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Yamaha TTR 250 1999-2006 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: TTR 250 Model Variants: Off-road/Dual-sport Generation Production Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Codes Engine Code: Likely 4ES (for 4-valve, 250cc SOHC, 4-stroke) Vin Code Year Representation: Varies by year (e.g., X for 1999, Y for 2000, 1 for 2001... 6 for 2006) 👋 Introduction Market Position Segment: Lightweight dual-sport/enduro motorcycle Target Audience: Trail riders, recreational off-road enthusiasts, commuters seeking versatile transport Competitive Analysis Key Competitors: Honda CRF230F, Kawasaki KLR250, Suzuki DR-Z250, older KTM 200/250 models Key Features Features Highlighted: Durable engine, capable suspension, user-friendly operation, reliability Manual Value Proposition Cost Effectiveness: Inexpensive way to maintain and repair the vehicle Information Source: Number one source for repair and service information 📋 Manual Details Coverage Areas Covered Years: 1999-2006 Geographic Coverage: Likely global, depending on original market release Page Count Estimated Page Count: High (typical for comprehensive workshop manuals, likely 300-500+ pages) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine Mechanical: Yes (Top end, bottom end, valve train, cooling, lubrication) Engine Electrical: Yes (Ignition, charging, starting, CDI, sensors) Emission Control: Yes (If applicable to the model years/regions) Fuel System: Yes (Carburetor tuning, fuel lines, pump if applicable) Suspension System: Yes (Front forks, rear shock absorber, linkages) Clutch System: Yes (Clutch operation, plates, actuation) Transmission System: Yes (Manual transaxle, gear inspection, shifting mechanisms) Driveshaft Axle: Yes (Rear wheel drive components, sprockets, chain maintenance if applicable) Steering System: Yes (Handlebar, steering stem, bearings) Brake System: Yes (Front and rear brakes, hydraulic lines, calipers, master cylinders, pads) Body Interior Exterior: Yes (Body panels, seat, fenders, plastics) Body Electrical System: Yes (Lighting, instrumentation, wiring harnesses) Restraint System: Yes (Likely refers to rider safety features or specific tie-downs if applicable) Procedures Included Preventive Maintenance: Yes (Oil changes, filter replacements, chain adjustment, lubrication) Troubleshooting: Yes (Diagnostic procedures for various systems) Repair Procedures: Yes (Step-by-step instructions for component disassembly, repair, and reassembly) Electrical Diagnostics: Yes (Utilizing wiring diagrams for fault finding) Component Overhaul: Yes (Engine rebuilds, carburetor overhauls, suspension rebuilds) Technical Depth Depth: Comprehensive (Suitable for both DIYers and experienced mechanics, covers detailed repair and diagnostics) Diagnostic Tools: Implied use of standard motorcycle tools and possibly basic electrical testing equipment 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Fully Printable Zoom Functionality: Yes (Zoom IN/OUT) Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Software Requirements PDF Reader: Adobe PDF Reader Unzipping Tool: WinZip (or similar) Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 4-valve, Air-cooled Displacement: 249cc (249 cm³) Bore X Stroke: 73.0 mm x 59.6 mm (typical for this engine family) Performance Horsepower Estimate: Approximately 20-23 HP (at the crank, dependent on specific tuning and region) Torque Estimate: Approximately 19-21 Nm (14-15 lb-ft) Fuel System Carburetor: Mikuni VM33 (typical for this model, may vary) Fuel Capacity: Likely around 10-12 Liters (2.6-3.2 Gallons) Ignition Ignition Type: CDI (Capacitor Discharge Ignition) Lubrication Oil Type Recommendation: Yamalube 4 (or equivalent API SE, SF, SG, SH, SJ, or higher quality SAE 10W-40 or 20W-50 motorcycle oil) Oil Capacity With Filter Change: Approximately 1.5-1.8 Liters (1.6-1.9 US qt) 🔧 Transmission Standard Transmission Type: Constant-mesh 6-speed sequential Optional Transmission Options: N/A (Only manual transmission offered) Features Clutch Type: Wet, multiple-disc, cable-actuated Final Drive: Chain drive 📐 Dimensions Exterior Overall Length: Approx. 2150 mm (84.6 in) Overall Width: Approx. 