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New to me '06 set up my way.. #138386 09/14/17 06:39 PM
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Az4x4 Offline OP
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Here's my '06 XT225 the day I brought it home.



Lots of good things about it from the get go; relatively low mileage, been professionally serviced, carburetor 3 turn mod done, custom ride comfort seat, super duty heavy steel cargo rack, etc. Nevertheless a number of things needed doing to bring it up to what I wanted it to be.

Earlier I'd purchased a '93 XT225 and added custom touches to that bike including a set of Bill's oversize footpegs along with a new drive chain and sprockets. Having picked up this newer XT my intention now is to sell the '93. So everything new that I'd put on it I removed and swapped with the '06.

The '06 didn't idle well and was hard starting when I got it home. It seriously needed service, and that's what I've done these past couple of days.

After stripping the bike down, power washing it clean and letting it dry, I pulled the air filter and found it choked with dirt. Washed it clean and back in it went. Checked for the 3 turn mod and it had already been done.

Next I pulled the end cap and spark arrestor and looked into the muffler with a flashlight. Found the Z1 mod hadn't been done. A few minutes work with a hammer and long punch and the exhaust was opened up. With the end cap and spark arrestor back in place the sound of the free flowing exhaust wasn't at all loud.

Installed a new fuel line filter, put the gas tank back in place, then started the bike. With the air filter clean and unrestricted, the 3 turn mod verified, a fuel line filter in place and the Z1 exhaust mod done, the bike started right up and ran perfectly, no hesitation at all!

Checked the oil level, pulled the filter cover and found it had just recently been changed. It was absolutely clean so I left it as is and buttoned it back up.

Next I swapped the oversize custom comfort ride seat that came on the '06 with the stock OEM XT225 seat on the '93. The custom seat wasn't something I needed and was too tall for my tastes. However the stock seat from the '93 was the wrong color. So I used a specialty vinyl spray paint from ACE Hardware and changed the seat color to black. Tough, impressive stuff that works perfectly!

Finally I removed the heavy store bought cargo rack from the bike replacing it with a thick plastic cutting board cut to fit. Installed it using button head bolts with nyloc nuts and oversize washers through the wide flat spot on the fender just behind the seat. Mounted the Wolfman bag that came with the bike to that new light weight cargo platform and basically the bike was done.

Here's what it looks like now..







More to my tastes, plus it starts instantly and runs like a champ!



..I'd rather have questions I can't answer, than answers I can't question.. Dr. Phil
Re: New to me '06 [Re: Az4x4] #138388 09/14/17 06:58 PM
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bigcanoe Offline
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Very nice! I need to poke a hole in my muffler and do that three turns on the mixture screw too.


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Re: New to me '06 [Re: bigcanoe] #138390 09/14/17 08:46 PM
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Az4x4 Offline OP
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Originally Posted By: bigcanoe
..Very nice! I need to poke a hole in my muffler and do that three turns on the mixture screw too..

Couple of ways to go about doing the Z1 mod. The traditional way is pull the end cap off the muffler removing it and the attached spark arrestor. Now use a 3/4" or 1" metal hole saw on an extension driven by your electric drill, and drill a hole in the restrictor plate you'll see inside the muffler by using a flashlight. Hopefully the piece you drill out remains with the hole saw and comes out when you're finished. Then install the end cap and spark arrestor and you're done.

A simpler way, instead of drilling a hole in the restrictor plate, is to use a long punch and a hammer and break an edge of the restrictor plate away from where it's attached to the inside of the muffler. This way you don't have to worry about losing the center piece you'd drill out using the traditional method, plus it works just as well.

The mixture screw adjustment on a 225 is well documented here on the site. There's not a lot new that I can tell you about it other than it's absolutely necessary if you want your bike to perform as well as possible -- much better than the way it's set up from the factory.

Good luck, and enjoy!



..I'd rather have questions I can't answer, than answers I can't question.. Dr. Phil
Re: New to me '06 [Re: Az4x4] #138401 09/15/17 06:19 PM
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bigcanoe Offline
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So the point either way is just to let the exhaust flow more freely, got it. Thanks!


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Re: New to me '06 [Re: bigcanoe] #138402 09/15/17 08:16 PM
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Az4x4 Offline OP
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Yep, that's all you're doing with the 'Z1 mod' no matter how you go about it..


