Yamaha TT250RM 1999 Owner'S Manual Download Page 64

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6-23

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01269

Drive chain slack adjustment

1. Remove the cotter pin from

the axle nut.

2. Loosen the axle nut.
3. Turn both left and right chain

adjusting plates the same
amount. Make sure that they
are in the same position for
proper wheel alignment. To
tighten the chain, turn in direc-
tion

. To loosen the chain,

turn in direction

Cotter pin

Axle nut

Chain adjusting plate

EC000096

Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits.

4. After adjusting, tighten the

axle nut to the specified
torque.

Tightening torque:

Axle nut:

105 Nm (10.5 m

kg)

5. Insert a new cotter pin into the

axle nut and bend the end of
the cotter pin as shown in the
illustration. If the notch in the
nut and cotter pin hole do not
match, tighten the nut slightly
to align them.

EW000110

Always use a new cotter pin on
the axle nut.

Cotter pin

4PX-9-25-6(AUS) 4/17/0 12:43 PM Page 24

ProCarManuals.com

Summary of Contents for TT250RM 1999

Page 1: ...OWNER S MANUAL 4PX 28199 25 TT250RM 4PX 9 25 hyoushi AUS 4 17 0 1 30 PM Page 1 2 1 Magenta plate ProCarManuals com ...

Page 2: ...siro page 4 6 0 3 58 AM Page 1 ProCarManuals com ...

Page 3: ...acing machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic mainte nance of this motorcycle If you have any questions about the operation or maintenance of your motorcycle please consult a Yamaha dealer 4PX 9 25 0 1 2 AUS 4 17 0 12 37 PM Page 1 ProCarMan...

Page 4: ... to avoid damage to the motorcycle A NOTE provides key information to make procedures easier or clearer Q w cC NOTE NOTE 8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold 8 Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product inform...

Page 5: ...IMPORTANT MANUAL INFORMATION 1 2 3 4 5 6 7 8 9 EW000002 w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE 4PX 9 25 0 1 2 AUS 4 17 0 12 37 PM Page 3 ProCarManuals com ...

Page 6: ...a Motor Co Ltd 1st Edition July 1999 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EAU00008 4PX 9 25 0 1 2 AUS 4 17 0 12 37 PM Page 4 ProCarManuals com ...

Page 7: ...rake pedal 3 4 Fuel tank cap 3 5 Fuel 3 5 Fuel tank breather hose 3 6 Fuel cock 3 6 Starter choke 1 3 7 Kick starter 3 7 Steering lock 3 8 Seat 3 8 Helmet holder 3 9 Front fork adjustment 3 9 Rear shock absorber adjustment 3 11 Sidestand 3 12 Sidestand clutch switch operation check 3 13 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting and war...

Page 8: ...2 Drive chain slack adjustment 6 23 Drive chain lubrication 6 24 Cable inspection and lubrication 6 24 Throttle cable and grip lubrication 6 25 Brake and shift pedal lubrication 6 25 Brake and clutch lever lubrication 6 25 Sidestand lubrication 6 26 Front fork inspection 6 26 Steering inspection 6 27 Wheel bearings 6 27 Battery 6 28 Fuse replacement 6 29 Headlight bulb replacement 6 30 Turn signal...

Page 9: ... 9 CONSUMER INFORMATION 9 1 Identification number records 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 Noise regulation For Australia 9 2 4PX 9 25 0 1 2 AUS 4 17 0 12 37 PM Page 7 ProCarManuals com ...

Page 10: ...ARY BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 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 auto mobile driver who did not see the...

Page 11: ...rn due to EXCESSIVE SPEED or under cornering insufficient lean angle for the speed a Always obey the speed limits and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure other motorists see you 6 The operator s and passenger s posture are important for proper control a The operator should keep both hands on the handlebars and...

Page 12: ...hey become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Modification Modifications made to the motorcycle not approved by Yamaha or the removal of original equipment may render your motorcycle unsafe for use and may cause severe personal injury Modifications may also make your motorcycle i...

Page 13: ...ing Recheck accessory mounts and cargo restraints frequently 3 Never attach any large or heavy items to the handlebars front forks or front fender These items including such cargo as sleeping bags duffle bags or tents can create unstable handling or slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all ...

