Yamaha TT-R230 Owner'S Manual Download Page 4

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IMPORTANT MANUAL INFORMATION

EAU10134

Particularly important information is distinguished in this manual by the following notations:

*Product and specifications are subject to change without notice.

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.

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.

WARNING

NOTICE

TIP

UB6820E0.book Page 1 Wednesday, July 9, 2014 10:50 AM

Summary of Contents for TT-R230

Page 1: ...B68 F8199 20 TT R230 JC 2014 ...

Page 2: ...EAU46091 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold UB6820E0 book Page 1 Wednesday July 9 2014 10 50 AM ...

Page 3: ... 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 cur rent...

Page 4: ...ntial 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 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 WARNING N...

Page 5: ...by Yamaha Motor da Amazônia Ltda 1st edition July 2014 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor da Amazônia Ltda is expressly prohibited Printed in Brazil UB6820E0 book Page 2 Wednesday July 9 2014 10 50 AM ...

Page 6: ...cking the spark plug 7 6 Engine oil and oil filter element 7 7 Cleaning the air filter element 7 10 Adjusting the carburetor 7 12 Adjusting the engine idling speed 7 12 Checking the throttle grip free play 7 13 Valve clearance 7 13 Tires 7 14 Spoke wheels 7 15 Adjusting the clutch lever free play 7 16 Checking the brake lever free play 7 16 Adjusting the brake pedal height and free play 7 17 Check...

Page 7: ...hooting 7 30 Troubleshooting chart 7 31 MOTORCYCLE CARE AND STORAGE 8 1 Care 8 1 Storage 8 3 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 INDEX 11 1 UB6820E0 book Page 2 Wednesday July 9 2014 10 50 AM ...

Page 8: ... 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 UB6820E0 book Page 1 Wednesday July 9 2014 10 50 AM ...

Page 9: ...LOCATION OF IMPORTANT LABELS 1 2 1 UB6820E0 book Page 2 Wednesday July 9 2014 10 50 AM ...

Page 10: ...on Failure to inspect or maintain the vehi cle 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 il legal 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 be fore r...

Page 11: ...s are the result of head in juries The use of a safety helmet is the single most critical factor in the pre vention 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 redu...

Page 12: ...genuine Yamaha accessories recog nize that some aftermarket accesso ries 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 responsib...

Page 13: ...nstruc tions before transporting the motorcy cle in another vehicle Remove all loose items from the motorcycle Check that the fuel cock if equipped is in the OFF position and that there are no fuel leaks Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to pre vent movement Shift the transmission in gear for models with a manual transmis sion Secure the...

Page 14: ...DESCRIPTION 3 1 3 EAU10411 Left view 1 Fuel cock page 4 5 2 Starter choke knob page 4 6 3 Air filter element page 7 10 4 Shift pedal page 4 2 UB6820E0 book Page 1 Wednesday July 9 2014 10 50 AM ...

Page 15: ...21 Right view 1 Fuse page 7 27 2 Battery page 7 25 3 Shock absorber assembly spring preload adjusting nut page 4 7 4 Engine oil filter element page 7 7 5 Brake pedal page 4 3 UB6820E0 book Page 2 Wednesday July 9 2014 10 50 AM ...

Page 16: ...Controls and instruments 1 Clutch lever page 4 2 2 Engine stop switch page 4 1 3 Start switch page 4 1 4 Brake lever page 4 2 5 Throttle grip page 7 13 6 Fuel tank cap page 4 3 UB6820E0 book Page 3 Wednesday July 9 2014 10 50 AM ...

Page 17: ...ical systems are off EAU1234H Handlebar switches Left Right EAU12672 Engine stop button ENGINE STOP Hold this button pushed until the en gine stops in case of an emergency such as when the vehicle overturns or when the throttle cable is stuck EAU12713 Start switch Push this switch to crank the engine with the starter See page 6 1 for start ing instructions prior to starting the en gine 1 Engine st...

Page 18: ...ch switch which is part of the start ing circuit cut off system See page 4 9 EAU12872 Shift pedal The shift pedal is located on the left side of the motorcycle and is used in combination with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU12892 Brake lever The brake lever is located on the right side of the handlebar To apply the ...

