely torender the vehicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regardto performance and emissions. Proper service with the correct tools is necessary to ensure that thevehicle will operate as designed. If there is any question about a service procedure, it is imperativethat you contact a Yamaha dealer for any service information changes that apply to this model. Thispolicy is intended to provide the customer with the most satisfaction from his vehicle and to conformto federal environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications andsignificant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-ers and will appear in future editions of this manual where applicable.

NOTE:@

• This Service Manual contains information regarding periodic maintenance to the emission controlsystem. Please read this material carefully.

• Designs and specifications are subject to change without notice. @@

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IMPORTANT MANUAL INFORMATIONParticularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person checking or repairing themotorcycle.

A CAUTION indicates special precautions that must be taken to avoid damageto the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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HOW TO USE THIS MANUALCONSTRUCTION OF THIS MANUALThis 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. (For the chapter “Periodic inspection and adjustment” the 3rd titleappears.)

3rd title 3: This is a final title.

MANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The informa-tion has been compiled to provide the mechanic with an easy to read, handy reference that containscomprehensive explanations of all disassembly, repair, assembly, and inspections.A set of particularly important procedure 4 is placed between a line of asterisks “*” with each pro-cedure preceded by “”.

IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol 5. 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. A condition of a faulty component will precede an arrow symbol and the course of action required

the symbol 9.

EXPLODED DIAGRAMEach chapter provides exploded diagrams before each disassembly section for ease in identifyingcorrect disassembly and assembly procedures.

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SYMBOLSThe following symbols are not relevant toevery vehicle. Symbols 1 to 8 indicate the subject of eachchapter.

1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion6 Chassis 7 Electrical system 8 Troubleshooting

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

Symbols F to K in the exploded diagramsindicate the types of lubricants and lubricationpoints.

F Engine oil G Gear oil H Molybdenum disulfide oilI Wheel bearing greaseJ Lithium soap base greaseK Molybdenum disulfide grease

Symbols L to M in the exploded diagramsindicate the following.

L Apply locking agent (LOCTITE®) M Replace the part

1 2

3 4

5 6

7 8

9 0

A B

C D E

F G H

I J K

L M

GENINFO SPEC

CHKADJ ENG

CARB CHAS

– +ELEC TRBLSHTG

T R..

E G M

B LS M

LTNew

CONTENTS

SPECIFICATIONS .............................................................................................1GENERAL SPECIFICATIONS ...................................................................1ENGINE SPECIFICATIONS.......................................................................2CHASSIS SPECIFICATIONS.....................................................................7ELECTRICAL SPECIFICATIONS ............................................................10TIGHTENING TORQUES ........................................................................12

ENGINE TIGHTENING TORQUES .....................................................12CHASSIS TIGHTENING TORQUES ...................................................12

CABLE ROUTING....................................................................................13

PERIODIC INSPECTION AND ADJUSTMENT ..............................................21ENGINE....................................................................................................21

THROTTLE CABLE FREE PLAY ADJUSTMENT ...............................21

ENGINE ...........................................................................................................23ENGINE ASSEMBLY AND ADJUSTMENT .............................................23

CLUTCH AND OIL PUMP....................................................................23CYLINDER HEAD................................................................................24CAMSHAFT AND TIMING CHAIN.......................................................25

CHASSIS .........................................................................................................26FRONT BRAKE........................................................................................26

ELECTRICAL ..................................................................................................27CHECKING OF SWITCHES ....................................................................27

SWITCH CONNECTION AS SHOWN IN MANUAL.............................27CHECKING SWITCH FOR TERMINAL CONNECTION......................27

XT225N WIRING DIAGRAM

- 1 -

SPEC

SPECIFICATIONSGENERAL SPECIFICATIONS

Item Standard Limit

Model code 4BEX ----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) ----Minimum ground clearance 285 mm (11.2 in) ----Minimum turning radius 1,900 mm (74.8 in) ----

WeightWet (with oil and a full fuel tank) 121 kg (267 lb) ----Dry (without oil and fuel) 108 kg (238 lb) ----Maximum load (total of cargo, rider,passenger, and accessories)

