🏷️ Basic Information

Make:

Yamaha

Model:

TTR 250

Year:

2005

Product Type:

Repair Service Manual

Product Format:

PDF Download

👋 Introduction

Segment:

Dual-sport / Off-road motorcycle.

Target Use:

Trail riding, light off-roading, and general recreational use.

Competitors:

Honda CRF250X, Kawasaki KLX250S, Suzuki DR-Z250.

Key Differentiators:

Yamaha's reputation for reliability, robust engineering, and capable off-road performance in this class.

Engine Type:

Air-cooled, 4-stroke, SOHC, 2-valve single-cylinder.

Suspension Setup:

Long-travel front forks and adjustable Monoshock rear suspension optimized for off-road terrain.

Braking System:

Front disc brake for effective stopping power, rear drum brake for durability and simplicity.

Starting System:

Kick-start only, emphasizing simplicity and weight reduction common in this class.

📋 Manual Details

Primary Coverage:

Complete service, maintenance, and repair for the 2005 Yamaha TTR 250.

Target Audience:

Professional technicians and advanced DIY enthusiasts.

Estimated Page Count:

Refer to specific manual for exact count, typically 300-600 pages for comprehensive service manuals.

Type:

Service Manual / Repair Manual

Language:

English

Digital Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, inspection, repair, and reassembly of engine components (cylinder, piston, crankshaft, valves, etc.).

Fuel System:

Carburetor (Teikei Y26P or similar) adjustment, cleaning, and overhaul; fuel tank inspection and cleaning; fuel line maintenance.

Ignition System:

CDI ignition system diagnosis, coil testing, spark plug specifications, and timing procedures.

Lubrication System:

Oil pump operation, oil filter replacement, oil change intervals, and oil specifications.

Cooling System:

Air-cooled system; emphasis on ensuring proper airflow and heat dissipation.

Transmission Drivetrain:

Clutch operation, adjustment, and replacement; gearbox disassembly, inspection, and reassembly; chain drive maintenance and adjustment.

Suspension Front:

Front fork disassembly, inspection, fluid replacement, seal replacement, and spring settings.

Suspension Rear:

Monoshock rear suspension overhaul, shock absorber adjustments, linkage bearing inspection and lubrication.

Brakes Front:

Hydraulic disc brake system diagnosis, caliper overhaul, pad replacement, fluid flush and bleed, master cylinder inspection.

Brakes Rear:

Drum brake system inspection, adjustment, and shoe replacement.

Electrical System:

Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), lighting system, starter system (kick start only).

Bodywork Chassis:

Frame inspection, plastic component removal and installation, seat, fenders, and handlebars.

Wheels Tires:

Wheel bearing inspection and replacement, spoke tensioning, tire pressure recommendations, and tire replacement procedures.

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, spark plug checks, air filter cleaning/replacement.

Troubleshooting:

Diagnostic charts and symptom-based troubleshooting guides for common issues.

Engine Rebuild:

Complete engine disassembly, cleaning, measurement of wear limits, parts replacement, and reassembly with torque specifications.

Carburetor Overhaul:

Step-by-step instructions for dismantling, cleaning, inspecting, and reassembling the carburetor with jet sizes and settings.

Suspension Service:

Fork seal replacement, oil level and viscosity specifications, shock absorber adjustments, and linkage maintenance.

Brake System Maintenance:

Brake fluid replacement, bleeding procedures, pad and shoe replacement, caliper and master cylinder servicing.

Electrical Diagnostics:

Troubleshooting electrical circuits using wiring diagrams, testing components like coils and regulators.

Wheel Truing:

Instructions for checking and adjusting spoke tension to true a wheel.

Depth:

Comprehensive; covers from basic maintenance to complete engine and component overhauls.

Diagnostic Information:

Detailed diagnostic procedures for identifying and rectifying mechanical and electrical faults.

Torque Specifications:

Extensive torque values provided for all critical fasteners and engine components.

Measurement Specifications:

Precise measurements for engine component wear limits (e.g., piston-to-cylinder clearance, valve seat runout).

Diagrams Illustrations:

Detailed exploded views, system diagrams, and step-by-step procedural illustrations.

📊 Manual Specifications

Format:

PDF

Searchable Text:

Likely to include searchable text for efficient navigation.

Quality:

High-resolution, suitable for printing key sections or the entire manual.

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code:

Likely 5FK or similar designation for the 2005 model.

Configuration:

Single-cylinder, 4-stroke, air-cooled.

