Yamaha TT-R230 Manuals

Manuals and User Guides for Yamaha TT-R230. We have 2 Yamaha TT-R230 manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha TT-R230 Service Manual

Yamaha TT-R230 Service Manual (300 pages)

Brand: Yamaha | Category: Motorcycle | Size: 24.2 MB

Table of Contents

Info Gen

7
- Important Information
  3
- How to Use this Manual
  4
- General Information
  5
- Table of Contents
  7
- Chapter 1. General Information
  8
- Motorcycle Identification
  8
  - Frame Number
    8
  - Model Identification
    8
- Important Information
  9
- Special Tools
  11
  - For Adjusting
    11
  - For Engine Services
    12
  - For Frame Services
    15
  - For Electric Components
    16
Table of Contents

17
- Chapter 2. Specifications
  18
- General Specifications
  18
- Maintenance Specifications
  21
  - Engine
    21
  - Frame
    28
  - Electric System
    33
- General Torque Specifications
  34
- Lubrication Points and Lubricant Types
  35
  - Engine
    35
  - Frame
    36
- Lubrication Diagram
  37
- Cable Routing
  39
  - Handle Bar
    39
  - Front
    40
  - Motorcycle - Right Side
    41
  - Motorcycle - Left Side
    42
  - Internal Opening
    43
  - Battery and Components
    44
Chapter 3. Periodic Inspection and Adjustments

45
- Electric System
  46
- Introduction
  47
- Periodic Inspection and Adjustments
  47
- Periodic Maintenance / Pollutant Emission Control
  47
  - Maintenance Schedule Table
    47
- General Maintenance / Lubrication
  48
  - Seat, Fuel Tank and Covers
    49
  - Removal
    49
  - Installation
    51
- Engine
  52
  - Valve Clearance Adjustment
    52
  - Camshaft Chain Adjustment
    55
  - Idle Speed Adjustment
    55
  - Throttle Cable Free Play Adjustment
    56
  - Spark Plug Inspection
    58
  - Ignition Point Inspection
    59
  - Compression Pressure Measurement
    60
  - Engine Oil Level Check
    63
  - Engine Oil Change
    64
  - Oil Pressure Check
    69
  - Clutch Adjustment
    69
  - Air Filter Cleaning
    70
  - Carburetor Connection Check
    72
  - Fuel Hose Check
    72
  - Engine Breather Hose Check
    72
  - Exhaust System Check
    73
  - Core Clearing
    73
- Frame
  73
  - Front Brake Pad Check
    74
  - Air Bleeding (Front Brake System)
    75
    
    Rear Brake Adjustment
    76
    
    Brake Lining Check
    77
    
    Transmission Chain Free Play Adjustment
    78
    
    Transmission Chain Lubrication
    79
    
    Steering Column Adjustment
    80
    
    Front Suspension Inspection
    82
    
    Rear Shock Absorber Adjustment
    82
    
    Tire Inspection
    84
  - Wheel Inspection
    86
  - Wheel Spoke Inspection and Tightening
    86
  - Cable Inspection and Lubrication
    86
  - Pedal/Lever and Side Support Lubrication
    87
  - Rear Suspension Lubrication
    87
- Battery Inspection
  88
- Electric System
  88
- Fuse Inspection
  91
Engine Inspection

93
- Chapter 4. Engine Inspection
  95
- Engine Removal
  95
  - Seat, Fuel Tank and Covers
    95
  - Crankcase Guard
    95
  - Engine Oil
    95
  - Battery Cables
    96
  - Exhaust Tube and Muffler
    96
  - Breather Hose and Carburetor
    97
  - Cables and Wiring
    97
  - Transmission Chain
    99
  - Engine Removal
    100
- Engine Dismounting
  102
  - Head, Cylinder and Piston
    102
  - Magnet Rotor and Starting Gears
    106
  - Clutch, Oil Pump and Balancer Gear
    109
  - Case (Right)
    113
  - Balancer, Transmission and Shifting Fork
    114
  - Crankshaft
    115
  - Rocker and Camshaft
    116
  - Valves
    117
- Inspection and Repair
  119
  - Head
    119
  - Valve Seat
    120
  - Valves and Valve Guides
    123
  - Valve Spring
    125
  - Camshaft
    126
  - Rocker and Rocker Shaft
    127
- Camshaft Chain, Gear, Chain Guide and Tensioner
  128
- Cylinder and Piston
  129
- Piston Rings
  131
- Piston Pin
  132
- Crankshaft
  133
- Balancer Gears
  134
- Primary Gear
  134
- Clutch
  135
- Transmission and Shifting Fork
  137
- Oil Pump and Filter Strainer
  139
- Cases
  141
- Locks and Washers
  141
- Roller Bearings and Retainers
  141
- Engine Mounting and Adjustments
  142
- Valves
  143
- Rocker
  144
- Crankshaft
  146
- Balancer and Transmission
  148
- Balancer, Transmission and Shifting Fork
  150
- Cases
  153
- Shift Shaft
  155
- Clutch, Oil Pump and Balancer Gear
  160
- Oil Filter
  165
- Magnet Rotor and Starting Gears
  166
- Head, Cylinder and Piston
  172
- Reinstalling the Engine
  177
Carburation

