Yamaha TT-R250 TT250R 1999-2006 Repair Service Manual

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The TT-R250, also known by its model designation TT250R, is a versatile dual-sport motorcycle produced from 1993 to 2006. This model is recognized for its torquey, air-cooled 249 cc four-stroke...

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Typ: Motorcycle

Anbieter:

Art.-Nr: 60654

Stichworte: 1999 2000 2001 2002 2003 2004 2005 2006 Motorcycle Motorcycles TT Models TT-R250 TT250R Yamaha

Produktvarianten

Beschreibung

The TT-R250, also known by its model designation TT250R, is a versatile dual-sport motorcycle produced from 1993 to 2006. This model is recognized for its torquey, air-cooled 249 cc four-stroke engine, electric start, and capable long-travel suspension, making it well-suited for both light trail riding and street commuting. Its design emphasizes reliability and user-friendliness, reflecting a strong legacy in motorcycle manufacturing and its evolution from the competitive 'TT' dirt bike lineage. The TT-R250 competed effectively in its segment, offering a comfortable riding position and robust performance for a variety of terrains. This comprehensive workshop repair and service manual provides detailed guidance for the maintenance and repair of the TT-R250 models from 1999 to 2006. It covers all major systems, including the engine, fuel system, transmission, suspension, brakes, and electrical system, with step-by-step procedures for disassembly, repair, and reassembly. The manual also includes essential information on scheduled maintenance, troubleshooting common issues, and critical technical specifications such as torque values and fluid requirements. Its in-depth coverage is designed to assist owners, mechanics, and technicians in keeping the TT-R250 in optimal working condition.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

TT-R250

Model Designation:

TT250R

Generation

Generation Code:

First Generation (1993-2006)

Codes

Chassis Code:

4GY, 4EG

👋 Introduction

Market Position

Positioning:

The Yamaha TT-R250 was positioned as a versatile dual-sport motorcycle, capable of light trail riding, off-road excursions, and street legal commuting. It was known for its reliability and user-friendly nature.

Competitive Analysis

Competitors:

Competed with other dual-sport motorcycles of its era such as the Honda XR250L, Kawasaki KLR250, and Suzuki DR250SE.

Key Features

Features:

Torquey single-cylinder engine, reliable performance, capable suspension for varied terrain, electric start (on most models), dual-sport tires, comfortable riding position.

📋 Manual Details

Coverage Areas

Years Covered:

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

Page Count

Estimated Page Count:

Approx. 400-500 pages (typical for this era/type of manual)

Manual Type

Manual Type:

Workshop Repair and Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, including top-end (cylinder head, piston, valves), bottom-end (crankshaft, connecting rod, bearings), timing, lubrication system, cooling system.

Fuel System:

Carburetor service and tuning (Mikuni VM34), fuel delivery, fuel tank, fuel lines.

Transmission:

Gearbox disassembly and assembly, clutch operation and replacement, shift mechanism.

Suspension:

Front fork (KYB USD) overhaul, seal replacement, oil levels and specifications, rear shock absorber service and adjustments, linkage maintenance.

Brakes:

Front and rear hydraulic brake systems, caliper overhaul, pad replacement, fluid flush and bleeding, master cylinder service, rotor inspection.

Electrical System:

Ignition system (CDI), lighting (headlight, taillight, indicators), charging system (stator, regulator/rectifier), battery maintenance, wiring diagrams, troubleshooting electrical faults.

Chassis And Frame:

Frame inspection, steering head bearing service, swingarm maintenance, wheel bearing replacement.

Bodywork:

Plastic panel removal and installation, seat, fender, and fuel tank maintenance.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements (oil, air), spark plug servicing, chain adjustment and lubrication, brake checks, tire pressure.

Troubleshooting:

Diagnostic procedures for common running issues, starting problems, electrical faults, brake performance, suspension behavior.

Repair:

Step-by-step instructions for component removal, repair, and reinstallation across all major vehicle systems.

Disassembly Assembly:

Detailed breakdown and reassembly procedures for all major components and sub-assemblies.

Specifications And Measurements:

Torque specifications for fasteners, component clearances, wear limits, fluid capacities, and other critical measurements.

