2001-2007 Yamaha XT225 Service Manual Repair Manuals -and- Owner's Manual, Ultimate Set

LIT-11626-19-29 5RK-28199-14 XT225VC OWNER’S MANUAL XT225V

EAU10041

INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha XT225V/XT225VC. 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 you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer. The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.

IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations: NOTE: ● This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. ● Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer. WARNING EWA10010 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 MOTORCY- CLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in se vere injur y or death to the motorcycle operator, a bystander or a person inspecting 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. WARNING CAUTION: NOTE:

IMPORTANT MANUAL INFORMATION EAU10192 XT225V/XT225VC OWNER’S MANUAL ©2005 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2005 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-11626-19-29 AFFIX DEALER LABEL HERE

TABLE OF CONTENTS SAFETY INFORMATION ................... 1-1 Location of important labels ............. 1-5 DESCRIPTION ................................... 2-1 Left view ........................................... 2-1 Right view ......................................... 2-2 Controls and instruments.................. 2-3 INSTRUMENT AND CONTROL FUNCTIONS ........................................ 3-1 Main switch/steering lock ................. 3-1 Indicator lights ................................. 3-2 Speedometer unit ............................ 3-2 Handlebar switches ......................... 3-3 Clutch lever ...................................... 3-4 Shift pedal ........................................ 3-4 Brake lever ...................................... 3-4 Brake pedal ..................................... 3-5 Fuel tank cap ................................... 3-5 Fuel .................................................. 3-6 Fuel cock ......................................... 3-7 Starter (choke) knob “ 1 ” ................. 3-8 Seat ................................................. 3-8 Helmet holder .................................. 3-9 Adjusting the shock absorber assembly ...................................... 3-9 Sidestand ....................................... 3-11 Ignition circuit cut-off system ......... 3-12 PRE-OPERATION CHECKS ............... 4-1 Pre-operation check list ................... 4-2 OPERATION AND IMPORTANT RIDING POINTS .................................. 5-1 Starting and warming up a cold engine .......................................... 5-1 Starting a warm engine ................... 5-2 Shifting ............................................ 5-2 Engine break-in ............................... 5-4 Parking ............................................ 5-4 PERIODIC MAINTENANCE AND MINOR REPAIR .................................. 6-1 PERIODIC MAINTENANCE ............ 6-1 Owner’s tool kit ................................ 6-1 Periodic maintenance chart for the emission control system .............. 6-3 General maintenance and lubrication chart ............................................. 6-4 Removing and installing the cowling and panels ................................... 6-8 Checking the spark plug .................. 6-9 Canister (for California only) ......... 6-10 Engine oil and oil filter element ..... 6-11 Cleaning the air filter element ....... 6-14 Cleaning the spark arrester ........... 6-15 Carburetor ..................................... 6-16 Checking the throttle cable free play ............................................ 6-17 Valve clearance ............................. 6-17 Tires .............................................. 6-17 Spoke wheels ................................ 6-19 Accessories and replacement parts ........................................... 6-20 Adjusting the clutch lever free play ............................................ 6-20 Adjusting the brake lever free play ............................................ 6-21 Adjusting the brake pedal position and free play .............................. 6-22 Adjusting the rear brake light switch ......................................... 6-23 Checking the front brake pads and rear brake shoes ........................ 6-24 Checking the front brake fluid level ........................................... 6-25 Changing the brake fluid ............... 6-26 Drive chain slack ........................... 6-26 Cleaning and lubricating the drive chain .......................................... 6-27 Checking and lubricating the cables ........................................ 6-28 Checking and lubricating the throttle grip and cable ............................ 6-28 Checking and lubricating the brake and shift pedals ......................... 6-29 Checking and lubricating the brake and clutch levers ........................ 6-29 Checking and lubricating the sidestand ................................... 6-29 Lubricating the rear suspension .... 6-30 Checking the front fork .................. 6-30 Checking the steering ................... 6-31