Page 14: ... may attempt to lift the motorcycle or the motorcycle may become unstable in cross winds These accessories may also cause instability when being passed by or passing large vehicles c Certain accessories can displace the operator from his or her normal riding position This improper position limits the freedom of movement of the operator and may limit control ability Therefore such accessories are n...

Page 15: ...hot areas b Do not park the motorcycle on a slope or soft ground the motorcycle may fall over c Do not park the motorcycle near a flammable source e g a kerosene heater or near an open flame The motorcycle could catch fire 4 When transporting the motorcycle in another vehicle be sure it is kept upright and that the fuel cock s is turned to ON or RES for vacuum type OFF for manual type If it should...

Page 16: ... INFORMATION 1 2 3 4 5 6 7 8 9 EAU02977 Location of the important labels Please read the following labels carefully before operating this motorcycle 1 2 4PX 9 25 0 1 2 AUS 4 17 0 12 37 PM Page 14 ProCarManuals com ...

Page 17: ...8 Q SAFETY INFORMATION 1 2 3 4 5 6 7 8 9 WARNING Before you operate this vehicle read the owner s manual English 3HP 21568 00 4AA 22259 40 1 2 4PX 9 25 0 1 2 AUS 4 17 0 12 37 PM Page 15 ProCarManuals com ...

Page 18: ... 1 Headlight page 6 30 2 Fuel cock page 3 6 3 Starter choke 1 page 3 7 4 Air filter page 6 12 5 Tool kit page 6 1 6 Helmet holder page 3 9 7 Shift pedal page 3 4 8 Front fork damping adjusting screw page 3 10 4PX 9 25 0 1 2 AUS 4 17 0 12 37 PM Page 16 ProCarManuals com ...

Page 19: ...hock absorber compression damping adjuster page 3 11 3 12 13 Main switch page 3 1 14 Front fork spring preload adjusting valve page 3 9 15 Steering lock page 3 8 16 Oil filter page 6 9 6 12 17 Rear brake pedal page 3 4 6 19 18 Rear shock absorber rebound damping adjuster page 3 11 3 12 4PX 9 25 0 1 2 AUS 4 17 0 12 37 PM Page 17 ProCarManuals com ...

Page 20: ...nts 19 Clutch lever page 3 3 20 Left handlebar switches page 3 2 21 Speedometer page 3 2 22 Right handlebar switches page 3 3 23 Front brake lever page 3 4 24 Throttle grip page 6 14 6 25 25 Fuel tank cap page 3 5 4PX 9 25 0 1 2 AUS 4 17 0 12 37 PM Page 18 ProCarManuals com ...

Page 21: ... position EAU00038 OFF All electrical circuits are switched off The key can be removed in this position EAU00056 Indicator lights EAU00057 Turn indicator light 5 This indicator flashes when the turn switch is moved to the left or right EAU00061 Neutral indicator light N This indicator comes on when the transmission is in neutral EAU00063 High beam indicator light This indicator comes on when the h...

Page 22: ...eedometer 3 Odometer 4 Trip odometer 1 2 3 1 Dimmer switch 2 Turn signal switch 3 Horn switch EAU00118 Handlebar switches EAU00121 Dimmer switch Turn the switch to for the high beam and to for the low beam EAU00127 Turn signal switch To signal a right hand turn push the switch to 6 To signal a left hand turn push the switch to 4 Once the switch is released it will return to the center position To ...

Page 23: ...1 Engine stop switch 2 Start switch START EC000005 cC See starting instructions prior to starting the engine 1 EAU00152 Clutch lever The clutch lever is located on the left handlebar and the ignition cir cuit cut off system is incorporated in the clutch lever holder Pull the clutch lever to the handlebar to dis engage the clutch and release the lever to engage the clutch The lever should be pulled...

Page 24: ...engine and is used in combination with the clutch when shifting EAU00158 Front brake lever The front brake lever is located on the right handlebar Pull it toward the handlebar to apply the front brake 1 EAU00162 Rear brake pedal The rear brake pedal is on the right side of the motorcycle Press down on the brake pedal to apply the rear brake 1 Front brake lever 1 Rear brake pedal 4PX 9 25 3 4 5 AUS...