Displacement:

249 cc

Bore X Stroke:

71.0 mm x 62.2 mm

Compression Ratio:

9.5:1

Valve Train:

SOHC, 2-valve

Horsepower:

Approximately 17-19 HP (at crankshaft, actual may vary).

Torque:

Approximately 19-21 Nm (at crankshaft, actual may vary).

Carburetor Model:

Teikei Y26P or similar, constant velocity (CV) type.

Fuel Type:

Unleaded gasoline, octane rating 87 or higher recommended.

Fuel Tank Capacity:

Approximately 10 liters (2.6 US gal).

🔧 Transmission

Transmission Type:

Constant mesh, 6-speed sequential.

Clutch Type:

Wet, multi-plate, manual operation.

Final Drive:

Chain drive.

Gear Ratios:

Specific gear ratios available in the manual (e.g., 1st: 2.571, 2nd: 1.813, 3rd: 1.381, 4th: 1.130, 5th: 0.960, 6th: 0.821).

Lubricant:

Yamalube 4 (or equivalent API SG, SAE 10W-40) motorcycle oil.

📐 Dimensions

Length:

Approximately 2110 mm (83.1 in).

Width:

Approximately 815 mm (32.1 in).

Height:

Approximately 1235 mm (48.6 in).

Wheelbase:

Approximately 1440 mm (56.7 in).

Ground Clearance:

Approximately 320 mm (12.6 in).

Seat Height:

Approximately 890 mm (35.0 in).

Dry Weight:

Approximately 116 kg (256 lbs).

Wet Weight:

Approximately 124 kg (273 lbs) (with all fluids).

Gross Vehicle Weight Rating:

Not specified, but typically around 250-300 kg for this class.

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycles are not subject to the same standardized crash testing as cars).

Braking:

Front hydraulic disc brake, rear drum brake.

Lighting:

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

Frame Construction:

Steel semi-double cradle frame designed for rigidity and impact resistance in off-road conditions.

Ergonomics:

Handlebar position and control layout designed for rider comfort and control during off-road riding.

💡 Technology Features

System:

None (basic motorcycle instrumentation).

Instrumentation:

Analog speedometer, tachometer, odometer, trip meter, neutral indicator, and basic warning lights.

Features:

N/A (No electronic rider aids like ABS or traction control).

🔧 Maintenance

Engine Oil Change:

Every 4,000 km (2,500 miles) or 6 months, whichever comes first.

Oil Filter Replacement:

Every 8,000 km (5,000 miles) or 12 months.

Spark Plug Inspection Cleaning:

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

Air Filter Cleaning:

Every 2,000 km (1,250 miles) or more frequently in dusty conditions.

Clutch Cable Adjustment:

As needed, typically inspect every 4,000 km (2,500 miles).

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after washing/riding in rain.

Brake Fluid Replacement:

Every 24 months or as needed.

Engine Oil:

Yamalube 4 (or equivalent API SG, JASO MA, SAE 10W-40).

Fork Oil:

Yamaha Fork Oil 10W or equivalent, specific volume per leg (e.g., 460 ml).

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid.

Common Wear Items:

Clutch plates, brake pads/shoes, chain and sprockets, fork seals, wheel bearings due to off-road usage.

Carburetor Performance:

Can be sensitive to altitude and temperature; requires periodic cleaning and adjustment for optimal performance.

Kickstarter Return Spring:

In some instances, the return spring mechanism can wear over time, though generally robust.

📚 Vehicle History

Brand Legacy:

Yamaha's long-standing reputation for producing high-quality, reliable, and performance-oriented motorcycles, particularly in off-road disciplines.

Previous Generations:

The TTR line has a history of robust, trail-focused machines, with the TTR250 evolving from earlier models with incremental updates to suspension, engine tuning, and styling.

Key Updates For 2005:

While specific major overhauls for the 2005 model year are not broadly documented, typical updates often involve refinements to suspension settings, carburetor tuning for emissions or performance, and minor aesthetic changes.

Manufacturing Location:

Primarily Japan, with potential assembly in other regions depending on the market.

Production Period:

The TTR250 was produced for a significant period, with variations in specifications across different model years and markets.

🏆 Awards & Recognition

Awards Received:

Specific awards for the 2005 model year are not widely publicized. The TTR line generally receives praise for its durability and trail capability.

Customer Satisfaction:

Generally high for reliability and ease of maintenance within its class.

Emissions Standards:

Compliant with relevant emissions standards for its production year and market.