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Yamaha TTR 250

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  • Yamaha TT-R 250

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OWNER’S MANUAL

TTR250V(C)

LIT-11626-19-30

5GF-28199-17

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Summary of Contents for Yamaha TTR250V(C)

  • Page 1
    OWNER’S MANUAL TTR250V(C) LIT-11626-19-30 5GF-28199-17…
  • Page 3
    INTRODUCTION EAU10060 Congratulations on your purchase of the Yamaha TTR250V. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

  • Page 4: Important Manual Information

    This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual.

  • Page 5
    IMPORTANT MANUAL INFORMATION EWA10040 WARNING THIS MACHINE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS ILLEGAL TO OPERATE THIS MACHINE ON ANY PUBLIC STREET, ROAD OR HIGHWAY. SUCH USE IS PROHIBITED BY LAW. THIS MA- CHINE COMPLIES WITH ALMOST ALL STATE OFF-HIGHWAY NOISE LEVEL AND SPARK ARRESTER LAWS AND REGULATIONS.
  • Page 6
    IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE TTR250V OWNER’S MANUAL ©2005 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2005 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION ….1-1 OPERATION AND IMPORTANT Adjusting the clutch lever free Location of important labels …..1-5 RIDING POINTS……..5-1 play ……….6-18 Starting and warming up a cold Adjusting the brake lever free DESCRIPTION ……..2-1 engine ………. 5-1 play ……….

  • Page 8
    Troubleshooting chart ….6-35 MACHINE CARE AND STORAGE ………..7-1 Care ……….7-1 Storage ……….7-3 SPECIFICATIONS ……8-1 CONSUMER INFORMATION….9-1 Identification numbers …..9-1 Motorcycle noise regulation …..9-3 Maintenance record ……9-4 YAMAHA MOTOR CORPORATION, U.S.A. OFF-ROAD MOTORCYCLE LIMITED WARRANTY ….9-5 YAMAHA EXTENDED SERVICE (Y.E.S.) ………9-7…

  • Page 9: Safety Information

    SAFETY INFORMATION Safe riding the speed). Never travel faster EAU10332 Always make pre-operation than warranted by conditions. THIS MACHINE IS A SINGLE TRACK checks. Careful checks may help Ride cautiously in unfamiliar ar- VEHICLE. ITS SAFE USE AND OPER- prevent an accident. eas.

  • Page 10
    Modifications made to this machine not Cargo accessory weight stallation and use of non-Yamaha approved by Yamaha, or the removal of should be kept as low and close to accessories. Use extreme caution original equipment, may render the ma- the machine as possible. Make…
  • Page 11
    SAFETY INFORMATION or cornering clearance, limit sus- Use caution when adding electri- leaving the machine unattended pension travel, steering travel or cal accessories. If electrical acces- and remove the key from the main control operation, or obscure lights sories exceed the capacity of the switch.
  • Page 12
    SAFETY INFORMATION line, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediate- ly. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes.

  • Page 13: Location Of Important Labels

    SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.

  • Page 14
    This unit contains high pressure nitrogen gas. follows. Mishandling can cause explosion. FRONT : 100 kPa,{1.00 kgf/cm }, 15 psi Read owner’s manual for instructions. REAR 100 kPa,{1.00 kgf/cm }, 15 psi Do not incinerate, puncture or open. 3RV-21668-A0 YAMAHA 4AA-22259-80…

  • Page 15: Description

    DESCRIPTION EAU10410 Left view 1. Headlight (page 6-29) 8. Front fork damping adjusting screw (page 3-7) 2. Front fork air valve (page 3-7) 3. Fuel cock (page 3-5) 4. Starter (choke) knob (page 3-6) 5. Air filter element (page 6-12) 6.

  • Page 16: Right View

    DESCRIPTION EAU10420 Right view 1. Spark arrester (page 6-13) 8. Shock absorber assembly spring preload adjusting nut (page 3-9) 2. Battery (page 6-27) 3. Fuse (page 6-28) 4. Shock absorber assembly compression damping force adjusting knob (page 3-9) 5. Main switch (page 3-1) 6.

  • Page 17: Controls And Instruments

    DESCRIPTION EAU10430 Controls and instruments 1. Clutch lever (page 3-2) 2. Left handlebar switch (page 3-1) 3. Tripmeter (page 3-1) 4. Right handlebar switches (page 3-1) 5. Brake lever (page 3-3) 6. Throttle grip (page 6-14) 7. Fuel tank cap (page 3-3)

  • Page 18: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS EAU10450 EAU11830 EAU12343 Main switch Tripmeter Handlebar switches Left The main switch controls the ignition 1. Tripmeter and lighting systems. The various main 1. Light switch “ ” 2. Tripmeter reset knob switch positions are described below. The tripmeter shows the distance trav- Right eled since it was last set to zero with the…

  • Page 19: Clutch Lever

    INSTRUMENT AND CONTROL FUNCTIONS EAU12540 EAU31640 EAU12870 Light switch “ ” Clutch lever Shift pedal Set this switch to “ ” to turn on the headlight and the taillight. ECA10980 CAUTION: Always turn the key to “OFF” and light switch to “OFF” when the en- gine is not running, otherwise the headlight will stay on and the battery may discharge due to extended use.

  • Page 20: Brake Lever

    INSTRUMENT AND CONTROL FUNCTIONS EAU12890 EAU12941 EAU13180 Brake lever Brake pedal Fuel tank cap 1. Brake lever 1. Brake pedal 1. Fuel tank cap 2. Remove. The brake lever is located at the right The brake pedal is on the right side of To remove the fuel tank cap, turn it handlebar grip.

  • Page 21: Fuel

    10%. Gasohol UNLEADED GASOLINE ONLY containing methanol is not recom- Fuel tank capacity: mended by Yamaha because it can 9.5 L (2.51 US gal) (2.09 Imp.gal) cause damage to the fuel system or ve- Fuel reserve amount: 2.0 L (0.53 US gal) (0.44 Imp.gal)

  • Page 22: Fuel Tank Breather Hose

    INSTRUMENT AND CONTROL FUNCTIONS EAU13410 EAU13560 Fuel tank breather hose Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it al- The fuel cock has three positions: FUEL 1. Arrow mark positioned over “ON” 1.

  • Page 23: Starter (Choke) Knob «1

    INSTRUMENT AND CONTROL FUNCTIONS fuel while riding, move the lever to this EAU13600 EAU13960 Starter (choke) knob “ ” Seat position. Fill the tank at the first oppor- tunity. Be sure to set the lever back to To remove the seat “ON”…

  • Page 24: Adjusting The Front Fork

    Make sure that the seat is properly se- An optional air pressure gauge is avail- NOTE: cured before riding. able at a Yamaha dealer. When checking and adjusting the air 4. To increase the spring rate and pressure, there should be no weight on thereby harden the suspension, in- the front end of the vehicle.

  • Page 25
    INSTRUMENT AND CONTROL FUNCTIONS Spring rate: Minimum (soft): Air pressure = 0 kPa (0 psi) (0 kgf/cm Standard: Air pressure = 0 kPa (0 psi) (0 kgf/cm Maximum (hard): Air pressure = 40 kPa (5.8 psi) (0.4 kgf/cm ECA10090 1. Rubber cap 1.

  • Page 26: Adjusting The Shock Absorber Assembly

    Never attempt to turn an adjusting ifications due to small differences in obtained at a Yamaha dealer. mechanism beyond the maximum or production, the actual number of clicks The spring preload setting is deter- minimum settings.

  • Page 27
    INSTRUMENT AND CONTROL FUNCTIONS rection (b). pression damping force and thereby Tightening torque: soften the compression damping, turn Locknut: Rebound damping setting: the adjusting knob in direction (b). 70 Nm (7.0 m·kgf, 51 ft·lbf) Minimum (soft): 16 clicks in direction (b)* Compression damping setting: ECA11240 Standard:…

  • Page 28: Starting Circuit Cut-Off System

    WARNING high heat sources, otherwise it If a malfunction is noted, have a may explode due to excessive Yamaha dealer check the system be- gas pressure. fore riding. Do not deform or damage the gas cylinder in any way, as this will result in poor damping per- formance.