..I'd rather have questions I can't answer, than answers I can't question.. Dr. Phil
Re: New to me '06 [Re: Az4x4] #138420 09/17/17 10:29 AM
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Paul49 Offline
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Ayup az4x4, that's a nice looking bike you got.


Current: 1958 Ariel 650 FH, 2014 Tiger Sport1050, 1995 XT225 Serow, 2016 Tiger 800 XRx.
Re: New to me '06 [Re: Paul49] #138424 09/17/17 04:35 PM
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Az4x4 Offline OP
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Thanks Paul. It was a lucky find and a long trip to go collect it, but it's proving its worth day by day!


..I'd rather have questions I can't answer, than answers I can't question.. Dr. Phil
Re: New to me '06 [Re: Az4x4] #138443 09/19/17 12:21 AM
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Beaker Offline
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Originally Posted By: Az4x4

... A simpler way, instead of drilling a hole in the restrictor plate, is to use a long punch and a hammer and break an edge of the restrictor plate away from where it's attached to the inside of the muffler. This way you don't have to worry about losing the center piece you'd drill out using the traditional method, plus it works just as well...


Got back from a ride today with quite a few hills and am now contemplating doing the Z-mod thing.

For the above method after breaking loose one of the spot welds are you then bending the baffle to open things up or fully removing it?


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Re: New to me '06 [Re: Az4x4] #138447 09/19/17 01:40 AM
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Beaker Offline
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Never mind - found the original reference for this method. Sounds like the lower weld is broke and the plate bent back approximately 45 degrees. I like that it doesn't generate metal shavings but it seems like there is greater chance of the remaining weld failing due to vibrations.

While reading through the Z1-mod posts and seeing some regrets it occurred to me that one could make several smaller holes, then re-seal some or all of them with screws if the results were unsatisfactory. I may try that.


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Re: New to me '06 [Re: Beaker] #138448 09/19/17 02:19 PM
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Az4x4 Offline OP
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It's been said "there's more than one way to skin a cat," and I imagine that applies to doing the Z1 mod as well! However you go about it the idea is to create a less restricted more free flowing exhaust system.

As far as the weld on the restrictor plate breaking from vibration on the opposite side from where you punched it loose and bent it back, that won't happen. You'll find that the weld is far too tough to completely fail no matter that you've used a punch and hammer to break it loose in a certain area.

Nevertheless your idea of drilling several small holes then sealing them with metal screws if the result isn't what you're after might be worth pursuing. The only downside I see would be that drilling all those small holes will be labor intensive to begin with, and closing them off with metal screws if you don't like the result would be quite a chore. If you tackle it that way take lots of photos and let us know what you think as the project progresses.

As far as I'm concerned doing the Z1 with a hammer and long punch is a quick and relatively easy solution that works well..



..I'd rather have questions I can't answer, than answers I can't question.. Dr. Phil
Re: New to me '06 [Re: Az4x4] #138453 09/19/17 10:36 PM
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cogitech Offline
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The '06 is the sexiest of them all, IMHO!

Nice score!

Last edited by cogitech; 09/19/17 10:36 PM.

'06 XT225, 2" hole in airbox, Z1 mod, 127.5 main jet, UNI air filter, Corbin seat, PIAA 500Hz, custom aluminum rear rack.
Re: New to me '06 [Re: cogitech] #138465 09/20/17 09:05 PM
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Az4x4 Offline OP
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Thanks, Cogitech. A simple change in paint scheme colors makes quite a difference in the looks of what otherwise are identical bikes the last few years that Yamaha manufactured the XT225. Next to the '06's colors, the '05 paint scheme is second on my list, followed closely by the '07. That's just me. However like you I've always been partial to the colors used on the '06s. They really stand out from my point of view..


..I'd rather have questions I can't answer, than answers I can't question.. Dr. Phil
Re: New to me '06 [Re: Az4x4] #141258 04/09/18 10:43 PM
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Jayman Offline
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Hi Az4x4, nice work! I just recently purchased an '06 xt225 as well.

I am a tall (6'2") rider and am trying to figure out how to modify my seat to be taller. Unfortunately for me, the last owner of the bike was 5'5" and removed a lot of foam from the stock seat.

Are you willing to part with the tall seat that came with your bike? I would be grateful!!

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