Yamaha TTR230 A 2010, TTR230 A 2011 Owner's manual
Read this manual carefully before operating this vehicle.
TT-R230A
1C6-F8199-26
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Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
INTRODUCTION
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Welcome to the Yamaha world of motorcycling!
As the owner of the TT-R230A, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TT-R230A. The Owner’s Manual
does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and
others from trouble and injury.
In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any
further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
Yamaha continually seeks advancements in product design and quality. Therefore, 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 a Yamaha dealer.
WARNING
Please read this manual carefully and completely before operating this motorcycle.
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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury
or death.
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WARNING
NOTICE
TIP
A WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the
vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
IMPORTANT MANUAL INFORMATION
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TT-R230A
OWNER’S MANUAL
©2010 by Yamaha Motor da Amazônia Ltda.
1st edition, June 2010
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor da Amazônia Ltda.
is expressly prohibited.
Printed in Brazil.
TABLE OF CONTENTS
LOCATION OF IMPORTANT
LABELS .............................................1-1
SAFETY INFORMATION ..................2-1
DESCRIPTION ..................................3-1
Left view ..........................................3-1
Right view........................................3-2
Controls and instruments.................3-3
INSTRUMENT AND CONTROL
FUNCTIONS .......................................4-1
Ignition switch .................................4-1
Handlebar switches ........................4-1
Clutch lever .....................................4-2
Shift pedal .......................................4-2
Brake lever .....................................4-2
Brake pedal ....................................4-3
Fuel tank cap ..................................4-3
Fuel .................................................4-3
Fuel tank breather hose ..................4-4
Fuel cock ........................................4-5
Starter (choke) knob .......................4-6
Seat ................................................4-6
Adjusting the shock absorber
assembly .....................................4-7
Sidestand ........................................4-8
Starting circuit cut-off system .........4-8
FOR YOUR SAFETY –
PRE-OPERATION CHECKS .............5-1
OPERATION AND IMPORTANT
RIDING POINTS.................................6-1
Starting and warming up a cold
engine .........................................6-1
Starting a warm engine .................. 6-2
Shifting ...........................................6-2
Engine break-in ..............................6-3
Parking ...........................................6-3
PERIODIC MAINTENANCE AND
ADJUSTMENT ................................... 7-1
Periodic maintenance chart for the
emission control system .............7-2
General maintenance and
lubrication chart ..........................7-4
Removing and installing the
panel ...........................................7-7
Checking the spark plug .................7-7
Engine oil and oil filter element ...... 7-8
Cleaning the air filter element ......7-11
Adjusting the carburetor ............... 7-13
Adjusting the engine idling
speed ........................................7-13
Checking the throttle cable free
play ........................................... 7-14
Valve clearance ............................ 7-14
Tires .............................................7-15
Spoke wheels ...............................7-16
Adjusting the clutch lever free
play ........................................... 7-17
Checking the brake lever free
play ........................................... 7-17
Adjusting the brake pedal position
and free play ............................. 7-18
Checking the front brake pads
and rear brake shoes ............... 7-19
Checking the front brake fluid
level .......................................... 7-20
Changing the brake fluid .............. 7-21
Drive chain slack .......................... 7-21
Cleaning and lubricating the drive
chain ......................................... 7-22
Checking and lubricating the
cables ....................................... 7-23
Checking and lubricating the
throttle grip and cable ............... 7-23
Checking and lubricating the
brake and clutch levers ............ 7-24
Checking and lubricating the
brake pedal ............................... 7-24
Checking and lubricating the
sidestand .................................. 7-24
Checking the front fork ................. 7-25
Checking the steering .................. 7-25
Checking the wheel bearings ....... 7-26
Battery ......................................... 7-26
Replacing the fuse ....................... 7-27
Supporting the motorcycle ........... 7-28
Front wheel .................................. 7-29
Rear wheel ...................................7-30
Troubleshooting ............................7-31
Troubleshooting chart ...................7-32
MOTORCYCLE CARE AND
STORAGE ..........................................8-1
Care ................................................8-1
Storage ...........................................8-3
SPECIFICATIONS .............................9-1
CONSUMER INFORMATION...........10-1
Identification numbers ..................10-1
TABLE OF CONTENTS
LOCATION OF IMPORTANT LABELS
Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of
your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label
1
is available from your Yamaha dealer.
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1-1
LOCATION OF IMPORTANT LABELS
1-212-1
SAFETY INFORMATION
Be a Responsible Owner
As the vehicle’s owner, you are respon-
sible for the safe and proper operation
2
of your motorcycle.
