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.