Yamaha TT-R230Z Owner's Manual
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Yamaha TT-R230Z Owner's Manual

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TT-R230Z
1C6-F8199-25

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Summary of Contents for Yamaha TT-R230Z

  • Page 1 Read this manual carefully before operating this vehicle. TT-R230Z 1C6-F8199-25...
  • Page 2 EAU46090 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
  • Page 3 Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TT-R230Z. The Owner’s Manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury.
  • Page 4 IMPORTANT MANUAL INFORMATION EAU10132 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
  • Page 5 IMPORTANT MANUAL INFORMATION EAUW0011 TT-R230Z OWNER’S MANUAL ©2009 by Yamaha Motor da Amazônia Ltda. 1st edition, july 2009 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor da Amazônia Ltda. is expressly prohibited. Printed in Brazil.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS LOCATION OF IMPORTANT FOR YOUR SAFETY – Adjusting the clutch lever free LABELS ..........1-1 PRE-OPERATION CHECKS ..... 5-1 play ........... 7-17 Checking the front brake lever SAFETY INFORMATION ....2-1 OPERATION AND IMPORTANT free play ........7-18 RIDING POINTS......... 6-1 Adjusting the brake pedal DESCRIPTION ........3-1 Starting and warming up a cold...
  • Page 7 TABLE OF CONTENTS Rear wheel ........7-30 Troubleshooting ......7-31 Troubleshooting chart ....7-33 MOTORCYCLE CARE AND STORAGE ..........8-1 Care ..........8-1 Storage ...........8-3 SPECIFICATIONS ......9-1 CONSUMER INFORMATION...10-1 Identification numbers ....10-1...

  • Page 8: Location Of Important Labels

    Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.
  • Page 9 LOCATION OF IMPORTANT LABELS...

  • Page 10: Safety Information

    SAFETY INFORMATION EAU10334 Safe Riding yourself conspicuous appears to Perform the pre-operation checks each be very effective in reducing the time you use the vehicle to make sure it chance of this type of accident. Be a Responsible Owner is in safe operating condition. Failure to Therefore: As the vehicle’s owner, you are respon- inspect or maintain the vehicle properly...
  • Page 11 SAFETY INFORMATION Many accidents have been caused Wear a face shield or goggles. carbon monoxide can collect rapidly by error of the motorcycle opera- Wind in your unprotected eyes and you can quickly be overcome and tor. A typical error made by the op- could contribute to an impairment unable to save yourself.
  • Page 12 • Properly adjust the suspension mended by Yamaha, even if sold and cle: for your load, and check the con- installed by a Yamaha dealer.
  • Page 13 SAFETY INFORMATION Never install accessories or carry tor and may limit control ability, cargo that would impair the perfor- therefore, such accessories are mance of your motorcycle. Care- not recommended. fully inspect the accessory before Use caution when adding electri- using it to make sure that it does cal accessories.

  • Page 14: Description

    DESCRIPTION EAU10410 Left view 1. Fuel cock (page 4-5) 2. Starter (choke) knob (page 4-6) 3. Air filter element (page 7-11) 4. Shift pedal (page 4-2)

  • Page 15: Right View

    DESCRIPTION EAU10420 Right view 1. Fuse (page 7-28) 2. Battery (page 7-26) 3. Shock absorber assembly spring preload adjusting nut (page 4-7) 4. Engine oil filter element (page 7-8) 5. Brake pedal (page 4-3)

  • Page 16: Controls And Instruments

    DESCRIPTION EAU10430 Controls and instruments 1. Clutch lever (page 4-2) 2. Engine stop button (page 4-1) 3. Start switch (page 4-1) 4. Brake lever (page 4-2) 5. Throttle grip (page 7-14) 6. Fuel tank cap (page 4-3)

  • Page 17: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS EAUW1880 EAU12348 EAU12670 Ignition switch Handlebar switches “ENGINE STOP” button Hold this button pushed until the engine Left stops in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck. EAU12711 Start switch “...

  • Page 18: Clutch Lever

    INSTRUMENT AND CONTROL FUNCTIONS EAU31640 EAU12870 EAU12890 Clutch lever Shift pedal Brake lever 1. Clutch lever 1. Shift pedal 1. Brake lever The clutch lever is located at the left The shift pedal is located on the left The brake lever is located at the right handlebar grip.

  • Page 19: Brake Pedal

    INSTRUMENT AND CONTROL FUNCTIONS EAU12941 EAU13182 EAU13212 Brake pedal Fuel tank cap Fuel Make sure there is sufficient gasoline in the tank. EWA10881 WARNING Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions.

