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TT250 RN 2001
Owner's manual
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Yamaha TT250 RN 2001 Owner's manual

OWNER’S MANUAL
TT250R(N)
4PX-28199-26

INTRODUCTION

Congratulations on your purchase of the Yamaha TT250R. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting 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 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 remain
8 Yamaha continually seeks advancements in product design and quality. Therefore, while this
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.
with it even if the motorcycle is subsequently sold.
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 you have any ques­tions concerning this manual, please consult your Yamaha dealer.
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IMPORTANT MANUAL INFORMATION
EW000002
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
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TT250R(N)
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OWNER’S MANUAL
©2000 by Yamaha Motor Co., Ltd.
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1st Edition, June 2000
All rights reserved.
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Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd. is expressly prohibited.
Printed in Japan.

TABLE OF CONTENTS

SAFETY INFORMATION.....................................1-1
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Safe riding..........................................................1-1
Protective apparel..............................................1-3
Modifications......................................................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 and instruments...................................2-3
INSTRUMENT AND CONTROL
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FUNCTIONS........................................................3-1
Main switch........................................................3-1
Indicator lights....................................................3-1
Speedometer unit ..............................................3-2
Handlebar switches............................................3-2
Clutch lever........................................................3-3
Shift pedal..........................................................3-4
Brake lever.........................................................3-4
Brake pedal........................................................3-4
Fuel tank cap .....................................................3-5
Fuel....................................................................3-5
Fuel tank breather hose.....................................3-6
Fuel cock............................................................3-6
Starter (choke) knob “
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
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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......................................5-2
Shifting...............................................................5-3
Tips for reducing fuel consumption....................5-3
Engine break-in..................................................5-4
Parking...............................................................5-5
PERIODIC MAINTENANCE AND MINOR
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REPAIR................................................................6-1
Owner’s tool kit ..................................................6-1
1”...................................3-7
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TABLE OF CONTENTS
Periodic maintenance and lubrication chart.......6-2
Removing and installing the cowling and
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panels ..............................................................6-5
Checking the spark plug ....................................6-6
Engine oil and oil filter element..........................6-8
Cleaning the air filter element..........................6-11
Adjusting the carburetor...................................6-13
Adjusting the engine idling speed....................6-13
Adjusting the throttle cable free play................6-14
Adjusting the valve clearance..........................6-14
Tires.................................................................6-14
Spoke wheels ..................................................6-17
Adjusting the clutch lever free play..................6-17
Adjusting the brake lever free play...................6-18
Adjusting the brake pedal position...................6-18
Adjusting the brake light switch........................6-19
Checking the front and rear brake pads ..........6-19
Checking the brake fluid level..........................6-20
Changing the brake fluid..................................6-21
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 headlight bulb ...........................6-30
Replacing a turn signal light bulb.....................6-31
Replacing the tali/brake light bulb....................6-32
Replacing the license plate light bulb ..............6-32
Supporting the motorcycle...............................6-33
Front wheel......................................................6-34
Rear wheel.......................................................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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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

MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPER-
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TISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE­MENTS BEFORE RIDING THIS MOTORCYCLE. 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 approaching and passing through intersections, since intersections
are the most likely places for motorcycle accidents to occur.
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 that you are qualified and that you only lend your motorcycle to other qualified oper-
ators. b. Know your skills and limits. Staying within your limits may help you to avoid an accident. c. We recommend that you practice riding your motorcycle where there is no traffic until you have
become thoroughly familiar with the motorcycle and all of its controls.
5. Many accidents have been caused by error of the motorcycle operator. 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 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 both hands on the handlebar and both feet on the operator footrests
during operation to maintain control of the motorcycle.
b. The passenger should always hold onto the operator, the seat strap or grab bar, if 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 other drugs.
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Q SAFETY INFORMATION
Protective apparel
The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety
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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 in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard.
3. The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations.
4. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an 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. Passengers should also observe the precautions mentioned above.
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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 also make your motorcycle illegal to use.
Loading and accessories
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Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcy­cle that 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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Loading
The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 180 kg. When loading within this weight limit, keep the following in mind:
1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle 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. 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.
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Accessories
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories. Keep the following guidelines in mind, as well as those provided under “Loading” when mounting accessories.
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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 that it does not in any way reduce
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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 aerody-
namic 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 accessories are not recommended.
2. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycleís electrical system an electric failure could result, which could cause a dangerous loss of lights or engine power.
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Gasoline and exhaust gas
1. GASOLINE IS HIGHLY FLAMMABLE: a. Always turn the engine off 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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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 the engine off before leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following: a. The engine and exhaust system may be hot, therefore, 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, 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 the motor­cycle 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 into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediate­ly wash the affected area with soap and water and change your clothes.
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Location of important labels
Please read the following important labels carefully before operating this motorcycle.
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Q SAFETY INFORMATION
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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) 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)
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Right view
DESCRIPTION
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9. Battery (page 6-27)
10. Fuse (page 6-29)
11. Kickstarter (page 3-7)
12. Rear 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)
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DESCRIPTION
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Controls and instruments
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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)
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OFF
ON

