The TTR250 is a versatile dual-sport motorcycle produced from 1999 to 2006, designed to excel in both off-road adventures and everyday street riding. Building on a renowned heritage in motorcycle engineering, the TTR250 features a robust single-cylinder, 4-stroke, oil-cooled engine with a 5-speed transmission, delivering reliable performance for a wide range of conditions. Its balanced chassis, hydraulic disc brakes, and comfortable ergonomics make it a capable and enjoyable machine for riders seeking adventure and practicality. This workshop service manual provides comprehensive guidance for the maintenance, repair, and troubleshooting of the TTR250 models from 1999 through 2006. It covers all essential systems, including the engine, transmission, fuel, electrical, chassis, suspension, and braking systems, offering detailed step-by-step instructions, diagnostic procedures, and technical specifications. This manual is an indispensable resource for professional technicians and owner mechanics alike, enabling efficient and accurate upkeep to ensure the longevity and optimal performance of the TTR250. 🏷️ Basic Information Identification Make: Yamaha Model: TTR250 Model Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Vehicle Type: Dual-Sport Motorcycle 👋 Introduction Market Position Target Audience: Professional technicians and DIY mechanics Competitive Analysis Advantage: Official manufacturer documentation, comprehensive coverage, instant digital access Key Features Accuracy: Original workshop manual, accurate and complete information Usability: Easy to follow, practical repair instructions Cost Effectiveness: Enables DIY repairs, saving labor costs 📋 Manual Details Coverage Areas General Coverage: Comprehensive repair, maintenance, and troubleshooting Specific Systems: Engine, transmission, chassis, electrical, fuel, exhaust, suspension, braking, bodywork Page Count Estimated Page Count: Hundreds of pages (exact count not specified but implied by comprehensive nature) Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, piston, crankshaft, camshaft, valve timing, lubrication system Fuel System: Carburetor overhaul and adjustment, fuel tank, fuel lines Transmission Drivetrain: Clutch operation, gearbox disassembly and assembly, chain adjustment Electrical System: Ignition system, lighting, charging system, starter motor, wiring diagrams Chassis Suspension: Front fork service and adjustment, rear shock absorber service, swingarm maintenance Braking System: Brake caliper overhaul, master cylinder service, brake pad replacement, hydraulic system bleeding Bodywork: Fairings, fenders, seat, fuel tank removal and installation Exhaust System: Exhaust pipe and muffler inspection and replacement Cooling System Maintenance: Oil cooler inspection and maintenance Procedures Included Maintenance: Periodic maintenance charts, oil changes, filter replacements, spark plug checks, chain lubrication Repair: Step-by-step repair instructions for all major components Troubleshooting: Diagnostic procedures and common problem identification Overhaul: Complete engine and component overhaul procedures Diagnostics: Troubleshooting guides for common electrical and mechanical issues Wiring Diagrams: Included, essential for electrical diagnostics and repairs Technical Depth Depth: Suitable for professional technicians and experienced DIY mechanics Detail Level: Detailed torque specifications, clearances, and assembly procedures 📊 Manual Specifications File Format Format: PDF File Type: PDF (Portable Document Format) Print Quality Printability: Full Printable Zoom Functionality: Yes (Zoom IN/OUT) Binding Type Binding: Digital Download (no physical binding) Paper Type Paper Type: N/A (Digital PDF) Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinRAR Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, SOHC, 4-valve Displacement: 249cc (approximately, exact spec may vary by specific market version but generally within this range for TTR250) Performance Horsepower: Approx. 22-24 HP (at crank, figures may vary) Torque: Approx. 15-17 lb-ft (at crank, figures may vary) Fuel System Carburetion: Mikuni VM34 (typical, may vary) Cooling System Cooling Method: Oil-cooled with a front-mounted oil cooler 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Clutch Type: Wet, multi-plate Features Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approx. 2,150 mm (84.6 in) Width: Approx. 800 mm (31.5 in) Height: Approx. 1,180 mm (46.5 in) Weights Dry Weight: Approx. 116 kg (256 lbs) Wet Weight: Approx. 125 kg (276 lbs) Fuel Capacity: Approx. 10 Liters (2.6 US gal) 🛡️ Safety Features Ratings Safety Certification: As per relevant motorcycle safety standards of the era Active Features Braking System: Hydraulic disc brakes front and rear Passive Features Lighting: Headlight, taillight, turn signals (depending on market configuration) 💡 Technology Features Infotainment Infotainment System: N/A (Basic motorcycle instrumentation) Driver Assistance ABS: Not typically equipped on this model generation Connectivity Connectivity Features: N/A Instrumentation Instrument Cluster: Analog speedometer, tachometer, odometer, trip meter, indicator lights 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-5,000 km or annually (refer to manual for exact specifications) Valve Clearance Check: Typically every 10,000-15,000 km (refer to manual for exact specifications) Fluid Specifications Engine Oil Type: Yamalube (or equivalent high-quality 4-stroke motorcycle oil) SAE 10W-40 or 20W-40 API SG or higher (check manual for precise recommendation) Engine Oil Capacity: Approx. 1.5 - 1.8 Liters (with filter change, refer to manual for exact) Brake Fluid Type: DOT 3 or DOT 4 (refer to manual for exact specification) Known Issues Common...