Yamaha TTR250L Manuals

Manuals and User Guides for Yamaha TTR250L. We have 2 Yamaha TTR250L manuals available for free PDF download: Service Manual

Yamaha TTR250L Service Manual

Yamaha TTR250L Service Manual (299 pages)

Brand: Yamaha | Category: Motorcycle | Size: 12.31 MB

Table of Contents

Table of Contents
7
Motorcycle Identification

14
- Vehicle Identification Number
  14
- Engine Serial Number
  14
Chapter 1. General Information

14
Important Information

15
Special Tools

17
- For Tune up
  17
- For Engine Service
  18
- For Chassis Service
  19
- For Electrical Components
  20
General Specifications

22
Chapter 2. Specifications

22
Maintenance Specifications

25
- Engine
  25
- Chassis
  33
- Electrical
  37
General Torque Specifications

39
Lubrication Points and Lubricant Types

40
- Engine
  40
- Chassis
  41
Lubrication Diagram

42
Cable Routing

45
Chapter 3

50
Periodic Inspection and Adjustment

50
Introduction

50
Periodic Maintenance/Lubrication

50
Seat, Fuel Tank and Covers

52
- Removal
  52
- Installation
  53
Engine

55
- Valve Clearance Adjustment
  55
- Timing Chain Adjustment
  62
Adj

62
- Idling Speed Adjustment
  63
- Throttle Cable Free Play Adjustment
  63
- Spark Plug Inspection
  64
- Ignition Timing Check
  66
- Compression Pressure Measurement
  67
- Engine Oil Level Inspection
  68
- Engine Oil Replacement
  69
- Oil Pressure Inspection
  73
- Clutch Adjustment
  73
- Air Filter Cleaning
  74
- Spark Arrester Cleaning
  76
- Crankcase Breather Hose Inspection
  77
- Fuel Line Inspection
  77
- Exhaust System Inspection
  77
- Carburetor Joint Inspection
  77
Chassis

78
- Front Brake Adjustment
  78
- Rear Brake Adjustment
  78
- Brake Fluid Level Inspection
  80
- Air Bleeding (Hydraulic Brake System)
  81
- Brake Pad Inspection
  82
- Brake Hose Inspection
  83
- Drive Chain Slack Adjustment
  83
- Drive Chain Lubrication
  85
- Steering Head Adjustment
  85
- Front Fork Inspection
  87
- Front Fork Adjustment
  88
- Rear Shock Absorber Adjustment
  90
- Tire Inspection
  92
- Wheel Inspection
  95
- Spokes Inspection and Tightening
  95
- Cable Inspection and Lubrication
  95
- Lever and Pedal Lubrication
  96
- Sidestand Lubrication
  96
Electrical

97
- Battery Inspection
  97
- Fuse Inspection
  104
- Headlight Beam Adjustment
  105
- Headlight Bulb Replacement
  105
Engine Removal

106
- Seat, Fuel Tank and Covers
  106
- Carburetor
  106
- Engine Guard
  106
- Engine Oil
  106
- Battery
  107
- Exhaust Pipe
  107
- Crankcase Breather Hose
  107
- Starter Motor
  107
- Clutch Cable and Leads
  108
- Drive Sprocket
  108
- Footrest and Brake Pedal
  109
- Engine Removal
  109
Chapter 4. Engine Overhaul

106
Engine Disassembly

110
- Cylinder Head, Camshafts, Cylinder and Piston
  110
- Clutch, Oil Pump and Balancer Gear
  113
- Shift Shaft
  115
- Rotor and Starter Drives
  115
- Oil Filter
  117
- Crankcase
  117
- Balancer, Transmission and Shifter
  118
- Crankshaft
  119
- Bearings and Oil Seals
  119
- Valve
  119
Inspection and Repair

