Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Chassis Type:
Dual Sport / Enduro Motorcycle
Product Type:
Master Service Repair Manual
Category:
Dual-sport / Off-road motorcycle, known for its versatility and reliability in trail riding and light off-road use.
Competitors:
Competed with models like the Honda CRF230F, Kawasaki KLX250S, and Suzuki DR-Z250, offering a balance of trail capability and street legality (depending on market configuration).
Features Of Vehicle:
Lightweight, durable construction, accessible seat height for its class, reliable engine, capable suspension for varied terrain.
Value Proposition Of Manual:
Provides the most complete information available for the TTR-250, essential for owners and technicians to maintain, diagnose, and repair the motorcycle effectively.
Primary Coverage:
Comprehensive service, repair, troubleshooting, and maintenance for the Yamaha TTR-250 (1996-2006 models).
Secondary Coverage:
Technical specifications, exploded diagrams, repair tips, and diagnostic procedures.
Estimated Page Count:
Likely over 300 pages (based on typical comprehensive service manuals for this era and vehicle type).
Manual Type:
Service Manual / Repair Manual
Engine Systems:
Engine disassembly, assembly, inspection, tuning, lubrication, cooling system, exhaust system, and emissions control.
Fuel System:
Carburetor (Mikuni BS34) overhaul, adjustment, jetting, fuel pump, fuel lines, and fuel tank maintenance.
Drivetrain Transmission:
Clutch operation and service, gearbox disassembly and assembly, shift drum and forks, drive chains, and sprockets.
Suspension Steering:
Front fork (conventional or upside-down variants) overhaul, seal replacement, oil viscosity and level, rear shock absorber service, linkage maintenance, and steering head bearing service.
Braking System:
Front and rear brake caliper service, piston replacement, brake pad replacement, master cylinder overhaul, brake hose inspection and replacement, and bleeding procedures.
Electrical System:
Ignition system (CDI, spark plug), lighting system (headlight, taillight, turn signals), charging system (stator, regulator/rectifier), battery maintenance, wiring diagrams, and starter system.
Frame Bodywork:
Frame inspection and repair, subframe, body panel removal and installation, seat, fenders, and handlebars.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, spark plug inspection and replacement, air filter cleaning/replacement, valve clearance checks and adjustments.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues related to engine performance, electrical faults, starting problems, and handling.
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation, including detailed torque specifications.
Wiring Diagrams:
Detailed electrical system schematics for accurate diagnosis and repair of electrical faults.
Depth:
Comprehensive, covering everything from basic user maintenance to complete engine and transmission rebuilds, including advanced diagnostics.
Printability:
Yes, fully printable.
Searchability:
Likely includes searchable text for easy navigation and information retrieval.
Binding Type:
Digital (PDF)
Paper Type:
N/A (Digital File)
Operating Systems:
Compatible with all versions of Windows, macOS, and Linux.
Required Software:
Adobe PDF Reader (or compatible PDF viewer).
Download Type:
Instant High-Speed Download
Engine Type:
Four-stroke, SOHC, air-cooled
Bore X Stroke:
73.0 mm x 59.6 mm
Compression Ratio:
9.2:1 (typical, may vary slightly by year)
Lubrication System:
Wet sump, often with a separate oil filter.
Horsepower:
Approximately 18-20 HP (at crankshaft, may vary by tuning and emission controls).
Torque:
Approximately 19-21 Nm (at crankshaft, may vary by tuning and emission controls).
Carburetor Type:
Mikuni BS34 (Constant Velocity)
Fuel Capacity:
Approximately 10-12 liters (2.6-3.2 gallons), depending on tank variant (standard vs. larger aftermarket).
Fuel Type:
Unleaded gasoline, typically 87 octane (or higher).
Overall Length:
Approximately 2175 mm (85.6 in)
Overall Width:
Approximately 830 mm (32.7 in)
Overall Height:
Approximately 1230 mm (48.4 in)
Seat Height:
Approximately 880 mm (34.6 in)
Dry Weight:
Approximately 121 kg (267 lbs)
Wet Weight:
Approximately 130 kg (287 lbs) (estimated, with fluids).
Ground Clearance:
Approximately 320 mm (12.6 in)
Safety Standards:
Meets relevant DOT and EPA standards for street-legality in many regions; specific safety ratings not applicable in the same way as automobiles.
Braking System Type:
Front: Disc brake; Rear: Disc brake.
Tires:
Dual-sport oriented tires (e.g., 80/100-21 front, 110/100-18 rear). Specific tire pressures and types are covered in the manual.
Lighting:
Headlight, taillight, brake light, and often turn signals (depending on market configuration).
Engine Oil Change:
Every 3,000 km (1,860 miles) or 6 months, whichever comes first (refer to manual for exact, potentially year-specific recommendations).
Air Filter Cleaning:
Every 1,000 km (620 miles) or more frequently in dusty conditions.
Valve Clearance Check:
Every 6,000 km (3,720 miles) or 12 months.
Chain Lubrication Adjustment:
Every 500 km (310 miles) or after washing/wet riding.
Engine Oil Type:
Yamalube 4-stroke motorcycle oil or equivalent, SAE 10W-40 or 20W-40 (refer to manual for specific ambient temperature recommendations).
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 4 hydraulic brake fluid.
Fork Oil Type:
Specific Showa SS-01 or equivalent fork oil (viscosity and quantity detailed in manual).
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, chain and sprockets.
Potential Carburetor Issues:
Pilot jet clogging leading to hard starting or poor idle, needle wear affecting mid-range fuel delivery.
Electrical System Notes:
Degradation of wiring insulation in extreme conditions, stator output checks for charging system health.
Yamaha Heritage:
Yamaha Motor Corporation, a global leader in motorcycles, musical instruments, and powersports, known for innovation and performance.
Ttr Series Context:
The TTR series represents Yamaha's robust lineup of off-road and dual-sport motorcycles, emphasizing durability and accessibility.
Production Period:
1996-2006 (as covered by this manual). Later iterations may exist under different designations or with significant updates.
Manufacturing Origin:
Typically manufactured in Japan, though assembly may have occurred in other locations depending on the market.