183 kg (404 lb) ----

GENERAL SPECIFICATIONS

- 2 -

SPECENGINE SPECIFICATIONS

ENGINE SPECIFICATIONS

Item Standard Limit

EngineEngine type Air-cooled, 4-stroke, SOHC ----Displacement 223 cm3 ----Cylinder arrangement Forward inclined single cylinder ----Bore × stroke 70 × 58 mm (2.76 × 2.28 in) ----Compression ratio 9.5 : 1 ----Engine idling speed 1,300 ~ 1,500 r/min ----Standard compression pressure (at sea level)

1,200 kPa(12.0 kgf/cm2, 174 psi) at 1,000 r/min

----

CamshaftDrive system Chain drive (left) ----Camshaft cap inside diameter 25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in) ----Camshaft journal diameter 24.960 ~ 24.980 mm (0.9827 ~ 0.9835 in) ----Camshaft-journal-to-camshaft-capclearance

0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in) ----

Intake camshaft lobe dimensions

Measurement A 36.51 ~ 36.61 mm (1.437 ~ 1.441 in) 36.41 mm (1.43 in)

Measurement B 30.1 ~ 30.2 mm (1.185 ~ 1.189 in) 30.0 mm (1.18 in)

Measurement C 6.50 ~ 6.62 mm (0.256 ~ 0.261 in) ----Exhaust camshaft lobe dimensions

Measurement A 36.51 ~ 36.61 mm (1.437 ~ 1.441 in) 36.41 mm (1.43 in)

Measurement B 30.15 ~ 30.25 mm (1.187 ~ 1.191 in) 30.05 mm (1.18 in)

Measurement C 6.50 ~ 6.62 mm (0.256 ~ 0.261 in) ----

C

A

B

C

A

B

- 3 -

SPECENGINE SPECIFICATIONS

Max. camshaft runout ---- 0.03 mm (0.0012 in)

Timing chainModel/number of links Borg Warner 92RH/104 ----Tensioning system Automatic ----

Valve springsInner springs

Free lengthIntake 36.17 mm (1.42 in) 34.35 mm

(1.35 in)Exhaust 36.17 mm (1.42 in) 34.35 mm

(1.35 in)Installed length (valve closed)

Intake 30.5 mm (1.20 in) ----Exhaust 30.5 mm (1.20 in) ----

Compressed spring force (installed)Intake 75.0 ~ 91.7 N

(7.50 ~ 9.17 kgf, 16.9 ~ 20.6 lb)----

Exhaust 75.0 ~ 91.7 N (7.50 ~ 9.17 kgf, 16.9 ~ 20.6 lb)

----

Spring tilt

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

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

Winding direction (top view)Intake Counterclockwise ----Exhaust Counterclockwise ----

Item Standard Limit

- 4 -

SPECENGINE SPECIFICATIONS

Outer springsFree 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 128.5 ~ 157.9 N

(12.9 ~ 15.8 kgf, 28.9 ~ 35.5 lb)----

Exhaust 128.5 ~ 157.9 N (12.9 ~ 15.8 kgf, 28.9 ~ 35.5 lb)

----

Spring tilt

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

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

Winding direction (top view)Intake Clockwise ----Exhaust Clockwise ----

PistonPiston-to-cylinder clearance 0.025 ~ 0.050 mm (0.001 ~ 0.002 in) 0.15 mm

(0.0059 in)Diameter D 69.960 ~ 69.975 mm (2.7543 ~ 2.7549 in) ----

Height H 5.0 mm (0.2 in) ----

Item Standard Limit

H

D

- 5 -

SPECENGINE SPECIFICATIONS

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 pinOutside diameter 15.991 ~ 16.000 mm (0.6296 ~ 0.6299 in) 15.971 mm

(0.6288 in)Piston-pin-to-piston-pin-bore clear-ance

0.002 ~ 0.022 mm(0.000079 ~ 0.000866 in)

0.072 mm (0.0028 in)

Piston ringsTop ring

Ring type Barrel ----Dimensions (B × T) 1.2 × 2.8 mm (0.05 × 0.11 in) ----End gap (installed) 0.15 ~ 0.30 mm (0.006 ~ 0.011 in) 0.55 mm

(0.02 in)Ring side clearance 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 0.12 mm

(0.0047 in)2nd ring

Ring type Taper ----Dimensions (B × T) 1.2 × 2.8 mm (0.05 × 0.11 in) ----End gap (installed) 0.15 ~ 0.30 mm (0.006 ~ 0.011 in) 0.65 mm

