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Table of Contents
Troubleshooting
Related Manuals for Yamaha TT-R 110
Summary of Contents for Yamaha TT-R 110
- Page 1 OWNER’S MANUAL TT-R110EX LIT-11626-21-48 5B6-28199-10...
- Page 2 EAU10041...
- Page 3 Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.
- Page 4 INTRODUCTION MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERA- TOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
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Page 5: Important Manual Information
This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle... - Page 6 IMPORTANT MANUAL INFORMATION EWA14460 WARNING PLEASE READ THIS MANUAL, THE “TIPS AND PRACTICE GUIDE FOR THE OFF HIGHWAY MOTORCYCLIST” AND THE “PARENTS, YOUNGSTERS AND OFF-HIGHWAY MOTORCYCLES” BOOKLETS CAREFULLY AND COMPLETE- LY BEFORE OPERATING OR ALLOWING YOUR CHILD TO OPERATE THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
- Page 7 IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE TT-R110EX OWNER’S MANUAL ©2007 by Yamaha Motor Corporation, U.S.A. 1st edition, June 2007 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.
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Page 8: Table Of Contents
TABLE OF CONTENTS SAFETY INFORMATION ....1-1 OPERATION AND IMPORTANT Accessories and replacement Safe riding ........1-1 RIDING POINTS......... 5-1 parts ......... 6-16 Location of important labels ....1-4 Starting and warming up a cold Adjusting the clutch free play ..6-17 engine ......... 5-1 Adjusting the brake lever free DESCRIPTION ........2-1 Starting a warm engine .... - Page 9 Troubleshooting chart ....6-32 MOTORCYCLE CARE AND STORAGE ..........7-1 Matte color caution ......7-1 Care ..........7-1 Storage ...........7-3 SPECIFICATIONS ......8-1 CONSUMER INFORMATION.....9-1 Identification numbers ....9-1 Motorcycle noise regulation ....9-3 YAMAHA MOTOR CORPORATION, U.S.A. OFF-ROAD MOTORCYCLE LIMITED WARRANTY .......9-4 YAMAHA EXTENDED SERVICE (Y.E.S.) ........9-6...
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Page 10: Safety Information
Modifications made to this motorcycle Staying within your limits may cycle accidents are the result of head not approved by Yamaha, or the re- help you to avoid an accident. injuries. The use of a safety helmet is moval of original equipment, may ren-... - Page 11 Since Yamaha cannot • Bulky or large accessories may your motorcycle. Use extra care when test all other accessories that may be...
- Page 12 SAFETY INFORMATION Gasoline and exhaust gas where pedestrians or children GASOLINE IS HIGHLY FLAMMA- are not likely to touch these hot BLE: areas. • Always turn the engine off when • Do not park the motorcycle on a refueling. slope or soft ground, otherwise it •...
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Page 13: Location Of Important Labels
SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle. TIRE INFOMATION Cold tire normal pressure should be set as follows. FRONT : 100 kPa, {1.00 kgf/cm }, 15 psi REAR : 100 kPa, {1.00 kgf/cm }, 15 psi 3RV-21668-A0 WARNING... -
Page 14: Description
DESCRIPTION EAU10410 Left view 1. Fuel cock (page 3-4) 2. Starter (choke) lever (page 3-5) 3. Fuse (page 6-27) 4. Battery (page 6-26) 5. Clutch adjusting screw (page 6-17) 6. Engine oil drain bolt (page 6-8) 7. Shift pedal (page 3-2) 8. -
Page 15: Right View
DESCRIPTION EAU10420 Right view 1. Spark arrester (page 6-12) 2. Seat (page 3-6) 3. Fuel tank (page 3-3) 4. Air filter element (page 6-10) 5. Spark plug cap (page 6-7) 6. Engine oil filler cap (page 6-8) 7. Brake pedal (page 3-2) 8. -
Page 16: Controls And Instruments
DESCRIPTION EAU10430 Controls and instruments 1. Left handlebar switch (page 3-1) 2. Main switch (page 3-1) 3. Right handlebar switch (page 3-1) 4. Brake lever (page 3-2) 5. Throttle grip (page 6-14) 6. Fuel tank cap (page 3-3) -
Page 17: Instrument And Control Functions
INSTRUMENT AND CONTROL FUNCTIONS EAU40340 EAU12347 EAU12660 Main switch Handlebar switches Engine stop switch “ ” Set this switch to “ ” before starting Left the engine. Set this switch to “ ” to stop the engine in case of an emergen- cy, such as when the vehicle overturns or when the throttle cable is stuck. -
Page 18: Shift Pedal
INSTRUMENT AND CONTROL FUNCTIONS EAU39850 EAU12890 EAU12941 Shift pedal Brake lever Brake pedal 1. Shift pedal 1. Brake lever 1. Brake pedal This motorcycle is equipped with a con- The brake lever is located at the right The brake pedal is on the right side of stant-mesh 4-speed transmission. -
Page 19: Fuel Tank Cap
Avoid spilling fuel on the hot en- as well as to the exhaust system. gine. Your Yamaha engine has been de- signed to use regular unleaded gaso- line with a pump octane number [(R+M)/2] of 86 or higher, or a research... -
Page 20: Fuel Tank Breather Hose
