Page 3
INTRODUCTION EAU10060 Congratulations on your purchase of the Yamaha TTR250 This model is the result of Yamaha’s vast experience in the pro- duction of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reli- ability that have made Yamaha a leader in these fields.
This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine...
Page 5
IMPORTANT MANUAL INFORMATION EWA10010 WARNING PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
TABLE OF CONTENTS SAFETY INFORMATION ....1-1 OPERATION AND IMPORTANT Adjusting the clutch lever free Location of important labels ....1-6 RIDING POINTS........5-1 play ..........6-18 Starting and warming up a cold Adjusting the brake lever free DESCRIPTION ........2-1 engine .......... 5-1 play ..........6-18 Left view ...........2-1 Starting a warm engine ....
Page 8
TABLE OF CONTENTS MACHINE CARE AND STORAGE ..7-1 Care ..........7-1 Storage ..........7-3 SPECIFICATIONS ......8-1 CONSUMER INFORMATION....9-1 Identification numbers .....9-1 Motorcycle noise regulation .....9-3 Maintenance record ......9-4 YAMAHA MOTOR CORPORATION, U.S.A. OFF-ROAD MOTORCYCLE LIMITED WARRANTY ....9-5 YAMAHA EXTENDED SERVICE (Y.E.S.) .........9-7...
SAFETY INFORMATION EAU10330 TIONS. is veering wide on a turn due to MACHINES ARE SINGLE TRACK VE- Safe riding EXCESSIVE SPEED or undercor- HICLES. THEIR SAFE USE AND OP- Always make pre-operation nering (insufficient lean angle for ERATION ARE DEPENDENT UPON checks.
Page 10
Modifications made to this machine not keep the following in mind: available, you must personally be re- approved by Yamaha, or the removal of Cargo accessory weight sponsible for the proper selection, in-...
Page 11
SAFETY INFORMATION those provided under “Loading”. winds. the vicinity of an open flame. Never install accessories or carry Certain accessories can dis- Never start the engine or let it run cargo that would impair the perfor- place the operator from his or for any length of time in a closed mance of your machine.
Page 12
SAFETY INFORMATION flame), otherwise it could catch fire. When transporting the machine in another vehicle, make sure that it is kept upright and that the fuel cock(s) are turned to “ON” or “RES” (for vacuum type)/“OFF” (for manual type). If the machine should lean over, gasoline may leak out of the carburetor or fuel tank.
SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
Page 14
This unit contains high pressure nitrogen gas. follows. Mishandling can cause explosion. FRONT : 100 kPa,{1.00 kgf/cm }, 15 psi Read owner's manual for instructions. REAR 100 kPa,{1.00 kgf/cm }, 15 psi Do not incinerate, puncture or open. 3RV-21668-A0 YAMAHA 4AA-22259-80...
INSTRUMENT AND CONTROL FUNCTIONS EAU10450 EAU11830 EAU12343 Main switch Tripmeter Handlebar switches Left The main switch controls the ignition 1. Tripmeter 1. Light switch “ ” and lighting systems. The various main 2. Tripmeter reset knob switch positions are described below. Right The tripmeter shows the distance trav- eled since it was last set to zero with the...
INSTRUMENT AND CONTROL FUNCTIONS EAU12540 tions prior to starting the engine. EAU31640 Light switch “ ” Clutch lever Set this switch to “ ” to turn on the headlight and the taillight. ECA10980 CAUTION: Always turn the key to “OFF” and light switch to “OFF”...
INSTRUMENT AND CONTROL FUNCTIONS EAU12870 EAU12890 EAU12941 Shift pedal Brake lever Brake pedal 1. Shift pedal 1. Brake lever 1. Brake pedal The shift pedal is located on the left The brake lever is located at the right The brake pedal is on the right side of side of the engine and is used in com- handlebar grip.
EWA10880 WARNING wise. Your Yamaha engine has been de- Do not overfill the fuel tank, oth- EWA11090 signed to use regular unleaded gaso- WARNING erwise it may overflow when the...
10%. Gasohol containing methanol is not recom- mended by Yamaha because it can cause damage to the fuel system or ve- hicle performance problems. 1. Fuel tank breather hose...
