1991 Yamaha XT225-C (D-G) Service Manual

Yamaha XT225D and XT225DC Technical Scope and Data

• Covers 1991 Yamaha XT225D and XT225DC motorcycle variants, including US-market non-California, US-California, and Canadian-market configurations
• Official Yamaha publication P/N LIT-11616-XT-25, 1st Edition, June 1991
• Contains 8 major sections with detailed exploded-view diagrams, comprehensive electrical circuit schematics, and factory torque specifications for chassis and engine components
• Delivered as a direct download the moment payment clears
• Indexed PDF search covers every chapter and appendix
• Laid out for standard letter and A4 printing
• This 1991 first edition is the original technical reference documentation provided to authorized Yamaha dealers for the XT225D-series launch

Manual Content and Structure

The 1991 Yamaha XT225D and XT225DC service manual is organized into distinct chapters covering general information, maintenance, engine overhaul, carburetion, chassis components, electrical systems, and troubleshooting. Each section provides specific service parameters, lubrication diagrams, and inspection criteria necessary for maintaining the 4-stroke SOHC engine and the diamond-frame chassis geometry. The document also includes specific emission control system maintenance instructions for the XT225DC California-only model, including canister and hose routing references.

Technical Specification Highlights

General specifications include the 223.21 cm3 displacement rating and the 9.5:1 compression ratio for the forward-inclined single cylinder engine. Engine assembly data includes critical torque values for internal components, such as the 50 Nm specified for the AC generator rotor and the 60 Nm requirement for the cam sprocket bolt. Electrical system depth includes reference values for the CDI unit, such as pickup coil resistance (656–984 ohms at 20°C) and charging coil resistance (584–876 ohms at 20°C). Valve clearance for the intake is listed at 0.05–0.09 mm in the cylinder head specification table. The coolant system is not applicable to this air-cooled unit, though oil capacity is documented at 1.1 liters with filter replacement. The Suzuki QuadRunner LT300E magneto pick-up coil resistance is specified at 450–650 ohms. For additional guidance on how factory workshop documentation is structured, see what an OEM service publication covers.

An official 371-page Yamaha OEM workshop manual covering the 1991 XT225D and XT225DC, documenting engine, chassis, electrical, and fuel-system specifications for the 4BE-series build.