Page 19: ...e tank WARNING EWA10882 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 en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or while in the vi cinity of sparks open flames or other sources of ignition such as the pilot lights...

Page 20: ...o internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line 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 Gasohol There are tw...

Page 21: ... fuel cock supplies fuel from the tank to the carburetor while filtering it also The fuel cock has three positions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not run ning ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES 1 Fuel tank breather hose 1 Arrow m...

Page 22: ... 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 EAU13962 Seat To remove the seat Remove the bolts and then pull the seat off To install the seat 1 Insert the projections on the front of the seat into the seat holders as shown 1 Starter choke kn...

Page 23: ...To increase the spring preload and thereby harden the suspen sion turn the spring preload ad justing nut in direction a To decrease the spring preload and thereby soften the suspension turn the adjusting nut in direction b The spring preload setting is de termined by measuring distance A shown in the illustration The shorter distance A is the lower the spring preload the longer dis tance A is the ...

Page 24: ...e gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out shock absorber as sembly yourself Take the shock absorber assembly to a Yamaha dealer for any service EAU37491 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the ...

Page 25: ...tch and the neutral switch prevents starting when the transmission is in gear and the clutch lever is not pulled Periodically check the operation of the starting circuit cut off system accord ing to the following procedure TIP This check is most reliable if performed with a warmed up engine UB6820E0 book Page 9 Wednesday July 9 2014 10 50 AM ...

Page 26: ...INSTRUMENT AND CONTROL FUNCTIONS 4 10 4 UB6820E0 book Page 10 Wednesday July 9 2014 10 50 AM ...

Page 27: ... Yamaha dealer Before using this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 3 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 7 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free ...

Page 28: ...n condition Lubricate if necessary 7 20 7 21 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 14 7 15 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 7 23 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 23 Sidestand Make su...

Page 29: ... Turn the fuel cock lever to ON 2 Push the ignition switch to set it to ON 3 Shift the transmission into the neutral position 4 Turn the starter choke on and completely close the throttle See page 4 6 5 Start the engine by pushing the start switch If the engine fails to start release the start switch wait a few sec onds and then try again Each starting attempt should be as short as possible to pre...

Page 30: ...on press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE ECA10261 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmi...

Page 31: ... 2 throttle After every hour of operation stop the engine and then let it cool for five to ten minutes Vary the engine speed from time to time Do not operate the engine at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine freely through the gears but do not use full throttle at any time After break in Avoid prolonged full throttle operation Vary the ...

Page 32: ...km 3000 mi or 12 months or 150 hours 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check condition Adjust gap and clean 3 Valve clearance Check and adjust valve clearance when engine is cold 4 Air filter element Clean with solvent Replace if necessary 5 Crankcase breather sys tem Check ventilation hose for cracks or damage and drain any deposits Replace if nec...

Page 33: ...an Check engine oil level and for leakage No ITEM CHECKS AND MAINTENANCE JOBS INITIAL ODOMETER READINGS 1000 km 600 mi or 1 month or 30 hours 3000 km 1800 mi or 6 months or 90 hours 5000 km 3000 mi or 12 months or 150 hours UB6820E0 book Page 2 Wednesday July 9 2014 10 50 AM ...

Page 34: ...ours 5000 km 3000 mi or 12 months or 150 hours 1 Clutch Check operation Adjust if necessary 2 Front brake Check operation fluid level and for fluid leakage Replace brake pads Whenever worn to the limit 3 Rear brake Check operation Adjust brake pedal free play and replace brake shoes if necessary 4 Brake hoses Check for cracks or damage Check for correct routing and clamping Replace Every 4 years 5...

Page 35: ...t if necessary 13 Brake lever pivot shaft Apply silicone grease lightly 14 Brake pedal pivot shaft Apply lithium soap based grease lightly 15 Clutch lever pivot shaft Apply lithium soap based grease all purpose grease lightly 16 Shift pedal pivot shaft Apply lithium soap based grease all purpose grease lightly 17 Sidestand pivot Check operation Apply lithium soap based grease lightly 18 Front fork...