(0.025 in)Ring side clearance 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) 0.12 mm

(0.0047 in)Oil ring

Dimensions (B × T) 2.5 × 2.8 mm (0.10 × 0.11 in) ----End gap (installed) 0.3 ~ 0.9 mm (0.01 ~ 0.04 in) ----

ClutchClutch type Wet, multiple disc ----Clutch release method Inner push, cam push ----Operation Left-hand operation ----Friction plates

Thickness 2.9 ~ 3.1 mm (0.11 ~ 0.12 in) 2.8 mm (0.110 in)

Plate quantity 6 ----

Item Standard Limit

TB

BT

B

T

- 6 -

SPECENGINE SPECIFICATIONS

Clutch platesThickness 1.5 ~ 1.7 mm (0.06 ~ 0.07 in) ----Plate quantity 5 ----Max. warpage ---- 0.2 mm

(0.008 in)Clutch springs

Free length 37.3 mm (1.47 in) ----Spring quantity 4 ----Minimum length ---- 35.3 mm

(1.39 in)Clutch housing thrust clearance 0.010 ~ 0.044 mm (0.0004 ~ 0.0017 in) ----Clutch housing radial clearance 0.10 ~ 0.35 mm (0.0039 ~ 0.0138 in) ----Push rod bending limit ---- 0.5 mm

(0.02 in)Carburetor

Model (manufacturer) × quantity BST34 (MIKUNI) × 1 ----Throttle cable free play (at the flangeof the throttle grip)

3 ~ 5 mm (0.12 ~ 0.20 in) ----

ID mark 4BEV 30 ----Main jet #125 ----Main air jet 1.0 ----Jet needle 5DL27-1 ----Needle jet 0-1 ----Pilot air jet 1 #70 ----Pilot air jet 2 #1.2 ----Pilot outlet 0.85 ----Pilot jet #40 ----Bypass 1 0.8 ----Valve seat size 2.0 ----Starter jet 1 #65 ----Starter jet 2 0.8 ----Throttle valve size #130 ----Fuel level (below from the floatchamber mating surface)

11.5 mm (0.45 in) ----

Item Standard Limit

- 7 -

SPECCHASSIS SPECIFICATIONS

CHASSIS SPECIFICATIONS

Item Standard Limit

Front tireTire 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/cm2, 18 psi) ----90 ~ 183 kg (198 ~ 404 lb) 150 kPa (1.5 kg/cm2, 22 psi) ----

Min. tire tread depth ---- 1.0 mm (0.04 in)

Rear tireTire type With tube ----Size 120/80-18-62P ----Model (manufacturer) TW30 (BRIDGESTONE) ----

C-6006 (CHENG SHIN) ----Tire pressure (cold)

0 ~ 90 kg (0 ~ 198 lb) 150 kPa (1.5 kg/cm2, 21.8 psi) ----90 ~ 197 kg (198 ~ 434 lb) 175 kPa (1.75 kg/cm2, 25.4 psi) ----

Min. tire tread depth ---- 1.0 mm (0.04 in)

Front brakeBrake type Single-disc brake ----Operation Right-hand operation ----Brake lever free play (at lever end) 2 ~ 5 mm (0.08 ~ 0.20 in) ----Recommended fluid DOT 4 ----Brake disc

Diameter × thickness 220 × 3.5 mm (8.66 × 0.14 in) ----Min. thickness ---- 3.0 mm

(0.12 in)Max. deflection ---- 0.15 mm

(0.0059 in)Brake pad lining thickness 5.3 mm (0.21 in) 0.8 mm

(0.03 in)Master cylinder inside diameter 11 mm (0.43 in) ----Caliper cylinder inside diameter 26.9 mm (1.06 in) and 22.2 mm (0.87 in) ----

- 8 -

SPECCHASSIS SPECIFICATIONS

Rear brakeBrake 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 (0.06 in)

Shoe spring free length 50.5 mm (1.99 in) ----Front suspension

Suspension type Telescopic fork ----Front fork type Coil spring/oil damper ----Front fork travel 225 mm (8.86 in) ----Spring

Free length 594.7 mm (23.41 in) 582.8 mm(22.94 in)