Page 25: ...rfill the fuel tank Avoid spilling fuel on the hot engine Do not fill the fuel tank above the bot tom of the filler tube or it may overflow when the fuel heats up later and expands EAU00185 cC Always wipe off spilled fuel imme diately with a dry and clean soft cloth Fuel may deteriorate painted surfaces or plastic parts EAU00192 1 Filler tube 2 Fuel level Recommended fuel Regular gasoline For Aust...

Page 26: ... FUEL RES OFF 1 ON 1 Arrow mark EAU01121 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while fil tering 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 running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in...

Page 27: ...fore starting is recom mended 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 fuel cock back to ON after refueling OFF ON FUEL RES 1 RES 1 Arrow mark RES 1 a b EAU02976 Starter choke 1 Starting a cold engine requires a richer air fuel mixture A separate starter circuit supplies this mixture Mov...

Page 28: ...se After checking to see that the steer ing is locked remove the key from the lock and close the cover To release the lock reverse the above procedure 1 Steering lock EAU01072 Seat To remove the rider seat remove the bolts To reinstall the rider seat insert the projection on the front of the seat into the seat holder then tighten the bolts NOTE Make sure that the seat is securely fitted 1 Bolt 2 1...

Page 29: ...front end of the motorcycle 2 1 EAU00260 Helmet holder To open the helmet holder insert the key in the lock and turn it as shown To lock the helmet holder replace the holder in its original position EW000030 w Never ride with a helmet in the helmet holder The helmet may hit objects causing loss of control and possibly an accident 1 Helmet holder 2 Open b Remove the valve cap from each fork leg c U...

Page 30: ...er exceed the maximum pres sure or oil seal damage may occur EW000036 w There must not be more than 10 kPa 0 1 kgf cm2 0 1 bar differ ence in air pressure between the left and right fork legs d Install the valve caps securely Standard air pressure 0 kPa 0 kgf cm2 0 bar Maximum air pressure 40 kPa 0 4 kgf cm2 0 4 bar Minimum air pressure 0 kPa 0 kgf cm2 0 bar 1 2 Adjust damping force as fol lows a ...

Page 31: ...compression damping force adjuster 1 Spring preload adjustment should be left to a Yamaha dealer 2 Adjust rebound damping force as follows Turn adjuster in direction a to increase rebound damping force and in direction b to decrease rebound damping force 1 b a 1 Adjuster Standard 10 clicks out Minimum 16 clicks out Maximum 1 click out EC000017 cC Be sure to fit the rubber cap to prevent malfunctio...

Page 32: ...amper with or attempt to open the cylinder assembly 8 Do not subject the shock absorber to an open flame or other high heat source This may cause the unit to explode due to excessive gas pressure 8 Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance 8 Take your shock absorber to a Yamaha dealer for any service 3 Adjust compression damping force a...

Page 33: ...tructions listed below and if there is any indication of a malfunction return the motor cycle to a Yamaha dealer immedi ately for repair EAU00331 Sidestand clutch switch operation check Check the operation of the side stand switch and clutch switch against the information below TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO TRANSMISSION IS IN GEAR AND SIDESTAND IS UP PULL IN CLUTCH LEVER...

Page 34: ...el and fluid leakage 3 4 6 19 6 22 9 Fill with DOT 4 brake fluid if necessary Clutch 9 Check operation and free play 3 3 6 18 9 Adjust if necessary Throttle grip and housing 9 Check for smooth operation 6 14 6 25 9 Lubricate if necessary Engine oil 9 Check oil level 6 9 6 12 9 Fill with oil if necessary Drive chain 9 Check chain slack and condition 6 22 6 24 9 Adjust if necessary Wheels and tires ...

Page 35: ...ion checks should be made each time the motorcycle is used Such an inspection can be thoroughly accomplished in a very short time and the added safety it assures is more than worth the time involved w If any item in the PRE OPERATION CHECKS is not working properly have it inspected and repaired before oper ating the motorcycle 4PX 9 25 3 4 5 AUS 4 17 0 12 40 PM Page 15 ProCarManuals com ...

