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Yamaha TTR250L Manuals
Manuals and User Guides for Yamaha TTR250L. We have
2
Yamaha TTR250L manuals available for free PDF download: Service Manual
Yamaha TTR250L Service Manual (299 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 12.31 MB
Table of Contents
Table of Contents
7
Motorcycle Identification
14
Vehicle Identification Number
14
Engine Serial Number
14
Chapter 1. General Information
14
Important Information
15
Preparation for Removal and Disassembly
15
All Replacement Parts
16
Gaskets, Oil Seals, and O-Rings
16
Lock Washers/Plates and Cotter Pins
16
Bearings and Oil Seals
16
Special Tools
17
For Tune up
17
For Engine Service
18
For Chassis Service
19
For Electrical Components
20
General Specifications
22
Chapter 2. Specifications
22
Maintenance Specifications
25
Engine
25
Chassis
33
Electrical
37
General Torque Specifications
39
Lubrication Points and Lubricant Types
40
Engine
40
Chassis
41
Lubrication Diagram
42
Cable Routing
45
Chapter 3
50
Periodic Inspection and Adjustment
50
Introduction
50
Periodic Maintenance/Lubrication
50
Seat, Fuel Tank and Covers
52
Removal
52
Installation
53
Engine
55
Valve Clearance Adjustment
55
Timing Chain Adjustment
62
Adj
62
Idling Speed Adjustment
63
Throttle Cable Free Play Adjustment
63
Spark Plug Inspection
64
Ignition Timing Check
66
Compression Pressure Measurement
67
Engine Oil Level Inspection
68
Engine Oil Replacement
69
Oil Pressure Inspection
73
Clutch Adjustment
73
Air Filter Cleaning
74
Spark Arrester Cleaning
76
Crankcase Breather Hose Inspection
77
Fuel Line Inspection
77
Exhaust System Inspection
77
Carburetor Joint Inspection
77
Chassis
78
Front Brake Adjustment
78
Rear Brake Adjustment
78
Brake Fluid Level Inspection
80
Air Bleeding (Hydraulic Brake System)
81
Brake Pad Inspection
82
Brake Hose Inspection
83
Drive Chain Slack Adjustment
83
Drive Chain Lubrication
85
Steering Head Adjustment
85
Front Fork Inspection
87
Front Fork Adjustment
88
Rear Shock Absorber Adjustment
90
Tire Inspection
92
Wheel Inspection
95
Spokes Inspection and Tightening
95
Cable Inspection and Lubrication
95
Lever and Pedal Lubrication
96
Sidestand Lubrication
96
Electrical
97
Battery Inspection
97
Fuse Inspection
104
Headlight Beam Adjustment
105
Headlight Bulb Replacement
105
Engine Removal
106
Seat, Fuel Tank and Covers
106
Carburetor
106
Engine Guard
106
Engine Oil
106
Battery
107
Exhaust Pipe
107
Crankcase Breather Hose
107
Starter Motor
107
Clutch Cable and Leads
108
Drive Sprocket
108
Footrest and Brake Pedal
109
Engine Removal
109
Chapter 4. Engine Overhaul
106
Engine Disassembly
110
Cylinder Head, Camshafts, Cylinder and Piston
110
Clutch, Oil Pump and Balancer Gear
113
Shift Shaft
115
Rotor and Starter Drives
115
Oil Filter
117
Crankcase
117
Balancer, Transmission and Shifter
118
Crankshaft
119
Bearings and Oil Seals
119
Valve
119
Inspection and Repair
121
Cylinder Head
121
Valve Seat
121
Valve and Valve Guide
125
Valve Spring
126
Camshaft
127
Valve Lifter
129
Timing Chain, Sprocket and Chain Guide
129
Cylinder and Piston
130
Piston Ring
132
Piston Pin
132
Crankshaft
133
Balancer Drive Gear and Balancer Gear
134
Primary Drive
135
Clutch
