Yamaha TT-R110EX User Manual
OWNER’S MANUAL
TT-R110EX
LIT-11626-21-48
5B6-28199-10
EAU10041
INTRODUCTION
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Congratulations on your purchase of the Yamaha TT-R110EX. This model is the result of Yamaha’s vast experience in the
production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and
reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you
have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at
the date of manufacture. 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.
AN IMPORTANT SAFETY MESSAGE:
● READ THIS MANUAL, THE “PARENTS, YOUNGSTERS AND OFF-HIGHWAY MOTORCYCLES” BOOKLET, AND
THE “TIPS AND PRACTICE GUIDE FOR THE OFF HIGHWAY MOTORCYCLIST” BOOKLET CAREFULLY AND
COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.
● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MOTORCYCLE.
● NEVER OPERATE A MOTORCYCLE WITHOUT PROPER TRAINING OR INSTRUCTION.
● WEIGHT OF THE RIDER SHOULD NOT EXCEED 60 kg (132 lb).
AN IMPORTANT NOTE TO PARENTS:
This motorcycle is not a toy. Before you let your child ride this motorcycle, you should understand the instructions and warnings in this Owner’s Manual. Then be sure your child understands and will follow them. Also read the “PARENTS, YOUNGSTERS AND OFF-HIGHWAY MOTORCYCLES” and the “TIPS AND PRACTICE GUIDE FOR THE OFF HIGHWAY
MOTORCYCLIST” booklets supplied with this motorcycle when new or available from your Yamaha dealer. Children differ
in skills, physical abilities, and judgment. Some children may not be able to operate a motorcycle safely. Parents should supervise their child’s use of the motorcycle at all times. Parents should permit continued use only if they determine that the
child has the ability to operate the motorcycle safely.
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 OPERATOR 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.
● OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
● OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
● OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN
MADE NECESSARY BY MECHANICAL CONDITIONS.
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
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WARNING
Failure to follow WARNING instructions could result in severe injury or death
motorcycle operator, a bystander or a person inspecting or repairing the motor-
to the
cycle.
CAUTION:
NOTE:
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
NOTE:
● 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
and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
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 COMPLETELY 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.
REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE
THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
EWA14350
WARNING
THIS MOTORCYCLE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS ILLEGAL TO OPERATE THIS MOTORCYCLE ON ANY PUBLIC STREET, ROAD OR HIGHWAY. SUCH USE IS PROHIBITED BY LAW.
THIS MOTORCYCLE COMPLIES WITH ALMOST ALL STATE OFF-HIGHWAY NOISE LEVEL AND SPARK ARRESTER
LAWS AND REGULATIONS. PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERATING THIS MOTORCYCLE.
*Product and specifications are subject to change without notice.
IMPORTANT MANUAL INFORMATION
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.
Printed in Japan.
P/N LIT-11626-21-48
EAU10192
TABLE OF CONTENTS
SAFETY INFORMATION ..................1-1
Safe riding ......................................1-1
Location of important labels ............1-4
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS .......................................3-1
Main switch .....................................3-1
Handlebar switches ........................3-1
Shift pedal .......................................3-2
Brake lever .....................................3-2
Brake pedal ....................................3-2
Fuel tank cap ..................................3-3
Fuel .................................................3-3
Fuel tank breather hose ..................3-4
Fuel cock ........................................3-4
Starter (choke) lever .......................3-5
Kickstarter .......................................3-6
Seat ................................................3-6
Sidestand ........................................3-7
Starting circuit cut-off system .........3-7
PRE-OPERATION CHECKS..............4-1
Pre-operation check list ..................4-2
OPERATION AND IMPORTANT
RIDING POINTS.................................5-1
Starting and warming up a cold
engine .........................................5-1
Starting a warm engine .................. 5-2
Shifting ...........................................5-2
Engine break-in ..............................5-3
Parking ...........................................5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR ................................. 6-1
PERIODIC MAINTENANCE ........... 6-1
Owner’s tool kit ...............................6-2
Periodic maintenance chart for
the emission control system ....... 6-3
General maintenance and
lubrication chart ..........................6-4
Removing and installing panels ..... 6-6
Checking the spark plug .................6-7
