Yamaha TT-R User manual

PRINTED IN JAPAN
2002·5–0.6×1(E) !
PRINTED ON RECYCLED PAPER
YAMAHA MOTOR CO., LTD.
OWNER’S MANUAL
5GF-28199-14
LIT-11626-16-24
TTR250R(C)

EAU03438

EAU00000 INTRODUCTION
Congratulations on your purchase of the Yamaha TTR250R. This model is the result of Yamaha’s
vast experience in the production of fine sporting, touring, and pacesetting racing machines. It repre-
sents the high degree of craftsmanship and reliability that have made Yamaha a leader in these
fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of
this machine. If you have any questions concerning the operation or maintenance of your machine,
please consult a Yamaha dealer.
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EAU00003
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death
to the machine operator, a bystander or a person inspecting or repairing the
machine.
A CAUTION indicates special precautions that must be taken to avoid damage
to the machine.
A NOTE provides key information to make procedures easier or clearer.
Q
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cC
NOTE:
NOTE:
8This manual should be considered a permanent part of this machine and should remain with
it even if the machine is subsequently sold.
8Yamaha 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 and this manual. If you have any ques-
tions concerning this manual, please consult your Yamaha dealer.
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IMPORTANT MANUAL INFORMATION
EW000000
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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. REGULAR INSPECTIONS
AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT
YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.
EAU00006
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THIS MACHINE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS
ILLEGAL TO OPERATE THIS MACHINE ON ANY PUBLIC STREET, ROAD OR HIGHWAY.
SUCH USE IS PROHIBITED BY LAW. THIS MACHINE COMPLIES WITH ALMOST ALL
STATE OFF-HIGHWAY NOISE LEVEL AND SPARK ARRESTER LAWS AND REGULATIONS.
PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERATING
THIS MACHINE.
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TTR250R
OWNER’S MANUAL
©2002 by Yamaha Motor Corporation, U.S.A.
1st edition, April 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-16-24
EAU04247
AFFIX DEALER
LABEL HERE
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EAU00009 TABLE OF CONTENTS
SAFETY INFORMATION ...................................1-1
Safe riding .......................................................1-1
Protective apparel ...........................................1-2
Modifications ...................................................1-3
Loading and accessories ................................1-3
Gasoline and exhaust gas ...............................1-5
Location of important labels ............................1-7
DESCRIPTION ...................................................2-1
Left view ..........................................................2-1
Right view ........................................................2-2
Controls and instruments ................................2-3
INSTRUMENT AND CONTROL
FUNCTIONS ......................................................3-1
Main switch .....................................................3-1
Tripmeter .........................................................3-1
Handlebar switches .........................................3-1
Clutch lever .....................................................3-2
Shift pedal .......................................................3-2
Brake lever ......................................................3-3
Brake pedal .....................................................3-3
Fuel tank cap ...................................................3-3
Fuel .................................................................3-4
Fuel tank breather hose ..................................3-5
Fuel cock .........................................................3-5
Starter (choke) knob ........................................3-6
Seat .................................................................3-7
Adjusting the front fork ....................................3-7
Adjusting the shock absorber assembly ........3-10
Starting circuit cut-off system ........................3-12
PRE-OPERATION CHECKS .............................4-1
Pre-operation check list ...................................4-1
OPERATION AND IMPORTANT RIDING
POINTS ..............................................................5-1
Starting and warming up a cold engine ...........5-1
Starting a warm engine ...................................5-3
Shifting ............................................................5-3
Engine break-in ...............................................5-4
Parking ............................................................5-5
PERIODIC MAINTENANCE AND MINOR
REPAIR ..............................................................6-1
Owner’s tool kit ................................................6-1
Periodic maintenance and lubrication chart ....6-2
Removing and installing the cowling and
panels ..........................................................6-5
Checking the spark plug ..................................6-6
1
2
3
4
5
6
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Engine oil and oil filter element .......................6-8
Cleaning the air filter element .......................6-12
Cleaning the spark arrester ...........................6-13
Adjusting the carburetor ................................6-14
Adjusting the throttle cable free play .............6-14
Adjusting the valve clearance .......................6-15
Tires ..............................................................6-15
Spoke wheels ................................................6-17
Accessories and replacement parts ..............6-18
Adjusting the clutch lever free play ...............6-19
Adjusting the brake lever free play ................6-19
Adjusting the brake pedal position ................6-20
Checking the front and rear brake pads ........6-21
Checking the brake fluid level .......................6-21
Changing the brake fluid ...............................6-22
Drive chain slack ...........................................6-23
Lubricating the drive chain ............................6-24
Checking and lubricating the cables .............6-25
Checking and lubricating the throttle grip
