Related Manuals for Yamaha TT-230RA
Summary of Contents for Yamaha TT-230RA
- Page 1 Read this manual carefully before operating this vehicle. TT-R230 LIT-11626-24-03 1C6-F8199-1...
- Page 2 EAU10042 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
- Page 3 Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.
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Page 4: Important Manual Information
IMPORTANT MANUAL INFORMATION EAU10132 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. - Page 5 IMPORTANT MANUAL INFORMATION EAUW0710 TT-R230A OWNER’S MANUAL ©2010 by Yamaha Motor da Amazônia Ltda. 1st edition, June 2010 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor da Amazônia Ltda. is expressly prohibited. Printed in Brazil.
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Page 6: Table Of Contents
TABLE OF CONTENTS LOCATION OF IMPORTANT FOR YOUR SAFETY – Spoke wheels ......7-17 LABELS ..........1-1 PRE-OPERATION CHECKS ..... 5-1 Adjusting the clutch lever free play ........... 7-18 SAFETY INFORMATION ....2-1 OPERATION AND IMPORTANT Checking the brake lever free RIDING POINTS......... 6-1 play ........... - Page 7 Troubleshooting chart ....7-33 MOTORCYCLE CARE AND STORAGE ..........8-1 Care ..........8-1 Storage ...........8-3 SPECIFICATIONS ......9-1 CONSUMER INFORMATION...10-1 Identification numbers ....10-1 Motorcycle noise regulation ..10-2 Maintenance record ......10-3 YAMAHA MOTOR CORPORATION, U.S.A. OFF-ROAD MOTORCYCLE LIMITED WARRANTY ....10-4 YAMAHA EXTENDED SERVICE (Y.E.S.) ........10-6...
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Page 8: Location Of Important Labels
Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. - Page 9 LOCATION OF IMPORTANT LABELS...
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Page 10: Safety Information
SAFETY INFORMATION EAU41465 Safe Riding yourself conspicuous appears to Perform the pre-operation checks each be very effective in reducing the time you use the vehicle to make sure it chance of this type of accident. Be a Responsible Owner is in safe operating condition. Failure to Therefore: As the vehicle’s owner, you are respon- inspect or maintain the vehicle properly... - Page 11 SAFETY INFORMATION Many accidents have been caused Protective Apparel Avoid Carbon Monoxide Poisoning by error of the motorcycle opera- The majority of fatalities from motorcy- All engine exhaust contains carbon tor. A typical error made by the op- cle accidents are the result of head in- monoxide, a deadly gas.
- Page 12 Yamaha accessories, which are avail- or others. Installing aftermarket prod- or front fork area, they must be able only from a Yamaha dealer, have ucts or having other modifications per- as lightweight as possible and been designed, tested, and approved formed to your vehicle that change any should be kept to a minimum.
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Page 13: Specifications
SAFETY INFORMATION electric failure could result, which Shift the transmission in gear (for could cause a dangerous loss of models with a manual transmis- lights or engine power. sion). Secure the motorcycle with tie- Aftermarket Tires and Rims downs or suitable straps that are The tires and rims that came with your attached to solid parts of the mo- motorcycle were designed to match the... -
Page 14: Description
DESCRIPTION EAU10410 Left view 1. Fuel cock (page 4-5) 2. Starter (choke) knob (page 4-6) 3. Air filter element (page 7-11) 4. Shift pedal (page 4-2) -
Page 15: Right View
DESCRIPTION EAU10420 Right view 1. Fuse (page 7-28) 2. Battery (page 7-27) 3. Shock absorber assembly spring preload adjusting nut (page 4-7) 4. Engine oil filter element (page 7-8) 5. Brake pedal (page 4-3) -
Page 16: Controls And Instruments
DESCRIPTION EAU10430 Controls and instruments 1. Clutch lever (page 4-2) 2. Engine stop switch (page 4-1) 3. Start switch (page 4-1) 4. Brake lever (page 4-2) 5. Throttle grip (page 7-15) 6. Fuel tank cap (page 4-3) -
Page 17: Instrument And Control Functions
INSTRUMENT AND CONTROL FUNCTIONS EAUW1880 EAU12348 EAU12670 Ignition switch Handlebar switches “ENGINE STOP” button Hold this button pushed until the engine Left stops in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck. EAU12711 Start switch “... -
Page 18: Clutch Lever
INSTRUMENT AND CONTROL FUNCTIONS EAU31640 EAU12870 EAU12890 Clutch lever Shift pedal Brake lever 1. Clutch lever 1. Shift pedal 1. Brake lever The clutch lever is located at the left The shift pedal is located on the left The brake lever is located at the right handlebar grip. -
Page 19: Brake Pedal
INSTRUMENT AND CONTROL FUNCTIONS EAU12941 EAU13182 EAU13212 Brake pedal Fuel tank cap Fuel Make sure there is sufficient gasoline in the tank. EWA10881 WARNING Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions. - Page 20 EWA15151 WARNING Your Yamaha engine has been de- Gasoline is poisonous and can signed to use regular unleaded gaso- cause injury or death. Handle gaso- line with a pump octane number line with care.
