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Old 03-18-2013, 11:12 PM   #1
Te Hopo OP
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Joined: Sep 2007
Location: Picton, New Zealand
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Grumble, the mighty XT225 that just keeps on going

Well just over 2 years ago now I found myself newly single, without a vehicle and some money burning a hole in my pocket.
After a week of moping around home I found myself attending the devastating Christchurch Earthquake with the search teams and over the next three weeks gained a new appreciation of how we have to make the most of this life.

So as soon as I got home I was on TM, found an XT225 with less than 5000kms on it and an asking price of only $3000 as the guy needed some quick cash.
Perfect.
Back out the out the door again and brought my self the lil beauty of a bike you see here:


From the looks of it 0kms was offroad so I set about rectifying that on the way home!
Of course I had to take the long way home through Port Underwood and get to know my new toy, I met my brother on his bike and proceeded to teach him how to ride on gravel:
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Old 03-18-2013, 11:14 PM   #2
Te Hopo OP
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Now seeing as this was also my only form of transport beside foot I find it essential to have a dry lockable boot space, a backpack just doesn't cut it anymore.
Using some flat stock steel and aluminum I had in the shed I fashioned a basic rack and mounted a tail box to it:





Perhaps a little shortsighted I used steel that was not strong enough on the horizontal brackets and after a few thousand kilometers it crack, more to come on that later.
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Old 03-18-2013, 11:19 PM   #3
Te Hopo OP
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The hand guards were next, factory Yamaha brush guards had been fitted but these were very very flimsy so some reinforcing was needed:


I removed the bar end weights and welded a nut inside the bar, bent up some 3mm aluminum and bolted them on:


A sleeve spacer was made for the throttle side so the twist grip would still rotate but the bracket is close enough in that you wouldn't notice it at all:


After many thousand of kilometers and quite a few offs (including one by my brother which included replacing the front forks) these simple guards have stood up well, I have not had a single broken or even bent lever and they cost all of $5.
They might not be as strong as Barkbusters but hey, they also don't carry the price tag.


After these mods it was time to really test the bike and see what it could do.
A two day trip was planned including some mud, stream crossings, a bit of altitude, some rocky snow covered single trail and lots and lots of gravel roads.
http://www.youtube.com/watch?feature...&v=RG3im-N5lJ8

I spent the night out under the tarp only, curled up in my winter sleeping bag, smoking away and sipping at a flask of whiskey.
It was the best night out I'd had in a long time:
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Old 03-18-2013, 11:20 PM   #4
Te Hopo OP
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About this time I was pleased with how things were progressing but i wanted a little more power and efficiency from the engine.
The air box was left standard but a better quality and freer flowing K&N filter was fitted.
Now the exhaust, aftermarket units are expensive or if cheap they require a custom fit but a little searching of the net showed these bikes respond well to having the muffler internals cleaned up a little.
I went to a specialist exhaust shop and in exchange for a bottle of whiskey we cut the end off, gutted out the muffler and fitted just a few baffles in place.
A larger end cap was welded on and I now have a factory looking muffler with all factory markings still imprinted.


The bike was then taken to a mechanic and we changed the jets in the carburetor to get it running right.
I now have a bike that will top out at 130km/h on a good day, sit on 100km/h in all but the strongest winds and I get 3.5L/100km (70mpg).

And it sounds throaty like a dirt bike should.

Not long after these mods I went on a ride to see some friends with a 6yo son and as soon as he heard it the bike was christened Grumble.
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Old 03-18-2013, 11:23 PM   #5
Te Hopo OP
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A common modification to these bikes is to relocate the rear turn signals as in the stock position they stick waaaay out and are quite far forward.