Technical Depth

Depth:

Comprehensive, covering everything from basic owner maintenance to complete engine and transmission rebuilds. Suitable for professional mechanics and advanced DIY enthusiasts.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution scans suitable for printing, ensuring legibility of diagrams and text.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Searchability

Searchable Text:

Likely (dependent on PDF conversion quality) - enables quick access to specific information.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, SOHC, air-cooled

Displacement:

249 cc

Bore X Stroke:

73.0 mm x 59.6 mm

Compression Ratio:

9.5:1

Performance

Horsepower:

Approx. 20-23 HP (estimated, varies by region and tuning)

Torque:

Approx. 14-16 lb-ft (estimated)

Fuel System

Carburetor:

Mikuni VM34 (single constant velocity)

Fuel Type:

Unleaded gasoline (minimum 87 octane recommended)

Lubrication

Oil Capacity:

1.80 L (1.90 US qt) with filter change

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition)

Cooling

Cooling System:

Forced air-cooled

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Features

Gear Ratios:

Specific ratios will be detailed within the manual (e.g., 1st: 2.500, 2nd: 1.750, 3rd: 1.333, 4th: 1.090, 5th: 0.913)

Final Drive:

O-ring sealed chain

Transmission Oil Type:

Yamalube 4 (or equivalent API SG, SAE 20W-40 or SAE 10W-30)

Transmission Oil Capacity:

0.80 L (0.85 US qt)

📐 Dimensions

Exterior

Overall Length:

2,170 mm (85.4 in)

Overall Width:

805 mm (31.7 in)

Overall Height:

1,225 mm (48.2 in)

Seat Height:

880 mm (34.6 in)

Wheelbase:

1,420 mm (55.9 in)

Ground Clearance:

305 mm (12.0 in)

Weights

Dry Weight:

119 kg (262 lbs)

Wet Weight:

Approx. 130 kg (287 lbs) (fully fueled)

Fuel Tank Capacity:

10 L (2.6 US gal)

Fuel Reserve Capacity:

Approx. 2 L (0.5 US gal)

🛡️ Safety Features

Ratings

Safety Certification:

Road-legal with DOT/ECE compliant lighting and safety equipment.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Lighting:

Halogen headlight, LED taillight, front and rear turn signals.

Passive Features

Frame Construction:

Steel diamond frame for rigidity and impact absorption.

Suspension Design:

Long-travel suspension designed to absorb impacts and maintain stability on rough terrain.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle design of its era)

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

Instrumentation

Instrument Cluster:

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

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000 km (1,800 miles) or 6 months.

Oil Filter Replacement:

Every 3,000 km (1,800 miles) or 6 months (concurrent with oil change).

Air Filter Cleaning:

Every 1,000 km (600 miles) or every 6 months; replace as needed.

Spark Plug Inspection:

Every 3,000 km (1,800 miles).

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after washing/rain.

Fluid Specifications

Engine Oil Specification:

Yamalube 4 (or equivalent API SG, SAE 20W-40 or SAE 10W-30)

Brake Fluid Specification:

DOT 3 or DOT 4 hydraulic brake fluid.

Fork Oil Specification:

Yamaha Fork Oil G-10 (or equivalent SAE 10W fork oil)

Coolant Specification:

N/A (Air-cooled engine)

Known Issues

Common Wear Items:

Clutch wear, wheel bearings, steering head bearings, fork seals, chain and sprockets due to off-road use.

Carburetor Tuning:

Carburetor (VM34) can require periodic cleaning and adjustment for optimal performance, especially after storage or heavy off-road use.

Electrical Connections:

Corrosion on electrical connectors can sometimes lead to intermittent issues, particularly in humid or off-road environments.

📚 Vehicle History

Brand Heritage

Yamaha Legacy:

Yamaha Motor Company is renowned for its extensive history in motorcycle racing and production, consistently delivering reliable and performance-oriented machines across various categories.

Model Evolution

Tt R Series:

The TT-R line evolved from Yamaha's successful 'TT' lineage of competition dirt bikes, adapted for broader dual-sport and recreational use with features like electric start and lights.

Production

Production Period:

The TT-R250 was produced globally from 1993 to 2006, with this manual covering the later iterations of the first generation.

Manufacturing Location:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Awards And Accolades:

While specific awards are not widely publicized for this model, it consistently received positive reviews for its reliability and all-around capability in the dual-sport segment during its production run.

Ratings

Customer Satisfaction:

Generally high due to Yamaha's reputation for build quality and durability.