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Yamaha TT-R230V 2005, Owner'S Manual, Page: 29 / 72

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Yamaha TT-R230V 2005 Owner'S Manual Download Page 29

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4

PRE-OPERATION CHECKS

Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short
time; and the added safety it assures is more than worth the time involved.

If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.

ProCarManuals.com

Summary of Contents for TT-R230V 2005

Page 1: ...1C6 F8199 21 OWNER S MANUAL TT R230V ProCarManuals com ...

Page 2: ...etting racing machines It represents the high degree of craftsmanship and reliability that have madeYamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer ProCarManuals com ...

Page 3: ...that must be taken to avoid damage to the motorcycle A NOTE provides key information to make procedures easier or clearer This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informati...

Page 4: ...NIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE THIS MACHINE IS DESIGNED AND MANUFACTURED FOR OFF ROAD USE ONLY IT IS ILLEGAL TO OPERATE THIS MACHINE ON ANY PUBLIC STREET ROAD OR HIGHWAY SUCH USE IS PROHIBITED BY LAW THIS MACHINE COMPLIES WITH ALMOST ALL STATE OFF HIGHWAY NOIS...

Page 5: ...NUAL c c c c c 2005 byYamaha Motor da Amazônia Ltda 1st edition May 2005 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor da Amazônia Ltda is expressly prohibited Printed in Brazil ProCarManuals com ...

Page 6: ... 6 Checking the spark plug 6 7 Engine oil and oil filter element 6 8 Cleaning the air filter element 6 11 Adjusting the carburetor 6 13 Adjusting the throttle cable free play 6 13 Adjusting the valve clearance 6 13 Tires 6 14 Spoke wheels 6 16 Adjusting the clutch lever free play 6 16 Adjusting the brake pedal position6 17 Checking the front brake pads and rear brake shoes 6 18 Checking the brake ...

Page 7: ...TABLE OF CONTENTS CONSUMER INFORMATION 9 1 Identification numbers 9 1 Maintenance record 9 2 ProCarManuals com ...

Page 8: ...ure that you are qualified and that you only lend your machine to other qualified operators Know your skills and limits Staying within your limits may help you to avoid an accident Many accidents have been caused by error of the machine 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...

Page 9: ...st not exceed the maximum load limit of 90 kg 198 lb When loading within this weight limit keep the following in mind Cargo and accessory weight should be kept as low and close to the machine as possible Make sure to distribute the weight as evenly as possible on both sides of the machine to minimize imbalance or instability Shifting weights can create a sudden imbalance Make sure that accessories...

Page 10: ... HIGHLY FLAMMABLE Always turn the engine off when refueling Take care not to spill any gasoline on the engine or exhaust pipe s muffler s when refueling Never refuel while smoking or in the vicinity of an open flame Never start the engine or let it run for any length of time in a closed area The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time Always op...

Page 11: ...1 4 1 SAFETY INFORMATION see your doctor immediately If any gasoline spills on your skin or clothing immediately wash the affected area with soap and water and change your clothes ProCarManuals com ...

Page 12: ...1 5 1 SAFETY INFORMATION ProCarManuals com ...

Page 13: ...1 6 1 SAFETY INFORMATION Location of important labels Please read the following important labels carefully before operating this vehicle ProCarManuals com ...

Page 14: ...1 7 1 SAFETY INFORMATION 1 3 2 3RV 21668 A0 TIRE INFORMATION Cold tire normal pressure should be set as follows FRONT 100kPa 1 00kgf cm2 15psi REAR 100kPa 1 00kgf cm2 15psi ProCarManuals com ...

Page 15: ...2 1 2 DESCRIPTION Left view 1 Fuel cock page 3 5 2 Starter choke knob page 3 6 3 Air filter element page 6 11 4 Shift pedal page 3 2 ProCarManuals com ...

Page 16: ... 2 DESCRIPTION Right view 1 Fuse page 6 26 2 Battery page 6 24 3 Shock absorver assembly spring preload adjusting nut page 3 7 4 Engine oil filter element page 6 8 5 Brake pedal page 3 3 ProCarManuals com ...

Page 17: ... Controls and instruments 1 Clutch lever page 3 2 2 Engine stop switch page 3 1 3 Main switch page 3 1 4 Start switch page 3 1 5 Brake lever page 3 2 6 Throttle grip page 6 13 7 Fuel tank cap page 3 3 ProCarManuals com ...