INSTRUMENT AND CONTROL FUNCTIONS fuel while riding, move the lever to this EAU13600 Starter (choke) knob “ ” position. Fill the tank at the first oppor- tunity. Be sure to set the lever back to “ON” after refueling! FUEL 1. Arrow mark positioned over “ON” 1.
INSTRUMENT AND CONTROL FUNCTIONS EAU13960 EAU14671 (×2) Seat Adjusting the front fork To remove the seat The front fork is equipped with air 1. Remove the bolts, and then pull valves for adjusting the spring rate and the seat off. screws for adjusting the damping force.
Page 25
An optional air pressure gauge is avail- EWA10180 WARNING soften the damping, turn the ad- able at a Yamaha dealer. Always adjust both fork legs equal- justing screw on each fork leg in di- 4. To increase the spring rate and ly, otherwise poor handling and loss rection (b).
INSTRUMENT AND CONTROL FUNCTIONS EAU15070 ECA10960 Adjusting the shock absorber CAUTION: assembly Be sure to install the rubber caps to This shock absorber assembly is prevent dust, etc. from entering the equipped with a spring preload adjust- fork legs. ing nut, a rebound damping force ad- NOTE: justing dial...
Page 27
A special wrench is needed to Rebound damping force make this adjustment and it can be Compression damping force obtained at a Yamaha dealer. The spring preload setting is deter- mined by measuring distance A, shown in the illustration. The short- er the distance A is, the higher the spring preload;...
If a malfunction is noted, have a Although the total number of clicks of a high heat sources, otherwise it Yamaha dealer check the system be- damping force adjusting mechanism may explode due to excessive fore riding.
Page 29
4. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. 5. Turn the engine off. 6. Shift the transmission into gear. 7. Keep the clutch lever pulled.
PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
Lubricate cable if necessary. Clutch 6-18 Check lever free play. Adjust if necessary. Make sure that operation is smooth. Check cable free play. Throttle grip 6-14, 6-24 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.
Page 32
PRE-OPERATION CHECKS ITEM CHECKS PAGE Make sure that operation is smooth. Control cables 6-23 Lubricate if necessary. Check chain slack. Adjust if necessary. Drive chain 6-21, 6-23 Check chain condition. Lubricate if necessary. Check for damage. Check tire condition and tread depth. Wheels and tires 6-15, 6-17 Check air pressure.
OPERATION AND IMPORTANT RIDING POINTS EAU15960 EAU16451 completely close the throttle. (See EWA10280 Starting and warming up a page 3-6.) WARNING cold engine 5. Start the engine by pushing the This model is designed for In order for the starting circuit cut-off start switch.
OPERATION AND IMPORTANT RIDING POINTS (choke) turned off. EAU16640 EAU16671 Starting a warm engine Shifting Follow the same procedure as for start- ing a cold engine with the exception that the starter (choke) is not required when the engine is warm. 1.
If any engine trouble should occur od for the engine. To allow the engine during the engine break-in period, to cool down from the temporary build- immediately have a Yamaha dealer up of heat, cruise at a lower engine check the vehicle. speed.
OPERATION AND IMPORTANT RIDING POINTS EAU17170 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. EWA10310 WARNING Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them.
If you are not familiar with mainte- If you do not have the tools or experi- nance work, have a Yamaha dealer ence required for a particular job, have do it for you. a Yamaha dealer perform it for you. EWA10340 WARNING Modifications approved...
From 1800 mi (3000 km) or 18 months, repeat the maintenance intervals starting from 600 mi (1000 km) or 6 months. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU35340 General maintenance and lubrication chart INITIAL EVERY 100 mi 600 mi 1200 mi ITEM CHECKS AND MAINTENANCE JOBS (150 km) (1000 km) (2000 km) 1 month 6 months 12 months Check operation. √ √ √...
Page 40
17 * Shock absorber assembly Replace if necessary. √ 18 * Rear suspension link pivots Apply molybdenum disulfide grease lightly. Apply Yamaha chain and cable lube or engine oil 10W-30 thor- √ √ √ 19 * Control and meter cables oughly.
