Yamaha TT-R230V 2005 User manual
1
INTRODUCTION
Congratulations on your purchase of the Yamaha TTR230V.This model is the result of Yamaha’s vast experience in the
production of fine sporting, touring, and pacesetting racing machines.It represents the high degree of craftsmanship and
reliability that have madeYamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you
have any questions concerning the operation or maintenance of your motorcycle, please consult aYamaha dealer.
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1
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 followWARNING instructions could result in severe injury or death to the motorcycle
operator, a bystander or a person inspecting or repairing the motorcycle.
ACAUTION indicates specialprecautionsthatmust betaken to avoiddamage tothe motorcycle.
A NOTE provides key information to make procedures easier or clearer.
●Thismanualshould be considered a permanentpartof this motorcycle and should remain with it evenifthemotorcycle
is subsequently sold.
●Yamahacontinuallyseeksadvancementsin product design and quality.Therefore, while this manual contains the most
currentproductinformationavailableat the time of printing, there maybe minor discrepancies betweenyour motorcycle
and this manual.If you have any questions concerning this manual, please consult yourYamaha dealer.
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IMPORTANT MANUAL INFORMATION
PLEASE READ THIS MANUAL ANDTHE “YOU ANDYOUR MOTORCYCLE: RIDINGTIPS” BOOKLET CAREFULLY
AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPTTO OPERATETHIS MOTORCYCLE
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 ANDTHE RELIABILITY OF THIS MOTORCYCLE.
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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TABLE OF CONTENTS
SAFETY INFORMATION ....................1-1
Location of important labels............1-6
DESCRIPTION ...................................2-1
Left view ..........................................2-1
Right view........................................2-2
Controls and instruments ................2-3
INSTRUMENT AND CONTROL
FUNCTION .........................................3-1
Main switch .....................................3-1
Handlebar switches ........................3-1
Clutch lever .....................................3-2
Shift pedal .......................................3-2
Brake lever ......................................3-2
Brake pedal .....................................3-3
Fuel tank cap...................................3-3
Fuel .................................................3-3
Fuel tank breather hose ..................3-5
Fuel cock .........................................3-5
Starter (choke) knob........................3-6
Seat .................................................3-6
Adjusting the shock absorber
assembly......................................3-7
Starting circuit cut-off system ..........3-8
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 ...................5-2
Shifting ............................................5-2
Engine break-in...............................5-3
Parking ............................................5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR..................................6-1
Periodic maintenance chart for the
emission control system ..............6-2
General maintenance and lubrication
chart .............................................6-3
Removing and installing the panels6-6
Checking the spark plug .................6-7
Engine oil and oil filter element ......6-8
Cleaning the air filter element.......6-11
Adjusting the carburetor................6-13
Adjusting the throttle cable
free play .....................................6-13
Adjusting the valve clearance.......6-13
Tires...............................................6-14
Spoke wheels................................6-16
Adjusting the clutch lever
free play.....................................6-16
Adjusting the brake pedal position6-17
Checking the front brake
pads and rear brake shoes .......6-18
Checking the brake fluid level ......6-18
Changing the brake fluid ..............6-19
Drive chain slack...........................6-19
Lubricating the drive chain ...........6-20
Checking and lubricating
the cables ..................................6-21
Checking and lubricating
the throttle grip and cable ..........6-21
Checking and lubricating
the brake and clutch levers .......6-22
Lubricating the brake pedal ..........6-22
Checking and lubricating
the sidestand .............................6-22
Checking the front fork ..................6-23
Checking the steering ...................6-23
Checking the wheel bearings .......6-24
Battery ...........................................6-24
Replacing the fuse ........................6-26
Supporting the motorcycle ............6-26
Front wheel....................................6-27
Rear wheel....................................6-27
Troubleshooting ............................6-29
Troubleshooting chart ...................6-30
MOTORCYCLE CARE AND
STORAGE...........................................7-1
Care.................................................7-1
Storage............................................7-3
SPECIFICATIONS ..............................8-1
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1-1
1
SAFETY INFORMATION
MACHINES ARE SINGLE TRACK
VEHICLES. THEIR SAFE USE AND
OPERATIONAREDEPENDENTUPON
THE USE OF PROPER RIDING
TECHNIQUES AS WELL AS THE
EXPERTISE OF THE OPERATOR.
