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1999-2006 Yamaha TTR250 2000 2001 2002 2003 2004 2005 Service Repair Factory Manual

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🏷️ Basic Information Identification Make: Yamaha Model: TTR250 Model Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Specific Model Codes: TT-R250L/LC (1999), TT-R250M/MC (2000), TT-R250N/NC (2001), TT-R250P/PC (2002), TT-R250R/RC (2003), TT-R250S/SC (2004), TT-R250T/TC (2005), TT-R250V/VC (2006) Vehicle Type: Dual-Sport Motorcycle 👋 Introduction Market Position Vehicle Purpose: A versatile dual-sport motorcycle designed for off-road capability and on-road legality, often used for trail riding, light commuting, and adventure touring. Competitive Analysis Competitive Segment: Competed against other lightweight dual-sport motorcycles from brands like Honda (e.g., XR250L), Kawasaki (e.g., KLR250), and Suzuki (e.g., DR250). Key Features Key Selling Points: Reliability, manageable power, durable construction, suitability for both trail and street use, ease of maintenance. Manual Value Proposition Target Audience: DIY enthusiasts, home mechanics, and professional technicians seeking to maintain, repair, or restore their Yamaha TTR250. Cost Saving Benefit: Enables owners to perform their own maintenance and repairs, saving money on labor costs. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive service, repair, and maintenance Page Count Estimated Page Count: Variable (Digital Download, can be large, up to 5GB) Manual Type Manual Type: Service Repair Factory Manual / Workshop Manual / Repair Guide Language Language: English Format Digital Format: PDF (Downloadable, may be zipped/RAR) 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, tuning, fuel system (carburetor), lubrication, cooling system, ignition system, exhaust system Drivetrain Systems: Transmission, clutch, final drive (chain/sprockets) Chassis Systems: Frame, suspension (front forks, rear shock), steering, wheels, tires, brakes (front and rear) Electrical Systems: Wiring diagrams, lighting, battery, starter motor, charging system, instrumentation Bodywork And Fittings: Body panels, seating, fuel tank, fenders, fairings (if applicable) Procedures Included Maintenance Procedures: Periodic checks and adjustments, lubrication, filter changes, chain maintenance, tire pressure, brake adjustments Repair Procedures: Step-by-step instructions for component disassembly, inspection, repair, and reassembly Troubleshooting Procedures: Diagnostic guides, identification of common problems and their solutions Rebuild Procedures: Detailed instructions for engine, transmission, and suspension component rebuilding Technical Depth Diagnostic Capabilities: Advanced diagnostics, fault finding, and component testing Specifications Detail: Precise technical specifications, torque values, clearances, and tolerances Illustrations And Diagrams: Illustrated with clear step-by-step instructions, zoomable illustrations, exploded views, detailed component breakdowns 📊 Manual Specifications File Format File Compatibility: Compatible with all operating systems (Windows, Linux, Mac) via PDF reader File Protection: No printing or saving restrictions Print Quality Digital Quality: High-resolution digital format suitable for viewing on various devices Binding Type Delivery Method: Instant Digital Download (No physical copy, CD, or DVD) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, air-cooled single-cylinder Displacement: 249 cc (approx.) Performance Bore X Stroke: Typically around 73.0 mm x 59.6 mm (verify specific year) Compression Ratio: Typically around 9.5:1 or 10.5:1 (verify specific year) Horsepower: Approx. 22-24 HP (at crank, vary by year/tuning) Torque: Approx. 15-17 lb-ft (at crank, vary by year/tuning) Fuel System Carburetor: Mikuni VM33 (or similar 33mm constant velocity carburetor) Fuel Type: Unleaded gasoline Lubrication System Oil Capacity: Approximately 1.6-1.8 Liters (check manual for exact specification and oil type) Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Transmission Type: Constant mesh 6-speed sequential Features Clutch Type: Wet, multiple disc, cable-actuated Final Drive: Chain drive Fluid Type Transmission Oil Specification: Yamalube 4 (or equivalent API SG, SAE 10W-40 or 20W-40) 📐 Dimensions Exterior Length: Approx. 85.2 inches (2165 mm) Width: Approx. 32.3 inches (820 mm) Height: Approx. 47.4 inches (1205 mm) Weights Dry Weight: Approx. 262 lbs (119 kg) Wet Weight: Approx. 284 lbs (129 kg) Fuel Capacity: Approx. 3.17 US gallons (12 Liters) Suspension Travel Front Suspension Travel: Approx. 10.4 inches (265 mm) Rear Suspension Travel: Approx. 