Page 1
Read this manual carefully before operating this vehicle.
Il convient de lire attentivement ce manuel avant la pre-
mière utilisation du véhicule.
Bitte lesen Sie diese Bedienungsanleitung sorgfältig
durch, bevor Sie das Fahrzeug in Betrieb nehmen.
OWNER’S MANUAL
MANUEL DU PROPRIÉTAIRE
BEDIENUNGSANLEITUNG
TT-R110E(Y)
5B6-28199-81
Page 2
PRINTED ON RECYCLED PAPER
IMPRIMÉ SUR PAPIER RECYCLÉ
AUF RECYCLINGPAPIER GEDRUCKT
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2008.06-1.1×1 CR
(E,F,G)
Page 3
Read this manual carefully before operating this vehicle.
OWNER’S MANUAL
TT-R110E(Y)
5B6-28199-81-E0
Page 4
EAU46231
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
EC Declaration of Conformity
conforming to Directive 98/ 37/
We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan,
declare in sole responsibility, that the product
TT-R110E (JYACE17W000001466~)
to
this declaration applies, conforms to the essential health
which
and safety requirements of Directive 98/ 37/ EC,
)
(
If
applicable
to
the other relevant Directives of EEC
and
(
and /or
Title
(
If
applicable
To effect
stated in the Directives of EEC,the following
specifications were consulted:
and date of issue of the other Direc tives of
number
)
correct
application of the essential health and safet y requirements
(
and /or number and date of issue of
Title
(Make, model)
89/
336/ EEC or 2004/ 108/EC
EC
)
EEC
standards and/ or technical
standards and/or specifications
)
Authorized Representative
MOTOR
YAMAHA
Koolhovenlaan 101,1119NCSchiphol
EUROPE
N.V.
The Netherlands
Rijk,
Signature
Senior E xecutive Officer
Motorcycle Headquarters
Product Development Operations
Date of Issue
Akira Araki
March
24
, 2008
Page 5
INTRODUCTION
EAU41663
Congratulations on your purchase of the Yamaha TT-R110E(Y). 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.
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 there is any question concerning this manual, please consult a Yamaha dealer.
WARNING
Please read this manual carefully and completely before operating this motorcycle.
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 offhighway noise level and spark arrester laws and regulations. Please check your local riding laws and regulations
before operating this motorcycle.
EWA10031
EWA14351
AN IMPORTANT SAFETY MESSAGE:
● Read this manual completely before operating your motorcycle. Make sure you understand all instructions.
● Pay close attention to the warning and notice labels on the motorcycle.
● Never operate a motorcycle without proper training or instruction.
Page 6
INTRODUCTION
● Weight of the rider should not exceed 60.0 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. 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.
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 this Owner’s Manual.
● Obtain qualified training in safe and proper riding techniques.
● Obtain professional technical service as indicated in this Owner’s Manual and/or when made necessary by mechanical
conditions.
Page 7
IMPORTANT MANUAL INFORMATION
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.
EAU10132
WARNING
NOTICE
TIP
A WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the
vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
Page 8
IMPORTANT MANUAL INFORMATION
TT-R110E(Y)
OWNER’S MANUAL
©2008 by Yamaha Motor Co., Ltd.
1st edition, June 2008
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
EAU10200
Page 9
TABLE OF CONTENTS
SAFETY INFORMATION ..................1-1
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 ....................................3-3
Fuel tank cap ..................................3-3
Fuel ................................................3-3
Fuel tank breather hose .................3-5
Fuel cock ........................................3-5
Starter (choke) lever .......................3-6
Kickstarter ......................................3-7
Seat ................................................3-7
Shock absorber assembly ..............3-8
Sidestand .......................................3-8
Starting circuit cut-off system .........3-8
FOR YOUR SAFETY –
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
ADJUSTMENT................................... 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
Adjusting the clutch free play ....... 6-16
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 ..........................................6-25
Replacing the fuse .......................6-27
Supporting the motorcycle ...........6-27
Front wheel ..................................6-28
Rear wheel ...................................6-29
Troubleshooting ...........................6-31
Troubleshooting chart ..................6-32
Page 10
TABLE OF CONTENTS
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
Page 11
SAFETY INFORMATION
EAU41214
Be a Responsible Owner
As the vehicle’s owner, you are responsible for the safe and proper operation
of your motorcycle.
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 mainte-
nance requirements in this Owner’s Manual.
● Obtain qualified training in safe
and proper riding techniques.
● Obtain professional technical ser-
vice as indicated in this Owner’s
Manual and/or when made necessary by mechanical conditions.
Safe Riding
Perform the pre-operation checks each
time you use the vehicle to make sure it
is in safe operating condition. Failure to
inspect or maintain the vehicle properly
increases the possibility of an accident
or equipment damage. See page 4-1
for a list of pre-operation checks.
● 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.
● The failure of motorists to detect
and recognize motorcycles in traffic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when you are
approaching and passing
through intersections, since intersections are the most likely
places for motorcycle accidents
to occur.
• Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
● Many accidents involve inexperi-
enced operators.
• Make sure that you are 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.
• We recommend that you practice riding your motorcycle until
you have become thoroughly familiar with the motorcycle and all
of its controls.
1
1-1
Page 12
SAFETY INFORMATION
● Many accidents have been caused
by error of the motorcycle operator. A typical error made by the op-
1
erator is veering wide on a turn
due to excessive speed or undercornering (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.
● Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust system become very hot during or after operation and can cause burns.
1-2
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing carbon monoxide can cause headaches,
dizziness, drowsiness, nausea, confusion, and eventually death.
Carbon Monoxide is a colorless, odorless, tasteless gas which may be
present even if you do not see or smell
any engine exhaust. Deadly levels of
carbon monoxide can collect rapidly
and you can quickly be overcome and
unable to save yourself. Also, deadly
levels of carbon monoxide can linger
for hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poisoning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREATMENT.
● Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rapidly reach dangerous levels.
● Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or carports.
Page 13
SAFETY INFORMATION
● Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loading
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:
Operation of an overloaded vehicle
could cause an accident.
● The weight of the operator must
not exceed 60.0 kg (132 lb).
● Accessory weight should be kept
as low and close to the motorcycle
as possible. Securely pack your
heaviest items as close to the center of the vehicle as possible and
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.
• Properly adjust the suspension
for your load, and check the condition and pressure of your tires.
• Never attach any large or heavy
items to the handlebar, front
fork, or front fender.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are available only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection to
Yamaha manufacture parts and accessories or offer other modifications for
Yamaha vehicles. Yamaha is not in a
position to test the products that these
aftermarket companies produce.
1-3
Therefore, Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or
modifications not specifically recommended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories, and
Modifications
While you may find aftermarket products similar in design and quality to
genuine Yamaha accessories, recognize that some aftermarket accessories
or modifications are not suitable because of potential safety hazards to you
or others. Installing aftermarket products or having other modifications performed to your vehicle that change any
of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or death.
