Yamaha TTR230 Z 2010 Owner's manual

Read this manual carefully before operating this vehicle.

TT-R230Z

1C6-F8199-25

EAU46090

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-R230Z, 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-R230Z. 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-R230Z

OWNER’S MANUAL

©2009 by Yamaha Motor da Amazônia Ltda.

1st edition, july 2009

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 front brake lever

free play .................................... 7-18

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

Checking and lubricating the

cables ....................................... 7-23

Checking and lubricating the

throttle grip and cable ............... 7-24

Checking and lubricating the

brake and clutch levers ............ 7-24

Checking and lubricating the

brake pedal ............................... 7-24

Checking and lubricating the

sidestand .................................. 7-25

Checking the front fork ................. 7-25

Checking the steering .................. 7-26

Checking the wheel bearings ....... 7-26

Battery ......................................... 7-26

Replacing the fuse ....................... 7-28

Supporting the motorcycle ........... 7-28

Front wheel .................................. 7-29

Rear wheel ...................................7-30

Troubleshooting ............................7-31

Troubleshooting chart ...................7-33

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.

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.

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

2-2

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.

● Do not run engine outdoors where

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

Loading

Adding accessories or cargo to your
motorcycle can adversely affect stabili­ty and handling if the weight distribution
of the motorcycle is changed. To avoid

2

SAFETY INFORMATION

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

2

follow if loading cargo to your motorcy­cle:
The total weight of the operator, acces­sories and cargo must not exceed the
maximum load limit. Operation of an

overloaded vehicle could cause an
accident.

Maximum load:

150 kg (331 lb) (ZAF)

When loading within this weight limit,
keep the following in mind:

● Cargo and accessory weight

should be kept 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.

● Shifting weights can create a sud-

den imbalance. Make sure that ac­cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.

• Properly adjust the suspension
for your load, and check the con­dition and pressure of your tires.

• 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.

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

2-3

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.

SAFETY INFORMATION

● 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 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. 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 opera-

tor 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
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.

2-4

2

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 7-28)

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 button (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

[ECA10071]

parts.

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)

ECA11400

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

INSTRUMENT AND CONTROL FUNCTIONS

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Adjusting the shock absorber assembly

This shock absorber assembly is
equipped with a spring preload adjust­ing nut.

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NOTICE

To avoid damaging the mechanism,
do not attempt to turn beyond the
maximum or minimum settings.

Adjust the spring preload as follows.

1. Loosen the locknut.

1. Locknut

2. Adjusting nut

2. To increase the spring preload and
thereby harden the suspension,
turn the adjusting nut in direction
(a). To decrease the spring pre-

load and thereby soften the sus­pension, turn the adjusting nut in
direction (b).
The spring preload setting is deter­mined by measuring distance A,
shown in the illustration. The short­er distance A is, the lower the
spring preload; the longer distance
A is, the higher the spring preload.
Use the special wrench and exten­sion bar included in the owner’s
tool kit to make the adjustment.

Spring preload:

Minimum (soft):

Distance A = 194 mm (7.6 in)

Standard:

Distance A = 204 mm (8.0 in)

Maximum (hard):

Distance A = 206 mm (8.1 in)

4-7

3. Tighten the locknut to the specified

torque. NOTICE: Always tighten

the locknut against the adjust­ing nut, and then tighten the
locknut to the specified torque.

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Tightening torque:

Locknut:

70 Nm (7.0 m·kgf, 51 ft·lbf)

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WARNING

This shock absorber assembly con­tains highly pressurized nitrogen
gas. Read and understand the fol­lowing information before handling
the shock absorber assembly.

● Do not tamper with or attempt to

open the cylinder assembly.

● Do not subject the shock ab-

sorber assembly to an open
flame or other high heat source.
This may cause the unit to ex­plode due to excessive gas
pressure.

4