Yamaha TT-R230 Manuel utilisateur

SERVICE MANUAL

1C6-F8197-101C6-F8197-10

1C6-F8197-10

TTR230T

LITLIT

LIT-11616-18-40-11616-18-40

-11616-18-40-11616-18-40

-11616-18-40

SERVICE MANUAL

Feb/2005 - Yamaha Motor da Amazônia Ltda

Post-Sales Service Department

of all contents in this manual is forbidden

without the previous written authorization

from Yamaha Motor da Amazônia Ltda.

Printed in Brazil.

LIT-11616-18-40

TTR 230(T)

The alert sign means ATTENTION! ALERT! YOUR SAFETY IS

INVOLVED!

The failure in fulfilling a WARNING instruction may cause serious

accident and even the death of the vehicle driver, an observer, or

someone examining or repairing the vehicle.

A CAUTION instruction indicates special precautions to be taken to

prevent damages in the vehicle.

A NOTE provides information in order to clarify or facilitate the

procedures.

PREFACE

This manual has been prepared by YAMAHA MOTOR DA AMAZÔNIA LTDA. for the exclusive

use by the Yamaha Authorized Dealer and its qualified mechanicians. Since all mechanics

information cannot be included in a single manual, it is assumed that the people reading

this manual, to execute maintenance and repair services on the Yamaha motorcycles, have

a basic knowledge of the mechanical conceptions and procedures, inherent to the

motorcycle repair technology. Without these knowledge, any repair or service attempt on

this model could cause difficulties for its utilization and/or safety.

YAMAHA MOTOR DA AMAZÔNIA LTDA. will make its best efforts to enhance continuously

all products in its line. The significant changes and modifications in the specifications or

procedures will be informed to all YAMAHA Dealers, and will be included in the proper

places in future editions of this manual.

NOTE:

This model design and specifications are subject to changes with no previous notice.

The especially important information will be marked in this manual with the notations

below.

WARNING

CAUTION:

NOTE:

IMPORTANT INFORMATION

1. An exploded view diagram 4is supplied to enable easy view of the mounting and

dismounting services.

2. Numbers 5indicate the service order in the exploded view diagrams. A number

surrounded by a circle indicates a dismounting step.

3. A service and note explanation is provided in an easy reading way by using symbols 6.

The meaning of each symbol is provided in the next page.

4. An instruction chart 7is supplied with the exploded view diagram, and provides the

services order, part names, notes, etc.

5. For services requiring more information, a step-by-step supplement is provided 8in

addition to the exploded view diagram and instruction chart.

This manual is constituted by chapters for the major subject categories. (See “Illustrative

Symbols”)

1st title 1: This is the chapter title with the symbol in the upper right corner in each page.

2nd title 2:This title indicates the section in each chapter and only appears on the first page

of each section. It is located in the upper left corner of the page.

3rd title 3: This title indicates a subsection followed by step-by-step instructions and with

the corresponding illustrations.

HOW TO USE THIS MANUAL

MANUAL FORMAT

In order to identify parts and procedure steps, there are exploded view diagrams in the beginning

of each dismounting and mounting section.

EXPLODED VIEW DIAGRAMS

ILLUSTRATIVE SYMBOLS

1 2

5 6

20 22

17 19

INFO

GEN SPEC

ENGINE

INSP

ADJUS

General information

Specifications

Periodic inspection and adjustments

Engine

Carburation

Frame

Electric system

Troubleshooting

ELECT

CHASCARB

PROB

The illustrative symbols from 1 to 8are

assigned as per the table aside, in order to

indicate the chapter numbers and contents.

9Replenish with fluid

0Lubricant

ASpecial tool

BTighten with torque wrench

CWear limit, clearance

DEngine speed

EΩ, V, A

The illustrative symbols from 9to Eare

used to identify the specifications

appearing in the text.

F Apply locking agent (LOCTITE®)

GApply engine oil

HApply gear oil

IApply molybdenum disulfide oil

JApply grease for wheel roller bearing

KApply lithium-based grease

LApply molybdenum disulfide-based

grease

The illustrative symbols from Fto L, in

the exploded view diagrams, indicate the

lubricant types and the lubrication points

to be applied.