Page 18: ...n be started OFF All electrical systems are off Handlebar switches Left 1 Engine stop switch Right 1 Start switch Engine stop switch Push this switch to stop the engine in case of an emergency such as when the motorcycle overturns or when the throttle cable is stuck Start switch Push this switch to crank the engine with the starter See page 5 1 for starting instructions prior to starting the engin...

Page 19: ...n The clutch lever is equipped with a clutch switch which is part of the starting circuit cut off system See page 3 8 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 Brake lever 1 Brake lever The brake lever is located at...

Page 20: ...then pull it off To install the fuel tank cap insert it into the tank opening and then turn it clockwise Make sure that the fuel tank cap is properly closed before riding Fuel 1 2 1 Fuel tank filter tube 2 Fuel lever Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown Do not overfill the fuel tank otherwise it may overflow when the fuel ...

Page 21: ...t system YourYamaha engine has been designed to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or 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 two types of gasohol gasohol containing eth...

Page 22: ...and clean it if necessary Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also The fuel cock has three positions OFF RES ON FUEL OFF 1 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 ON FUEL RES OFF 1 ON 1 Arrow mark positioned over ON With the lev...

Page 23: ...ter refueling Starter choke knob 1 a b 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 Seat To remove the seat Remove the bolts and then pull the seat off 1 Bold To install the seat 1 Insert the projections on the...

Page 24: ...ings Spring preload 1 Locknut 2 Adjusting nut 1 Loosen the locknut 2 To increase the spring preload and thereby harden the suspension turn the adjusting nut in direction a To decrease the spring preload and thereby soften the suspension turn the adjusting nut in direction b A special wrench is needed to make this adjustment and it can be obtained at aYamaha dealer The spring preload setting is det...

Page 25: ...nal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock absorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping performance Always have a Yamaha dealer service the shock absorber Startin...

Page 26: ...3 9 3 INSTRUMENT AND CONTROL FUNCTIONS ProCarManuals com ...

Page 27: ... tank Refuel if necessary Check fuel line for leakage Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid t...

Page 28: ...ssary Make sure that operation is smooth Lubricate pedal pivoting points if necessary Make sure that operation is smooth Lubricate lever pivoting points if necessary Make sure that operation is smooth Lubricate pivot if necessary Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Check operation Correct if necessary Check operation PAGE 6 13 6 21 6 21 6 19 6 20 6 ...

Page 29: ...e is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the vehicle ProCarManuals com ...

Page 30: ...mission is in the neutral position The transmission is in gear with the clutch lever pulled Before starting the engine check the function of the starting circuit cut off system according to the procedure described on page 3 8 Never ride with the sidestand down 1 Turn the fuel cock lever to ON 2 Push the main switch to ON 3 Shift the transmission into the neutral position 4 Turn the starter choke o...

Page 31: ...t the starter choke is not required when the engine is warm Shifting 1 Shift pedal 2 Neutral position Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the illustration To shift the transmission into the neutral position press the shift pedal down repeatedly until it reaches the end of its travel an...

Page 32: ...ing clearances During this period prolonged full throttle operation or any condition that might result in engine overheating must be avoided However momentary full throttle operation under load i e two to three seconds maximum does not harm the engine Each full throttle acceleration should be followed with a substantial rest period for the engine To allow the engine to cool down from the temporary...

Page 33: ...the main switch to OFF and then turn the fuel cock lever to OFF Since the engine and exhaust system can become very hot park in a place where pedestrians or children are not likely to touch them Do not park on a slope or on soft ground otherwise the vehicle may overturn ProCarManuals com ...

Page 34: ...roved by Yamaha may cause loss of performance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before attempting any changes Caution for high pressured water using Water comes in exhaust silencer port and going to inside of the engine if no protection From air intake port of side cover also water going to inside of the engine Technique for cover assembly disassembl...

Page 35: ...and clean Check and adjust valve clearance when engine is cold Clean with solvent Replace if necessary Check ventilation hose for cracks or damage and drain any deposits Repalce if necessary Check engine idling speed and starter operation Adjust if necessary Check for leakage Tighten if necessary Replace gasket s if necessary Change warm engine before draining Clean INITIAL EVERY 1000 km 3000 km 5...

Page 36: ... or damage Replace Check runout spoke tightness and for damage Tighten spokes if necessary Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary Check bearing for smooth operation Replace if necessary Check bearing assemblies for looseness Moderately repack with lithium soap based grease Check chain slack alignment and condition Adjust and lubricate chain wi...

