Yamaha TTR250L(C) Service Manual 1999–2006 (P/N LIT-11616-12-57)

This is Yamaha’s January 1999 first-edition factory service manual for the TT-R250 models TTR250L and TTR250LC. Yamaha groups them under TTR250L(C) and lists model codes 5GF1 and 5GF2. The cover carries P/N LIT-11616-12-57 and the identifier 5GF-28197-E0.

Chapter Bookmarks and Wiring Diagrams

Finding procedures and diagrams: Bookmarks jump to all eight chapters. PDF text search is unavailable. Small wire codes and connector markings are readable when zoomed in. Open the color wiring diagram from the last page.

The ZIP contains one printable PDF with 295 pages, including the cover, front matter, and final color wiring diagram.

Engine Overhaul, Chassis Service, and Electrical Tests

The selected workshop topics below cover major repair and service jobs. Yamaha also explains how to charge the maintenance-free battery and adjust headlight aim.

• Engine overhaul: Engine removal and refitting, cylinder-head and valve-train work, cylinder and piston inspection, and crankshaft, balancer, clutch, and transmission service.

• Periodic service: Valve-clearance shim selection, ignition timing and compression checks, oil-pressure inspection, clutch adjustment, air-filter cleaning, and spark-arrester service.

• Carburetor service: Removal, disassembly, inspection, and reassembly of the Teikei Y30P, with adjustments for fuel level and throttle valve position.

• Chassis and brakes: Wheel removal and static balancing, steering-head and swingarm service, front-fork teardown, hydraulic brake bleeding, and drive-chain and sprocket replacement.

• Electrical diagnosis: Circuit diagrams and fault charts for CDI ignition, the starter interlock and motor, AC-magneto charging, and lighting.

• Workshop references: Exploded assembly views, tightening sequences, component-specific torque tables, fluid capacities, wear limits, lubrication points, and cable-routing drawings.

Yamaha wrote the manual primarily for its dealers and qualified mechanics and assumes familiarity with motorcycle repair procedures.

Cylinder Head, Crankcase, and Transmission

Cylinder-head inspection covers valve-seat contact and refacing, valve-guide replacement, spring condition, camshaft-to-cap clearance, valve lifters, and timing-chain components. Yamaha warns that uneven loosening or tightening of the camshaft-cap fasteners can damage the head, caps, or camshafts. Crankshaft movement during camshaft installation can disturb valve timing.

The bottom-end procedures cover crankcase separation and assembly, balancer timing, bearings and seals, and inspection of the transmission shafts, gears, shift forks, and shift cam. Yamaha shows how to service the clutch pack and oil pump with the engine still in the frame. The engine chapter also covers the oil strainer, rotor, starter gears, and one-way starter clutch.

Carburetor and Running Faults

The carburetor inspection covers the accelerator-pump diaphragm, throttle valve, jets, jet needle, float, needle valve, and starter plunger. The symptom-based troubleshooting chapter lists fuel, ignition, compression, and valve-train causes for hard starting, poor idle, and weak midrange or high-speed performance.

Wheels, Brakes, and Suspension

The wheel procedures cover tire handling, spokes, rim runout, axle checks, and bearing and seal replacement. Brake repair includes pad replacement and front and rear caliper and master-cylinder rebuilds, with hose routing and fluid filling instructions.

Front-fork service reaches the damper rod, seals, and bushings, with oil filling and damping adjustment covered. Rear shock service includes removal, inspection, preload and damping adjustment, installation, and disposal precautions. Yamaha directs replacement of a damaged or leaking rear shock and warns against opening the pressurized nitrogen unit. The swingarm, relay arm, connecting rod, and Polylube bearings have separate service coverage.

Starting, Charging, and Lighting Faults

For a no-crank condition, the starting-system chart helps distinguish a starter motor fault from a relay or neutral/clutch interlock problem. Connector checks and component-location views support the electrical tests. Yamaha also covers starter motor disassembly, brush and armature inspection, stator and rectifier/regulator diagnosis, and tests for the headlight, high-beam indicator, and taillight.

The troubleshooting chapter also lists causes of gear jump-out, clutch slip or drag, overheating, poor braking, fork leaks or malfunction, unstable handling, and lighting faults.

Special Tools and Shop Diagrams

Yamaha lists the crankcase separating tool YU-01135-A, rotor puller 2K7-85555-00, valve spring compressor YM-04019, and damper rod holder YM-01418. Electrical tests call for tools such as the dynamic spark tester YM-34487 and pocket tester YU-03112. The shop illustrations include the engine lubrication diagram, valve shim selection chart, cable-routing drawings, and the full TTR250L(C) wiring diagram.

Selected Carburetor, Fork, and Charging Checks

For the TTR250L(C), the Teikei Y30P fuel level is 7.5–9.5 mm below the front float chamber mating surface with the carburetor upright.

The front-fork assembly procedure specifies an oil level of 130 mm from the top of each outer tube, with the inner tube and damper rod fully compressed and the spring removed.

The charging-system test specifies 13.0–15.0 V at the battery at 3,000 rpm with a fully charged battery.