Segment:
Dual-sport / Enduro motorcycle
Target Audience:
Off-road enthusiasts, trail riders, recreational dual-sport riders.
Competitors 1999-2006:
Honda XR250/XR400, Kawasaki KDX200/KDX250, Suzuki DR-Z250/DR350, KTM EXC series.
Vehicle Philosophy:
Yamaha's reputation for robust, reliable off-road machinery, blending trail capability with street legality (depending on market registration).
Manual Value Proposition:
Provides authoritative, factory-level information essential for maintaining, troubleshooting, and repairing the TT-R250, ensuring longevity and optimal performance.
Engine Mechanical:
Detailed overhaul, diagnosis, and repair of all engine components including cylinder, piston, crankshaft, camshaft, valves, and lubrication system.
Fuel System:
Carburetor tuning, disassembly, cleaning, and adjustment; fuel tank and petcock service.
Cooling System:
Radiator, fan, thermostat, and coolant flow diagnostics and repair (if applicable for model variant).
Exhaust System:
Muffler, head pipe inspection and repair.
Transmission And Drivetrain:
Clutch operation, gear shifting mechanism, transmission disassembly and assembly, drive chain maintenance.
Suspension Front:
Front fork disassembly, seal replacement, oil level and specification, damper rod service.
Suspension Rear:
Monoshock linkage inspection, bearing service, shock absorber adjustment and overhaul.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, fluid bleeding, rotor inspection.
Electrical System:
Ignition system (CDI, spark plug), lighting system, battery maintenance, charging system (stator, rectifier/regulator), starter motor, wiring diagrams, troubleshooting electrical faults.
Frame And Bodywork:
Chassis inspection, swingarm service, steering head bearing replacement, body panel removal and installation.
Routine Maintenance:
Oil change intervals, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid flush, coolant flush.
Troubleshooting:
Diagnostic procedures for common performance issues, starting problems, electrical faults, and component failures.
Engine Rebuild:
Complete step-by-step instructions for engine disassembly, component inspection, measurement, and reassembly, including torque specifications.
Suspension Overhaul:
Detailed guides for servicing front forks and rear shock absorbers, including fluid types, quantities, and assembly procedures.
Carburetor Tuning:
Idle speed adjustment, mixture screw settings, jetting recommendations for different conditions.
Electrical Diagnostics:
Testing of ignition coils, alternators, rectifiers, starter circuits, and lighting components using multimeters and specific test procedures.
Wheel And Tire Service:
Spoke tensioning, wheel bearing replacement, tire mounting and balancing.
Depth:
Comprehensive, covering everything from basic rider maintenance to full engine and chassis overhauls.
Diagnostic Charts:
Includes detailed troubleshooting flowcharts for various mechanical and electrical issues.
Specifications:
Provides all critical technical specifications including clearances, tolerances, torque values, fluid types, and electrical resistances.
Wiring Diagrams:
Detailed, factory-accurate electrical schematics for easy fault tracing.
Engine Oil Change:
Every 3,000 km (1,860 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
Every 6,000 km (3,730 miles) or 12 months, or at every oil change if possible.
Air Filter Cleaning:
Every 1,000 km (620 miles) or 6 months, or more frequently in dusty conditions.
Spark Plug Replacement:
Every 6,000 km (3,730 miles).
Chain Lubrication Adjustment:
Every 1,000 km (620 miles).
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 10W-30 API SE, SF type or ACEA E2, or higher quality. Semi-synthetic or fully synthetic recommended for demanding use.
Engine Oil Capacity:
1.80 L (1.90 US qt) without filter change; 2.00 L (2.10 US qt) with filter change.
Fork Oil Type:
Yamaha Suspension Fluid 01 (or equivalent) SAE 5W.
Fork Oil Quantity:
Approx. 500 ml (16.9 US fl oz) per leg (specific value in manual).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Type:
Ethylene glycol-based non-metallic coolant, 50% solution with distilled water (if liquid-cooled).
Common Wear Items:
Clutch plates, brake pads, fork seals, wheel bearings, chain and sprockets due to off-road usage.
Potential Failures:
Starter motor (if equipped), rectifier/regulator, carburetor jetting issues from fuel quality variations, overheating if cooling system is not maintained.
Ignition Timing Specs:
Provided in manual, typically checked via timing strobe.
Valve Clearance Specs:
Intake: 0.08 - 0.13 mm; Exhaust: 0.12 - 0.17 mm (typical cold settings, refer to manual for exact values).
Manufacturer:
Yamaha Motor Company, Japan. Known for performance motorcycles, musical instruments, and other powered products.
Predecessors:
Successor to earlier Yamaha dual-sport models like the TT350 and XT series, building on their off-road DNA.
Key Developments 1999-2006:
Generally consistent platform with minor updates to suspension settings, graphics, and emissions controls over the production run. Some variants featured electric start. Notably the TT-R250 'Raid' version offered longer-travel suspension and larger fuel tank.
Manufacturing Location:
Japan