Yamaha TT250 RM 2000 Owner's manual

OWNER’S MANUAL
TT250RM
4PX-28199-25
INTRODUCTION
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This manual will give you an understanding of the operation, inspection, and basic mainte­nance of this motorcycle. If you have any questions about the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
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NOTE:
NOTE:
8 This manual should be considered a permanent part of this motorcycle and should
8 Yamaha continually seeks advancements in product design and quality. Therefore,
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
remain with it even if the motorcycle is subsequently sold.
while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manu­al. If there is any question concerning this manual, please consult your Yamaha dealer.
IMPORTANT MANUAL INFORMATION
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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
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TT250RM
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OWNER’S MANUAL
©1999 by Yamaha Motor Co., Ltd.
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1st Edition, July 1999
All rights reserved. Any reprinting or
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unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
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TABLE OF CONTENTS
SAFETY INFORMATION ....................................1-1
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Safe riding ........................................................1-1
Protective apparel ............................................1-3
Modification......................................................1-3
Loading and accessories .................................1-3
Gasoline and exhaust gas ...............................1-5
Location of the important labels.....................1-7
DESCRIPTION .....................................................2-1
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Left view............................................................2-1
Right view.........................................................2-2
Controls/Instruments .......................................2-3
INSTRUMENT AND CONTROL
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FUNCTIONS........................................................3-1
Main switch ......................................................3-1
Indicator lights..................................................3-1
Speedometer....................................................3-2
Handlebar switches..........................................3-2
Clutch lever.......................................................3-3
Shift pedal.........................................................3-4
Front brake lever ..............................................3-4
Rear brake pedal ..............................................3-4
Fuel tank cap.....................................................3-5
Fuel....................................................................3-5
Fuel tank breather hose...................................3-6
Fuel cock ...........................................................3-6
Starter (choke) “1”.........................................3-7
Kick starter........................................................3-7
Steering lock.....................................................3-8
Seat ...................................................................3-8
Helmet holder...................................................3-9
Front fork adjustment ......................................3-9
Rear shock absorber adjustment..................3-11
Sidestand........................................................3-12
Sidestand/clutch switch operation check.....3-13
PRE-OPERATION CHECKS.................................4-1
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Pre-operation check list ...................................4-1
OPERATION AND IMPORTANT RIDING
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POINTS................................................................5-1
Starting and warming up a cold engine.........5-1
Starting a warm engine...................................5-4
Shifting..............................................................5-4
Tips for reducing fuel consumption ...............5-5
Engine break-in ................................................5-5
Parking ..............................................................5-6
PERIODIC MAINTENANCE AND MINOR
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REPAIR ................................................................6-1
Tool kit ..............................................................6-1
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TABLE OF CONTENTS
Periodic maintenance and lubrication............6-3
Cowling and panel removal and
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installation ........................................................6-6
Cowling A .........................................................6-6
Panel A..............................................................6-7
Panel B ..............................................................6-7
Spark plug.........................................................6-7
Engine oil..........................................................6-9
Air filter ...........................................................6-12
Carburetor adjustment ..................................6-13
Idle speed adjustment ...................................6-14
Throttle cable free play inspection ...............6-14
Valve clearance adjustment ..........................6-15
Tires.................................................................6-15
Wheels ............................................................6-17
Clutch lever free play adjustment.................6-18
Front brake lever free play adjustment ........6-18
Rear brake pedal height adjustment ............6-19
Brake light switch adjustment.......................6-20
Checking the front and rear brake pads.......6-20
Inspecting the brake fluid level.....................6-21
Brake fluid replacement.................................6-22
Drive chain slack check..................................6-22
Drive chain slack adjustment ........................6-23
Drive chain lubrication...................................6-24
Cable inspection and lubrication ..................6-24
Throttle cable and grip lubrication ...............6-25
Brake and shift pedal lubrication..................6-25
Brake and clutch lever lubrication ................6-25
Sidestand lubrication.....................................6-26
Front fork inspection......................................6-26
Steering inspection........................................6-27
Wheel bearings ..............................................6-27
Battery.............................................................6-28
Fuse replacement...........................................6-29
Headlight bulb replacement..........................6-30
Turn signal light bulb replacement ..............6-31
Tail light bulb replacement ...........................6-32
License light bulb replacement.....................6-32
Supporting the motorcycle ...........................6-33
Front wheel removal......................................6-34
Front wheel installation.................................6-35
Rear wheel removal.......................................6-36
Rear wheel installation ..................................6-36
Troubleshooting.............................................6-37
Troubleshooting chart ...................................6-38
MOTORCYCLE CARE AND STORAGE ..............7-1
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Care ...................................................................7-1
Storage..............................................................7-4
SPECIFICATIONS................................................8-1
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How to use the conversion table ....................8-5
CONSUMER INFORMATION .............................9-1
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Identification number records.........................9-1
Key identification number...............................9-1
Vehicle identification number.........................9-1
Model label.......................................................9-2
Noise regulation (For Australia)......................9-2
TABLE OF CONTENTS
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Q SAFETY INFORMATION

TWO-WHEELED MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPER­ATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE
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EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING. HE OR SHE SHOULD:
1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MAN­UAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANU­AL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.