and cable ...................................................6-26
Checking and lubricating the brake and
shift pedals .................................................6-26
Checking and lubricating the brake and
clutch levers ...............................................6-26
Checking and lubricating the sidestand ........6-27
Checking the front fork ..................................6-27
Checking the steering ...................................6-28
Checking the wheel bearings ........................6-28
Battery ...........................................................6-29
Replacing the fuse .......................................6-30
Replacing the headlight bulb .........................6-31
Replacing the taillight bulb ............................6-33
Supporting the machine ................................6-33
Front wheel ...................................................6-34
Rear wheel ....................................................6-36
Troubleshooting ............................................6-38
Troubleshooting chart ...................................6-39
MACHINE CARE AND STORAGE ....................7-1
Care ................................................................7-1
Storage ............................................................7-4
SPECIFICATIONS .............................................8-1
Specifications ..................................................8-1
CONSUMER INFORMATION ............................9-1
Identification numbers .....................................9-1
Key identification number ................................9-1
Vehicle identification number ..........................9-1
Model label ......................................................9-2
TABLE OF CONTENTS
7
8
9
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TABLE OF CONTENTS
Motorcycle noise regulation ............................9-3
Maintenance record ........................................9-5
Off-road motorcycle limited warranty ..............9-7
Yamaha extended service (Y.E.S.) .................9-9
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1-1
EAU02912
QSAFETY INFORMATION
1
MACHINES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPEN-
DENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF
THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS MACHINE.
HE OR SHE SHOULD:
1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS
OF MACHINE OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MAN-
UAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.
Safe riding
1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. This machine is designed for off-road use only, therefore, it is illegal to operate it on public
streets, roads, or highways. Off-road use on public lands may be illegal. Please check local regu-
lations before riding.
3. This machine is designed to carry the operator only. No passengers.
4. Many accidents involve inexperienced operators.
a. Make sure that you are qualified and that you only lend your machine to other qualified opera-
tors.
b. Know your skills and limits. Staying within your limits may help you to avoid an accident.
5. Many accidents have been caused by error of the machine operator. A typical error made by the
operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient
lean angle for the speed). Never travel faster than warranted by conditions.
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1-2
QSAFETY INFORMATION
1
6. Ride cautiously in unfamiliar areas. You may encounter hidden obstacles that could cause an
accident.
7. The posture of the operator is important for proper control. The operator should keep both hands
on the handlebar and both feet on the operator footrests during operation to maintain control of
the machine.
8. Never ride under the influence of alcohol or other drugs.
Protective apparel
The majority of fatalities from machine accidents are the result of head injuries. The use of a safety
helmet is the single most critical factor in the prevention or reduction of head injuries.
1. Always wear an approved helmet.
2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment
of vision that could delay seeing a hazard.
3. The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing
abrasions or lacerations.
4. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or
wheels and cause injury or an accident.
5. Never touch the engine or exhaust system during or after operation. They become very hot and
can cause burns. Always wear protective clothing that covers your legs, ankles, and feet.
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1-3
QSAFETY INFORMATION
1
Modifications
Modifications made to this machine not approved by Yamaha, or the removal of original equipment,
may render the machine unsafe for use and may cause severe personal injury. Modifications may
also make your machine illegal to use.
Loading and accessories
Adding accessories or cargo to your machine can adversely affect stability and handling if the weight
distribution of the machine is changed. To avoid the possibility of an accident, use extreme caution
when adding cargo or accessories to your machine. Use extra care when riding a machine that has
added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding
accessories to your machine:
Loading
The total weight of the operator, accessories and cargo must not exceed the maximum load limit of
90 kg (198 lb). When loading within this weight limit, keep the following in mind:
1. Cargo and accessory weight should be kept as low and close to the machine as possible. Make
sure to distribute the weight as evenly as possible on both sides of the machine to minimize
imbalance or instability.
2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are
securely attached to the machine before riding. Check accessory mounts and cargo restraints
frequently.
3. Never attach any large or heavy items to the handlebar, front fork, or front fender. These items,
including such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or a
slow steering response.
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1-4
QSAFETY INFORMATION
1
Accessories
Genuine Yamaha accessories have been specifically designed for use on this machine. Since
Yamaha cannot test all other accessories that may be available, you must personally be responsible
for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when
selecting and installing any accessories.
Keep these guidelines in mind for mounting accessories in addition to those provided under
“Loading”.