  • Page 29
    4. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. 5. Turn the engine off. 6. Shift the transmission into gear. 7. Keep the clutch lever pulled.

  • Page 30: Pre-Operation Checks

    PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.

  • Page 31: Pre-Operation Check List

    Lubricate cable if necessary. Clutch 6-18 Check lever free play. Adjust if necessary. Make sure that operation is smooth. Check cable free play. Throttle grip 6-14, 6-24 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.

  • Page 32
    PRE-OPERATION CHECKS ITEM CHECKS PAGE Make sure that operation is smooth. Control cables 6-23 Lubricate if necessary. Check chain slack. Adjust if necessary. Drive chain 6-21, 6-23 Check chain condition. Lubricate if necessary. Check for damage. Check tire condition and tread depth. Wheels and tires 6-15, 6-17 Check air pressure.

  • Page 33: Operation And Important Riding Points

    OPERATION AND IMPORTANT RIDING POINTS 5. Start the engine by pushing the EAU15960 EAU16451 Starting and warming up a start switch. cold engine EWA10280 NOTE: WARNING In order for the starting circuit cut-off If the engine fails to start, release the This model is designed for system to enable starting, one of the start switch, wait a few seconds, and…

  • Page 34: Starting A Warm Engine

    OPERATION AND IMPORTANT RIDING POINTS the neutral position, do not EAU16640 EAU16671 Starting a warm engine Shifting coast for long periods of time Follow the same procedure as for start- with the engine off, and do not ing a cold engine with the exception tow the machine for long dis- that the starter (choke) is not required tances.

  • Page 35: Engine Break-In

    If any engine trouble should occur maximum) does not harm the engine. during the engine break-in period, Each full-throttle acceleration should immediately have a Yamaha dealer be followed with a substantial rest peri- check the vehicle. od for the engine. To allow the engine…

  • Page 36: Periodic Maintenance And Minor Repair

    If you do not have the tools or experi- If you are not familiar with mainte- ence required for a particular job, have nance work, have a Yamaha dealer a Yamaha dealer perform it for you. do it for you. EWA10340 WARNING…

  • Page 37: Periodic Maintenance Chart For The Emission Control System

    From 1800 mi (3000 km) or 18 months, repeat the maintenance intervals starting from 600 mi (1000 km) or 6 months. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

  • Page 38: General Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU35340 General maintenance and lubrication chart INITIAL EVERY 100 mi 600 mi 1200 mi ITEM CHECKS AND MAINTENANCE JOBS (150 km) (1000 km) (2000 km) 1 month 6 months 12 months Check operation. √ √ √…

  • Page 39
    17 * Shock absorber assembly Replace if necessary. √ 18 * Rear suspension link pivots Apply molybdenum disulfide grease lightly. Apply Yamaha chain and cable lube or engine oil 10W-30 thor- √ √ √ 19 * Control and meter cables oughly.
  • Page 40
    PERIODIC MAINTENANCE AND MINOR REPAIR EAU18670 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

  • Page 41: Removing And Installing The Cowling And Panels

    PERIODIC MAINTENANCE AND MINOR REPAIR To install the cowling EAU18721 Removing and installing the Place the cowling in the original posi- cowling and panels tion, and then install the screws. The cowling and panels shown need to be removed to perform some of the EAU19292 Panels A and B maintenance jobs described in this…

  • Page 42: Checking The Spark Plug

    Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. 1. Spark plug cap 2. Check the spark plug for electrode 2. Remove the spark plug as shown,…

  • Page 43: Engine Oil And Oil Filter Element

    PERIODIC MAINTENANCE AND MINOR REPAIR 3. Install the spark plug with the EAU19784 Engine oil and oil filter Specified spark plug: spark plug wrench, and then tight- NGK/CR9E element en it to the specified torque. DENSO/U27ESR-N The engine oil level should be checked Tightening torque: before each ride.

  • Page 44
    PERIODIC MAINTENANCE AND MINOR REPAIR to collect the used oil. NOTE: 3. Remove the engine oil filler bolt The engine oil should be between the and drain bolt to drain the oil from minimum and maximum level marks. the crankcase. 1.
  • Page 45
    PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: (×3) Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) (×2) NOTE: Make sure that the O-rings are properly seated. 10. Install the engine oil drain bolt, and then tighten it to the specified 1.
  • Page 46
    If this occurs, mix any chemical additives. Do 7 Nm (0.7 m·kgf, 5.0 ft·lbf) have a Yamaha dealer repair the not use oils with a diesel speci- vehicle. fication of “CD” or oils of a high- After checking the oil pressure, er quality than specified.

  • Page 47: Cleaning The Air Filter Element

    The sponge material should be wet but (×3) not dripping. Recommended oil: Yamaha foam air filter oil or other quality air filter oil 1. Holding clip 7. Install the sponge material onto 3. Pull the air filter element out of the the frame, insert the air filter ele- air filter case.

  • Page 48: Cleaning The Spark Arrester

    PERIODIC MAINTENANCE AND MINOR REPAIR side of the tailpipe housing. EAU21241 ECA10480 Cleaning the spark arrester CAUTION: The spark arrester should be cleaned Make sure that the air filter ele- at the intervals specified in the periodic ment is properly seated in the maintenance and lubrication chart.

  • Page 49: Carburetor

    3.0–5.0 mm (0.12–0.20 in) at the 6. Stop the engine and allow the ex- throttle grip. Periodically check the haust pipe to cool. throttle cable free play and, if neces- 7. Install the purging bolt and tighten sary, have a Yamaha dealer adjust it. 6-14…

  • Page 50: Valve Clearance

    100 kPa (15 psi) (1.00 kgf/cm from occurring, the valve clearance specified tires. Maximum load*: 90 kg (198 lb) must be adjusted by a Yamaha dealer * Total weight of rider, cargo and ac- at the intervals specified in the periodic Tire air pressure cessories maintenance and lubrication chart.

  • Page 51
    Front tire: Securely pack the heaviest the sidewall is cracked, have a Yamaha Size: items close to the center of the dealer replace the tire immediately. 80/100-21 51M…

  • Page 52: Spoke Wheels

    If any dam- should be designed specifically for age is found, have a Yamaha this model, and they must be se- dealer replace the wheel. Do not curely mounted to maintain the in-…

  • Page 53: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE AND MINOR REPAIR been approved by Yamaha. lever free play, turn the adjusting EAU22030 Adjusting the clutch lever free bolt in direction (b). play 3. If the specified clutch lever free play could be obtained as de- scribed above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows.

  • Page 54: Adjusting The Brake Lever Free Play

    If there is air in the hy- draulic system, have a Yamaha dealer bleed the system before 1. Brake lever free play adjusting screw operating the machine. Air in 2.

  • Page 55: Checking The Brake Fluid Level

    Observe these precautions: cator almost touches the brake disc, When checking the fluid level, have a Yamaha dealer replace the make sure that the top of the brake brake pads as a set. fluid reservoir is level.

  • Page 56: Changing The Brake Fluid

    EAU22760 Changing the brake fluid Drive chain slack lower the boiling point of the fluid Have a Yamaha dealer change the The drive chain slack should be and may result in vapor lock. brake fluid at the intervals specified in…

  • Page 57
    PERIODIC MAINTENANCE AND MINOR REPAIR are in the same position for proper Tightening torque: wheel alignment. Axle nut: 105 Nm (10.5 m·kgf, 76 ft·lbf) 4. Insert a new cotter pin into the axle nut, and then bend its ends as shown.

  • Page 58: Cleaning And Lubricating The Drive Chain

    If a cable is damaged wet areas. Service the drive chain as or does not move smoothly, have a follows. Yamaha dealer check or replace it. ECA10581 CAUTION: Recommended lubricant: Yamaha Chain and Cable Lube or…

  • Page 59: Checking And Lubricating The Throttle Grip And Cable

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU23111 EAU23140 EAU23180 Checking and lubricating the Checking and lubricating the Lubricating the brake pedal throttle grip and cable brake and clutch levers The operation of the throttle grip should be checked before each ride. In addi- tion, the cable should be lubricated at the intervals specified in the periodic maintenance chart.