Page 36: ...fore starting out always be sure the sidestand is up Failure to retract the sidestand completely can result in a seri ous accident when you try to turn a corner EAU00411 Starting and warming up a cold engine NOTE This motorcycle is equipped with a starting and an ignition circuit cut off switch The engine can be started only under one of the following condi tions 8 The transmission is in neutral 8...

Page 37: ...NE WILL START RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP PULL IN CLUTCH LEVER AND PUSH START SWITCH OR KICK THE KICK STARTER ENGINE WILL START TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO 4PX 9 25 3 4 5 AUS 4 17 0 12 40 PM Page 17 ProCarManuals com ...

Page 38: ...tart switch wait a few sec onds then try again Each attempt should be as short as possible to preserve the battery Do not crank the engine more than 10 seconds on any one attempt If the engine does not start with the starter motor kick the kick starter to start the engine 6 After starting the engine move the starter choke to the halfway position NOTE For maximum engine life always warm up the engi...

Page 39: ...ng periods with the engine off and do not tow the motorcycle a long distance Even with gears in neutral the transmission is only properly lubricated when the engine is running Inadequate lubrication may damage the transmission 8 Always use the clutch when changing gears The engine transmission and driveline are not designed to withstand the shock of forced shifting and can be damaged by shifting w...

Page 40: ... For this reason we ask that you carefully read the fol lowing material Because the engine is brand new you must not put an excessive load on it for the first 1 000 km The various parts in the engine wear and polish them selves to the correct operating clearances During this period pro longed full throttle operation or any condition which might result in excessive heating of the engine must be avo...

Page 41: ...tely EAU00457 Parking When parking the motorcycle stop the engine and remove the ignition key Turn the fuel cock to OFF whenever stopping the engine EW000058 w The exhaust system is hot Park the motorcycle in a place where pedestrians or children are not likely to touch the motorcycle Do not park the motorcycle on a slope or soft ground the motorcycle may overturn RES ON FUEL OFF 1 1 Arrow mark 4P...

Page 42: ...ALL TEND TO DEMAND THAT EACH OWNER ALTER THIS TIME SCHEDULE TO SHORTER INTERVALS TO MATCH THE ENVIRONMENT The most important points of motorcycle inspection adjustment and lubri cation are explained in the follow ing pages 1 EAU01175 Tool kit The tool kit is located behind panel A See page 6 7 for panel removal and installation procedures The tools provided in the owner s tool kit are to assist yo...

Page 43: ...ring a service opera tion take your motorcycle to a Yamaha dealer for service EW000063 w Modifications to this motorcycle not approved by Yamaha may cause loss of performance and render it unsafe for use Consult a Yamaha dealer before attempting any changes 4PX 9 25 6 AUS 4 17 0 12 43 PM Page 3 ProCarManuals com ...

Page 44: ...eplace if necessary 5 Clutch 9 Check operation 9 Adjust or replace cable 9 Check operation fluid level and vehicle for fluid leakage 6 Front brake See NOTE on page 6 5 9 Correct accordingly 9 Replace brake pads if necessary 9 Check operation fluid level and vehicle for fluid leakage 7 Rear brake See NOTE on page 6 5 9 Correct accordingly 9 Replace brake pads if necessary 8 Wheels 9 Check balance r...

Page 45: ...Lubricate with lithium soap base grease every 24 000 km or 24 months whichever comes first 14 Chassis fasteners 9 Make sure that all nuts bolts and screws are properly tightened 9 Tighten if necessary 15 Sidestand 9 Check operation 9 Lubricate and repair if necessary 16 Sidestand switch 9 Check operation 9 Replace if necessary 17 Front fork 9 Check operation and for oil leakage 9 Correct according...

Page 46: ...rake fluid level regularly and fill as required 8 Replace the oil seals on the inner parts of the master cylinder and caliper every two years 8 Replace the brake hoses every four years or if cracked or damaged EVERY EVERY 6 000 km 12 000 km No ITEM CHECKS AND MAINTENANCE JOBS INITIAL or or 1 000 km 6 months 12 months Whichever Whichever comes first comes first 9 Check oil level and vehicle for oil...