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Page 21: Fuel Tank Breather Hose
INSTRUMENT AND CONTROL FUNCTIONS EAU13412 EAU13561 Fuel tank breather hose Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it al- The fuel cock has three positions: 1. Arrow mark positioned over “ON” 1. Fuel tank breather hose With the lever in this position, fuel flows Before operating the motorcycle: to the carburetor. -
Page 22: Starter (Choke) Knob
INSTRUMENT AND CONTROL FUNCTIONS This indicates reserve. If you run out of EAU13600 EAU13960 Starter (choke) knob “ ” Seat fuel while riding, move the lever to this position. Fill the tank at the first oppor- To remove the seat tunity. -
Page 23: Adjusting The Shock Absorber Assembly
INSTRUMENT AND CONTROL FUNCTIONS EAU14816 load and thereby soften the sus- Adjusting the shock absorber pension, turn the adjusting nut in assembly direction (b). This shock absorber assembly is The spring preload setting is deter- equipped with a spring preload adjust- mined by measuring distance A, ing nut. -
Page 24: Sidestand
Do not dispose of a damaged or worn-out shock absorber as- [ECA10121] sembly yourself. Take the shock Tightening torque: absorber assembly to a Yamaha Locknut: dealer for any service. 70 Nm (7.0 m·kgf, 51 ft·lbf) EWA10221 WARNING 1. -
Page 25: Starting Circuit Cut-Off System
INSTRUMENT AND CONTROL FUNCTIONS EAUW0801 Starting circuit cut-off system The starting circuit cut-off system (com- prising the clutch switch and the neutral switch) prevents starting when the transmission is in gear and the clutch lever is not pulled. Periodically check the operation of the starting circuit cut-off system according to the following procedure. - Page 26 INSTRUMENT AND CONTROL FUNCTIONS 4-10...
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Page 27: For Your Safety - Pre-Operation Checks
• If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check lever free play. • Adjust if necessary. Front brake •... - Page 28 • Make sure that operation is smooth. • Check cable free play. Throttle grip 7-15, 7-24 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 7-24 •...
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Page 29: Operation And Important Riding Points
[ECA11041] understand, ask your Yamaha dealer. following conditions must be met: 7. When the engine is warm, turn the EWA10271 The transmission is in the neutral starter (choke) off. -
Page 30: Starting A Warm Engine
OPERATION AND IMPORTANT RIDING POINTS EAU16640 EAU16671 ECA10260 Starting a warm engine Shifting NOTICE Follow the same procedure as for start- Even with the transmission in ing a cold engine with the exception the neutral position, do not that the starter (choke) is not required coast for long periods of time when the engine is warm. -
Page 31: Engine Break-In
To allow the engine If any engine trouble should occur to cool down from the temporary build- during the engine break-in period, up of heat, cruise at a lower engine immediately have a Yamaha dealer speed. check the vehicle. -
Page 32: Periodic Maintenance And Adjustment
If use. To avoid possible burns, let you are not familiar with vehicle ser- brake components cool before vice, have a Yamaha dealer perform touching them. service. EWA15121 WARNING Turn off the engine when performing maintenance... -
Page 33: Periodic Maintenance Chart For The Emission Control System
From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. - Page 34 PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL ODOMETER READINGS 1000 km 3000 km 5000 km ITEM CHECKS AND MAINTENANCE JOBS (600 mi) or (1800 mi) or (3000 mi) or 1 month or 6 months or 12 months or 30 hours 90 hours 150 hours •...
