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Yamaha ttr230 User Manual

Yamaha ttr230
300 pages
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SERVICE MANUAL
1C6-F8197-101C6-F8197-10
1C6-F8197-101C6-F8197-10
1C6-F8197-10
TTR230T
LITLIT
LITLIT
LIT
-11616-18-40-11616-18-40
-11616-18-40-11616-18-40
-11616-18-40

Table of Contents

Questions and Answers:

Yamaha ttr230 Specifications

General IconGeneral
Engine Type223cc air-cooled SOHC 4-stroke; 2 valves
Bore x Stroke70.0mm x 58.0mm
Compression Ratio9.5:1
IgnitionCDI
TransmissionConstant-mesh 6-speed; multiplate wet clutch
Final DriveChain
Rear SuspensionSingle shock; 8.7-in travel
Front Tire80/100-21
Rear Tire100/100-18
Length81.3 in
Width31.5 in
Seat Height34.3 in
Wheelbase54.5 in
Ground Clearance11.6 in
Front SuspensionTelescopic fork
Rear BrakeDrum

Summary

Preface

Important Information

General guidance and warnings for using the manual.

How to Use This Manual

Manual Format

Explains the structure and components of the manual.

Exploded View Diagrams

Explains the use of visual diagrams for assembly and disassembly.

General Information

Motorcycle Identification

Details on frame and model identification numbers.

Special Tools

Lists tools required for specific adjustments and services.

Specifications

General Specifications

Provides overall technical data for the motorcycle.

Maintenance Specifications

Details technical specifications for maintenance tasks.

General Torque Specifications

Lists tightening torque values for various components.

Lubrication Points and Lubricant Types

Identifies lubrication points and recommended lubricants.

Cable Routing

Illustrates the correct routing of cables and wiring.

Periodic Inspection and Adjustments

Maintenance Schedule Table

Outlines recommended maintenance intervals and tasks.

General Maintenance / Lubrication

Covers general maintenance and lubrication procedures.

Seat, Fuel Tank, and Covers

Procedures for removing seat, fuel tank, and covers.

Valve Clearance Adjustment

Step-by-step guide for adjusting valve clearance.

Camshaft Chain Adjustment / Idle Speed

Procedure for adjusting the engine's idle speed.

Throttle Cable Free Play Adjustment

Steps to adjust the throttle cable free play.

Spark Plug Inspection

Guide for inspecting and checking the spark plug.

Ignition Point Inspection

Procedure for inspecting the ignition timing.

Compression Pressure Measurement

Steps for measuring engine compression.

Engine Oil Level Check

How to check the engine oil level.

Engine Oil Change

Procedures for changing engine oil.

Oil Pressure Check / Clutch Adjustment

How to check engine oil pressure and adjust the clutch.

Air Filter Cleaning

Instructions for cleaning the air filter element.

Exhaust System Check/ Core Clearing

How to inspect the exhaust system and clear the core.

Front Brake Fluid Level Check/Front Brake Pad Check

How to check front brake fluid level and pads.

Air Bleeding

Steps for bleeding the front brake system.

Rear Brake Adjustment

How to adjust the rear brake.

Brake Lining Check

Procedure for checking brake linings.

Transmission Chain Free Play Adjustment / Transmission Chain Lubrication

How to adjust chain free play and lubricate the chain.

Steering Column Adjustment

Steps for adjusting the steering column.

Front Suspension Inspection

How to inspect the front suspension.

Rear Shock Absorber Adjustment

Procedure for adjusting the rear shock absorber.

Tire Inspection

Guide for inspecting tires and checking pressure.

Pedal and Side Support Lubrication/ Rear Suspension Lubrication

Lubrication points for pedals, levers, side support, and rear suspension.

Battery Inspection

How to inspect the battery.

Fuse Inspection

How to inspect and replace fuses.

Engine Inspection

Engine Removal

Steps for removing the engine from the motorcycle.

Engine Dismounting

Procedures for disassembling engine components.

Head

Procedures for inspecting and repairing the cylinder head.

