Yamaha TTR250 1999-2006 Workshop Service Manual Repair

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The TTR250 is a versatile dual-sport motorcycle produced from 1999 to 2006, designed to excel in both off-road adventures and everyday street riding. Building on a renowned heritage in motorcycle...

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Typ: Motorcycle

Anbieter:

Art.-Nr: 56704

Stichworte: 1999 2000 2001 2002 2003 2004 2005 2006 Marine Motorcycle Sterndrive TTR250 Yamaha

Produktvarianten

Beschreibung

The TTR250 is a versatile dual-sport motorcycle produced from 1999 to 2006, designed to excel in both off-road adventures and everyday street riding. Building on a renowned heritage in motorcycle engineering, the TTR250 features a robust single-cylinder, 4-stroke, oil-cooled engine with a 5-speed transmission, delivering reliable performance for a wide range of conditions. Its balanced chassis, hydraulic disc brakes, and comfortable ergonomics make it a capable and enjoyable machine for riders seeking adventure and practicality. This workshop service manual provides comprehensive guidance for the maintenance, repair, and troubleshooting of the TTR250 models from 1999 through 2006. It covers all essential systems, including the engine, transmission, fuel, electrical, chassis, suspension, and braking systems, offering detailed step-by-step instructions, diagnostic procedures, and technical specifications. This manual is an indispensable resource for professional technicians and owner mechanics alike, enabling efficient and accurate upkeep to ensure the longevity and optimal performance of the TTR250.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

TTR250

Model Years Covered:

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

Vehicle Type:

Dual-Sport Motorcycle

👋 Introduction

Market Position

Target Audience:

Professional technicians and DIY mechanics

Competitive Analysis

Advantage:

Official manufacturer documentation, comprehensive coverage, instant digital access

Key Features

Accuracy:

Original workshop manual, accurate and complete information

Usability:

Easy to follow, practical repair instructions

Cost Effectiveness:

Enables DIY repairs, saving labor costs

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive repair, maintenance, and troubleshooting

Specific Systems:

Engine, transmission, chassis, electrical, fuel, exhaust, suspension, braking, bodywork

Page Count

Estimated Page Count:

Hundreds of pages (exact count not specified but implied by comprehensive nature)

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, cylinder head, piston, crankshaft, camshaft, valve timing, lubrication system

Fuel System:

Carburetor overhaul and adjustment, fuel tank, fuel lines

Transmission Drivetrain:

Clutch operation, gearbox disassembly and assembly, chain adjustment

Electrical System:

Ignition system, lighting, charging system, starter motor, wiring diagrams

Chassis Suspension:

Front fork service and adjustment, rear shock absorber service, swingarm maintenance

Braking System:

Brake caliper overhaul, master cylinder service, brake pad replacement, hydraulic system bleeding

Bodywork:

Fairings, fenders, seat, fuel tank removal and installation

Exhaust System:

Exhaust pipe and muffler inspection and replacement

Cooling System Maintenance:

Oil cooler inspection and maintenance

Procedures Included

Maintenance:

Periodic maintenance charts, oil changes, filter replacements, spark plug checks, chain lubrication

Repair:

Step-by-step repair instructions for all major components

Troubleshooting:

Diagnostic procedures and common problem identification

Overhaul:

Complete engine and component overhaul procedures

Diagnostics:

Troubleshooting guides for common electrical and mechanical issues

Wiring Diagrams:

Included, essential for electrical diagnostics and repairs

Technical Depth

Depth:

Suitable for professional technicians and experienced DIY mechanics

Detail Level:

Detailed torque specifications, clearances, and assembly procedures

📊 Manual Specifications

File Format

Format:

File Type:

PDF (Portable Document Format)

Print Quality

Printability:

Full Printable

Zoom Functionality:

Yes (Zoom IN/OUT)

Binding Type

Binding:

Digital Download (no physical binding)

Paper Type

Paper Type:

N/A (Digital PDF)

Delivery

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader, WinRAR

Compatibility

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, 4-stroke, SOHC, 4-valve

Displacement:

249cc (approximately, exact spec may vary by specific market version but generally within this range for TTR250)

Performance

Horsepower:

Approx. 22-24 HP (at crank, figures may vary)

Torque:

Approx. 15-17 lb-ft (at crank, figures may vary)

Fuel System

Carburetion:

Mikuni VM34 (typical, may vary)

Cooling System

Cooling Method:

Oil-cooled with a front-mounted oil cooler

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Features

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Length:

Approx. 2,150 mm (84.6 in)

Width:

Approx. 800 mm (31.5 in)

Height:

Approx. 1,180 mm (46.5 in)

Weights

Dry Weight:

Approx. 116 kg (256 lbs)

Wet Weight:

Approx. 125 kg (276 lbs)

Fuel Capacity:

Approx. 10 Liters (2.6 US gal)

🛡️ Safety Features

Ratings

Safety Certification:

As per relevant motorcycle safety standards of the era

Active Features

Braking System:

Hydraulic disc brakes front and rear

Passive Features

Lighting:

Headlight, taillight, turn signals (depending on market configuration)

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation)

Driver Assistance

Not typically equipped on this model generation

Connectivity

Connectivity Features:

Instrumentation

Instrument Cluster:

Analog speedometer, tachometer, odometer, trip meter, indicator lights

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 km or annually (refer to manual for exact specifications)

Valve Clearance Check:

Typically every 10,000-15,000 km (refer to manual for exact specifications)

Fluid Specifications

Engine Oil Type:

Yamalube (or equivalent high-quality 4-stroke motorcycle oil) SAE 10W-40 or 20W-40 API SG or higher (check manual for precise recommendation)

Engine Oil Capacity:

Approx. 1.5 - 1.8 Liters (with filter change, refer to manual for exact)

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for exact specification)

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, fork seals, wheel bearings

Engine Considerations:

Proper regular maintenance is crucial for the longevity of the oil-cooled engine.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Company

Model Evolution

Development Context:

Part of Yamaha's successful line of TTR off-road motorcycles, adapted for dual-sport use.

Design Philosophy:

Designed for versatility, capable of handling off-road trails and street use.

Production

Production Period:

Originally introduced in the mid-1990s, with this specific manual covering the 1999-2006 generation.