Page 47: ... of the maintenance described in this chapter Refer to this section each time a cowling or panel has to be removed or reinstalled 1 Panel B 1 Screw EAU01145 Cowling A To remove Remove the cowling screw and pull outward on the areas shown To install Place in the original position and install the screw 1 2 1 Cowling A 2 Panel A 1 4PX 9 25 6 AUS 4 17 0 12 43 PM Page 7 ProCarManuals com ...

Page 48: ...A To remove Pull outward on the panel and slide it down as shown To install Place it in the original position and push inward 1 1 EAU00488 Panel B To remove Remove the screw and pull out ward on the areas shown To install Place the panel in the original posi tion and install the screw 1 Screw 4PX 9 25 6 AUS 4 17 0 12 43 PM Page 8 ProCarManuals com ...

Page 49: ... should periodically remove and inspect the spark plug because heat and deposits will cause any spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification 2...

Page 50: ...ailable when you are installing a spark plug a good estimate of the cor rect torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possible 4 Install the spark plug cap EAU01440 Engine oil Oil level measurement 1 Place the motorcycle on a level place and hold it in an upright position Warm up the engine for several minutes NOTE Be sure the mot...

Page 51: ...d remove the oil filler cap 1 3 2 4 Check each gasket If dam aged replace 5 Remove the filter cover screws and the oil filter cover NOTE The oil filter cover is secured by three screws The lower one should be removed first so that the filter cavity will drain 6 Clean the filter element with solvent Replace if necessary 1 Oil filter cover 2 Oil filter drain bolt 3 Oil filler cap 4PX 9 25 6 AUS 4 17...

Page 52: ...ap and tighten Tightening torque Drain bolt 20 Nm 2 0 m0kg Filter cover screw 10 Nm 1 0 m0kg Air bleed screw 10 Nm 1 0 m0kg EC000066 cC 8 Do not put in any chemical additives Engine oil also lubri cates the clutch and additives could cause clutch slippage 8 Be sure no foreign material enters the crankcase Recommended oil See page 8 1 Oil quantity Total amount 1 45 L Periodic oil change 1 1 L With ...

Page 53: ...iately and check for the cause 11 Stop the engine and check the oil level EC000076 cC After replacing the engine oil be sure to check the oil pressure as described below 8 Remove the air bleed screw from the oil filter cover 8 Start the engine and keep it idling until oil flows out of the bleed hole If no oil comes out after one minute turn off the engine immediately so it will not seize In such a...

Page 54: ...he air filter installed Excessive piston and or cylinder wear may result EAU00629 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisti cated adjustment Most adjust ments should be left to a Yamaha dealer who has the professional knowledge and experience to do so However the following may be serviced by the owner as part of routine maintenance EC000094 cC Th...

Page 55: ...EAU00635 Throttle cable free play inspection There should be a free play of 3 5 mm at the throttle grip If the free play is incorrect ask a Yamaha dealer to make this adjustment a a Free play EAU01168 Idle speed adjustment NOTE A diagnostic tachometer must be used for this procedure 1 Attach the tachometer Start the engine and warm it up for a few minutes at approximate ly 1 000 to 2 000 r min Occ...

Page 56: ...orcycle EW000082 w Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature Tire infla tion pressure must be adjusted according to total weight of cargo rider passenger and accessories fairing saddlebags etc if approved for this model and vehi cle speed Maximum load 180 kg Cold tire pressure Front Rear 125 kPa 150 kPa Up to 90 kg lo...

Page 57: ...r this model does not exceed the maximum load of the motorcycle Operation of an over loaded motorcycle could cause tire damage an accident or even injury 3 2 1 1 Tread depth 2 Side wall 3 Wear indicator Tire inspection Always check the tires before oper ating the motorcycle If center tread depth reaches the limit as shown if the tire has a nail or glass fragments in it or if the side wall is crack...

