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#142474 - 08/09/18 02:42 AM rebuilding! '02 xt225
charleslabri Offline
Junior Member

Registered: 08/01/18
Posts: 9
Loc: San Francisco
I just got the ol girl running today.

knowns from previous owner:
'doesnt go into 6th gear'
left in the tahoe winter for 2 years without riding it
doesnt work for some reason
14k original miles, may or may not have done maintenance, only done street riding.
all bone stock


I took it into the garage and removed the carb, drained the oil and put the battery on a tender.

The oil was gray and water logged:


The carb made me want to vomit (does this classify as child abuse?):


But after a lemon juice boil, the carb was lookin better:


I got some new gaskets and a few rubbers for the carb, oil filters (10), battery (was totally dead), cleaned out the gas tank and a can on molli engine flush.
put it mostly back together and fired it up... turned over, no spark.. turned out the spark plug wasnt passing electricity- new plug and she fired right up.

doing now about 5 oil changes- getting it warm, idling, movement, flush...
excited to get it on the road.

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#142476 - 08/09/18 02:56 AM Re: rebuilding! '02 xt225 [Re: charleslabri]
charleslabri Offline
Junior Member

Registered: 08/01/18
Posts: 9
Loc: San Francisco
anyone have a service manual? i want to see how hard the 6th gear is to replace..

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#142482 - 08/09/18 12:27 PM Re: rebuilding! '02 xt225 [Re: charleslabri]
peejman Offline
Platinum Member
*****

Registered: 06/03/13
Posts: 2935
Loc: East TN USA
There's a downloadable service manual floating around, just don't post a link to it here. I have the paper book from Yamaha and consider it a good investment. https://www.yamahapubs.com/ The Haynes/Clymer manuals are cheaper but not bad if you're familiar with wrenching.

"Doesn't go into 6th gear" probably means the shift fork is bent or the drum is buggered up (or both). Having done similar work on a different bike, I'd guess the whole thing has to come apart.
_________________________
This shall pass, be still and know.
2006 XT225, UNI filter, ProTaper bars, MSR handguards, SS front brake line, Shinko 241's.

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#142487 - 08/09/18 04:08 PM Re: rebuilding! '02 xt225 [Re: charleslabri]
Muniac Offline


Platinum Member
*****

Registered: 01/16/04
Posts: 5483
Loc: Montrose, CO
Thanks for the copyright consideration. Helps avoid problems. And yes, please don't engage in pirating copyrighted materials here. I too have a paper service manual which is a great investment. For 2003 XTs, it comes with a supplement too.
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Evolve & Simplify
Be There or Be Nowhere! A Few Adventures & Video

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#142552 - 08/15/18 02:55 AM Re: rebuilding! '02 xt225 [Re: charleslabri]
Rocky Baker Offline
Junior Member

Registered: 05/10/18
Posts: 32
Loc: Timmins, Ontario
Hey Charles!

I just finished rebuilding a 92 XT 225 and let me say this; If you have the time to put the work into it, it's a great machine when finished and a very rewarding experience to get it done. I am a teacher, not a mechanic, but this website covers pretty much everything you'll ever need to know and then some. Whatever problems you run into (there usually is when buying someone else's unwanted used and abused motorcycle), it's nice to know you can rely on this site for lots of information from people with experience on the same model.

Nice job getting it running and good luck with it in the future.
_________________________
Keep it simple

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