You are responsible for injuries related
to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
● Never install accessories that
would impair the performance of
your motorcycle. Carefully inspect
1
Page 14
SAFETY INFORMATION
the accessory before using it to
make sure that it does not in any
way reduce ground clearance or
1
cornering clearance, limit suspension travel, steering travel or control operation.
• Accessories fitted to the handlebar or the front fork area can
create instability due to improper
weight distribution. 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. 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
lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match the
performance capabilities and to provide
the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be
appropriate. Refer to page 6-15 for tire
specifications and more information on
replacing your tires.
1-4
Page 15
Left view
DESCRIPTION
EAU10410
123 4
2
1. Fuel cock (page 3-5)
2. Star ter (choke) lever (page 3-6)
3. Fuse (page 6-27)
4. Battery (page 6-25)
5. Clutch adjusting screw (page 6-16)
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
Page 16
DESCRIPTION
Right view
2
EAU10420
123 4
1. Spark arrester (page 6-12)
2. Seat (page 3-7)
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 3-3)
8. Kickstarter (page 3-7)
857
6
2-2
Page 17
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)
DESCRIPTION
EAU10430
1234
2
56
2-3
Page 18
INSTRUMENT AND CONTROL FUNCTIONS
Main switch
3
The main switch controls the ignition
system. The main switch positions are
described below.
ON
All electrical systems are supplied with
power, and the engine can be started.
The key cannot be removed.
OFF
All electrical systems are off. The key
can be removed.
EAU40340
EAU10630
EAU45751
EWA10072
WARNING
Never turn the key to “OFF” while
the vehicle is moving, otherwise the
electrical systems will be switched
off, which may result in loss of control or an accident.
EAU12347
Handlebar switches
Left
1. Engine stop switch “ / ”
Right
1
1. Start switch “”
3-1
Page 19
INSTRUMENT AND CONTROL FUNCTIONS
Engine stop switch “ / ”
EAU12660
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.
EAU12711
Start switch “”
Push this switch to crank the engine
with the starter. See page 5-1 for starting instructions prior to starting the engine.
EAU39850
Shift pedal
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.
EAU12890
Brake lever
1
3
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.
3-2
Page 20
INSTRUMENT AND CONTROL FUNCTIONS
Brake pedal
3
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.
EAU12941
1
EAU13182
Fuel tank cap
1. Fuel tank cap
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 clockwise.
EWA11091
WARNING
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.
EAU13212
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.
1. Before refueling, turn off the engine and be sure that no one is sitting on the vehicle. Never refuel
while smoking, or while in the vicinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters and
clothes dryers.
2. Do not overfill the fuel tank. Stop
filling when the fuel reaches the
bottom of the filler tube. Because
fuel expands when it heats up,
heat from the engine or the sun
can cause fuel to spill out of the
fuel tank.
3-3
Page 21
INSTRUMENT AND CONTROL FUNCTIONS
1. Fuel tank filler tube
2. Fuel level
3. Wipe up any spilled fuel immediately. NOTICE: Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteriorate painted surfaces or plastic
parts.
[ECA10071]
4. Be sure to securely close the fuel
tank cap.
EWA15151
WARNING
Gasoline is poisonous and can
cause injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you should swallow
some gasoline or inhale a lot of gasoline vapor, or get some gasoline in
your eyes, see your doctor immedi-
ately. If gasoline spills on your skin,
wash with soap and water. If gasoline spills on your clothing, change
your clothes.
EAU41931
For Canada
Recommended fuel:
REGULAR 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
NOTICE
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
3-4
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 cost.
Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing
ethanol can be used if ethanol content
does not exceed 10% (E10). Gasohol
containing methanol is not recommended by Yamaha because it can
cause damage to the fuel system or vehicle performance problems.
For Europe, Oceania and South Africa
Recommended fuel:
For Europe: REGULAR UNLEADED
GASOLINE ONLY
For Oceania and South Africa: 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)
3
Page 22
INSTRUMENT AND CONTROL FUNCTIONS
NOTICE
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 de-
3
signed to use regular unleaded gasoline with a research octane number of
91 or higher. If 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.
ECA11400
EAU13412
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.
EAU13561
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.
3-5
Page 23
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!
EAU13590
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”
3-6
Page 24
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.
EAU37650
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.
TIP
Make sure that the seat is properly secured before riding.
3-7
Page 25
INSTRUMENT AND CONTROL FUNCTIONS
EAU46021
Shock absorber assembly
EWA10221
WARNING
This shock absorber assembly contains highly pressurized nitrogen
gas. Read and understand the following information before handling
the shock absorber assembly.
● Do not tamper with or attempt to
open the cylinder assembly.
● Do not subject the shock ab-
sorber assembly to an open
flame or other high heat source.
This may cause the unit to explode due to excessive gas
pressure.
● Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.
● Do not dispose of a damaged or
worn-out shock absorber assembly yourself. Take the shock
absorber assembly to a Yamaha
dealer for any service.
EAU37490
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.
EAU41611
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.
TIP
This check is most reliable if performed
with a warmed-up engine.
3
3-8
Page 26
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?
”.
YESNO
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.
NO
3-9
WARNING
If a malfunction is noted, have a Yamaha
dealer check the system before riding.
The neutral switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The neutral switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
Page 27
FOR YOUR SAFETY – PRE-OPERATION CHECKS
EAU15595
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
EWA11151
WARNING
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
4
4-1
Page 28
FOR YOUR SAFETY – PRE-OPERATION CHECKS
Pre-operation check list
ITEM CHECKS PAGE
Fuel
Engine oil
Front brake
4
Rear brake
Throttle grip
Control cables
Drive chain
Wheels and tires
Shift pedal
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
• Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.
• Check operation.
• Check pedal free play.
• Adjust if necessary.
• Make sure that operation is smooth.
• Check cable free play.
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
• Make sure that operation is smooth.
• Lubricate if necessary.
• Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.
• Make sure that operation is smooth.
• Correct if necessary.
EAU15605
3-3
6-8
6-17, 6-19
6-18, 6-19
6-14, 6-22
6-22
6-20, 6-21
6-15, 6-16
6-19
4-2
Page 29
FOR YOUR SAFETY – PRE-OPERATION CHECKS
ITEM CHECKS PAGE
Brake pedal
Brake lever
Sidestand
Chassis fasteners
Engine stop switch • Check operation. 3-1
• Make sure that operation is smooth.
• Lubricate pedal pivoting point if necessary.
• Make sure that operation is smooth.
• Lubricate lever pivoting point if necessary.
• Make sure that operation is smooth.
• Lubricate pivot if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
6-23
6-23
6-23
—
4
4-3
Page 30
OPERATION AND IMPORTANT RIDING POINTS
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
Failure to familiarize yourself with
the controls can lead to loss of control, which could cause an accident
or injury.
