Yamaha TTR 250 1999-2006 Workshop Service Repair Manual

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Typ: Motorcycle

Anbieter:

Art.-Nr: 66742

Stichworte: 1999 2000 2001 2002 2003 2004 2005 2006 Motorcycle Motorcycles TTR 250 TTR Models Yamaha

Produktvarianten

Beschreibung

The TTR 250 is a versatile lightweight dual-sport and enduro motorcycle, produced from 1999 through 2006. Renowned for its durable 4-stroke, SOHC, 4-valve, air-cooled 249cc engine, the TTR 250 offers user-friendly operation and reliable performance, making it an excellent choice for trail riders, recreational off-road enthusiasts, and those seeking adaptable transportation. Its capable suspension with approximately 270mm of travel at both the front and rear, combined with effective disc brakes, ensures a confident and enjoyable riding experience across varied terrains. This comprehensive workshop service repair manual, written in English, provides detailed information for the maintenance and repair of TTR 250 models from 1999 to 2006. It covers all essential systems, including engine mechanical and electrical components, fuel, clutch, transmission, suspension, steering, and braking systems, as well as bodywork and electrical systems. The manual includes step-by-step repair procedures, preventive maintenance schedules, troubleshooting guides, and electrical diagnostics, making it an indispensable resource for owners and technicians aiming to keep their TTR 250 in optimal condition.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

TTR 250

Model Variants:

Off-road/Dual-sport

Generation

Production Years Covered:

1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006

Codes

Engine Code:

Likely 4ES (for 4-valve, 250cc SOHC, 4-stroke)

Vin Code Year Representation:

Varies by year (e.g., X for 1999, Y for 2000, 1 for 2001... 6 for 2006)

👋 Introduction

Market Position

Segment:

Lightweight dual-sport/enduro motorcycle

Target Audience:

Trail riders, recreational off-road enthusiasts, commuters seeking versatile transport

Competitive Analysis

Key Competitors:

Honda CRF230F, Kawasaki KLR250, Suzuki DR-Z250, older KTM 200/250 models

Key Features

Features Highlighted:

Durable engine, capable suspension, user-friendly operation, reliability

Manual Value Proposition

Cost Effectiveness:

Inexpensive way to maintain and repair the vehicle

Information Source:

Number one source for repair and service information

📋 Manual Details

Coverage Areas

Covered Years:

1999-2006

Geographic Coverage:

Likely global, depending on original market release

Page Count

Estimated Page Count:

High (typical for comprehensive workshop manuals, likely 300-500+ pages)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF (Downloadable)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Yes (Top end, bottom end, valve train, cooling, lubrication)

Engine Electrical:

Yes (Ignition, charging, starting, CDI, sensors)

Emission Control:

Yes (If applicable to the model years/regions)

Fuel System:

Yes (Carburetor tuning, fuel lines, pump if applicable)

Suspension System:

Yes (Front forks, rear shock absorber, linkages)

Clutch System:

Yes (Clutch operation, plates, actuation)

Transmission System:

Yes (Manual transaxle, gear inspection, shifting mechanisms)

Driveshaft Axle:

Yes (Rear wheel drive components, sprockets, chain maintenance if applicable)

Steering System:

Yes (Handlebar, steering stem, bearings)

Brake System:

Yes (Front and rear brakes, hydraulic lines, calipers, master cylinders, pads)

Body Interior Exterior:

Yes (Body panels, seat, fenders, plastics)

Body Electrical System:

Yes (Lighting, instrumentation, wiring harnesses)

Restraint System:

Yes (Likely refers to rider safety features or specific tie-downs if applicable)

Procedures Included

Preventive Maintenance:

Yes (Oil changes, filter replacements, chain adjustment, lubrication)

Troubleshooting:

Yes (Diagnostic procedures for various systems)

Repair Procedures:

Yes (Step-by-step instructions for component disassembly, repair, and reassembly)

Electrical Diagnostics:

Yes (Utilizing wiring diagrams for fault finding)

Component Overhaul:

Yes (Engine rebuilds, carburetor overhauls, suspension rebuilds)

Technical Depth

Depth:

Comprehensive (Suitable for both DIYers and experienced mechanics, covers detailed repair and diagnostics)

Diagnostic Tools:

