Yamaha TTR230 X 2008 Owner's manual
OWNER’S MANUAL
TT-R230X
1C6-F8199-23
INTRODUCTION
Congratulations on your purchase of the Yamaha TTR230X. 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.
1
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
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.
● This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle
is subsequently sold.
● 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 you have any questions concerning this manual, please consult your Yamaha dealer.
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IMPORTANT MANUAL INFORMATION
PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY
AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE
UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND
UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND
CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE
CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
THIS MACHINE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS ILLEGAL TO OPERATE
THIS MACHINE ON ANY PUBLIC STREET, ROAD OR HIGHWAY. SUCH USE IS PROHIBITED BY LAW. THIS MACHINE
COMPLIES WITH ALMOST ALL STATE OFF-HIGHWAY NOISE LEVEL AND SPARK ARRESTER LAWS AND
REGULATIONS. PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERATING THIS
MACHINE.
IMPORTANT MANUAL INFORMATION
TTR230X
OWNER’S MANUAL
cc
c 2007 by Yamaha Motor da Amazônia Ltda.
cc
1st edition, May 2007
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor da Amazônia Ltda.
is expressly prohibited.
Printed in Brazil.
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TABLE OF CONTENTS
SAFETY INFORMATION .................... 1-1
Location of important labels ............ 1-6
DESCRIPTION ................................... 2-1
Left view .......................................... 2-1
Right view ........................................ 2-2
Controls and instruments ................ 2-3
INSTRUMENT AND CONTROL
FUNCTION ......................................... 3-1
Main switch ..................................... 3-1
Handlebar switches ........................3-1
Clutch lever .....................................3-2
Shift pedal .......................................3-2
Brake lever ......................................3-2
Brake pedal ..................................... 3-3
Fuel tank cap ................................... 3-3
Fuel ................................................. 3-3
Fuel tank breather hose .................. 3-5
Fuel cock .........................................3-5
Starter (choke) knob ........................ 3-6
Seat ................................................. 3-6
Adjusting the shock absorber
assembly ...................................... 3-7
Starting circuit cut-off system .......... 3-8
PRE-OPERATION CHECKS .............. 4-1
Pre-operation check list ..................4-1
OPERATION AND IMPORTANT RIDING
POINTS ...............................................5-1
Starting and warming up a cold
engine .......................................... 5-1
Starting a warm engine ................... 5-2
Shifting ............................................ 5-2
Engine break-in ............................... 5-3
Parking ............................................5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR .................................. 6-1
Periodic maintenance chart for the
emission control system ..............6-2
General maintenance and lubrication
chart ............................................. 6-3
Removing and installing the panels 6-6
Checking the spark plug ................. 6-7
Engine oil and oil filter element ......6-8
Cleaning the air filter element .......6-11
Adjusting the carburetor ................6-13
Adjusting the throttle cable
free play .....................................6-13
Adjusting the valve clearance .......6-13
Tires ............................................... 6-14
Spoke wheels ................................ 6-16
Adjusting the clutch lever
free play ..................................... 6-16
Adjusting the brake pedal position 6-17
Checking the front brake
pads and rear brake shoes ....... 6-18
Checking the brake fluid level ......6-18
Changing the brake fluid ..............6-19
Drive chain slack ........................... 6-19
Lubricating the drive chain ...........6-20
Checking and lubricating
the cables .................................. 6-21
Checking and lubricating
the throttle grip and cable .......... 6-21
Checking and lubricating
the brake and clutch levers ....... 6-22
Lubricating the brake pedal ..........6-22
Checking and lubricating
the sidestand .............................6-22
Checking the front fork ..................6-23
Checking the steering ................... 6-23
Checking the wheel bearings ....... 6-24
Battery ........................................... 6-24
Replacing the fuse ........................ 6-26
Supporting the motorcycle ............ 6-26
Front wheel .................................... 6-27
Rear wheel ....................................6-27
Troubleshooting ............................6-29
Troubleshooting chart ................... 6-30
MOTORCYCLE CARE AND
STORAGE ...........................................7-1
Care................................................. 7-1
Storage ............................................ 7-3
SPECIFICATIONS .............................. 8-1
TABLE OF CONTENTS
CONSUMER INFORMATION ............. 9-1
Identification numbers ..................... 9-1
Maintenance record ........................ 9-2
SAFETY INFORMATION
MACHINES 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 MACHINE.
