Yamaha TT-R230 User manual

SERVICE MANUAL
1C6-F8197-101C6-F8197-10
1C6-F8197-101C6-F8197-10
1C6-F8197-10
TTR230T
LITLIT
LITLIT
LIT-11616-18-40-11616-18-40
-11616-18-40-11616-18-40
-11616-18-40

SERVICE MANUAL
Feb/2005 - Yamaha Motor da Amazônia Ltda
Post-Sales Service Department
All rights reserved. The copy or reproduction
of all contents in this manual is forbidden
without the previous written authorization
from Yamaha Motor da Amazônia Ltda.
Printed in Brazil.
LIT-11616-18-40
TTR 230(T)

The alert sign means ATTENTION! ALERT! YOUR SAFETY IS
INVOLVED!
The failure in fulfilling a WARNING instruction may cause serious
accident and even the death of the vehicle driver, an observer, or
someone examining or repairing the vehicle.
A CAUTION instruction indicates special precautions to be taken to
prevent damages in the vehicle.
A NOTE provides information in order to clarify or facilitate the
procedures.
PREFACE
This manual has been prepared by YAMAHA MOTOR DA AMAZÔNIA LTDA. for the exclusive
use by the Yamaha Authorized Dealer and its qualified mechanicians. Since all mechanics
information cannot be included in a single manual, it is assumed that the people reading
this manual, to execute maintenance and repair services on the Yamaha motorcycles, have
a basic knowledge of the mechanical conceptions and procedures, inherent to the
motorcycle repair technology. Without these knowledge, any repair or service attempt on
this model could cause difficulties for its utilization and/or safety.
YAMAHA MOTOR DA AMAZÔNIA LTDA. will make its best efforts to enhance continuously
all products in its line. The significant changes and modifications in the specifications or
procedures will be informed to all YAMAHA Dealers, and will be included in the proper
places in future editions of this manual.
NOTE:
This model design and specifications are subject to changes with no previous notice.
The especially important information will be marked in this manual with the notations
below.
WARNING
CAUTION:
NOTE:
IMPORTANT INFORMATION
!

1. An exploded view diagram 4is supplied to enable easy view of the mounting and
dismounting services.
2. Numbers 5indicate the service order in the exploded view diagrams. A number
surrounded by a circle indicates a dismounting step.
3. A service and note explanation is provided in an easy reading way by using symbols 6.
The meaning of each symbol is provided in the next page.
4. An instruction chart 7is supplied with the exploded view diagram, and provides the
services order, part names, notes, etc.
5. For services requiring more information, a step-by-step supplement is provided 8in
addition to the exploded view diagram and instruction chart.
This manual is constituted by chapters for the major subject categories. (See “Illustrative
Symbols”)
1st title 1: This is the chapter title with the symbol in the upper right corner in each page.
2nd title 2:This title indicates the section in each chapter and only appears on the first page
of each section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a subsection followed by step-by-step instructions and with
the corresponding illustrations.
HOW TO USE THIS MANUAL
MANUAL FORMAT
In order to identify parts and procedure steps, there are exploded view diagrams in the beginning
of each dismounting and mounting section.
EXPLODED VIEW DIAGRAMS
1
23
4
5
6
7
8

ILLUSTRATIVE SYMBOLS
1 2
34
5 6
78
9
11
13
15
20 22
17 19
21
18
INFO
GEN SPEC
ENGINE
INSP
ADJUS
1
2
3
4
5
6
7
8
General information
Specifications
Periodic inspection and adjustments
Engine
Carburation
Frame
Electric system
Troubleshooting
ELECT
CHASCARB
?
PROB
The illustrative symbols from 1 to 8are
assigned as per the table aside, in order to
indicate the chapter numbers and contents.
9Replenish with fluid
0Lubricant
ASpecial tool
BTighten with torque wrench
CWear limit, clearance
DEngine speed
EΩ, V, A
The illustrative symbols from 9to Eare
used to identify the specifications
appearing in the text.
F Apply locking agent (LOCTITE®)
GApply engine oil
HApply gear oil
IApply molybdenum disulfide oil
JApply grease for wheel roller bearing
KApply lithium-based grease
LApply molybdenum disulfide-based
grease
The illustrative symbols from Fto L, in
the exploded view diagrams, indicate the
lubricant types and the lubrication points
to be applied.
10
12
14
16

GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENTS
ENGINE INSPECTION
CARBURATION
FRAME
ELECTRIC SYSTEM
TROUBLESHOOTING
INFO
GEN
SPEC
ENGINE
CARB
CHAS
ELECT
PROB
INSP
ADJUS
1
2
3
4
5
6
7
8
TABLE OF CONTENTS
?