830 mm (32.7 in) Overall Height: Approx. 1205 mm (47.4 in) Seat Height: Approx. 875 mm (34.4 in) Wheelbase: Approx. 1405 mm (55.3 in) Weights Dry Weight: Approx. 120 kg (265 lbs) Wet Weight: Approx. 127 kg (280 lbs) Suspension Travel Front Suspension Travel: Approx. 270 mm (10.6 in) Rear Suspension Travel: Approx. 270 mm (10.6 in) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety ratings are typically not standardized like automotive) Active Features Active Safety: Effective disc brakes (front and rear), responsive handling Passive Features Passive Safety: Sturdy frame construction, durable bodywork Lighting Headlight Type: Halogen 💡 Technology Features Infotainment Infotainment System: N/A (Basic motorcycle instrumentation) Driver Assistance Driver Assistance Features: N/A Connectivity Connectivity Features: N/A Instrumentation Instrument Cluster: Analog speedometer, odometer, trip meter, engine temperature warning light, neutral indicator, turn signal indicators, high beam indicator 🔧 Maintenance Service Intervals Engine Oil Change: Every 3,000 km (1,860 miles) or 6 months Oil Filter Replacement: Every 3,000 km (1,860 miles) or annually, coinciding with oil changes Air Filter Cleaning: Every 1,000 km (620 miles) or more frequently in dusty conditions Spark Plug Inspection: Every 3,000 km (1,860 miles) Valve Clearance Check: Every 6,000 km (3,730 miles) or 12 months Chain Lubrication: Every 500 km (310 miles) or after washing/riding in wet conditions Fluid Specifications Brake Fluid: DOT 3 or DOT 4 Coolant Type:...
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Yamaha TTR 250 1999-2006 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TTR 250
Model Variants:
Off-road/Dual-sport
Generation
Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Codes
Engine Code:
Likely 4ES (for 4-valve, 250cc SOHC, 4-stroke)
Vin Code Year Representation:
Varies by year (e.g., X for 1999, Y for 2000, 1 for 2001... 6 for 2006)
👋 Introduction
Market Position
Segment:
Lightweight dual-sport/enduro motorcycle
Target Audience:
Trail riders, recreational off-road enthusiasts, commuters seeking versatile transport
Competitive Analysis
Key Competitors:
Honda CRF230F, Kawasaki KLR250, Suzuki DR-Z250, older KTM 200/250 models
Key Features
Features Highlighted:
Durable engine, capable suspension, user-friendly operation, reliability
Manual Value Proposition
Cost Effectiveness:
Inexpensive way to maintain and repair the vehicle
Information Source:
Number one source for repair and service information
📋 Manual Details
Coverage Areas
Covered Years:
1999-2006
Geographic Coverage:
Likely global, depending on original market release
Page Count
Estimated Page Count:
High (typical for comprehensive workshop manuals, likely 300-500+ pages)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Yes (Top end, bottom end, valve train, cooling, lubrication)
Engine Electrical:
Yes (Ignition, charging, starting, CDI, sensors)
Emission Control:
Yes (If applicable to the model years/regions)
Fuel System:
Yes (Carburetor tuning, fuel lines, pump if applicable)
Suspension System:
Yes (Front forks, rear shock absorber, linkages)
Clutch System:
Yes (Clutch operation, plates, actuation)
Transmission System:
Yes (Manual transaxle, gear inspection, shifting mechanisms)
Driveshaft Axle:
Yes (Rear wheel drive components, sprockets, chain maintenance if applicable)
Steering System:
Yes (Handlebar, steering stem, bearings)
Brake System:
Yes (Front and rear brakes, hydraulic lines, calipers, master cylinders, pads)
Body Interior Exterior:
Yes (Body panels, seat, fenders, plastics)
Body Electrical System:
Yes (Lighting, instrumentation, wiring harnesses)
Restraint System:
Yes (Likely refers to rider safety features or specific tie-downs if applicable)
Procedures Included
Preventive Maintenance:
Yes (Oil changes, filter replacements, chain adjustment, lubrication)
Troubleshooting:
Yes (Diagnostic procedures for various systems)
Repair Procedures:
Yes (Step-by-step instructions for component disassembly, repair, and reassembly)
Electrical Diagnostics:
Yes (Utilizing wiring diagrams for fault finding)
Component Overhaul:
Yes (Engine rebuilds, carburetor overhauls, suspension rebuilds)
Technical Depth
