Yamaha TT-R TT250R, Owner'S Manual

Page 1: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000 7 0 6 1 E OWNER S MANUAL 4PX 28199 26 TT250R N YAMAHA MOTOR CO LTD ...

Page 2: ...tting racing machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcy cle please consult a Yamaha dealer 4PX 9 26 0 1 2 AUS 7 25 00 5 25 PM Page...

Page 3: ...be taken to avoid damage to the motorcycle A NOTE provides key information to make procedures easier or clearer Q w cC NOTE NOTE 8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold 8 Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current produc...

Page 4: ...IMPORTANT MANUAL INFORMATION 1 2 3 4 5 6 7 8 9 EW000002 w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE 4PX 9 26 0 1 2 AUS 7 25 00 5 25 PM Page 3 ...

Page 5: ...0 by Yamaha Motor Co Ltd 1st Edition June 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EAU03337 4PX 9 26 0 1 2 AUS 7 25 00 5 25 PM Page 4 ...

Page 6: ...rake pedal 3 4 Fuel tank cap 3 5 Fuel 3 5 Fuel tank breather hose 3 6 Fuel cock 3 6 Starter choke knob 1 3 7 Kickstarter 3 7 Steering lock 3 8 Seat 3 8 Helmet holder 3 9 Adjusting the front fork 3 9 Adjusting the rear shock absorber assembly 3 11 Sidestand 3 13 Ignition circuit cut off sysem 3 13 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starti...

Page 7: ...21 Drive chain slack 6 22 Lubricating the drive chain 6 23 Checking and lubricating the cables 6 24 Checking and lubricating the brake and shift pedals 6 25 Checking and lubricating the brake and clutch levers 6 25 Checking and lubricating the sidestand 6 25 Checking the front fork 6 26 Checking the steering 6 26 Checking the wheel bearing 6 27 Battery 6 27 Replacing the fuse 6 29 Replacing the he...

Page 8: ...TABLE OF CONTENTS 1 2 3 4 5 6 7 8 9 Vehicle identification number 9 1 Model label 9 2 Noise regulation For Australia 9 2 4PX 9 26 0 1 2 AUS 7 25 00 5 25 PM Page 7 ...

Page 9: ...NECESSARY BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not se...

Page 10: ...veering wide on a turn due to EXCESSIVE SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic condi tions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep bo...

Page 11: ...er operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may als...

Page 12: ...cle before riding Check accessory mounts and cargo restraints frequently 3 Never attach any large or heavy items to the handlebar front fork or front fender These items including such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cann...

Page 13: ... effects Wind may attempt to lift the motorcycle or the motorcycle may become unstable in cross winds These accessories may also cause instability when passing or being passed by large vehicles c Certain accessories can displace the operator from his or her normal riding position This improper position limits the freedom of movement of the operator and may limit control ability therefore such acce...

Page 14: ...ese hot areas b Do not park the motorcycle on a slope or soft ground otherwise it may fall over c Do not park the motorcycle near a flammable source e g a kerosene heater or near an open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock s are turned to ON or RES for vacuum type OFF for manual type If t...

Page 15: ...U02977 Q SAFETY INFORMATION 1 2 3 4 5 6 7 8 9 Location of important labels Please read the following important labels carefully before operating this motorcycle 1 2 4PX 9 26 0 1 2 AUS 7 25 00 5 25 PM Page 14 ...

Page 16: ...1 8 Q SAFETY INFORMATION 1 2 3 4 5 6 7 8 9 WARNING Before you operate this vehicle read the owner s manual English 3HP 21568 00 4AA 22259 40 1 2 4PX 9 26 0 1 2 AUS 7 25 00 5 25 PM Page 15 ...

Page 17: ...dlight page 6 30 2 Fuel cock page 3 6 3 Starter choke knob page 3 7 4 Air filter element page 6 11 5 Owner s tool kit page 6 1 6 Helmet holder page 3 9 7 Shift pedal page 3 4 8 Front fork compression damping adjusting screw page 3 11 4PX 9 26 0 1 2 AUS 7 25 00 5 26 PM Page 16 ...