10.0 inches (255 mm) 🛡️ Safety Features Ratings Safety Features: N/A (Motorcycle safety is primarily based on rider skill and adherence to traffic laws; specific ratings are not applicable like in cars). Active Features Braking System: Disc brakes front and rear Lighting: Headlight, tail light, brake light, turn signals Passive Features Frame Construction: Steel semi-double cradle frame 💡 Technology Features Infotainment Infotainment System: N/A (Basic motorcycle instrumentation: speedometer, odometer, trip meter, indicator lights) Driver Assistance Rider Aids: N/A (No electronic rider aids like ABS or traction control on this model) 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-4,000 km or 6 months, whichever comes first (refer to manual for precise interval). Air Filter Cleaning: Regular cleaning recommended, especially after off-road use (e.g., every 1,000-2,000 km or as needed). Chain Lubrication Adjustment: Lubricate every 500-1,000 km, adjust tension as needed (refer to manual for correct slack). Fluid Specifications Engine Oil Specification: API SG, JASO MA certified 4-stroke motorcycle oil. Viscosity: SAE 10W-40 or 20W-40 (check manual for specific recommendations based on climate). Brake Fluid Specification: DOT 3 or DOT 4 hydraulic brake fluid Coolant Specification: N/A (Air-cooled engine) Known Issues Common Wear Items: Clutch wear, chain and sprockets, brake pads, wheel bearings, fork seals. Carburetor Tuning: Carburetor...
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1999-2006 Yamaha TTR250 2000 2001 2002 2003 2004 2005 Service Repair Factory Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TTR250
Model Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Specific Model Codes:
TT-R250L/LC (1999), TT-R250M/MC (2000), TT-R250N/NC (2001), TT-R250P/PC (2002), TT-R250R/RC (2003), TT-R250S/SC (2004), TT-R250T/TC (2005), TT-R250V/VC (2006)
Vehicle Type:
Dual-Sport Motorcycle
👋 Introduction
Market Position
Vehicle Purpose:
A versatile dual-sport motorcycle designed for off-road capability and on-road legality, often used for trail riding, light commuting, and adventure touring.
Competitive Analysis
Competitive Segment:
Competed against other lightweight dual-sport motorcycles from brands like Honda (e.g., XR250L), Kawasaki (e.g., KLR250), and Suzuki (e.g., DR250).
Key Features
Key Selling Points:
Reliability, manageable power, durable construction, suitability for both trail and street use, ease of maintenance.
Manual Value Proposition
Target Audience:
DIY enthusiasts, home mechanics, and professional technicians seeking to maintain, repair, or restore their Yamaha TTR250.
Cost Saving Benefit:
Enables owners to perform their own maintenance and repairs, saving money on labor costs.
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Comprehensive service, repair, and maintenance
Page Count
Estimated Page Count:
Variable (Digital Download, can be large, up to 5GB)
Manual Type
Manual Type:
Service Repair Factory Manual / Workshop Manual / Repair Guide
Language
Language:
English
Format
Digital Format:
PDF (Downloadable, may be zipped/RAR)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, tuning, fuel system (carburetor), lubrication, cooling system, ignition system, exhaust system
Drivetrain Systems:
Transmission, clutch, final drive (chain/sprockets)
Chassis Systems:
Frame, suspension (front forks, rear shock), steering, wheels, tires, brakes (front and rear)
Electrical Systems:
Wiring diagrams, lighting, battery, starter motor, charging system, instrumentation
Bodywork And Fittings:
Body panels, seating, fuel tank, fenders, fairings (if applicable)
Procedures Included
Maintenance Procedures:
Periodic checks and adjustments, lubrication, filter changes, chain maintenance, tire pressure, brake adjustments
Repair Procedures:
Step-by-step instructions for component disassembly, inspection, repair, and reassembly
Troubleshooting Procedures:
Diagnostic guides, identification of common problems and their solutions
Rebuild Procedures:
Detailed instructions for engine, transmission, and suspension component rebuilding
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics, fault finding, and component testing
Specifications Detail:
Precise technical specifications, torque values, clearances, and tolerances
Illustrations And Diagrams:
Illustrated with clear step-by-step instructions, zoomable illustrations, exploded views, detailed component breakdowns
📊 Manual Specifications
File Format
File Compatibility:
Compatible with all operating systems (Windows, Linux, Mac) via PDF reader
File Protection:
No printing or saving restrictions
Print Quality
Digital Quality:
High-resolution digital format suitable for viewing on various devices
Binding Type
Delivery Method:
Instant Digital Download (No physical copy, CD, or DVD)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, SOHC, air-cooled single-cylinder
Displacement:
249 cc (approx.)
