🏷️ Basic Information

Make:

Yamaha

Model:

TT-R250

Year:

2003

Product Name:

2003 Yamaha TT-R250 Motorcycle Service Repair Manual

Product Description:

This Manual Covers 2003 Yamaha TT-R250 Motorcycle Service Manual. This manual is just like what the Yamaha dealership uses to do any repairs or maintenance!

Vehicle Code:

TT-R250

Manual Code:

Yamaha Service Manual

👋 Introduction

Positioning:

The Yamaha TT-R250 is a versatile dual-sport motorcycle, popular for trail riding, recreational off-roading, and light street use. This manual targets owners and independent repair shops looking for comprehensive service information.

Competitors:

Competes with models like Honda CRF250L, Kawasaki KLX250S, Suzuki DR-Z250.

Vehicle Features:

Air-cooled engine, electric start, accessible performance, rugged build quality.

Value:

Provides dealership-level repair and maintenance knowledge, enabling owners to perform complex tasks and save on labor costs.

📋 Manual Details

Engine Service:

Comprehensive

Transmission Service:

Comprehensive

Chassis Service:

Comprehensive

Electrical System Service:

Comprehensive

Fuel System Service:

Comprehensive

Cooling System Service:

Comprehensive

Suspension Service:

Comprehensive

Brake System Service:

Comprehensive

Troubleshooting:

Extensive

Maintenance Procedures:

Detailed

Estimated Pages:

300-500

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine:

Internal engine components, top-end, bottom-end, valve clearance, timing, piston, connecting rod, crankshaft.

Transmission:

Gearbox disassembly/assembly, clutch operation, shifting mechanism, lubrication.

Fuel System:

Carburetor tuning, jetting, float bowl adjustment, fuel delivery, fuel tank, petcock.

Electrical System:

Ignition system (CDI, spark plug), lighting, charging system (stator, regulator/rectifier), wiring diagrams, battery service, starting system.

Cooling System:

Radiator, fan, coolant, hoses, thermostat (if applicable).

Suspension:

Front fork service (oil changes, seal replacement), rear shock absorber service, linkage maintenance.

Brakes:

Front and rear brake caliper service, master cylinder, brake lines, bleeding procedures, pad replacement, rotor inspection.

Exhaust System:

Muffler, header pipe, heat shields, gasket replacement.

Wheel And Tire:

Wheel bearing inspection, tire changes, spoke tensioning.

Frame And Bodywork:

Body panel removal/installation, frame inspection, seat, fenders.

Routine Maintenance:

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

Troubleshooting Guides:

Systematic diagnostic procedures for common and uncommon issues, fault finding charts.

Engine Rebuild:

Complete engine disassembly, inspection, measurement, and reassembly procedures.

Carburetor Overhaul:

Detailed steps for cleaning, re-jetting, and adjusting the carburetor for optimal performance.

Fork Rebuild:

Front suspension fork seal replacement, oil level and viscosity specification, spring installation.

Brake System Overhaul:

Caliper piston removal, seal replacement, master cylinder overhaul, bleeding techniques.

Electrical Diagnostics:

Testing ignition coil resistance, stator output, rectifier/regulator function, starter motor testing.

Timing Adjustment:

Valve clearance adjustment, ignition timing verification (if adjustable).

Depth:

Factory-level diagnostic and repair information, including internal component specifications and tolerances.

Diagnostic Tools:

Information on required special tools and general workshop tools for accurate repairs.

Torque Specifications:

Precise torque values for all critical fasteners and component assemblies.

Wiring Diagrams:

Detailed, color-coded electrical schematics for accurate troubleshooting.

📊 Manual Specifications

Format:

Searchable PDF

Quality:

High-resolution, clear text and diagrams suitable for printing.

