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Yamaha TTR250 1999-2006 Factory Service Repair Manual

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Basic Information Identification Make: Yamaha Model: TTR250 Year: 1999-2006 Generation Generation Designation: First Generation (4GY/4RR) Codes Chassis Codes: 4GY (Early models), 4RR (Later models) Introduction Market Position Target Audience: Yamaha TTR250 owners, independent motorcycle repair shops, and DIY enthusiasts seeking genuine factory repair information. Competitive Analysis Source Authenticity: Actual Genuine Repair Service Factory Manuals, not third-party alternatives. Provides the same information used by professional technicians. Key Features Content Richness: Hundreds of pages with detailed illustrations, diagrams, and specifications for all repair and maintenance procedures. Usability: Easy to use, with numbered instructions, bold figure numbers, and an easy-to-use table of contents. No advanced computer skills required. Value Proposition Cost Savings: Enables owners to perform servicing themselves, potentially saving $50-$60 per hour in shop labor costs. Manual Details Coverage Areas Models Covered: Yamaha TTR250 (all styles) for model years 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Page Count Estimated Page Count: Hundreds of pages (exact count not specified, but described as 'complete') Manual Type Type: Official Factory Service Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Systems: Engine top end, Fuel system, Cooling system, Engine lubrication system Drivetrain Systems: Clutch, Crankshaft, Transmission, Final Drive Chassis Systems: Wheels/Tires, Brakes, Suspension, Steering, Frame Electrical Systems: Electrical System, Wiring Diagrams Procedures Included Maintenance Procedures: Routine maintenance, Scheduled servicing, Fluid checks and changes Diagnostic Procedures: Engine fault diagnosis, Troubleshooting common issues, Electrical system diagnosis Repair Procedures: Step-by-step repair instructions for all major components, Engine rebuilds, Transmission overhauls, Brake system repairs, Suspension servicing Assembly Disassembly: Engine Removal/Installation, Component disassembly and reassembly Technical Depth Depth: Comprehensive, covering fundamental maintenance to advanced repair and diagnostics. Equips users with factory-level knowledge. Manual Specifications File Format Format: PDF Print Quality Printability: Printable without restriction (entire manual or selected pages) Binding Type Binding: N/A (Digital Download - Printable) Paper Type Paper Type: N/A (Digital Download - User prints on desired paper) Software Requirements Reader Requirement: Adobe PDF Reader Searchability Text Search: Searchable text for quick information retrieval Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, Air-cooled, Forward-inclined single cylinder Displacement: 249 cc (Actual displacement may vary slightly by specific model revision within the 1999-2006 range) Bore X Stroke: 73.0 mm x 59.6 mm (Typical specification for this engine family) Compression Ratio: 9.5:1 (Typical specification) Performance Horsepower: Approximately 20-22 HP (Actual figures vary by market and specific tune) Torque: Approximately 19-20 Nm (Actual figures vary by market and specific tune) Fuel System Carburetor: Mikuni VM28 (Typical specification, may vary slightly by market or model year) Fuel Delivery: Carburetor Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) Transmission Standard Transmission Type: Constant mesh 6-speed sequential Features Clutch Type: Wet, multiple disc, cable operated Gear Ratios: Detailed gear ratios are provided within the manual. Dimensions Weights Dry Weight: Approximately 121 kg (267 lbs) (May vary slightly by model year) Wet Weight: Approximately 131 kg (289 lbs) (With all fluids, may vary) Exterior Overall Length: 2180 mm (85.8 in) (Approximate, may vary) Overall Width: 820 mm (32.3 in) (Approximate, may vary) Overall Height: 1230 mm (48.4 in) (Approximate, may vary) Seat Height: 880 mm (34.6 in) (Approximate, may vary) Ground Clearance: 305 mm (12.0 in) (Approximate, may vary) Wheelbase: 1450 mm (57.1 in) (Approximate, may vary) Safety Features Ratings Safety Standards: As a dirt/dual-sport motorcycle, it adheres to relevant motorcycle safety standards for its intended use. Specific crash ratings are not applicable in the same way as cars. Active Features Braking System: Disc brakes front and rear for effective stopping power. Specifics on caliper type and rotor size are detailed in the manual. Passive Features Lighting: Headlight, taillight, and turn signals (depending on market specification) for visibility. Technology Features Infotainment Instrumentation: Analog speedometer, odometer, tripmeter, and indicator lights (e.g., neutral, turn signals, high beam). A tachometer may be present depending on specific market configuration. Driver Assistance ABS: Anti-lock Braking System (ABS) is not a standard feature on this model. Connectivity Electronic Aids: Primarily mechanical systems. Modern electronic rider aids are not present. Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time intervals. Typically every 3,000-5,000 km (1,800-3,100 miles) or annually, whichever comes first. Air Filter Cleaning: Regular inspection and cleaning based on usage conditions (off-road use requires more frequent attention). Detailed interval in manual. Spark Plug Replacement: Refer to manual for specific mileage intervals and plug type (e.g., NGK CR8E or equivalent). Fluid Specifications Engine Oil Type: API SG or higher, JASO MA certified motorcycle oil. Viscosity typically 10W-40 or 20W-50, depending on ambient temperature. Exact specification in manual. Engine Oil Capacity: Approximately 1.5-1.8 liters (1.6-1.9 US qt) for oil change without filter replacement. Refer to manual for precise capacity. Coolant Type: Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio) for liquid-cooled variants (Note: TTR250 is air-cooled, this is a general Yamaha spec if a...