10%. Gasohol containing methanol is not recom- 1. Fuel tank breather hose mended by Yamaha because it can Before operating the motorcycle: cause damage to the fuel system or ve- Check the fuel tank breather hose hicle performance problems. -
Page 21: Starter (Choke) Lever
INSTRUMENT AND CONTROL FUNCTIONS This indicates reserve. If you run out of EAU13590 Starter (choke) lever “ ” fuel while riding, move the lever to this position. Fill the tank at the first oppor- tunity. Be sure to set the lever back to “ON”... -
Page 22: Kickstarter
INSTRUMENT AND CONTROL FUNCTIONS EAU37650 EAU13960 Kickstarter Seat To remove the seat Remove the bolts, and then pull the seat off. 1. Projection 2. Seat holder 1. Kickstarter lever 2. Place the seat in the original posi- If the engine fails to start by pushing the tion, and then tighten the bolts. -
Page 23: Sidestand
If a malfunction is noted, have a (or does not stay up), otherwise the Yamaha dealer check the system be- sidestand could contact the ground fore riding. and distract the operator, resulting... - Page 24 5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. 6. Shift the transmission into the neutral position. 7. Push the start switch. Does the engine start? The neutral switch may be defective.
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Page 25: Pre-Operation Checks
PRE-OPERATION CHECKS EAU15593 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. -
Page 26: Pre-Operation Check List
• Make sure that operation is smooth. • Check cable free play. Throttle grip 6-14, 6-22 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 6-22 •... - Page 27 PRE-OPERATION CHECKS ITEM CHECKS PAGE • Make sure that operation is smooth. Brake pedal 6-23 • Lubricate pedal pivoting point if necessary. • Make sure that operation is smooth. Brake lever 6-23 • Lubricate lever pivoting point if necessary. • Make sure that operation is smooth. Sidestand 6-23 •...
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Page 28: Operation And Important Riding Points
“ ”. ing controls and their functions 3. Shift the transmission into the neu- before riding. Consult a Yamaha tral position. dealer regarding any control or EWA14410 WARNING function that you do not thor- oughly understand. -
Page 29: Starting A Warm Engine
OPERATION AND IMPORTANT RIDING POINTS EAU16640 EAU39901 ECA15441 Starting a warm engine Shifting CAUTION: 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
5 immediately have a Yamaha dealer gears, close the throttle. hours of operation. The various parts in check the vehicle. -
Page 31: Parking
OPERATION AND IMPORTANT RIDING POINTS EAU17170 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. EWA10310 WARNING Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them. -
Page 32: Periodic Maintenance And Minor Repair
ARE ALSO VITAL TO PROPER EN- systems may be performed by any repair establishment or individual that is certified (if applicable). EWA10320 WARNING If you are not familiar with mainte- nance work, have a Yamaha dealer do it for you. -
Page 33: Owner's Tool Kit
NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you. EWA10340 WARNING Modifications approved Yamaha may cause loss of perfor- mance, excessive emissions, and render the vehicle unsafe for use. -
Page 34: 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 35: General Maintenance And Lubrication Chart
7 * 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 • Replace if necessary. Shock absorber assem- • Check operation and for oil leakage. √ 16 * • Replace if necessary. • Apply Yamaha chain and cable lube or engine oil 10W-30 √ √ √ 17 * Control cables thoroughly.
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Page 37: Removing And Installing Panels
PERIODIC MAINTENANCE AND MINOR REPAIR EAU18771 Removing and installing pan- The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. -
Page 38: Checking The Spark Plug
If the spark plug shows a distinctly dif- ferent color, the engine could be oper- ating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check 1. Spark plug cap the vehicle. 2. Remove the spark plug as shown, with the spark plug wrench includ- ed in the owner’s tool kit. -
Page 39: Engine Oil
PERIODIC MAINTENANCE AND MINOR REPAIR 2. Check the spark plug for electrode 2. Clean the surface of the spark plug EAU39841 Engine oil erosion and excessive carbon or gasket and its mating surface, and The engine oil level should be checked other deposits, and replace it if then wipe off any grime from the before each ride. - Page 40 PERIODIC MAINTENANCE AND MINOR REPAIR To change the engine oil 5. Add the specified amount of the 1. Start the engine, warm it up for recommended engine oil, and then several minutes, and then turn it install and tighten the engine oil fill- off.