Type:

N/A (Digital)

Type:

N/A (Digital)

⚙️ Engine Specifications

Engine Type:

249cc, 4-stroke, SOHC, 4-valve, Single Cylinder

Bore X Stroke:

73.0 mm x 57.8 mm

Compression Ratio:

9.5:1

Carburetor:

Mikuni BSR33, 33mm

Ignition:

CDI (Capacitor Discharge Ignition)

Valve Clearance Intake:

0.05 - 0.09 mm (cold)

Valve Clearance Exhaust:

0.07 - 0.11 mm (cold)

Spark Plug Type:

NGK CR9E / Denso U27FER9

Horsepower:

Approx. 20-22 HP (at crankshaft, estimated)

Torque:

Approx. 14-15 lb-ft (at crankshaft, estimated)

Fuel Type:

Unleaded Gasoline, 87 Octane Minimum

Fuel Tank Capacity:

2.6 Gallons (9.8 Liters)

🔧 Transmission

Transmission Type:

Constant-mesh 6-speed

Clutch Type:

Wet, multiple-disc

Gear Ratios:

1st: 2.833, 2nd: 2.063, 3rd: 1.556, 4th: 1.250, 5th: 1.050, 6th: 0.923

Final Drive:

O-ring sealed chain

Transmission Oil Type:

Yamalube 4 (or SAE 10W-40 API SG or higher)

Transmission Oil Capacity:

1.25 US qt (1.18 L)

📐 Dimensions

Length:

84.3 inches (2140 mm)

Width:

32.1 inches (815 mm)

Height:

47.0 inches (1195 mm)

Wheelbase:

56.7 inches (1440 mm)

Ground Clearance:

11.2 inches (285 mm)

Dry Weight:

258 lbs (117 kg)

Wet Weight:

Approx. 280 lbs (127 kg)

Front Suspension Travel:

10.4 inches (264 mm)

Rear Suspension Travel:

10.0 inches (254 mm)

🛡️ Safety Features

Classification:

Dual-Sport Motorcycle

Braking System:

Hydraulic disc brakes front and rear.

Lighting:

Headlight, taillight, brake lights, turn signals (market dependent).

Chassis Design:

Steel semi-double cradle frame for stability and durability.

Ergonomics:

Designed for comfortable riding position on varied terrain.

💡 Technology Features

Features:

Basic motorcycle instrumentation: speedometer, odometer, trip meter, indicator lights.

Features:

N/A (This is a basic motorcycle).

Features:

N/A (This is a basic motorcycle).

🔧 Maintenance

Engine Oil Change:

Every 3,000 km or 6 months, whichever comes first.

Oil Filter Replacement:

Every 3,000 km or 6 months, coinciding with oil changes.

Air Filter Cleaning:

Every 1,000 km or 6 months, more frequently in dusty conditions.

Valve Clearance Check:

Every 6,000 km or 12 months.

Spark Plug Replacement:

Inspect every 3,000 km; replace as needed or every 10,000 km.

Brake Fluid Change:

Every 2 years or as recommended by visual inspection.

Chain Lubrication Adjustment:

Every 500 km or as needed.

Engine Oil Grade:

Yamalube 4 (or SAE 10W-40 API SG or higher)

Engine Oil Capacity:

1.56 US qt (1.48 L) with filter change

Fork Oil Type:

Yamaha Fork Oil G-10 or equivalent (SAE 10W)

Fork Oil Quantity:

390 cc (13.2 US oz) per leg

Brake Fluid Type:

DOT 3 or DOT 4

Common Wear Items:

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

Carburetor Performance:

Potential for gumming if fuel is left in the system for extended periods; may require periodic cleaning/re-jetting for optimal performance.

Electrical Connections:

Corrosion can occur on connectors, especially if used in wet environments, requiring inspection and cleaning.

📚 Vehicle History

Yamaha Heritage:

Yamaha Motor Company, founded in 1955, has a rich history in motorsports and motorcycle manufacturing, known for innovation and performance.

Tt R Lineage:

The TT-R line evolved from Yamaha's successful motocross and enduro bikes, offering a more street-legal and user-friendly package.

Production Period:

The TT-R250 was produced from the late 1990s into the early 2000s, with this manual specifically covering the 2003 model year.

Manufacturing Location:

Typically manufactured in Japan or other Yamaha global production facilities.

🏆 Awards & Recognition

Market Reception:

Praised for its reliability, ease of use, and suitability for entry-level to intermediate riders in off-road and recreational use.

Durability Rating:

High, known for robust construction and longevity with proper maintenance.