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2004 Yamaha TT-R250 Motorcycle Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: TT-R250 Year: 2004 Product Type: Service Repair Manual 👋 Introduction Market Position Motorcycle Segment: Dual-sport / Off-road trailbike Competitive Analysis Key Competitors: Honda...
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类型: Motorcycle
厂商:
斯库: 409505
2004 Yamaha TT-R250 Motorcycle Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TT-R250
Year:
2004
Product Type:
Service Repair Manual
👋 Introduction
Market Position
Motorcycle Segment:
Dual-sport / Off-road trailbike
Competitive Analysis
Key Competitors:
Honda CRF230F, Kawasaki KLX250S, Suzuki DR-Z250
Key Features
Vehicle Attributes:
Reliable air-cooled engine, user-friendly power delivery, capable off-road suspension, street-legal.
Manual Value Proposition
Dealer Equivalency:
Provides the same information and procedures used by authorized Yamaha dealerships for all repair and maintenance tasks.
📋 Manual Details
Coverage Areas
Primary Coverage:
2004 Yamaha TT-R250 Motorcycle
Page Count
Estimated Page Count:
300+
Manual Type
Type:
Comprehensive Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Service:
Complete overhaul, top-end, bottom-end, lubrication, cooling system, carburetion, exhaust.
Transmission Drivetrain:
Clutch operation, gear shifting mechanisms, final drive (chain and sprockets), gearbox disassembly and assembly.
Chassis Suspension:
Front fork (disassembly, sealing, fluid replacement), rear shock absorber (adjustment, overhaul), swingarm, linkages, bearings.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake line replacement, bleeding procedures, pad and rotor specifications.
Electrical System:
Wiring diagrams, ignition system components (CDI, spark plug), lighting circuits, battery maintenance, charging system (stator, regulator/rectifier), starter motor.
Fuel System:
Carburetor disassembly, cleaning, jetting, float level adjustment, fuel tank inspection, fuel petcock service.
Frame Bodywork:
Frame inspection, plastics removal and installation, seat, fuel tank mounting, fenders.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustments, spark plug replacement, air filter cleaning/replacement, valve clearance checks and adjustments.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common performance issues, electrical faults, and mechanical problems.
Rebuilds Overhauls:
Detailed instructions for engine, carburetor, suspension, and brake system rebuilds.
Assembly Disassembly:
Comprehensive disassembly and reassembly procedures for all major components and sub-assemblies.
Technical Depth
Depth Level:
Factory-level diagnostic and repair procedures, suitable for professional mechanics and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Digital Quality:
High-resolution scans, clear legible text and diagrams.
Binding Type
Physical Binding:
N/A (Digital)
Paper Type
Physical Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, SOHC, air-cooled
Displacement:
249 cc (15.2 cu. in.)
Bore X Stroke:
73.0 mm x 59.5 mm (2.87 in. x 2.34 in.)
Compression Ratio:
9.5:1
Performance
Estimated Horsepower:
Approximately 20-22 HP (at crank, dependent on tuning)
Estimated Torque:
Approximately 15-17 lb-ft (at crank, dependent on tuning)
Fuel System
Carburetor Type:
Mikuni BSR33, 33mm, flat-slide, CV type
Fuel Capacity:
2.6 gal (9.8 L)
Ignition
Ignition System:
Digital CDI
Lubrication
Oil Type Specification:
Yamalube 4 or equivalent SAE 10W-40 API SE, SF, or SG
Cooling System
Cooling Method:
Air-cooled
🔧 Transmission
Standard
Transmission Type:
Constant-mesh, 6-speed
Clutch Type:
Wet, multi-plate
Features
Gear Ratios:
1st: 2.571, 2nd: 1.813, 3rd: 1.350, 4th: 1.130, 5th: 0.960, 6th: 0.850
Final Drive:
Sealed O-ring chain, 520 pitch
Fluid Type
Transmission Oil Type:
Yamalube 4 or equivalent SAE 10W-40 API SE, SF, or SG
📐 Dimensions
Exterior
Overall Length:
85.4 in (2170 mm)
Overall Width:
32.3 in (820 mm)
Overall Height:
48.6 in (1235 mm)
Seat Height:
35.2 in (895 mm)
Wheelbase:
57.7 in (1465 mm)
Weights
Dry Weight:
262 lbs (119 kg)
Wet Weight:
Approx. 287 lbs (130 kg) with fluids
Wheels Tires
Front Tire:
80/100-21 M/C 51P
Rear Tire:
110/100-18 M/C 64P
Front Wheel Size:
21 x 1.60
Rear Wheel Size:
18 x 2.15
🛡️ Safety Features
Ratings
Crash Safety Rating:
Not applicable for off-road motorcycles in standard automotive terms.
Active Features
Braking System Type:
Hydraulic disc front and rear
Front Brake Spec:
245 mm disc
Rear Brake Spec:
220 mm disc
Passive Features
Lighting:
Halogen headlight, LED taillight, turn signals.
💡 Technology Features
Infotainment
Dashboard Features:
Analog speedometer, odometer, tripmeter, neutral indicator, high-beam indicator, turn signal indicators.
Driver Assistance
ABS Availability:
Not equipped with ABS.
Connectivity
Connectivity Features:
N/A (Basic motorcycle electronics)
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 1,000 miles (1,600 km) or 6 months, whichever comes first.
Oil Filter Replacement Interval:
Every 1,000 miles (1,600 km) or 6 months.
Air Filter Cleaning Interval:
Every 600 miles (1,000 km) or as needed in dusty conditions.
Valve Clearance Check Interval:
Every 3,000 miles (5,000 km) or 12 months.
Chain Lubrication Adjustment:
Every 300 miles (500 km) or after washing/wet riding.
Fluid Specifications
Engine Oil Capacity:
1.60 L (1.70 US qt) without filter change; 1.80 L (1.90 US qt) with filter change.
Fork Oil Type:
Yamaha Fork Oil G10 or equivalent (e.g., Showa SS-8 or Bel-Ray SAE 5W)
Fork Oil Level:
118 mm (4.65 in)
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, chain and sprockets.
Potential Performance Quirks:
Carburetor jetting may need adjustment for altitude or modifications. Stock exhaust can be restrictive.
📚 Vehicle History
Brand Heritage
Motorcycle Focus:
Yamaha has a long and successful history in off-road and dual-sport motorcycles, known for performance and reliability.
Model Evolution
Tt R Series Lineage:
The TT-R series represents Yamaha's commitment to accessible and capable trail riding, building upon previous TT and TTR models.
Production
Initial Production Year:
1998
Model Life Cycle:
The TT-R250 was produced for many years with updates, making it a consistent player in its segment.
🏆 Awards & Recognition
Recognitions
Motorcycle Journal Awards:
While specific awards for the 2004 model may not be widely documented, the TT-R250 has consistently received praise in motorcycle reviews for its reliability and suitability as a trail-riding platform.
Ratings
User Satisfaction Ratings:
Generally high user satisfaction reported for its intended use as a durable and easy-to-maintain trail bike.
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