Page 36: ...ontrol cables Apply Yamaha cable lubricant or other suitable cable lu bricant thoroughly 22 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing No ITEM CHECKS AND MAINTENANCE JOBS INITIAL ODOMETER READINGS 1000 km 600 mi or 1 month or 30 hours 3000 km 1800 mi or 6 months or 90 hours 5000 km 3000 mi or 12 months or 150 hours UB6820E0 ...

Page 37: ...deposits will cause any spark plug to slowly erode it should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addi tion the condition of the spark plug can reveal the condition of the engine The porcelain insulator around the center electrode of the spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally If the spar...

Page 38: ...uld be checked before each ride In addition the oil must be changed and the oil filter ele ment cleaned at the intervals specified in the periodic maintenance and lubri cation chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and th...

Page 39: ... bolt and drain bolt to drain the oil from the crankcase NOTICE When removing the engine oil drain bolt the O ring compression spring and oil strainer will fall out Take care not to lose these parts ECA11002 5 Remove the oil filter element drain bolt to drain the oil from the oil fil ter element TIP Skip steps 5 9 if the oil filter element is not being cleaned 6 Remove the oil filter element cover...

Page 40: ...he recommended engine oil and then install and tighten the engine oil filler bolt TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust sys tem have cooled down NOTICE ECA11621 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci 1 Oil filter element cover 2 Oil filter elem...

Page 41: ...dling until oil flows out If no oil comes out after one minute turn the engine off immediately so it will not seize If this occurs have a Yamaha dealer repair the vehicle After checking the oil pressure tighten the bleed bolt to the specified torque EAUW0634 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubricati...

Page 42: ... do not twist or wring it ECA10512 6 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the excess oil out TIP The sponge material should be wet but not dripping 7 Pull the sponge material over the air filter element frame 8 Install the washer and wing nut and then insert the air filter ele ment into the air filter case NOTICE Make sure that the air fil...

Page 43: ...en set and ex tensively tested at the Yamaha fac tory Changing these settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine EAU21363 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart TIP A diagnostic tachomete...

Page 44: ...t the inner edge of the throttle grip Periodi cally check the throttle grip free play and if necessary have a Yamaha deal er adjust it EAU21402 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance an...

Page 45: ...ed for this model WARNING EWA10512 Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident Tire inspection The tires must be checked before each ride If a tire tread depth reaches the specified limit if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer re place the tire immediately TIP The tire tread depth limits may dif...

Page 46: ...ate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics EAU21944 Spoke wheels WARNING EWA10611 The wheels on this model are not designed for use with tubeless tires Do not attempt to use tubeless tires on this model To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding...

Page 47: ...crease the clutch lever free play turn the clutch lever free play adjusting nut in direction a To decrease the clutch lever free play turn the adjusting nut in di rection b 7 Tighten the locknut at the clutch cable 8 Tighten the locknut at the clutch lever and then slide the rubber cover to its original position EAU37914 Checking the brake lever free play There should be no free play at the brake ...

Page 48: ...ecessary adjust it as follows 1 Loosen the locknut at the brake pedal 2 To raise the brake pedal turn the adjusting bolt in direction a To lower the brake pedal turn the ad justing bolt in direction b 3 Tighten the locknut WARNING EWA11232 After adjusting the brake pedal height the brake pedal free play must be adjusted Brake pedal free play The brake pedal free play should mea sure 20 0 30 0 mm 0...

Page 49: ...ded with wear indicators which allows you to check the brake pad wear without hav ing to disassemble the brake To check the brake pad wear check the position of the wear indicators while applying the brake If a brake pad has worn to the point that a wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set EAU22541 Rear brake shoes The rear brake is provided...

Page 50: ...ll with the same type of brake fluid Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction Be careful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly lower the boiling point of the fluid and may result in vapor lock NOTICE ECA17641 Brake fluid may damage painted surfaces or plastic parts Always clean up spilled fluid immediatel...

Page 51: ...n the side stand TIP When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neutral position 3 Measure the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows EAUW0663 To adjust the drive chain slack Consult a Yamaha dealer before ad justing the drive chain slack 1 Loosen the brake pedal fr...