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Page 35: General Maintenance And Lubrication Chart
From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. - Page 36 8 * Swingarm pivot bearings • Moderately repack with lithium-soap-based grease. • Check chain slack/alignment and condition. Drive chain • Adjust and lubricate chain with Yamaha chain and cable Every ride lube thoroughly. • Check bearing assemblies for looseness. √...
- Page 37 1 month or 6 months or 12 months or 30 hours 90 hours 150 hours • Apply Yamaha chain and cable lube or engine oil thor- √ √ √ 20 * Control cables oughly. • Check operation and free play.
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Page 38: Removing And Installing The Panel
Do not attempt to diagnose such problems yourself. Instead, have EAU19210 Panel A a Yamaha dealer check the vehicle. If the spark plug shows signs of elec- To remove the panel trode erosion and excessive carbon or Remove the screws, and then take the other deposits, it should be replaced. -
Page 39: Engine Oil And Oil Filter Element
PERIODIC MAINTENANCE AND ADJUSTMENT Before installing a spark plug, the spark EAUW0612 Engine oil and oil filter ele- plug gap should be measured with a If a torque wrench is not available when ment wire thickness gauge and, if necessary, installing a spark plug, a good estimate The engine oil level should be checked adjusted to specification. - Page 40 PERIODIC MAINTENANCE AND ADJUSTMENT 4. Remove the engine oil filler bolt and drain bolt to drain the oil from the crankcase. NOTICE: When removing the engine oil drain bolt, the O-ring, compression spring, and oil strainer will fall out. Take care not to lose these parts.
- Page 41 PERIODIC MAINTENANCE AND ADJUSTMENT 9. Clean the oil filter element with sol- 13. Refill with the specified amount of vent, and then install it. the recommended engine oil, and then install and tighten the engine oil filler bolt. Check the oil filter element for damage and replace it if necessary.
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Page 42: Cleaning The Air Filter Element
If this occurs, 1. Air filter case cover have a Yamaha dealer repair the 2. Screw vehicle. 2. Pull the air filter element out of the After checking the oil pressure, air filter case. - Page 43 NOTICE: To avoid dam- [EWAW0021] Recommended oil: aging the foam material, handle Yamaha foam air filter oil or other it gently and carefully, and do quality foam air filter oil not twist or wring it. [ECA10511] 7.
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Page 44: Cleaning The Spark Arrester
PERIODIC MAINTENANCE AND ADJUSTMENT in the air filter case. The engine EAU40421 1. Remove the tailpipe by removing Cleaning the spark arrester should never be operated with- the bolts, and then pulling it out of The spark arrester should be cleaned out the air filter element in- the muffler. -
Page 45: Adjusting The Carburetor
Therefore, most car- checked and, if necessary, adjusted as buretor adjustments should be left to a follows at the intervals specified in the Yamaha dealer, who has the neces- periodic maintenance and lubrication sary professional knowledge and expe- chart. -
Page 46: Checking The Throttle Cable Free Play
(b). resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. 1. Throttle cable free play 1. -
Page 47: Tires
PERIODIC MAINTENANCE AND ADJUSTMENT EAUW2201 glass fragments in it, or if the sidewall is Front: Tires cracked, have a Yamaha dealer re- 100 kPa (1.00 kgf/cm², 15 psi) To maximize the performance, durabil- place the tire immediately. Rear: ity, and safe operation of your motorcy- 100 kPa (1.00 kgf/cm², 15 psi) -
Page 48: Spoke Wheels
If any dam- tires decreases riding stability age is found, have a Yamaha and can lead to loss of control. dealer replace the wheel. Do not The replacement of all wheel-... -
Page 49: Adjusting The Clutch Lever Free Play
3. Locknut (clutch cable) brake lever end. If there is free play, 4. Adjusting nut adjusting nut in direction (a). To have a Yamaha dealer inspect the 5. Clutch lever free play decrease the clutch lever free play, brake system. -
Page 50: Adjusting The Brake Pedal Position And Free Play
Brake pedal free play 1. Brake pedal position 2. Brake pedal free play EWA10670 WARNING It is advisable to have a Yamaha dealer make these adjustments. Brake pedal position The top of the brake pedal should be 1. Adjusting bolt positioned approximately 3.0 mm (0.12... -