  • Page 20: Fuel Tank Breather Hose

    EWA15151 WARNING clean it if necessary. Your Yamaha engine has been de- Gasoline is poisonous and can signed to use regular unleaded gaso- cause injury or death. Handle gaso- line with a research octane number of line with care.

  • Page 21: Fuel Cock

    INSTRUMENT AND CONTROL FUNCTIONS EAU13561 This indicates reserve. If you run out of Fuel cock fuel while riding, move the lever to this The fuel cock supplies fuel from the position. Fill the tank at the first oppor- tank to the carburetor while filtering it al- tunity.

  • Page 22: Starter (Choke) Knob

    INSTRUMENT AND CONTROL FUNCTIONS EAU13600 EAU13960 Starter (choke) knob “ ” Seat To remove the seat Remove the bolts, and then pull the seat off. 1. Projection 2. Seat holder 1. Starter (choke) knob “ ” 2. Place the seat in the original posi- Starting a cold engine requires a richer tion, and then tighten the bolts.

  • Page 23: Adjusting The Shock Absorber Assembly

    INSTRUMENT AND CONTROL FUNCTIONS EAU14815 load and thereby soften the sus- 3. Tighten the locknut to the specified Adjusting the shock absorber pension, turn the adjusting nut in torque. NOTICE: Always tighten assembly direction (b). the locknut against the adjust- This shock absorber assembly is The spring preload setting is deter- ing nut, and then tighten the...

  • Page 24: Sidestand

    Take the shock Periodically check the operation of the absorber assembly to a Yamaha starting circuit cut-off system according dealer for any service. to the following procedure. 1. Sidestand This check is most reliable if performed with a warmed-up engine.
  • Page 25 INSTRUMENT AND CONTROL FUNCTIONS...

  • Page 26: For Your Safety - Pre-Operation Checks

    • 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. Front brake •...
  • Page 27 • Make sure that operation is smooth. • Check cable free play. Throttle grip 7-14, 7-24 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 7-23 •...

  • Page 28: Operation And Important Riding Points

    [ECA11041] understand, ask your Yamaha dealer. following conditions must be met: 7. When the engine is warm, turn the EWA10271 The transmission is in the neutral starter (choke) off.

  • Page 29: Starting A Warm Engine

    OPERATION AND IMPORTANT RIDING POINTS EAU16640 EAU16671 ECA10260 Starting a warm engine Shifting NOTICE Follow the same procedure as for start- Even with the transmission in ing a cold engine with the exception the neutral position, do not that the starter (choke) is not required coast for long periods of time when the engine is warm.

  • Page 30: Engine Break-In

    To allow the engine If any engine trouble should occur to cool down from the temporary build- during the engine break-in period, up of heat, cruise at a lower engine immediately have a Yamaha dealer speed. check the vehicle.

  • Page 31: Periodic Maintenance And Adjustment

    If you are not familiar with vehicle ser- vice, have a Yamaha dealer perform service. EWA15121 WARNING Turn off the engine when performing...

  • Page 32: Periodic Maintenance Chart For The Emission Control System

    From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 33 PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL ODOMETER READINGS 1000 km 3000 km 5000 km ITEM CHECKS AND MAINTENANCE JOBS (600 mi) or (1800 mi) or (3000 mi) or 1 month or 6 months or 12 months or 30 hours 90 hours 150 hours •...

  • Page 34: General Maintenance And Lubrication Chart

    From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 35 8 * Swingarm pivot bearings • Moderately repack with lithium-soap-based grease. • Check chain slack/alignment and condition. Drive chain • Adjust and lubricate chain with Yamaha chain and cable Every ride lube thoroughly. • Check bearing assemblies for looseness. √...
  • Page 36 1 month or 6 months or 12 months or 30 hours 90 hours 150 hours • Apply Yamaha chain and cable lube or engine oil thor- √ √ √ 20 * Control cables oughly. • Check operation and free play.

