Yamaha TTR 250 1999-2005 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Yamaha Model: TTR 250 Model Year Range: 1999, 2000, 2001, 2002, 2003, 2004, 2005 Generation Generation Identifier: 2nd Generation (4-valve SOHC) Codes Chassis Code: Often referred to by engine type or specific sub-model, but generally associated with the 4-valve, air-cooled, single-cylinder design prevalent in this era. 👋 Introduction Market Position Category: Dual-Sport Motorcycle Target User: Off-road enthusiasts, trail riders, general recreational riders seeking robust maintenance capabilities. Competitive Analysis Competitors: Honda XR series, Kawasaki KLR series, Suzuki DR series of similar displacement and era. Key Features Distinctive Features: Renowned for its reliable air-cooled engine, robust chassis, and versatility for both trail riding and mild street use. Manual Advantage: Provides professional-level repair and maintenance guidance, empowering owners to perform extensive work, thus saving on dealership service costs. 📋 Manual Details Coverage Areas Primary Coverage: Full Service Repair and Maintenance Secondary Coverage: Diagnostics, Troubleshooting, Electrical Systems, Component Rebuilds Page Count Estimated Page Count: Detailed manuals of this nature for motorcycles of this complexity typically range from 300 to 600+ pages, depending on the level of detail for each section. Manual Type Type: Full Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine disassembly, assembly, inspection, repair, top-end components (cylinder head, valves, camshaft), bottom-end components (crankshaft, connecting rod, piston), lubrication system, cooling system (if applicable), fuel system (carburetor). Transmission: Clutch operation and adjustment, gearbox disassembly, assembly, inspection, gear selection mechanism, shift drum, transmission bearings. Chassis: Frame inspection and repair, suspension (front forks, rear shock absorber), swingarm, bearings, steering system, brakes (front and rear hydraulic systems, calipers, master cylinders, pads, rotors), wheels, tires. Electrical: Ignition system, charging system (stator, rectifier/regulator), starting system (starter motor, solenoid), lighting system (headlight, taillight, turn signals), wiring diagrams, component testing, fault diagnosis. Fuel System: Carburetor disassembly, cleaning, adjustment, jetting, fuel tank, fuel lines, petcock. Exhaust System: Exhaust pipe inspection, muffler, heat shields, gasket replacement. Procedures Included Maintenance: Routine checks, oil changes, filter replacement, chain adjustment, brake adjustments, valve clearance checks and adjustment, spark plug replacement. Repair: Detailed step-by-step instructions for component removal, installation, and overhaul for all major systems. Troubleshooting: Systematic diagnostic procedures for identifying and resolving common and uncommon problems, including electrical troubleshooting with wiring diagrams. Rebuilds: Complete engine and transmission rebuild procedures, including component specifications for wear limits and tolerances. Diagnostics: Procedures for diagnosing electrical faults, engine performance issues, and mechanical problems. Technical Depth Depth Level: Comprehensive (Professional Technician Level) Detail Level: Includes detailed sub-steps, notes, cautions, and warnings for critical information. Illustrations: Abundant detailed illustrations, drawings, and photos, with enlarged inset views for specific parts. 📊 Manual Specifications File Format Format: PDF Compatibility: All versions of Windows & Mac Print Quality Printability: Full Printable (All pages) Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinRAR ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, Air-Cooled, DOHC, 4-Valve Displacement: 249 cc (Cubic Centimeters) Bore X Stroke: Specifications vary slightly by specific model year but are typically around 73.0 mm x 59.5 mm. Compression Ratio: Around 10.5:1 (specifics may vary by sub-model). Performance Horsepower: Typically in the range of 20-25 HP, depending on tuning and specific year. Torque: Estimated torque figures would be in the range of 18-20 Nm (Newton-meters). Fuel System Carburetor Type: Single Mikuni carburetor (e.g., VM28 or similar). Fuel Type: Unleaded Gasoline 🔧 Transmission Standard Type: Constant-mesh, 6-speed Optional Optional Transmission: N/A (Standard 6-speed gearbox) Features Clutch Type: Wet, multi-disc 📐 Dimensions Exterior Length: Approx. 2,170 mm (85.4 in) Width: Approx. 840 mm (33.1 in) Height: Approx. 1,245 mm (49.0 in) Wheelbase: Approx. 1,435 mm (56.5 in) Weights Dry Weight: Approx. 119 kg (262 lbs) Wet Weight: Specifications not readily available, but typically higher than dry weight due to fluids. 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycles are not subjected to formal crash test ratings like cars). Active Features Braking System: Hydraulic disc brakes (front and rear). Suspension Stability: Telescopic front forks and Monocross rear suspension contribute to stability and control. Passive Features Lighting: Headlight, taillight, brake light, and optional turn signals (depending on market configuration) for visibility. 💡 Technology Features Infotainment Infotainment System: N/A (This is a performance-oriented dual-sport motorcycle, not equipped with infotainment features). Driver Assistance Assistance Features: N/A (No electronic driver assistance systems like ABS or traction control are featured on this model). Connectivity Connectivity Options: N/A (No connectivity features available). Instrumentation Dashboard Features: Analog speedometer, tachometer, odometer, trip meter, and indicator lights for neutral, high beam, and turn signals. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 2,000 - 3,000 km (1,200 - 1,800 miles) or as specified in the manual for optimal engine life. Valve Clearance Interval: Recommended every 6,000 - 8,000 km (3,700 - 5,000 miles), or annually,...