So the whole rear of the bike was dismantled, the lights unplugged and the project was on:


New mounting holes in the brake light bracket were marked and drilled:


All the electrical gear was gathered:
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Old 03-18-2013, 11:24 PM   #6
Te Hopo OP
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Due to the fact the lights were being moved about 200mm to the rear I needed to extend the wires, a suitable length of wire was spliced in, all joins being soldered, greased and then covered individually in heat shrink:


Then both joins were covered in another layer of heat shrink to produce a tidy, lasting join:


Then the wires were rerouted and ziptied along the frame and everything mounted back up:

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Old 03-19-2013, 11:49 AM   #7
Padmei
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Good writeup except I can't see any pics till the last post. that is on IE & Chrome.

We've got a bach in trevalli Bay & I rode the tracks across to Opua Bay etc.
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Old 03-19-2013, 12:31 PM   #8
Mark_S
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Quote:
Originally Posted by Padmei View Post
Good writeup except I can't see any pics till the last post. that is on IE & Chrome..
wot he said

Show us the piccies
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Old 03-19-2013, 01:39 PM   #9
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Yeah, wot they said.


Ridge Tracks eh?
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Old 03-20-2013, 01:05 AM   #10
Te Hopo OP
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Damn it, I can see the pics but it seems I have the album locked up, will get it sorted.

Well when riding from Picton to Port Underwood, at the saddle above the Port is a track off to the left that is the access track for the powerlines.
Plenty of sidetracks, easily accessable and frequently there are other trail riders/4x4s up there.

Trails lead out through the forestry and with the right set of keys, all the way to Tory Channel

Lots of the forestry roads are unlocked over that way anyway, and on weekends make a great ride handy to home.
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Old 06-12-2013, 06:12 PM   #11
GlennR
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I was happy to see you finally changed that rear tire.

The panniers are great.

I installed the larger foot pegs and really like them. You should think about adding them to your DIY project list.

Thanks for sharing all the mods & the great scenery of NZ. I guess it's winter there now.
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Old 07-16-2014, 02:48 AM   #12
Te Hopo OP
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Well it's been a while since I posted here, the bike was running real good with a daily commute of 70kms and some big rides around the toip of the South Island.

Then a few weeks back after having dinner with the Marlborough ADV lads and on the way home it developed a very noticable vibration in 6th gear about 5km from home.
Damn, changed down to 5th and it smoothed out again so I made my way home then parked the bike up for the night.

The next day I drained the oil and the filter was nearly clogged with filings.

So it was rolled into the carport and work began.






It was suprisingly easy to get the engine out:
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Old 07-16-2014, 03:09 AM   #13
Te Hopo OP
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Starting the tear down:


I was surprised at how good the bore looked, the quality oils I've been feeding the beast seem to have been doing their job as there was absolutely no vertical scoring and even some cross hatching still:


Once I got to the flywheel I ran into a problem, I've never taken a flywheel off a bike engine and the service manual was not that clear.
So I got talking to Kiwibul who had offered to help.
I took the cases in to his cool workshop one night after work and he already had the right bolt out on the work bench ready.
10mins later the flywheel was off, damn that is easy when you know how.
A shine with a torch down the piston hole gave an inkling of the problem.
So we spent the next 45mins shooting the shit and checking out his VMX bikes.

Once some more stuff was pulled off, I was able to split the cases this evening and get to the heart of it:




Yuppers, thats 6th gear missing 3 teeth and the rest are pretty damned rugged:


The rest of the gear set looks perfectly fine, I'm thinking this is due to the fact I commute and spend the most time in 6th gear, it's probably done 80% of the 80,000+km the bike has now done.

I'm off to see the local Yamaha dealer on Friday and order some parts.
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Old 03-20-2013, 01:45 AM   #14
Te Hopo OP
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Quote:
Originally Posted by Padmei View Post
Good writeup except I can't see any pics till the last post. that is on IE & Chrome.

We've got a bach in trevalli Bay & I rode the tracks across to Opua Bay etc.
Fixed now mate

Hey nice spot out there, I grew up out Lochmara Bay and used to travel into Oyster bay a fair bit and have camped in Ngaruru a LOT
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Old 03-20-2013, 02:06 AM   #15
innathyzit
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good stuff...........
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