Yamaha TT-R250 User manual

OWNER’S MANUAL
5GF-28199-16
TTR250T(C)
PRINTED IN JAPAN
2002·5–0.6×1(E) !
PRINTED ON RECYCLED PAPER
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2004.5–0.7×1 !
(E)
LIT-11626-18-24
5GF-16_hyoushi 4/29/04 3:48 PM Page 1

5GF-16_hyoushi2&3 4/14/04 8:00 PM Page 1

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 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.

IMPORTANT MANUAL INFORMATION
EAU10160
Particularly important information is distinguished in this manual by the following notations:
NOTE:
●
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
and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
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.
WARNING
CAUTION:
NOTE:

IMPORTANT MANUAL INFORMATION
WARNING
EWA10010
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 CARE-
FUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPA-
BILITIES AND THE RELIABILITY OF THIS MACHINE.
WARNING
EWA10040
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 MA-
CHINE 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.

IMPORTANT MANUAL INFORMATION
EAU10192
AFFIX DEALER
LABEL HERE
TTR250T
OWNER’S MANUAL
©2004 by Yamaha Motor Corporation, U.S.A.
1st edition, April 2004
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-11626-18-24

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
FUNCTIONS ........................................3-1
Main switch ......................................3-1
Tripmeter .........................................3-1
Handlebar switches .........................3-1
Clutch lever .....................................3-2
Shift pedal .......................................3-3
Brake lever ......................................3-3
Brake pedal .....................................3-3
Fuel tank cap ...................................3-4
Fuel .................................................3-4
Fuel tank breather hose ..................3-5
Fuel cock .........................................3-5
Starter (choke) knob “ 1 ”................3-6
Seat .................................................3-7
Adjusting the front fork ....................3-7
Adjusting the shock absorber
assembly ......................................3-9
Starting circuit cut-off system ........3-11
PRE-OPERATION CHECKS ...............4-1
Pre-operation check list ...................4-2
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
Owner’s tool kit ................................ 6-1
Periodic maintenance chart for the
emission control system .............. 6-2
General maintenance and
lubrication chart ........................... 6-3
Removing and installing the cowling
and panels ................................... 6-6
Checking the spark plug .................. 6-7
Engine oil and oil filter element ....... 6-8
Cleaning the air filter element ....... 6-11
Cleaning the spark arrester ........... 6-13
Adjusting the carburetor ................ 6-14
Adjusting the throttle cable free
play ............................................ 6-14
Adjusting the valve clearance ....... 6-14
Tires .............................................. 6-15
Spoke wheels ................................ 6-17
Accessories and replacement
parts ........................................... 6-17
Adjusting the clutch lever free
play .............................................6-18
Adjusting the brake lever free
play .............................................6-18
Checking the front and rear brake
pads ............................................6-19
Checking the brake fluid level ........6-20
Changing the brake fluid ................6-21
Drive chain slack ............................6-21
Lubricating the drive chain .............6-23
Checking and lubricating the
cables .........................................6-23
Checking and lubricating the
throttle grip and cable .................6-24
Checking and lubricating the brake
and clutch levers ........................6-24
Lubricating the brake pedal ...........6-24
Checking and lubricating the
sidestand ....................................6-25
Checking the front fork ...................6-25
Checking the steering ....................6-26
Checking the wheel bearings .........6-26
Battery ...........................................6-27
Replacing the fuse .........................6-28
Replacing the headlight bulb .........6-29
Replacing the taillight bulb .............6-30
Supporting the machine .................6-31
Front wheel ....................................6-31
Rear wheel .....................................6-33
Troubleshooting .............................6-34
Troubleshooting chart ....................6-35

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

1-1
1
SAFETY INFORMATION
EAU10330
MACHINES ARE SINGLE TRACK VE-
HICLES. THEIR SAFE USE AND OP-
ERATION ARE DEPENDENT UPON
THE USE OF PROPER RIDING
TECHNIQUES AS WELL AS THE EX-
PERTISE OF THE OPERATOR. EV-
ERY OPERATOR SHOULD KNOW
THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS MACHINE.
HE OR SHE SHOULD:
● OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MACHINE OPERATION.
● OBSERVE THE WARNINGS
AND MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S MAN-
UAL.
● OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
● OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDI-
TIONS.
Safe riding
● Always make pre-operation
checks. Careful checks may help
prevent an accident.
● This machine is designed for
off-road use only, therefore, it is il-
legal to operate it on public streets,
roads, or highways. Off-road use
on public lands may be illegal.
Please check local regulations be-
fore riding.
● This machine is designed to carry
the operator only. No passengers.
● Many accidents involve inexperi-
enced operators.
● Make sure that you are qualified
and that you only lend your ma-
chine to other qualified opera-
tors.
● Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
● 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 undercor-
nering (insufficient lean angle for
the speed). Never travel faster
than warranted by conditions.
● Ride cautiously in unfamiliar ar-
eas. You may encounter hidden
obstacles that could cause an ac-
cident.
● The posture of the operator is im-
portant for proper control. The op-
erator should keep both hands on
the handlebar and both feet on the
operator footrests during operation
to maintain control of the machine.
● Never ride under the influence of
alcohol or other drugs.
Protective apparel
The majority of fatalities from machine
accidents are the result of head inju-
ries. The use of a safety helmet is the
single most critical factor in the preven-
tion or reduction of head injuries.
● Always wear an approved helmet.
● Wear a face shield or goggles.
Wind in your unprotected eyes