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Yamaha TTR250 1999-2006 Factory Service Repair Manual
Basic Information
Identification
Make: Yamaha
Model: TTR250
Year: 1999-2006
Generation
Generation Designation: First Generation (4GY/4RR)
Codes
Chassis Codes: 4GY (Early models), 4RR (Later models)
Introduction
Market Position
Target Audience: Yamaha TTR250 owners, independent motorcycle repair shops, and DIY enthusiasts seeking genuine factory repair information.
Competitive Analysis
Source Authenticity: Actual Genuine Repair Service Factory Manuals, not third-party alternatives. Provides the same information used by professional technicians.
Key Features
Content Richness: Hundreds of pages with detailed illustrations, diagrams, and specifications for all repair and maintenance procedures.
Usability: Easy to use, with numbered instructions, bold figure numbers, and an easy-to-use table of contents. No advanced computer skills required.
Value Proposition
Cost Savings: Enables owners to perform servicing themselves, potentially saving $50-$60 per hour in shop labor costs.
Manual Details
Coverage Areas
Models Covered: Yamaha TTR250 (all styles) for model years 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Page Count
Estimated Page Count: Hundreds of pages (exact count not specified, but described as 'complete')
Manual Type
Type: Official Factory Service Repair Manual
Language
Language: English
Format
Format: PDF Download
Manual Coverage
Systems Covered
Engine Systems: Engine top end, Fuel system, Cooling system, Engine lubrication system
Drivetrain Systems: Clutch, Crankshaft, Transmission, Final Drive
Chassis Systems: Wheels/Tires, Brakes, Suspension, Steering, Frame
Electrical Systems: Electrical System, Wiring Diagrams
Procedures Included
Maintenance Procedures: Routine maintenance, Scheduled servicing, Fluid checks and changes
Diagnostic Procedures: Engine fault diagnosis, Troubleshooting common issues, Electrical system diagnosis
Repair Procedures: Step-by-step repair instructions for all major components, Engine rebuilds, Transmission overhauls, Brake system repairs, Suspension servicing
Assembly Disassembly: Engine Removal/Installation, Component disassembly and reassembly
Technical Depth
Depth: Comprehensive, covering fundamental maintenance to advanced repair and diagnostics. Equips users with factory-level knowledge.
Manual Specifications
File Format
Format: PDF
Print Quality
Printability: Printable without restriction (entire manual or selected pages)
Binding Type
Binding: N/A (Digital Download - Printable)
Paper Type
Paper Type: N/A (Digital Download - User prints on desired paper)
Software Requirements
Reader Requirement: Adobe PDF Reader
Searchability
Text Search: Searchable text for quick information retrieval
Engine Specifications
Primary Engine
Engine Type: 4-stroke, SOHC, Air-cooled, Forward-inclined single cylinder
Displacement: 249 cc (Actual displacement may vary slightly by specific model revision within the 1999-2006 range)
Bore X Stroke: 73.0 mm x 59.6 mm (Typical specification for this engine family)
Compression Ratio: 9.5:1 (Typical specification)
Performance
Horsepower: Approximately 20-22 HP (Actual figures vary by market and specific tune)
Torque: Approximately 19-20 Nm (Actual figures vary by market and specific tune)
Fuel System
Carburetor: Mikuni VM28 (Typical specification, may vary slightly by market or model year)
Fuel Delivery: Carburetor
Ignition System
Ignition Type: CDI (Capacitor Discharge Ignition)
Transmission
Standard
Transmission Type: Constant mesh 6-speed sequential
Features
Clutch Type: Wet, multiple disc, cable operated
Gear Ratios: Detailed gear ratios are provided within the manual.