5
EAU15951
EWA10271
EAU44811
Starting and warming up a
cold engine
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
3. Shift the transmission into the neutral position.
EWA14410
WARNING
● Be sure to shift the transmis-
sion into neutral before starting
the engine.
● Never ride with the sidestand
down.
4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-6.)
5. Start the engine by pushing the
start switch or by pushing the kickstarter lever down. NOTICE: For
maximum engine life, always
warm the engine up before
starting off. Never accelerate
hard when the engine is cold!
[ECA11131]
6. When the engine is warm, turn the
starter (choke) off.
TIP
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
5-1
Page 31
OPERATION AND IMPORTANT RIDING POINTS
EAU16640
Starting a warm engine
Follow the same procedure as for starting a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
EAU39901
Shifting
4
3
2
1
2
1
1. Shift pedal
2. Neutral position
This motorcycle has a 4-speed transmission with a centrifugal, automatic
clutch. Shifting gears lets you control
the amount of engine power available
for starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the illustration.
TIP
To shift the transmission into the neutral position, press the shift pedal down
repeatedly until it reaches the end of its
travel.
5-2
ECA15441
NOTICE
● Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long distances. The transmission is
properly lubricated only when
the engine is running. Inadequate lubrication may damage
the transmission.
● Always release the throttle grip
before changing gears to avoid
damaging the engine, transmission, and drive train, which are
not designed to withstand the
shock of shifting when the throttle grip is open.
To start out and accelerate
EAU39911
1. Close the throttle.
2. Shift into first gear and release the
shift pedal. NOTICE: Always
close the throttle before shifting
gears, otherwise damage to the
engine and drive train may result.
[ECA15461]
5
Page 32
OPERATION AND IMPORTANT RIDING POINTS
3. Open the throttle gradually.
4. Once the motorcycle has reached
a speed high enough to change
gears, close the throttle.
5. Shift into second gear and release
the shift pedal.
6. Open the throttle gradually.
7. Follow the same procedure when
shifting to the next higher gear.
To decelerate
1. Close the throttle and apply both
5
the front and the rear brakes to
slow the motorcycle.
2. Downshift through the gears and
shift the transmission into the neutral position when the motorcycle
is almost completely stopped.
EAU16710
EAU39920
Engine break-in
There is never a more important period
in the life of your engine than the first 5
hours of riding. It is also important to accustom the rider to the motorcycle during this time. Please read the following
information carefully.
Since the engine is brand new, do not
put an excessive load on it for the first 5
hours of operation. The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throttle operation or any condition that might
result in engine overheating must be
avoided. However, momentary fullthrottle operation under load (i.e., two
to three seconds maximum) does not
harm the engine. Each full-throttle acceleration should be followed with a
substantial rest period for the engine.
To allow the engine to cool down from
the temporary buildup of heat, cruise at
a lower engine speed.
After the first 5 hours of operation, thoroughly check the motorcycle for loose
parts, oil leakage and any other problems. Be sure to inspect and make ad-
justments thoroughly, especially cable
and drive chain slack and loose
spokes. In addition, check all fittings
and fasteners for looseness, and tighten if necessary.
ECA10270
NOTICE
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
5-3
Page 33
EAU17171
Parking
When parking, stop the engine, remove
the key from the main switch, and then
turn the fuel cock lever to “OFF”.
EWA10311
WARNING
● Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them and be burned.
● Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn, increasing the
risk of a fuel leak and fire.
● Do not park near grass or other
flammable materials which
might catch fire.
OPERATION AND IMPORTANT RIDING POINTS
5
5-4
Page 34
PERIODIC MAINTENANCE AND ADJUSTMENT
Periodic inspection, adjustment, and lubrication will keep your vehicle in the
safest and most efficient condition possible. Safety is an obligation of the vehicle owner/operator. The most important
points of vehicle inspection, adjustment, and lubrication are explained on
the following pages.
WARNING
Failure to properly maintain the vehicle or performing maintenance activities incorrectly may increase
your risk of injury or death during
6
service or while using the vehicle. If
you are not familiar with vehicle service, have a Yamaha dealer perform
service.
WARNING
Turn off the engine when performing
maintenance unless otherwise
specified.
EAU41951
EWA10321
EWA15121
● A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
● Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more information about carbon monoxide.
EAU17302
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services related to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replacement,
or repair of the emission control devices and systems may be performed by
any repair establishment or individual
that is certified (if applicable). Yamaha
dealers are trained and equipped to
perform these particular services.
6-1
Page 35
EAU17311
Owner’s tool kit
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. However, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
TIP
If you do not have the tools or experience required for a particular job, have
a Yamaha dealer perform it for you.
PERIODIC MAINTENANCE AND ADJUSTMENT
6
6-2
Page 36
PERIODIC MAINTENANCE AND ADJUSTMENT
Periodic maintenance chart for the emission control system
TIP
● 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.
INITIAL ODOMETER READINGS
No. ITEM CHECKS AND MAINTENANCE JOBS
1 * Fuel line
2 Spark plug
6
3 * Valve clearance • Check and adjust valve clearance when engine is cold. √
4 * Air filter element
Crankcase breather sys-
5 *
tem
6 * Carburetor
7 Exhaust system
8 Engine oil • Change (warm engine before draining). √√√
• Check fuel hoses for cracks or damage.
• Replace if necessary.
• Check condition.
• Adjust gap and clean.
• Clean with solvent.
• Replace if necessary.
• Check ventilation hose for cracks or damage and drain
any deposits.
• Replace if necessary.
• Check engine idling speed and starter operation.
• Adjust if necessary.
• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
1000 km
(600 mi) or
1 month or
30 hours
√√√
√√√
3000 km
(1800 mi) or
6 months or
90 hours
√√
√√
√√
√√
5000 km
(3000 mi) or
12 months or
150 hours
EAU39943
6-3
Page 37
PERIODIC MAINTENANCE AND ADJUSTMENT
General maintenance and lubrication chart
No. ITEM CHECKS AND MAINTENANCE JOBS
1 * Clutch
2 * Front brake
3 * Rear brake
4 * Wheels
5 * Tires
6 * Wheel bearings
7 * Swingarm pivot bearings
8Drive chain
9 * Steering bearings
• Check operation.
• Adjust if necessary.
• Check operation.
• Adjust brake lever free play and replace brake shoes if
necessary.
• Check operation.
• Adjust brake pedal free play and replace brake shoes if
necessary.
• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
• Check bearings for smooth operation.
• Replace if necessary.
• Check bearing assemblies for looseness.
• Moderately repack with lithium-soap-based grease.
• Check chain slack/alignment and condition.
• Adjust and lubricate chain with Yamaha chain and cable
lube thoroughly.
• Check bearing assemblies for looseness.
• Moderately repack with lithium-soap-based grease.
