Yamaha XT350 1999 Owner’s Manual & XT225/XT250 Collection (P/N LIT-11626-13-18)

Use the owner’s manuals for routine care of their respective models, the training guide for selected XT350 service references, and the catalog for XT250 parts identification.

Repair coverage: The 1985 training guide refers to a separate service manual for detailed procedures. This collection does not replace a complete workshop manual for internal engine or transmission repair, and its XT250 coverage is parts identification rather than repair instructions.

PDF Search, Bookmarks and File Contents

Search and chapter access: The XT250 catalog has searchable parts lists and section bookmarks. Both owner’s manuals have chapter bookmarks but no text search. The Service Guide has neither text search nor bookmarks; its small wiring labels require zooming, and the full wiring diagram requires page rotation for comfortable viewing.

The ZIP contains four printable PDFs totaling 281 pages, including original covers and front matter. These counts include two safety/reply-card pages and three promotional pages in the XT350 owner’s manual, plus two safety/reply-card pages, two promotional pages and one divider page in the XT225 owner’s manual.

Owner Maintenance, XT350 Service Notes and XT250 Parts

The following selected contents highlight the main maintenance and technical references. Additional topics include cleaning and long-term storage preparation.

• Lubrication and intake: Owner procedures for oil and filter service, post-change oil-circulation checks, air-filter cleaning and oiling, and exhaust spark-arrester cleaning.

• Clutch and drive chain: Free-play and slack adjustments, wheel alignment, and lubrication guidance for sealed chains, control cables and throttle grips.

• Brakes and wheels: Front-disc and rear-drum inspections, lever and pedal adjustments, wear checks, and step-by-step front and rear wheel removal and installation.

• Suspension and chassis: Rear-shock spring-preload and damping adjustments, plus inspections of fork operation, steering play, wheel bearings, tires and spokes.

• XT350 engine service notes: Y.D.I.S. operation, carburetor synchronization, valve-shim selection, camshaft installation and clutch assembly references in the training guide.

• Electrical diagnosis: Owner interlock and starting checks, plus XT350 ignition, charging, lighting and signal-system schematics, troubleshooting charts and a wiring diagram.

• XT250 parts identification: Exploded views, part numbers and quantities for engine, drivetrain, chassis and electrical assemblies, including California-specific carburetor and fuel-tank sections.

The maintenance and minor repair sections suit owners familiar with motorcycle service and equipped with the owner’s tool kit plus additional tools such as a torque wrench; the XT350 Service Guide is intended for technical service training.

Operating Procedures and Scheduled Maintenance

The owner’s manuals provide pre-operation inspection checklists, cold- and warm-engine starting guidance, and instrument descriptions. Fuel-cock and choke operation, shifting and engine break-in are covered, with kick-starting instructions for the XT350 and electric-starting instructions for the XT225.

The Periodic Maintenance Chart for Emission Control System and General Maintenance and Lubrication Chart organize service by mileage and elapsed time. Asterisks distinguish jobs requiring specialized tools, data and technical skills, helping owners separate routine maintenance from work referred to Yamaha service personnel.

California equipment: Canister and hose inspections are accompanied by an Emission Hose Routing diagram and illustrations identifying the fuel-tank, carburetor and canister connections, vent hose and overflow pipe.

The oil-service cautions explain the risk of engine seizure if oil fails to circulate after a change. In the XT350 battery section, breather-hose warnings explain how incorrect routing can discharge electrolyte onto the frame and cause structural damage.

Battery differences: The XT350 instructions cover electrolyte-level checks and battery storage. The XT225 uses a sealed battery, with different charging requirements and cautions against removing its sealing caps.

Review the manufacturer’s fuel-handling and electrical-safety warnings before maintenance.

Troubleshooting and Adjustment Limits

The XT350 Sidestand Switch Operation Check and XT225 Sidestand/Clutch Switch Operation Check address their respective ignition interlocks. Starting-fault charts organize fuel, compression and ignition checks; the XT225 chart also includes battery checks.

The owner’s manuals refer carburetor and valve-clearance adjustment to Yamaha service personnel. The XT350 manual also refers decompression-cable adjustment to the dealer, while brake bleeding, brake-fluid replacement and internal shock service require qualified service.

XT350 Training References and Electrical Fault Tracing

The Service Guide explains the Yamaha Dual-Intake System and coasting enricher. Valve-pad selection charts, camshaft/camcap alignment views, clutch-plate arrangement and balancer timing marks provide assembly references; the valve section identifies adjusting tool YM4106.

Carburetor notes distinguish primary full-opening adjustment from secondary synchronization. Chassis coverage includes fork service references, front-brake pad replacement and rear-arm lubrication points.

The Ignition System, Charging System, Lighting System and Signal System sections pair circuit diagrams with component and connector views. Their test specifications and fault charts support tracing poor spark, battery discharge and lighting faults through the relevant circuit and component checks.

XT250 Parts and California Variants

Separate carburetor and fuel-tank sheets distinguish XT250K from XT250KC California equipment, including the canister and roll-over valve. Reference numbers connect the exploded views to part descriptions and quantities for identifying assemblies and individual components.

XT350 Specifications and Selected Brake-Wear and Charging Values

The XT350 owner’s manual identifies the TEIKEI Y24PV carburetor, wet multi-disc clutch, CDI ignition and magneto charging system. Reference tables cover lubricant selection, oil quantities by service type, spark-plug gaps, load-dependent tire pressures, battery types, bulb ratings and fuse capacity, with tightening torques alongside the relevant service procedures.

For XT350M/XT350MC brake inspection, the owner’s manual specifies replacement when front-pad thickness is below 0.8 mm or rear-shoe thickness is below 2 mm.

In the 1985 XT350 Service Guide, the charging-system coil resistance is specified as 0.46 Ω ±10% at 20°C between the black and white leads. This test reference belongs to the guide’s documented charging circuit.