Performance
Bore X Stroke:
Typically around 73.0 mm x 59.6 mm (verify specific year)
Compression Ratio:
Typically around 9.5:1 or 10.5:1 (verify specific year)
Horsepower:
Approx. 22-24 HP (at crank, vary by year/tuning)
Torque:
Approx. 15-17 lb-ft (at crank, vary by year/tuning)
Fuel System
Carburetor:
Mikuni VM33 (or similar 33mm constant velocity carburetor)
Fuel Type:
Unleaded gasoline
Lubrication System
Oil Capacity:
Approximately 1.6-1.8 Liters (check manual for exact specification and oil type)
Ignition System
Ignition Type:
CDI (Capacitor Discharge Ignition)
🔧 Transmission
Standard
Transmission Type:
Constant mesh 6-speed sequential
Features
Clutch Type:
Wet, multiple disc, cable-actuated
Final Drive:
Chain drive
Fluid Type
Transmission Oil Specification:
Yamalube 4 (or equivalent API SG, SAE 10W-40 or 20W-40)
📐 Dimensions
Exterior
Length:
Approx. 85.2 inches (2165 mm)
Width:
Approx. 32.3 inches (820 mm)
Height:
Approx. 47.4 inches (1205 mm)
Weights
Dry Weight:
Approx. 262 lbs (119 kg)
Wet Weight:
Approx. 284 lbs (129 kg)
Fuel Capacity:
Approx. 3.17 US gallons (12 Liters)
Suspension Travel
Front Suspension Travel:
Approx. 10.4 inches (265 mm)
Rear Suspension Travel:
Approx. 10.0 inches (255 mm)
🛡️ Safety Features
Ratings
Safety Features:
N/A (Motorcycle safety is primarily based on rider skill and adherence to traffic laws; specific ratings are not applicable like in cars).
Active Features
Braking System:
Disc brakes front and rear
Lighting:
Headlight, tail light, brake light, turn signals
Passive Features
Frame Construction:
Steel semi-double cradle frame
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic motorcycle instrumentation: speedometer, odometer, trip meter, indicator lights)
Driver Assistance
Rider Aids:
N/A (No electronic rider aids like ABS or traction control on this model)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-4,000 km or 6 months, whichever comes first (refer to manual for precise interval).
Air Filter Cleaning:
Regular cleaning recommended, especially after off-road use (e.g., every 1,000-2,000 km or as needed).
Chain Lubrication Adjustment:
Lubricate every 500-1,000 km, adjust tension as needed (refer to manual for correct slack).
Fluid Specifications
Engine Oil Specification:
API SG, JASO MA certified 4-stroke motorcycle oil. Viscosity: SAE 10W-40 or 20W-40 (check manual for specific recommendations based on climate).
Brake Fluid Specification:
DOT 3 or DOT 4 hydraulic brake fluid
Coolant Specification:
N/A (Air-cooled engine)
Known Issues
Common Wear Items:
Clutch wear, chain and sprockets, brake pads, wheel bearings, fork seals.
Carburetor Tuning:
Carburetor may require periodic cleaning and adjustment for optimal performance, especially after prolonged storage or changes in altitude.
Electrical Connections:
Corrosion or looseness in electrical connectors can lead to intermittent issues; regular inspection is advised.
📚 Vehicle History
Brand Heritage
Yamaha Motorcycles:
Yamaha Motor Company is a Japanese manufacturer of motorcycles, marine products, and other motorized products. Known for innovation and performance across various motorsports.
Model Evolution
Ttr Lineup:
The TTR series represents Yamaha's line of off-road and dual-sport motorcycles, emphasizing versatility and durability.
Production
Production Period:
The TTR250 was produced for an extended period, with this manual covering models from 1999 to 2006, indicating consistent popularity and minor updates.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
While specific awards for the TTR250 may not be widely documented, it was generally well-regarded for its reliability and capability as a dual-sport machine within its class during its production run.
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