EVERY OPERATOR SHOULD KNOW
THE FOLLOWING REQUIREMENTS
BEFORERIDINGTHIS MACHINE.
HEORSHESHOULD:
●OBTAIN THOROUGH
INSTRUCTIONS FROM A
COMPETENT SOURCE ON ALL
ASPECTS OF MACHINE
OPERATION.
●OBSERVETHEWARNINGSAND
MAINTENANCE
REQUIREMENTS IN THE
OWNER’SMANUAL.
●OBTAIN QUALIFIEDTRAININGIN
SAFE AND PROPER RIDING
TECHNIQUES.
●OBTAIN PROFESSIONAL
TECHNICAL SERVICE AS
INDICATED BY THE OWNER’S
MANUAL AND/OR WHEN MADE
NECESSARY BY MECHANICAL
CONDITIONS.
Safe riding
●Alwaysmakepre-operationchecks.
Careful checks may help prevent
an accident.
●This machine is designed for off-
roaduseonly, therefore, it is illegal
to operate it on public streets,
roads,orhighways.Off-roaduseon
publiclandsmaybeillegal. Please
check local regulations before
riding.
●This machine is designed to carry
theoperatoronly.Nopassengers.
●Many accidents involve
inexperiencedoperators.
•Makesurethatyouarequalified
and that you only lend your
machine to other qualified
operators.
•Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
●Manyaccidents have beencaused
byerrorofthemachineoperator.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
fasterthanwarrantedbyconditions.
●Ridecautiously inunfamiliarareas.
You may encounter hidden
obstacles that could cause an
accident.
●The posture of the operator is
important for proper control. The
operatorshouldkeepbothhandson
thehandlebarandbothfeetonthe
operatorfootrests during operation
tomaintaincontrolofthe machine.
●Never ride under the influence of
alcoholorotherdrugs.
Protectiveapparel
The majority of fatalities from machine
accidents are the result of head injuri-
es. The use of a safety helmet is the
single most critical factor in the
preventionor reduction ofheadinjuries.
●Alwayswearanapproved helmet.
●Wearafaceshieldorgoggles.Wind
in your unprotected eyes could
contribute to an impairment of
vision that could delay seeing a
hazard.
●The use of a jacket, heavy boots,
trousers, gloves, etc., is effective
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SAFETY INFORMATION
inpreventingorreducing abrasions
orlacerations.
●Never wear loose-fitting clothes,
otherwise they could catch on the
controllevers,footrests,orwheels
and cause injury or an accident.
●Nevertouchtheengineor exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear
protectiveclothing that coversyour
legs, ankles, and feet.
Modifications
Modificationsmadetothismachine not
approvedbyYamaha,ortheremoval of
original equipment, may render the
machineunsafefor use and maycause
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
andhandlingif theweightdistributionof
the machine is changed. To avoid the
possibility of an accident, use extreme
caution when adding cargo or
accessories to your machine. Use ex-
tracarewhen riding a machine thathas
added cargo or accessories. Here are
some general guidelines to follow if
loading cargo or adding accessories to
yourmachine:
Loading
The total weight of the operator,
accessoriesand cargomustnot exceed
themaximumloadlimitof90kg(198 lb).
When loading within this weight limit,
keep the following in mind:
●Cargoandaccessoryweightshould
be kept as low and close to the
machineaspossible. Make sureto
distribute the weight as evenly as
possible on both sides of the
machinetominimize imbalance or
instability.
●Shifting weights can create a
suddenimbalance.Make sure that
accessoriesandcargoaresecurely
attached to the machine before
riding. Check accessory mounts
andcargorestraintsfrequently.
●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
createunstable handling or a slow
steeringresponse.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
thismachine.SinceYamaha cannottest
all other accessories that may be
available, you must personally be
responsible for the proper selection,
installation and use of non-Yamaha
accessories.Useextremecautionwhen
selectingandinstallinganyaccessories.
Keep these guidelines in mind for
mounting accessories in addition to
thoseprovided under“Loading”.
●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
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SAFETY INFORMATION
doesnot in anywayreduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or
obscure lights or reflectors.