Page 41
PERIODIC MAINTENANCE AND MINOR REPAIR EAU18670 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU18721 To install the cowling Removing and installing the Place the cowling in the original posi- cowling and panels tion, and then install the screws. The cowling and panels shown need to be removed to perform some of the EAU19292 Panels A and B maintenance jobs described in this...
Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. 1. Spark plug cap 2. Remove the spark plug as shown, 2. Check the spark plug for electrode...
Page 44
PERIODIC MAINTENANCE AND MINOR REPAIR necessary. 3. Install the spark plug with the EAU19784 Engine filter spark plug wrench, and then tight- Specified spark plug: element en it to the specified torque. NGK/CR9E The engine oil level should be checked DENSO/U27ESR-N Tightening torque: before each ride.
Page 45
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Remove the engine oil filler bolt place them if necessary. NOTE: and drain bolt to drain the oil from The engine oil should be between the 4. Remove the oil filter element drain the crankcase. minimum and maximum level marks.
Page 46
PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Recommended oil: (×3) Oil filter element cover bolt: See page 8-1. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil quantity: Without oil filter element replace- ment: NOTE: 1.10 L (1.16 US qt) (0.97 Imp.qt) Make sure that the O-rings are properly With oil filter element replacement: seated.
7 Nm (0.7 m·kgf, 5.0 ft·lbf) turn the engine off immediately so it will not seize. If this occurs, (×3) have a Yamaha dealer repair the vehicle. After checking the oil pressure, tighten the bleed bolt to the specified torque.
Page 48
NOTE: The sponge material should be wet but not dripping. Recommended oil: Yamaha foam air filter oil or other quality air filter oil 7. Install the sponge material onto 1. Sponge material the frame, insert the air filter ele- 2.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU21240 Cleaning the spark arrester NOTE: Make sure to select a well-ventilated area free of combustible materials to clean the spark arrester. 1. Remove the tailpipe by removing the bolts, and then pulling it out of the muffler.
Yamaha dealer, who has the neces- must be adjusted by a Yamaha dealer sary professional knowledge and expe- at the intervals specified in the periodic rience. However, the following may be maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU35830 during a ride. Tires Off-road riding: Securely pack the heaviest Front: To maximize the performance, durabil- items close to the center of the 100 kPa (15 psi) (1.00 kgf/cm ity, and safe operation of your machine, Rear: vehicle distribute...
Page 52
PERIODIC MAINTENANCE AND MINOR REPAIR has a nail or glass fragments in it, or if very carefully and replace it as Front tire: the sidewall is cracked, have a Yamaha soon possible with Size: dealer replace the tire immediately. high-quality product.
If any dam- this model, and they must be se- age is found, have a Yamaha curely mounted to maintain the in- dealer replace the wheel. Do not herent stability of the original attempt even the smallest repair to design.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22030 lever free play, turn the adjusting EAU22092 Adjusting the clutch lever free Adjusting the brake lever free bolt in direction (b). play play 3. If the specified clutch lever free play could be obtained as de- scribed above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows.
However, if the make sure that the top of the brake brake fluid level goes down sud- fluid reservoir is level. denly, have a Yamaha dealer 1. Minimum level mark Use only the recommended quality check the cause.
EAU22730 EAU22760 Changing the brake fluid Drive chain slack Have a Yamaha dealer change the The drive chain slack should be brake fluid at the intervals specified in checked before each ride and adjusted the NOTE after the periodic mainte- if necessary.
Page 58
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Tighten the axle nut to the speci- EWA10700 NOTE: WARNING fied torque. Make sure that both adjusting plates Always use a new cotter pin for the are in the same position for proper Tightening torque: axle nut.
Service the drive chain as ed if necessary. If a cable is damaged follows. or does not move smoothly, have a ECA10581 Yamaha dealer check or replace it. CAUTION: Recommended lubricant: The drive chain must be lubricated Yamaha Chain and Cable Lube...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23110 EAU23140 EAU23180 Checking and lubricating the Checking and lubricating the Lubricating the brake pedal throttle grip and cable brake and clutch levers The operation of the throttle grip should be checked before each ride. In addi- tion, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.
2. Hold the lower ends of the front fork legs and try to move them for- ward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering. 6-26...