  • Page 60: Checking And Lubricating The Sidestand

    Check the inner tubes for scratches, fork does not operate smoothly, The operation of the sidestand should damage and excessive oil leakage. have a Yamaha dealer check or re- be checked before each ride, and the pair it. sidestand pivot and metal-to-metal…

  • Page 61: Checking The Steering

    2. Hold the lower ends of the front fork legs and try to move them for- ward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering. 6-26…

  • Page 62: Battery

    To charge the battery EAU23380 Battery furic acid, which causes severe Have a Yamaha dealer charge the bat- burns. Avoid any contact with tery as soon as possible if it seems to skin, eyes or clothing and al- have discharged. Keep in mind that the…

  • Page 63: Replacing The Fuse

    If you do not have access to a avoid causing extensive damage to sealed-type (MF) battery charg- the electrical system and possibly a er, have a Yamaha dealer fire. charge your battery. 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate.

  • Page 64: Replacing The Headlight Bulb

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU23841 Replacing the headlight bulb This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove cowling A together with the headlight unit. (See page 6-6.) 2.

  • Page 65: Replacing The Taillight Bulb

    1. Screw the headlight unit. 4. Install the lens by installing the 2. Taillight lens 7. Have a Yamaha dealer adjust the screws. 2. Remove the defective bulb by headlight beam if necessary. ECA10680 pushing it in and turning it counter- CAUTION: clockwise.

  • Page 66: Supporting The Machine

    ECA11070 WARNING CAUTION: requiring the machine to stand upright. It is advisable to have a Yamaha Check that the machine is in a stable Do not apply the brake after the dealer service the wheel. and level position before starting any…

  • Page 67
    PERIODIC MAINTENANCE AND MINOR REPAIR 2. Lift the wheel up between the fork 4. Tighten the wheel axle holder nuts fork compresses and rebounds legs. to the specified torque. smoothly. 6. Connect the tripmeter cable. NOTE: NOTE: Make sure that there is enough space Tighten the upper nuts first, and then between the brake pads before insert- the lower ones.

  • Page 68: Rear Wheel

    3. Remove each swingarm end cover by removing the screws. EAU25280 To remove the rear wheel EWA10820 WARNING (×2) It is advisable to have a Yamaha dealer service the wheel. (×2) Securely support the machine (×2) so that there is no danger of it NOTE: falling over.

  • Page 69: Troubleshooting

    However, should your machine re- ter pin. quire any repair, take it to a Yamaha dealer, whose skilled technicians have Tightening torque: the necessary tools, experience, and…

  • Page 70: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.

  • Page 71: Machine Care And Storage

    MACHINE CARE AND STORAGE ucts onto seals, gaskets, sprock- cleaning products, solvent or EAU26000 Care ets, the drive chain and wheel thinner, fuel (gasoline), rust re- While the open design of a machine re- axles. Always rinse the dirt and de- movers or inhibitors, brake flu- veals the attractiveness of the technol- greaser off with water.

  • Page 72
    MACHINE CARE AND STORAGE After normal use salt. 7. Wax all painted surfaces. Remove dirt with warm water, a mild 8. Let the machine dry completely 2. Apply a corrosion protection spray detergent, and a soft, clean sponge, before storing or covering it. on all metal, including chrome- and and then rinse thoroughly with clean EWA10930…

  • Page 73: Storage

    Storage by loosening the drain bolt; this will NOTE: prevent fuel deposits from building Consult a Yamaha dealer for advice on Short-term up. Pour the drained fuel into the what products to use. Always store your machine in a cool, fuel tank.

  • Page 74
    MACHINE CARE AND STORAGE spark plug cap. than 30 °C (90 °F)]. For more in- EWA10950 formation on storing the battery, WARNING see page 6-27. To prevent damage or injury from NOTE: sparking, make sure to ground the Make any necessary repairs before spark plug electrodes while turning storing the machine.

  • Page 75: Specifications

    SPECIFICATIONS Engine oil: Spark plug (s): EAU2633D Dimensions: Type: Manufacturer/model: Overall length: YAMALUBE 4, SAE10W30 or SAE20W40 NGK/CR9E 2095 mm (82.5 in) Manufacturer/model: 0° 10° 30° 50° 70° 90° 110° 130°F Overall width: DENSO/U27ESR-N 835 mm (32.9 in) YAMALUBE 4 (10W30) Spark plug gap: or SAE 10W30 Overall height:…

  • Page 76
    SPECIFICATIONS Tire air pressure (measured on cold Front suspension: 5th: 24/27 (0.889) tires): Type: 6th: Telescopic fork Off-road riding: 22/29 (0.759) Spring/shock absorber type: Front: Chassis: Coil-air spring/oil damper 100 kPa (15 psi) (1.00 kgf/cm Frame type: Wheel travel: Rear: Semi double cradle 280.0 mm (11.02 in) 100 kPa (15 psi) (1.00 kgf/cm…
  • Page 77
    SPECIFICATIONS Fuse: Fuse: 15.0 A…

  • Page 78: Consumer Information

    Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1.

  • Page 79
    1. Model label The model label is affixed to the frame under the seat. (See page 3-6.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.

  • Page 80: Motorcycle Noise Regulation

    CONSUMER INFORMATION EAU26560 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new ve- hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 81: Maintenance Record

    CONSUMER INFORMATION EAU26651 Maintenance record Have a Yamaha dealer complete this record when the machine is serviced. Maintenance Date of Servicing dealer Mileage Remarks interval service name and address…

  • Page 82: Yamaha Motor Corporation, U.s.a. Off-Road Motorcycle Limited Warranty

    CONSUMER INFORMATION EAU26670 YAMAHA MOTOR CORPORATION, U.S.A. OFF-ROAD MOTORCYCLE LIMITED WARRANTY…

  • Page 83
    CONSUMER INFORMATION…

  • Page 84: Yamaha Extended Service (Y.e.s.)

    This excellent Y.E.S. plan coverage is only available to dealer to see how comforting uninterrupted factory- Yamaha owners like you, and only while your Yamaha is still backed protection can be. within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts.

  • Page 85
    Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
  • Page 86
    INDEX Fuel …………3-4 Sidestand, checking and lubricating..6-25 Fuel cock ……….. 3-5 Spark plug, checking……… 6-7 Accessories and replacement parts ..6-17 Fuel tank breather hose ……3-5 Specifications ……….8-1 Air filter element, cleaning …….6-12 Fuel tank cap……….3-3 Starter (choke) knob……..
  • Page 87
    YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2005.5–1.1×1 !

This manual is also suitable for:

Ttr250v

Источник

YAMAHA

TTR250L(C)

РУКОВОДСТВО ПО ТЕХНИЧЕСКОМУ ОБСЛУЖИВАНИЮ

LIT 11616-12-57

5GF-28197-E0

Yamaha TTR250L(C) Service Manual Rev_01

Sargas Kiev 14/05/11

TTR250L(C)

РУКОВОДСТВО ПО ТЕХНИЧЕСКОМУ ОБСЛУЖИВАНИЮ

©2011 Саргас Издание 1-е, Май 2011 Все права защищены :)

Воспроизведение или использование любой части данного документа без моего письменного разрешения будет жестоко наказано Вашей совестью.

Yamaha TTR250L(C) Service Manual Rev_01

2/276

ПРИМЕЧАНИЕ

Изначально этот руководство разрабатывалось Yamaha Motor Company для использования в авторизированных дилерских и сервисных центрах Yamaha. Поскольку невозможно вместить всю информацию в одно руководство, подразумевается, что каждый, использующий данное руководство, обладает базовыми знаниями в области обслуживания и ремонта мотоциклов. Попытки проведения ремонта без таковых знаний могут сделать Ваш мотоцикл небезопасным или даже непригодным к эксплуатации.

Yamaha Motors постоянно работает над усовершенствованием своих моделей. Информация о модификации и значительных изменениях в спецификациях или процедурах направляется во все авторизированные дилерские центры Yamaha и отображается в последующих редакциях данного руководства.

ПРИМЕЧАНИЕ:______________________________________________________________________________

Дизайн и спецификации могут быть изменены без уведомления.