121
- Cylinder Head
  121
- Valve Seat
  121
- Valve and Valve Guide
  125
- Valve Spring
  126
- Camshaft
  127
- Valve Lifter
  129
- Timing Chain, Sprocket and Chain Guide
  129
- Cylinder and Piston
  130
- Piston Ring
  132
- Piston Pin
  132
- Crankshaft
  133
- Balancer Drive Gear and Balancer Gear
  134
- Primary Drive
  135
- Clutch
  135
- Transmission and Shifter
  136
- Oil Pump and Strainer
  138
- Electric Starter Drive
  139
- Crankcase
  140
- Bearing and Oil Seal
  140
- Circlip and Washer
  140
Engine Assembly and Adjustment

141
- Crankshaft and Balancer
  141
- Crankshaft and Balancer Shaft
  142
- Transmission
  143
- Shifter
  144
- Transmission and Shifter
  145
- Crankcase
  147
- Crankcase (Right)
  148
- Shift Shaft
  148
- Oil Pump
  150
- Clutch
  151
- Oil Pump
  152
- Oil Filter
  155
- Rotor and Starter Drives
  156
- Cylinder and Piston
  159
- Cylinder and Piston
  160
- Cylinder Head
  162
- Valve, Camshaft and Cam Chain
  163
- Valve and Camshaft
  164
- Cylinder Head
  166
- Remounting Engine
  168
Carburetor

174
- Removal
  175
- Disassembly
  176
- Inspection
  178
- Assembly
  180
- Installation
  182
- Fuel Level Adjustment
  183
- Throttle Valve Position
  184
Chapter 5. Carburetor

174
Front Wheel

185
- Removal
  186
- Inspection
  186
- Installation
  189
- Wheel Static Balance Adjustment
  190
Chapter 6. Chassis

185
Rear Wheel

192
- Removal
  193
- Inspection
  193
- Installation
  194
- Wheel Static Balance Adjustment
  195
Front and Rear Brake

196
- Brake Pad Replacement
  198
- Caliper Disassembly
  202
- Master Cylinder Disassembly
  205
- Inspection and Repair
  208
- Caliper Assembly
  210
- Master Cylinder Assembly
  215
Front Fork

219
- Removal
  220
- Disassembly
  221
- Inspection
  222
- Assembly
  224
- Installation
  228
Steering Head and Handlebar

230
- Removal
  232
- Inspection
  235
- Installation
  236
Rear Shock Absorber and Swingarm

242
- Handling Notes
  244
- Notes on Disposal
  244
- Removal
  245
- Inspection
  250
- Installation
  252
Drive Chain and Sprockets

256
- Removal
  257
- Inspection
  258
- Installation
  259
Ttr250L(C) Circuit Diagram

262
Chapter 7. Electrical

262
Electrical Components

264
Checking of Connections

266
Ignition System

267
Electrical Starting System

273
- Starting Circuit Operation
  274
- Starter Motor
  280
Elec

280
Charging System

284
Lighting System

287
- Lighting System Check
  290
Starting Failure/Hard Starting

292
- Fuel System
  292
- Electrical System
  292
- Compression System
  292
Chapter 8. Troubleshooting

292
Trbl

292
Shtg

292
Poor Idle Speed Performance

293
Poor Medium and High Speed Performance

293
Faulty Gear Shifting

294
- Hard Shifting
  294
- Shift Pedal Does Not Move
  294
- Jump-Out Gear
  294
Clutch Slipping/Dragging

294
- Clutch Slipping
  294
- Clutch Dragging
  294
Overheating

295
Faulty Brake

295
- Poor Braking Effect
  295
Front Fork Oil Leakage and Front Fork Malfunction

295
- Oil Leakage
  295
- Malfunction
  295
Instable Handling

296
Faulty Signal and Lighting System

297
- Headlight Dark
  297
- Bulb Burnt out
  297
Ttr250L(C) Wiring Diagram

298

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Yamaha TTR250L Service Manual

Yamaha TTR250L Service Manual (296 pages)

Brand: Yamaha | Category: Motorcycle | Size: 29.74 MB

Table of Contents

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