Page 58: ...afe operation note the following 8 Always inspect the wheels before a ride Check for cracks bends or warpage of the wheel Be sure the spokes are tight and undamaged If any abnormal condition exists in a wheel consult a Yamaha deal er Do not attempt even small repairs to the wheel If a wheel is deformed or cracked it must be replaced 8 Tires and wheels should be balanced whenever either one is chan...

Page 59: ...ined proceed with the follow ing steps 4 Loosen the locknut 1 5 Turn the adjusting bolt 2 in direction a to loosen the cable 6 Loosen the locknut 3 7 Turn the adjusting nut 4 in direction a to increase free play or in direction b to decrease free play 8 Tighten both locknuts 1 2 3 a b EAU00696 Front brake lever free play adjustment The free play at the front brake lever should be 2 5 mm 1 Loosen t...

Page 60: ...ealer inspect and bleed the system if necessary 1 EAU00712 Rear brake pedal height adjustment The top of the brake pedal should be positioned 10 mm below the top of the footrest If not ask a Yamaha dealer to adjust it 1 Pedal height EW000109 w A soft or spongy feeling in the brake pedal can indicate the pres ence of air in the brake system This air must be removed by bleeding the brake system befo...

Page 61: ...efore braking takes effect To adjust the rear brake light switch hold the switch body so it does not rotate while turning the adjusting nut Turn the adjusting nut in direction a to make the brake light come on earlier Turn the adjusting nut in direction b to make the brake light come on later 1 Brake light switch 2 Adjusting nut EAU00716 Checking the front and rear brake pads A wear indicator is p...

Page 62: ...ted quali ty brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor brake performance 8 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance 1 1 Minimum level mark REAR Recommended brake fluid DOT 4 8 Be careful that water does not enter the master cylinder when refilling Water will significant ...

Page 63: ...n checking chain slack EAU00742 Brake fluid replacement The brake fluid should be replaced only by trained Yamaha service personnel Have the Yamaha deal er replace the following compo nents during periodic maintenance or when they are damaged or leak ing 8 oil seals every two years 8 brake hoses every four years EAU00743 Drive chain slack check NOTE Spin the wheel several times and find the tighte...

Page 64: ... pin 2 Axle nut 3 Chain adjusting plate EC000096 cC Too little chain slack will overload the engine and other vital parts Keep the slack within the specified limits 4 After adjusting tighten the axle nut to the specified torque Tightening torque Axle nut 105 Nm 10 5 m0kg 5 Insert a new cotter pin into the axle nut and bend the end of the cotter pin as shown in the illustration If the notch in the ...

Page 65: ...n the drive chain Wipe it dry and thoroughly lubri cate it with SAE 30 50W motor oil Do not use any other lubricants on the drive chain They may con tain solvents that could damage the sealed chain EC000097 cC Be sure to oil the chain after wash ing the motorcycle or riding in the rain EAU02962 Cable inspection and l ubrication EW000112 w Damage to the outer housing of cables may lead to internal ...

Page 66: ...moving the screws hold the end of the cable up in the air and put in several drops of lubricant With the throttle grip disassembled coat the metal surface of the grip assembly with a suitable all purpose grease EAU02984 Brake and shift pedal lubrication Lubricate the pivoting parts EAU02985 Brake and clutch lever lubrication Lubricate the pivoting parts Recommended lubricant Engine oil Recommended...

Page 67: ...sual check EW000115 w Securely support the motorcycle so there is no danger of it falling over Check for scratches or damage on the inner tube and excessive oil leakage from the front fork Operation check 1 Place the motorcycle on a level place 2 Hold the motorcycle in an upright position and apply the front brake 3 Push down hard on the han dlebars several times and check if the fork rebounds smo...

Page 68: ...he front forks and try to move them forward and backward If any free play can be felt ask a Yamaha dealer to inspect and adjust the steering Inspection is easier if the front wheel is removed EAU01144 Wheel bearings If there is play in the front or rear wheel hub or if the wheel does not turn smoothly have a Yamaha dealer inspect the wheel bearings EW000115 w Securely support the motorcycle so the...

Page 69: ...of the battery cells The bat tery will be damaged EW000116 w Battery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing ANTIDOTE 8 EXTERNAL Flush with water 8 INTERNAL Drink large quanti ties of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately 8 EYES Flush with water f...