Page 18: ...ear shock absorber compression damping adjusting knob page 3 12 13 Main switch page 3 1 14 Front fork spring preload adjusting valve page 3 9 15 Steering lock page 3 8 16 Engine oil filter element page 6 10 17 Brake pedal page 3 4 6 18 18 Rear shock absorber rebound damping adjusting dial page 3 12 4PX 9 26 0 1 2 AUS 7 25 00 5 26 PM Page 17 ...

Page 19: ...s and instruments 1 Clutch lever page 3 3 2 Left handlebar switches page 3 2 3 Speedometer unit page 3 2 4 Right handlebar switches page 3 3 5 Brake lever page 3 4 6 Throttle grip page 6 13 7 Fuel tank cap page 3 5 4PX 9 26 0 1 2 AUS 7 25 00 5 26 PM Page 18 ...

Page 20: ... be removed EAU00038 OFF All electrical systems are off The key can be removed EAU00056 Indicator lights EAU00057 Turn signal indicator light 5 This indicator light flashes when the turn signal switch is pushed to the left or right EAU00063 High beam indicator light This indicator light comes on when the high beam of the headlight is switched on EAU00061 Neutral indicator light N This indicator li...

Page 21: ...rmation will enable you to plan future fuel stops 1 Speedometer 2 Odometer 3 Trip odometer 4 Reset knob 1 2 3 1 Dimmer switch 2 Turn signal switch 3 Horn switch EAU00118 Handlebar switches EAU00121 Dimmer switch Set this switch to for the high beam and to for the low beam EAU00127 Turn signal switch To signal a right hand turn push this switch to 6 To signal a left hand turn push this switch to 4 ...

Page 22: ... page 5 1 for starting instruc tions prior to starting the engine 1 EAU00152 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the han dlebar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of ...

Page 23: ...hifting the gears of the 6 speed constant mesh transmission equipped on this motorcycle EAU00158 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the han dlebar grip 1 EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Brake lever 1 Brake pedal 4PX 9 26 ...

Page 24: ...ficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown in the illustration EW000130 w 8 Do not overfill the fuel tank otherwise it may overflow when the fuel warms up and expands 8 Avoid spilling fuel on the hot engine EAU00185 cC Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted sur faces or plastic parts EAU00192 1 Fil...

Page 25: ... Arrow mark positioned over ON EAU03050 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also The fuel cock has three positions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in t...

Page 26: ...fore starting is recom mended RES This indicates reserve If you run out of fuel while riding move the lever to this position Fill the tank at the first opportunity Be sure to set the lever back to ON after refueling OFF ON FUEL RES 1 RES 1 Arrow mark positioned over RES RES Reserve position 1 a b EAU03032 Starter choke knob 1 Starting a cold engine requires a rich er air fuel mixture which is supp...

Page 27: ...s locked remove the key and then close the lock cover To unlock the steering Reverse the above procedure 1 Steering lock 1 2 To install the seat 1 Insert the projections on the front of the seat into the seat holders as shown 2 Place the seat in the original position and then tighten the bolts NOTE Make sure that the seat is properly secured before riding 1 Projection 2 2 Seat holder 2 1 EAU00240 ...

Page 28: ...ressure there should be no weight on the front end of the motorcycle 2 Remove the air valve cap from each fork leg 3 Check the air pressure in each fork leg with an air pressure gauge NOTE An optional air pressure gauge is available at a Yamaha dealer 1 2 1 Air valve cap 2 Air valve 1 EAU00260 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lo...

Page 29: ...eby harden the suspension increase the air pressure with an air pump or compressed air To decrease the spring rate and thereby soften the suspension decrease the air pressure by pushing each valve stem down EC000012 cC Never exceed the maximum air pressure otherwise the front fork oil seals may become damaged Spring rate Minimum soft Air pressure 0 kPa 0 kgf cm2 0 psi Standard Air pressure 0 kPa 0...

Page 30: ... preload rebound and com pression damping force adjuster 1 Spring preload adjustment should be left to a Yamaha deal er EC000015 cC Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings 3 Securely install the rubber caps ECA00034 cC Be sure to install the rubber caps to prevent dust etc from entering the fork legs 1 a b 1 Compression damping adjusting screw Minimum so...