Often referred to by engine type or specific sub-model, but generally associated with the 4-valve, air-cooled, single-cylinder design prevalent in this era.
Detailed manuals of this nature for motorcycles of this complexity typically range from 300 to 600+ pages, depending on the level of detail for each section.
Detailed step-by-step instructions for component removal, installation, and overhaul for all major systems.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and uncommon problems, including electrical troubleshooting with wiring diagrams.
Rebuilds:
Complete engine and transmission rebuild procedures, including component specifications for wear limits and tolerances.
Diagnostics:
Procedures for diagnosing electrical faults, engine performance issues, and mechanical problems.
Technical Depth
Depth Level:
Comprehensive (Professional Technician Level)
Detail Level:
Includes detailed sub-steps, notes, cautions, and warnings for critical information.
Illustrations:
Abundant detailed illustrations, drawings, and photos, with enlarged inset views for specific parts.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
All versions of Windows & Mac
Print Quality
Printability:
Full Printable (All pages)
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader, WinRAR
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-Stroke, Air-Cooled, DOHC, 4-Valve
Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
Specifications vary slightly by specific model year but are typically around 73.0 mm x 59.5 mm.
Compression Ratio:
Around 10.5:1 (specifics may vary by sub-model).
Performance
Horsepower:
Typically in the range of 20-25 HP, depending on tuning and specific year.
Torque:
Estimated torque figures would be in the range of 18-20 Nm (Newton-meters).
Fuel System
Carburetor Type:
Single Mikuni carburetor (e.g., VM28 or similar).
Fuel Type:
Unleaded Gasoline
🔧 Transmission
Standard
Type:
Constant-mesh, 6-speed
Optional
Optional Transmission:
N/A (Standard 6-speed gearbox)
Features
Clutch Type:
Wet, multi-disc
📐 Dimensions
Exterior
Length:
Approx. 2,170 mm (85.4 in)
Width:
Approx. 840 mm (33.1 in)
Height:
Approx. 1,245 mm (49.0 in)
Wheelbase:
Approx. 1,435 mm (56.5 in)
Weights
Dry Weight:
Approx. 119 kg (262 lbs)
Wet Weight:
Specifications not readily available, but typically higher than dry weight due to fluids.
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles are not subjected to formal crash test ratings like cars).
Active Features
Braking System:
Hydraulic disc brakes (front and rear).
Suspension Stability:
Telescopic front forks and Monocross rear suspension contribute to stability and control.
Passive Features
Lighting:
Headlight, taillight, brake light, and optional turn signals (depending on market configuration) for visibility.
💡 Technology Features
Infotainment
Infotainment System:
N/A (This is a performance-oriented dual-sport motorcycle, not equipped with infotainment features).
Driver Assistance
Assistance Features:
N/A (No electronic driver assistance systems like ABS or traction control are featured on this model).
Connectivity
Connectivity Options:
N/A (No connectivity features available).
Instrumentation
Dashboard Features:
Analog speedometer, tachometer, odometer, trip meter, and indicator lights for neutral, high beam, and turn signals.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 2,000 - 3,000 km (1,200 - 1,800 miles) or as specified in the manual for optimal engine life.
Valve Clearance Interval:
Recommended every 6,000 - 8,000 km (3,700 - 5,000 miles), or annually, as valve seats can wear.
Chain Maintenance:
Regular cleaning and lubrication (every 500-1000 km or after off-road use), tension adjustment as needed.
Fluid Specifications
Engine Oil Type:
Yamalube 4 (or equivalent SAE 10W-40 API SG or higher) - specific viscosity may vary by climate.
Engine Oil Capacity:
Approximately 1.6 liters (1.7 US qt) with filter change, 1.4 liters (1.5 US qt) without filter change. Exact capacity should be confirmed in the manual.
Carburetor gumming from fuel degradation if left sitting, potential for wear in the transmission if not properly maintained, kickstart mechanism wear.
Preventative Maintenance
Key Practices:
Regular cleaning after off-road use to prevent corrosion and mud buildup, proper chain tensioning, timely fluid changes.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Yamaha has a long and successful history in motorcycle manufacturing, known for performance, innovation, and durability across various disciplines.
Model Evolution
Ttr Lineage:
The TTR series represents Yamaha's commitment to off-road performance, with the TTR 250 evolving from earlier models to offer a balance of power, handling, and reliability.
Production
Production Period:
The TTR 250 was produced for several years, with this manual specifically covering the 1999-2005 models, which represent a significant iteration of the platform.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Specific industry awards for this model are not widely documented, but it received praise for its reliability and capability in its class.
Ratings
Customer Reviews:
Generally positive reviews from owners highlighting its robustness, ease of maintenance, and versatility for trail riding.
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