Engine oil .......................................6-8
Cleaning the air filter element ......6-10
Cleaning the spark arrester .......... 6-12
Adjusting the carburetor ............... 6-13
Adjusting the engine idling
speed ........................................6-13
Checking the throttle cable
free play .................................... 6-14
Valve clearance ............................ 6-14
Tires .............................................6-15
Spoke wheels ...............................6-16
Accessories and replacement
parts ......................................... 6-16
Adjusting the clutch free play ....... 6-17
Adjusting the brake lever free
play ........................................... 6-17
Adjusting the brake pedal free
play ........................................... 6-18
Checking the shift pedal .............. 6-19
Checking the front and
rear brake shoes ...................... 6-19
Drive chain slack .......................... 6-20
Cleaning and lubricating
the drive chain .......................... 6-21
Checking and lubricating
the cables ................................. 6-22
Checking and lubricating
the throttle grip and cable ......... 6-22
Checking and lubricating
the brake lever .......................... 6-23
Checking and lubricating
the brake pedal ......................... 6-23
Checking and lubricating
the sidestand ............................ 6-23
Lubricating the swingarm
pivots ........................................ 6-24
Checking the front fork ................. 6-24
Checking the steering .................. 6-25
Checking the wheel bearings ....... 6-25
Battery ......................................... 6-26
Replacing the fuse ....................... 6-27
Supporting the motorcycle ........... 6-28
Front wheel ...................................6-28
Rear wheel ...................................6-30
Troubleshooting ............................6-31
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
TABLE OF CONTENTS
SAFETY INFORMATION
Safe riding
● Always make pre-operation
1
checks. Careful checks may help
prevent an accident.
● This motorcycle is designed for off-
road use only, therefore, it is illegal
to operate it on public streets,
roads, or highways, even a dirt or
gravel one. Off-road use on public
lands may be illegal. Please check
local regulations before riding.
● This motorcycle is designed to car-
ry the operator only. No passengers.
● Many accidents involve inexperi-
enced operators.
• Make sure that the operator is
qualified and that you only lend
your motorcycle to other qualified operators.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
● Many accidents have been caused
by error of the motorcycle operator. A typical error made by the operator is veering wide on a turn
due to EXCESSIVE SPEED or un-
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dercornering (insufficient lean angle for the speed). Never travel
faster than warranted by conditions.
● Ride cautiously in unfamiliar ar-
eas. You may encounter hidden
obstacles that could cause an accident.
● The posture of the operator is im-
portant for proper control. The operator should keep both hands on
the handlebar and both feet on the
operator footrests during operation
to maintain control of the motorcycle.
● Never ride under the influence of
alcohol or other drugs.
● Be sure the transmission is in neu-
tral before starting the engine.
Protective apparel
The majority of fatalities from motorcycle accidents are the result of head
injuries. The use of a safety helmet is
the single most critical factor in the prevention or reduction of head injuries.
● Always wear an approved helmet.
● Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
● The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
● Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
● Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protective clothing that covers your legs,
ankles, and feet.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your
motorcycle illegal to use.
1-1
SAFETY INFORMATION
Loading and accessories
Adding accessories to your motorcycle
can adversely affect stability and handling if the weight distribution of the
motorcycle is changed. To avoid the
possibility of an accident, use extreme
caution when adding accessories to
your motorcycle. Use extra care when
riding a motorcycle that has added accessories. Here are some general
guidelines to follow if adding accessories to your motorcycle:
Loading
● The weight of the operator must
not exceed 60 kg (132 lb).
● Accessory weight should be kept
as low and close to the motorcycle
as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle
to minimize imbalance or instability.
● Shifting weights can create a sud-
den imbalance. Make sure that accessories are securely attached to
the motorcycle before riding.
Check accessory mounts frequently.
● Never attach any large or heavy
items to the handlebar, front fork,
or front fender.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be responsible for the proper selection, installation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any accessories.
Keep these guidelines in mind for
mounting accessories in addition to
those provided under “Loading”.
