maintenance YAMAHA TTR110 2012 Owners Manual

INTRODUCTION
EAU41663
Congratulations on your purchase of the Yamaha TT-R110E/TT-R110EB. This model is the result of Yamaha’s vast experi-
ence in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsman-
ship 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 cur- rent 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
EWA10031
Please read this manual carefully and completely before operating this motorcycle.
WARNING
EWA14351
This motorcycle is designed and manufactured for off-road use only. It is illegal to operate this motorcycle on any
public street, road or highway. Such use is prohibited by law. This motorcycle complies with almost all state off-
highway noise level and spark arrester laws and regulations. Please check your local riding laws and regulations
before operating this motorcycle.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.
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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 warn-
ings in this Owner ’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abil-
ities, 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 t o
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.
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TABLE OF CONTENTS
LOCATION OF IMPORTANT
LABELS ............................................1-1
SAFETY INFORMATION .................. 2-1
DESCRIPTION .................................. 3-1
Left view .......................................... 3-1
Right view ........................................ 3-2
Controls and instruments ................3-3
INSTRUMENT AND CONTROL
FUNCTIONS ....................................... 4-1
Main switch ..................................... 4-1
Handlebar switches ........................ 4-1
Shift pedal ......................................4-2
Brake lever ..................................... 4-2
Brake pedal .................................... 4-3
Fuel tank cap .................................. 4-3
Fuel ................................................ 4-3
Fuel tank breather hose ................. 4-5
Fuel cock ........................................ 4-5
Starter (choke) lever ....................... 4-6
Kickstarter ......................................4-6
Seat ................................................ 4-7
Shock absorber assembly .............. 4-7
Sidestand ....................................... 4-8
Starting circuit cut-off system ......... 4-8 FOR YOUR SAFETY
–
PRE-OPERATION CHECKS ............. 5-1
OPERATION AND IMPORTANT
RIDING POINTS ................................ 6-1
Starting and warming up a cold engine ......................................... 6-1
Starting a warm engine .................. 6-2
Shifting ........................................... 6-2
Engine break-in .............................. 6-3
Parking ........................................... 6-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ................................... 7-1
Owner ’s tool kit .............................. 7-2
Periodic maintenance chart for the emission control system ............. 7-3
General maintenance and lubrication chart .......................... 7-4
Removing and installing panels ..... 7-7
Checking the spark plug ................ 7-8
Engine oil ....................................... 7-9
Cleaning the air filter element ...... 7-11
Cleaning the spark arrester ......... 7-13
Adjusting the carburetor ............... 7-14
Adjusting the engine idling
speed ........................................ 7-14
Checking the throttle grip free play ........................................... 7-15
Valve clearance ........................... 7-15
Tires ............................................. 7-15 Spoke wheels ............................... 7-17
Adjusting the clutch free play ....... 7-17
Adjusting the brake lever free
play ........................................... 7-18
Adjusting the brake pedal free
play ........................................... 7-19
Checking the shift pedal ............... 7-19
Checking the front and rear brake shoes ........................................ 7-20
Drive chain slack .......................... 7-20
Cleaning and lubricating the drive chain ......................................... 7-22
Checking and lubricating the cables ....................................... 7-22
Checking and lubricating the throttle grip and cable ............... 7-23
Checking and lubricating the
brake lever ................................ 7-23
Checking and lubricating the brake pedal ............................... 7-23
Checking and lubricating the sidestand .................................. 7-24
Lubricating the swingarm pivots ... 7-24
Checking the front fork ................. 7-24
Checking the steering .................. 7-25
Checking the wheel bearings ....... 7-25
Battery .......................................... 7-26
Replacing the fuse ....................... 7-27
Supporting the motorcycle ........... 7-28
Front wheel .................................. 7-28
Rear wheel ................................... 7-30
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INSTRUMENT AND CONTROL FUNCTIONS
4-4
43. Wipe up any spilled fuel immedi-ately. NOTICE: Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteri-
orate painted surfaces or plastic
parts.
[ECA10071]
4. Be sure to securely close the fuel tank cap.
WARNING
EWA15151
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gaso-
line by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline 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 gaso-
line spills on your clothing, change
your clothes.
EAU50250
NOTICE
ECA11400
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-
signed to use regular unleaded gaso-
line with a pump octane number
[(R+M)/2] of 86 or higher, or a researchoctane number of 91 or higher. If
knocking (or pinging) occurs, use a
gasoline of a different brand or premi-
um unleaded fuel. Use of unleaded fuel
will extend spark plug life and reduce
maintenance costs.