___________________________________________________________________________________________

ВАЖНАЯ ИНФОРМАЦИЯ

Особо важная информация в данном руководстве сопровождается следующими обозначениями.

Предостерегающий сигнал, означающий БУДЬТЕ ВНИМАТЕЛЬНЫ! ВЛИЯЕТ НА БЕЗОПАСНОСТЬ!

Игнорирование требований обозначенных ОСТОРОЖНО может привести к травмам или гибели мотоциклиста, находящих близко людей или человека, выполняющего ремонт/обслуживание мотоцикла.

Знаком ВНИМАНИЕ помечаются специальные меры, игнорирование которых может привести к повреждению мотоцикла.

ПРИМЕЧАНИЕ: В примечаниях приводится информация, позволяющая лучше понимать и выполнять действия.

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КАК ИСПОЛЬЗОВАТЬ ДАННОЕ РУКОВОДСТВО

СТРУКТУРА РУКОВОДСТВА

Это руководство разработано как простой, удобный для чтения справочник. Руководство поделено на главы, разделы и подразделы. Здесь не приведены всеобъемлющие пояснения по установке, снятию, сборке, разборке и диагностике.

ОРГАНИЗАЦИЯ СТРАНИЦ

Указанные ниже цифры в кружках относятся к примеру страницы (см. ниже).

Аббревиатура и изображение в верхнем правом углу каждой страницы соответствует текущей главе.

Текущий раздел указан в верхней части страницы.

Подраздел указан более мелким шрифтом, нежели раздел.

Линией из звездочек (*) обрамляются важные процедуры. Каждый шаг такой процедуры обозначается маркером (●).

Важная информация, такая как тип жидкости, момент затяжки, специальный инструмент помещена в рамку и помечена соответствующим символом.

Цифры в кружках относятся к графическим схемам и изображениям

Буквы нижнего регистра в кружках относятся к размерам, указанным на схемах или меткам

Буквы верхнего регистра в квадратах относятся к другим пояснениям по графическим схемам

Стрелки, помещенные после указания дефектов, сопровождают рекомендуемые действия.

В Главе 3, «Периодический Контроль и Регулировка», вместо раздела в верхней части страницы указывается подраздел.

СБОРОЧНЫЕ СХЕМЫ

Для облегчения идентификации частей и шагов процедуры в начале каждого раздела, посвященного разборке узла, приводится сборочная схема.

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ГРАФИЧЕСКИЕ СИМВОЛЫ

Графические символы с по размещаются в правом верхнем углу каждой страницы и указывают тему Главы.

Общая информация

Спецификации

Периодический контроль и регулировка

Двигатель

Карбюратор

Ходовая

Электрика Решение проблем

Графические символы с по служат для определения спецификаций, встречающихся в тексте.

Заливаемая жидкость

Смазка

Специальный инструмент

Момент затяжки

Предел износа, зазор, люфт

Обороты двигателя

Ω, V, A

Графические символы с по на сборочных схемах служат для указания типа смазки и точек нанесения смазки.

Моторное масло

Трансмиссионное масло

Дисульфид молибденовое масло

Консистентная смазка для подшипников колес

Легкая литиевая смазка Дисульфид молибденовая смазка

Графические символы с по на сборочных схемах указывают где необходимо применять

фиксатор и где необходимо устанавливать новые части .

Фиксатор (LOCTITE®)

Замена

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ОГЛАВЛЕНИЕ

ОБЩАЯ ИНФОРМАЦИЯ

СПЕЦИФИКАЦИИ

ПЕРИОДИЧЕСКИЙ КОНТРОЛЬ И РЕГУЛИРОВКА

ДВИГАТЕЛЬ

КАРБЮРАТОР

ХОДОВАЯ

БОРТОВАЯ СЕТЬ

РЕШЕНИЕ ПРОБЛЕМ

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ОГЛАВЛЕНИЕ ГЛАВА 1.

ОБЩАЯ ИНФОРМАЦИЯ

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29.12.07 01:29


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ВМЕСТО FAQ’а

Мануалы

Сервис-мануал на Yamaha TT250R(L) на русском языке

Партфиши (официальный каталог Yamaha с номерами запчастей)

Различные мануалы на английском и японском языках

Статьи по обслуживанию и ремонту Yamaha TT250R

Неоригинальные расходники и запчасти на Yamaha TT250R

Размеры, партнамберы и аналоги сальников и подшипников на Yamaha TT250R

Мотохимия: чего, куда и сколько заливать

Замена моторного масла

Замена масла и сальников вилки на ОЕ.     Замена масла, сальников, пыльников и направляющих на Райде 94 года

Замена передних тормозных колодок.    Замена задних тормозных колодок

Ревизия прогрессии. Установка пресс-масленок.

Ремонт заднего амортизатора

Замена подшипников заднего колеса

Снятие, разборка и чистка карбюратора

Замена клапанов и маслосъемных колпачков. 

Замена обгонной муфты

Замена дисков сцепления. Регулировка сцепления.

Ремонт пластика и кожи сиденья 

Вопросы по форуму

Как вставить фотографию в пост?

Как отредактировать профиль

Локальные материалы и обсуждения

> ВОПРОСЫ ПО ПОКУПКЕ

Хочу купить TT250R Raid через мотоаукцион…Как по номеру рамы судить о годе выпуска? Аукционная оценка «4» — это хороший моцик или следует искать с оценкой «5»? 

На что(какие узлы, слабые места) нужно обращать внимание при покупке, чтобы потом не сидеть дома и не ждать заказанных запчастей?

Отличия TTR-Raid и TT-R (Open Enduro), очень подробное сравнение Райда и ОЕ. 

TT-R или WR250R(F,X,Z)

Вопрос по годам выпуска. История модели.

Где заказывать запчасти и расходники на TT250R

Заказ запчастей. Ценообразование. Взаимозаменяемость OEM-деталей Yamaha
 
>ОБЩИЕ ВОПРОСЫ

Какой у Raid-а моторесурс?

Максимальная скорость и динамика разгона

Расход топлива

Какой бензин лить 

Какое масло лучше использовать 

Езда на заднем колесе,   маслозаборник

Завод с кикстартера 

Минимальная температура запуска

на Raid’е по грязюке

Утопил мот, что делать?  +статья о том, как вернуть мот к жизни после купания. Вода в маслоотделителе (адсорбере) 

Поменял масло, в масляном фильтре немного металлической стружки
 
> ПРИБОРНАЯ ПАНЕЛЬ И ЭЛЕКТРИКА

Электрическая схема мотоцикла Yamaha TT250R

Спидометр: «Установка времени и режим замера растояний»
Корректировка работы спидометра под другие звезды

Проблемы с приборкой: не включается совсем, только подсветка горит (больше ничего не показывает), подсветка не горит, обнуляется одометр (скидывается пробег), отказал спидометр (подбор датчика Холла)

Датчик Холла (коленвала)

Нет заряда аккумулятора

Выбор аккумулятора

Защитить контакты и разьемы

Течь масла из под винта с проводом нейтрали

Самодельный ключ
 
 >МОТОР

Замена масла

Периодичность пропитки поролонового фильтра

мотоцикл ест масло, замер компрессии. Замер компрессии

Сравнение старого и нового (<95) двигателей на ТТР

Сорваны/сломаны болты: болт слива масла, болт залива масла, болт крышки масляного фильтра, болт крышки стартера, сорвана резьба штуцера масляной магистрали 

Прокладки двигателя: старые, самодельные (паронит, герметик), от ТТР 99-06. Чем смазывать перед установкой?

Течет масло из-под: болта над выпуском, заглушки декомпрессора, клапанной крышки, головки цилиндра, цилиндра, штока выжима сцепления, винта с датчиком нейтрали, проводов генератора, вала кикстартера, стыка половинок картера

Мотоцикл дымит: синим дымом и жрет масло, синим дымом только на холодную, черным дымом при резком открытии газа, белым дымом, 

Жрет 200мл масла на сотню и не дымит 

Выпускная труба возле цилиндра краснеет при прогревании.  