Valve Seat

How to inspect and repair valve seats.

Valves and Valve Guides

Procedures for inspecting and repairing valves and guides.

Valve Spring

How to inspect and replace valve springs.

Camshaft

Procedures for inspecting and repairing the camshaft.

Cylinder and Piston

Procedures for inspecting and repairing the cylinder and piston.

Piston Rings

How to inspect and replace piston rings.

Piston Pin

Procedures for inspecting and repairing the piston pin.

Crankshaft

How to inspect and repair the crankshaft.

Balancer Gears

Procedures for inspecting and repairing balancer gears.

Clutch

Procedures for inspecting and repairing the clutch.

Transmission and Shifting Fork

How to inspect and repair the transmission and shifting fork.

Oil Pump and Filter Strainer

Procedures for inspecting and repairing the oil pump and filter strainer.

Electric Starting System Gears

How to inspect and repair electric starting gears.

Cases

Procedures for inspecting and repairing engine cases.

Valves, Rocker, and Camshaft

Steps for mounting and adjusting valves, rockers, and camshaft.

Valves

Procedures for mounting and adjusting valves.

Rocker

Steps for mounting and adjusting the rocker assembly.

Crankshaft

Procedures for mounting and adjusting the crankshaft.

Balancer and Transmission

Steps for mounting and adjusting balancer and transmission components.

Shifting Fork

Procedures for mounting and adjusting the shifting fork.

Cases

Procedures for mounting and adjusting engine cases.

Shift Shaft

Procedures for mounting and adjusting the shift shaft.

Balancer Gear

Steps for mounting and adjusting balancer gears.

Clutch and Oil Pump

Procedures for mounting and adjusting the clutch and oil pump.

Oil Filter

Steps for mounting and adjusting the oil filter.

Magnet Rotor and Starting Gears

Procedures for mounting and adjusting the magnet rotor and starting gears.

Cylinder and Piston

Steps for mounting and adjusting the cylinder and piston.

Head

Procedures for mounting and adjusting the cylinder head.

Camshaft and Camshaft Chain

Steps for mounting and adjusting the camshaft and chain.

Carburation

Carburetor

Procedures for carburetor removal, inspection, mounting, and installation.

Removal

Steps for removing the carburetor.

Dismounting

Procedures for disassembling carburetor components.

Inspection

How to inspect carburetor parts.

Mounting

Steps for mounting carburetor components.

Installation

Procedures for installing the carburetor.

Fuel Level Adjustment

How to adjust the fuel level in the carburetor.

Frame

Front Wheel

Procedures for front wheel removal, inspection, mounting, and installation.

Front Brake

Steps for front brake maintenance and repair.

Rear Wheel

Procedures for rear wheel removal, inspection, mounting, and installation.

Front Fork

Steps for front fork removal, dismounting, inspection, mounting, and installation.

Steering Column and Handle-bars

Procedures for steering column and handle-bar maintenance.

Rear Shock Absorber and Balance

How to handle, discard, remove, inspect, and install rear shock absorbers.

Transmission Ratio

Procedures for transmission ratio removal, inspection, and installation.

Electric System

Electric Circuit Diagram - TTR230

Electrical schematic diagram of the TTR230.

Electric Components

Identification of electrical components.

Switch Checks

How to check electrical switches for continuity.

Ignition System

Explanation and troubleshooting of the ignition system.

Electric Starting System

Troubleshooting for the electric starting system.

Starter Motor

Inspection and repair of the starter motor.

Charging System

Troubleshooting for the battery charging system.

Troubleshooting

Starting Failure / Difficulty

Diagnosing starting problems, focusing on the fuel system.

Gear Shifting Difficulty/Clutch Problems

Diagnosing issues with gear shifting and clutch operation.

Overheating

Identifying causes and solutions for engine overheating.

Brake Fault/ Leakage on the Front Fork

Troubleshooting front brake faults and oil leaks.

Unstable Driving

Diagnosing causes of unstable driving conditions.

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