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND

ADJUSTMENTS

ENGINE INSPECTION

CARBURATION

FRAME

ELECTRIC SYSTEM

TROUBLESHOOTING

INFO

GEN

SPEC

ENGINE

CARB

CHAS

ELECT

PROB

INSP

ADJUS

TABLE OF CONTENTS

INFO

GEN

MOTORCYCLE IDENTIFICATION ..................................................................

1-1

FRAME NUMBER ............................................................................ 1-1

MODEL IDENTIFICATION ................................................................ 1-1

IMPORTANT INFORMATION .........................................................................

1-2

PREPARING FOR REMOVING AND DISMOUNTING ..................... 1-2

REPLACEMENT PARTS .................................................................. 1-3

GASKETS, RETAINERS AND O-RINGS .......................................... 1-3

LOCK WASHERS/SPACERS AND COTTER PINS .......................... 1-3

ROLLER BEARINGS AND RETAINERS .......................................... 1-3

LOCK RINGS .................................................................................... 1-4

SPECIAL TOOLS ............................................................................................

1-4

FOR ADJUSTING ............................................................................. 1-4

FOR ENGINE SERVICES .................................................................. 1-5

FOR FRAME SERVICES .................................................................. 1-8

FOR ELECTRIC COMPONENTS ...................................................... 1-9

CONTENTS

CHAPTER 1.

GENERAL INFORMATION

INFO

GEN

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

The serial number of the frame 1is engraved

on the tube of the steering column.

MOTORCYCLE IDENTIFICATION

FRAME NUMBER

1-1

MODEL IDENTIFICATION

The model ID label 1is stuck on the frame.

This information will be required for

replacement part orders.

The vehicle’s ID number is used to identify

the motorcycle, when registering and

licensing it with the local traffic authority.

NOTE:

INFO

GEN

IMPORTANT INFORMATION

1-2

PREPARING FOR REMOVING AND

DISMOUNTING

2. Use the proper tools and cleaning

equipment.

See the “SPECIAL TOOLS” section.

3. When dismounting the motorcycle, keep

the matching parts together. This includes

gears, cylinders, pistons and other

matching parts that suffered natural wear

together. The matching parts must be

remounted as an assembly or replaced.

4. When dismounting the motorcycle, clean

all parts and put them on trays by

keeping the dismounting order. This will

speed the mounting and will assure the

correct part installation.

5. Keep fire sources away.

IMPORTANT INFORMATION

1. Clean all dirty, mud, dust and other

materials before removing and

dismounting.

DONT

SMOKE

INFO

GEN

IMPORTANT INFORMATION

LOCK WASHERS/SPACERS

AND COTTER PINS

ROLLER BEARINGS AND RETAINERS

1-3

GASKETS, RETAINERS AND O-RINGS

REPLACEMENT PARTS

1. Use only YAMAHA genuine parts for

replacement. Use oils/greases reco-

mmended by YAMAHA for mounting and

adjusting. Other brands may seem similar

in terms of function and appearance, but

have lower quality.

1. All gaskets, retainers and O-rings must be

replaced when overhauling the engine. All

gasket surfaces, retainer lips and O-rings

must be clean.

2. Apply oil on all points and roller bearings

when mounting. Apply grease on the

retainers’ lips.

Do not use compressed air for drying the

roller bearings. This will cause damages to

the roller bearing surfaces.

CAUTION:

1. Install the roller bearings 1 and retainers

2 ‚ with the manufacturer’s marks facing

out. (In other words, the stamped letters

must be exposed for facilitating the identi-

fication). When installing the retainers,

apply a thin lithium-based grease layer on

the retainer’s lips. Apply oil when installing

the roller bearing.

1. All lockwashers/cotter pins 1 must be

replaced when removed. The cotter pin

legs must be folded around the bolts or

nuts after applying the specific torque.

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