Сечет приемная труба глушителя: коллектор проржавел

Стреляет в выпуск: хлопки в глушаке 

Как снять ротор генератора, болт для снятия ротора генератора, генератор от Стелса

Обгонная муфта: звук такой, как будто при остановке двигателя что-то из зацепления выходит или входит; шестерня стартера

Китайская обгонная муфта и шестерни стартера: отзывы, подбор аналогов

Стартер: ремонт, подбор аналогов

Ремонт клапанов, натяжитель цепи ГРМ, изготовление новых прокладок

Цокот клапанов.   Регулировка зазоров клапанов. 

Как выставить фазы ГРМ (поставить валы ГРМ по меткам)?

Замена маслосъемных колпачков

Замена поршневых колец

Пересухарить не снимая цилиндр   или другими способами

Шум цепи ГРМ.   Цепь ГРМ: натяжение, причины и признаки износа,   длина цепи ГРМ

Натяжитель цепи ГРМ

Патрубок от карба до цилиндра пропускает, мот стал хуже держать обороты и потерял в динамике. Самодельный патрубок  

Дренажные шланги карбюратора. Снятие карбюратора (с фото). Как снять карбюратор, не потревожив патрубок. Разборка и чистка карбюратора

Карбюратор: винты качества и количества (регулировка)

Регулировка уровня топлива в карбюраторе, еще 

Карб: если на скорости с полностью выкрученно ручкой газа резко её бросить, моц просто как будто вырубается

Не работает подсос

Бензин течет из карбюратора: из-под крышки ускорительного насоса, непонятно откуда

Самопальный ускорительный насос

Ремонт стойки поплавка карбюратора

Трубка из сапуна идет сначала в какой то отстойник с отросточком-аппендиксом.       Масло гонит через сапун

Виноват ли воздушный фильтр? поднёс руку к глушителю… погазовал немного и на руке моментально осела сажа адсорбер

Плохо заводится, глохнет на подсосе
 
>ТОРМОЗА

Замена передних тормозных колодок на TTR + Замена задних тормозных колодок на TTR + тема на форуме про замену тормозных колодок

Отзывы о тормозных колодках, самодельные тормозные колодки

Отзывы о китайских тормозных дисках, изготовление тормозных дисков,  

Замена тормозной жидкости, прокачка -при наличии в системе воздуха

Плохо работает передний тормоз, задний тормоз. На ходу заклинило передний тормоз

Армированные тормозные шланги
 
 >АМОРТИЗАТОРЫ, ПОДВЕСКА, РУЛЬ

Замена масла и сальников вилки: Open Enduro, Raid + простой способ замены масла на Райде

Замена сальников без разборки вилки

Передняя вилка сопливит маслом

Люфт передней вилки

Масло в переднюю вилку: сколько заливать и какое?

инструмент для ремонта передней вилки, альтернативные варианты используемых приспособлений

регулировка поджатия передней вилки

Замена подшипников, рулевой колонки

Принцип работы аморта

Разборка заднего амортизатора, как открутить шток амортизатора

Ремонт заднего амортизатора (статья)

Временная замена родного амортизатора на волговский

Ревизия прогрессии. Смазка/замена подшипников

Шприцевание подвески

Чем смазывать подшипники прогрессии   еще

Люфт в рычагах задней подвески
Альтернатива родным подшипникам в прогрессии
отечественая замена подшипника № 28(требует изготовления тонкой втулки)
Установка шарнирного подшипника ШС-12 в нижнем креплении амортизатора (требует изготовления втулок)
Все размеры оригинальных подшипников прогрессии

Размер cферического подшипника прогрессии
Альтернатива оригинальному cферическому подшипнику прогрессии (GEH 12)  и цена его в Москве

Капролоновые (фторопластовые, эратолановые и т.д.) втулки вместо подшипников прогрессии
 
 >ЦЕПЬ и ЗВЕЗДЫ

Подойдет ли звезда для ТТР от 99 года на 93 год?    Болты под конус на задней звезде JTR

Изготовление звезд, расчеты и чертежи

ЛИЧНЫЕ ОТЗЫВЫ об использованных звёздах

Программа для расчета скорости в зависимости от оборотов и передачи, передаточные числа.

Сколько звеньев должно быть в цепи?  +программка по расчету звеньев в цепи

Решение проблемы забивающейся передней звезды

Как измерить провис цепи.  Растяжения цепи

Смазка цепи

Выбор цепи и подборка разборного замочка. Замена замка цепи на «под расклепку»

Удлинение цепи и изготовление замка

Альтернативные ловушки цепи.   Доработка ловушки цепи под 49/52 звезду.    

Установка защиты цепи от Raid на Опен Эндуро

Успокоитель цепи
чертёж оригинального ролика

Слайдер (скользяк) цепи на TTR от YZ, WR
 
>КОЛЕСА и РЕЗИНА
Подбор резины для Reid,а
Камеры
Давление в шинах 

Какая резина нужна и как шиповать резину (бюджетный вариант)?
Как подготовить tt-r к зиме?

Установка «Пятёрки» на Рэйд (Петрошина 5.00).

Замена подшипников заднего колеса.

Мотардовские колеса
 
>ЗЕРКАЛА, ПЛАСТИК, и все что коцается при падениях

Ремонт зеркал

Неоригинальные зеркала

Ремонт пластика и кожи сидения

Ремонт пластика TT-R

Чистка пластика

Наклейки
 
>ТЮНИНГ

Как занизить мотоцикл

Альтернативные вилки: перевёртыш на ТТР

Демпфер руля

Поршень Wiseco — вместо оригинала

325сс

Более мощный двигатель на ТТР: от XR400, от DR600

Тюнинг двигателя, жиклеры

тюнинг ускорительного насоса

Доработка впуска, нулевик

Дополнительный фильтр тонкой очистки топлива

Прямоток.   Переделка глушителя TT250R в прямоток

Датчик давления масла

Декомпрессор своими силами

Кикстартер.  Установка кикстартера.    Рычаг кикстартера от IRBIS/Lifan.        

Кик only: удаление электростартера

Увеличенные бензобаки на ТТР: родной бак от синего ТТРа ’99 года (10л), Clarke от XT225 (15,5л),  Acerbis от Honda XR250 (22л), Acerbis от Suzuki DR650 (25л).

Ветровик

Ручки с подогревом

самодельный багажник, размеры оригинального багажника, где могут изготовить багажник, багажник от Совы и ЗИД 200

бугели под боковые сумки , еще

усилить подрамник

Установка би-ксенона.    Xenon на TTR250, быть или не быть?
отключить ближний свет

светодиодная фара

Замена фары на OE без потери товарного вида

Крепление для номера

Самодельное крепление защиты рук, почти самодельная защита руля Ацербис

Усиление родной защиты рук

Тюнинговать или нет?

Идеи доработок или что бы Вы сделали?
 
> ИНСТРУМЕНТ и ПРИСПОСОБЛЕНИЯ

Изготовление мотоциклетного компрессометра

Конструкция упора для вывешивания TT250R Raid

набор родных ключей

ВИДЕО

Дефектовка двигателя Yamaha TT250R

Притирка клапанов YAMAHA TT250R

Ремонт впускного патрубка Yamaha TT250R

Ремонт натяжителя цепи ГРМ

Стук обгонной муфты стартера при глушении двигателя

ВНЕШНИЕ МАТЕРИАЛЫ, ПОЛЕЗНЫЕ СТАТЬИ

Английский F.A.Q.

Японская TT-R Wiki

Еще одна японская страничка про ТТР

Обзор эндурно-кроссовой резины 

Бортировка резины и замена камеры

Обслуживание поролоновых воздушных фильтров

Карбюратор: настройка качества смеси на ХХ методом падения оборотов

Настройка подвески: статья 1, статья 2, статья 3, статья 4

Турист из Райда: 25литровый бак от Suzuki DR650. Про дальнейший тюнинг этого Райда можно прочесть тут

 ПРОЧЕЕ 

 3х мерная модель TT250R Raid для GTA SA

GPS на TTR

< Предыдущая   Следующая >


Последнее обновление 04.04.16 12:42

 
Источник
  • Page 1
    OWNER’S MANUAL TTR250R(C) LIT-11626-16-24 5GF-28199-14…
  • Page 2
    EAU03438…
  • Page 3
    Congratulations on your purchase of the Yamaha TTR250R. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It repre- sents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

  • Page 4: Important Manual Information

    8 This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold. 8 Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual.