INFO
GEN
MOTORCYCLE IDENTIFICATION .................................................................. 1-1
FRAME NUMBER ............................................................................ 1-1
MODEL IDENTIFICATION ................................................................ 1-1
IMPORTANT INFORMATION ......................................................................... 1-2
PREPARING FOR REMOVING AND DISMOUNTING ..................... 1-2
REPLACEMENT PARTS .................................................................. 1-3
GASKETS, RETAINERS AND O-RINGS .......................................... 1-3
LOCK WASHERS/SPACERS AND COTTER PINS .......................... 1-3
ROLLER BEARINGS AND RETAINERS .......................................... 1-3
LOCK RINGS .................................................................................... 1-4
SPECIAL TOOLS ............................................................................................ 1-4
FOR ADJUSTING ............................................................................. 1-4
FOR ENGINE SERVICES .................................................................. 1-5
FOR FRAME SERVICES .................................................................. 1-8
FOR ELECTRIC COMPONENTS ...................................................... 1-9
CONTENTS
CHAPTER 1.
GENERAL INFORMATION

INFO
GEN
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
The serial number of the frame 1is engraved
on the tube of the steering column.
MOTORCYCLE IDENTIFICATION
FRAME NUMBER
1-1
MODEL IDENTIFICATION
The model ID label 1is stuck on the frame.
This information will be required for
replacement part orders.
The vehicle’s ID number is used to identify
the motorcycle, when registering and
licensing it with the local traffic authority.
NOTE:

INFO
GEN
IMPORTANT INFORMATION
1-2
PREPARING FOR REMOVING AND
DISMOUNTING
2. Use the proper tools and cleaning
equipment.
See the “SPECIAL TOOLS” section.
3. When dismounting the motorcycle, keep
the matching parts together. This includes
gears, cylinders, pistons and other
matching parts that suffered natural wear
together. The matching parts must be
remounted as an assembly or replaced.
4. When dismounting the motorcycle, clean
all parts and put them on trays by
keeping the dismounting order. This will
speed the mounting and will assure the
correct part installation.
5. Keep fire sources away.
IMPORTANT INFORMATION
1. Clean all dirty, mud, dust and other
materials before removing and
dismounting.
DONT
SMOKE

INFO
GEN
IMPORTANT INFORMATION
LOCK WASHERS/SPACERS
AND COTTER PINS
ROLLER BEARINGS AND RETAINERS
1-3
GASKETS, RETAINERS AND O-RINGS
REPLACEMENT PARTS
1. Use only YAMAHA genuine parts for
replacement. Use oils/greases reco-
mmended by YAMAHA for mounting and
adjusting. Other brands may seem similar
in terms of function and appearance, but
have lower quality.
1. All gaskets, retainers and O-rings must be
replaced when overhauling the engine. All
gasket surfaces, retainer lips and O-rings
must be clean.
2. Apply oil on all points and roller bearings
when mounting. Apply grease on the
retainers’ lips.
Do not use compressed air for drying the
roller bearings. This will cause damages to
the roller bearing surfaces.
CAUTION:
1. Install the roller bearings 1 and retainers
2 ‚ with the manufacturer’s marks facing
out. (In other words, the stamped letters
must be exposed for facilitating the identi-
fication). When installing the retainers,
apply a thin lithium-based grease layer on
the retainer’s lips. Apply oil when installing
the roller bearing.
1. All lockwashers/cotter pins 1 must be
replaced when removed. The cotter pin
legs must be folded around the bolts or
nuts after applying the specific torque.

