1999–2004 Yamaha XT225-C / TTR225L / TTR225M Service Manual (P/N LIT-11616-TT-25)

• OEM workshop publication (P/N LIT-11616-TT-25, dated October 1999)
• Covers 1999–2004 Yamaha XT225-C, TTR225L, and TTR225M, including California-specific variants, international configurations, and the 4BE-series build
• Contains 47 exploded-view diagrams, 8 wiring schematics, and 5 detailed engine torque specification tables
• Serves as the primary documentation for the TTR225 series, offering an authoritative reference for engine, chassis, and electrical specifications on these trail-oriented units

Technical Overview and Data

This manual provides a structured look at maintenance and overhaul parameters for the 4-stroke air-cooled engine. Whether you are reviewing the 223.21 cm³ SOHC power plant or inspecting the diamond-type chassis frames, the reference lays out exact specifications, inspection sequences, and electrical component layouts. It cuts straight to the hard data technicians need on the bench, ensuring a clear understanding of the mechanical baseline.

Specifications and Reference Values

Inside, detailed tables document critical engine clearances and frame dimensions. For example, intake valve clearance sits right at 0.05–0.09 mm according to the cylinder head maintenance charts. You will also find multi-stage torque sequences, such as the 22 Nm final-stage specification for cylinder head flange bolts. Rear shock absorber gas pressure values are clearly listed at 1,500–1,961 kPa, varying slightly by model configuration. When working with these highly pressurized components or handling internal engine timing, always verify procedures with a certified mechanic to ensure safe operation.