Spring rate (K1) 3.4 N/mm (0.34 kgf/mm, 19.4 lb/in) ----Spring stroke (K1) 0 ~ 105 mm (0 ~ 4.13 in) ----Spring rate (K2) 3.9 N/mm (0.39 kgf/mm, 22.27 lb/in) ----Spring stroke (K2) 105 ~ 230 mm (4.13 ~ 9.06 in) ----

Optional spring available No ----Standard enclosed gas/air pressure 2,000 kPa (20 kgf/cm2, 290 psi) ----Fork oil ----

Recommended oil Fork oil 10 W or equivalent ----Quantity (each front fork leg) 366 cm3 (12.9 Imp oz, 12.4 US oz) ----Level (from the top of the inner tube,with the inner tube fully compressed,and without the fork spring)

140 mm (5.51 in) ----

SteeringSteering bearing type Ball and taper roller bearing ----No./size of steel balls (upper) 19 pcs./0.1875 in ----

Rear suspensionSuspension type Swingarm (link suspension) ----Rear shock absorber assembly type Coil spring, gas/oil damper ----Rear shock absorber assembly travel 72 mm (2.83 in) ----Spring

Installed length 174 mm (6.85 in) ----Spring rate (K1) 60.3 N/mm (6.03 kgf/mm, 344.3 lb/in) ----Spring stroke (K1) 0 ~ 87 mm (0 ~ 3.43 in) ----

Optional spring available No ----

Item Standard Limit

- 9 -

SPECCHASSIS SPECIFICATIONS

Drive chainModel (manufacturer) 428V2 (DAIDO) ----Link quantity 120 ----Drive chain slack 35 ~ 45 mm (1.38 ~ 1.77in) ----

Item Standard Limit

- 10 -

SPECELECTRICAL SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

Item Standard Limit

Ignition coilModel (manufacturer) 2JN (YAMAHA) ----Minimum ignition spark gap 6 mm (0.24 in) ----Primary coil resistance 0.18 ~ 0.28 Ω ----Secondary coil resistance 6.32 ~ 9.48 kΩ ----

CDICDI magneto model (manufacturer) 4JG1 (YAMAHA) ----CDI unit model (manufacturer) 3GX (YAMAHA) ----Pickup coil resistance 803.6 ~ 836.4 Ω/R-W ----Source coil resistance 600 ~ 900 Ω/Br-G ----

472 ~ 708 Ω/Y-G ----Charging system

System type AC magneto ----Model (manufacturer) 4JG1 (YAMAHA) ----Nominal output 14 V/12.1 A at 5,000 r/min ----Stator coil resistance 0.48 ~ 0.72 Ω ----

Rectifier regulatorRegulator type Semiconductor, short circuit ----Model (manufacturer) SH629A-12 (SHINDENGEN) ----No-load regulated voltage 14.1 ~ 14.9 V ----Rectifier capacity 10 A ----Withstand voltage 200 V ----

BatteryBattery type GT6B-3 ----Battery voltage/capacity 12 V/6 AH ----Specific gravity 1.320 ----

Bulbs (voltage/wattage × quantity)Headlight 12 V 60 W/55 W × 1 ----Tail/brake light 12 V 8 W/27 W × 1 ----Front turn signal light 12 V 27 W/8 W × 2 ----Rear turn signal light 12 V 27 W × 2 ----Meter light 12 V 3.4 W × 1 ----

Electric starting systemSystem type Constant mesh ----Starter motor

Model (manufacturer) 4JG (YAMAHA) ----Power output 0.4 kW ----Brushes

Overall length 10 mm (0.39 in) 3.5 mm (0.14 in)

Spring force 5.52 ~ 8.28 N (552 ~ 828 gf, 19.9 ~ 29.8 oz) ----Armature coil resistance 0.013 ~ 0.015 Ω ----Commutator diameter 22 mm (0.87 in) 21 mm

(0.83 in)Mica undercut 1.5 mm (0.06 in) ----

- 11 -

SPECELECTRICAL SPECIFICATIONS

Starter relayModel (manufacturer) MS5F-651 (JIDECO) ----Amperage 180 A ----Coil resistance 3.52 ~ 5.28 Ω ----

HornHorn type Plane ----Model (manufacturer) × quantity GF-12 (NIKKO) × 1 ----Max. amperage 1.5 A ----Performance 95 ~ 105 db/2 m ----Coil resistance 4.3 ~ 4.8 Ω ----