  • Page 5
    IMPORTANT MANUAL INFORMATION EW000000 PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
  • Page 6
    AFFIX DEALER LABEL HERE EAU04247 TTR250R OWNER’S MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2002 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan.

  • Page 7: Table Of Contents

    EAU00009 TABLE OF CONTENTS SAFETY INFORMATION ……..1-1 Fuel cock …………3-5 Safe riding …………1-1 Starter (choke) knob ……..3-6 Protective apparel ………..1-2 Seat …………..3-7 Modifications ………..1-3 Adjusting the front fork ……..3-7 Loading and accessories ……..1-3 Adjusting the shock absorber assembly ..3-10 Gasoline and exhaust gas …….1-5 Starting circuit cut-off system ……3-12 Location of important labels ……1-7 PRE-OPERATION CHECKS ……4-1…

  • Page 8
    TABLE OF CONTENTS Engine oil and oil filter element …….6-8 Checking the front fork ……..6-27 Cleaning the air filter element …….6-12 Checking the steering ……..6-28 Cleaning the spark arrester ……6-13 Checking the wheel bearings ……6-28 Adjusting the carburetor ……..6-14 Battery …………6-29 Adjusting the throttle cable free play …..6-14 Replacing the fuse ……..6-30 Adjusting the valve clearance …….6-15…
  • Page 9
    TABLE OF CONTENTS Motorcycle noise regulation ……9-3 Maintenance record ……..9-5 Off-road motorcycle limited warranty ….9-7 Yamaha extended service (Y.E.S.) ….9-9…

  • Page 10: Safety Information

    EAU02912 Q SAFETY INFORMATION MACHINES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPEN- DENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MACHINE. HE OR SHE SHOULD: 1.

  • Page 11: Protective Apparel

    Q SAFETY INFORMATION 6. Ride cautiously in unfamiliar areas. You may encounter hidden obstacles that could cause an accident. 7. The posture of the operator is important for proper control. The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the machine.

  • Page 12: Modifications

    Q SAFETY INFORMATION Modifications Modifications made to this machine not approved by Yamaha, or the removal of original equipment, may render the machine unsafe for use and may cause severe personal injury. Modifications may also make your machine illegal to use.

  • Page 13
    Genuine Yamaha accessories have been specifically designed for use on this machine. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories.

  • Page 14: Gasoline And Exhaust Gas

    Q SAFETY INFORMATION Gasoline and exhaust gas 1. GASOLINE IS HIGHLY FLAMMABLE: a. Always turn the engine off when refueling. b. Take care not to spill any gasoline on the engine or exhaust pipe(s)/muffler(s) when refueling. c. Never refuel while smoking or in the vicinity of an open flame. 2.

  • Page 15
    Q SAFETY INFORMATION…

  • Page 16: Location Of Important Labels

    Q SAFETY INFORMATION EAU02977 Location of important labels Please read the following important labels carefully before operating this machine.

  • Page 17
    This unit contains high pressure nitrogen gas. follows. Mishandling can cause explosion. FRONT : 100 kPa,{1.00 kgf/cm }, 15 psi Read owner’s manual for instructions. REAR 100 kPa,{1.00 kgf/cm }, 15 psi Do not incinerate, puncture or open. 3RV-21668-A0 YAMAHA 4AA-22259-80…

  • Page 18: Description

    EAU00026 DESCRIPTION Left view 1. Headlight (page 6-31) 6. Shock absorber rebound 2. Front fork air valve (page 3-7) damping adjusting dial (page 3-11) 3. Fuel cock (page 3-5) 7. Shift pedal (page 3-2) 4. Starter (choke) knob (page 3-6) 8.

  • Page 19: Right View

    DESCRIPTION Right view 9. Spark arrester (page 6-13) 14. Engine oil filter element (page 6-9) 10. Battery (page 6-29) 15. Brake pedal (page 3-3, 6-20) 11. Fuse (page 6-30) 16. Shock absorber spring preload 12. Shock absorber compression adjusting nut (page 3-10) damping adjusting knob (page 3-11)

  • Page 20: Controls And Instruments

    DESCRIPTION Controls and instruments 1. Clutch lever (page 3-2, 6-19) 6. Throttle grip (page 6-14) 2. Left handlebar switch (page 3-1) 7. Fuel tank cap (page 3-3) 3. Tripmeter (page 3-1) 4. Right handlebar switches (page 3-2) 5. Brake lever (page 3-3, 6-19)

  • Page 21: Instrument And Control Functions

    EAU00027 INSTRUMENT AND CONTROL FUNCTIONS 1. Tripmeter 1. Light switch “:” 2. Reset knob EAU00028 EAU00118 EAU01760 Main switch Handlebar switches Tripmeter The main switch controls the ignition The tripmeter shows the distance EAU04305 and lighting systems. The various traveled since it was last set to zero Light switch “:”…

  • Page 22: Clutch Lever

    INSTRUMENT AND CONTROL FUNCTIONS 1. Engine stop switch “#/$” 1. Clutch lever 1. Shift pedal 2. Start switch “START” EAU00152 EAU00157 EAU03890 Clutch lever Shift pedal Engine stop switch “#/$” The clutch lever is located at the left The shift pedal is located on the left Set this switch to “#”…

  • Page 23: Brake Lever

    INSTRUMENT AND CONTROL FUNCTIONS 1. Brake lever 1. Brake pedal 1. Fuel tank cap a. Remove. EAU00158 EAU00162 EAU00179 Brake lever Brake pedal Fuel tank cap The brake lever is located at the right The brake pedal is on the right side To remove the fuel tank cap, turn it handlebar grip.

  • Page 24: Fuel

    INSTRUMENT AND CONTROL FUNCTIONS EAU00185 EAU04265 Recommended fuel: Immediately wipe off spilled fuel UNLEADED GASOLINE with a clean, dry, soft cloth, since ONLY fuel may deteriorate painted sur- Fuel tank capacity: faces or plastic parts. Total amount: 10.0 L (2.2 lmp gal, 2.64 US gal) Reserve amount: 1.

  • Page 25: Fuel Tank Breather Hose

    INSTRUMENT AND CONTROL FUNCTIONS Your Yamaha engine has been OFF: closed position designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. knocking pinging) FUEL occurs, use a gasoline of a different brand or premium unleaded fuel.

  • Page 26: Starter (Choke) Knob

    INSTRUMENT AND CONTROL FUNCTIONS ON: normal position RES: reserve position FUEL FUEL 1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES” 1. Starter (choke) knob “1” EAU04038 Starter (choke) knob “1” With the lever in this position, fuel This indicates reserve.

  • Page 27: Seat

    INSTRUMENT AND CONTROL FUNCTIONS EAU04834 Adjusting the front fork The front fork is equipped with air valves for adjusting the spring rate and screws for adjusting the damping force. EW000036 There should be no difference in air pressure between the fork legs. 1.

  • Page 28
    Air pressure = 0 kPa gauge. (0 kgf/cm , 0 psi) Maximum (hard): NOTE: Air pressure = 40 kPa An optional air pressure gauge is (0.4 kgf/cm , 5.8 psi) available at a Yamaha dealer.
  • Page 29
    INSTRUMENT AND CONTROL FUNCTIONS EC000015 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. 3. Securely install the rubber caps. ECA00034 1. Rubber cap 1. Damping force adjusting screw Be sure to install the rubber caps to prevent dust, etc.

  • Page 30: Adjusting The Shock Absorber Assembly

    NOTE: Adjusting the shock 8 A special wrench is needed to absorber assembly make this adjustment and it can This shock absorber assembly is be obtained at a Yamaha dealer. equipped with spring preload 8 The spring preload setting is…

  • Page 31
    INSTRUMENT AND CONTROL FUNCTIONS Tightening torque: Locknut: 70 Nm (7.0 m0kgf, 51 ft0lbf) ECA00076 Always tighten the locknut against the adjusting nut, and then tighten the locknut to the specified torque. 1. Rebound damping force adjusting dial 1. Compression damping force adjusting knob Rebound damping force Compression damping force…

  • Page 32: Starting Circuit Cut-Off System

    8 Do not deform or damage the gas cylinder in any way, as this will result in poor damp- ing performance. 8 Always have a Yamaha dealer service the shock absorber. 3-12…

  • Page 33
    4. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. 5. Turn the engine off. 6. Shift the transmission into gear. 7. Keep the clutch lever pulled.

