🏷️ Basic Information

Make:

Yamaha

Model:

TT-R225/L

Year:

2002

Manual Product Name:

2002 Yamaha TT-R225/L Motorcycle Service Repair Manual

Product Description:

This Manual Covers 2002 Yamaha TT-R225 / L Motorcycle Service Manual. This manual is just like what the Yamaha dealership uses to do any repairs or maintenance!

👋 Introduction

Segment:

Entry-level to mid-range dual-sport motorcycle.

Target Audience:

Riders seeking a versatile machine for trail riding, recreational off-roading, and light on-road use.

Key Competitors:

Honda CRF230F, Kawasaki KLX250S, Suzuki DR-Z250. The TT-R225 offered a blend of simplicity, reliability, and trail-oriented capability.

Engine Type:

Reliable and torquey air-cooled four-stroke engine, favored for its ease of maintenance and broad power delivery.

Suspension:

Comfortable and capable suspension for absorbing trail imperfections, suitable for its intended use.

Durability:

Known for Yamaha's robust build quality and reliability, making it a low-maintenance option.

📋 Manual Details

Vehicle Make:

Yamaha

Vehicle Model:

TT-R225

Vehicle Model Variant:

TT-R225L (L-model designation likely indicates a specific configuration, potentially different suspension or styling)

Applicable Years:

2002

Estimated Page Count:

Likely 300-500 pages (typical for comprehensive service manuals of this era)

Type:

Service Repair Manual

Purpose:

Dealership-level maintenance, repair, and diagnostic procedures

Language:

English

Format:

Likely printed (original OEM manual) or high-quality PDF reproduction

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, including disassembly, inspection, assembly of top-end (cylinder, piston, rings, valve train) and bottom-end (crankshaft, connecting rod, bearings).

Engine Fuel System:

Carburetor (Mikuni VM series likely) service, adjustment, jetting, and troubleshooting. Fuel tank and petcock maintenance.

Engine Ignition System:

CDI ignition system diagnosis, troubleshooting, and component testing (coil, spark plug, stator).

Transmission:

Clutch operation, adjustment, and replacement. Gearbox inspection, lubrication, and repair. Shifter mechanism.

Chassis Suspension:

Front fork (telescopic) service, seal replacement, oil level and type. Rear shock absorber adjustment and service. Swingarm and linkage lubrication and inspection.

Brakes:

Front and rear brake system maintenance, including disc and pad inspection/replacement, caliper service, brake fluid flush and bleeding procedures. Master cylinder inspection.

Electrical System:

Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), lighting system (headlight, taillight, turn signals), horn, starter system (if applicable, though typically kick-start).

Cooling System:

Air-cooled engine, so no coolant system service, but general engine cooling principles and maintenance related to airflow.

Exhaust System:

Exhaust pipe and muffler inspection and maintenance. De-carbonizing (if applicable).

Wheels Tires:

Wheel bearing maintenance, spoke tension adjustment, tire inspection and replacement, tube replacement.

Frame Bodywork:

Frame inspection for cracks or damage, seat, fenders, fuel tank, and other body panel removal and installation.

Routine Maintenance:

Oil changes, filter replacement, chain lubrication and adjustment, spark plug inspection/replacement, air filter cleaning/replacement, brake adjustments.

Troubleshooting:

Systematic diagnostic procedures for common issues, including starting problems, performance issues, electrical faults, and braking concerns.

Component Rebuild:

Detailed step-by-step instructions for overhauling the engine, carburetor, forks, and brake calipers.

Wiring Diagrams:

Full electrical system schematics for accurate diagnosis and repair of electrical components.

Torque Specifications:

Precise torque values for all critical fasteners to ensure proper assembly and prevent component failure.

Special Tools:

Identification of any specific Yamaha or aftermarket tools required for specialized procedures.

Depth:

Comprehensive, covering everything from basic rider maintenance to complete engine and chassis rebuilds.

Diagnostic Focus:

Detailed troubleshooting trees and symptom-based diagnostic guides.

Illustrations:

Likely includes numerous diagrams, exploded views, and photographs to illustrate procedures.

📊 Manual Specifications

File Type:

If digital: PDF. If printed: bound paper document.

Searchability:

If PDF, likely text-searchable for quick information retrieval.

Print Resolution:

High-resolution for clear text and diagrams, suitable for professional use.

Binding:

If printed: Likely perfect bound or spiral bound for durability and ease of use in a workshop environment.

Paper Quality:

If printed: Durable, high-quality paper that can withstand workshop conditions.