EAU35348
INITIAL ODOMETER READINGS
1000 km
(600 mi) or
1 month or
30 hours
√√√
√√√
√√√
√√√
√√
3000 km
(1800 mi) or
6 months or
90 hours
√√
√√
√√
Every ride
5000 km
(3000 mi) or
12 months or
150 hours
6
6-4
Page 38
PERIODIC MAINTENANCE AND ADJUSTMENT
INITIAL ODOMETER READINGS
No. ITEM CHECKS AND MAINTENANCE JOBS
10 * Chassis fasteners
11 Brake lever pivot shaft • Apply lithium-soap-based grease lightly. √√
12 Brake pedal pivot shaft • Apply lithium-soap-based grease lightly. √√
13 Sidestand pivot
14 * Spark arrester • Clean. √
15 * Front fork
Shock absorber assem-
16 *
6
bly
17 * Control cables
Throttle grip housing and
18 *
cable
• Check all chassis fitting and fasteners.
• Correct if necessary.
• Check operation.
• Apply lithium-soap-based grease lightly.
• Check operation and for oil leakage.
• Replace if necessary.
• Check operation and for oil leakage.
• Replace if necessary.
• Apply Yamaha chain and cable lube or engine oil thor-
oughly.
• Check operation and free play.
• Adjust the throttle cable free play if necessary.
• Lubricate the throttle grip housing and cable.
1000 km
(600 mi) or
1 month or
30 hours
√√√
√√
√√√
√√√
3000 km
(1800 mi) or
6 months or
90 hours
√√
5000 km
(3000 mi) or
12 months or
150 hours
√
EAU40000
TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
6-5
Page 39
EAU18771
Removing and installing panels
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.
PERIODIC MAINTENANCE AND ADJUSTMENT
1
2
3
3
1
1. Panel A
1
1. Panel B
EAU41110
Panel A
To remove the panel
1. Remove the seat. (See page 3-7.)
2. Remove the bolts and the quick
fastener screws, and then take the
panel off.
6-6
1. Panel A
2. Bolt
3. Quick fastener screw
To install the panel
1. Place the panel in the original position, and then install the bolts and
the quick fastener screws.
2. Install the seat.
EAU33020
Panel B
To remove the panel
1. Remove the seat. (See page 3-7.)
2. Remove the bolt, and then pull the
panel off as shown.
6
Page 40
PERIODIC MAINTENANCE AND ADJUSTMENT
1
2
1. Panel B
2. Bolt
3. Projection
To install the panel
1. Place the panel in the original posi-
6
tion, and then install the bolt.
2. Install the seat.
3
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic maintenance and lubrication chart. In addition,
the condition of the spark plug can reveal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
1. Spark plug cap
2. Remove the spark plug as shown,
with the spark plug wrench included in the owner’s tool kit.
1
EAU19603
1
1. Spark plug wrench
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
TIP
If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to
diagnose such problems yourself. Instead, have a Yamaha dealer check
the vehicle.
6-7
Page 41
PERIODIC MAINTENANCE AND ADJUSTMENT
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
Specified spark plug:
NGK/CR6HSA
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if necessary, adjust the gap to specification.
1. Spark plug gap
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tighten it to the specified torque.
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
TIP
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the specified torque as soon as possible.
4. Install the spark plug cap.
EAU39842
Engine oil
The engine oil level should be checked
before each ride. In addition, the oil
must be changed at the intervals specified in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright position. A slight tilt to the side can result in a false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil settles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
6
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
6-8
Page 42
PERIODIC MAINTENANCE AND ADJUSTMENT
2
3
4
1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
TIP
6
The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is at or below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
To change the engine oil
1. Start the engine, warm it up for
several minutes, and then turn it
1
off.
5. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the engine
oil filler cap.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
Recommended engine oil:
See page 8-1.
Oil change quantity:
0.80 L (0.85 US qt, 0.70 Imp.qt)
ECA11620
NOTICE
1
● In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In
1. Engine oil drain bolt
4. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
● Make sure that no foreign mate-
rial enters the crankcase.
6-9
Page 43
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU41635
1
2
Cleaning the air filter element
The air filter element should be cleaned
or replaced at the intervals specified in
the periodic maintenance and lubrication chart. Clean or, if necessary, replace the air filter element more
frequently if you are riding in unusually
wet or dusty areas.
1
2
1. “CD” specification
2. “ENERGY CONSERVING II”
6. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, immediately turn the engine off and
check for the cause.
7. Turn the engine off, and then
check the oil level and correct it if
necessary.
To clean the air filter element
1. Remove panel A. (See page 6-6.)
2. Remove the air filter case cover by
removing the screws.
1
2
1. Air filter case cover
2. Screw
3. Pull the sponge material and the
mesh out.
6-10
1. Sponge material
2. Air filter mesh
4. Clean the mesh with solvent, and
then wipe the solvent off.
5. Clean the sponge material with
solvent, and then squeeze the remaining solvent out. WARNING!
Use only a dedicated parts
cleaning solvent. To avoid the
risk of fire or explosion, do not
use gasoline or solvents with a
low flash point.
[EWA10431] NOTICE:
To avoid damaging the foam
material, handle it gently and
carefully, and do not twist or
wring it.
[ECA10511]
6
Page 44
PERIODIC MAINTENANCE AND ADJUSTMENT
mesh and the sponge material
installed, otherwise the piston(s) and/or cylinder(s) may
become excessively worn.
[ECA15572]
1
1
6. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the excess oil out.
TIP
6
The sponge material should be wet but
not dripping.
Recommended oil:
Yamaha foam air filter oil or other
quality foam air filter oil
7. Insert the mesh and the sponge
material into the air filter case.
NOTICE: Make sure that the
mesh and the sponge material
are properly seated in the air filter case. The engine should
never be operated without the
8. Install the air filter case cover by installing the screws.
TIP
Make sure that the spark plug cable is
routed as shown.
6-11
1. Spark plug cable
9. Install the panel.
To clean the air filter check hose
1. Check the hoses at the bottom of
the air filter case for accumulated
dirt or water.
1
1. Air filter check hose
Page 45
PERIODIC MAINTENANCE AND ADJUSTMENT
2. If dirt or water is visible, remove
the hoses, clean them, and then
reinstall them.
EAU40421
Cleaning the spark arrester
The spark arrester should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
EWA10980
WARNING
● Always let the exhaust system
cool prior to touching exhaust
components.
● Do not start the engine when
cleaning the exhaust system.
TIP
Make sure to select a well-ventilated
area free of combustible materials to
clean the spark arrester.
1. Remove the tailpipe by removing
the bolts, and then pulling it out of
the muffler.
1
2
1. Tailpipe
2. Bolt
2. Tap the tailpipe lightly, and then
use a wire brush to remove any
carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing.
1
6
6-12
1. Spark arrester
Page 46
PERIODIC MAINTENANCE AND ADJUSTMENT
3. Insert the tailpipe into the muffler,
and then install and tighten the
bolts to the specified torque.
Tightening torque:
Tailpipe bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
Make sure to align the bolt holes when
inserting the tailpipe.
