Yamaha TTR 250 1999-2005 Full Service Repair Manual

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Stichworte: 1999 2000 2001 2002 2003 2004 2005 Motorcycle Motorcycles TTR 250 TTR Models Yamaha

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Beschreibung

The TTR 250, produced from 1999 to 2005, is a capable dual-sport motorcycle renowned for its reliable air-cooled, 4-valve SOHC engine and robust chassis. This second-generation model is celebrated for its versatility, excelling in off-road trail riding while also providing a functional option for general recreational use. Its engineering emphasizes durability and ease of maintenance, making it a popular choice among enthusiasts seeking a dependable machine for varied terrains. The TTR 250 stands out for its balance of performance and user-friendliness, distinguishing it within its competitive segment. This comprehensive English-language service manual provides full repair and maintenance coverage for the TTR 250 models from 1999-2005. It offers detailed procedures for all major systems, including engine, transmission, chassis, electrical, and fuel systems, along with routine maintenance schedules and troubleshooting guidance. The manual is designed for professional technicians and owners alike, equipping them with the knowledge to perform diagnostics, repairs, and rebuilds effectively. With abundant illustrations and in-depth explanations, it serves as an essential resource for maintaining the longevity and optimal performance of the TTR 250.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

TTR 250

Model Year Range:

1999, 2000, 2001, 2002, 2003, 2004, 2005

Generation

Generation Identifier:

2nd Generation (4-valve SOHC)

Codes

Chassis Code:

Often referred to by engine type or specific sub-model, but generally associated with the 4-valve, air-cooled, single-cylinder design prevalent in this era.

👋 Introduction

Market Position

Category:

Dual-Sport Motorcycle

Target User:

Off-road enthusiasts, trail riders, general recreational riders seeking robust maintenance capabilities.

Competitive Analysis

Competitors:

Honda XR series, Kawasaki KLR series, Suzuki DR series of similar displacement and era.

Key Features

Distinctive Features:

Renowned for its reliable air-cooled engine, robust chassis, and versatility for both trail riding and mild street use.

Manual Advantage:

Provides professional-level repair and maintenance guidance, empowering owners to perform extensive work, thus saving on dealership service costs.

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Service Repair and Maintenance

Secondary Coverage:

Diagnostics, Troubleshooting, Electrical Systems, Component Rebuilds

Page Count

Estimated Page Count:

Detailed manuals of this nature for motorcycles of this complexity typically range from 300 to 600+ pages, depending on the level of detail for each section.

Manual Type

Type:

Full Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine disassembly, assembly, inspection, repair, top-end components (cylinder head, valves, camshaft), bottom-end components (crankshaft, connecting rod, piston), lubrication system, cooling system (if applicable), fuel system (carburetor).

Transmission:

Clutch operation and adjustment, gearbox disassembly, assembly, inspection, gear selection mechanism, shift drum, transmission bearings.

Chassis:

Frame inspection and repair, suspension (front forks, rear shock absorber), swingarm, bearings, steering system, brakes (front and rear hydraulic systems, calipers, master cylinders, pads, rotors), wheels, tires.

Electrical:

Ignition system, charging system (stator, rectifier/regulator), starting system (starter motor, solenoid), lighting system (headlight, taillight, turn signals), wiring diagrams, component testing, fault diagnosis.

Fuel System:

Carburetor disassembly, cleaning, adjustment, jetting, fuel tank, fuel lines, petcock.

Exhaust System:

Exhaust pipe inspection, muffler, heat shields, gasket replacement.

Procedures Included

Maintenance:

Routine checks, oil changes, filter replacement, chain adjustment, brake adjustments, valve clearance checks and adjustment, spark plug replacement.

Repair:

Detailed step-by-step instructions for component removal, installation, and overhaul for all major systems.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and uncommon problems, including electrical troubleshooting with wiring diagrams.

Rebuilds:

Complete engine and transmission rebuild procedures, including component specifications for wear limits and tolerances.

Diagnostics:

Procedures for diagnosing electrical faults, engine performance issues, and mechanical problems.

Technical Depth

Depth Level:

Comprehensive (Professional Technician Level)

Detail Level:

Includes detailed sub-steps, notes, cautions, and warnings for critical information.

Illustrations:

Abundant detailed illustrations, drawings, and photos, with enlarged inset views for specific parts.