Page 31: ...ce as follows Turn the adjusting knob in direction a to increase compression damping force and in direction b to decrease compression damping force EC000016 cC Never attempt to turn the adjuster beyond the maximum or minimum setting 1 a b 1 Compression damping force adjusting knob 2 Adjust rebound damping force as follows Turn the adjusting dial in direction a to increase rebound damping force and...

Page 32: ...to assist the operator in fulfilling the responsibility of rais ing the sidestand before starting off Therefore check this system regularly as described below and have a Yamaha dealer repair it if it does not function properly EAU00331 Ignition circuit cut off system The ignition circuit cut off system comprising the sidestand switch clutch switch and neutral switch has the following functions 8 I...

Page 33: ...sion into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle should not be ridden until checked by a Yamaha ...

Page 34: ...d level and for fluid leakage 3 4 6 18 6 21 9 Fill with DOT 4 brake fluid if necessary Clutch 9 Check operation condition and free play 3 3 6 17 9 Adjust if necessary Throttle grip and housing 9 Check smooth operation 6 13 9 Lubricate if necessary Engine oil 9 Check oil level 6 8 6 11 9 Add oil if necessary Drive chain 9 Check chain slack and condition 6 22 6 24 9 Adjust if necessary Wheels and ti...

Page 35: ...es NOTE Pre operation checks should be made each time the motorcycle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved EWA00033 w If any item in the Pre operation check list is not working properly have it inspected and repaired before operat ing the motorcycle 4PX 9 26 3 4 5 AUS 7 25 00 5 26 PM Page 16 ...

Page 36: ...ss of control EAU00411 Starting and warming up a cold engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met 8 The transmission is in the neutral position 8 The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 w 8 Before starting the engine check the function of the igni tion circuit cut off system ac...

Page 37: ...an 10 seconds on any one attempt If the engine does not start with the starter motor try using the kickstarter 6 After starting the engine move the starter choke knob lever back halfway ECA00055 cC For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold 7 When the engine is warm turn the starter choke off NOTE The engine is warm when it r...

Page 38: ...ricated only when the engine is running Inadequate lubrication may damage the transmission 8 Always use the clutch while changing gears to avoid dam aging the engine transmis sion and drive train which are not designed to withstand the shock of forced shifting EAU00424 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style Consider the follow ing tips to reduce fu...

Page 39: ...ged operation above 1 3 throttle 8 After every hour of operation stop the engine and then let it cool for five to ten minutes 8 Vary the engine speed from time to time Do not operate the engine at one set throttle posi tion 150 500 km 8 Avoid prolonged operation above 1 2 throttle 8 Rev the engine freely through the gears but do not use full throttle at any time 500 1 000 km Avoid prolonged operat...

Page 40: ...en turn the fuel cock lever to OFF EW000058 w 8 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them 8 Do not park on a slope or on soft ground otherwise the motorcycle may overturn RES ON FUEL OFF 1 1 Arrow mark positioned over OFF 4PX 9 26 6 AUS 7 25 00 5 27 PM Page 1 ...

Page 41: ...n the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions However DEPENDING ON THE WEATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTE NANCE INTERVALS MAY NEED TO BE SHORTENED EW000060 w If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you 1 EAU01175 Owner s tool kit The own...

Page 42: ...ER READING 1 000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plug Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 20 000 km 4 Air filter element Clean Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Whenever worn to ...

Page 43: ... bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20 000km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Rear shock absorber assembly Check operation and shock absorber for oil lea...

Page 44: ...Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid 8 Replace the brake hoses every four years and if cracked or damaged 24 Front and rear brake switches Check operation 25 Moving parts and cables Lubricate 26 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1 000 km A...

Page 45: ...enance jobs described in this chapter Refer to this section each time the cowling or a panel needs to be removed and installed 1 Panel B 1 Screw EAU01145 Cowling A To remove the cowling Remove the screw and then pull the cowling off as shown To install the cowling Place the cowling in the original posi tion and then install the screw 1 2 1 Cowling A 2 Panel A 1 4PX 9 26 6 AUS 7 25 00 5 27 PM Page ...

Page 46: ...condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 1 Spark plug cap 1 1 Screw EAU00488 Panel A To remove the panel Remove the screw and then pull the panel off as shown To install the panel Place the panel in the original posi tion and then install the screw 1 1 EAU00488 Panel B To remove the panel Remove the screw and then pull ...