6
EAU39930
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a
Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment described in the
following section, however, may be serviced by the owner as part of routine
maintenance.
ECA10550
NOTICE
The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings
without sufficient technical knowledge may result in poor performance of or damage to the engine.
EAU21362
Adjusting the engine idling
speed
The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
TIP
A diagnostic tachometer is needed to
make this adjustment.
1. Attach the tachometer to the spark
plug lead.
2. Start the engine and warm it up for
several minutes at 1000–2000
r/min while occasionally revving it
to 4000–5000 r/min.
TIP
The engine is warm when it quickly responds to the throttle.
3. Check the engine idling speed
and, if necessary, adjust it to specification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
6-13
Page 47
PERIODIC MAINTENANCE AND ADJUSTMENT
rection (a). To decrease the engine idling speed, turn the screw in
direction (b).
(a) (b)
1
1
1. Throttle stop screw
Engine idling speed:
1600–1800 r/min
TIP
If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
EAU21382
Checking the throttle cable
free play
1
1. Throttle cable free play
The throttle cable free play should measure 4.0–6.0 mm (0.16–0.24 in) at the
throttle grip. Periodically check the
throttle cable free play and, if necessary, have a Yamaha dealer adjust it.
EAU21401
Valve clearance
The valve clearance changes with use,
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.
6
6-14
Page 48
PERIODIC MAINTENANCE AND ADJUSTMENT
Tires
To maximize the performance, durability, and safe operation of your motorcycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING
Operation of this vehicle with improper tire pressure may cause severe injury or death from loss of
6
control.
● The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
● The tire air pressure must be ad-
justed in accordance with the
weight of the rider, the riding
speed, and the riding conditions.
EAU39821
EWA14381
Standard tire air pressure:
Front :
100 kPa (1.00 kgf/cm², 15 psi)
Rear:
100 kPa (1.00 kgf/cm², 15 psi)
Tire inspection
2
1
1. Tire sidewall
2. Tire tread depth
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer replace the tire immediately.
Minimum tire tread depth (front and
rear):
4.0 mm (0.16 in)
Tire information
This motorcycle is equipped with spoke
wheels and tube tires.
EWA10461
WARNING
The front and rear tires should be of
the same make and design, otherwise the handling characteristics of
the vehicle may be different, which
could lead to an accident.
After extensive tests, only the tires listed below have been approved for this
model by Yamaha Motor Co., Ltd.
Front tire:
Size:
2.50-14 4PR
Manufacturer/model:
CHEN SHIN/C-803-2
Rear tire:
Size:
3.00-12 4PR
Manufacturer/model:
CHEN SHIN/C-803-2
EWA14390
WARNING
● Have a Yamaha dealer replace
excessively worn tires. Operating the motorcycle with exces-
6-15
Page 49
PERIODIC MAINTENANCE AND ADJUSTMENT
sively worn tires decreases
riding stability and can lead to
loss of control.
● The replacement of all wheel-
and brake-related parts, including the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowledge and experience.
● It is not recommended to patch
a punctured tube. If unavoidable, however, patch the tube
very carefully and replace it as
soon as possible with a highquality product.
EAU21940
Spoke wheels
To maximize the performance, durability, and safe operation of your motorcycle, note the following points
regarding the specified wheels.
● The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or damage before each ride. If any damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.
● The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse handling characteristics, and a shortened tire life.
● Ride at moderate speeds after
changing a tire since the tire surface must first be “broken in” for it
to develop its optimal characteristics.
EAU44663
Adjusting the clutch free play
The clutch free play must be checked
and, if necessary, adjusted as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Loosen the locknut.
2. Slowly turn the clutch adjusting
screw in direction (a) until resistance is felt, and then turn it 1/8
turn in direction (b).
(b)
1
1. Locknut
2. Clutch adjusting screw
3. Tighten the locknut to the specified
torque.
Tightening torque:
Locknut:
8.0 Nm (0.8 m·kgf, 5.8 ft·lbf)
(a)
2
6
6-16
Page 50
PERIODIC MAINTENANCE AND ADJUSTMENT
TIP
When tightening the locknut, hold the
clutch adjusting screw with a screwdriver so that it does not turn together with
the locknut.
6
EAU44881
Adjusting the brake lever free
play
1
(b)
(a)
1. Rubber cover
2. Brake lever free play adjusting bolt
3. Locknut
4. Brake lever free play
The brake lever free play should measure 10.0–20.0 mm (0.39–0.79 in) as
shown. Periodically check the brake lever free play and, if necessary, adjust it
as follows.
1. Slide the rubber cover back.
2. Loosen the locknut at the brake lever.
3
2
3. To increase the brake lever free
play, turn the adjusting bolt in direction (a). To decrease the brake
4
lever free play, turn the adjusting
bolt in direction (b).
4. If the specified brake lever free
play could be obtained as described above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.
5. Fully turn the adjusting bolt at the
brake lever in direction (a) to loosen the brake cable.
6. Loosen the locknut at the brake
shoe plate.
7. To increase the brake lever free
play, turn the adjusting bolt in direction (a). To decrease the brake
lever free play, turn the adjusting
bolt in direction (b).
6-17
Page 51
PERIODIC MAINTENANCE AND ADJUSTMENT
(a)
(b)
2
1
1. Locknut
2. Brake lever free play adjusting bolt
8. Tighten the locknut at the brake
shoe plate and at the brake lever.
9. Slide the rubber cover to its original position.
EAU44670
Adjusting the brake pedal free
play
1. Brake pedal free play adjusting nut
2. Brake pedal free play
The brake pedal free play should measure 10.0–20.0 mm (0.39–0.79 in) at
the brake pedal end as shown. Periodically check the brake pedal free play
and, if necessary, adjust it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).
EWA14820
WARNING
● After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.
● If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this adjustment.
6
6-18
Page 52
PERIODIC MAINTENANCE AND ADJUSTMENT
Checking the shift pedal
The operation of the shift pedal should
be checked before each ride. If operation is not smooth, have a Yamaha
dealer check the vehicle.
6
EAU44820
EAU22361
Checking the front and rear
brake shoes
Front
1
2
1. Brake shoe wear indicator
2. Brake shoe wear limit line
Rear
2
1
The front and rear brake shoes must be
checked for wear at the intervals specified in the periodic maintenance and
lubrication chart. Each brake is provided with a wear indicator, which allows
you to check the brake shoe wear without having to disassemble the brake.
To check the brake shoe wear, check
the position of the wear indicator while
applying the brake. If a brake shoe has
worn to the point that the wear indicator
reaches the wear limit line, have a
Yamaha dealer replace the brake
shoes as a set.
1. Brake shoe wear indicator
2. Brake shoe wear limit line
6-19
Page 53
EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
PERIODIC MAINTENANCE AND ADJUSTMENT
To check the drive chain slack
EAU22773
1. Place the motorcycle on the sidestand.
TIP
When checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.
