Yamaha TTR230 Y 2008 Owner's manual

Read this manual carefully before operating this vehicle.

TT-R230Y

1C6-F8199-24

Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it
is sold.

INTRODUCTION

Welcome to the Yamaha world of motorcycling!

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As the owner of the TT-R230Y, 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-R230Y. 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.

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Please read this manual carefully and completely before operating this motorcycle.

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.

A WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.

NOTICE

TIP

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.

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IMPORTANT MANUAL INFORMATION

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TT-R230Y

OWNER’S MANUAL

© 2008 by Yamaha Motor da Amazônia Ltda

1st edition, May 2008

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 ........................4-5

Seat ................................................. 4-6

Adjusting the shock absorber

assembly ...................................... 4-6

Sidestand ........................................ 4-7

Starting circuit cut-off system .......... 4-8

FOR YOUR SAFETY

- PRE-OPERATION CHECKS ...... 5-1

Pre-operation check list ............... 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 ........................... 7-3

Removing and installing

the panel ...................................... 7-6

Checking the spark plug ................. 7-6

Engine oil and oil filter element ...... 7-7

Cleaning the air filter element .......7-10

Adjusting the carburetor ................7-11

Adjusting the engine idling

speed .........................................7-12

Checking the throttle cable

free play .....................................7-12

Valve clearance .............................7-13

Tires ............................................... 7-13

Spoke wheels ................................ 7-14

Adjusting the clutch lever

free play .....................................7-15

Checking the front brake

lever free play ............................7-15

Adjusting the brake pedal

position and free play ................7-16

Checking the front brake

pads and rear brake shoes ....... 7-17

Checking the front brake

fluid level ....................................7-18

Changing the brake fluid ..............7-18

Drive chain slack ...........................7-19

Cleaning and lubricating

the drive chain ...........................7-20

Checking and lubricating

the cables .................................. 7-20

Checking and lubricating

the throttle grip and cable ........... 7-20

Checking and lubricating

the brake and clutch levers ....... 7-21

Checking and lubricating

the brake pedal ..........................7-21

Checking and lubricating

the sidestand .............................7-21

Checking the front fork ..................7-22

Checking the steering ................... 7-22

Checking the wheel bearings ....... 7-23

Battery ........................................... 7-23

Replacing the fuse ........................7-24

Supporting the motorcycle ............7-25

Front wheel ....................................7-25

Rear wheel ....................................7-26

Troubleshooting ............................ 7-27

Troubleshooting chart ................... 7-29

MOTORCYCLE CARE

AND STORAGE ............................8-1

Care................................................. 8-1

Storage ............................................8-3

SPECIFICATIONS .............................. 9-1

CONSUMER INFORMATION ...........10-1

Identification numbers ...................10-1

Vehicle identification number .... 10-1

Model label.................................. 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
is available from your Yamaha dealer.

1

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1-1

LOCATION OF IMPORTANT LABELS

1

1-2

SAFETY INFORMATION

Be a Responsible Owner

As the vehicle’s owner, you are
responsible for the safe and proper
operation of your motorcycle.
Motorcycles are single-track vehicles.

2

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:

z Obtain thorough instructions from

a competent source on all aspects
of motorcycle operation.

z Observe the warnings and

maintenance requirements in this
Owner’s Manual.

z Obtain qualified training in safe and

proper riding techniques.

z Obtain professional technical

service as indicated in this Owner’s
Manual and/or when made
necessary by mechanical
conditions.

Safe Riding

Perform the pre-operation checks each
time you use the vehicle to make sure

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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.

z 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.

z This motorcycle is designed to

carry the operator only. No
passengers.

z 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:

z Wear a brightly colored jacket.

2-1

z Use extra caution when you are

approaching and passing through
intersections, since intersections
are the most likely places for
motorcycle accidents to occur.

z Ride where other motorists can

see you. Avoid riding in another
motorist’s blind spot.

z Many accidents involve

inexperienced operators.

z Make sure that you are qualified

and that you only lend your
motorcycle to other qualified
operators.

z Know your skills and limits.

Staying within your limits may
help you to avoid an accident.

z We recommend that you

practice riding your motorcycle
until you have become
thoroughly familiar with the
motorcycle and all of its controls.

z 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

SAFETY INFORMATION

warranted by conditions.

z Ride cautiously in unfamiliar areas.