📊 Manual Specifications

File Format

Format:

Compatibility:

All versions of Windows & Mac

Print Quality

Printability:

Full Printable (All pages)

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

Delivery

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader, WinRAR

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-Stroke, Air-Cooled, DOHC, 4-Valve

Displacement:

249 cc (Cubic Centimeters)

Bore X Stroke:

Specifications vary slightly by specific model year but are typically around 73.0 mm x 59.5 mm.

Compression Ratio:

Around 10.5:1 (specifics may vary by sub-model).

Performance

Horsepower:

Typically in the range of 20-25 HP, depending on tuning and specific year.

Torque:

Estimated torque figures would be in the range of 18-20 Nm (Newton-meters).

Fuel System

Carburetor Type:

Single Mikuni carburetor (e.g., VM28 or similar).

Fuel Type:

Unleaded Gasoline

🔧 Transmission

Standard

Type:

Constant-mesh, 6-speed

Optional

Optional Transmission:

N/A (Standard 6-speed gearbox)

Features

Clutch Type:

Wet, multi-disc

📐 Dimensions

Exterior

Length:

Approx. 2,170 mm (85.4 in)

Width:

Approx. 840 mm (33.1 in)

Height:

Approx. 1,245 mm (49.0 in)

Wheelbase:

Approx. 1,435 mm (56.5 in)

Weights

Dry Weight:

Approx. 119 kg (262 lbs)

Wet Weight:

Specifications not readily available, but typically higher than dry weight due to fluids.

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycles are not subjected to formal crash test ratings like cars).

Active Features

Braking System:

Hydraulic disc brakes (front and rear).

Suspension Stability:

Telescopic front forks and Monocross rear suspension contribute to stability and control.

Passive Features

Lighting:

Headlight, taillight, brake light, and optional turn signals (depending on market configuration) for visibility.

💡 Technology Features

Infotainment

Infotainment System:

N/A (This is a performance-oriented dual-sport motorcycle, not equipped with infotainment features).

Driver Assistance

Assistance Features:

N/A (No electronic driver assistance systems like ABS or traction control are featured on this model).

Connectivity

Connectivity Options:

N/A (No connectivity features available).

Instrumentation

Dashboard Features:

Analog speedometer, tachometer, odometer, trip meter, and indicator lights for neutral, high beam, and turn signals.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 2,000 - 3,000 km (1,200 - 1,800 miles) or as specified in the manual for optimal engine life.

Valve Clearance Interval:

Recommended every 6,000 - 8,000 km (3,700 - 5,000 miles), or annually, as valve seats can wear.

Chain Maintenance:

Regular cleaning and lubrication (every 500-1000 km or after off-road use), tension adjustment as needed.

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or equivalent SAE 10W-40 API SG or higher) - specific viscosity may vary by climate.

Engine Oil Capacity:

Approximately 1.6 liters (1.7 US qt) with filter change, 1.4 liters (1.5 US qt) without filter change. Exact capacity should be confirmed in the manual.

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid.

Coolant Type:

N/A (Air-cooled engine).

Known Issues

Common Wear Items:

Clutch plates, brake pads, fork seals, carburetor diaphragms, wheel bearings, swingarm bearings, chain and sprockets.

Potential Problems:

Carburetor gumming from fuel degradation if left sitting, potential for wear in the transmission if not properly maintained, kickstart mechanism wear.

Preventative Maintenance

Key Practices:

Regular cleaning after off-road use to prevent corrosion and mud buildup, proper chain tensioning, timely fluid changes.

📚 Vehicle History

Brand Heritage

Brand Legacy:

Yamaha has a long and successful history in motorcycle manufacturing, known for performance, innovation, and durability across various disciplines.

Model Evolution

Ttr Lineage:

The TTR series represents Yamaha's commitment to off-road performance, with the TTR 250 evolving from earlier models to offer a balance of power, handling, and reliability.

Production

Production Period:

The TTR 250 was produced for several years, with this manual specifically covering the 1999-2005 models, which represent a significant iteration of the platform.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Specific industry awards for this model are not widely documented, but it received praise for its reliability and capability in its class.

Ratings

Customer Reviews:

Generally positive reviews from owners highlighting its robustness, ease of maintenance, and versatility for trail riding.