135
Transmission and Shifter
136
Oil Pump and Strainer
138
Electric Starter Drive
139
Crankcase
140
Bearing and Oil Seal
140
Circlip and Washer
140
Engine Assembly and Adjustment
141
Crankshaft and Balancer
141
Crankshaft and Balancer Shaft
142
Transmission
143
Shifter
144
Transmission and Shifter
145
Crankcase
147
Crankcase (Right)
148
Shift Shaft
148
Oil Pump
150
Clutch
151
Oil Pump
152
Oil Filter
155
Rotor and Starter Drives
156
Cylinder and Piston
159
Cylinder and Piston
160
Cylinder Head
162
Valve, Camshaft and Cam Chain
163
Valve and Camshaft
164
Cylinder Head
166
Remounting Engine
168
Carburetor
174
Removal
175
Disassembly
176
Inspection
178
Assembly
180
Installation
182
Fuel Level Adjustment
183
Throttle Valve Position
184
Chapter 5. Carburetor
174
Front Wheel
185
Removal
186
Inspection
186
Installation
189
Wheel Static Balance Adjustment
190
Chapter 6. Chassis
185
Rear Wheel
192
Removal
193
Inspection
193
Installation
194
Wheel Static Balance Adjustment
195
Front and Rear Brake
196
Brake Pad Replacement
198
Caliper Disassembly
202
Master Cylinder Disassembly
205
Inspection and Repair
208
Caliper Assembly
210
Master Cylinder Assembly
215
Front Fork
219
Removal
220
Disassembly
221
Inspection
222
Assembly
224
Installation
228
Steering Head and Handlebar
230
Removal
232
Inspection
235
Installation
236
Rear Shock Absorber and Swingarm
242
Handling Notes
244
Notes on Disposal
244
Removal
245
Inspection
250
Installation
252
Drive Chain and Sprockets
256
Removal
257
Inspection
258
Installation
259
Ttr250L(C) Circuit Diagram
262
Chapter 7. Electrical
262
Electrical Components
264
Checking of Connections
266
Ignition System
267
Electrical Starting System
273
Starting Circuit Operation
274
Starter Motor
280
Elec
280
Charging System
284
Lighting System
287
Lighting System Check
290
Starting Failure/Hard Starting
292
Fuel System
292
Electrical System
292
Compression System
292
Chapter 8. Troubleshooting
292
Trbl
292
Shtg
292
Poor Idle Speed Performance
293
Poor Medium and High Speed Performance
293
Faulty Gear Shifting
294
Hard Shifting
294
Shift Pedal Does Not Move
294
Jump-Out Gear
294
Clutch Slipping/Dragging
294
Clutch Slipping
294
Clutch Dragging
294
Overheating
295
Faulty Brake
295
Poor Braking Effect
295
Front Fork Oil Leakage and Front Fork Malfunction
295
Oil Leakage
295
Malfunction
295
Instable Handling
296
Faulty Signal and Lighting System
297
Headlight Dark
297
Bulb Burnt out
297
Ttr250L(C) Wiring Diagram
298
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Yamaha TTR250L Service Manual (296 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 29.74 MB
Table of Contents
Illustrated Symbols
5
Table of Contents
6
General Information
7
Motorcycle Identification
14
Vehicle Identification Number
14
Engine Serial Number
14
Important Information
15
Preparation for Removal and Disassembly
15
All Replacement Parts
16
Gaskets, Oil Seals, and O-Rings
16
Lock Washers/Plates and Cotter Pins
16
Bearings and Oil Seals
16
Special Tools
17
Circlips
17
For Engine Service
18
For Chassis Service
19
For Electrical Components
20
Specifications
21
Maintenance Specifications
24
Tightening Torques
34
Electrical
36
General Torque Specifications
38