Page 47: ...rself Instead have a Yamaha dealer check the motorcycle 2 Check the spark plug for elec trode erosion and excessive car bon or other deposits and replace it if necessary To install the spark plug 1 Measure the spark plug gap with a wire thickness gauge and if necessary adjust the gap to specification 2 Clean the surface of the spark plug gasket and its mating sur face and then wipe off any grime f...

Page 48: ...vel mark add suffi cient oil of the recommended type to raise it to the correct level NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 4 Install the spark plug cap EAU03670 Engine oil and oil filter element The engine oi...

Page 49: ...engine to collect the used oil 3 Remove the engine oil filler bolt and drain bolt to drain the oil from the crankcase 2 1 4 3 4 Remove the oil filter element drain bolt to drain the oil from the oil filter element NOTE Skip steps 5 9 if the oil filter element is not being cleaned 5 Remove the oil filter element cover by removing the bolts 1 Oil filter element drain bolt 2 Oil filter element cover ...

Page 50: ...th the oil 8 Make sure that no foreign material enters the crankcase Recommended engine oil See page 8 1 Oil quantity Without oil filter element removal 1 1 L With oil filter element removal 1 2 L Total amount dry engine 1 45 L 10 Install the oil filter element drain bolt and then tighten it to the specified torque NOTE Make sure that the O rings are prop erly seated 11 Install the engine oil drai...

Page 51: ...et it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 14 Turn the engine off and then check the oil level and correct it if necessary ECA00075 cC After changing the engine oil make sure to check the oil pres sure as described below 8 Remove the bleed bolt 8 Start the engine and keep it idling until oil flows out I...

Page 52: ...ial and then squeeze the excess oil out NOTE The sponge material should be wet but not dripping 1 2 3 4 7 Install the sponge material onto the frame insert the air filter ele ment into the air filter case and then install the air filter case cover by installing the holding clips EC000082 cC 8 Make sure that the air filter ele ment is properly seated in the air filter case 8 The engine should never...

Page 53: ...is adjustment 1 Attach the tachometer to the spark plug lead 2 Start the engine and warm it up for several minutes at 1 000 2 000 r min while occa sionally revving it to 4 000 5 000 r min NOTE The engine is warm when it quickly responds to the throttle a b 1 1 Throttle stop screw EAU00629 Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisti cated ad...

Page 54: ...usted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EAU03573 Tires To maximize the performance dura bility and safe operation of your motorcycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride EW000082 w 8 The tire air pressure must be check...

Page 55: ...ountry Always com ply with the local regulations Minimum tire tread depth front and rear 1 0 mm Tire air pressure measured on cold tires Load Front Rear Up to 90 kg 125 kPa 1 25 kgf cm2 1 25 bar 150 kPa 1 50 kgf cm2 1 50 bar 90 kg maximum 150 kPa 1 50 kgf cm2 1 50 bar 175 kPa 1 75 kgf cm2 1 75 bar Off road riding 125 kPa 1 25 kgf cm2 1 25 bar 150 kPa 1 50 kgf cm2 1 50 bar Maximum load 180 kg Total...

Page 56: ...cteristics of the motorcy cle cannot be guaranteed 8 After extensive tests only the tires listed below have been approved for this model by Yamaha Motor Co Ltd EAU00680 w 8 It is dangerous to ride with a worn out tire When a tire tread begins to show cross wise lines have a Yamaha dealer replace the tire immedi ately 8 The replacement of all wheel and brake related parts including the tires should...

Page 57: ...r down the clutch cable 6 To increase the clutch lever free play turn the adjusting nut in direction a To decrease the clutch lever free play turn the adjusting nut in direction b 7 Tighten both locknuts EAU00685 Spoke wheels To maximize the performance dura bility and safe operation of your motorcycle note the following points regarding the specified wheels 8 The wheel rims should be checked for ...

Page 58: ...sting the brake lever free play check the free play and make sure that the brake is working properly 8 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will diminish the braking performance which may result in ...

Page 59: ... To make the brake light come on later turn the adjusting nut in direc tion b 1 Brake light switch 2 Adjusting nut EW000109 w A soft or spongy feeling in the brake pedal can indicate the pres ence of air in the hydraulic system If there is air in the hydraulic sys tem have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will diminish the braking perform...