Turn signal relayRelay type Full transistor ----Model (manufacturer) FE246BH (DENSO) ----Self-cancelling device built-in No ----Turn signal blinking frequency 75 ~ 95 cycles/min. ----Wattage 27 W × 2 + 3.4 W ----

Fuses (amperage × quantity)Main fuse 20 A × 1 ----Reserve fuse 20 A × 1 ----

Item Standard Limit

- 12 -

SPECTIGHTENING TORQUES

TIGHTENING TORQUESENGINE TIGHTENING TORQUES

CHASSIS TIGHTENING TORQUES

Part to be tightened Part nameThread

sizeQ’ty

Tightening torqueRemarks

Nm m·kgf ft·lb

Breather assembly Screw M6 2 10 1.0 7.2Tensioner Bolt M6 2 7.5 0.75 5.4Air filter case Bolt M6 2 10 1.0 7.2Carburetor joint clamp Screw M4 2 2 0.2 1.4Air filter case (front) Screw M6 1 7 0.7 5.1Air filter case (rear) Bolt M6 2 7 0.7 5.1Exhaust pipe protector Screw M6 3 7 0.7 5.1Muffler protector Screw M6 2 7 0.7 5.1Exhaust pipe and muffler link Bolt M8 1 20 2.0 14Crankcase 1 & 2 Bolt M6 7 10 1.0 7.2Crankcase 1 & 2 Bolt M6 2 10 1.0 7.2Crankcase 1 & 2 Bolt M6 2 10 1.0 7.2Crankcase 1 & 2 Bolt M6 1 10 1.0 7.2Crankcase cover 1 Bolt M6 6 10 1.0 7.2Crankcase cover 1 Bolt M6 2 10 1.0 7.2Ignition coil lead clamp Bolt M6 1 10 1.0 7.2Crankcase cover 2 Bolt M6 2 10 1.0 7.2Crankcase cover 3 Bolt M6 5 10 1.0 7.2Crankcase cover 3 Bolt M6 3 10 1.0 7.2Crankcase cover 3 Bolt M6 2 10 1.0 7.2Starter clutch assembly Bolt M8 3 30 3.0 22

Part to be tightenedThread

size

Tightening torqueRemarks

Nm m·kgf ft·lb

Shift pedal assembly M6 10 1.0 7.2

- 13 -

SPECCABLE ROUTING

CABLE ROUTING1 Clutch cable2 Brake hose3 Throttle cable4 Band5 Front brake switch lead6 Handlebar switch lead (right)7 Handlebar switch lead (left)8 Clutch switch lead9 Flasher light lead (right)

0 Indicator light box leadA Main switch leadB Speedometer cableC Speedometer leadD Flasher light lead (left)È Pass the starter cable to the front of the clutch

cable and the throttle cable.É Pass the throttle cable through the guide.Ê Pass the brake hose through the guide.

- 14 -

SPECCABLE ROUTING

Ë Align the end of the brake master cylinder holderwith the punch mark in the handlebar.

Ì Align the slit of clutch lever holder with the punchmark on the handlebar.

Í Align the end of the handlebar switch (left) withthe punch mark on the handlebar.

Î Route the front brake switch lead and handlebarswitch lead (right) between the handlebar crownand speedometer, then through the head pipeguide (left).

Ï Route the clutch switch lead between the han-dlebar crown and speedometer and through thehead pipe guide (left).

Ð Clamp the flasher light lead (left), speedometer lead,main switch lead and handlebar switch lead (left).

Ñ To headlight.Ò Align the locating tape on the wireharness with

the headlight stay.Ó Clamp the wireharness.Ô 10°

- 15 -

SPECCABLE ROUTING

1 Speedometer cable2 Cable holder3 Brake hose4 Brake hose holder5 Cable guide6 Cable guide7 Front brake switch lead8 Handle switch lead (right)9 Throttle cable0 Starter cableA Clutch cable

B Sidestand switch leadC Overflow hoseD Horn leadE Cable holderF Rear brake switch lead

- 16 -

SPECCABLE ROUTING

È Pass the handlebar switch lead (right), front brakeswitch lead, clutch switch lead, starter cable,throttle cable and clutch cable through the guide.

É Fasten the front brake switch lead, clutch switchlead and handlebar switch lead (right) with aplastic locking tie.

