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EAU00000 INTRODUCTION Congratulations on your purchase of the Yamaha TTR250. 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 made Yamaha a leader in these fields.
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.
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IMPORTANT MANUAL INFORMATION EW000000 PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MACHINE: RIDING TIPS” BOOK- LET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWL- EDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
EAU00009 TABLE OF CONTENTS SAFETY INFORMATION........1-1 Fuel cock............3-5 Safe riding............1-1 Starter (choke) knob “ ” ........3-6 Protective apparel ..........1-2 Seat ..............3-6 Modifications ............1-3 Adjusting the front fork ........3-7 Loading and accessories ........1-3 Adjusting the shock absorber assembly ....3-9 Gasoline and exhaust gas .........1-5 Ignition circuit cut-off system......3-12 Location of important labels .......1-7 PRE-OPERATION CHECKS .......4-1...
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TABLE OF CONTENTS Engine oil and oil filter element ......6-8 Checking the wheel bearings......6-27 Cleaning the air filter element ......6-11 Battery..............6-27 Cleaning the spark arrester......6-13 Replacing the fuse ...........6-29 Adjusting the carburetor........6-14 Replacing the headlight bulb ......6-30 Adjusting the throttle cable free play....6-14 Replacing the taillight bulb .......6-31 Adjusting the valve clearance ......6-14 Supporting the machine ........6-32...
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TABLE OF CONTENTS Off-road motorcycle limited warranty ....9-7 Yamaha extended service (Y.E.S.)....9-9...
EAU02912 SAFETY INFORMATION 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.
SAFETY INFORMATION 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.
SAFETY INFORMATION 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.
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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.
SAFETY INFORMATION 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.
SAFETY INFORMATION EAU02977 Location of important labels Please read the following important labels carefully before operating this machine.
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Cold tire normal pressure should be set as follows. Mishandling can cause explosion. FRONT : 100 kPa,{1.00 kgf/cm }, 15 psi Read owner's manual for instructions. REAR 100 kPa,{1.00 kgf/cm }, 15 psi Do not incinerate, puncture or open. 3RV-21668-A0 YAMAHA 4AA-22259-00...
EAU00027 INSTRUMENT AND CONTROL FUNCTIONS 1. Tripmeter 1. Light switch 2. Reset knob EAU00028 EAU00118 EAU01760 Main switch Handlebar switches Tripmeter The main switch controls the ignition The tripmeter shows the distance and lighting systems. The various EAU01865 traveled since it was last set to zero Light switch main switch positions are described with the reset knob.
INSTRUMENT AND CONTROL FUNCTIONS 1. Engine stop switch 1. Clutch lever 1. Shift pedal 2. Start switch “START” N. Neutral EAU00152 EAU00138 EAU00157 Clutch lever Shift pedal Engine stop switch The clutch lever is located at the left Set this switch to “$” to stop the The shift pedal is located on the left handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS 1. Brake lever 1. Brake pedal 1. Fuel tank cap a. Open. EAU00158 EAU00162 EAU00179 Brake lever Brake pedal Fuel tank cap The brake lever is located at the right The brake pedal is on the right side To remove the fuel tank cap, turn it handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS EAU00185 Your Yamaha engine has been designed to use regular unleaded Immediately wipe off spilled fuel gasoline with a pump octane number with a clean, dry, soft cloth, since [(R+M)/2] of 86 or higher, or a...
INSTRUMENT AND CONTROL FUNCTIONS OFF: closed position ON: normal position 1. Fuel tank breather hose 1. Arrow mark pointing to “OFF” 1. Arrow mark pointing to “ON” EAU02955 EAU03050 Fuel tank breather hose Fuel cock With the lever in this position, fuel Before operating the machine: The fuel cock supplies fuel from the flows to the carburetor.
INSTRUMENT AND CONTROL FUNCTIONS RES: reserve position 1. Starter (choke) knob “ ” 1. Bolt (×2) 1. Arrow mark pointing to “RES” EAU03032 EAU00240 Starter (choke) knob “ ” Seat This indicates reserve. If you run out Starting a cold engine requires a rich- To remove the seat of fuel while riding, move the lever to er air-fuel mixture, which is supplied...
NOTE: engine. bolts. An optional air pressure gauge is available at a Yamaha dealer. NOTE: NOTE: When checking and adjusting the air Make sure that the seat is properly pressure, there should be no weight 4.
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INSTRUMENT AND CONTROL FUNCTIONS Spring rate Minimum (soft): Air pressure = 0 kPa (0 kgf/cm , 0 psi) Standard: Air pressure = 0 kPa (0 kgf/cm , 0 psi) Maximum (hard): Air pressure = 40 kPa 1. Rubber cap 1. Compression damping adjusting screw (0.4 kgf/cm , 5.8 psi) Damping force...
