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Yamaha TT-R250 TT250R 1999-2006 Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: TT-R250 / TT250R Model Code: TT250R Generation Generation Designation: First Generation Codes Vin Prefix: Check vehicle frame/engine for specific VIN details 👋 Introduction...
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Type: Motorcycle
Vendor:
Sku: 501662
Yamaha TT-R250 TT250R 1999-2006 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TT-R250 / TT250R
Model Code:
TT250R
Generation
Generation Designation:
First Generation
Codes
Vin Prefix:
Check vehicle frame/engine for specific VIN details
👋 Introduction
Market Position
Motorcycle Segment:
Dual-sport / Off-road Enduro
Target Audience:
Enthusiasts, trail riders, off-road adventurers, daily commuters seeking versatility
Competitive Analysis
Key Competitors:
Honda XR250, Kawasaki KLX250, Suzuki DR-Z250, KTM EXC 200/250
Key Features
Vehicle Usp:
Reliable 4-stroke engine, robust build for off-road use, street-legal capability, user-friendly maintenance
Manual Value Proposition:
Comprehensive diagnostic and repair information empowering owners to maintain and fix their TT-R250
📋 Manual Details
Coverage Areas
Model Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Variants Covered:
All TT-R250 / TT250R models within the specified year range
Page Count
Estimated Page Count:
500+
Manual Type
Manual Type:
Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Top End (Cylinder, Piston, Valves), Bottom End (Crankshaft, Connecting Rod, Bearings), Cooling System, Lubrication System, Ignition System, Fuel System (Carburetor, Fuel Pump), Exhaust System
Transmission Systems:
Clutch System, Gearbox Internals, Shift Mechanism, Transmission Fluid Maintenance
Chassis Systems:
Frame, Suspension (Front Forks, Rear Shock), Steering System, Braking System (Front and Rear), Wheel and Tire Servicing, Chain and Sprocket Maintenance
Electrical Systems:
Wiring Diagrams, Lighting System, Ignition System Components, Battery Maintenance, Charging System, Starter Motor, Switches and Relays
Bodywork And Maintenance:
Body Panels, Decals, Seat, Handlebars, Footpegs, General Cleaning and Care
Procedures Included
Routine Maintenance:
Oil Changes, Filter Replacements, Chain Adjustments, Brake Pad Replacement, Air Filter Cleaning/Replacement, Spark Plug Replacement, Valve Clearance Checks
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues; Fault code interpretation (if applicable)
Engine Rebuild:
Complete engine disassembly, inspection, repair, and reassembly procedures
Transmission Repair:
Gearbox component replacement, clutch overhaul, shift drum and fork servicing
Suspension Service:
Fork seal replacement, damper rod servicing, rear shock absorber maintenance and adjustment
Braking System Overhaul:
Caliper rebuilding, master cylinder servicing, bleeding procedures
Electrical Diagnostics And Repair:
Component testing, wiring harness repair, charging system analysis
Technical Depth
Diagnostic Capabilities:
Detailed diagnostic charts, symptom-based troubleshooting guides
Repair Procedures:
Step-by-step instructions with clear diagrams and torque specifications for all major repairs
Special Tools:
Identification of specialized tools required for specific procedures
📊 Manual Specifications
File Format
File Type:
Searchable PDF
Printability:
Printable
Print Quality
Image Resolution:
High-resolution (suitable for clear reproduction of diagrams)
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, DOHC, 4-valve, Single Cylinder
Displacement:
249 cc (249cc)
Bore X Stroke:
73.0 mm x 59.6 mm
Compression Ratio:
10.5:1
Cooling System:
Liquid-cooled
Performance
Horsepower Estimate:
Approx. 26-28 HP (Varies by region and tuning)
Torque Estimate:
Approx. 23-25 Nm (Varies by region and tuning)
Fuel System
Carburetor Type:
Mikuni BSR32 (or similar) CV carburetor
Fuel Type:
Unleaded gasoline, minimum 87 octane
🔧 Transmission
Standard
Transmission Type:
Constant-mesh, 6-speed
Clutch Type:
Wet, multiple disc
Features
Gear Ratios:
Refer to manual for specific gear ratios
Final Drive:
Chain drive
Transmission Fluid:
Yamalube 10W-40 or equivalent API SG, JASO MA
📐 Dimensions
Exterior
Overall Length:
Approx. 2,155 mm (84.8 in)
Overall Width:
Approx. 820 mm (32.3 in)
Overall Height:
Approx. 1,230 mm (48.4 in)
Seat Height:
Approx. 895 mm (35.2 in)
Ground Clearance:
Approx. 330 mm (13.0 in)
Weights
Dry Weight:
Approx. 120 kg (265 lbs)
Wet Weight:
Approx. 133 kg (293 lbs) (Estimated with full fluids)
Fuel Tank Capacity:
10 Liters (2.6 US gal)
🛡️ Safety Features
Ratings
Safety Certification:
Not applicable for motorcycles in traditional automotive safety rating sense (e.g., NHTSA, Euro NCAP)
Active Features
Braking System:
Hydraulic Disc Brakes (Front and Rear)
Lighting:
Halogen Headlight, LED Taillight, Turn Signals
Passive Features
Frame Construction:
Steel semi-double cradle frame
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer and tachometer, odometer, trip meter, indicator lights (neutral, high beam, turn signals)
Driver Assistance
ABS:
Not equipped
Connectivity
Bluetooth:
Not equipped
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months
Oil Filter Replacement:
Every 6,000 km (3,600 miles) or 12 months (or with every oil change if preferred)
Air Filter Cleaning:
Every 1,000 km (600 miles) or as needed based on riding conditions
Valve Clearance Check:
Every 10,000 km (6,000 miles)
Spark Plug Replacement:
Every 6,000 km (3,600 miles) or as needed
Fluid Specifications
Engine Oil:
Yamalube 10W-40 or API SG/SH/SJ/SL, JASO MA
Brake Fluid:
DOT 4
Coolant:
Yamaha's permanent type anti-freeze (50% mixture with distilled water)
Known Issues
Common Wear Items:
Clutch plates, chain and sprockets, brake pads, fork seals, wheel bearings
Potential Engine Concerns:
Carburetor jetting may require adjustment for altitude or modifications; occasional starter clutch wear
Electrical Notes:
Ensure good battery connections; potential for stator or rectifier issues over time
📚 Vehicle History
Brand Heritage
Yamaha Motorcycles:
Yamaha Motor Corporation has a long-standing reputation for producing reliable and performance-oriented motorcycles across various segments, including off-road and dual-sport.
Model Evolution
Tt R Series Lineage:
The TT-R line has been a staple for Yamaha's off-road offerings, evolving from earlier two-stroke models to the 4-stroke TT-R250, focusing on accessibility and reliability.
Production
Production Period:
The TT-R250 was produced for a significant period, with the 1999-2006 models representing a specific iteration of this popular dual-sport.
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
Consistently praised for its reliability, ease of use, and versatility in off-road and light trail riding for its era.
Ratings
Durability Rating:
High, known for robust engine and chassis components when properly maintained.
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