Ê Fasten the wireharness, throttle cable, clutchcable and starter cable with a plastic clamp.

Ë Fasten the wireharness with a plastic locking tie.

Ì Fasten the flasher light lead (left) and sidestandswitch lead with a plastic locking tie.

Í Fasten the flasher light lead (left) with a plasticlocking tie.

Î Fasten the sidestand switch lead with a metalclamp.

Ï Fasten the sidestand switch lead with a plasticlocking tie.

Ð Guide (engine side)

- 17 -

SPECCABLE ROUTING

Ñ Fasten the handlebar switch lead, clutch switchlead, front brake switch lead, starter cable,clutch cable and throttle cable with a plastic lock-ing tie.

Ò Align the portion of the front brake hose markedwith white paint with the clamp.

Ó Clamp the front brake hose.Ô Fasten the front brake hose and speedometer

cable with a plastic locking tie.

Õ Fasten the flywheel magneto lead, pulser coillead, battery lead (–), starter motor lead and rearbrake switch leads with a plastic locking tie.

Ö Fasten the flywheel magneto lead, pulser coillead, battery lead (–) and starter motor lead witha metal clamp.

× To engine.

- 18 -

SPECCABLE ROUTING

1 Starter motor lead2 Battery lead (–)3 Battery4 Ground lead5 Pulser lead6 Flywheel magneto lead7 Wireharness8 Horn lead9 Diode0 Canister (for California only)A Overflow hose (for California only)

B CDI unit leadC Battery lead (+)D Starter relayÈ Fasten the flasher light lead (right) and taillight

lead with a plastic locking tie.É Fasten the flywheel magneto lead, pulser coil

lead, battery lead (–), starter motor lead andwireharness with a plastic locking tie.

- 19 -

SPECCABLE ROUTING

Ê Align the white tape with the arrow mark.Ë Fasten the clutch cable with a plastic locking tie.Ì Pass the canister hose through the guide (for

California only).Í Fasten the canister hose (for California only)

and wireharness with a plastic clip.Î Fasten the wireharness with a plastic clamp.Ï Pass the canister hose through the guide (for

California only).

Ð Fasten the starter motor lead with a metalclamp.

Ñ Fasten the battery lead (+) with a plastic clamp.Ò Fasten the flasher light lead (right) and taillight

lead with a locking tie.

- 20 -

SPECCABLE ROUTING

1 Wireharness2 Rectifier/regulator3 Flasher light lead (right)4 Tail/brake light lead5 Flasher light lead (left)6 Sidestand switch leadÈ Fasten the flasher light lead (right) and taillight

lead with a metal clamp.É Fasten the taillight lead with a metal clamp.

Ê Fasten the flasher light lead (left) with a metalclamp.

Ë Fasten the relay lead, flasher light lead (left) andsidestand switch lead with a plastic clip.

Ì Clamp the flywheel magneto lead.

- 21 -

CHKADJ

PERIODIC INSPECTION AND ADJUSTMENT

ENGINETHROTTLE 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)a

2. Remove: Side covers Seat Air scoops Fuel tank

Refer to the “SEAT, FUEL TANK ANDCOVER” section.

THROTTLE CABLE FREE PLAY ADJUSTMENT

- 22 -

CHKADJTHROTTLE CABLE FREE PLAY ADJUSTMENT

3. Adjust: Throttle cable free play

*********************************Adjustment steps:

NOTE:When accelerating, throttle cable #1 1 ispulled 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.Second step: Loosen the locknut 5 on throttle cable #1. Turn the adjuster 6 in or out until the speci-

fied free play is obtained.

Tighten the locknut.

NOTE:If the free play can not be adjusted here, adjustit at the throttle grip side of the cable.

Final step: Loosen the locknut 7. Turn the adjuster 8 in or out until the speci-

fied free play is obtained.

Tighten the locknut.

WARNINGAfter adjusting the free play, turn the han-dlebar to right and left, and make sure thatthe engine idling does not run faster.

Install the fuel tank, seat and the side covers.

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

Turning in Free play is increased.

Turning out Free play is decreased.

Turning in Free play is increased.

Turning out Free play is decreased.

T R..