INFO
GEN
IMPORTANT INFORMATION
1-4
SPECIAL TOOLS
FOR ADJUSTING
The special tools are required for complete
and accurate adjustment and mounting. By
using the proper special tool, you will
prevent damages caused by the improper
use of impromptu tools or techniques.
LOCK RINGS
3. Strobe light
90890-03141
This tool is used for checking the ignition
point.
1. All lock rings must be carefully checked
before remounting. Always replace the
piston pin locks after every use. Replace
warped locks. When installing a lock 1 ,
make sure that the side with sharp corner
2 is positioned opposingly to the force
3 applied on it. See the aside figure.
4 Shaft
1. Valve clearance adjuster
90890 - 01311 -09
This tool is required for adjusting valve
clearances.
2. Digital inductive tachometer
90890-06760
This tool is required for detecting the
engine speed.

INFO
GEN
SPECIAL TOOLS
1-5
1. Piston pin puller
90890-01304
This tool is used for removing the piston
pin.
FOR ENGINE SERVICES
6. Castellated nut wrench
90890-01403
This tool is used for removing the handle
bar nut.
5. Fuel level meter
90890-01312
This meter is used to measure the fuel
level in the carburetor bowl.
4. Compression meter
90890-03081 - 1
Adapter:
90890-04082 - 2
This meter is used for measuring the
engine compression.
2. Rotor fastener
90890-01701
This tool is used to fasten the rotor when
removing or installing the rotor fastening
nut.

INFO
GEN
1-6
SPECIAL TOOLS
6. Crankshaft protector
90890-01382
This tool is used for removing the
crankshaft.
5. Crankcase separator
90890-01135
This tool is required for separating the
crankcases.
4. Universal clutch fastener
90890-04086
This tool is used to hold the clutch when
removing or installing the clutch hub
fastening nut.
3. Rotor puller
90890-01080
This tool is used for removing the magnet
rotor.
7. Sliding hammer set
Sliding hammer bolt
90890-01083 - 1
Weight
90890-01084 - 2
These tools are used for removing the
rockers’ shaft.

INFO
GEN
1-7
SPECIAL TOOLS
10. Guide expander for 6-mm valve
90890-04066
This tool is used for grinding the new
valve guides.
9. Guide remover for 6-mm valve
90890-04064
This tool is required to remove the valve
guides.
8. Valve spring clamp
90890-04019
This tool is required for removing and
installing valves.
11. Guide installer for 6-mm valve
90890-04065
This tool is required for installing the
valve guides in a proper way.
12. Crankshaft puller
90890-01274 - 1
Bolt
90890-01275 - 2

INFO
GEN
FOR FRAME SERVICES
15. Glue
Yamaha Bond nº1215®
90890-85505
This glue is used for gluing the
crankcases.
13. Adapter
90890-01383
This tool is used for installing the
crankshaft.
SPECIAL TOOLS
1-8
14. Crankshaft spacer
90890-04081
This tool is used for installing the
crankshaft.
1. Internal tube cylinder fastener
90890-01326 - 1
Fastener
90890-01294 - 2
This tool is used for loosening and
tightening the front fork bar fastening
bolt.
2.Sliding hammer for the fork retaining
installer
90890-01367 - 1
Adapter 36mm
90890-01370 - 2
These tools are used when installing the
fork retainer.

INFO
GEN
SPECIAL TOOLS
FOR ELECTRIC COMPONENTS
4. Transmission chain pin puller
90890-01286
This tool is used for mounting and
dismounting the transmission chain.
1. Dynamic spark tester
90890-06754
This equipment is used for checking
ignition system components.
3. Adjustment nut wrench
90890-1403
This tool is used for loosening or
tightening the handle bar adjusting nut.
2. Multi-tester
90890-03112
This equipment is used for testing the
electric system.
1-9