Motorcycles are single-track vehicles.
Their safe use and operation are dependent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements before
riding this motorcycle.
He or she should:
● Obtain thorough instructions from
a competent source on all aspects
of motorcycle operation.
● Observe the warnings and mainte-
nance requirements in this Owner’s Manual.
● Obtain qualified training in safe
and proper riding techniques.
● Obtain professional technical ser-
vice as indicated in this Owner’s
Manual and/or when made necessary by mechanical conditions.
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Safe Riding
Perform the pre-operation checks each
time you use the vehicle to make sure it
is in safe operating condition. Failure to
inspect or maintain the vehicle properly
increases the possibility of an accident
or equipment damage. See page 5-1
for a list of pre-operation checks.
● This motorcycle is designed for off-
road use only, therefore, it is illegal
to operate it on public streets,
roads, or highways, even a dirt or
gravel one. Off-road use on public
lands may be illegal. Please check
local regulations before riding.
● This motorcycle is designed to car-
ry the operator only. No passengers.
● 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:
• Wear a brightly colored jacket.
• Use extra caution when you are
approaching and passing
through intersections, since intersections are the most likely
places for motorcycle accidents
to occur.
• Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
● Many accidents involve inexperi-
enced operators.
• Make sure that you are qualified
and that you only lend your motorcycle to other qualified operators.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
• We recommend that you practice riding your motorcycle until
you have become thoroughly familiar with the motorcycle and all
of its controls.
SAFETY INFORMATION
● 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). Never travel faster
than warranted by conditions.
● Ride cautiously in unfamiliar ar-
eas. You may encounter hidden
obstacles that could cause an accident.
● The posture of the operator is im-
portant for proper control. The operator should keep both hands on
the handlebar and both feet on the
operator footrests during operation
to maintain control of the motorcycle.
● Never ride under the influence of
alcohol or other drugs.
● Be sure the transmission is in neu-
tral before starting the engine.
Protective Apparel
The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the
single most critical factor in the prevention or reduction of head injuries.
● Always wear an approved helmet.
● Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
● The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
● Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
● Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust system become very hot during or after operation and can cause burns.
2-2
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing carbon monoxide can cause headaches,
dizziness, drowsiness, nausea, confusion, and eventually death.
Carbon Monoxide is a colorless, odorless, tasteless gas which may be
present even if you do not see or smell
any engine exhaust. Deadly levels of
carbon monoxide can collect rapidly
and you can quickly be overcome and
unable to save yourself. Also, deadly
levels of carbon monoxide can linger
for hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poisoning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREATMENT.
● Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rapidly reach dangerous levels.
● Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or carports.
2
SAFETY INFORMATION
● Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Genuine Yamaha Accessories
2
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are available only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection to
Yamaha manufacture parts and accessories or offer other modifications for
Yamaha vehicles. Yamaha is not in a
position to test the products that these
aftermarket companies produce.
Therefore, Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or
modifications not specifically recommended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories, and
Modifications
While you may find aftermarket products similar in design and quality to
genuine Yamaha accessories, recognize that some aftermarket accessories
or modifications are not suitable because of potential safety hazards to you
or others. Installing aftermarket products or having other modifications performed to your vehicle that change any
of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or death.
You are responsible for injuries related
to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
● Never install accessories 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 ground clearance or
2-3
cornering clearance, limit suspension travel, steering travel or control operation.
• Accessories fitted to the handlebar or the front fork area can
create instability due to improper
weight distribution. 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.
• Bulky or large accessories may
seriously affect the stability of
the motorcycle. Wind may attempt to lift the motorcycle, or
the motorcycle may become unstable in cross winds.
• 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.
● Use caution when adding electri-
cal accessories. If electrical accessories exceed the capacity of the
motorcycle’s electrical system, an
SAFETY INFORMATION
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match the
performance capabilities and to provide
the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be
appropriate. Refer to page 7-15 for tire
specifications and more information on
replacing your tires.
Transporting the motorcycle
Be sure to observe following instructions before transporting the motorcycle in another vehicle.
● Remove all loose items from the
motorcycle.
● Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.
● Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to prevent movement.
● Shift the transmission in gear (for
models with a manual transmission).
● Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the motorcycle, such as the frame or upper front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or parts
that could break). Choose the location for the straps carefully so
the straps will not rub against
painted surfaces during transport.