INSTRUMENT AND CONTROL FUNCTIONS EC000015 EAU03676 Adjusting the shock absorber assembly Never attempt to turn an adjusting This shock absorber assembly is mechanism beyond the maximum equipped with spring preload or minimum settings. adjusting nut, a rebound damping force adjusting dial and a compres- 3.
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A special wrench is needed to Always tighten the locknut against make this adjustment and it can the adjusting nut, and then tighten be obtained at a Yamaha dealer. the locknut to the specified torque. The spring preload setting is determined by measuring dis- tance A, shown in the illustration.
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Standard 11 clicks in direction this will result in poor damp- Maximum (hard) 15 clicks in direction ing performance. * With the adjusting knob fully turned in direction Always have a Yamaha dealer service the shock absorber. 3-11...
3. Apply the front or rear brake. 4. Push the start switch. If the engine does not start, the clutch switch is OK. EW000045 If a malfunction is noted, have a Yamaha dealer check the system before riding. 3-12...
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4. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. 5. Turn the engine off. 6. Shift the transmission into gear. 7. Keep the clutch lever pulled.
• If necessary, add recommended oil to specified level. 6-8–6-11 • Check vehicle for oil leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check lever free play. Front brake • Adjust if necessary.
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• Make sure that operation is smooth. • Lubricate throttle grip, housing and cables if necessary. Throttle grip 6-14 • Check free play. • If necessary, have Yamaha dealer make adjustment. • Make sure that operation is smooth. Control cables 6-24 • Lubricate if necessary.
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PRE-OPERATION CHECKS ITEM CHECKS PAGE Engine stop switch • Check operation. NOTE: Pre-operation checks should be made each time the machine is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved. EWA00033 If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat- ing the machine.
EAU00372 OPERATION AND IMPORTANT RIDING POINTS EAU00374 EAU00376 EAU03600 Starting and warming up a cold engine This model is designed for off- Make sure not to store person- In order for the ignition circuit cut-off road only. most al items near the air cleaner system to enable starting, one of the instances, it is illegal to ride intake, otherwise air intake will...
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OPERATION AND IMPORTANT RIDING POINTS NOTE: NOTE: If the engine fails to start, release the The engine is warm when it responds start switch, wait a few seconds, and normally to the throttle with the starter then try again. Each starting attempt (choke) turned off.
OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 Starting a warm engine Follow the same procedure as for Even with the transmission in starting a cold engine with the excep- the neutral position, do not tion that the starter (choke) is not coast for long periods of time required when the engine is warm.
After every hour of operation, first 20 hours of riding. For this rea- immediately have a Yamaha dealer stop the engine, and then let it son, you should read the following check the vehicle.
OPERATION AND IMPORTANT RIDING POINTS EAU00457 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. EW000058 Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them.
If you do not have the tools or experi- maintenance work, have a Yamaha ence required for a particular job, dealer do it for you. have a Yamaha dealer perform it for you. EW000062 Modifications not approved by Yamaha may cause loss of perfor- mance, excessive emissions, and render the vehicle unsafe for use.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00473 Periodic maintenance and lubrication chart Initial EVERY 100 mi 600 mi 1,200 mi ITEM CHECKS AND MAINTENANCE JOBS (150 km) or (1,000 km) or (2,000 km) or 1 month 6 months 12 months Check fuel hoses for cracks or damage. √...
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PERIODIC MAINTENANCE AND MINOR REPAIR Initial EVERY 100 mi 600 mi 1,200 mi ITEM CHECKS AND MAINTENANCE JOBS (150 km) or (1,000 km) or (2,000 km) or 1 month 6 months 12 months Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 6-4.) √...
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23 * pivoting point Lubricate with molybdenum disulfide grease. *Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU03057 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cowling A 1. Panel B 1. Screw (×3) 2. Panel A EAU00484 Refer to this section each time the EAU03516 Cowling A Removing and installing the cowling or a panel needs to be To remove the cowling cowling and panels removed and installed.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw 1. Screw 1. Spark plug cap EAU00488 EAU00488 EAU01833 Checking the spark plug Panel A Panel B To remove the panel To remove the panel The spark plug is an important Remove the screw, and then pull the Remove the screw, and then pull the engine component, which is easy to panel off as shown.