184
- Carburetor
  185
- Chapter 5
  185
- Removal
  186
- Dismounting
  187
- Inspection
  189
- Mounting
  191
- Installation
  193
- Frame
  194
- Fuel Level Adjustement
  194
Chapter 6 Frame

195
- Front Wheel
  196
- Removal
  197
- Inspection
  198
- Static Wheel Balancing
  201
- Front Brake
  203
  - Brake Pad Replacement
    204
  - Brake Caliper Dismounting
    207
  - Master Cylinder Dismounting
    209
  - Inspection and Repairs
    210
  - Caliper Mounting
    212
  - Master Cylinder Mounting
    215
- Rear Wheel
  218
  - Inspection
    219
  - Mounting
    221
  - Installation
    223
- Front Fork
  224
  - Removal
    225
  - Dismounting
    226
  - Inspection
    229
  - Mounting
    230
  - Installation
    233
- Steering Column and Handle-Bars
  235
  - Removal
    236
  - Steering Column
    237
  - Inspection
    240
  - Installation
    242
- Rear Shock Absorber and Balance
  248
  - Notes on Handling
    250
  - Notes on Discarding
    250
  - Removal
    251
  - Inspection
    254
  - Installation
    255
- Transmission Ratio
  258
  - Removal
    259
  - Inspection
    260
  - Installation
    262
Electric System

265
- Electric Circuit Diagram Ttr230
  266
- Chapter 7
  267
- Electric Components
  267
- Switch Checks
  268
  - Understanding the Switch Connections
    268
  - Checking the Switch Connections
    269
- Ignition System
  271
  - Ignition Circuit Operation
    271
  - Troubleshooting
    272
- Electric Starting System
  280
  - Starter Motor
    282
- Charging System
  290
? Prob Chapter 8. Troubleshooting

292
- Troubleshooting
  292
- Chapter 8. Troubleshooting
  293
- Starting Failure / Difficulty
  293
  - Fuel System
    293
  - Electric System
    294
  - Compression System
    294
  - Poor Performance at Idle Speed
    295
  - Poor Performance at Medium and High Speeds
    295
  - Gear Shifting Difficulty
    296
  - Unstable Gear
    296
- Clutch Problems
  296
  - Slipping Clutch
    296
  - Dragging Clutch
    297
- Overheating
  297
- Brake Fault
  298
  - Defective Braking System
    298
- Leakage on the Front Fork and Malfunction
  298
  - Malfunction
    298
  - Unstable Driving
    299

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Yamaha TT-R230 Owner's Manual

Yamaha TT-R230 Owner's Manual (71 pages)

Brand: Yamaha | Category: Motorcycle | Size: 2.17 MB

Table of Contents

Important Manual Information
4
Table of Contents
6
Location of Important Labels

8
Safety Information

10
Description

14
- Left View
  14
- Right View
  15
- Controls and Instruments
  16
Instrument and Control Functions

17
- Ignition Switch
  17
- Handlebar Switches
  17
- Clutch Lever
  18
- Shift Pedal
  18
- Brake Lever
  18
- Brake Pedal
  19
- Fuel Tank Cap
  19
- Fuel
  19
- Fuel Tank Breather Hose
  21
- Fuel Cock
  21
- Starter (Choke) Knob
  22
- Seat
  22
- Adjusting the Shock Absorber Assembly
  23
- Sidestand
  24
- Starting Circuit Cut-Off System
  25
For Your Safety - Pre-Operation Checks

27
Operation and Important Riding Points

29
- Starting and Warming up a Cold Engine
  29
- Starting a Warm Engine
  30
- Shifting
  30
- Engine Break-In
  31
- Parking
  31
Periodic Maintenance and Adjustment

32
Motorcycle Care and Storage

63
- Care
  63
- Storage
  65
Specifications

67
Consumer Information

69
- Identification Numbers
  69
Index

70

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