● Never install accessories or that
would impair the performance of
your motorcycle. Carefully inspect
the accessory before using it to
make sure that it does not in any
way reduce ground clearance or
cornering clearance, limit suspen-
sion travel, steering travel or con-
trol operation.
• Accessories fitted to the handlebar or the front fork area can
create instability due to improper
1-2
weight distribution or aerodynamic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
• Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or
the motorcycle may become unstable in cross winds.
• Certain accessories can displace the operator from his or
her normal riding position. This
improper position limits the freedom of movement of the operator and may limit control ability,
therefore, such accessories are
not recommended.
● Use caution when adding electri-
cal accessories. If electrical accessories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
engine power.
1
SAFETY INFORMATION
Gasoline and exhaust gas
● GASOLINE IS HIGHLY FLAMMA-
BLE:
1
• Always turn the engine off when
refueling.
• Take care not to spill any gasoline on the engine or exhaust
pipe(s)/muffler(s) when refueling.
• Never refuel while smoking or in
the vicinity of an open flame.
● Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poisonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has adequate ventilation.
● Always turn the engine off before
leaving the motorcycle unattended
and remove the key from the main
switch. When parking the motorcycle, note the following:
• The engine and exhaust pipe(s)/
muffler(s) may be hot, therefore,
park the motorcycle in a place
where pedestrians or children
are not likely to touch these hot
areas.
• Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.
• Do not park the motorcycle near
a flammable source (e.g., a kerosene heater, or near an open
flame), otherwise it could catch
fire.
● When transporting the motorcycle
in another vehicle, make sure that
it is kept upright and that the fuel
cock(s) are turned to “ON” or
“RES” (for vacuum type)/“OFF”
(for manual type). If the motorcycle
should lean over, gasoline may
leak out of the carburetor or fuel
tank.
● If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediately.
If any gasoline spills on your skin
or clothing, immediately wash the
affected area with soap and water
and change your clothes.
1-3
Location of important labels
Please read the following important labels carefully before operating this vehicle.
SAFETY INFORMATION
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1
21 3
1-4
1
Cold tire normal pressure should be set as
follows.
FRONT : 100 kPa, {1.00 kgf/cm2}, 15 psi
REAR : 100 kPa, {1.00 kgf/cm
TIRE INFOMATION
2
2
3
BEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER’S
MANUAL AND ALL LABELS.
NEVER CARRY A PASSENGER. You increase your risk of losing
control if you carry a passenger.
NEVER OPERATE THIS VEHICLE ON PUBLIC ROADS. You can
collide with another vehicle if you operate this vehicle on a public road.
ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET,
eye protection, and protective clothing.
WARNING
}, 15 psi
3RV-21668-A0
3PT-2118K-A0
DESCRIPTION
Left view
2
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123 4
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. Throttle stop screw (page 6-13)
2-1
678
5
Right view
DESCRIPTION
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123 4
2
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. Kickstarter (page 3-6)
857
6
2-2
DESCRIPTION
Controls and instruments
2
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)
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1234
56
2-3
INSTRUMENT AND CONTROL FUNCTIONS
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Main switch
The main switch controls the ignition
system. The main switch positions are
described below.
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ON
All electrical systems are supplied with
power, and the engine can be started.
The key cannot be removed.
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OFF
All electrical systems are off. The key
can be removed.
Handlebar switches
Left
1. Engine stop switch “ / ”
Right
1
1. Start switch “”
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Engine stop switch “ / ”
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Set this switch to “” before starting
the engine. Set this switch to “” to
stop the engine in case of an emergency, such as when the vehicle overturns
or when the throttle cable is stuck.
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Start switch “”
Push this switch to crank the engine
with the starter.
ECA10050
CAUTION:
See page 5-1 for starting instructions prior to starting the engine.
3
3-1
INSTRUMENT AND CONTROL FUNCTIONS
Shift pedal
3
1
1. Shift pedal
This motorcycle is equipped with a constant-mesh 4-speed transmission. The
shift pedal is located on the left side of
the engine. Neutral is at the bottom position.
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Brake lever
1
1. Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handlebar grip.