SPEC
CONTENTS
GENERAL SPECIFICATIONS ......................................................................... 2-1
MAINTENANCE SPECIFICATIONS . .............................................................. 2-4
ENGINE ............................................................................................ 2-4
FRAME ........................................................................................... 2-11
ELECTRIC SYSTEM ....................................................................... 2-15
GENERAL TORQUE SPECIFICATIONS ....................................................... 2-17
UNIT DEFINITION ......................................................................................... 2-17
LUBRICATION POINTS AND LUBRICANT TYPES ..................................... 2-18
ENGINE .......................................................................................... 2-18
FRAME ........................................................................................... 2-19
LUBRICATION DIAGRAM ............................................................................ 2-20
CABLE ROUTING ......................................................................................... 2-22
HANDLE BAR ................................................................................ 2-22
FRONT ............................................................................................ 2-23
MOTORCYCLE – RIGHT SIDE ....................................................... 2-24
MOTORCYCLE – LEFT SIDE ......................................................... 2-25
INTERNAL OPENING ..................................................................... 2-26
BATTERY AND COMPONENTS .................................................... 2-27
CHAPTER 2.
SPECIFICATIONS

SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
2-1
GENERAL SPECIFICATIONS
Model name: TTR230T
YAMALUBE4, SAE10W30 or SAE20W40
(for USA/ CAN)
SAE10W30 or SAE10W40 or SAE20W40
or SAE20W50 (for AUS)
1.0 L
1.1 L
1.3 L
Oil type:
Engine oil
Periodic oil change
With filter replacement
Total capacity
Wet crankcase
Lubrication system:
Type
Air cooled, 4-stroke, SOHC
Single cylinder, front inclined
223cm3
70x58mm
9,5:1
1.200 kPa (12kg/cm² at 1000 rpm)
Electric start
Engine:
Type
Cylinder arrangement
Displacement
Diameter vs. stroke
Compression rate
Compression pressure (STD)
Starting system
110 Kg
116 Kg
Basic weight:
Basic weight
With oil and full fuel tank
Minimum turning radius: 2,100 mm
Model code:
Dimensions:
Total length
Total width
Total height
Seat height
Wheel base:
Minimum height from ground
TT-R230
1C61 USA
1C63 CDN
1C64 AUS
2,065 mm (81.30 in)
800 mm (31.50 in)
1,180 mm (46.46 in)
870 mm (34.25 in)
1,385 mm (54.53)
295 mm (11.61)

SPEC
GENERAL SPECIFICATIONS
2-2
Tires:
Manufacturer
Type
Size
Pressure
Frame:
Frame type
Caster angle
Trail
Diamond
27°
111 mm
Transmission:
Type
Command
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Gear ratio 1st
2nd
3rd
4th
5th
6th
6-gera constant mesh
Left foot drive
Square teeth gears
73/22 (3,318)
Transmission chain
49/13 (3,769)
38/13 (2,923)
34/18 (1,889 )
30/21 (1,428 )
27/24 (1,125 )
25/27 (0,925 )
23/29 (0,793 )
Clutch type: wet, multiple discs
Spark plug:
Type
Manufacturer
Electrode gap
DR8EA
NGK
0.6 ~ 0.7 mm
Carburetor:
Type
Manufacturer
Y26P x 1
TEIKEI
Fuel:
Type
Fuel tank capacity
Reserve volume
Gasoline with additive
8 L
1.8L
FRONT
MT320H/Pirelli
With tube
80/100 - 21 NHS
100KPa(1.00Kgf/cm2.15 psi)
REAR
MT320/Pirelli
With tube
110/100 - 18 NHS
100KPa(1.00Kgf/cm2.15 psi)

SPEC
Telescopic fork
Swing arm (monocross)
GENERAL SPECIFICATIONS
2-3
C.D.I.
Magneto A.C.
YTX5L-B5
12V, 4AH
10.0 A
Shock absorber:
Front
Rear
Helical spring / Hydraulic shock absorber
Helical spring / Hydraulic shock absorber with gas
Suspension:
Front
Rear
Brakes:
Front type
operation
Rear type
operation
Disc brake (single)
Right-hand drive
Drum brake
Right foot drive
Wet-type elementAir filter:
Electric:
Ignition system
Charging system
Battery type
Battery capacity
Fuse
Suspension travel:
Front
Rear
240 mm
220 mm
Wheels:
Front type
size
Rear type
size
Spoked
21 x 1.60
Spoked
18 x 1.85