•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
handlebaror frontforkarea, they
must be as lightweight as
possibleandshouldbekeptto a
minimum.
•Bulky or large accessories may
seriouslyaffectthestability ofthe
machine due to aerodynamic
effects.Wind may attempt to lift
themachine,orthemachinemay
becomeunstable incrosswinds.
•Certainaccessoriescan displace
the operator from his or her nor-
malridingposition.Thisimproper
position limits the freedom of
movement of the operator and
may limit control ability,
therefore, such accessories are
notrecommended.
●Usecaution whenaddingelectrical
accessories. If electrical
accessoriesexceed thecapacityof
themachine’selectrical system an
electric failure could result, which
could cause a dangerous loss of
lightsorengine power.
Gasoline and exhaust gas
●GASOLINE IS HIGHLY
FLAMMABLE:
•Always turn the engine off when
refueling.
•Takecarenottospillanygasoline
onthe engineorexhaustpipe(s)/
muffler(s)when refueling.
•Neverrefuelwhilesmokingorin
the vicinity of an open flame.
●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
adequateventilation.
●Always turn the engine off before
leaving the machine unattended
and remove the key from the main
switch.Whenparkingthemachine,
notethefollowing:
•Theengineand exhaust pipe(s)/
muffler(s)maybe hot, therefore,
park the machine in a place
wherepedestriansorchildrenare
not likely to touch these hot
areas.
•Do not park the machine on a
slopeorsoft ground,otherwiseit
may fall over.
•Do not park the machine near a
flammable source (e.g., a
keroseneheater, ornearanopen
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)areturnedto “ON”or “RES”
(forvacuumtype)/”OFF”(formanual
type). If the machine should lean
over, gasoline may leak out of the
carburetororfueltank.
●Ifyou shouldswallowanygasoline,
inhale a lot of gasoline vapor, or
allowgasolinetogetintoyoureyes,
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3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch
The main switch controls the ignition
systems. The various main switch
positionsaredescribedbelow.
ON
All electrical systems are supplied with
power,andtheenginecanbestarted.
OFF
All electrical systems are off.
Handlebar switches
Left
1. Engine stop switch “ “
Right
1. Start switch “ “
Engine stop switch“ ”
Push this switch to stop the engine in
case of an emergency, such as when
the motorcycle overturns or when the
throttle cable is stuck.
Start switch“ ”
Pushthisswitchtocranktheenginewith
the starter.
Seepage 5-1 forstarting instructions
prior to starting the engine.
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3
INSTRUMENT AND CONTROL FUNCTIONS
Clutch lever
1. Clutch lever
The clutch lever is located at the left
handlebargrip.Todisengage theclutch,
pullthelever toward the handlebargrip.
To engage the clutch, release the lever.
The lever should be pulled rapidly and
released slowly for smooth clutch
operation.
Theclutchleverisequippedwithaclutch
switch, which is part of the starting
circuit cut-off system. (See page 3-8.)
Shift pedal
1. Shift pedal
Theshift pedalislocated ontheleftside
oftheengineand isusedincombination
with the clutch lever when shifting the
gears of the 6-speed constant-mesh
transmission equipped on this
motorcycle.
Brake lever
1. Brake lever
The brake lever is located at the right
handlebargrip.Toapply the frontbrake,
pullthe lever towardthehandlebargrip.
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INSTRUMENT AND CONTROL FUNCTIONS
Brake pedal
1. Brake pedal
The brake pedal is on the right side of
themotorcycle.To apply the rear brake,
pressdownonthebrakepedal.
Fuel tank cap
1
2
1. Fuel tank cap
2. Remove
To remove the fuel tank cap, turn it
counterclockwise, and then pull it off.
To install the fuel tank cap, insert it into
the tank opening, and then turn it
clockwise.
Make sure that the fuel tank cap is
properly closed before riding.
Fuel
12
1. Fuel tank filter tube
2. Fuel lever
Makesurethatthereissufficientfuelin
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
●●
●●
●Do not overfill the fuel tank,
otherwise it may overflow when
the fuel warms up and expands.
●●
●●
●Avoid spilling fuel on the hot
engine.
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Table of contents
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