Page 70: ...tery charger contact your Yamaha dealer 8 Always make sure the connec tions are correct when rein stalling the battery EAU00804 Fuse replacement If the fuse is blown turn off the main switch and the switch of the circuit in question Install a new fuse of specified amperage Turn on the switches and see if the elec trical device operates If the fuse immediately blows again consult a Yamaha dealer 1 ...

Page 71: ...ld er counterclockwise 1 Bolt 3 EW000120 w Keep flammable products and your hands away from the bulb while it is on as it is hot Do not touch the bulb until it cools down 5 Put a new bulb into position and secure it in place with the bulb holder 1 1 Bulb holder 1 1 Don t touch EC000106 cC Avoid touching the glass part of the bulb Keep it free from oil oth erwise the transparency of the glass life ...

Page 72: ...o make that adjustment 1 2 1 Screw 2 Lense EAU01095 Turn signal light bulb replacement 1 Remove the screw and the lens 2 Remove the defective bulb by pushing it inward and turning it counterclockwise 1 1 Bulb 3 Install a new bulb by pushing it inward and turning it clock wise 4 Install the lens and tighten the screw 4PX 9 25 6 AUS 4 17 0 12 43 PM Page 32 ProCarManuals com ...

Page 73: ... turning it counterclockwise 3 Install a new bulb by pushing it inward and turning it clock wise 4 Install the lense and tighten the screws EC000108 cC Do not over tighten the screws as the lens may break EAU01624 License light bulb replacement 1 Remove the license light assembly by removing the nuts 1 Screw 2 2 Lense 1 Bulb 1 Nut 2 4PX 9 25 6 AUS 4 17 0 12 43 PM Page 33 ProCarManuals com ...

Page 74: ...en removing the front and rear wheel or performing other maintenance requiring the motor cycle 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 Front wheel service To stabilize the rear of the motor cycle either use a motorcycle stand or place a motorcycle jack under t...

Page 75: ...er service the wheel 8 Securely support the motorcy cle so there is no danger of it falling over 1 Remove the speedometer cable from the front wheel side 2 Loosen the wheel axle holder nuts and wheel axle 1 Meter cable 2 Axle holder nut 4 3 Elevate the front wheel by placing a suitable stand under the engine 4 Remove the wheel axle and the front wheel Make sure the motorcycle is properly sup porte...

Page 76: ...3 Make sure the slot in the speedometer gear unit fits over the stopper on the front fork outer tube 4 Install the wheel axle and tighten it to the specified torque 5 Before tightening the holder nuts push down on the han dlebars several times and check if the fork rebounds smoothly 6 Tighten the axle holder nuts to the specified tightening torque Tighten the upper nuts first and then lower ones W...

Page 77: ...mbly NOTE 8 Do not depress the brake pedal when the disc and caliper are separated 8 You do not have to disassem ble the chain in order to remove or install the rear wheel EAU01232 Rear wheel installation 1 Install the rear wheel and chain Guide the brake disc between the brake pads Make sure there is enough gap between the brake pads before inserting the brake disc 2 Make sure the wheel axle is i...

Page 78: ...leshooting chart describes a quick easy procedure for making checks If your motorcycle requires any repair bring it to a Yamaha dealer The skilled technicians at a Yamaha dealership have the tools experience and know how to properly service your motorcycle Use only genuine Yamaha parts on your motorcycle Imitation parts may look like Yamaha parts but they are often inferior Consequently they have ...

Page 79: ... with dry cloth and Open the throttle half way and start Ask a Yamaha dealer to inspect Engine turns over Engine turns over Battery good Check connections Use electric starter Check if there is fuel Enough fuel No fuel Go to compression check Supply fuel in the fuel tank electrode plug and check quickly slowly or recharge Engine doesn t start go to battery check the engine adjust plug gap or repla...

Page 80: ...nnectors including the spark plug cap are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such products onto seals gaskets sprockets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning After normal use Remove dirt with warm water a neutral detergent and a soft clean spon...