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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 see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident.
Therefore:
a. Wear a brightly colored jacket. b. Use extra caution when you approach and pass through intersections, since intersec-
tions are the most likely places for motorcycle accidents.
c. Ride where other motorists can see you. Avoid riding in another motorist’s “blind spot”.
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Q SAFETY INFORMATION
4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. a. Make sure you are qualified. Also, only lend your motorcycle to experienced operators. b. Know your skills and limits. Staying within your limits may help you to avoid an acci-
dent.
c. We recommend that you practice riding your motorcycle where there is no traffic until
you have become thoroughly familiar with your motorcycle and all of its controls.
5. Many motorcycle accidents have been caused by motorcycle operator errors. A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or under­cornering (insufficient lean angle for the speed). a. Always obey the speed limits and never travel faster than warranted by road and traffic
conditions.
b. Always signal before turning or changing lanes. Make sure other motorists see you.
6. The operator’s and passenger’s posture are important for proper control. a. The operator should keep both hands on the handlebars and both feet on the operator
footrests during operation to maintain control of the motorcycle.
b. The passenger should always hold on to the operator, or the seat strap or grab bar if the
motorcycle is so equipped with both hands and keep both feet on the passenger footrests.
c. Never carry a passenger unless he or she can firmly place both feet on the passenger
footrests.
7. Never ride under the influence of alcohol or drugs.
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Q SAFETY INFORMATION
Protective apparel
The majority of fatalities from motorcycle accidents are the result of head injuries.
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The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries.
1. Always wear an approved helmet.
2. Wear a face shield or goggles. Wind on your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard.
3. The use of heavy boots, jacket, trousers, gloves, etc. is effective in preventing or reducing abrasions or lacerations.
4. Never wear loose fitting clothing. It could catch on the control levers, footrests, or wheels and cause injury or accident.
5. Never touch the engine or exhaust system during or after operation. They become very hot and can cause burns. Always wear protective clothing that covers your legs, ankles, and feet.
6. A passenger should also observe the above precautions.
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Modification
Modifications made to the motorcycle not approved by Yamaha, or the removal of original equipment, may render your motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the machine is changed. To avoid the possibility of an accident, extreme caution should be used if adding cargo or accessories to your motorcycle. Use extra care if riding a motorcycle which has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle:
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Q SAFETY INFORMATION
Loading
The total weight of the operator, passenger, accessories and cargo must not exceed the maxi­mum load limit of 180 kg. When loading within these weight limits, keep the following in mind:
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1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Be sure to distribute the weight as evenly as possible on both sides of the machine to mini­mize imbalance or instability.
2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Recheck accessory mounts and cargo restraints frequently.
3. Never attach any large or heavy items to the handlebars, front forks, or front fender. These items, including such cargo as sleeping bags, duffle bags, or tents, can create unstable handling or slow steering response.
Accessories
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories which may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. You should use extreme caution when selecting and installing any accessories. Keep in mind these guidelines for mounting accessories in addition to those provided under “LOADING”.
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Q SAFETY INFORMATION
1. Never install accessories or carry cargo that would impair the performance of your motor­cycle. Carefully inspect the accessory before using it to make sure it does not in any way
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reduce ground clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors. a. Accessories fitted to the handlebar or the front fork area can create instability due to
improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum.
b. Bulky or large accessories may seriously affect the stability of the motorcycle due to
aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when being passed by or passing 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 accessories are not recommended.
2. Caution must be used if adding electrical accessories. If these accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power.