SAFETY INFORMATION
1-2
1
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 in
preventing or reducing abrasions
or lacerations.
● Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
● Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protec-
tive clothing that covers your legs,
ankles, and feet.
Modifications
Modifications made to this machine not
approved by Yamaha, or the removal of
original equipment, may render the ma-
chine 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 accesso-
ries 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, acces-
sories 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:
● 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 imbal-
ance or instability.
● Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the machine before
riding. Check accessory mounts
and cargo restraints frequently.
● Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slow
steering response.
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 re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac-
cessories.
Keep these guidelines in mind for
mounting accessories in addition to

SAFETY INFORMATION
1-3
1
those provided under “Loading”.
● Never install accessories or carry
cargo that would impair the perfor-
mance 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 sus-
pension travel, steering travel or
control operation, or obscure lights
or reflectors.
● Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic 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.
● Bulky or large accessories may
seriously affect the stability of
the machine due to aerodynam-
ic effects. Wind may attempt to
lift the machine, or the machine
may become unstable in cross
winds.
● Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.
● Use caution when adding electri-
cal accessories. If electrical acces-
sories 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.
Gasoline and exhaust gas
● GASOLINE IS HIGHLY FLAMMA-
BLE:
● Always turn the engine off when
refueling.
● Take care not to spill any gaso-
line on the engine or exhaust
pipe(s)/muffler(s) when refuel-
ing.
● Never refuel while smoking or in
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 poi-
sonous and may cause loss of
consciousness and death within a
short time. Always operate your
machine in an area that has ade-
quate ventilation.
● Always turn the engine off before
leaving the machine unattended
and remove the key from the main
switch. When parking the ma-
chine, note the following:
● 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.
● Do not park the machine on a
slope or soft ground, otherwise it
may fall over.
● Do not park the machine near a
flammable source (e.g., a kero-
sene heater, or near an open

SAFETY INFORMATION
1-4
1
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.
● If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediate-
ly. If any gasoline spills on your
skin or clothing, immediately wash
the affected area with soap and
water and change your clothes.

SAFETY INFORMATION
1-6
1
EAU10381
Location of important labels
Please read the following important labels carefully before operating this vehicle.
1234

SAFETY INFORMATION
1-7
1
WARNING
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
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
WARNING
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
13
24
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-A1
WARNING

2-1
1
2
3
4
5
6
7
8
9
DESCRIPTION
EAU10410
Left view
1345
6
78
2
1. Headlight (page 6-29)
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 6-11)
6. Shock absorber assembly rebound damping force adjusting dial
(page 3-9)
7. Shift pedal (page 3-3)
8. Front fork damping adjusting screw (page 3-7)

DESCRIPTION
2-2
2
3
4
5
6
7
8
9
EAU10420
Right view
12345
67
8
1. Spark arrester (page 6-13)
2. Battery (page 6-27)
3. Fuse (page 6-28)
4. Shock absorber assembly compression damping force adjusting
knob (page 3-9)
5. Main switch (page 3-1)
6. Engine oil filter element (page 6-8)
7. Brake pedal (page 3-3)
8. Shock absorber assembly spring preload adjusting nut (page 3-9)

DESCRIPTION
2-3
1
2
3
4
5
6
7
8
9
EAU10430
Controls and instruments
1234
5
6
7
1. Clutch lever (page 3-2)
2. Left handlebar switch (page 3-1)
3. Tripmeter (page 3-1)
4. Right handlebar switches (page 3-1)
5. Brake lever (page 3-3)
6. Throttle grip (page 6-14)
7. Fuel tank cap (page 3-4)

3-1
2
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU10450
Main switch
The main switch controls the ignition
and lighting systems. The various main
switch positions are described below.
EAU10630
ON
All electrical systems are supplied with
power, and the engine can be started.
The key cannot be removed.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU11830
Tripmeter
The tripmeter shows the distance trav-
eled since it was last set to zero with the
reset knob. The tripmeter can be used
to estimate the distance that can be
traveled with a full tank of fuel. This in-
formation will enable you to plan future
fuel stops.
EAU12343
Handlebar switches
Left
Right
OFF
ON
1. Tripmeter
2. Tripmeter reset knob
1
2
1. Light switch “”
1. Engine stop switch “/”
2. Start switch “START”
1
12

INSTRUMENT AND CONTROL FUNCTIONS
3-2
1
2
3
4
5
6
7
8
9
EAU12540
Light switch “”
Set this switch to “”to turn on the
headlight and the taillight.
CAUTION:
ECA10980
Always turn the key to “OFF”and
light switch to “OFF”when the en-
gine is not running, otherwise the
headlight will stay on and the battery
may discharge due to extended use.
EAU12660
Engine stop switch “/”
Set this switch to “”before starting
the engine. Set this switch to “”to
stop the engine in case of an emergen-
cy, such as when the vehicle overturns
or when the throttle cable is stuck.
EAU12690
Start switch “START”
Push this switch to crank the engine
with the starter.
CAUTION:
ECA10050
See page 5-1 for starting instruc-
tions prior to starting the engine.
EAU31640
Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the start-
ing circuit cut-off system. (See
page 3-11.)
1. Clutch lever
1

INSTRUMENT AND CONTROL FUNCTIONS
3-3
2
3
4
5
6
7
8
9
EAU12870
Shift pedal
The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 6-speed con-
stant-mesh transmission equipped on
this machine.
EAU12890
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
EAU12941
Brake pedal
The brake pedal is on the right side of
the machine. To apply the rear brake,
press down on the brake pedal.
1. Shift pedal
1
1. Brake lever
1
1. Brake pedal
1