1. Never install accessories or carry cargo that would impair the performance of your machine.
Carefully inspect the accessory before using it to make sure that it does not in any way reduce
ground clearance or cornering clearance, limit suspension travel, steering travel or control opera-
tion, or obscure lights or reflectors.
a. Accessories fitted to the handlebar or the front fork area can create instability due to improper
weight distribution or aerodynamic changes. If accessories are added to the handlebar or front
fork area, they must be as lightweight as possible and should be kept to a minimum.
b. Bulky or large accessories may seriously affect the stability of the machine due to aerodynamic
effects. Wind may attempt to lift the machine, or the machine may become unstable in cross
winds.
c. Certain accessories can displace the operator from his or her normal riding position. This
improper position limits the freedom of movement of the operator and may limit control ability,
therefore, such accessories are not recommended.
2. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of
the machine’s electrical system an electric failure could result, which could cause a dangerous
loss of lights or engine power.
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1-5
QSAFETY INFORMATION
1
Gasoline and exhaust gas
1. GASOLINE IS HIGHLY FLAMMABLE:
a. Always turn the engine off when refueling.
b. Take care not to spill any gasoline on the engine or exhaust pipe(s)/muffler(s) when refueling.
c. Never refuel while smoking or in the vicinity of an open flame.
2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are
poisonous and may cause loss of consciousness and death within a short time. Always operate
your machine in an area that has adequate ventilation.
3. Always turn the engine off before leaving the machine unattended and remove the key from the
main switch. When parking the machine, note the following:
a. The engine and exhaust pipe(s)/muffler(s) may be hot, therefore, park the machine in a place
where pedestrians or children are not likely to touch these hot areas.
b. Do not park the machine on a slope or soft ground, otherwise it may fall over.
c. Do not park the machine near a flammable source (e.g., a kerosene heater, or near an open
flame), otherwise it could catch fire.
4. 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.
5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into
your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediate-
ly wash the affected area with soap and water and change your clothes.
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1-6
QSAFETY INFORMATION
1
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1-7
QSAFETY INFORMATION
1
EAU02977
Location of important labels
Please read the following important labels carefully before operating this machine.
1234
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1-8
QSAFETY INFORMATION
1
Riding as a passenger can cause
the vehicle to go out of control.
Loss of control can cause a
collision or rollover, which can
result in severe injury or death.
NEVER ride as a passenger.
3XJ-2151H-A0
WARNING
q
WARNING
q
8
8
This unit contains high pressure nitrogen gas.
Mishandling can cause explosion.
Read owner's manual for instructions.
Do not incinerate, puncture or open.
YAMAHA
4AA-22259-80
1
2
WARNING
q
THE OWNER'S MANUAL AND ALL LABELS.
NEVER CARRY A PASSENGER. You increase
you operate this vehicle on a public road.
EXPERIENCED RIDER ONLY.
8
8
8
8
8
5PA-2118K-00
ALWAYS WEAR AN APPROVED MOTORCYCLE
HELMET,eye protection, and protective clothing.
ROADS. You can collide with another vehicle if
NEVER OPERATE THIS VEHICLE ON PUBLIC
your risk of losing control if you carry a passenger.
BEFORE YOU OPERATE THIS VEHICLE, READ
TIRE INFORMATION
follows.
FRONT :
:REAR
3RV-21668-A0
Cold tire normal pressure should be set as
100 kPa,{1.00 kgf/cm2}, 15 psi
100 kPa,{1.00 kgf/cm2}, 15 psi
3
4
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2-1
EAU00026
DESCRIPTION
2
1. Headlight (page 6-31)
2. Front fork air valve (page 3-7)
3. Fuel cock (page 3-5)
4. Starter (choke) knob (page 3-6)
5. Air filter element (page 6-12)
6. Shock absorber rebound
damping adjusting dial (page 3-11)
7. Shift pedal (page 3-2)
8. Front fork damping adjusting
screw (page 3-9)
1345
6
78
2
Left view
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2-2
DESCRIPTION
2
9. Spark arrester (page 6-13)
10. Battery (page 6-29)
11. Fuse (page 6-30)
12. Shock absorber compression
damping adjusting knob (page 3-11)
13. Main switch (page 3-1)
14. Engine oil filter element (page 6-9)
15. Brake pedal (page 3-3, 6-20)
16. Shock absorber spring preload
adjusting nut (page 3-10)
910111213
1415
16
Right view
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2-3
DESCRIPTION
2
1. Clutch lever (page 3-2, 6-19)
2. Left handlebar switch (page 3-1)
3. Tripmeter (page 3-1)
4. Right handlebar switches (page 3-2)
5. Brake lever (page 3-3, 6-19)
6. Throttle grip (page 6-14)
7. Fuel tank cap (page 3-3)
1234
5
6
7
Controls and instruments
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