Gasoline and exhaust gas
1. GASOLINE IS HIGHLY FLAMMABLE: a. Always turn off the engine when refueling. b. Take care not to spill any gasoline on the engine or exhaust system when refueling. c. Never refuel while smoking or in the vicinity of an open flame.
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Q SAFETY INFORMATION
2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation.
3. Always turn off the engine before leaving the motorcycle unattended and remove the igni­tion key. When parking the motorcycle, note the following: a. The engine and exhaust system may be hot. Park the motorcycle in a place where
pedestrians or children are not likely to touch these hot areas. b. Do not park the motorcycle on a slope or soft ground; the motorcycle may fall over. c. Do not park the motorcycle near a flammable source, e.g. a kerosene heater, or near an
open flame. The motorcycle could catch fire.
4. When transporting the motorcycle in another vehicle, be sure it is kept upright and that the fuel cock(s) is turned to “ON” or “RES” (for vacuum type)/”OFF” (for manual type). If it should lean over, gasoline may leak out of the carburetor or fuel tank.
5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get in your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash it off with soap and water and change your clothes.
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Location of the important labels
Please read the following labels carefully before operating this motorcycle.
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Q SAFETY INFORMATION
WARNING
Before you operate this vehicle, read the owner’s manual.
English
3HP-21568-00
4AA-22259-40
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DESCRIPTION

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Left view
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1. Headlight (page 6-30)
2. Fuel cock (page 3-6)
3. Starter (choke) “1 (page 3-7)
4. Air filter (page 6-12)
5. Tool kit (page 6-1)
6. Helmet holder (page 3-9)
7. Shift pedal (page 3-4)
8. Front fork damping adjusting screw (page 3-10)
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Right view
DESCRIPTION
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9. Battery (page 6-28)
10. Fuse (page 6-29)
11. Kick starter (page 3-7)
12. Rear shock absorber compression damping adjuster (page 3-11 ~ 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. Oil filter (page 6-9 ~ 6-12)
17. Rear brake pedal (page 3-4, 6-19)
18. Rear shock absorber rebound damping adjuster (page 3-11 ~ 3-12)
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DESCRIPTION
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Controls/Instruments
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19. Clutch lever (page 3-3)
20. Left handlebar switches (page 3-2)
21. Speedometer (page 3-2)
22. Right handlebar switches (page 3-3)
23. Front brake lever (page 3-4)
24. Throttle grip (page 6-14, 6-25)
25. Fuel tank cap (page 3-5)
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OFF
ON
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INSTRUMENT AND CONTROL FUNCTIONS

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OFF
All electrical circuits are switched off. The key can be removed in this position.
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Main switch
The main switch controls the igni­tion and lighting systems. Its oper­ation is described below.
ON
Electrical circuits are switched on, and the headlight, meter light, tail­light and license light come on. The engine can be started. The key cannot be removed in this position.
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1. Turn indicator light “5”
2. High beam indicator light “&”
3. Neutral indicator light “N”
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Indicator lights
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Turn indicator light “5”
This indicator flashes when the turn switch is moved to the left or right.
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Neutral indicator light “N”
This indicator comes on when the transmission is in neutral.
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High beam indicator light “&”
This indicator comes on when the headlight high beam is used.
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INSTRUMENT AND CONTROL FUNCTIONS
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1. Reset knob
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2. Speedometer
3. Odometer
4. Trip odometer
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Speedometer
The speedometer shows riding
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speed. This speedometer is equipped with an odometer and
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trip odometer. The trip odometer can be reset to “0” with the reset
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knob. Use the trip odometer to estimate how far you can ride on a
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tank of fuel. This information will enable you to plan fuel stops in the future.
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1. Dimmer switch
2. Turn signal switch
3. Horn switch “*”
Handlebar switches
Dimmer switch
Turn the switch to “&” for the high beam and to “ ” for the low beam.
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Turn signal switch
To signal a right-hand turn, push the switch to “6”. To signal a left­hand turn, push the switch to “4”. Once the switch is released it will return to the center position. To cancel the signal, push the switch in after it has returned to the center position.
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Horn switch “*”
Press the switch to sound the horn.
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INSTRUMENT AND CONTROL FUNCTIONS
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See starting instructions prior to starting the engine.
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1. Engine stop switch
2. Start switch “START”
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Engine stop switch
The engine stop switch is a safety device for use in an emergency such as when the motorcycle over­turns or if trouble occurs in the throttle system. Turn the switch to “#” to start the engine. In case of emergency, turn the switch to “$” to stop the engine.