Page 51: Checking The Front Brake Pads And Rear Brake Shoes
Checking the front brake pads turn the adjusting nut at the brake rod in touches the brake disc, have a Yamaha and rear brake shoes direction (a). To decrease the brake dealer replace the brake pads as a set. -
Page 52: Checking The Front Brake Fluid Level
However, if the leakage and poor braking perfor- brake fluid level goes down sud- mance. denly, have a Yamaha dealer check the cause. Recommended brake fluid: DOT 4 1. Lower level Insufficient brake fluid may allow air to... -
Page 53: Changing The Brake Fluid
EAU22721 EAU22760 Changing the brake fluid Drive chain slack Have a Yamaha dealer change the The drive chain slack should be brake fluid at the intervals specified in checked before each ride and adjusted the TIP after the periodic maintenance if necessary. -
Page 54: Cleaning And Lubricating The Drive Chain
PERIODIC MAINTENANCE AND ADJUSTMENT of the motorcycle and can lead 5. Adjust the brake pedal free play. EAU23025 Cleaning and lubricating the to chain slippage or breakage. (See page 7-19.) drive chain To prevent this from occurring, The drive chain must be cleaned and keep the drive chain slack with- lubricated at the intervals specified in in the specified limits. -
Page 55: Checking And Lubricating The Cables
Yamaha dealer at the intervals speci- ed if necessary. If a cable is damaged fied in the periodic maintenance chart. -
Page 56: Checking And Lubricating The Brake Pedal
WARNING Recommended lubricants: Brake lever: If the sidestand does not move up Silicone grease and down smoothly, have a Yamaha Clutch lever: dealer check or repair it. Otherwise, Lithium-soap-based grease the sidestand could contact the ground and distract the operator, re- sulting in a possible loss of control. -
Page 57: Checking The Front Fork
WARNING! To avoid injury, of it falling over. have a Yamaha dealer check or re- [EWA10751] securely support the vehicle so 2. Hold the lower ends of the front pair it. -
Page 58: Checking The Wheel Bearings
If there is play in the wheel burns. Avoid any contact with hub or if the wheel does not turn skin, eyes or clothing and al- smoothly, have a Yamaha dealer check ways shield your eyes when the wheel bearings. working near batteries. In case of contact, administer the fol- lowing FIRST AID. -
Page 59: Replacing The Fuse
To charge the battery once a month and fully charge it if Have a Yamaha dealer charge the bat- necessary. tery as soon as possible if it seems to 3. Fully charge the battery before in- have discharged. -
Page 60: Supporting The Motorcycle
4. If the fuse immediately blows requiring the motorcycle to stand up- again, have a Yamaha dealer right. Check that the motorcycle is in a check the electrical system. stable and level position before starting any maintenance. -
Page 61: Front Wheel
PERIODIC MAINTENANCE AND ADJUSTMENT EAU24360 4. Pull the wheel axle out, and then 5. Push down hard on the handlebar Front wheel remove the wheel. NOTICE: Do several times to check for proper not apply the brake after the fork operation. EAUW0542 wheel has been removed to- To remove the front wheel... -
Page 62: Rear Wheel
PERIODIC MAINTENANCE AND ADJUSTMENT EAU25080 EAU25762 Rear wheel To install the rear wheel 1. Insert the wheel axle from the left- hand side. EAU25421 To remove the rear wheel EWA10821 WARNING Make sure that the drive chain adjust- ing plates are installed with the To avoid injury, securely support the punched sides facing to the outside vehicle so there is no danger of it... -
Page 63: Troubleshooting
(See page 7-19.) self. However, should your motorcycle EWA10660 require any repair, take it to a Yamaha WARNING dealer, whose skilled technicians have After adjusting the brake pedal free the necessary tools, experience, and... -
Page 64: Troubleshooting Chart
Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good. -
Page 65: Motorcycle Care And Storage
MOTORCYCLE CARE AND STORAGE EAU41356 ucts onto seals, gaskets, sprock- off any detergent residue using Care ets, the drive chain and wheel plenty of water, as it is harmful While the open design of a motorcycle axles. Always rinse the dirt and de- to plastic parts. - Page 66 MOTORCYCLE CARE AND STORAGE Test the product on a small hid- 2. Apply a corrosion protection spray EWA11131 WARNING den part of the windshield to on all metal, including chrome- and make sure that it does not leave nickel-plated, surfaces to prevent Contaminants on the brakes or tires any marks.