  • Page 37: Removing And Installing The Panel

    Do not attempt to diagnose such problems yourself. Instead, have EAU19210 Panel A a Yamaha dealer check the vehicle. If the spark plug shows signs of elec- To remove the panel trode erosion and excessive carbon or Remove the screws, and then take the other deposits, it should be replaced.
  • Page 38 PERIODIC MAINTENANCE AND ADJUSTMENT Before installing a spark plug, the spark EAUW0612 Engine oil and oil filter ele- plug gap should be measured with a If a torque wrench is not available when ment wire thickness gauge and, if necessary, installing a spark plug, a good estimate The engine oil level should be checked adjusted to specification.
  • Page 39 PERIODIC MAINTENANCE AND ADJUSTMENT 4. Remove the engine oil filler bolt and drain bolt to drain the oil from the crankcase. NOTICE: When removing the engine oil drain bolt, the O-ring, compression spring, and oil strainer will fall out. Take care not to lose these parts.
  • Page 40 PERIODIC MAINTENANCE AND ADJUSTMENT 9. Clean the oil filter element with sol- 13. Refill with the specified amount of vent, and then install it. the recommended engine oil, and then install and tighten the engine oil filler bolt. Check the oil filter element for damage and replace it if necessary.

  • Page 41: Cleaning The Air Filter Element

    If this occurs, 1. Air filter case cover have a Yamaha dealer repair the 2. Screw vehicle. 2. Pull the air filter element out of the After checking the oil pressure, air filter case.
  • Page 42 NOTICE: To avoid dam- [EWAW0021] Recommended oil: aging the foam material, handle Yamaha foam air filter oil or other it gently and carefully, and do quality foam air filter oil not twist or wring it. [ECA10511] 7.

  • Page 43: Adjusting The Carburetor

    [ECA10481] Yamaha dealer, who has the neces- periodic maintenance and lubrication 9. Install the air filter case cover and sary professional knowledge and expe- chart.

  • Page 44: Checking The Throttle Cable Free Play

    (b). resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. 1. Throttle cable free play 1.

  • Page 45: Tires

    The tire air pressure must be cracked, have a Yamaha dealer re- checked and adjusted on cold tires (i.e., when the temperature place the tire immediately.

  • Page 46: Spoke Wheels

    Yamaha Motor Co., Ltd. soon as possible with a high- cle, note the following points regarding quality product.

  • Page 47: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE AND ADJUSTMENT Ride at moderate speeds after EAU22034 decrease the clutch lever free play, Adjusting the clutch lever free changing a tire since the tire sur- turn the adjusting bolt in direction play face must first be “broken in” for it (b).

  • Page 48: Checking The Front Brake Lever Free Play

    There should be no free play at the EWA10670 brake lever end. If there is free play, WARNING have a Yamaha dealer inspect the It is advisable to have a Yamaha brake system. dealer make these adjustments. EWA14211 WARNING A soft or spongy feeling in the brake...

  • Page 49: Checking The Front Brake Pads And Rear Brake Shoes

    2. Locknut obtained as described, have a ing to disassemble the brake. To check Yamaha dealer make this ad- The brake pedal free play should mea- the brake pad wear, check the position justment.

  • Page 50: Checking The Front Brake Fluid Level

    EAU37001 When checking the fluid level, Checking the front brake fluid touches the brake disc, have a Yamaha make sure that the top of the mas- level dealer replace the brake pads as a set.

  • Page 51: Changing The Brake Fluid

    Brake fluid may deteriorate paint- EAU22721 EAU22760 Changing the brake fluid Drive chain slack ed surfaces or plastic parts. Al- Have a Yamaha dealer change the The drive chain slack should be ways clean spilled fluid brake fluid at the intervals specified in checked before each ride and adjusted immediately.
  • Page 52 PERIODIC MAINTENANCE AND ADJUSTMENT of the motorcycle and can lead 5. Adjust the brake pedal free play. to chain slippage or breakage. (See page 7-18.) To prevent this from occurring, keep the drive chain slack with- in the specified limits. [ECA10571] Make sure that both adjusting plates are in the same position for proper...

  • Page 53: Cleaning And Lubricating The Drive Chain

    If a cable is damaged wet areas. Service the drive chain as or does not move smoothly, have a follows. Yamaha dealer check or replace it. WARNING! Damage to the outer ECA10583 NOTICE sheath may interfere with proper ca-...

  • Page 54: Checking And Lubricating The Throttle Grip And Cable

    Brake lever be checked before each ride. In addi- tion, the cable should be lubricated by a Yamaha dealer at the intervals speci- fied in the periodic maintenance chart. The operation of the brake pedal should be checked before each ride,...

  • Page 55: Checking And Lubricating The Sidestand

    WARNING! To avoid injury, have a Yamaha dealer check or re- sidestand pivot and metal-to-metal securely support the vehicle so pair it.