Depth:
Comprehensive (Suitable for both DIYers and experienced mechanics, covers detailed repair and diagnostics)
Diagnostic Tools:
Implied use of standard motorcycle tools and possibly basic electrical testing equipment
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printability:
Fully Printable
Zoom Functionality:
Yes (Zoom IN/OUT)
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Software Requirements
PDF Reader:
Adobe PDF Reader
Unzipping Tool:
WinZip (or similar)
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, 4-valve, Air-cooled
Displacement:
249cc (249 cm³)
Bore X Stroke:
73.0 mm x 59.6 mm (typical for this engine family)
Performance
Horsepower Estimate:
Approximately 20-23 HP (at the crank, dependent on specific tuning and region)
Torque Estimate:
Approximately 19-21 Nm (14-15 lb-ft)
Fuel System
Carburetor:
Mikuni VM33 (typical for this model, may vary)
Fuel Capacity:
Likely around 10-12 Liters (2.6-3.2 Gallons)
Ignition
Ignition Type:
CDI (Capacitor Discharge Ignition)
Lubrication
Oil Type Recommendation:
Yamalube 4 (or equivalent API SE, SF, SG, SH, SJ, or higher quality SAE 10W-40 or 20W-50 motorcycle oil)
Oil Capacity With Filter Change:
Approximately 1.5-1.8 Liters (1.6-1.9 US qt)
🔧 Transmission
Standard
Transmission Type:
Constant-mesh 6-speed sequential
Optional
Transmission Options:
N/A (Only manual transmission offered)
Features
Clutch Type:
Wet, multiple-disc, cable-actuated
Final Drive:
Chain drive
📐 Dimensions
Exterior
Overall Length:
Approx. 2150 mm (84.6 in)
Overall Width:
Approx. 830 mm (32.7 in)
Overall Height:
Approx. 1205 mm (47.4 in)
Seat Height:
Approx. 875 mm (34.4 in)
Wheelbase:
Approx. 1405 mm (55.3 in)
Weights
Dry Weight:
Approx. 120 kg (265 lbs)
Wet Weight:
Approx. 127 kg (280 lbs)
Suspension Travel
Front Suspension Travel:
Approx. 270 mm (10.6 in)
Rear Suspension Travel:
Approx. 270 mm (10.6 in)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety ratings are typically not standardized like automotive)
Active Features
Active Safety:
Effective disc brakes (front and rear), responsive handling
Passive Features
Passive Safety:
Sturdy frame construction, durable bodywork
Lighting
Headlight Type:
Halogen
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic motorcycle instrumentation)
Driver Assistance
Driver Assistance Features:
N/A
Connectivity
Connectivity Features:
N/A
Instrumentation
Instrument Cluster:
Analog speedometer, odometer, trip meter, engine temperature warning light, neutral indicator, turn signal indicators, high beam indicator
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000 km (1,860 miles) or 6 months
Oil Filter Replacement:
Every 3,000 km (1,860 miles) or annually, coinciding with oil changes
Air Filter Cleaning:
Every 1,000 km (620 miles) or more frequently in dusty conditions
Spark Plug Inspection:
Every 3,000 km (1,860 miles)
Valve Clearance Check:
Every 6,000 km (3,730 miles) or 12 months
Chain Lubrication:
Every 500 km (310 miles) or after washing/riding in wet conditions
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4
Coolant Type:
Pre-mixed, ethylene glycol-based antifreeze (e.g., Yamalube Coolant)
Known Issues
Common Wear Items:
Clutch plates, brake pads, fork seals, chain and sprockets, carburetor jets (especially from ethanol exposure)
Carburetor Idling:
Some owners report occasional rough idling or jetting issues, often resolved with cleaning or adjustment.
Suspension Softness:
While good for its class, some aggressive riders may find the stock suspension a bit soft for hard off-road use.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Yamaha has a long and successful history in motorcycle manufacturing, known for innovation and performance in off-road and street bikes.
Model Evolution
Ttr Series Introduction:
The TTR line was Yamaha's answer to the growing demand for reliable, user-friendly off-road and dual-sport machines.
Ttr 250 Development:
The TTR 250 was designed to be a versatile machine capable of handling trails, fire roads, and even some street use. It aimed for a balance of performance and ease of use.
Production
Manufacturing Location:
Likely Japan or other Yamaha manufacturing facilities
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