You may encounter hidden
obstacles that could cause an
accident.

z 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
motorcycle.

z Never ride under the influence of

alcohol or other drugs.

z Be sure the transmission is in

neutral 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.

z Always wear an approved helmet.
z Wear a face shield or goggles. Wind

in your unprotected eyes could
contribute to an impairment of
vision that could delay seeing a
hazard.

z The use of a jacket, heavy boots,

trousers, gloves, etc., is effective
in preventing or reducing abrasions
or lacerations.

z Never wear loose-fitting clothes,

otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.

z 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.

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

2-2

areas. If you experience any symptoms
of carbon monoxide poisoning, leave the
area immediately, get fresh air, and
SEEK MEDICAL TREATMENT.

z 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.

z Do not run engine in poorly

ventilated or partially enclosed
areas such as barns, garages, or
carports.

z Do not run engine outdoors where

engine exhaust can be drawn into
a building through openings such
as windows and doors.

Loading

Adding accessories 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 accessories to
your motorcycle. Use extra care when
riding a motorcycle that has added
accessories. Here are some general
guidelines to follow if adding accessories
to your motorcycle:

2

SAFETY INFORMATION

Operation of an overloaded vehicle
could cause an accident.

z The weight of the operator must not

exceed 150 kg (331 lb).

z Accessory weight should be kept

2

as low and close to the motorcycle
as possible. Securely pack your
heaviest items as close to the
center of the vehicle as possible
and make sure to distribute the
weight as evenly as possible on
both sides of the motorcycle to
minimize imbalance or instability.

z Shifting weights can create a

sudden imbalance. Make sure that
accessories are securely attached
to the motorcycle before riding.
Check accessory mounts
frequently.

z Properly adjust the suspension

for your load, and check the
condition and pressure of your
tires.

z Never attach any large or heavy

items to the handlebar, front fork,
or front fender.

Genuine Yamaha Accessories

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

2-3

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
“Loading” when mounting accessories.

z 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
cornering clearance, limit
suspension travel, steering travel
or control operation.

z 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.

z Bulky or large accessories may

seriously affect the stability of the

SAFETY INFORMATION

motorcycle. Wind may attempt to
lift the motorcycle, or the
motorcycle may become
unstable in cross winds.

z 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.

z Use caution when adding electrical

accessories. If electrical
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.

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 7-13 for tire
specifications and more information on
replacing your tires.

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 is available from your
Yamaha dealer.

2-4

2

DESCRIPTION

Left view

3

1. Fuel cock (page 4-5)

2. Starter (choke) knob (page 4-5)

3. Air filter element (page 7-10)

4. Shift pedal (page 4-2)

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3-1

Right view

1. Fuse (page 7-6)

2. Battery (page 7-23)

3. Shock absorber assembly spring preload adjusting nut (page 4-6)

4. Engine oil filter element (page 7-7)

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 button (page 4-1)

3. Ignition switch (page 4-1)

4. Start switch (page 4-1)

5. Brake lever (page 4-2)

6. Throttle grip (page 7-12)

7. 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.

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Handlebar switches

Left

1. Engine stop button “ ”

Right

1. Start switch “ ”

“ENGINE STOP” button

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 “ ”

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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

1. Clutch lever

4

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 4-8.)

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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.

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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.

4-2

INSTRUMENT AND CONTROL FUNCTIONS

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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.

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Fuel tank cap

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.

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Make sure that the fuel tank cap is
properly closed after filling fuel. Leak­ing fuel is a fire hazard.

4-3

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Fuel

1. Fuel tank filler tube

2. Fuel level

Make sure there is sufficient gasoline
in the tank.

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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.

4

INSTRUMENT AND CONTROL FUNCTIONS

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.

3. Wipe up any spilled fuel immedi­ately.

NOTICE:

Immediately wipe

off spilled fuel with a clean, dry,

4

soft cloth, since fuel may dete­riorate painted surfaces or plas­tic parts. [ECA10071]

4. Be sure to securely close the fuel
tank cap.

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 immediately. 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.

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Fuel tank breather hose

1. Fuel tank breather hose

Before operating the motorcycle:

z Check the fuel tank breather hose

connection.

z Check the fuel tank breather hose

for cracks or damage, and replace
it if damaged.

z Make sure that the fuel tank breather

hose is not blocked, and clean it if
necessary.

4-4

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

With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.

RES

1. Arrow mark positioned over “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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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).

1. Arrow mark positioned over “ON”
4-5