Start switch “START”
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The starter motor cranks the engine when pushing the start switch.
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1. Clutch lever
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Clutch lever
The clutch lever is located on the left handlebar, and the ignition cir­cuit cut-off system is incorporated in the clutch lever holder. Pull the clutch lever to the handlebar to dis­engage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. (Refer to the engine starting procedures for a descrip­tion of the ignition circuit cut-off system.)
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INSTRUMENT AND CONTROL FUNCTIONS
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N
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1. Shift pedal
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N. Neutral
Shift pedal
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This motorcycle is equipped with a constant-mesh 6-speed transmis-
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sion. The shift pedal is located on the
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left side of the engine and is used in combination with the clutch
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when shifting.
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1. Front brake lever 1. Rear brake pedal
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Front brake lever
The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake.
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Rear brake pedal
The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to apply the rear brake.
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INSTRUMENT AND CONTROL FUNCTIONS
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Always wipe off spilled fuel imme­diately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts.
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1. Fuel tank cap
2. Open
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Fuel tank cap
Remove the fuel tank cap by turn­ing it counterclockwise.
1. Filler tube
2. Fuel level
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Fuel
Make sure there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown in the illustration.
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Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the fuel tank above the bot­tom of the filler tube or it may overflow when the fuel heats up later and expands.
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Recommended fuel:
Regular gasoline
For Australia:
Unleaded fuel only
Fuel tank capacity:
Total:
10.0 L
Reserve:
2.0 L
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INSTRUMENT AND CONTROL FUNCTIONS
ON
FUEL
RES
OFF
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ON
RES
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FUEL
OFF
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1. Fuel tank breather hose
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Fuel tank breather hose
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This model is equipped with a fuel tank breather hose.
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Before using this motorcycle:
8 Check the hose connection.
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8 Check the hose for cracks or
damage and replace it if dam­aged.
8 Make sure the end of the hose
is not blocked and clean it if necessary.
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OFF
1. Arrow mark
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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
1. Arrow mark
ON
With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.
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OFF
ON
FUEL
RES
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RES
RES
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INSTRUMENT AND CONTROL FUNCTIONS
b
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1. Arrow mark
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 fuel cock back to “ON” after refueling!
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1. Starter (choke) “1”
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Starter (choke) “1”
Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke).
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1. Kick starter
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Kick starter
Rotate the kick starter away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary-coupled kick starter so the engine can be started in any gear if the clutch is disengaged. However, shifting to neutral before starting is recom­mended.
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INSTRUMENT AND CONTROL FUNCTIONS
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1. Steering lock
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Steering lock
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To lock the steering, turn the han­dlebars all the way to the left.
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Open the steering lock cover, turn the key 1/8 counterclockwise then push the key in and turn it 1/8 turn
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clockwise.
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After checking to see that the steer­ing is locked, remove the key from the lock and close the cover. To release the lock, reverse the above procedure.
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1. Bolt (× 2)
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Seat
To remove the rider seat, remove the bolts. To reinstall the rider seat, insert the projection on the front of the seat into the seat holder, then tighten the bolts.
NOTE:
Make sure that the seat is securely fitted.
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1. Helmet holder
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2. Open
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Helmet holder
To open the helmet holder, insert the key in the lock and turn it as shown. To lock the helmet holder, replace the holder in its original position.
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Never ride with a helmet in the helmet holder. The helmet may hit objects, causing loss of control and possibly an accident.
INSTRUMENT AND CONTROL FUNCTIONS
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Front fork adjustment
This front fork is equipped with a spring preload and damping force adjuster.
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Always adjust each fork leg to the same setting. Uneven adjustment can cause poor handling and loss of stability.
1. Adjust spring preload as fol­lows. The spring preload is adjusted by changing the air pressure.
a. Elevate the front wheel by
placing a suitable stand under the engine.
NOTE:
When checking and adjusting the air pressure, there should be no weight on the front end of the motorcycle.
1. Valve cap
b. Remove the valve cap from
each fork leg.
c. Using the air check gauge,
check and adjust the air pres­sure.
Increasing the air pressure increas­es the spring preload and decreas­ing it, decreases spring preload. To increase: Use an air pump or pressurized air supply. To decrease: Release the air by pushing the valve.
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