2. Shift the transmission into the neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tightest portion of the drive chain, and
then measure the drive chain slack
as shown.
Drive chain slack:
40.0–56.0 mm (1.57–2.20 in)
1
1. Drive chain slack
4. If the drive chain slack is incorrect,
adjust it as follows.
EAU40111
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut, axle nut, and locknut
at each end of the swingarm.
6-20
1. Brake pedal free play adjusting nut
2. Locknut
3. Drive chain slack adjusting nut
2. To tighten the drive chain, turn the
drive chain slack adjusting nut at
each end of the swingarm in direction (a). To loosen the drive chain,
turn the adjusting nut at each end
of the swingarm in direction (b),
and then push the rear wheel forward. NOTICE: Improper drive
chain slack will overload the engine as well as other vital parts
of the motorcycle and can lead
to chain slippage or breakage.
To prevent this from occurring,
keep the drive chain slack within the specified limits.
[ECA10571]
6
Page 54
PERIODIC MAINTENANCE AND ADJUSTMENT
TIP
Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same position for proper wheel alignment.
6
1. Axle nut
2. Drive chain slack adjusting nut
3. Locknut
4. Alignment marks
3. Tighten both locknuts and the axle
nut to the specified torques.
Tightening torques:
Locknut:
7.0 Nm (0.7 m·kgf, 5.1 ft·lbf)
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
4. Adjust the brake pedal free play.
(See page 6-18.)
EAU23013
Cleaning and lubricating the
drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrication chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
ECA10581
NOTICE
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.
TIP
For a thorough cleaning, have a
Yamaha dealer remove the drive chain
and soak it in solvent.
2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on both sides
and on the middle of the chain,
6-21
Page 55
PERIODIC MAINTENANCE AND ADJUSTMENT
making sure that all side plates
and rollers have been sufficiently
oiled.
EAU23093
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
housing of cables may result in internal rusting and cause interference with cable movement. Replace
damaged cables as soon as possible to prevent unsafe conditions.
[EWA10711]
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil
EAU23111
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
6
6-22
Page 56
PERIODIC MAINTENANCE AND ADJUSTMENT
Checking and lubricating the
brake lever
The operation of the brake lever should
be checked before each ride, and the
lever pivot should be lubricated if nec-
6
essary.
Recommended lubricant:
Lithium-soap-based grease
EAU43622
EAU23182
Checking and lubricating the
brake pedal
The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
EAU23202
Checking and lubricating the
sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
EWA10731
WARNING
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the sidestand could contact the
ground and distract the operator, resulting in a possible loss of control.
6-23
Recommended lubricant:
Lithium-soap-based grease
Page 57
PERIODIC MAINTENANCE AND ADJUSTMENT
EAUM1650
Lubricating the swingarm pivots
The swingarm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
EAU23272
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level surface and hold it in an upright position. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10751]
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
ECA10590
NOTICE
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or repair it.
6
6-24
Page 58
PERIODIC MAINTENANCE AND ADJUSTMENT
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground. (See page 6-27 for more
information.) WARNING! To
avoid injury, securely support
the vehicle so there is no danger
of it falling over.
2. Hold the lower ends of the front
6
fork legs and try to move them forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
[EWA10751]
EAU23283
EAU23290
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrication chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAU23395
Battery
2
3
1
1. Battery coupler
2. Battery band
3. Battery
The battery is located behind panel B.
(See page 6-6.)
This model is equipped with a VRLA
(Valve Regulated Lead Acid) battery.
There is no need to check the electrolyte or to add distilled water. However,
the battery coupler needs to be
checked and, if necessary, securely
fastened.
WARNING
● Electrolyte is poisonous and
dangerous since it contains sulfuric acid, which causes severe
EWA10760
6-25
Page 59
PERIODIC MAINTENANCE AND ADJUSTMENT
burns. Avoid any contact with
skin, eyes or clothing and always shield your eyes when
working near batteries. In case
of contact, administer the following FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quantities of water or milk and immediately call a physician.
• EYES: Flush with water for 15
minutes and seek prompt
medical attention.
● Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide sufficient ventilation when
charging it in an enclosed
space.
● KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
To charge the battery
Have a Yamaha dealer charge the battery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.
ECA16520
NOTICE
To charge a VRLA (Valve Regulated
Lead Acid) battery, a special (constant-voltage) battery charger is required. Using a conventional battery
charger will damage the battery. If
you do not have access to a constant-voltage battery charger, have a
Yamaha dealer charge your battery.
To store the battery
1. If the model will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
NOTICE: When removing the
battery, be sure the key is
turned to “OFF” before disconnecting the coupler.
[ECA16322]
2. If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
necessary.
3. Fully charge the battery before installation.
ECA16530
NOTICE
Always keep the battery charged.
Storing a discharged battery can
cause permanent battery damage.
6
6-26
Page 60
PERIODIC MAINTENANCE AND ADJUSTMENT
Replacing the fuse
2
1
1. Fuse
2. Spare fuse
The fuse is located inside the battery
coupler. (See page 6-25.)
6
If the fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
2. Disconnect the battery coupler.
3. Remove the blown fuse, and then
install a new fuse of the specified
amperage. WARNING! Do not
use a fuse of a higher amperage
rating than recommended to
avoid causing extensive damage to the electrical system and
possibly a fire.
[EWA15131]
EAU42023
Specified fuse:
10.0 A
4. Connect the battery coupler.
5. Turn the key to “ON”.
6. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU24350
Supporting the motorcycle
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand upright. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack under the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motorcycle stand is not available, by placing
6-27
Page 61
PERIODIC MAINTENANCE AND ADJUSTMENT
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU24360
Front wheel
To remove the front wheel
WARNING
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.
1. Slide the rubber cover back.
2. Loosen the locknut at the brake lever, and then turn the adjusting
bolt fully in direction (a).
1
3
2
(a)
1. Rubber cover
2. Brake lever free play adjusting bolt
3. Locknut
3. Loosen the axle nut.
EAU41813
EWA10821
1. Axle nut
2. Washer
4. Lift the front wheel off the ground
according to the procedure on
page 6-27.
5. Remove the axle nut and washer.
6. Pull the wheel axle out.
1. Wheel axle
6
6-28
Page 62
PERIODIC MAINTENANCE AND ADJUSTMENT
7. Remove the brake shoe assembly
from the wheel hub by pulling it
out.
1
1. Brake shoe assembly
8. Remove the wheel.
6
To install the front wheel
1. Install the brake shoe assembly
into the wheel hub.
2. Lift the wheel up between the fork
legs.
TIP
Make sure that the slot in the brake
shoe plate fits over the retainer on the
fork leg.
EAU41692
1. Slot
2. Retainer
3. Insert the wheel axle from the
right-hand side, and then install
the washer and the axle nut.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the axle nut to the specified torque.
