Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Vehicle Platform:
TTR250 (specific chassis codes may vary by region, common internal designation)
Segment:
Dual-sport motorcycle, off-road focused with street legality in some configurations.
Target Audience:
Enthusiasts seeking robust maintenance and repair capabilities for trail riding, adventure touring, and general dual-sport use.
Key Competitors:
Honda XR250, Kawasaki KLX250, Suzuki DR-Z250.
Vehicle Focus:
Durability, simplicity, off-road capability, user-serviceability.
Manual Value Proposition:
Empowers owners with comprehensive diagnostic and repair knowledge, reducing reliance on expensive shop labor.
Engine:
Complete overhaul, diagnosis, tuning, fuel system, ignition system, lubrication, cooling.
Transmission:
Clutch, gearbox operation, maintenance, repair, torque specifications.
Chassis And Frame:
Frame inspection, suspension (forks, shock absorber), swingarm, steering head bearings.
Wheels And Tires:
Spoke tensioning, rim maintenance, tire pressure recommendations, wheel bearing service.
Brakes:
Hydraulic system, caliper maintenance, pad replacement, disc inspection, bleeding procedures.
Electrical System:
Wiring diagrams, lighting, ignition, charging system (stator, regulator/rectifier), battery maintenance, troubleshooting.
Fuel System:
Carburetor disassembly, cleaning, adjustment (jetting), fuel tank and petcock.
Exhaust System:
Muffler and header pipe inspection and maintenance.
Bodywork:
Fairings, seat, fenders, tank removal and installation.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, air filter cleaning, spark plug replacement.
Troubleshooting:
Diagnostic charts for common performance issues, starting problems, electrical faults.
Engine Rebuild:
Piston, cylinder, valve train, crankshaft service and replacement procedures.
Suspension Service:
Fork seal replacement, oil levels, rear shock absorber inspection.
Carburetor Tuning:
Detailed instructions for jetting and adjustments based on altitude and modifications.
Electrical Diagnostics:
Fault finding using multimeter, testing components, wiring harness repair.
Depth:
Comprehensive, covering everything from basic checks to complete engine and transmission overhauls.
Diagnostic Capability:
Advanced troubleshooting flowcharts and common issue identification.
Engine Type:
4-stroke, SOHC, 4-valve, air-cooled
Bore X Stroke:
73.0 mm x 59.6 mm
Compression Ratio:
9.5:1 (typical, may vary slightly by year/region)
Horsepower Rating:
~20-25 HP (estimated, actual figures vary)
Torque Rating:
~19-21 Nm (estimated, actual figures vary)
Carburetor:
Mikuni VM33 (typical, may vary by region/submodel)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Safety Certification:
Not applicable (motorcycle regulations vary by region, typically meets emissions and noise standards for street legality where applicable).
Braking System:
Hydraulic disc brakes front and rear.
Lighting:
Headlight, taillight, brake light, turn signals (depending on configuration).
Frame Construction:
Steel diamond frame for strength and rigidity.
Instrumentation:
Analog speedometer, tachometer, odometer, trip meter, neutral indicator, high beam indicator, turn signal indicators.
N/A:
No electronic rider aids present on this model.
N/A:
No connectivity features available.
Engine Oil Change:
Every 3,000 km or 6 months, whichever comes first.
Oil Filter Replacement:
Every 6,000 km or 12 months (or with major service).
Air Filter Cleaning:
Every 1,000 km or as needed in dusty conditions.
Spark Plug Check:
Every 6,000 km.
Valve Clearance Check:
Every 12,000 km.
Engine Oil:
Yamalube 10W-40 or equivalent API SG/SH/SJ or higher (refer to manual for precise API classification and capacity).
Fork Oil:
Specific weight and level detailed in manual (e.g., Showa SS-8 or equivalent).
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, wheel bearings, suspension seals.
Carburetor Related:
Pilot jet clogging can occur with infrequent use or poor fuel quality, affecting idle and low-speed running.
Electrical Notes:
Ensure good grounds for reliable operation of lighting and ignition.