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Brake pedal
1
1. Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
3-2
INSTRUMENT AND CONTROL FUNCTIONS
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Fuel tank cap
1. Fuel tank cap 1. Fuel tank filler tube
To remove the fuel tank cap, turn it
counterclockwise, and then pull it off.
To install the fuel tank cap, insert it into
the tank opening, and then turn it clock-
Fuel
2. Fuel level
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
wise.
EWA11090
WARNING
Make sure that the fuel tank cap is
properly closed before riding.
WARNING
● Do not overfill the fuel tank, oth-
erwise it may overflow when the
fuel warms up and expands.
● Avoid spilling fuel on the hot en-
gine.
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EWA10880
ECA10070
CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfaces or plastic parts.
EAU13300
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
3.8 L (1.00 US gal) (0.84 Imp.gal)
Fuel reserve amount:
0.5 L (0.13 US gal) (0.11 Imp.gal)
ECA11400
CAUTION:
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number
[(R+M)/2] of 86 or higher, or a research
octane number of 91 or higher. If
3
3-3
INSTRUMENT AND CONTROL FUNCTIONS
knocking (or pinging) occurs, use a
gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel
will extend spark plug life and reduce
maintenance costs.
Gasohol
There are two types of gasohol: gasohol containing ethanol and that contain-
3
ing methanol. Gasohol containing
ethanol can be used if the ethanol content does not exceed 10%. Gasohol
containing methanol is not recommended by Yamaha because it can
cause damage to the fuel system or vehicle performance problems.
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Fuel tank breather hose
1
1. Fuel tank breather hose
Before operating the motorcycle:
● Check the fuel tank breather hose
connection.
● Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.
● Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.
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Fuel cock
The fuel cock supplies fuel from the
tank to the carburetor while filtering it also.
The fuel cock has three positions:
OFF
1. Arrow mark positioned over “OFF”
With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.
3-4
INSTRUMENT AND CONTROL FUNCTIONS
ON
1. Arrow mark positioned over “ON”
With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
RES
This indicates reserve. If you run out of
fuel while riding, move the lever to this
position. Fill the tank at the first opportunity. Be sure to set the lever back to
“ON” after refueling!
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Starter (choke) lever “”
3
1. Starter (choke) lever “”
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the lever in direction (a) to turn on
the starter (choke).
Move the lever in direction (b) to turn off
the starter (choke).
1. Arrow mark positioned over “RES”
3-5
INSTRUMENT AND CONTROL FUNCTIONS
Kickstarter
1
3
1. Kickstarter lever
If the engine fails to start by pushing the
start switch, try to start it by using the
kickstarter. To start the engine, fold out
the kickstarter lever, move it down lightly with your foot until the gears engage,
and then push it down smoothly but
forcefully.
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EAU13960
Seat
To remove the seat
Remove the bolts, and then pull the
seat off.
1
1. Bolt
To install the seat
1. Insert the projections on the front
of the seat into the seat holders as
shown.
1
2
1. Projection
2. Seat holder
2. Place the seat in the original position, and then tighten the bolts.
NOTE:
Make sure that the seat is properly secured before riding.
3-6
INSTRUMENT AND CONTROL FUNCTIONS
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Sidestand
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.
EWA14190
WARNING
The vehicle must not be ridden with
the sidestand down, or if the sidestand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
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Starting circuit cut-off system
The starting circuit cut-off system prevents starting when the transmission is
in gear.
Periodically check the operation of the
starting circuit cut-off system according
to the following procedure.
EWA10250
WARNING
If a malfunction is noted, have a
Yamaha dealer check the system before riding.
3
3-7
INSTRUMENT AND CONTROL FUNCTIONS
With the engine turned off:
3
1. Make sure that the engine stop switch is set to “
2. Turn the key to “ON”.
3. Shift the transmission into gear.
4. Keep the front or rear brake applied.
5. Push the start switch.
Does the engine start?
NO
6. Shift the transmission into the neutral position.
7. Push the start switch.
Does the engine start?
YES
The system is OK. The motorcycle can be ridden.
YES
NO
”.
3-8
NOTE:
This check is most reliable if performed with
a warmed-up engine.
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
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