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#138445 - 09/19/17 12:42 AM Intake manifold replacement on a '93 XT225..
Az4x4 Online   content
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Registered: 08/18/08
Posts: 4323
Loc: Heber/Overgaard, AZ

The '93 XT225 I bought in Flagstaff turned out to have a broken intake manifold causing it to idle roughly and run lean.

Ordered a new OEM Yamaha molded rubber manifold for the bike. It was waiting for me at the Post Office today. Went home, wheeled the bike into the shop, stripped it down and removed the carburetor. A 4.5mm allen wrench worked to remove the old rubber manifold from the cilendar head.

This is what the bike's original intake manifold looked like after 24 years of service:





No wonder it was sucking excess air at idle..

Removed the original rubber gasket from the old intake manifold and found it in good shape. The replacement manifold was an exact duplicate of the original, however there was no new manifold gasket in the package it came in. Fortunately the original gasket fit the new manifold perfectly, which was a relief.

Here's the new intake manifold with the carburetor in place:



Put the tank back in place, hooked everything up, and once the carb filled with gas it started and ran perfectly. No more rough idle, lean running or sucking excess air. Runs like an XT225 is supposed to!

Yea!..
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#138468 - 09/20/17 09:35 PM Re: Intake manifold replacement on a '93 XT225.. [Re: Az4x4]
Az4x4 Online   content
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Registered: 08/18/08
Posts: 4323
Loc: Heber/Overgaard, AZ

For anyone who may be interested, this low mileage '93 XT225 Serow is ready to roll and up for sale. It runs like a champ once again with the new intake manifold in place, and looks great to boot! Check it out in the "I Am Selling" section of the site for details..
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#138925 - 10/24/17 05:45 PM Re: Intake manifold replacement on a '93 XT225.. [Re: Az4x4]
Theo Offline
Junior Member

Registered: 10/10/17
Posts: 5
Loc: Greece
Hello, I am going to change the intake manifold on my 1995 xt225. Do i need to use some sealant between the engine and the manifold or the gasket is enough?

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#138927 - 10/24/17 06:40 PM Re: Intake manifold replacement on a '93 XT225.. [Re: Theo]
Az4x4 Online   content
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Registered: 08/18/08
Posts: 4323
Loc: Heber/Overgaard, AZ

Clean the mating surfaces thoroughly, make sure the gasket is securely in place, and don't use any form of sealant..
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Lovin' life in Arizona's Mogollon Rim Mountain Country!!

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#138939 - 10/25/17 10:45 AM Re: Intake manifold replacement on a '93 XT225.. [Re: Az4x4]
Theo Offline
Junior Member

Registered: 10/10/17
Posts: 5
Loc: Greece
Thanks, I will replace it during the weekend.

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#145941 - 08/29/19 04:35 PM Re: Intake manifold replacement on a '93 XT225.. [Re: Az4x4]
redninja Offline
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Registered: 06/04/06
Posts: 512
Loc: SW CO and AZ
Hey, George.....Is this correct what I'm seeing.....a 4.5mm allen wrench ? It that for real ? That would explain why I was able to get one bolt out, but the head on the other one stripped. I was using a 4 mm.
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#145946 - 08/31/19 12:16 AM Re: Intake manifold replacement on a '93 XT225.. [Re: redninja]
Az4x4 Online   content
Platinum Member
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Registered: 08/18/08
Posts: 4323
Loc: Heber/Overgaard, AZ

Originally Posted By: redninja
..Hey, George.....Is this correct what I'm seeing.....a 4.5mm allen wrench ? It that for real ? That would explain why I was able to get one bolt out, but the head on the other one stripped. I was using a 4 mm.

That's what it took, a 4.5mm allen wrench. A 4mm feels 'almost right', but it will easily strip a 4.5mm bolt head - as you found out. Not fun when that happens..
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#145980 - 09/11/19 05:09 AM Re: Intake manifold replacement on a '93 XT225.. [Re: Az4x4]
redninja Offline
Bronze Member
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Registered: 06/04/06
Posts: 512
Loc: SW CO and AZ
Dremel to the rescue ! Examination of the new part showed it had a plastic base, so we figured we would just cut the old one off. Of course, the old one turned out to be metal. Was able to cut it off anyway, then was able to grab the screw.
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