Gasohol
There are two types of gasohol: gaso-
hol containing ethanol and that contain-
ing methanol. Gasohol containing
ethanol can be used if the ethanol con-
tent does not exceed 10% (E10). Gas-
ohol containing methanol is not
recommended by Yamaha because it
can cause damage to the fuel system
or vehicle performance problems.
1. Fuel tank filler tube
2. Maximum fuel level
Recommended fuel:
TT-R110E Regular unleaded gaso-
line or gasohol (E10)
TT-R110EB Regular unleaded gaso-
line or gasohol (E10) (CAN)(ZAF)
TT-R110EB Unleaded gasoline or
gasohol (E10) (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)
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-1
5
EAU15596
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.
WARNING
EWA11151
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:
ITEM CHECKS PAGE
Fuel 
Check fuel level in fuel tank.
 Refuel if necessary.
 Check fuel line for leakage.
 Check fuel tank breather hose for obstructions, cracks or damage, and check
hose connection. 4-3, 4-5
Engine oil 
Check oil level in engine.
 If necessary, add recommended oil to specified level.
 Check vehicle for oil leakage. 7-9
Front brake 
Check operation.
 Lubricate cable if necessary.
 Check lever free play.
 Adjust if necessary. 7-18, 7-20
Rear brake 
Check operation.
 Check pedal free play.
 Adjust if necessary. 7-19, 7-20
Throttle grip 
Make sure that operation is smooth.
 Check throttle grip free play.
 If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable
and grip housing. 7-15, 7-23
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-1
7
EAU17244
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING
EWA15122
Turn off the engine when performing
maintenance unless otherwise
specified.

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 2-2 for more in-
formation about carbon monox-
ide.WARNING
EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
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 relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replacement,
or repair of the emission control devic-
es 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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-2
7
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. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.TIPIf you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-3
7
EAU39944
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.
No.ITEM CHECKS AND MAINTENANCE JOBS INITIAL ODOMETER READINGS
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
1 *Fuel line 
Check fuel hoses for cracks or damage.
 Replace if necessary. √√
2 Spark plug 
Check condition.
 Adjust gap and clean. √√
3 *Valve clearance Check and adjust valve clearance when engine is cold. √
4 Air filter element 
Clean with solvent.
 Replace if necessary. √√
5 *Crankcase breather sys-
tem 
Check ventilation hose for cracks or damage and drain
any deposits.
 Replace if necessary. √√√
6 *Carburetor 
Check engine idling speed and starter operation.
 Adjust if necessary. √√√
7 Exhaust system 
Check for leakage.
 Tighten if necessary.
 Replace gasket(s) if necessary. √√
8 *Spark arrester Clean. √
9 Engine oil Change (warm engine before draining). √√√
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
7
EAU3534B
General maintenance and lubrication chart 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.
No.ITEM CHECKS AND MAINTENANCE JOBS INITIAL ODOMETER READINGS
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
1 *Clutch 
Check operation.
 Adjust if necessary. √√√
2 *Front brake 
Check operation.
 Adjust brake lever free play and replace brake shoes if
necessary. √√√
3 *Rear brake 
Check operation.
 Adjust brake pedal free play and replace brake shoes if
necessary. √√√
4 *Wheels 
Check runout, spoke tightness and for damage.
 Tighten spokes if necessary. √√√
5 *Tires 
Check tread depth and for damage.
 Replace if necessary.
 Check air pressure.
 Correct if necessary. √√
6 *Wheel bearings 
Check bearings for smooth operation.
 Replace if necessary. √√
7 *Swingarm pivot bearings 
Check bearing assemblies for looseness.
 Moderately repack with lithium-soap-based grease. √√
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-5
7
8 Drive chain
Check chain slack/alignment and condition.
 Adjust and lubricate chain with Yamaha chain and cable
lube thoroughly. Every ride
9 *Steering bearings 
Check bearing assemblies for looseness.
 Moderately repack with lithium-soap-based grease. √√
10 *Chassis fasteners 
Check all chassis fitting and fasteners.
 Correct if necessary. √√√
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 
Check operation.
 Apply lithium-soap-based grease lightly. √√
14 *Front fork 
Check operation and for oil leakage.
 Replace if necessary. √√
15 *Shock absorber assem-
bly 
Check operation and for oil leakage.
 Replace if necessary. √
16 *Control cables 
Apply Yamaha chain and cable lube or engine oil thor-
oughly. √√√
17 *Throttle grip 
Check operation.
 Check throttle grip free play, and adjust if necessary.
 Lubricate cable and grip housing. √√√
No. ITEM CHECKS AND MAINTENANCE JOBS
INITIAL ODOMETER READINGS
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
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