HE OR SHE SHOULD:
● OBTAIN THOROUGH
INSTRUCTIONS FROM A
COMPETENT SOURCE ON ALL
ASPECTS OF MACHINE
OPERATION.
● OBSERVE THE WARNINGS AND
MAINTENANCE
REQUIREMENTS IN THE
OWNER’S MANUAL.
● OBTAIN QUALIFIED TRAINING IN
SAFE AND PROPER RIDING
TECHNIQUES.
● OBTAIN PROFESSIONAL
TECHNICAL SERVICE AS
INDICATED BY THE OWNER’S
MANUAL AND/OR WHEN MADE
NECESSARY BY MECHANICAL
CONDITIONS.
Safe riding
● Always make pre-operation checks.
Careful checks may help prevent
an accident.
● This machine is designed for off-
road use only, therefore, it is illegal
to operate it on public streets,
roads, or highways. Off-road use on
public lands may be illegal. Please
check local regulations before
riding.
● This machine is designed to carry
the operator only. No passengers.
● Many accidents involve
inexperienced operators.
• Make sure that you are qualified
and that you only lend your
machine to other qualified
operators.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
● Many accidents have been caused
by error of the machine 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 areas.
You may encounter hidden
obstacles that could cause an
accident.
● The posture of the operator is
important 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 machine.
● Never ride under the influence of
alcohol or other drugs.
Protective apparel
The majority of fatalities from machine
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
1
1-1
SAFETY INFORMATION
in preventing or reducing abrasions
or lacerations.
● Never wear loose-fitting clothes,
1
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
● 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.
Modifications
Modifications made to this machine not
approved by Yamaha, or the removal of
original equipment, may render the
machine unsafe for use and may cause
severe personal injury. Modifications
may also make your machine illegal to
use.
Loading and accessories
Adding accessories or cargo to your
machine can adversely affect stability
and handling if the weight distribution of
the machine is changed. To avoid the
possibility of an accident, use extreme
caution when adding cargo or
accessories to your machine. Use extra care when riding a machine that has
added cargo or accessories. Here are
some general guidelines to follow if
loading cargo or adding accessories to
your machine:
Loading
The total weight of the operator,
accessories and cargo must not exceed
the maximum load limit of 90 kg (198 lb).
When loading within this weight limit,
keep the following in mind:
● Cargo and accessory weight should
be kept as low and close to the
machine as possible. Make sure to
distribute the weight as evenly as
possible on both sides of the
machine to minimize imbalance or
instability.
● Shifting weights can create a
sudden imbalance. Make sure that
accessories and cargo are securely
1-2
attached to the machine before
riding. Check accessory mounts
and cargo restraints frequently.
● 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 machine. 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 these guidelines in mind for
mounting accessories in addition to
those provided under “Loading”.
● Never install accessories or carry
cargo that would impair the
performance of your machine.
Carefully inspect the accessory
before using it to make sure that it
SAFETY INFORMATION
does not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or
obscure lights or reflectors.
• 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.
• Bulky or large accessories may
seriously affect the stability of the
machine due to aerodynamic
effects. Wind may attempt to lift
the machine, or the machine 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 electrical
accessories. If electrical
accessories exceed the capacity of
the machine’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas
● GASOLINE IS HIGHLY
FLAMMABLE:
• Always turn the engine off when
refueling.
• Take care not to spill any gasoline
on the engine or exhaust pipe(s)/
muffler(s) when refueling.
• Never refuel while smoking or in
the vicinity of an open flame.
● 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
machine in an area that has
adequate ventilation.
● Always turn the engine off before
1-3
leaving the machine unattended
and remove the key from the main
switch. When parking the machine,
note the following:
• The engine and exhaust pipe(s)/
muffler(s) may be hot, therefore,
park the machine in a place
where pedestrians or children are
not likely to touch these hot
areas.
• Do not park the machine on a
slope or soft ground, otherwise it
may fall over.
• Do not park the machine near a
flammable source (e.g., a
kerosene heater, or near an open
flame), otherwise it could catch
fire.
