Segment:
Lightweight Dual-Sport / Trail Motorcycle
Target Audience:
Off-road enthusiasts, trail riders, dual-sport riders seeking a capable and reliable machine for mixed terrain.
Key Competitors:
Honda CRF250X (later models), Kawasaki KLX250S, Suzuki DR-Z250
Vehicle Selling Points:
Lightweight, agile handling, capable off-road performance, reliable Yamaha engine, suitable for both trail riding and limited street use.
Benefit To Owner:
Empowers owners to perform all necessary maintenance and repairs, saving money on dealership labor and ensuring proper upkeep for longevity and optimal performance.
Professional Standard:
This manual replicates the factory-issued documentation used by authorized Yamaha technicians.
Engine:
Complete engine overhaul, internal components, top-end, bottom-end, lubrication system, cooling system (if applicable, though TT-R250 is air-cooled), timing
Transmission:
Gearbox disassembly, inspection, repair, clutch operation and service, shift mechanism
Fuel System:
Carburetor (Mikuni BS30) service, cleaning, adjustment, fuel delivery system, fuel tank, petcock
Electrical System:
Ignition system (CDI), charging system (stator, regulator/rectifier), lighting (headlight, taillight, turn signals), battery, starter motor, wiring diagrams, troubleshooting electrical faults
Chassis And Suspension:
Frame inspection, front fork (USD forks) overhaul, rear shock absorber service, linkages, swingarm maintenance
Brakes:
Front and rear brake system (hydraulic disc brakes), caliper service, master cylinder overhaul, bleeding procedure, brake pad replacement, rotor inspection
Wheels And Tires:
Spoke wheel maintenance, tire replacement, wheel bearing service, balancing
Controls:
Throttle control, clutch lever, brake lever, shift lever adjustment and service
Exhaust System:
Exhaust pipe and muffler inspection, gasket replacement
Routine Maintenance:
Oil changes, filter replacement, air filter cleaning/replacement, spark plug service, chain adjustment, lubrication points
Troubleshooting:
Diagnostic procedures for common mechanical and electrical issues, symptom-based troubleshooting guides
Repair And Rebuild:
Step-by-step instructions for component disassembly, inspection, repair, and reassembly for all major vehicle systems
Specifications And Data:
Torque specifications, clearances, measurements, fluid capacities, electrical values
Depth:
Comprehensive: Covers everything from basic rider maintenance to full engine and transmission rebuilds, including electrical diagnostics and suspension tuning.
Engine Type:
Four-stroke, SOHC, 2-valve, Air-cooled
Bore X Stroke:
73.0 mm x 57.8 mm (typical for this model)
Compression Ratio:
10.5:1 (typical for this model)
Power Output:
Approximately 22-25 HP (subject to tuning and specific market variations)
Torque:
Approximately 19-21 Nm (subject to tuning and specific market variations)
Carburetor Model:
Mikuni BS30
Starting System:
Electric Starter
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity:
Approximately 10 Liters (2.6 US gallons)
Overall Length:
Approximately 2175 mm (85.6 in)
Overall Width:
Approximately 820 mm (32.3 in)
Overall Height:
Approximately 1205 mm (47.4 in)
Seat Height:
Approximately 895 mm (35.2 in)
Wheelbase:
Approximately 1455 mm (57.3 in)
Dry Weight:
Approximately 120 kg (264.6 lbs)
Wet Weight:
Approximately 129 kg (284.4 lbs) (with fluids)
Front Tire Size:
80/100-21M/C 51P
Rear Tire Size:
110/100-18M/C 64P
Front Brake Type:
Hydraulic Disc
Rear Brake Type:
Hydraulic Disc
Front Suspension Travel:
Approximately 270 mm (10.6 in)
Rear Suspension Travel:
Approximately 270 mm (10.6 in)
Safety Certification:
Meets EPA and DOT (for street-legal variants, if applicable) standards.
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Lighting:
Headlight, taillight, and brake light for visibility.
Frame Construction:
Steel semi-double cradle frame for durability and rigidity.
Instrument Cluster:
Analog speedometer, odometer, trip meter, and basic indicator lights (neutral, high beam, turn signals).
ABS:
Not equipped with Anti-lock Braking System (ABS).
Usb Charging:
No integrated USB charging ports.
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months (check manual for exact recommendation)
Air Filter Cleaning:
Every 1,000 km (600 miles) or more frequently in dusty conditions
Spark Plug Inspection:
Every 3,000 km (1,800 miles)
Chain Lubrication And Adjustment:
Every 500 km (300 miles) or after washing/riding in wet conditions
Engine Oil Type:
Yamaha Genuine 4-ATV Oil (API SG, JASO MA) or equivalent SAE 10W-40 motorcycle oil
Engine Oil Capacity:
Approximately 1.8 Liters (1.9 US qt) without filter change, 2.0 Liters (2.1 US qt) with filter change (verify in manual)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, carburetor jets (clogging).
Potential Electrical Concerns:
Regulator/rectifier failure, stator winding degradation (less common but possible with age).
Carburetor Performance:
Mikuni BS30 carburetor can be prone to clogging with debris or varnish if fuel is left sitting for extended periods.
Manufacturer:
Yamaha Motor Company is a renowned Japanese manufacturer with a long history of producing high-performance motorcycles and recreational vehicles.
Tt R Series Lineage:
The TT-R line has a history of dirt-focused and dual-sport motorcycles, known for their reliability and off-road prowess.
Production Period:
The TT-R250 was produced from the late 1990s through the mid-2000s, with variations and updates throughout its lifecycle.
Key Updates Pre 2002:
While the manual focuses on the 2002 model, earlier versions may have had different carburetor setups, suspension components, or styling.