To charge the battery burns. Avoid any contact with Have a Yamaha dealer charge the bat- skin, eyes or clothing and al- tery as soon as possible if it seems to ways shield your eyes when have discharged.
2. Spare fuse sealed-type (MF) battery charg- devices operate. The fuse holder is located behind panel er, have a Yamaha dealer 4. If the fuse immediately blows B. (See page 6-6.) charge your battery. again, have a Yamaha dealer If the fuse is blown, replace it as fol- check the electrical system.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23841 Replacing the headlight bulb This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove cowling A together with the headlight unit. (See page 6-6.) 2.
1. Screw the headlight unit. 4. Install the lens by installing the 2. Taillight lens 7. Have a Yamaha dealer adjust the screws. 2. Remove the defective bulb by headlight beam if necessary. ECA10680 pushing it in and turning it counter- CAUTION: clockwise.
WARNING (×4) requiring the machine to stand upright. It is advisable to have a Yamaha Check that the machine is in a stable dealer service the wheel. and level position before starting any Securely support the machine maintenance.
Page 68
PERIODIC MAINTENANCE AND MINOR REPAIR the wheel hub so that the projec- tions mesh with the slots. (×4) 1. Retainer 1. Upper nut 2. Wheel axle 2. Lower nut 3. Wheel axle holder nut 3. Gap 1. Tripmeter gear unit 3.
3. Remove each swingarm end cover by removing the screws. EAU25280 To remove the rear wheel EWA10820 WARNING (×2) It is advisable to have a Yamaha dealer service the wheel. Securely support the machine (×2) (×2) so that there is no danger of it NOTE: falling over.
However, should your machine re- ter pin. quire any repair, take it to a Yamaha dealer, whose skilled technicians have Tightening torque: the necessary tools, experience, and Axle nut: 105 Nm (10.5 m·kgf, 76 ft·lbf)
Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.
MACHINE CARE AND STORAGE EAU26000 brush, but never apply such prod- sponges which have been in Care ucts onto seals, gaskets, sprock- contact with strong or abrasive While the open design of a machine re- ets, the drive chain and wheel cleaning products, solvent or veals the attractiveness of the technol- axles.
Page 73
MACHINE CARE AND STORAGE any marks. If the windshield is and a mild detergent, after the en- tection spray metal, scratched, use a quality plastic gine has cooled down. including chrome- and nickel-plat- polishing compound after ed, surfaces. ECA10790 CAUTION: washing.
NOTE: from corrosion. will allow water and humidity to Consult a Yamaha dealer for advice on a. Remove the spark plug cap seep in and cause rust. what products to use. and spark plug.
Page 75
MACHINE CARE AND STORAGE install the spark plug and the Do not store the battery in an ex- spark plug cap. cessively cold or warm place [less than 0 °C (30 °F) or more EWA10950 WARNING than 30 °C (90 °F)]. For more in- To prevent damage or injury from formation on storing the battery, sparking, make sure to ground the...
Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1.
Page 80
1. Model label The model label is affixed to the frame under the seat. (See page 3-7.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
CONSUMER INFORMATION EAU26560 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new ve- hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
CONSUMER INFORMATION EAU26651 Maintenance record Have a Yamaha dealer complete this record when the machine is serviced. Maintenance Date of Servicing dealer Mileage Remarks interval service name and address...
This excellent Y.E.S. plan coverage is only available to dealer to see how comforting uninterrupted factory- Yamaha owners like you, and only while your Yamaha is still backed protection can be. within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts.
Page 86
Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
Page 87
INDEX Fuel............3-4 Sidestand, checking and lubricating..6-25 Fuel cock ...........3-5 Spark plug, checking ......... 6-7 Accessories and replacement parts..6-17 Fuel tank breather hose......3-5 Specifications ..........8-1 Air filter element, cleaning....... 6-11 Fuel tank cap ..........3-4 Starter (choke) knob........3-6 Fuse, replacing ........6-28 Starting and warming up a cold Battery.............
Page 88
YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2002·5–0.6×1(E) 2004.5–0.7×1 !
Need help?
Do you have a question about the TT-R250 and is the answer not in the manual?
Questions and answers