  • Page 34: Pre-Operation Checks

    • If necessary, add recommended oil to specified level. 6-8–6-11 • Check vehicle for oil leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check lever free play. Front brake • Adjust if necessary.

  • Page 35
    • Make sure that operation is smooth. • Check cable free play. Throttle grip 6-14 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 6-25 •…
  • Page 36
    PRE-OPERATION CHECKS NOTE: Pre-operation checks should be made each time the machine is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved. EWA00033 If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat- ing the machine.

  • Page 37: Operation And Important Riding Points

    EAU00372 OPERATION AND IMPORTANT RIDING POINTS EAU00374 EAU00376 EAU04383 Starting and warming up a cold engine 8 This model is designed for off- 8 8 Make sure not to store person- In order for the starting circuit cut-off road only. most al items near the air cleaner system to enable starting, one of the…

  • Page 38
    OPERATION AND IMPORTANT RIDING POINTS NOTE: NOTE: If the engine fails to start, release the The engine is warm when it responds start switch, wait a few seconds, and normally to the throttle with the starter then try again. Each starting attempt (choke) turned off.

  • Page 39: Starting A Warm Engine

    OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 Starting a warm engine Follow the same procedure as for 8 Even with the transmission in starting a cold engine with the excep- the neutral position, do not tion that the starter (choke) is not coast for long periods of time required when the engine is warm.

  • Page 40: Engine Break-In

    8 After every hour of operation, first 20 hours of riding. For this rea- immediately have a Yamaha dealer stop the engine, and then let it son, you should read the following check the vehicle.

  • Page 41: Parking

    OPERATION AND IMPORTANT RIDING POINTS EAU00457 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. EW000058 8 Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them.

  • Page 42: Periodic Maintenance And Minor Repair

    Yamaha If you do not have the tools or experi- dealer do it for you. ence required for a particular job, have a Yamaha dealer perform it for you. EW000062 Modifications not approved by Yamaha may cause loss of perfor- mance, excessive emissions, and render the vehicle unsafe for use.

  • Page 43: Periodic Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU00473 Periodic maintenance and lubrication chart Initial EVERY 100 mi 600 mi 1,200 mi ITEM CHECKS AND MAINTENANCE JOBS (150 km) or (1,000 km) or (2,000 km) or 1 month 6 months 12 months 9 Check fuel hoses for cracks or damage. √…

  • Page 44
    PERIODIC MAINTENANCE AND MINOR REPAIR Initial EVERY 100 mi 600 mi 1,200 mi ITEM CHECKS AND MAINTENANCE JOBS (150 km) or (1,000 km) or (2,000 km) or 1 month 6 months 12 months 9 Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 6-4.) √…
  • Page 45
    PERIODIC MAINTENANCE AND MINOR REPAIR Initial EVERY 100 mi 600 mi 1,200 mi ITEM CHECKS AND MAINTENANCE JOBS (150 km) or (1,000 km) or (2,000 km) or 1 month 6 months 12 months 9 Check operation and shock absorber for oil leakage. Shock absorber √…

  • Page 46: Removing And Installing The Cowling And Panels

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cowling A 1. Panel B 1. Screw (×3) 2. Panel A EAU00484 Refer to this section each time the EAU03516 Cowling A cowling or a panel needs to be Removing and installing the To remove the cowling removed and installed.

  • Page 47: Checking The Spark Plug

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw 1. Screw 1. Spark plug cap 2. Panel A 2. Panel B EAU01833 EAU04003 Checking the spark plug Panels A and B The spark plug is an important To remove one of the panels engine component, which is easy to Remove the screw, and then pull the check.

  • Page 48
    Instead, shown, with the spark plug 1. Measure the spark plug gap with have a Yamaha dealer check the wrench included in the owner’s a wire thickness gauge and, if machine. tool kit. necessary, adjust the gap to specification.

  • Page 49: Engine Oil And Oil Filter Element

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU04614 3. Install the spark plug with the Engine oil and oil filter spark plug wrench, and then element tighten it to the specified torque. The engine oil level should be checked before each ride. In addition, Tightening torque: the oil must be changed and the oil Spark plug:…

  • Page 50
    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil filler bolt 1. Engine oil drain bolt 1. Oil filter element drain bolt 2. Oil filter element cover bolt (×2) To change the engine oil (with or Check the washer for damage and 3.
  • Page 51
    PERIODIC MAINTENANCE AND MINOR REPAIR 12. Add the specified amount of the Tightening torque: recommended engine oil, and Oil filter element cover bolt: then install and tighten the oil 10 Nm filler bolt. (1.0 m0kgf, 7.2 ft0lbf) 10. Install the oil filter element drain Recommended oil: bolt, and then tighten it to the See page 8-1.
  • Page 52
    II ” or higher. seize. If this occurs, have a idle for several minutes while 8 8 Make sure that no foreign Yamaha dealer repair the vehi- checking it for oil leakage. If oil is material enters the crankcase. cle.

  • Page 53: Cleaning The Air Filter Element

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Holding clip (×3) 1. Air filter element 2. Sponge material EAU03602 5. Clean the sponge material with 3. Air filter element frame Cleaning the air filter solvent, and then squeeze the 3. Pull the air filter element out of element remaining solvent out.

  • Page 54: Cleaning The Spark Arrester

    PERIODIC MAINTENANCE AND MINOR REPAIR 7. Install the sponge material onto the frame, insert the air filter ele- ment into the air filter case, and then install the air filter case cover by installing the holding clips. EC000082 8 Make sure that the air filter ele- 1.

  • Page 55: Adjusting The Carburetor

    The carburetor is an important part of the engine and requires very sophisti- cated adjustment. Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. However, the follow- ing may be serviced by the owner as 1.

  • Page 56: Adjusting The Valve Clearance

    * Total weight of rider, cargo and accessories this from occurring, the valve clear- ance must be adjusted by a Yamaha Tire air pressure dealer at the intervals specified in the The tire air pressure should be…

  • Page 57
    Yamaha maximum load for the vehicle. dealer replace the tire immediately. 8 8 Do not carry along loosely…

  • Page 58: Spoke Wheels

    If any damage is 8 8 After extensive tests, only the including the tires, should be found, have a Yamaha dealer left to a Yamaha dealer, who tires listed below have been replace wheel. has the necessary profession-…

  • Page 59: Accessories And Replacement Parts

    PERIODIC MAINTENANCE AND MINOR REPAIR 8 Ride at moderate speeds after EAU00691 Yamaha cannot be held liable for Accessories and changing a tire since the tire sur- any consequences caused by the replacement parts face must first be “broken in” for…

  • Page 60: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE AND MINOR REPAIR 3. If the specified clutch lever free play could obtained described above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows. 4. Fully turn the adjusting bolt in direction a to loosen the clutch cable.

  • Page 61: Adjusting The Brake Pedal Position

    (0.39 in) below the top of the footrest ing performance, which may as shown. Periodically check the result in loss of control and an brake pedal position and, if neces- accident. sary, have a Yamaha dealer adjust it. 6-20…

  • Page 62: Checking The Front And Rear Brake Pads

    Yamaha dealer specified in the periodic maintenance causing it to become ineffective. replace the brake pads as a set.

  • Page 63: Changing The Brake Fluid

    EAU03976 REAR Changing the brake fluid fluid. Mixing fluids may result in a Have a Yamaha dealer change the harmful chemical reaction and brake fluid at the intervals specified in lead to poor braking perfor- the NOTE after the periodic mainte- mance.

  • Page 64: Drive Chain Slack

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU00744 Drive chain slack The drive chain slack should be checked before each ride and adjust- ed if necessary. To check the drive chain slack 1. Place the machine on a level surface and hold it in an upright position.