⚙️ Engine Specifications

Engine Type:

4-stroke, SOHC, 2-valve

Displacement:

223 cc

Bore X Stroke:

66.5 mm x 64.0 mm

Cooling System:

Forced air cooling

Compression Ratio:

9.5:1

Valve Clearance Intake:

0.04 - 0.08 mm (cold)

Valve Clearance Exhaust:

0.06 - 0.10 mm (cold)

Horsepower Est:

Approximately 16-18 HP (at crankshaft, unconfirmed specific dyno data)

Torque Est:

Approximately 14-16 lb-ft (at crankshaft, unconfirmed specific dyno data)

Carburetor Type:

Mikuni VM26 (likely) or similar constant-velocity carburetor

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Fuel Tank Capacity:

Approx. 2.5 gallons (9.5 L)

Oil Type Recommendation:

Yamalube 4 (or equivalent API SG, SAE 10W-30)

Oil Capacity W Filter Change:

Approx. 1.5 L (1.6 US qt)

Recommended Spark Plug:

NGK CR7E (or equivalent, refer to manual for exact spec)

Spark Plug Gap:

0.7 - 0.8 mm (0.028 - 0.031 in)

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-disc

Final Drive:

O-ring sealed chain

Gear Ratios:

Refer to manual for specific gear ratios (typically close-ratio for off-road performance)

Transmission Oil Type:

Yamalube 4 (or equivalent API SG, SAE 10W-30) - Same as engine oil

Transmission Oil Capacity:

Refer to manual, typically around 0.8 L (0.85 US qt)

📐 Dimensions

Overall Length:

Approx. 82.7 in (2100 mm)

Overall Width:

Approx. 31.7 in (805 mm)

Overall Height:

Approx. 46.7 in (1185 mm)

Wheelbase:

Approx. 54.1 in (1375 mm)

Ground Clearance:

Approx. 11.6 in (295 mm)

Seat Height:

Approx. 34.7 in (880 mm)

Dry Weight:

Approx. 234 lbs (106 kg)

Wet Weight Est:

Approx. 250-260 lbs (113-118 kg) with fluids

Fuel Capacity:

2.5 gal (9.5 L)

🛡️ Safety Features

Safety Certification:

N/A for motorcycle segment, compliance with relevant roadworthiness standards if street-legal.

Braking System:

Hydraulic disc brakes front and rear for reliable stopping power.

Lighting:

Headlight, taillight, and brake light for visibility.

Frame Construction:

Steel diamond frame providing a rigid and stable platform.

Kickstand:

Side stand for secure parking.

💡 Technology Features

Infotainment System:

None (basic utility motorcycle, not equipped with infotainment features).

Rider Assistance:

None (traditional rider controls, no electronic aids).

Connectivity Features:

None.

🔧 Maintenance

Engine Oil Change:

Every 2,000 km (1,200 miles) or 6 months, whichever comes first.

Oil Filter Replacement:

At every oil change.

Air Filter Cleaning:

Every 1,000 km (600 miles) or more frequently in dusty conditions.

Spark Plug Inspection:

Every 4,000 km (2,500 miles).

Chain Lubrication Adjustment:

Every 500 km (300 miles) or after washing/riding in rain.

Valve Clearance Check:

Every 8,000 km (5,000 miles) or 1 year.

Brake Fluid Change:

Every 2 years, or as needed if fluid is contaminated.

Engine Oil Viscosity:

SAE 10W-30 (API SG, JASO MA)

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, fork seals, wheel bearings.

Carburetor Tuning:

May require periodic cleaning and adjustment to maintain optimal performance, especially after extended storage or changes in elevation.

Starting Issues:

Can sometimes be related to carburetor flooding or a weak spark plug, addressed by manual's troubleshooting section.

📚 Vehicle History

Manufacturer:

Yamaha Motor Company, renowned for its quality, innovation, and performance in motorcycles and other motorized products.

Tt R Lineage:

The TT-R line has a history of providing user-friendly and capable off-road machines, evolving from smaller displacements to this 225cc offering.

Predecessors:

The TT-R225 built upon the success of models like the TT-R200 and other trail bikes in Yamaha's lineup.

Successors:

Later models in the TT-R series, such as the TT-R230, offered updates and refinements. The WR250R/X line represents a more performance-oriented evolution in the dual-sport segment.

Production Years:

The TT-R225 was produced from approximately 2000 to 2004. The 2002 model falls within this core production run.

Manufacturing Location:

Primarily manufactured in Japan by Yamaha.

🏆 Awards & Recognition

Awards And Ratings:

While specific awards for the 2002 TT-R225 are not widely documented, it was generally well-regarded by riders for its reliability, ease of use, and value in the entry-level dual-sport category.