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Page 67: Storage
MOTORCYCLE CARE AND STORAGE EAU26152 2. For motorcycles equipped with a Storage fuel cock that has an “OFF” posi- Consult a Yamaha dealer for advice on tion: Turn the fuel cock lever to what products to use. Short-term “OFF”. Always store your motorcycle in a cool, 3. - Page 68 MOTORCYCLE CARE AND STORAGE WARNING! To prevent dam- cessively cold or warm place [less age or injury from sparking, than 0 °C (30 °F) or more than 30 make sure to ground the °C (90 °F)]. For more information spark plug electrodes while on storing the battery, see page turning the engine over.
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Page 69: Specifications
SPECIFICATIONS Dimensions: Engine oil: Clutch: Overall length: Recommended brand: Clutch type: 2065 mm (81.3 in) YAMALUBE Wet, multiple-disc Overall width: Type: Transmission: 800 mm (31.5 in) SAE 10W-30, 10W-40, 10W-50, 15W-40, Primary reduction system: Overall height: 20W-40 or 20W-50 Spur gear 1180 mm (46.5 in) Recommended engine oil grade: Primary reduction ratio:... - Page 70 SPECIFICATIONS Trail: Front brake: Voltage, capacity: 111.0 mm (4.37 in) 12 V, 4.0 Ah Type: Front tire: Fuse: Single disc brake Type: Operation: Fuse: With tube Right hand operation 10.0 A Size: Recommended fluid: 80/100-21 NHS DOT 4 Manufacturer/model: Rear brake: PIRELLI/MT320H Type: Rear tire:...
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Page 71: Consumer Information
Record the vehicle identification num- ber 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. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number 1. -
Page 72: Motorcycle Noise Regulation
CONSUMER INFORMATION EAU26560 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 ve- hicle 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 person. -
Page 73: Maintenance Record
CONSUMER INFORMATION EAU26651 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 10-3... -
Page 74: Yamaha Motor Corporation, U.s.a. Off-Road Motorcycle Limited Warranty
1. Operate and maintain the motorcycle as date limitations. Covered off-road motorcycles are specified in the appropriate Owner's Manual, those units certified by Yamaha to EPA noise reg- YAMAHA MOTOR CORPORATION, ulations and come equipped from the factory with MAKES NO OTHER WARRANTY OF ANY 2. - Page 75 CONSUMER INFORMATION 10-5...
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Page 76: Yamaha Extended Service (Y.e.s.)
This excellent Y.E.S. plan coverage is only available to dealer to see how comforting uninterrupted factory- Yamaha owners like you, and only while your Yamaha is still backed protection can be. within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. - Page 77 Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
- Page 78 INDEX Fuel cock ..........4-5 Starting and warming up a cold engine... 6-1 Fuel tank breather hose......4-5 Starting circuit cut-off system ....4-9 Air filter element, cleaning..... 7-11 Fuel tank cap .......... 4-3 Start switch..........4-1 Fuse, replacing ........7-28 Steering, checking.........7-26 Battery...........
- Page 80 YAMAHA MOTOR DA AMAZÔNIA LTDA. PRINTED IN BRAZIL 04,2010...