Implied use of standard motorcycle tools and possibly basic electrical testing equipment

📊 Manual Specifications

File Format

File Format:

Print Quality

Printability:

Fully Printable

Zoom Functionality:

Yes (Zoom IN/OUT)

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

Software Requirements

PDF Reader:

Adobe PDF Reader

Unzipping Tool:

WinZip (or similar)

Compatibility

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, 4-valve, Air-cooled

Displacement:

249cc (249 cm³)

Bore X Stroke:

73.0 mm x 59.6 mm (typical for this engine family)

Performance

Horsepower Estimate:

Approximately 20-23 HP (at the crank, dependent on specific tuning and region)

Torque Estimate:

Approximately 19-21 Nm (14-15 lb-ft)

Fuel System

Carburetor:

Mikuni VM33 (typical for this model, may vary)

Fuel Capacity:

Likely around 10-12 Liters (2.6-3.2 Gallons)

Ignition

Ignition Type:

CDI (Capacitor Discharge Ignition)

Lubrication

Oil Type Recommendation:

Yamalube 4 (or equivalent API SE, SF, SG, SH, SJ, or higher quality SAE 10W-40 or 20W-50 motorcycle oil)

Oil Capacity With Filter Change:

Approximately 1.5-1.8 Liters (1.6-1.9 US qt)

🔧 Transmission

Standard

Transmission Type:

Constant-mesh 6-speed sequential

Optional

Transmission Options:

N/A (Only manual transmission offered)

Features

Clutch Type:

Wet, multiple-disc, cable-actuated

Final Drive:

Chain drive

📐 Dimensions

Exterior

Overall Length:

Approx. 2150 mm (84.6 in)

Overall Width:

Approx. 830 mm (32.7 in)

Overall Height:

Approx. 1205 mm (47.4 in)

Seat Height:

Approx. 875 mm (34.4 in)

Wheelbase:

Approx. 1405 mm (55.3 in)

Weights

Dry Weight:

Approx. 120 kg (265 lbs)

Wet Weight:

Approx. 127 kg (280 lbs)

Suspension Travel

Front Suspension Travel:

Approx. 270 mm (10.6 in)

Rear Suspension Travel:

Approx. 270 mm (10.6 in)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety ratings are typically not standardized like automotive)

Active Features

Active Safety:

Effective disc brakes (front and rear), responsive handling

Passive Features

Passive Safety:

Sturdy frame construction, durable bodywork

Lighting

Headlight Type:

Halogen

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation)

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

Instrumentation

Instrument Cluster:

Analog speedometer, odometer, trip meter, engine temperature warning light, neutral indicator, turn signal indicators, high beam indicator

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000 km (1,860 miles) or 6 months

Oil Filter Replacement:

Every 3,000 km (1,860 miles) or annually, coinciding with oil changes

Air Filter Cleaning:

Every 1,000 km (620 miles) or more frequently in dusty conditions

Spark Plug Inspection:

Every 3,000 km (1,860 miles)

Valve Clearance Check:

Every 6,000 km (3,730 miles) or 12 months

Chain Lubrication:

Every 500 km (310 miles) or after washing/riding in wet conditions

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4

Coolant Type:

Pre-mixed, ethylene glycol-based antifreeze (e.g., Yamalube Coolant)

Known Issues

Common Wear Items:

Clutch plates, brake pads, fork seals, chain and sprockets, carburetor jets (especially from ethanol exposure)

Carburetor Idling:

Some owners report occasional rough idling or jetting issues, often resolved with cleaning or adjustment.

Suspension Softness:

While good for its class, some aggressive riders may find the stock suspension a bit soft for hard off-road use.

📚 Vehicle History

Brand Heritage

Brand Legacy:

Yamaha has a long and successful history in motorcycle manufacturing, known for innovation and performance in off-road and street bikes.

Model Evolution

Ttr Series Introduction:

The TTR line was Yamaha's answer to the growing demand for reliable, user-friendly off-road and dual-sport machines.

Ttr 250 Development:

The TTR 250 was designed to be a versatile machine capable of handling trails, fire roads, and even some street use. It aimed for a balance of performance and ease of use.

Production

Manufacturing Location:

Likely Japan or other Yamaha manufacturing facilities