Page 60: ...ake pad wear without having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicators have almost dis appeared have a Yamaha dealer replace the brake pads as a set 1 1 Indicator groove 3 FRONT EAU03196 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly cau...

Page 61: ...nly the recommended qual ity brake fluid otherwise the rub ber seals may deteriorate caus ing leakage and poor braking performance 1 1 Minimum level mark REAR Recommended brake fluid DOT 4 8 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking perfor mance 8 Be careful that water does not enter the master cylinder when refilling ...

Page 62: ...ition NOTE When checking and adjusting the drive chain slack the motorcycle should be positioned straight up and there should be no weight on it 2 Shift the transmission into the neutral position a a Drive chain slack b 3 2 1 a EAU01269 To adjust the drive chain slack 1 Remove the cotter pin from the axle nut and then loosen the axle nut 2 To tighten the drive chain turn the adjusting plate on eac...

Page 63: ...r inappropriate solvents 2 Wipe the drive chain dry NOTE Make sure that both adjusting plates are in the same position for proper wheel alignment EC000096 cC Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 3 Tighten the ...

Page 64: ... have a Yamaha dealer check or replace it Recommended lubricant Engine oil 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECA00052 cC Do not use engine oil or any other lubricants for the drive chain as they may contain substances that could damage the O rings EW000112 w Damage to the outer sheath may interfere with proper cable opera tion and will cause the inner cab...

Page 65: ...ting the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lubricated if necessary EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lubricated if necessary Recommended lubricant Lithium soap ba...

Page 66: ... an upright position 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and rebounds smoothly EC000098 cC If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or repair it EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the opera tion of the steerin...

Page 67: ...nently damage the battery 1 1 Battery 2 Hold the lower ends of the front fork legs and try to move them forward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in the wheel hu...

Page 68: ...provide sufficient ventilation when charging it in an enclosed space 8 KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the battery tends to dis charge more quickly if the motorcycle is equipped with optional electrical accessories To store the battery 1 If th...

Page 69: ...located behind panel B See page 6 6 for panel removal and installation procedures If the fuse is blown replace it as fol lows 1 Turn the key to OFF and turn off all electrical circuits 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 2 1 Fuse 2 Spare fuse EC000103 cC Do not use a fuse of a higher amperage rating than recommend ed to avoid causing extensive damage to ...

Page 70: ...e defective bulb 1 Bolt 3 EW000119 w Headlight bulbs get very hot Therefore keep flammable prod ucts away from a lit headlight bulb and do not touch the bulb until it has cooled down 5 Place a new bulb into position and then secure it with the bulb holder 1 1 Bulb holder a a Don t touch this area EC000105 cC Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the t...

Page 71: ...97 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it coun terclockwise 1 1 Bulb 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw ECA00065 cC Do not overtighten the screw oth erwise the lens may break 4PX 9 26 6 AU...

Page 72: ... in and turning it coun terclockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws EC000108 cC Do not overtighten the screws otherwise the lens may break EAU01624 Replacing the license plate light bulb 1 Remove the license plate light by removing the nuts 1 Screw 2 2 Lens 1 Bulb 1 Nut 2 4PX 9 26 6 AUS 7 25 00 5...

Page 73: ...ow these precau tions when removing the front and rear wheel or performing other main tenance requiring the motorcycle to stand upright Check that the motor cycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcy cle by using a motorcycle stand or if...

Page 74: ...have a Yamaha dealer service the wheel 8 Securely support the motorcy cle so that there is no danger of it falling over 1 Disconnect the speedometer cable from the front wheel 2 Loosen the wheel axle holder nuts then the wheel axle 1 Speedometer cable 2 Axle holder nut 4 3 Wheel axle 3 Lift the front wheel off the ground according to the procedure on page 6 33 4 Pull the wheel axle out and then re...

Page 75: ...03555 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the projections mesh with the slots 2 Lift the wheel up between the fork legs NOTE Make sure that there is enough space between the brake pads before insert ing the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg 3 Install the wheel axle 4 Lower the front...

Page 76: ...usting plate 2 Lift the rear wheel off the ground according to the procedure on page 6 33 3 Push the wheel forward and then remove the drive chain from the rear sprocket NOTE The drive chain does not need to be disassembled in order to remove and install the wheel 4 Remove the axle nut 5 Pull the wheel axle out 6 Remove the spacer the chain adjusting plates and the wheel ECA00048 cC Do not apply t...