Page 37: ... mi 2000 km or 12 months whichever comes first Check all chassis fitting and fasteners Correct if necessary Apply lithium soap based grease all purpose grease lightly Apply lithium soap based grease all purpose grease lightly Check operation Apply lithium soap based grease all purpose grease lightly Ckeck operation and for oil leakage Replace if necessary Ckeck operation and for oil leakage Replac...

Page 38: ...master cylinder and caliper always change the fluid Regularly check the brake fluid level and fill the reservoir as required Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged Apply Yamaha chain and cable lube or engine oil 10W 30 thoroughly Check operation and free p...

Page 39: ...o this section each time the panel needs to be removed and installed Panel A To remove the panel Remove the screw 1 Screw 2 Painel A To install the panel Place the panel in the original position and then install the screw Panel B To remove the panel 1 Remove the screw 2 Pull the panel B to your direction To make it easier use the opening 1 of the cover 2 3 Pull the panel B in the arrow direction P...

Page 40: ... plug should be removed and checked in accordance with the periodic maintenance and lubrication chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medium to light tan the id...

Page 41: ... torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 4 Install the spark plug cap Engine oil and oil filter element The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter element cleaned at the intervals specified in the General maintenance and lubrication chart To ch...

Page 42: ...f 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler bolt and drain bolt to drain the oil from the crankcase 1 Engine oil filter bolt 1 Drain plug 2 O ring 3 Compression spring 4 Oil strainer When removing the oil drain plug the o ring compression spring and oil strainer will fall out Take care not to lose these parts 4 Remove the oil filter element drain bo...

Page 43: ...ement drain bolt and then tighten it to the specified torque Tightening torques Engine oil drain bolt 43 Nm 4 3 m kgf 3 1 ft lbf Oil filter element drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf 12 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap Recommended oil See page 8 1 Oil quantity Without oil filter element replacement 1 0 L 1 06 us qt 0 91 imp q...

Page 44: ...maha dealer repair the vehicle After checking the oil pressure tighten the bleed bolt to the specified torque 1 Bleed bolt Tightening torque Bleed bolt 7Nm 0 7m kgf 5 0 ft lbf Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more frequently if you are riding in unusuall...

Page 45: ...r filter element and then squeeze the excess oil out The air filter element should be wet but not dripping Recommended oil Yamaha foam air filter oil or other quality air filter oil 6 Install the air filter guide air filter element washer wing nut onto the frame insert into the air filter case Make sure that the air filter element is properly seated in the air filter case The engine should never b...

Page 46: ...e settings without sufficient technical knowledge may result in poor performance of or damage to the engine Adjusting the throttle cable free play 1 Throttle cable free play The throttle cable free play should measure 3 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if necessary have a Yamaha dealer adjust it Adjusting the valve clearance The valve cle...

Page 47: ...mum load 90 0 kg 198 lb Total weight of rider cargo and accessories Because loading has an enormous impact on the handling braking performance and safety characteristics of your vehicle you should keep the following precautions in mind NEVER OVERLOAD THE VEHICLE Operation of an overloaded vehicle may result in tire damage loss of control or severe injury Make sure that the total weight of rider ca...

Page 48: ...ts only the ti res listed below have been approved for this model by Yamaha Motor da Amazônia Ltda Front tire Size 80 100 21 NHS Manufacturer model PIRELLI MT 320 H Rear tire Size 100 100 18 NHS Manufacturer model PIRELLI MT 320 Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the machine with excessively worn tires decreases riding stability and can lead to loss...

Page 49: ...haracteristics Adjusting the clutch lever free play 1 Locknut clutch lever 2 Adjusting bolt 3 Locknut clutch cable 4 Adjusting nut 5 Clutch lever free play The clutch lever free play should measure 10 15 mm 0 39 0 59 in as shown Periodically check the clutch lever free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch lever 2 To increase the clutch lever free play turn ...

Page 50: ...m 0 12 in below the top of footrest c Tighten the locknut After adjusting the pedal height adjust brake pedal free play 2 Free play The rear brake pedal free play should be adjusted to 20 30 mm 0 8 1 2 in at the brake pedal end Turn the adjuster on the brake rod clockwise to reduce play or counterclockwise to increase play 1 Adjuster a Pedal height b Free play Brake pedal free play should be check...

Page 51: ...r If the wear indicator is almost in contact with the disc plate ask a Yamaha dealer to replace the pads 1 Wear indicator groove Rear brake Apply the brake and inspect the wear indicator If the indicator reaches the wear limit line ask a Yamaha dealer to replace the shoes 1 Wear limit 2 Wear indicator Checking the brake fluid level Front brake LOWER 1 1 Lower level Insufficient brake fluid may all...