Tightening torque:
Axle nut:
35 Nm (3.5 m·kgf, 25 ft·lbf)
6. Adjust the brake lever free play.
(See page 6-17.)
7. While applying the front brake,
push down hard on the handlebar
several times to check for proper
fork operation.
6-29
Rear wheel
2
To remove the rear wheel
1
WARNING
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.
1. Disconnect the brake torque rod
from the brake shoe plate by removing the cotter pin, the nut and
the bolt.
1. Brake torque rod
2. Cotter pin
3. Brake torque rod bolt and nut
4. Brake shoe plate
EAU25080
EAU41643
EWA10821
Page 63
PERIODIC MAINTENANCE AND ADJUSTMENT
2. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod at the brake camshaft lever.
1. Brake rod
2. Brake pedal free play adjusting nut
3. Brake camshaft lever
4. Wheel axle
3. Loosen the locknut and the drive
chain slack adjusting nut on both
ends of the swingarm.
3
1
1. Axle nut
2. Washer
3. Drive chain slack adjusting nut
4. Locknut
4. Loosen the axle nut.
5. Lift the rear wheel off the ground
according to the procedure on
page 6-27.
6. Remove the axle nut and washer,
and then pull the wheel axle out.
7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
2
4
TIP
The drive chain does not need to be
disassembled in order to remove and
install the wheel.
8. Remove the wheel.
To install the rear wheel
1. Install the drive chain onto the rear
sprocket.
2. Insert the wheel axle from the
right-hand side.
3. Lower the rear wheel so that it is
on the ground.
4. Install the brake rod onto the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.
6
EAU41653
6-30
Page 64
PERIODIC MAINTENANCE AND ADJUSTMENT
5. Connect the brake torque rod to
the brake shoe plate by installing
the bolt and nut, and then tighten
the nut to the specified torque.
Tightening torque:
Brake torque rod nut:
26 Nm (2.6 m·kgf, 19 ft·lbf)
6. Insert a new cotter pin.
7. Adjust the drive chain slack. (See
page 6-20.)
8. Tighten the axle nut to the specified torque.
6
Tightening torque:
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
9. Adjust the brake pedal free play.
(See page 6-18.)
EAU25851
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur during operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems yourself. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replacement parts. Imitation parts may look like
Yamaha parts, but they are often inferior, have a shorter service life and can
lead to expensive repair bills.
EWA15141
WARNING
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the area, including pilot lights from water
heaters or furnaces. Gasoline or
gasoline vapors can ignite or explode, causing severe injury or
property damage.
6-31
Page 65
Troubleshooting chart
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU25902
1. Fuel
Check the fuel level in
the fuel tank.
2. Compression
Operate the electric starter.
3. Ignition
Remove the spark plug
and check the electrodes.
4. Battery
Operate the electric starter.
There is enough fuel.
There is no fuel.
There is compression.
There is no compression.
Wet
Dry
The engine turns over
quickly.
The engine turns over
slowly.
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
Check the compression.
Supply fuel.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
The battery is good.
Check the battery lead connections,
and charge the battery if necessary.
The engine does not start.
Check the compression.
Open the throttle halfway and operate
the electric starter.
The engine does not start.
Check the battery.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
6
6-32
Page 66
MOTORCYCLE CARE AND STORAGE
Matte color caution
NOTICE
Some models are equipped with
matte colored finished parts. Be
sure to consult a Yamaha dealer for
advice on what products to use before cleaning the vehicle. Using a
brush, harsh chemical products or
cleaning compounds when cleaning
these parts will scratch or damage
their surface. Wax also should not
be applied to any matte colored finished parts.
7
EAU37833
ECA15192
EAU40463
Care
While the open design of a motorcycle
reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts
from the overall appearance of a motorcycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-
7-1
ucts onto seals, gaskets, sprockets, the drive chain and wheel
axles. Always rinse the dirt and degreaser off with water.
Cleaning
ECA10771
NOTICE
● Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a corrosion protection spray.
● Improper cleaning can damage
plastic parts such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
● Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
Page 67
MOTORCYCLE CARE AND STORAGE
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
● Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.
● For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning compounds for plastic may leave
scratches on the windshield.
Test the product on a small hidden part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain or near the sea
Since sea salt is extremely corrosive,
carry out the following steps after each
ride in the rain or near the sea.
1. Clean the motorcycle with cold water and a mild detergent, after the
engine has cooled down.
NOTICE: Do not use warm water
since it increases the corrosive
action of the salt.
[ECA10791]
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
7-2
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainlesssteel parts, including the exhaust
system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.)
4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal,
including chrome- and nickel-plated, surfaces.
5. Use spray oil as a universal cleaner to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
EWA14501
WARNING
Contaminants on the brakes or tires
can cause loss of control.
7
Page 68
MOTORCYCLE CARE AND STORAGE
● Make sure that there is no oil or
wax on the tires.
● If necessary, wash the tires with
warm water and a mild detergent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cornering behavior.
NOTICE
● Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.
● Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
7
product.
● Avoid using abrasive polishing
compounds as they will wear
away the paint.
TIP
Consult a Yamaha dealer for advice on
what products to use.
ECA10800
EAU26151
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA10810
NOTICE
● Storing the motorcycle in a
poorly ventilated room or covering it with a tarp, while it is still
wet, will allow water and humidity to seep in and cause rust.
● To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.
Long-term
Before storing your motorcycle for several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” position: Turn the fuel cock lever to
“OFF”.
7-3
3. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to protect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit sparking during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
WARNING! To prevent damage or injury from sparking,
make sure to ground the
Page 69
MOTORCYCLE CARE AND STORAGE
spark plug electrodes while
turning the engine over.
[EWA10951]
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap.
6. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sidestand/centerstand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alternatively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an excessively cold or warm place [less
than 0 °C (30 °F) or more than 30
°C (90 °F)]. For more information
on storing the battery, see page
6-25.
TIP
Make any necessary repairs before
storing the motorcycle.