Page 52: ...ned and lubricated at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECA10584 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 1 Clean the drive chain with kero sene and a small soft brush NOTI...

Page 53: ...ent unsafe condi tions EWA10712 EAU23115 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addition the cable should be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance chart The throttle cable is equipped with a rubber cover Make sure that the cover is securely installed Even though th...

Page 54: ...lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10732 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss ...

Page 55: ...nt fork compresses and re bounds smoothly NOTICE ECA10591 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23284 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the periodic maintenance and lubrication chart 1 Place a...

Page 56: ...rings EAU23389 Battery The battery is located behind panel See page 7 6 This model is equipped with a VRLA Valve Regulated Lead Acid battery There is no need to check the electro lyte or to add distilled water However the battery lead connections need to be checked and if necessary tight ened WARNING EWA10761 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes seve...

Page 57: ... tional electrical accessories NOTICE ECA16522 To charge a VRLA Valve Regulated Lead Acid battery a special con stant voltage battery charger is re quired Using a conventional battery charger will damage the battery To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place NOTICE When removing the battery...

Page 58: ...ipped with a centerstand follow these precautions when removing the front and rear wheel or performing other mainte nance requiring the motorcycle to stand upright Check that the motorcy cle is in a stable and level position be fore starting any maintenance A strong wooden box can be placed un der the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcy cle by ...

Page 59: ...nd then remove the wheel NOTICE Do not apply the brake after the wheel and brake disc have been removed otherwise the brake pads will be forced shut ECA11073 To install the front wheel 1 Lift the wheel up between the fork legs TIP Make sure that there is enough space between the brake pads before insert ing the brake disc into the caliper 2 Insert the wheel axle and then in stall the washer and ax...

Page 60: ...cording to the procedure on page 7 27 5 Remove the axle nut and then pull the wheel axle out 6 Push the wheel forward and then remove the drive chain from the rear sprocket TIP The drive chain does not need to be disassembled in order to remove and install the wheel 7 Remove the wheel To install the rear wheel 1 Insert the wheel axle from the left hand side TIP Make sure that the drive chain adjus...

Page 61: ...or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamah...

Page 62: ...eck the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle The engine does not start Check the compression The engine does not start Check the ignition Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The battery is goo...

Page 63: ...move dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage plastic parts such as cowlings panels etc and the mufflers Use only a soft clean cloth or sponge with water to clean plastic However if the plastic parts cannot be thoroughly ...

Page 64: ...om mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 5 Use spray oil as a universal clean er to remove any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it WARNING EWA11132 Contaminants on the brakes or tires can cause loss of control M...

Page 65: ...protect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This wi...

Page 66: ...sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more information on storing the battery see page 7 25 TIP Make any necessary repairs before storing the motorcycle UB6820E0 book Page 4 Wednesday July 9 2014 10 50 AM ...

Page 67: ... JASO standard MA Engine oil quantity Without oil filter element replacement 1 00 L 1 06 US qt 0 88 Imp qt With oil filter element replacement 1 10 L 1 16 US qt 0 97 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Regular 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 Carburetor Type quantity Y26P x...

Page 68: ...ype Spoke wheel Rim size 18x1 85 Front brake Type Single disc brake Operation Right hand operation Specified brake fluid DOT 4 Rear brake Type Drum brake Operation Right foot operation Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 240 mm 9 4 in Rear suspension Type Swingarm link suspension Spring shock absorber type Coil spring gas oil damper ...

Page 69: ...e identification number is stamped into the steering head pipe Record this number in the space pro vided TIP The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area EAU26461 Model label The model label is affixed to the loca tion shown Record the information on this label in the space provided This...

Page 70: ...e replacing 7 27 H Handlebar switches 4 1 I Identification numbers 10 1 Ignition switch 4 1 L Labels location 1 1 M Maintenance and lubrication periodic 7 3 Maintenance emission control system 7 1 Model label 10 1 P Panel removing and installing 7 6 Parking 6 3 Part locations 3 1 S Safety information 2 1 Seat 4 6 Shifting 6 2 Shift pedal 4 2 Shock absorber assembly adjusting 4 7 Sidestand 4 8 Side...

Page 71: ...B68 F8199 20 TT R230 JC 2014 ...

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