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Page 41: Cleaning The Air Filter Element
PERIODIC MAINTENANCE AND MINOR REPAIR 7. Turn the engine off, and then EAU41633 Cleaning the air filter element check the oil level and correct it if The air filter element should be cleaned necessary. at the intervals specified in the periodic maintenance and lubrication chart. - Page 42 Recommended oil: inder(s) become Yamaha foam air filter oil or other excessively worn. quality foam air filter oil 8. Install the air filter case cover by in- 7. Insert the mesh and the sponge stalling the screws.
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Page 43: Cleaning The Spark Arrester
PERIODIC MAINTENANCE AND MINOR REPAIR 2. If dirt or water is visible, remove EAU40421 Cleaning the spark arrester the hoses, clean them, and then The spark arrester should be cleaned reinstall them. at the intervals specified in the periodic maintenance and lubrication chart. EWA10980 WARNING Always let the exhaust system... -
Page 44: Adjusting The Carburetor
Tailpipe bolt: follows at the intervals specified in the 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Yamaha dealer, who has the neces- periodic maintenance and lubrication sary professional knowledge and expe- chart. rience. The adjustment described in the... -
Page 45: 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 46: Tires
CHEN SHIN/C-803 glass fragments in it, or if the sidewall is Rear tire: temperature). cracked, have a Yamaha dealer re- Size: The tire air pressure must be ad- place the tire immediately. 3.00-12 4PR... -
Page 47: Spoke Wheels
If any dam- curely mounted to maintain the in- It is not recommended to patch age is found, have a Yamaha herent stability of the original a punctured tube. If unavoid- dealer replace the wheel. -
Page 48: Adjusting The Clutch Free Play
PERIODIC MAINTENANCE AND MINOR REPAIR EAU44661 3. Tighten the locknut to the specified EAU44880 Adjusting the clutch free play Adjusting the brake lever free torque. The clutch free play must be checked play and, if necessary, adjusted as follows Tightening torque: at the intervals specified in the periodic Locknut: 8.0 Nm (0.8 m·kgf, 5.8 ft·lbf) -
Page 49: Adjusting The Brake Pedal Free Play
If proper adjustment cannot be en the brake cable. obtained as described, have a 5. Loosen the locknut at the brake Yamaha dealer make this ad- shoe plate. justment. 6. To increase the brake lever free play, turn the adjusting bolt in di- rection (a). -
Page 50: Checking The Shift Pedal
If opera- lubrication chart. Each brake is provid- Front tion is not smooth, have a Yamaha ed with a wear indicator, which allows dealer check the vehicle. you to check the brake shoe wear with- out having to disassemble the brake. -
Page 51: Drive Chain Slack
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. EAU22773 To check the drive chain slack 1. Place the motorcycle on the side- stand. 1. Drive chain slack 1. -
Page 52: Cleaning And Lubricating
NOTE: to chain slippage or breakage. To For a thorough cleaning, have a prevent this from occurring, keep Yamaha dealer remove the drive chain the drive chain slack within the and soak it in solvent. specified limits. 2. Spray Yamaha Chain and Cable 3. -
Page 53: Checking And Lubricating The Cables
If a cable is damaged maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Yamaha Chain and Cable Lube or engine oil SAE 10W-30... -
Page 54: Checking And Lubricating The Brake Lever
Recommended lubricant: Recommended lubricant: EWA10730 Lithium-soap-based grease Lithium-soap-based grease WARNING If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease 6-23... -
Page 55: Lubricating The Swingarm Pivots
The swingarm pivots must be lubricat- fork does not operate smoothly, damage and excessive oil leakage. ed at the intervals specified in the peri- have a Yamaha dealer check or re- odic maintenance and lubrication chart. pair it. To check the operation 1. -
Page 56: Checking The Steering
2. Hold the lower ends of the front fork legs and try to move them for- ward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering. 6-25... -
Page 57: Battery
Batteries produce explosive hy- To charge the battery battery can cause permanent drogen gas. Therefore, keep Have a Yamaha dealer charge the bat- battery damage. sparks, flames, cigarettes, etc., tery as soon as possible if it seems to To charge a sealed-type (MF) away from the battery and pro- have discharged. -
Page 58: Replacing The Fuse
CAUTION: If you do not have access to a sealed-type (MF) battery charg- Do not use a fuse of a higher amper- er, have a Yamaha dealer age rating than recommended to charge your battery. avoid causing extensive damage to the electrical system and possibly a fire. -
Page 59: Supporting The Motorcycle
EWA10820 wheel or performing other maintenance WARNING requiring the motorcycle to stand up- It is advisable to have a Yamaha right. Check that the motorcycle is in a dealer service the wheel. stable and level position before starting Securely support the motor- any maintenance. - Page 60 PERIODIC MAINTENANCE AND MINOR REPAIR EAU41691 Tightening torque: To install the front wheel Axle nut: 1. Lift the wheel up between the fork 35 Nm (3.5 m·kgf, 25 ft·lbf) legs. 2. Insert the wheel axle from the 5. Adjust the brake lever free play. right-hand side.