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Instead, wrench included in the owner’s a wire thickness gauge and, if have a Yamaha dealer check the tool kit. necessary, adjust the gap to machine. specification. 2. Check the spark plug for elec- Spark plug gap: trode erosion and excessive car- 0.7–0.8 mm (0.03–0.03 in)
PERIODIC MAINTENANCE AND MINOR REPAIR EAU03670 3. Install the spark plug with the Engine oil and oil filter spark plug wrench, and then element tighten it to the specified torque. The engine oil level should be checked before each ride. In addition, Tightening torque: the oil must be changed and the oil Spark plug:...
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PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil filler bolt 1. Engine oil drain bolt 1. Oil filter element drain bolt 2. Oil filter element cover bolt (×2) To change the engine oil (with or Check the washer for damage and 3.
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PERIODIC MAINTENANCE AND MINOR REPAIR 12. Add the specified amount of the Tightening torque: recommended engine oil, and Oil filter element cover bolt: then install and tighten the oil 10 Nm filler bolt. (1.0 m kg, 7.2 ft lb) Recommended oil: 10.
If this occurs, have a procedures.) Yamaha dealer repair the vehi- 2. Remove the air filter case cover cle. by removing the holding clips. After checking the oil pres- sure, tighten the bleed bolt to the specified torque.
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PERIODIC MAINTENANCE AND MINOR REPAIR 7. Install the sponge material onto the frame, insert the air filter ele- ment into the air filter case, and then install the air filter case cover by installing the holding clips. EC000082 Make sure that the air filter ele- 1.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Bolt (×3) 1. Tailpipe 1. Purging bolt 2. Spark arrester EAU01761 4. Remove the purging bolt. Cleaning the spark arrester 2. Tap the tailpipe lightly, and then 5. Start the engine and rev it use a wire brush to remove any approximately twenty times while NOTE:...
To prevent to a Yamaha dealer, who has the this from occurring, the valve clear- necessary professional knowledge ance must be adjusted by a Yamaha and experience.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU03677 EW000077 Front Rear Tires 100 kPa 100 kPa To maximize the performance, dura- Off-road riding (1.00 kgf/cm (1.00 kgf/cm Because loading has an enormous 15.0 psi) 15.0 psi) bility, and safe operation of your impact on the handling, braking, motorcycle, note the following points performance and safety character-...
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Tread depth including the tires, should be After extensive tests, only the Tire inspection left to a Yamaha dealer, who tires listed below have been The tires must be checked before has the necessary profession- approved for this model by each ride.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00685 EAU00691 Yamaha cannot be held liable for Spoke wheels Accessories and any consequences caused by the replacement parts To maximize the performance, dura- use of items which have not been bility, and safe operation of your EW000098 approved by Yamaha.
PERIODIC MAINTENANCE AND MINOR REPAIR 3. If the specified clutch lever free play could obtained described above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows. 4. Fully turn the adjusting bolt in direction to loosen the clutch cable.
(0.39 in) below the top of the footrest ing performance, which may as shown. Periodically check the result in loss of control and an brake pedal position and, if neces- accident. sary, have a Yamaha dealer adjust it. 6-19...
Refill with the same type of brake REAR Changing the brake fluid fluid. Mixing fluids may result in a Have a Yamaha dealer change the harmful chemical reaction and brake fluid at the intervals specified in lead to poor braking perfor- the periodic maintenance and lubrica- mance.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00744 Drive chain slack The drive chain slack should be checked before each ride and adjust- ed if necessary. To check the drive chain slack 1. Place the machine on a level surface and hold it in an upright position.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU03006 NOTE: Lubricating the drive chain Make sure that both adjusting plates The drive chain must be cleaned and are in the same position for proper lubricated at the intervals specified in wheel alignment. the periodic maintenance and lubrica- tion chart, otherwise it will quickly EC000096 wear out, especially when riding in...
Recommended lubricant: Recommended lubricant: EW000113 Lithium-soap-based grease Lithium-soap-based grease (all-purpose grease) (all-purpose grease) If the sidestand does not move up down smoothly, have Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6-25...
If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 1. Battery EAU00800 2.
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To charge the battery severe burns. Avoid any con- place. Have a Yamaha dealer charge the tact with skin, eyes or clothing 2. If the battery will be stored for battery as soon as possible if it...
EAU01307 the battery. If you do not have 4. If the fuse immediately blows Replacing the fuse access to a sealed-type (MF) again, have a Yamaha dealer The fuse holder is located behind battery charger, have check the electrical system.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Coupler 1. Bulb holder cover 1. Bulb holder EAU01855 3. Remove the headlight bulb hold- Replacing the headlight bulb er by turning it counterclockwise, This machine is equipped with a and then remove the defective quartz bulb headlight.