Bolts (fuel tank, air scoops, seatand side cover):

7 Nm (0.7 m•kg, 5.1 ft•lb)

2

3

4

1

5

6

78

- 23 -

ENG

ENGINEENGINE ASSEMBLY AND ADJUSTMENTCLUTCH AND OIL PUMP1 Clutch spring2 Pressure plate3 Push plate4 Push rod 15 Clutch plate6 Friction plate

7 Clutch boss8 Thrust washer9 Primary driven gear0 BallA Push rod 2B Push lever

C Primary drive gearD Oil pump gear coverE Oil pump driven gearF Oil pumpG Gasket

ENGINE ASSEMBLY AND ADJUSTMENT

A

FRICTION PLATE THICKNESS:2.90 ~ 3.10 mm (0.114 ~ 0.122 in)

<LIMIT>:<2.8 mm (0.110 in)>

BCLUTCH SPRING MINIMUM FREE LENGTH:

35.3 mm (1.39 in)

CCLUTCH PLATE WARPAGE LIMIT:

0.2 mm (0.008 in)

- 24 -

ENGENGINE ASSEMBLY AND ADJUSTMENT

CYLINDER HEAD1 Bolt2 Washer3 Spark plug4 Tappet cover (intake)5 O-ring6 Bolt (oil check)7 Tappet cover (exhaust)8 O-ring9 Cylinder head

0 Dowel pinA GrommetB Cylinder head gasketC Breather coverD O-ringE O-ringF Cylinder head side cover

‘

ASPARK PLUG TYPE:

DR8EA (N.G.K.), X24ESR-U (DENSO)

BSPARK PLUG GAP:

0.6 ~ 0.7 mm (0.02 ~ 0.03 in)

CCYLINDER HEAD WARPAGE LIMIT:

0.03 mm (0.0012 in)

D TIGHTENING SEQUENCE:

- 25 -

ENGENGINE ASSEMBLY AND ADJUSTMENT

CAMSHAFT AND TIMING CHAIN1 Gasket2 Timing chain tensioner3 Gasket4 Timing chain guide (intake side)5 Camshaft6 Pin7 Cam sprocket8 Timing chain9 Timing chain guide (exhaust side)

ASHAFT-TO-CAP CLEARANCE:

0.020 ~ 0.061 mm(0.0008 ~ 0.0024 in)

BCAMSHAFT RUNOUT LIMIT:

0.03 mm (0.0012 in)

- 26 -

CHAS

CHASSISFRONT BRAKE1 Master cylinder cap2 Diaphragm3 Master cylinder kit4 Master cylinder5 Holder (brake hose and meter cable)6 Brake hose7 Brake caliper body8 Rubber boot

9 Pad spring0 Caliper bracketA Brake padsB PistonC Dust bootD Piston sealE Brake discF Cable holder

FRONT BRAKE

ABRAKE FLUID TYPE:

DOT 4

BBRAKE PAD WEAR LIMIT:

0.8 mm (0.03 in)

CBRAKE DISC WEAR LIMIT:

3.0 mm (0.12 in)

- 27 -

– +ELEC

ELECTRICALCHECKING OF SWITCHESNOTE:This section is written based on a general model.

Check the switches for the continuity betweenthe terminal to determine correct connection.

Read the following for switch inspection.

SWITCH CONNECTION AS SHOWN IN MANUALThe manual contains a connection chart asshown left showing the terminal connections ofthe switches (e.g., main switch, handlebarswitch, bracket switch, lighting switch etc.).

The extreme left column indicates the switchpositions and the top line indicates the colorsof leads of connected with the terminals in theswitch component.

“ ” indicates the terminals betweenwhich there is a continuity of electricity; i.e., aclosed circuit at the respective switch posi-tions.

In this chart:“R and Br” and “B/W and B” are continuouswith the “ON” switch position.

ONR Br B/W B

OFFLOCK

CHECKING SWITCH FOR TERMINAL CONNECTIONBefore checking the switch, refer to the con-nection 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.

CHECKING OF SWITCHES

- 28 -

– +ELEC

1. Disconnect the main switch coupler fromthe wireharness.

CAUTION:Never disconnect the main switch couplerby pulling the leads. Otherwise, leads maybe pulled off the terminals inside the cou-pler.

2. Inspect whether any lead is off the termi-nal inside the coupler. If it is, repair it.

NOTE:If the coupler is clogged with mud or dust, blowit off by compressed air.

3. Use the connection chart to check thecolor combination for continuity (a closedcircuit). In this example, the continuity isas follows.