INSTRUMENT AND CONTROL FUNCTIONS

Main switch
The main switch controls the ignition and lighting systems. The various main switch positions are described below.
ON
All electrical systems are supplied with power, and the headlight, meter lighting, taillight and license plate light come on, and the engine can be started. The key cannot be removed.
OFF
All electrical systems are off. The key can be removed.
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1. Turn signal indicator light “5”
2. High beam indicator light “&”
3. Neutral indicator light “N”
Indicator lights
Turn signal indicator light “5”
This indicator light flashes when the turn signal switch is pushed to the left or right.
High beam indicator light “&”
This indicator light comes on when the high beam of the headlight is switched on.
Neutral indicator light “N”
This indicator light comes on when the transmission is in the neutral position.
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INSTRUMENT AND CONTROL FUNCTIONS
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1. Speedometer
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2. Odometer
3. Trip odometer
4. Reset knob
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Speedometer unit
The speedometer unit is equipped
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with a speedometer, an odometer and a tripmeter. The speedometer
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shows riding speed. The odometer shows the total distance traveled.
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The tripmeter shows the distance traveled since it was last set to zero
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with the reset knob. The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops.
1. Dimmer switch
2. Turn signal switch
3. Horn switch “*”
Handlebar switches
Dimmer switch
Set this switch to “&” for the high beam and to “ ” for the low beam.
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”. When released, the switch returns to the center position. To cancel the turn signal lights, push the switch in after it has returned to the center position.
Horn switch “*”
Press this switch to sound the horn.
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INSTRUMENT AND CONTROL FUNCTIONS
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1. Engine stop switch
2. Start switch “START”
Engine stop switch
Set this switch to “$” to stop the engine in case of an emergency, such as when the motorcycle over­turns or when the throttle cable is stuck.
Start switch “START”
Push this switch to crank the engine with the starter.
See page 5-1 for starting instruc­tions prior to starting the engine.
1. Clutch lever
Clutch lever
The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the han­dlebar 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 the igni­tion circuit cut-off system. (See page 3-13 for an explanation of the ignition circuit cut-off system.)
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INSTRUMENT AND CONTROL FUNCTIONS
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1. Shift pedal
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N. Neutral
Shift pedal
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The shift pedal is located on the left side of the engine and is used in
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combination with the clutch lever when shifting the gears of the
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6-speed constant-mesh transmission equipped on this motorcycle.
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1. Brake lever 1. Brake pedal
Brake lever
The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the han­dlebar grip.
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Brake pedal
The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.
INSTRUMENT AND CONTROL FUNCTIONS
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1. Fuel tank cap a. Open.
Fuel tank cap
To remove the fuel tank cap, turn it counterclockwise, and then pull it off. To install the fuel tank cap, insert it into the tank opening, and then turn it clockwise.
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Make sure that the fuel tank cap is properly closed before riding.
1. Filler tube
2. Fuel level
Fuel
Make sure that 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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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.
Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted sur­faces or plastic parts.
Recommended fuel:
Regular gasoline
For Australia:
Unleaded fuel only
Fuel tank capacity:
Total amount:
10.0 L
Reserve amount:
2.0 L
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INSTRUMENT AND CONTROL FUNCTIONS
ON
FUEL
RES
OFF
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ON
RES
ON
FUEL
OFF
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1. Fuel tank breather hose
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Fuel tank breather hose
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Before operating the motorcycle:
8 Check the fuel tank breather
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hose connection.
8 Check the fuel tank breather
hose for cracks or damage, and replace it if damaged.
8 Make sure that the end of the
fuel tank breather hose is not blocked, and clean it if neces­sary.
OFF: Closed position
1. Arrow mark positioned over “OFF”
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: Normal position
1. Arrow mark positioned over “ON”
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: Reserve position
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INSTRUMENT AND CONTROL FUNCTIONS
b
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1. Arrow mark positioned over “RES”
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!
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1. Starter (choke) knob “1”
Starter (choke) knob “1”
Starting a cold engine requires a rich­er air-fuel mixture, which is supplied by the starter (choke). Move the knob in direction a to turn on the starter (choke). Move the knob in direction b to turn off the starter (choke).
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1. Kickstarter
Kickstarter
To start the engine, fold out the kick­starter lever, move it down lightly with your foot until the gears engage, and then push it down smoothly but force­fully. This model is equipped with a primary kickstarter, allowing the engine to be started in any gear if the clutch is disengaged. However, shift­ing the transmission into the neutral position 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
1. Turn the handlebar all the way to
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the left.
2. Open the steering lock cover, and then insert the key.
3. Turn the key 1/8 turn counter­clockwise, push it in, and then turn it 1/8 turn clockwise.
4. Check that the steering is locked, remove the key, and then close the lock cover.
To unlock the steering
Reverse the above procedure.
1. Bolt (×2)
Seat
To remove the seat
Remove the bolts, and then pull the seat off.
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1. Projection (×2)
2. Seat holder (×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.
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1. Helmet holder
Helmet holder
To open the helmet holder, insert the key into the lock, and then turn the key as shown.
To lock the helmet holder, place it in the original position, and then remove the key.
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Never ride with a helmet attached to the helmet holder, since the hel­met may hit objects, causing loss of control and possibly an acci­dent.
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INSTRUMENT AND CONTROL FUNCTIONS
Adjusting the front fork
The front fork is equipped with air valves for adjusting the spring rate and screws for adjusting the damping force.
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There should be no difference in air pressure between the fork legs.
Spring rate
The total spring rate is adjusted by changing the air pressure as follows.
1. 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. Air valve cap
2. Air valve
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.
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INSTRUMENT AND CONTROL FUNCTIONS
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4. To increase the spring rate and thereby harden the suspension,
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increase the air pressure with an air pump or compressed air. To decrease the spring rate and
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thereby soften the suspension, decrease the air pressure by
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pushing each valve stem down.
Spring rate Minimum (soft):
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Air pressure = 0 kPa (0 kgf/cm2, 0 psi)
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Standard:
Air pressure = 0 kPa (0 kgf/cm2, 0 psi)
Maximum (hard):
Air pressure = 40 kPa
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(0.4 kgf/cm2, 0.4 psi)
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Always adjust both fork legs equally, otherwise poor handling and loss of stability may result.
5. Securely install the air valve caps.
1. Rubber cap
Damping force
1. Remove the rubber cap from each fork leg.
EC000012
Never exceed the maximum air pressure, otherwise the front fork oil seals may become damaged.
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