  • Page 56: Checking The Steering

    There is no need to check the electro- ward and backward. If any free lyte or to add distilled water. However, play can be felt, have a Yamaha the battery lead connections need to be dealer check or repair the steering.
  • Page 57 [ECA16302] burns. Avoid any contact with 2. If the battery will be stored for more Have a Yamaha dealer charge the bat- skin, eyes or clothing and al- than two months, check it at least tery as soon as possible if it seems to...

  • Page 58: Replacing The Fuse

    4. If the fuse immediately blows requiring the motorcycle to stand up- again, have a Yamaha dealer right. Check that the motorcycle is in a check the electrical system. stable and level position before starting any maintenance.

  • Page 59: Front Wheel

    PERIODIC MAINTENANCE AND ADJUSTMENT a jack either under each side of the EAU24360 4. Pull the wheel axle out, and then Front wheel frame in front of the rear wheel or under remove the wheel. NOTICE: Do each side of the swingarm. not apply the brake after the EAUW0542 wheel has been removed to-...

  • Page 60: Rear Wheel

    PERIODIC MAINTENANCE AND ADJUSTMENT 5. Push down hard on the handlebar EAU25080 Rear wheel several times to check for proper fork operation. EAU25421 To remove the rear wheel EWA10821 WARNING To avoid injury, securely support the vehicle so there is no danger of it falling over.

  • Page 61: Troubleshooting

    (See page 7-18.) self. However, should your motorcycle EWA10660 require any repair, take it to a Yamaha WARNING dealer, whose skilled technicians have After adjusting the brake pedal free the necessary tools, experience, and...
  • Page 62 PERIODIC MAINTENANCE AND ADJUSTMENT heaters or furnaces. Gasoline or gasoline vapors can ignite or ex- plode, causing severe injury or property damage. 7-32...

  • Page 63: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.

  • Page 64: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE EAU41356 ucts onto seals, gaskets, sprock- off any detergent residue using Care ets, the drive chain and wheel plenty of water, as it is harmful While the open design of a motorcycle axles. Always rinse the dirt and de- to plastic parts.
  • Page 65 MOTORCYCLE CARE AND STORAGE Test the product on a small hid- 2. Apply a corrosion protection spray EWA11131 WARNING den part of the windshield to on all metal, including chrome- and make sure that it does not leave nickel-plated, surfaces to prevent Contaminants on the brakes or tires any marks.

  • Page 66: Storage

    MOTORCYCLE CARE AND STORAGE EAU26151 3. Drain the carburetor float chamber Storage by loosening the drain bolt; this will Consult a Yamaha dealer for advice on prevent fuel deposits from building what products to use. Short-term up. Pour the drained fuel into the Always store your motorcycle in a cool, fuel tank.
  • Page 67 MOTORCYCLE CARE AND STORAGE spark plug electrodes while °C (90 °F)]. For more information turning the engine over. on storing the battery, see page 7-26. [EWA10951] e. Remove the spark plug cap from the spark plug, and then Make any necessary repairs before install the spark plug and the storing the motorcycle.

  • Page 68: Specifications

    SPECIFICATIONS Dimensions: Engine oil: Fuel reserve amount: 1.8 L (0.48 US gal, 0.40 Imp.gal) Overall length: Recommended brand: Carburetor: 2065 mm (81.3 in) YAMALUBE Type × quantity: Overall width: Type: 800 mm (31.5 in) SAE 10W-30, 10W-40, 10W-50, 15W-40, Y26P x 1 Overall height: 20W-40 or 20W-50 Spark plug (s):...
  • Page 69 SPECIFICATIONS 4th: Tire air pressure (measured on cold Operation: 27/24 (1.125) Right foot operation tires): 5th: Front suspension: Loading condition: 25/27 (0.926) Type: 0–150 kg (0–331 lb) (ZAF) 6th: Telescopic fork Front: 23/29 (0.793) Spring/shock absorber type: 100 kPa (1.00 kgf/cm², 15 psi) Chassis: Coil spring/oil damper Rear:...

  • Page 70: Consumer Information

    Record the vehicle identification num- ber and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number 1.
  • Page 71 INDEX Fuel tank breather hose ......4-4 Supporting the motorcycle ....7-28 Fuel tank cap...........4-3 Air filter element, cleaning ....7-11 Fuse, replacing........7-28 Throttle cable free play, checking ..7-14 Throttle grip and cable, Battery ..........7-26 Handlebar switches .........4-1 checking and lubricating ..... 7-24 Brake and clutch levers, Tires............
  • Page 74 YAMAHA MOTOR DA AMAZÔNIA LTDA. PRINTED IN BRAZIL 07,2009...

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