PERIODIC MAINTENANCE AND MINOR REPAIR 6. Install the cowling together with the headlight unit. 7. Have a Yamaha dealer adjust the headlight beam if necessary. a. Do not touch this area. 1. Screw (×2) 2. Lens EC000105 EAU03604 Replacing the taillight bulb Do not touch the glass part of the 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 To service the rear wheel Supporting the machine Raise the rear wheel off the ground Since this model is not equipped with by using a machine stand or, if a a centerstand, follow these precau- machine stand is not available, by tions when removing the front and placing a jack either under each side...
EW000122 2. Lift the wheel up between the It is advisable to have a fork legs. Yamaha dealer service the wheel. Securely support the machine so that there is no danger of it falling over.
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PERIODIC MAINTENANCE AND MINOR REPAIR 6. After tighten the axle holder nuts, while applying the front brake, push down on the handlebars several times to check if the front frok compress and rebounds smoothly. 7. Connect the tripmeter cable. 1. Retainer 1.
The drive chain does not need to be It is advisable to have a disassembled in order to remove and Yamaha dealer service the install the wheel. wheel. Securely support the machine 5. Remove the wheel.
Use only genuine Yamaha replace- fied torque, and then install the ment parts. Imitation parts may look cotter pin. like Yamaha parts, but they are often inferior, have a shorter service life Tightening torque: and can lead to expensive repair Axle nut: bills.
2. Compression There is compression. Go to ignition check. Use the electric starter. No compression. Ask a Yamaha dealer to inspect. 3. Ignition Wipe clean with dry cloth and Open the throttle half-way and start Wet. Remove spark correct spark gap or replace plug.
EAU03521 MACHINE CARE AND STORAGE Care Before cleaning Cleaning 1. Cover the muffler outlet with a ECA00010 While the open design of a machine plastic bag after the engine has reveals the attractiveness of the tech- Avoid using strong acidic cooled down.
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MACHINE CARE AND STORAGE Do not use any harsh chemical motorcycles equipped After riding in the rain, near the sea products on plastic parts. Be with a windshield: Do not use or on salt-sprayed roads sure to avoid using cloths or strong cleaners hard...
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Before operating the machine NOTE: 4. To prevent corrosion, it is recom- test its braking performance Consult a Yamaha dealer for advice mended to apply a corrosion pro- and cornering behavior. tection spray on all metal, includ- on what products to use.
MACHINE CARE AND STORAGE Storage Long-term c. Install the spark plug cap onto Before storing your machine for sev- Short-term the spark plug, and then place eral months: Always store your machine in a cool, the spark plug on the cylinder 1.
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MACHINE CARE AND STORAGE 6. Lubricate all control cables and 9. Remove the battery and fully the pivoting points of all levers charge it. Store it in a cool, dry and pedals as well as of the place and charge it once a sidestand/centerstand.
EAU01038 SPECIFICATIONS Specifications Engine oil Model TTR250N(C) Type 0° 10° 30° 50° 70° 90° 110° 130°F Dimensions Overall length 2,095 mm (82.5 in) YAMALUBE 4 (10W30) Overall width 835 mm (32.9 in) or SAE 10W30 Overall height 1,260 mm (49.6 in) Seat height 915 mm (36 in) YAMALUBE 4 (20W40)
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SPECIFICATIONS Air filter Wet type element Gear ratio 2.467 Fuel 1.813 Type UNLEADED FUEL 1.364 RECOMMENDED 1.080 Fuel tank capacity 10 L (2.2 Imp gal, 2.64 US gal) 0.889 Reserve amount 2 L (0.44 Imp gal, 0.53 US gal) 0.759 Carburetor Chassis Manufacturer...
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SPECIFICATIONS Maximum load* 90 kg (198 lb) Suspension * Load is total weight of rider, cargo and accessories. Front Tire air pressure (measured on cold tires) Type Telescopic fork Front 100 kPa (1.00 kgf/cm , 15.0 psi) Rear Rear 100 kPa (1.00 kgf/cm , 15.0 psi) Type Swingarm (link suspension)
Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION 1. Key identification number 1.
The model label is affixed to the frame under the seat. (See page 3-6 for seat removal and installation pro- cedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
CONSUMER INFORMATION EAU01053 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any per- son.
CONSUMER INFORMATION EAU02932 Maintenance record Have a Yamaha dealer complete this record when the motorcycle is serviced. Maintenance Date of Servicing dealer Mileage Remarks interval service name and address...
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CONSUMER INFORMATION Maintenance Date of Servicing dealer Mileage Remarks interval service name and address...
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PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual. YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2000·7–0.7×1(E)