Page 52: ...se Changing the brake fluid Have aYamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart In addition have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every fou...

Page 53: ... slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 3 Tighten the axle nut to the specified torque Tightening torque Axle nut 80 Nm 8 0 m kgf 58 ft lbf Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart otherwise it will quickly wear out espec...

Page 54: ...aged or does not move smoothly have aYamaha dealer check or replace it Recommended lubricant Yamaha Chain and Cable Lube or engine oil SAE 10W 30 API SE Damage to the outer housing of cables may result in internal rusting and cause interference with cable movement Replace damaged cables as soon as possible to prevent unsafe conditions Checking and lubricating the throttle grip and cable The operat...

Page 55: ...the brake pedal should be checked before each ride and the pedal pivot should be lubricated if necessary Recommended lubricant Lithium soap based grease all purpose grease Checking and 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 If the sidestand does not mov...

Page 56: ...the handlebars several times to check if the front fork compresses and rebounds smoothly If any damage is found or the front fork does not operate smoothly have aYamaha dealer check or repair it Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubricat...

Page 57: ...el hub or if the wheel does not turn smoothly have aYamaha dealer check the wheel bearings Battery 1 Battery The battery is located behind panel A See page 6 6 This model is equipped with a sealed type MF battery which does not require any maintenance There is no need to check the electrolyte or to add distilled water Never attempt to remove the battery cell seals as this would permanently damage ...

Page 58: ...he battery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories 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 2 If the battery will be stored for more than two months che...

Page 59: ...le Since this model is not equipped with a centerstand follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand upright Check that the motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the r...

Page 60: ... otherwise the brake pads will be forced shut To install the front wheel 1 Insert the wheel axle and then tighten it to the specified torque Tightening torque Wheel axle 80 Nm 8 0 m kgf 58 ft lbf 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly Rear wheel To remove the rear wheel It is advisable to have aYam...

Page 61: ...he wheel To install the rear wheel 1 Install the wheel 2 Install the drive chain onto the rear sprocket 3 Be sure the slot in the brake shoe plate is fit over the stopper on the rear arm 4 Make sure the rear wheer axle is inserted from the left hand side and that the chain pullers are installed with the punched side outward 5 Adjust the drive chain slack See page 6 19 6 Tighten the axle nut to the...

Page 62: ...he following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself 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 genuineYamaha replacement parts Imitation parts may look like Yamaha parts but they are o...

Page 63: ...on Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is good Check the battery lead connections and charge th...

Page 64: ...l axles Always rinse the dirt and degreaser off with water Cleaning Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner on the affected area any longer than instructed Also thoroughly rinse the area off with water immediately dry it and then apply a corrosion protection spray Improper cleaning can damage win...

Page 65: ...o prevent corrosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally induced discoloring of stainless steel exhaust systems can be removed through polishing 4 To prevent corrosi...

Page 66: ...that has an OFF position Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosening the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to protect the cylinder pis...

Page 67: ... of its wheels are off the ground Alternatively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an excessively cold or warm place less tha...

Page 68: ...AE 20W 50 SAE 10W 40 Recommended engine oil glade API service SE SF SG type or higher Engine oil quantity Without oil filter element replacement 1 0 L 1 1 us qt 0 90 Imp qt With oil filter element replacement 1 1 L 1 2 us qt 1 0 Imp qt Air filter Air filter element Wet element Fuel 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...

Page 69: ... cm2 Rear 100 kPa 15 psi 1 00 kgf cm2 Front wheel Wheel type Spoke wheel Rim size 21x1 60 Rear wheel Wheel type Spoke wheel Rim size 18x1 85 Front brake Type Single disc brake Operation Right hand operation Recommended 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 0 mm 9...

Page 70: ...sing authority in your area Model label 1 Model label The model label is affixed to the frame Record the information on this label in the space provided This information will be needed when ordering spare parts from aYamaha dealer Identification numbers Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a ...

Page 71: ...MER INFORMATION Maintenance record Have aYamaha dealer complete this record when the motorcycle is serviced Maintenance Date of Mileage Servicing dealer Remarks interval service name and address ProCarManuals com ...

Page 72: ... LTDA 1C6 F8199 20 OWNER S MANUAL TT R230T PRINTED IN BRAZIL 500 09 2004 GYL E YAMAHA MOTOR DA AMAZÔNIA LTDA 1C6 F8199 10 LIT 11626 18 40 OWNER S MANUAL TT R230T TT R230TC PRINTED IN BRAZIL 3000 08 2004 GYL E ProCarManuals com ...

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