● The suspension should be com-
pressed somewhat by the tiedowns, if possible, so that the motorcycle will not bounce excessively during transport.
2
2-4
DESCRIPTION
Left view
3
1. Fuel cock (page 4-5)
2. Starter (choke) knob (page 4-6)
3. Air filter element (page 7-11)
4. Shift pedal (page 4-2)
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3-1
Right view
1. Fuse (page 7-27)
2. Battery (page 7-26)
3. Shock absorber assembly spring preload adjusting nut (page 4-7)
4. Engine oil filter element (page 7-8)
5. Brake pedal (page 4-3)
DESCRIPTION
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3
3-2
DESCRIPTION
Controls and instruments
3
1. Clutch lever (page 4-2)
2. Engine stop switch (page 4-1)
3. Start switch (page 4-1)
4. Brake lever (page 4-2)
5. Throttle grip (page 7-14)
6. Fuel tank cap (page 4-3)
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3-3
INSTRUMENT AND CONTROL FUNCTIONS
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Ignition switch
The ignition switch controls the ignition
system. The ignition switch positions
are described below.
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ON
All electrical systems are supplied with
power, and the engine can be started.
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OFF
All electrical systems are off.
Handlebar switches
Left
1. Engine stop switch
Right
1. Start switch
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“ENGINE STOP” button
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Hold this button pushed until the engine
stops in case of an emergency, such as
when the vehicle overturns or when the
throttle cable is stuck.
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Start switch “”
Push this switch to crank the engine
with the starter. See page 6-1 for starting instructions prior to starting the engine.
4
4-1
INSTRUMENT AND CONTROL FUNCTIONS
Clutch lever
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Shift pedal
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4
1. Clutch lever 1. Shift pedal 1. Brake 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
The shift pedal is located on the left
side of the engine and is used in combination with the clutch lever when
shifting the gears of the 6-speed constant-mesh transmission equipped on
this motorcycle.
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the starting circuit cut-off system. (See page
4-8.)
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Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handlebar grip.
4-2
INSTRUMENT AND CONTROL FUNCTIONS
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Brake pedal
1. Brake pedal 1. Fuel tank cap
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
Fuel tank cap
2. Remove.
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.
WARNING
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.
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Fuel
Make sure there is sufficient gasoline in
the tank.
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WARNING
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.
1. Before refueling, turn off the engine and be sure that no one is sitting on the vehicle. Never refuel
while smoking, or while in the vicinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters and
clothes dryers.
2. Do not overfill the fuel tank. Stop
filling when the fuel reaches the
bottom of the filler tube. Because
fuel expands when it heats up,
heat from the engine or the sun
can cause fuel to spill out of the
fuel tank.
4
4-3
INSTRUMENT AND CONTROL FUNCTIONS
1. Fuel tank filler tube
4
2. Maximum fuel level
3. Wipe up any spilled fuel immedi-
ately. NOTICE: Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteriorate painted surfaces or plastic
parts.
[ECA10071]
4. Be sure to securely close the fuel
tank cap.
WARNING
Gasoline is poisonous and can
cause injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you should swallow
some gasoline or inhale a lot of gasoline vapor, or get some gasoline in
your eyes, see your doctor immedi-
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ately. If gasoline spills on your skin,
wash with soap and water. If gasoline spills on your clothing, change
your clothes.
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Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
8.0 L (2.11 US gal, 1.76 Imp.gal)
Fuel reserve amount:
1.8 L (0.48 US gal, 0.40 Imp.gal)
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NOTICE
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane number of
91 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand
or premium unleaded fuel. Use of unleaded fuel will extend spark plug life
and reduce maintenance costs.
4-4
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Fuel tank breather hose
1. Fuel tank breather hose
Before operating the motorcycle:
● Check the fuel tank breather hose
connection.
● Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.
● Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.
INSTRUMENT AND CONTROL FUNCTIONS
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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
1. Arrow mark positioned over “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 positioned over “ON”
With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
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!
4
1. Arrow mark positioned over “RES”
4-5
INSTRUMENT AND CONTROL FUNCTIONS
Starter (choke) knob “”
4
1. Starter (choke) knob
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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Seat
To remove the seat
Remove the bolts, and then pull the
seat off.
1. Bolt
To install the seat
1. Insert the projections on the front
of the seat into the seat holders as
shown.
1. Projection
2. Seat holder
2. Place the seat in the original position, and then tighten the bolts.
TIP
Make sure that the seat is properly secured before riding.
4-6
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