Lubrication Points and Lubricant Types
39
Lubrication Diagram
41
Cable Routing
44
Periodic Inspection and Adjustment
48
Periodic Maintenance/Lubrication
48
Seal, Fuel Tank and Covers
50
Engine
53
Valve Clearance Adjustment
53
Intake
56
Exhaust
56
Timing Chain Adjustment
60
Idling Speed Adjustment
60
Throttle Cable Free Play Adjustment
61
Spark Plug Inspection
62
Ignition Timing Check
64
Compression Pressure Measurement
65
Engine Oil Level Inspection
66
Engine Oil Replacement
67
Oil Pressure Inspection
71
Clutch Adjustment
71
Air Filter Cleaning
72
Spark Arrester Cleaning
74
Crankcase Breather Hose Inspection
75
Fuel Line Inspection
75
Exhaust System Inspection
75
Front Brake Adjustment
76
Rear Brake Adjustment
76
Brake Fluid Level Inspection
78
Air Bleeding
79
Brake Pad Inspection
80
Brake Hose Inspection
80
Drive Chain Slack Adjustment
81
Steering Head Adjustment
83
Front Fork Inspection
85
Rear Shock Absorber Adjustment
88
Tire Inspection
90
Wheel Inspection
93
Spokes Inspection and Tightening
93
Cable Inspection and Lubrication
93
Battery Inspection
95
Charging
95
Charging Method Using a Variable-Current Type Charger
99
Charging Method Using a Constant-Voltage Type Charger
100
Fuse Inspection
101
Headlight Beam Adjustment
103
Headlight Bulb Replacement
103
Engine Overhaul
104
Engine Removal
104
Seat, Fuel, Tank and Covers
104
Carburetor
104
Battery
105
Exhaust Pipe
105
Crankcase Breather Hose
105
Starter Motor
105
Clutch Cable and Leads
106
Drive Sprocket
106
Footrest and Brake Pedal
107
Engine Disassembly
108
Clutch, Oil Pump and Balancer Gear
111
Shift Shaft
113
Rotor and Starter Drives
113
Oil Filter
115
Crankcase
115
Balancer, Transmission and Shifter
116
Crankshaft
117
Valve
117
Inspection and Repair
119
Cylinder Head
119
Valve Seat
119
Valve and Valve Guide
123
Valve Spring
124
Camshaft
125
Valve Lifter
127
Timing Chain, Sprocket and Chain Guide
127
Cylinder and Piston
128
Piston Ring
130
Piston Pin
130
Balancer Drive Gear and Balancer Gear
132
Primary Drive
133
Clutch
133
Transmission and Shifter
134
Oil Pump and Strainer
136
Electric Starter Drive
137
Bearing and Oil Seal
138
Engine Assembly and Adjustment
139
Crankshaft and Balancer
139
Crankshaft and Balancer Shaft
140
Transmission
141
Shifter
142
Oil Pump
148
Carburetor Removal
172
Carburetor Disassembly
173
Carburetor Inspection
175
Carburetor Assembly
177
Fuel Level Adjustment
180
Throttle Valve Position
181
Front Wheel
182
Oil Seal and Wheel Bearing Replacement Steps
185
Front Wheel Installation
186
Wheel Static Balance Adjustment
187
Rear Wheel
189
Rear Wheel Removal
190
Rear Wheel Inspection
190
Front and Rear Brake
193
Brake Pad Replacement
195
Caliper Assembly
207
Front Fork
216
Front Fork Removal
217
Front Fork Disassembly
218
Steering Head and Handlebar
228
Handlebar Removal
229
Steering Head
230
Rear Shock Absorber and Swingarm
239
Drive Chain and Sprockets
253
TTR50L(C) Circuit Diagram
259
Electrical Components
261
Checking of Connections
263
Ignition System
264
Circuit Diagram
264
Ignition System Troubleshooting
265
Electrical Starting System
270
Starting Circuit Operation
271
Starter Motor Does Not Operate
272
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