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.
Competitors:
Competed with other dual-sport motorcycles of its era such as the Honda XR250L, Kawasaki KLR250, and Suzuki DR250SE.
Features:
Torquey single-cylinder engine, reliable performance, capable suspension for varied terrain, electric start (on most models), dual-sport tires, comfortable riding position.
Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Estimated Page Count:
Approx. 400-500 pages (typical for this era/type of manual)
Manual Type:
Workshop Repair and Service Manual
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.
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.
Depth:
Comprehensive, covering everything from basic owner maintenance to complete engine and transmission rebuilds. Suitable for professional mechanics and advanced DIY enthusiasts.
Engine Type:
Four-stroke, SOHC, air-cooled
Bore X Stroke:
73.0 mm x 59.6 mm
Horsepower:
Approx. 20-23 HP (estimated, varies by region and tuning)
Torque:
Approx. 14-16 lb-ft (estimated)
Carburetor:
Mikuni VM34 (single constant velocity)
Fuel Type:
Unleaded gasoline (minimum 87 octane recommended)
Oil Capacity:
1.80 L (1.90 US qt) with filter change
Ignition System:
CDI (Capacitor Discharge Ignition)
Cooling System:
Forced air-cooled
Transmission Type:
5-speed constant mesh
Clutch Type:
Wet, multi-plate
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)
Safety Certification:
Road-legal with DOT/ECE compliant lighting and safety equipment.
Braking System:
Hydraulic disc brakes front and rear.
Lighting:
Halogen headlight, LED taillight, front and rear turn signals.
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.
Infotainment System:
N/A (Basic motorcycle design of its era)
Driver Assistance Features:
N/A
Connectivity Features:
N/A
Instrument Cluster:
Analog speedometer, tachometer, odometer, trip meter, and indicator lights (turn signals, neutral, high beam).
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.
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)
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.
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.
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 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.