TABLE OF CONTENTS Checking the wheel bearings ........ 6-31 Battery ........................................... 6-32 Replacing the fuse ......................... 6-33 Replacing the headlight bulb ......... 6-33 Replacing the tail/brake light bulb ............................................ 6-35 Replacing a turn signal light bulb ............................................ 6-35 Supporting the motorcycle ............. 6-36 Front wheel .................................... 6-37 Rear wheel .................................... 6-38 Troubleshooting ............................. 6-40 Troubleshooting chart .................... 6-41 MOTORCYCLE CARE AND STORAGE ........................................... 7-1 Care ................................................. 7-1 Storage ............................................ 7-3 SPECIFICATIONS .............................. 8-1 CONSUMER INFORMATION .............. 9-1 Identification numbers ..................... 9-1 Reporting safety defects .................. 9-3 Motorcycle noise regulation ............. 9-4 Maintenance record ......................... 9-5 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY ................................. 9-7 YAMAHA EXTENDED SERVICE (Y.E.S.) ........................................ 9-9

1-1 1 SAFETY INFORMATION EAU10311 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPEN- DENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERA- TOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE- MENTS BEFORE RIDING THIS MO- TORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUC- TIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. ● OBSERVE THE WARNINGS AND MAINTENANCE REQUIRE- MENTS IN THE OWNER’S MAN- UAL. ● OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES. ● OBTAIN PROFESSIONAL TECH- NICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN MADE NECES- SARY BY MECHANICAL CONDI- TIONS. Safe riding ● Always make pre-operation checks. Careful checks may help prevent an accident. ● This motorcycle is designed to carry the operator and a passenger. ● The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident. ● Therefore: ● Wear a brightly colored jacket. ● Use extra caution when ap- proaching and passing through intersections, since intersections are the most likely places for motorcycle accidents to oc- cur. ● Ride where other motorists can see you. Avoid riding in another motorist’s blind spot. ● Many accidents involve inexperi- enced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. ● Make sure that you are qualified and that you only lend your motorcycle to other qualified operators. ● Know your skills and limits. Staying within your limits may help you to avoid an accident. ● We recommend that you prac- tice riding your motorcycle where there is no traffic until you have become thoroughly famil- iar with the motorcycle and all of its controls. ● Many accidents have been caused by error of the motorcycle operator. A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or un- dercornering (insufficient lean an- gle for the speed). ● Always obey the speed limit and never travel faster than warrant-

SAFETY INFORMATION 1-2 1 ed by road and traffic conditions. ● Always signal before turning or changing lanes. Make sure that other motorists can see you. ● The posture of the operator and passenger is important for proper control. ● The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle. ● The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with both hands and keep both feet on the passenger footrests. ● Never carry a passenger unless he or she can firmly place both feet on the passenger footrests. ● Never ride under the influence of alcohol or other drugs. 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 preven- tion or reduction of head injuries. ● Always wear an approved helmet. ● Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard. ● The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations. ● Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident. ● Never touch the engine or exhaust system during or after operation. They become very hot and can cause burns. Always wear protective clothing that covers your legs, ankles, and feet. ● Passengers should also observe the precautions mentioned above. Modifications Modifications made to this motorcycle not approved by Yamaha, or the re- moval of original equipment, may ren- der the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use. Loading and accessories Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle: Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit. When loading within this weight limit, keep the following in mind: Maximum load: 183 kg (403 lb)

SAFETY INFORMATION 1-3 1 ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability. ● Shifting weights can create a sud- den imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently. ● Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, in- cluding such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or a slow steering response. Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be re- sponsible for the proper selection, in- stallation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories. Keep the following guidelines in mind, as well as those provided under “Load- ing” when mounting accessories. ● Never install accessories or carry cargo that would impair the performance of your motorcycle. Care- fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit suspension travel, steering travel or control operation, or ob- scure lights or reflectors. ● Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerody- namic 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. ● Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody- namic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when passing or being passed by large vehicles. ● Certain accessories can dis- place the operator from his or her normal riding position. This improper position limits the free- dom of movement of the operator and may limit control ability, therefore, such accessories are not recommended. ● Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMA- BLE: ● Always turn the engine off when

2001-2007 Yamaha XT225 Service Manual Repair Manuals -and- Owner's Manual, Ultimate Set

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