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Page 61: Rear Wheel
EAU41642 shaft lever. To remove the rear wheel EWA10820 WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motor- cycle so that there is no danger 1. Axle nut of it falling over. -
Page 62: Troubleshooting
The drive chain does not need to be self. However, should your motorcycle Tightening torques: disassembled in order to remove and require any repair, take it to a Yamaha Brake torque rod nut: install the wheel. 26 Nm (2.6 m·kgf, 19 ft·lbf) -
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
Rust and corrosion can develop matte colored finished parts. Be Cleaning even if high-quality components are sure to consult a Yamaha dealer for ECA10771 advice on what products to use be- used. A rusty exhaust pipe may go un- CAUTION: fore cleaning the vehicle. - Page 65 MOTORCYCLE CARE AND STORAGE contact with strong or abrasive scratched, use a quality plastic After cleaning cleaning products, solvent or polishing compound after 1. Dry the motorcycle with a chamois thinner, fuel (gasoline), rust re- washing. or an absorbing cloth. movers or inhibitors, brake flu- 2.
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Page 66: Storage
NOTE: grounded. (This will limit spark- Long-term Consult a Yamaha dealer for advice on ing during the next step.) Before storing your motorcycle for sev- what products to use. d. Turn the engine over several eral months: times with the starter. - Page 67 MOTORCYCLE CARE AND STORAGE EWA10950 °C (90 °F)]. For more information WARNING on storing the battery, see page To prevent damage or injury from 6-26. sparking, make sure to ground the NOTE: spark plug electrodes while turning Make any necessary repairs before the engine over.
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Page 68: Specifications
SPECIFICATIONS Dimensions: Engine oil: Carburetor: Overall length: Type: Manufacturer: 1565 mm (61.6 in) YAMALUBE 4, SAE10W-30 or SAE20W- MIKUNI Type × quantity: Overall width: 680 mm (26.8 in) VM16 x 1 Overall height: Spark plug (s): 923 mm (36.3 in) Manufacturer/model: 0 ˚... - Page 69 SPECIFICATIONS 4th: Front wheel: Electrical system: 23/21 (1.095) Wheel type: Ignition system: Chassis: Spoke wheel DC. CDI Frame type: Rim size: Charging system: Steel tube backbone 14x1.40 AC magneto Caster angle: Rear wheel: Battery: 26.00 ° Wheel type: Model: Trail: Spoke wheel GT4B-5 60.0 mm (2.36 in)
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Page 70: Consumer Information
Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1. - Page 71 1. Model label The model label is affixed to the frame behind panel B. (See page 6-6.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
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Page 72: Motorcycle Noise Regulation
CONSUMER INFORMATION EAU26560 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new ve- hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. -
Page 73: Yamaha Motor Corporation, U.s.a. Off-Road Motorcycle Limited Warranty
1. Operate and maintain the motorcycle as date limitations. Covered off-road motorcycles are specified in the appropriate Owner's Manual, those units certified by Yamaha to EPA noise reg- YAMAHA MOTOR CORPORATION, ulations and come equipped from the factory with MAKES NO OTHER WARRANTY OF ANY 2. - Page 74 CONSUMER INFORMATION...
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Page 75: Yamaha Extended Service (Y.e.s.)
This excellent Y.E.S. plan coverage is only available to dealer to see how comforting uninterrupted factory- Yamaha owners like you, and only while your Yamaha is still backed protection can be. within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. - Page 76 Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
- Page 77 INDEX Starter (choke) lever ....... 3-5 Starting and warming up Accessories and replacement parts ..6-16 Handlebar switches .........3-1 a cold engine ........5-1 Air filter element, cleaning ....6-10 Starting circuit cut-off system....3-7 Identification numbers ......9-1 Start switch ..........3-1 Battery ..........
- Page 80 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2007.07-2.1×1 CR...