Segment:
Dual-sport / Enduro motorcycle
Target Audience:
Off-road enthusiasts, trail riders, and adventure motorcyclists.
Key Competitors Era:
Honda CRF series, Kawasaki KLX series, Suzuki DR-Z series.
Vehicle Reputation:
Known for its robust build, tractable engine, and long-distance comfort for a dual-sport.
Manual Value Proposition:
Provides owners and mechanics with the necessary technical data to maintain and repair the TTR 250 effectively, maximizing its lifespan and performance.
Engine:
Detailed engine overhaul, component inspection, timing, and specifications.
Fuel System:
Carburetor tuning, fuel pump, fuel lines, and fuel tank maintenance.
Ignition System:
CDI unit, spark plug, ignition coil, and timing adjustments.
Cooling System:
Radiator, fan, coolant, and related components.
Transmission Clutch:
Clutch operation, cable adjustment, gearbox inspection, and oil changes.
Chassis Suspension:
Front forks (including internal components and adjustments), rear shock absorber, linkage, and swingarm.
Brakes:
Front and rear brake caliper overhaul, master cylinder, brake lines, pads, and fluid changes.
Electrical System:
Wiring diagrams, battery, lighting, starter, charging system, and switches.
Wheels Tires:
Wheel bearing inspection, spoke tension, and tire pressure recommendations.
Bodywork Frame:
Fairings, seat, fuel tank, fenders, and frame integrity checks.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug checks, and lubrication points.
Troubleshooting:
Diagnostic charts and procedures for common operational issues.
Engine Rebuild:
Detailed steps for piston, cylinder, crankshaft, and valve train servicing.
Suspension Tuning:
Fork oil changes, compression/rebound adjustments, and rear shock servicing.
Brake System Overhaul:
Bleeding procedures, seal replacement, and caliper piston servicing.
Carburetor Rebuild:
Jetting information, float height adjustment, and cleaning procedures.
Electrical Diagnosis:
Testing of charging system, ignition, and lighting circuits.
Depth:
Covers everything from basic rider maintenance to complete engine and chassis overhauls.
Diagnostic Capability:
Advanced troubleshooting guides and fault finding procedures.
Rebuild Instructions:
Detailed, step-by-step instructions for major component rebuilds.
Engine Type:
Four-stroke, single-cylinder, DOHC
Bore X Stroke:
73.0 mm x 59.5 mm
Compression Ratio:
10.2:1
Cooling System:
Liquid-cooled
Horsepower:
Approx. 23-25 HP (subject to tuning and exact model variant)
Torque:
Approx. 20-22 Nm (subject to tuning and exact model variant)
Fuel Delivery:
Carburetor (Mikuni BS32)
Fuel Tank Capacity:
10 Liters (approx. 2.6 US gal)
Recommended Fuel:
Unleaded gasoline, Octane rating 87 or higher
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.
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 Adjustment:
Every 500 km (300 miles) or as needed.
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40, API SG or higher.
Engine Oil Capacity:
1.80 L (1.90 US qt) without filter change; 2.00 L (2.10 US qt) with filter change.
Coolant Type:
Permanent type antifreeze coolant (50% solution with distilled water).
Brake Fluid Type:
SAE J1703 or FMVSS No. 116 DOT 3.
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, wheel bearings, and fork seals.
Potential Electrical Issues:
Corrosion in connectors, aging wiring harness, especially if stored outdoors or used in wet conditions.
Carburetor Tuning:
Can be sensitive to altitude and temperature changes, requiring periodic adjustment.