  • Page 65: Lubricating The Drive Chain

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU04366 NOTE: Lubricating the drive chain Make sure that both adjusting plates The drive chain must be cleaned and are in the same position for proper lubricated at the intervals specified in wheel alignment. the periodic maintenance and lubrica- tion chart, otherwise it will quickly EC000096 wear out, especially when riding in…

  • Page 66: Checking And Lubricating The Cables

    If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Yamaha Chain and Cable Lube…

  • Page 67: Checking And Lubricating The Throttle Grip And Cable

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU04034 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubri- cated or replaced at the intervals specified in the periodic maintenance chart.

  • Page 68: Checking And Lubricating The Sidestand

    If the sidestand does not move up down smoothly, have If any damage is found or the front Yamaha dealer check or repair it. fork does not operate smoothly, have a Yamaha dealer check or Recommended lubricant: repair it. Lithium-soap-based grease…

  • Page 69: Checking The Steering

    Yamaha 1. Place a stand under the engine dealer check the wheel bearings. to raise the front wheel off the ground.

  • Page 70: Battery

    To charge the battery severe burns. Avoid any con- Have a Yamaha dealer charge the tact with skin, eyes or clothing battery as soon as possible if it and always shield your eyes seems to have discharged.

  • Page 71: Replacing The Fuse

    The fuse holder is located beside the battery charger, have the battery leads are properly battery compartment behind panel B. Yamaha dealer charge your connected to the battery termi- (See page 6-6 for panel removal and battery. nals. installation procedures.) If the fuse is blown, replace it as fol- lows.

  • Page 72: Replacing The Headlight Bulb

    EAU04285 4. If the fuse immediately blows er by pushing it inward and turn- Replacing the headlight bulb again, have a Yamaha dealer ing it counterclockwise, and then This machine is equipped with a check the electrical system. remove the defective bulb.

  • Page 73
    PERIODIC MAINTENANCE AND MINOR REPAIR 6. Install the cowling together with the headlight unit. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Bulb a. Do not touch the glass part of the bulb. EW000119 EC000105 Headlight bulbs get very hot.

  • Page 74: Replacing The Taillight Bulb

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 Supporting the machine Since this model is not equipped with a centerstand, follow these precau- tions when removing the front and rear wheel or performing other main- tenance requiring the machine to stand upright. Check that machine is in a stable and level posi-…

  • Page 75: Front Wheel

    Front wheel brake pads will be forced shut. To remove the front wheel EW000122 8 It is advisable to have a Yamaha dealer service the wheel. 8 Securely support the machine so that there is no danger of it falling over.

  • Page 76
    PERIODIC MAINTENANCE AND MINOR REPAIR 4. Tighten the wheel axle holder nuts to the specified torque. 1. Tripmeter gear unit 1. Retainer 2. Wheel axle EAU04367 3. Wheel axle holder nut (×4) To install the front wheel NOTE: 1. Install the tripmeter gear unit into Make sure that there is enough the wheel hub so that the projec- space…

  • Page 77: Rear Wheel

    EW000122 tightened in this sequence, there should be a gap at the bottom of the 8 It is advisable to have a axle holder. Yamaha dealer service the wheel. 8 Securely support the machine Tightening torque: Wheel axle holder nut: so that there is no danger of it 10 Nm (1.0 m0kgf, 7.2 ft0lbf)

  • Page 78
    PERIODIC MAINTENANCE AND MINOR REPAIR EAU04368 To install the rear wheel 1. Install the wheel. NOTE: Make sure that there is enough space between brake pads before inserting brake disc between the pads. 1. Swingarm end cover (×2) 2. Screw (×4) 2.

  • Page 79: Troubleshooting

    Use only genuine Yamaha replace- ment parts. Imitation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills. 6-38…

  • Page 80: Troubleshooting Chart

    There is compression. Check the ignition. Operate the electric starter. There is no compression. Have a Yamaha dealer check the vehicle. 3. Ignition Wipe off with a dry cloth and correct the Open throttle halfway and operate Remove the spark spark plug gap, or replace the spark plug.

  • Page 81: Machine Care And Storage

    EAU03521 MACHINE CARE AND STORAGE Before cleaning Cleaning Care 1. Cover the muffler outlet with a ECA00010 While the open design of a machine plastic bag after the engine has reveals the attractiveness of the tech- 8 Avoid using strong acidic cooled down.

  • Page 82
    MACHINE CARE AND STORAGE 8 Do not use any harsh chemical 8 For machines equipped with a After riding in the rain, near the sea products on plastic parts. Be windshield: Do not use strong or on salt-sprayed roads sure to avoid using cloths or cleaners or hard sponges as Since sea salt or salt sprayed on sponges which have been in…
  • Page 83
    NOTE: test its braking performance 4. To prevent corrosion, it is recom- Consult a Yamaha dealer for advice and cornering behavior. mended to apply a corrosion pro- on what products to use. tection spray on all metal, includ- ing chrome- and nickel-plated, surfaces.

  • Page 84: Storage

    MACHINE CARE AND STORAGE Storage Long-term c. Install the spark plug cap onto Before storing your machine for sev- the spark plug, and then place Short-term eral months: the spark plug on the cylinder Always store your machine in a cool, 1.

  • Page 85
    MACHINE CARE AND STORAGE 6. Lubricate all control cables and 9. Remove the battery and fully the pivoting points of all levers charge it. Store it in a cool, dry and pedals as well as of the place and charge it once a sidestand/centerstand.

  • Page 86: Specifications

    EAU01038 SPECIFICATIONS Specifications Model TTR250R(C) Engine oil 0° 10° 30° 50° 70° 90° 110° 130°F Type Dimensions Overall length 2,095 mm (82.5 in) YAMALUBE 4 (10W30) Overall width 835 mm (32.9 in) or SAE 10W30 Overall height 1,260 mm (49.6 in) YAMALUBE 4 (20W40) Seat height 915 mm (36 in)

  • Page 87: Specifications

    SPECIFICATIONS Air filter Wet type element Gear ratio 2.467 Fuel 1.813 Type UNLEADED GASOLINE ONLY 1.364 Fuel tank capacity 10 L (2.2 Imp gal, 2.64 US gal) 1.080 Reserve amount 2 L (0.44 Imp gal, 0.53 US gal) 0.889 Carburetor 0.759 Manufacturer TEIKEI…

  • Page 88
    SPECIFICATIONS Maximum load* 90 kg (198 lb) Suspension * Load is total weight of rider, cargo and accessories. Front Tire air pressure (measured on cold tires) Type Telescopic fork Front 100 kPa (1.00 kgf/cm , 15.0 psi) Rear Rear 100 kPa (1.00 kgf/cm , 15.0 psi) Type Swingarm (link suspension)
  • Page 89
    SPECIFICATIONS Headlight type Halogen bulb Bulb voltage, wattage × quantity 12 V, 35/36.5W × 1 Headlight 12 V, 21/5W × 1 Taillight Fuse…

  • Page 90: Consumer Information

    Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION 1. Key identification number 1.

  • Page 91: Model Label

    The model label is affixed to the frame under the seat. (See page 3-7 for seat removal and installation pro- cedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.

  • Page 92: Motorcycle Noise Regulation

    CONSUMER INFORMATION EAU01053 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any per- son.

  • Page 93
    CONSUMER INFORMATION…

  • Page 94: Maintenance Record

    CONSUMER INFORMATION EAU02932 Maintenance record Have a Yamaha dealer complete this record when the machine is serviced. Maintenance Date of Servicing dealer Mileage Remarks interval service name and address…

  • Page 95
    CONSUMER INFORMATION Maintenance Date of Servicing dealer Mileage Remarks interval service name and address…

  • Page 96: Off-Road Motorcycle Limited Warranty

    CONSUMER INFORMATION EAU02922 YAMAHA MOTOR CORPORATION, U.S.A. OFF-ROAD MOTORCYCLE LIMITED WARRANTY…

  • Page 97
    CONSUMER INFORMATION…

  • Page 98: Yamaha Extended Service (Y.e.s.)

    CONSUMER INFORMATION EAU01063 YAMAHA EXTENDED SERVICE (Y.E.S.)

  • Page 99
    CONSUMER INFORMATION 9-10…
  • Page 100
    YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2002·5–0.6×1(E)
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