🏷️ Basic Information

Make:

Yamaha

Model:

TTR 250

Year:

2002

Product Name:

Yamaha TTR 250 2002 Repair Service Manual

Product Description:

Service Manual Repair PDF Download

👋 Introduction

Segment:

Dual-sport/Enduro Motorcycle

Target User:

Off-road enthusiasts, trail riders, casual dual-sport users

Key Competitors 2002:

Honda XR250L, Kawasaki KLR250, Suzuki DR-Z250

Yamaha Advantage:

Reputation for robust engines, reliable performance, and off-road prowess

Engine Type:

Air-cooled, 4-stroke, SOHC, 2-valve

Suspension Front:

Long-travel telescopic forks (KYB)

Suspension Rear:

Monoshock with linkage (KYB)

Brakes Front:

Disc

Brakes Rear:

Disc

Fuel Delivery:

Carburetor

📋 Manual Details

Primary Audience:

Professional Technicians

Secondary Audience:

Enthusiast Mechanics

Estimated Page Count:

Approximately 300-400 pages (typical for this model and year)

Manual Type:

Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Complete engine disassembly, assembly, inspection, and repair

Engine Electrical:

Ignition system, starting system, charging system, CDI unit, wiring diagrams

Fuel System:

Carburetor (Mikuni BSR33/BSR34), fuel pump, fuel lines, fuel tank

Transmission:

Gearbox internals, clutch operation, shift mechanism, lubrication

Suspension:

Front forks (KYB), rear shock absorber (Monoshock, KYB), linkage, bearings, seals

Brakes:

Front disc brake system, rear disc brake system, hydraulic lines, calipers, master cylinders

Electrical System:

Lighting, instrumentation, switches, battery, fuses, relays, wiring diagrams

Cooling System:

Oil cooler, oil lines, oil filter

Frame And Bodywork:

Chassis, subframe, body panels, seat, handlebars, footpegs

Wheels And Tires:

Rim specifications, spoke tension, tire fitting, wheel bearings

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning

Troubleshooting:

Diagnostic procedures for common mechanical and electrical issues

Engine Rebuild:

Piston and ring replacement, valve adjustment, bearing inspection, crankshaft service

Suspension Service:

Fork seal replacement, shock absorber service, linkage bearing maintenance

Brake System Overhaul:

Brake pad replacement, caliper service, master cylinder overhaul, bleeding procedures

Electrical Diagnostics:

Component testing, wiring harness inspection, troubleshooting electrical faults

Carburetor Tuning:

Adjustment of idle speed, mixture, jetting recommendations

Depth:

Comprehensive, covering from basic maintenance to complete engine and chassis overhauls

Diagnostic Codes:

Includes diagnostic procedures and potential fault codes (if applicable to the era/model)

Torque Specifications:

Detailed torque values for all critical fasteners

Clearances:

Specifications for valve clearances, piston-to-cylinder wall clearance, bearing clearances

Schematics:

Detailed wiring diagrams and exploded views of components

📊 Manual Specifications

File Format:

PDF

Searchability:

Likely text-searchable, enabling quick information retrieval

Image Quality:

High-resolution scans of original documentation, suitable for printing

Diagram Clarity:

Clear and legible diagrams and illustrations

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

4-stroke, Single-cylinder, Air-cooled, SOHC

Displacement:

249 cc

Bore X Stroke:

73.0 mm x 59.6 mm

Compression Ratio:

9.5:1

Valve Arrangement:

2 valves (SOHC)

Horsepower Est:

Approx. 20-22 HP (at crank)

Torque Est:

Approx. 18-20 Nm (at crank)

Carburetor Type:

Mikuni BSR33/BSR34

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

10 Liters (approx.)

Oil Capacity:

1.7 Liters (with filter change)

Ignition System:

CDI (Capacitor Discharge Ignition)

Spark Plug Type:

NGK CR8E (or equivalent)

🔧 Transmission

Type:

Constant mesh, 6-speed sequential

Clutch Type:

Wet, multi-disc

Final Drive:

O-ring sealed chain

Gear Ratios:

Refer to manual for specific gear ratios

Transmission Oil Type:

Yamalube 4 (or SAE 20W-40 API SE, SF)

Transmission Oil Capacity:

0.8 Liters

📐 Dimensions

Length:

2,120 mm (83.5 in)

Width:

810 mm (31.9 in)

Height:

1,230 mm (48.4 in)

Seat Height:

880 mm (34.6 in)

Wheelbase:

1,435 mm (56.5 in)

Ground Clearance:

315 mm (12.4 in)

Dry Weight:

119 kg (262 lbs)

Wet Weight:

129 kg (284 lbs) (approx., with fluids)

Front Tire Size:

80/100-21M/C 51P

Rear Tire Size:

110/100-18M/C 64P

Wheel Bolt Pattern:

N/A (Spoked wheels)

🛡️ Safety Features

Crash Test Results:

N/A (Motorcycle - typically not tested by regulatory bodies)

Braking System:

Hydraulic disc brakes front and rear for strong stopping power

Suspension Performance:

Long-travel suspension absorbs impacts and maintains tire contact

Chassis Design:

Robust frame designed for off-road durability

Ergonomics:

Designed for rider control and comfort during varied riding conditions

💡 Technology Features

Instrumentation:

Analog speedometer, odometer, trip meter, tachometer, neutral indicator, high-beam indicator

ABS:

Not equipped with ABS

Bluetooth Usb:

N/A (No integrated connectivity features)

🔧 Maintenance

Engine Oil Change:

Every 3,000 km or 6 months (whichever comes first)

Oil Filter Replacement:

Every 6,000 km or 12 months (or with every second oil change)

Air Filter Cleaning:

Every 1,000 km or 3 months (more frequently in dusty conditions)

Spark Plug Inspection:

Every 3,000 km

Valve Clearance Check:

Every 6,000 km

Chain Lubrication And Adjustment:

Every 500 km (or more often if riding in adverse conditions)

Engine Oil Grade:

Yamalube 4 (or SAE 20W-40 API SE, SF)

Brake Fluid Type:

DOT 3 or DOT 4

Common Wear Items:

Clutch plates, brake pads, fork seals, wheel bearings, steering head bearings

Carburetor Idling:

Occasional carburetor jetting or adjustment might be needed for optimal performance.

Suspension Seals:

Front fork seals can wear over time, especially with aggressive off-road use.

📚 Vehicle History

Yamaha Motorcycles:

Yamaha Motor Company, Ltd. has a long and storied history in motorcycle manufacturing, known for innovation and performance across various disciplines.

Ttr Series:

The TTR line represents Yamaha's commitment to the off-road segment, offering reliable and capable machines for trail riding and competition.

Ttr 250 Development:

The TTR250 was designed as a user-friendly, yet capable, dual-sport motorcycle bridging the gap between recreational trail bikes and more specialized competition models.

Manufacturing Location:

Primarily manufactured in Japan

Production Years:

The TTR250 model range has been produced for a significant period, with the 2002 model being part of a well-established generation.

🏆 Awards & Recognition

Awards:

While specific awards for the 2002 TTR250 are not prominently documented, the TTR series has generally been well-regarded for its reliability and capability in the dual-sport segment, earning praise from riders and publications for its class-leading features and performance.

Rider Satisfaction:

High rider satisfaction due to a balance of performance, durability, and ease of maintenance.