Page 77: ...service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills EAU01232 To install the rear wheel 1 Install the drive chain onto the rear sprocket and then insert the wheel axle from the left hand side NOTE 8 Make sure that there is enough space betw...

Page 78: ...y Wipe clean with dry cloth and Open the throttle half way and start Ask a Yamaha dealer to inspect Engine turns over Engine turns over Battery good Check connections Use electric starter Check if there is fuel Enough fuel No fuel Go to compression check Supply fuel in the fuel tank electrodes plug and check quickly slowly or recharge Engine doesn t start go to battery check the engine adjust plug...

Page 79: ...well as all electrical cou plers and connectors including the spark plug cap are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such products onto seals gaskets sprockets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 cC 8 Avoid using strong acidic wheel c...

Page 80: ...es not leave any marks If the windshield is scratched use a quality plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottle brush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few min...

Page 81: ...h up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry complete ly before storing or covering it EWA00001 w 8 Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or acetone and wash the tires with warm water and a mild detergent 8 Before operating the motorcy cl...

Page 82: ...n bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to protect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the...

Page 83: ...eels a little every month in order to pre vent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an excessively cold or warm place less than 0 C or more than 30 C For more information on storing th...

Page 84: ...ic and kick starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher cC Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled Energy Conserving contain anti friction additives which will cause clutch and or starter clutch slippage resulting in reduced component life and poor ...

Page 85: ...n system Spur gear Primary reduction ratio 74 24 3 083 Secondary reduction system Chain drive Secondary reduction ratio 3 143 Number of drive chain sprocket teeth rear front 44 14 Transmission type Constant mesh 6 speed Operation Left foot operation Gear ratio 1st 2 467 2nd 1 813 3rd 1 364 4th 1 080 5th 0 889 6th 0 759 Chassis Frame type Semi double cradle Caster angle 26 Trail 106 mm Tires Type W...

Page 86: ...2 1 50 bar Load is total weight of cargo rider passenger and accessories Wheels Front Type Spoke wheel Size 1 60 21 Rear Type Spoke wheel Size 2 15 18 Brakes Front Type Single disc brake Operation Right hand operation Fluid DOT 4 Rear Type Single disc brake Operation Right foot operation Fluid DOT 4 Suspension Front Type Telescopic fork Rear Type Swingarm link suspension Spring shock absorbers Fro...

Page 87: ... Headlight type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 60 55W 1 Tail brake light 12 V 5 21W 1 Front turn singal light 12 V 21W 2 Rear turn signal light 12 V 21W 2 License light 12 V 5W 2 Meter lighting 12 V 3 4W 1 Neutral indicator light 12 V 3 4W 1 High beam indicator light 12 V 3 4W 1 Turn indicator light 12 V 3 4W 1 Fuse 15 A 4PX 9 26 7 8 9 AUS 7 25 00 5 28 PM Page 10 ...

Page 88: ...nit Multiplier Imperial unit m kg 7 233 ft lb Torque m kg 86 794 in lb cm kg 0 0723 ft lb cm kg 0 8679 in lb Weight kg 2 205 lb g 0 03527 oz Speed km hr 0 6214 mph km 0 6214 mi m 3 281 ft Distance m 1 094 yd cm 0 3937 in mm 0 03937 in cc cm3 0 03527 oz IMP liq Volume cc cm3 0 06102 cu in Capacity L liter 0 8799 qt IMP liq L liter 0 2199 gal IMP liq kg mm 55 997 lb in Misc kg cm2 14 2234 psi lb in2...

Page 89: ... pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motor cycle with the licensing authority in your area EAU02944 Identification numbers Record the key identification number vehicle identification number and model label information in the spaces provided below for assistance when ordering spare...

Page 90: ... for Australia TAMPERING WITH NOISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inoper ative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehi cle for the purpose of noise con trol prior to its sale or delivery to the ultimate purchaser or while it is in ...

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Page 94: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000 7 0 6 1 E OWNER S MANUAL 4PX 28199 26 TT250R N YAMAHA MOTOR CO LTD ...