● When transporting the machine 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 machine should lean
over, gasoline may leak out of the
carburetor or fuel tank.
● If you should swallow any gasoline,
inhale a lot of gasoline vapor, or
allow gasoline to get into your eyes,
1
SAFETY INFORMATION
see your doctor immediately. If any
gasoline spills on your skin or
clothing, immediately wash the
1
affected area with soap and water
and change your clothes.
1-4
SAFETY INFORMATION
1
1-5
SAFETY INFORMATION
Location of important labels
Please read the following important labels carefully before operating this vehicle.
1
1-6
1
2
TIRE INFORMATION
Cold tire normal pressure should be set as
follows.
FRONT: 100kPa, (1.00kgf/cm2), 15psi
REAR: 100kPa, (1.00kgf/cm2), 15psi
3RV-21668-A0
3
SAFETY INFORMATION
1
1-7
DESCRIPTION
Left view
2
1. Fuel cock (page 3-5)
2. Starter (choke) knob (page 3-6)
3. Air filter element (page 6-11)
4. Shift pedal (page 3-2)
2-1
Right view
1. Fuse (page 6-26)
2. Battery (page 6-24)
3. Shock absorver assembly spring preload adjusting nut (page 3-7)
4. Engine oil filter element (page 6-8)
5. Brake pedal (page 3-3)
DESCRIPTION
2
2-2
DESCRIPTION
Controls and instruments
2
1. Clutch lever (page 3-2)
2. Engine stop switch (page 3-1)
3. Main switch (page 3-1)
4. Start switch (page 3-1)
5. Brake lever (page 3-2)
6. Throttle grip (page 6-13)
7. Fuel tank cap (page 3-3)
2-3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch
The main switch controls the ignition
systems. The various main switch
positions are described below.
ON
All electrical systems are supplied with
power, and the engine can be started.
OFF
All electrical systems are off.
Handlebar switches
Left
1. Engine stop switch “ “
Right
1. Start switch “ “
Engine stop switch “ ”
Push this switch to stop the engine in
case of an emergency, such as when
the motorcycle overturns or when the
throttle cable is stuck.
Start switch “ ”
Push this switch to crank the engine with
the starter.
See page 5-1 for starting instructions
prior to starting the engine.
3
3-1
INSTRUMENT AND CONTROL FUNCTIONS
Clutch lever
3
1. 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 starting
circuit cut-off system. (See page 3-8.)
Shift pedal
1. Shift pedal
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.
Brake lever
1. Brake lever
The brake lever is located at the right
handlebar grip. To apply the front brake,
pull the lever toward the handlebar grip.
3-2
INSTRUMENT AND CONTROL FUNCTIONS
1
2
Brake pedal
1. Brake pedal
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
1
2
1. 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.
Make sure that the fuel tank cap is
properly closed before riding.
Fuel
1. Fuel tank filter tube
2. Fuel lever
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
●●
● Do not overfill the fuel tank,
●●
otherwise it may overflow when
the fuel warms up and expands.
●●
● Avoid spilling fuel on the hot
●●
engine.
3
3-3
INSTRUMENT AND CONTROL FUNCTIONS
Your Yamaha engine has been designed
Immediately wipe off spilled fuel with
a clean, dry, soft cloth, since fuel may
deteriorate painted surfaces or plastic
parts.
3
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)
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.
to use regular unleaded gasoline with a
pump octane number [(R+M)/2] of 86 or
higher, or 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.
Gasohol
● There are two types of gasohol:
gasohol containing ethanol and that
containing methanol. Gasohol
containing ethanol can be used if
the ethanol content does not exceed
10%. Gasohol containing methanol
is not recommended by Yamaha
because it can cause damage to
the fuel system or vehicle
performance problems.
3-4
INSTRUMENT AND CONTROL FUNCTIONS
Fuel tank breather hose
1
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 end of the fuel
tank breather hose is not blocked,
and clean it if necessary.
Fuel cock
The fuel cock supplies fuel from the tank
to the carburetor while filtering it also.
The fuel cock has three positions:
OFF
RES
OFF
FUEL
ON
1
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
RES
OFF
FUEL
ON
ON
1. Arrow mark positioned over “ON”
1
With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
3
3-5
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