Dimensions
Weights
Dry Weight: Approximately 121 kg (267 lbs) (May vary slightly by model year)
Wet Weight: Approximately 131 kg (289 lbs) (With all fluids, may vary)
Exterior
Overall Length: 2180 mm (85.8 in) (Approximate, may vary)
Overall Width: 820 mm (32.3 in) (Approximate, may vary)
Overall Height: 1230 mm (48.4 in) (Approximate, may vary)
Seat Height: 880 mm (34.6 in) (Approximate, may vary)
Ground Clearance: 305 mm (12.0 in) (Approximate, may vary)
Wheelbase: 1450 mm (57.1 in) (Approximate, may vary)
Safety Features
Ratings
Safety Standards: As a dirt/dual-sport motorcycle, it adheres to relevant motorcycle safety standards for its intended use. Specific crash ratings are not applicable in the same way as cars.
Active Features
Braking System: Disc brakes front and rear for effective stopping power. Specifics on caliper type and rotor size are detailed in the manual.
Passive Features
Lighting: Headlight, taillight, and turn signals (depending on market specification) for visibility.
Technology Features
Infotainment
Instrumentation: Analog speedometer, odometer, tripmeter, and indicator lights (e.g., neutral, turn signals, high beam). A tachometer may be present depending on specific market configuration.
Driver Assistance
ABS: Anti-lock Braking System (ABS) is not a standard feature on this model.
Connectivity
Electronic Aids: Primarily mechanical systems. Modern electronic rider aids are not present.
Maintenance
Service Intervals
Oil Change Interval: Refer to manual for specific mileage/time intervals. Typically every 3,000-5,000 km (1,800-3,100 miles) or annually, whichever comes first.
Air Filter Cleaning: Regular inspection and cleaning based on usage conditions (off-road use requires more frequent attention). Detailed interval in manual.
Spark Plug Replacement: Refer to manual for specific mileage intervals and plug type (e.g., NGK CR8E or equivalent).
Fluid Specifications
Engine Oil Type: API SG or higher, JASO MA certified motorcycle oil. Viscosity typically 10W-40 or 20W-50, depending on ambient temperature. Exact specification in manual.
Engine Oil Capacity: Approximately 1.5-1.8 liters (1.6-1.9 US qt) for oil change without filter replacement. Refer to manual for precise capacity.
Coolant Type: Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio) for liquid-cooled variants (Note: TTR250 is air-cooled, this is a general Yamaha spec if a liquid-cooled model existed).
Brake Fluid Type: DOT 3 or DOT 4 hydraulic brake fluid. Refer to manual for exact specification and bleeding procedures.
Known Issues
Carburetor Cleaning: Like many motorcycles of its era, the carburetor may require periodic cleaning and adjustment, especially if the bike sits for extended periods or uses poor quality fuel.
Electrical Connections: Corrosion or loose connections in the electrical system can sometimes lead to intermittent issues. The manual's wiring diagrams are crucial for diagnosis.
Suspension Seals: Fork seals and shock seals can wear over time, leading to oil leaks and reduced damping performance, especially with off-road use. Regular inspection is recommended.
Clutch Adjustment: Clutch lever free play may need occasional adjustment to ensure proper engagement and disengagement. The manual will detail the procedure.
Vehicle History
Brand Heritage
Yamaha Motorcycle Legacy: Yamaha has a long-standing reputation for producing reliable and performance-oriented motorcycles across various disciplines, including off-road and dual-sport.
Model Evolution
Ttr250 Development: The TTR250 was developed as a capable and user-friendly dual-sport machine, bridging the gap between pure off-road bikes and street-legal commuters. It featured an air-cooled engine for simplicity and reliability.
Production
Production Period: The TTR250 model line, including the variants covered by this manual, was produced for a significant period, with this specific manual covering the 1999-2006 model years.
Manufacturing Location: Yamaha motorcycles are primarily manufactured in Japan, though production facilities may extend to other global locations.
Awards & Recognition
Recognitions
Industry Accolades: While specific awards for the 1999-2006 TTR250 are not extensively documented in product descriptions, Yamaha's dual-sport motorcycles are generally well-regarded for their reliability and off-road capability in their class.
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