Page 81: ... use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning compounds for plas tic may leave scratches on the windshield Test the product on a small hidden part of the windshield to make sure they do not leave any marks If the windshield is scratched use a quality plastic polishing com pound after washing After riding in the rain near the sea or on salt sprayed road...

Page 82: ... 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry com pletely before storing it or cov ering it EWA00001 w Make sure that there is no oil or wax on the brakes and tires If nec essary clean the brake discs and linings with a regular brake disc cleaner or acetone and wash the tires with warm water and mild soap Then carefully test the motorcycle ...

Page 83: ...r motorcycles equipped with a fuel cock which has an OFF position Turn the fuel cock to OFF 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rust ing and the fuel from deterio rating 5 Perform the following steps to 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 sp...

Page 84: ...rder to prevent the tires from becoming degraded in one spot 8 Cover up the muffler outlet with a plastic bag to prevent moisture from entering 9 Remove the battery and fully charge it Store it in a cool dry place and recharge it once a month Do not store the bat tery in an excessively cold or warm place less than 0 C or more than 30 C For more information see Battery stor age in the chapter PERIO...

Page 85: ...m Electric and kick starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher cC Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled Energy Conserving contain anti friction additives which will cause clutch and or starter clutch slippage resulting in reduced component life a...

Page 86: ...em Spur gear Primary reduction ratio 74 24 3 083 Secondary reduction system Chain drive Secondary reduction ratio 44 14 3 143 Transmission type Constant mesh 6 speed Operation Left foot operation Gear ratio 1st 2 467 2nd 1 813 3rd 1 364 4th 1 080 5th 0 889 6th 0 759 Chassis Frame type Semi double cradle Caster angle 26 Trail 106 mm Tires Type With tube Front Size 3 00 21 51P Manufacturer DUNLOP D6...

Page 87: ... is total weight of cargo rider passenger and accessories Wheels Front Type Spoke wheel Size 1 60 21 Rear Type Spoke wheel Size 2 15 18 Brakes Front Type Single disc brake Operation Right hand operation Fluid DOT 4 Rear Type Single disc brake Operation Right foot operation Fluid DOT 4 Suspension Front Type Telescopic fork Rear Type Swingarm link suspension Shock absorber Front Coil air spring oil ...

Page 88: ...t type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 60 55W 1 Stop tail light 12 V 21 5W 1 Front flasher light 12 V 21W 2 Rear flasher light 12 V 21W 2 License light 12 V 5W 2 Meter light 12 V 3 4W 1 Neutral indicator light 12 V 3 4W 1 High beam indicator light 12 V 3 4W 1 Turn indicator light 12 V 3 4W 1 Fuse Main fuse 15A 4PX 9 25 7 8 9 AUS 4 17 0 12 44 PM Page 10 ProCarManuals com ...

Page 89: ...t Multiplier Imperial unit m kg 7 233 ft lb Torque m kg 86 794 in lb cm kg 0 0723 ft lb cm kg 0 8679 in lb Weight kg 2 205 lb g 0 03527 oz Speed km hr 0 6214 mph km 0 6214 mi m 3 281 ft Distance m 1 094 yd cm 0 3937 in mm 0 03937 in cc cm3 0 03527 oz IMP liq Volume cc cm3 0 06102 cu in Capacity lt liter 0 8799 qt IMP liq lt liter 0 2199 gal IMP liq kg mm 55 997 lb in Misc kg cm2 14 2234 psi lb in2...

Page 90: ...rd this number in the space provided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state EAU02944 Identification number records Record the key identification num ber vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts fr...

Page 91: ...G WITH NOISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporat ed into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b The use of the ...

Page 92: ...4PX 9 25 7 8 9 AUS 4 17 0 12 44 PM Page 14 ProCarManuals com ...

Page 93: ...4PX 9 25 7 8 9 AUS 4 17 0 12 44 PM Page 15 ProCarManuals com ...

Page 94: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 99 7 0 7 1 E YAMAHA MOTOR CO LTD 4PX 9 25 hyoushi AUS 4 17 0 1 30 PM Page 1 1 1 Magenta plate ProCarManuals com ...

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Yamaha TT250RM 1999, Owner'S Manual

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