7
7-4
Page 70
SPECIFICATIONS
Dimensions:
Overall length:
1565 mm (61.6 in)
Overall width:
680 mm (26.8 in)
Overall height:
923 mm (36.3 in)
Seat height:
670 mm (26.4 in)
Wheelbase:
1080 mm (42.5 in)
Ground clearance:
180 mm (7.09 in)
Minimum turning radius:
1660 mm (65.4 in)
Weight:
With oil and fuel:
72.0 kg (159 lb)
Noise and vibration level:
Noise level (77/311/EEC):
TT-R110E 78.9 dB(A)
Vibration on seat (EN1032, ISO5008):
TT-R110E Will not exceed 0.5 m/s²
8
Vibration on handlebar (EN1032, ISO5008):
TT-R110E Will not exceed 2.5 m/s²
Engine:
Engine type:
Air cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
110.0 cm³
Bore × stroke:
51.0 × 54.0 mm (2.01 × 2.13 in)
Compression ratio:
9.30 :1
Starting system:
Electric starter and kickstarter
Lubrication system:
Wet sump
Engine oil:
Type:
TT-R110E SAE 10W-30, SAE 10W-40,
SAE 15W-40, SAE 20W-40 or SAE 20W50
TT-R110EY SAE 10W-30, SAE 10W-40,
SAE 15W-40, SAE 20W-40 or SAE 20W50 (AUS)
TT-R110EY YAMALUBE 4 10W-40 or
20W-50, SAE 10W-40 or SAE 20W-50
(CAN)
-20 -10 0
SAE 10W-30
20 30
10
SAE 10W-40
SAE 10W-50
SAE 15W-40
SAE 20W-40
SAE 20W-50
40
50 ˚C
0
10 30 50 70 90
YAMALUBE 4 10W-40
or SAE 10W-40
–20
–10 0 10 20 30
YAMALUBE 4 20W-50
or SAE 20W-50
110
40
Recommended engine oil grade:
API service SG type or higher, JASO
standard MA
Engine oil quantity:
Periodic oil change:
0.80 L (0.85 US qt, 0.70 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
TT-R110E Regular unleaded gasoline only
TT-R110EY Regular unleaded gasoline
only (CAN)
TT-R110EY Unleaded gasoline only (AUS)
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)
Carburetor:
Manufacturer:
MIKUNI
130
50
˚F
˚C
8-1
Page 71
SPECIFICATIONS
Type × quantity:
VM16 x 1
Spark plug (s):
Manufacturer/model:
NGK/CR6HSA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, multiple-disc and centrifugal
automatic
Transmission:
Primary reduction system:
Spur gear
Primary reduction ratio:
67/18 (3.722)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
35/14 (2.500)
Transmission type:
Constant mesh 4-speed
Operation:
Left foot operation
Gear ratio:
1st:
38/12 (3.166)
2nd:
33/17 (1.941)
3rd:
29/21 (1.380)
4th:
23/21 (1.095)
Chassis:
Frame type:
Steel tube backbone
Caster angle:
26.00 °
Trail:
60.0 mm (2.36 in)
Front tire:
Type:
With tube
Size:
2.50-14 4PR
Manufacturer/model:
CHEN SHIN/C-803-2
Rear tire:
Type:
With tube
Size:
3.00-12 4PR
Manufacturer/model:
CHEN SHIN/C-803-2
Loading:
Maximum rider weight:
60.0 kg (132 lb)
Tire air pressure (measured on cold
tires):
Front:
100 kPa (1.00 kgf/cm², 15 psi)
Rear:
100 kPa (1.00 kgf/cm², 15 psi)
Front wheel:
Wheel type:
Spoke wheel
8-2
Rim size:
14x1.40
Rear wheel:
Wheel type:
Spoke wheel
Rim size:
12x1.60
Front brake:
Type:
Drum brake
Operation:
Right hand operation
Rear brake:
Type:
Drum brake
Operation:
Right foot operation
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
115.0 mm (4.53 in)
Rear suspension:
Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
110.0 mm (4.33 in)
Electrical system:
Ignition system:
DC. CDI
8
Page 72
SPECIFICATIONS
Charging system:
AC magneto
Battery:
Model:
GT4B-5
Voltage, capacity:
12 V, 2.5 Ah
Fuse:
Fuse:
10.0 A
8
8-3
Page 73
CONSUMER INFORMATION
EAU26351
Identification numbers
Record the key identification number,
vehicle identification number 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.
KEY IDENTIFICATION NUMBER:
VEHICLE IDENTIFICATION
NUMBER:
MODEL LABEL INFORMATION:
Key identification number
1. Key identification number 1. Vehicle identification number
The key identification number is
stamped into the key. Record this number in the space provided and use it for
reference when ordering a new key.
EAU26390
Vehicle identification number
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space provided.
TIP
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcycle with the licensing authority in your
area.
EAU26400
1
9
9-1
Page 74
CONSUMER INFORMATION
Model label
1
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.
9
EAU36980
9-2
Page 75
INDEX
A
Air filter element, cleaning .................... 6-10
B
Battery .................................................. 6-25
Brake lever ............................................. 3-2
Brake lever, checking and lubricating ... 6-23
Brake lever free play, adjusting ............ 6-17
Brake pedal ............................................ 3-3
Brake pedal, checking and
lubricating........................................... 6-23
Brake pedal free play, adjusting ........... 6-18
Brake shoes, checking ......................... 6-19
C
Cables, checking and lubricating.......... 6-22
Carburetor, adjusting ............................ 6-13
Care........................................................ 7-1
Clutch free play, adjusting .................... 6-16
D
Drive chain, cleaning and lubricating .... 6-21
Drive chain slack .................................. 6-20
E
Engine break-in ...................................... 5-3
Engine idling speed .............................. 6-13
Engine oil................................................ 6-8
Engine, starting a warm.......................... 5-2
Engine stop switch.................................. 3-2
F
Front fork, checking .............................. 6-24
Fuel......................................................... 3-3
Fuel cock ................................................ 3-5
Fuel tank breather hose.......................... 3-5
Fuel tank cap.......................................... 3-3
Fuse, replacing..................................... 6-27
H
Handlebar switches.................................3-1
I
Identification numbers .............................9-1
K
Key identification number........................9-1
Kickstarter ...............................................3-7
M
Main switch .............................................3-1
Maintenance and lubrication, periodic..... 6-4
Maintenance, emission control system ...6-3
Matte color, caution.................................7-1
Model label..............................................9-2
P
Panels, removing and installing ..............6-6
Parking....................................................5-4
Part locations ..........................................2-1
Pre-operation check list...........................4-2
S
Safety information ...................................1-1
Seat.........................................................3-7
Shifting ....................................................5-2
Shift pedal ...............................................3-2
Shift pedal, checking .............................6-19
Shock absorber assembly ....................... 3-8
Sidestand ................................................3-8
Sidestand, checking and lubricating......6-23
Spark arrester, cleaning ........................ 6-12
Spark plug, checking...............................6-7
Specifications..........................................8-1
Starter (choke) lever................................3-6
Starting and warming up a cold engine ... 5-1
Starting circuit cut-off system .................. 3-8
Start switch..............................................3-2
Steering, checking ................................6-25
Storage ................................................... 7-3
Supporting the motorcycle .................... 6-27
Swingarm pivots, lubricating .................6-24
T
Throttle cable free play, checking ......... 6-14
Throttle grip and cable, checking and
lubricating ...........................................6-22
Tires...................................................... 6-15
Tool kit .................................................... 6-2
Troubleshooting .................................... 6-31
Troubleshooting chart ........................... 6-32
V
Valve clearance .................................... 6-14
Vehicle identification number.................. 9-1
W
Wheel bearings, checking..................... 6-25
Wheel (front) ......................................... 6-28
Wheel (rear).......................................... 6-29
Wheels.................................................. 6-16
Page 76
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2008.06-1.1×1 CR
(E)
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