“R and Br” and “B/W and B” are continu-ous with the “ON” switch position.

Please note that there is no continuity (anopen circuit) at all for the color combina-tions other than the above.

4. Check the switch component for the con-tinuity between “R and Br”.

ONR

R

Br

BrB/W

B

B/W B

OFFLOCK

CHECKING OF SWITCHES

- 29 -

– +ELECCHECKING 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” lead terminal.

NOTE:Use thin probes for checking the continuity.Otherwise, the probes may contact other ter-minals inside the coupler.

Check the continuity between “R” and “Br” atthe switch position “ON” 1, “OFF” 2 and“LOCK” 3.There must be continuity (the tester indicat-ing “0”) at the “ON” switch position, and theremust 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” posi-tion or if there is some continuity either at the“OFF” or “LOCK”.

NOTE:Check the switch for continuity several times.

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

5. Next go on to checking of the continuitybetween “B/W” and “B” at the respectiveswitch position, as in the same mannermentioned above.

6. If there is something wrong with any oneof the combinations, replace the switchcomponent.

XT225N WIRING DIAGRAM

Ch

Br

W

W

W W

W

W

Sb

Sb

Sb

1

2

W W W

W W W R

B

W

W W

R

(BLACK)3

B

B

R

R

8

7

9

0

4

6

R

R L/Y

Br L/B

B

B/W

B

B

B

R

R

B

B B

5

L/W

R/W

R/W

R

L/W

L/W

B/WSb

Br

(BLACK)

ON

OFF

LOCK

L

N

R

B/W BBrR Br

L/YL/BR

Br

B/Y L/W

Sb

L/WBr

Sb

A BB L/B

B/Y

B/YL/W

L/B

B/W

L/WBr

Sb

B/Y

L/B

D

B C

E

H

N

F

OFF

START

OFF

RUN

B/WB

B/WR/W

B/W BB/WR/WL/W

R/WR/WB

L/W

L/B

L/WB/WB

B

L/W

B/W

(BLUE)

B

G

L/Y

W/LW

W/RR

B/RBr

G/LYG/W

B/W

G OOB

I

W/RW/LWR

OL/YB

L/YB

O

G Y

Br

G/L G/W

B/R

(GRAY) (GRAY)

BBr

BY

BrBB

L

Sb BBr/W

B BrDgBr

SbBrCh

B

Y

Br

Sb

Br Ch

DgBr/W

O

Br

G/Y

LYB

LYB

LYB

P

Q

Br

R

Y

Y

BBY

Br

(BLACK)(BLACK)

P

P

Br

Dg

Br/W

Br/W

Br

SBr/WBr

B

B

B

L Dg

TU

[

Ch

B

Ch

B

Dg

GYB

GYB

BB

HIGH

LOW

G

BY

OFF

ON

Br ChBr/W

B DgP Br/W

Dg

Y/RP

Ch

B

(RED) (RED)

VP Br

WXY

ZM

K

L

J

1 CDI magneto2 Neutral switch3 Rectifier/regulator4 Battery (+) lead5 Battery6 Battery (–) lead7 Starter relay8 Starter motor9 Main switch0 Starting circuit cut-off relayA Clutch switchB Start switchC Engine stop switchD Right handlebar switchE DiodeF Sidestand switchG CDI unitH Neutral relayI Ignition coilJ Meter lightK Neutral indicator lightL Turn signal indicator lightM High beam indicator lightN Meter assemblyO Rear brake switchP Tail/brake light leadQ Tail/brake lightR Front brake switchS Turn signal relayT Front turn signal/position lightU Rear turn signalV HornW “TURN” switchX “LIGHTS” (Dimmer) switchY “HORN” switchZ Left handlebar switch[ Headlight

COLOR CODEB ............blackBr ...........brownCh ..........chocolateDg ..........dark greenG............greenL.............blue

O ........... orangeP............ pinkR............ redSb.......... sky blueW........... whiteY............ yellow

B/R.........black/redB/W........black/whiteB/Y.........black/yellowBr/W.......brown/whiteG/L.........green/blueB/W........green/white

G/Y........ green/yellowL/B ........ blue/blackL/W ....... blue/whiteL/Y ........ blue/yellowR/W....... red/whiteW/L ....... white/blue

W/R ....... white/redY/R ........ yellow/red