YAMAHA TT-R110E 2016 Service Manual

Operation and important ri din g points
6-2
6
EAU16641
Startin g a warm en gine
Follow the same procedure as for
starting a cold engine with the excep-
tion that the starter (choke) is not re-
quired when the engine is warm.
EAU39902
Shiftin g
This motorcycle has a 4-speed trans-
mission 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 il-
lustration.
TIP
To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel.
NOTICE
ECA15442
Even with the transmission in
the neutral position, d o not
coast for lon g period s of time
with the en gine off, an d d o not
tow the motorcycle for lon g d is-
tances. The transmission is
properly lu bricated only when
the en gine is runnin g. Ina de-
quate lu brication may damag e
the transmission.
 Always release the throttle grip
b efore chan gin g g ears to avoi d
d amag ing the en gine, transmis-
1. Shift pedal
2. Neutral position
1
2
1 2
3
4
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Operation and important rid ing points
6-3
6 sion, an
d d rive train, which are
not desi gne d to withstan d the
shock of shiftin g when the
throttle grip is open.
EAU39912To start out an d accelerate
1. Close the throttle.
2. Shift into first gear and release the shift pedal. NOTICE: Always
close the throttle before shiftin g
g ears, otherwise d amage to the
en gine an d d rive train may re-
sult.
[ECA15462]
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.
EAU16711To decelerate
1. Close the throttle and apply both the front and the rear brakes to
slow the motorcycle.
2. Downshift through the gears and shift the transmission into the neu-
tral position when the motorcycle
is almost completely stopped.
EAU39921
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 fol-
lowing 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 them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheating
must be avoided. However, momen-
tary full-throttle operation under load
(i.e., two to three seconds maximum)
does not harm the engine. Each full-
throttle acceleration should be fol-
lowed 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
adjustments thoroughly, especially ca-
ble and drive chain slack and loose
spokes. In addition, check all fittings
and fasteners for looseness, and tight-
en if necessary.
NOTICE
ECA10271
If any en gine trou ble shoul d occur
d uring the en gine break-in perio d,
imme diately have a Yamaha d ealer
check the vehicle.
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Operation and important ri din g points
6-4
6
EAU17172
Parkin g
When parking, stop the engine, re-
move the key from the main switch,
and then turn the fuel cock lever to
“OFF”.
WARNING
EWA10312
Since the en gine an d exhaust
system can become very hot,
park in a place where ped estri-
ans or chil dren are not likely to
touch them and b e burne d.
 Do not park on a slope or on soft
groun d, otherwise the vehicle
may overturn, increasin g the
risk of a fuel leak an d fire.
 Do not park near g rass or other
flammab le materials which
mi ght catch fire.
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Periodic maintenance an d a djustment
7-1
7
EAU17246
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 im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained 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
EWA10322
Failure to properly maintain the vehi-
cle or performin g maintenance ac-
tivities incorrectly may increase
your risk of injury or d eath durin g
service or while usin g the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha d ealer perform
service.
WARNING
EWA15123
Turn off the en gine when performin g
maintenance unless otherwise
specified .
 A runnin g en gine has movin g
parts that can catch on body
parts or clothin g an d electrical
parts that can cause shocks or
fires.
 Runnin g the en gine while ser-
vicin g can lead to eye injury,
b urns, fire, or car bon monoxi de
poisonin g – possi bly lea din g to d
eath. See pag e 2-2 for more in-
formation a bout car bon monox-
i d e.
WARNING
EWA15461
Brake discs, calipers, drums, an d
linin gs can b ecome very hot during
use. To avoi d possi ble burns, let
b rake components cool before
touchin g them.
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Periodic maintenance an d a djustment
7-2
7
EAU17303
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, replace-
ment, or repair of the emission control
devices and systems may be per-
formed by any repair establishment or
individual that is certified (if applicable).
Yamaha dealers are trained and equipped to perform these particular
services.
EAU17312
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.
TIP
If 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 an d a djustment
7-3
7
EAU69171
Perio dic 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 13 5
0.6 1.8 3 16 12
30 90 150
1 *Fuel line • Check fuel hoses for cracks or
damage.
• Replace if necessary. √√
2Spark plu g• Check condition.
• Adjust gap and clean.
√√
3 *Valve clearance • Check and adjust valve clear-
ance when engine is cold. √
4 Air filter element • Clean with solvent.
• Replace if necessary.
√√
5 *Crankcase
breather
system • Check ventilation hose for
cracks or damage and drain
any deposits.
• Replace if necessary. √√ √
6 *Car buretor • 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. √
9En gine oil • Change (warm engine before
draining). √√ √X 1000 km
X 1000 mi month
CHECKS AND
MAINTENANCE JOBS
hours
INITIALODOMETER READINGS
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Periodic maintenance an d a djustment
7-4
7
EAU69191
General maintenance an d lu brication 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 13 5
0.6 1.8 3 16 12
30 90 150
1 *Clutch • Check operation.
• Adjust if necessary.
√√ √
2 *Front brake • Check operation.
• Adjust brake lever free play and
replace brake shoes if neces-
sary. √√ √
3 *Rear brake • Check operation.
• Adjust brake pedal free play
and replace brake shoes if nec-
essary. √√ √
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 bearin gs • Check bearings for smooth op-
eration.
• Replace if necessary. √√
7 *Swin
garm pivot
b earin gs • Check bearing assemblies for
looseness.
• Moderately repack with lithium- soap-based grease. √√
8Drive chain • Check chain slack/alignment
and condition.
• Adjust and lubricate chain with Yamaha chain lubricant or other
suitable chain lubricant thor-
oughly. Every rideX 1000 km
X 1000 mi month
CHECKS AND
MAINTENANCE JOBS
hours
INITIALODOMETER READINGS
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Periodic maintenance an d a djustment
7-5
7
EAU40001
TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty
areas.
9 *Steerin g b earin gs • 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 pe
dal pivot
shaft • Apply lithium-soap-based
grease lightly. √√
13 Si destan d pivot • Check operation.
• Apply lithium-soap-based
grease lightly. √√
14 *Front fork • Check operation and for oil
leakage.
• Replace if necessary. √√
15 *Shock ab
sorber as-
sem bly • Check operation and for oil
leakage.
• Replace if necessary. √
16 *Control ca bles • Apply Yamaha cable lubricant
or other suitable cable lubricant
thoroughly. √√ √
17 *Throttle grip • Check operation.
• Check throttle grip free play,
and adjust if necessary.
• Lubricate cable and grip hous- ing. √√ √
No. ITEM
13 5
0.6 1.8 3 16 12
30 90 150
X 1000 km X 1000 mi month
CHECKS AND
MAINTENANCE JOBS
hours
INITIALODOMETER READINGS
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Periodic maintenance an d a djustment
7-6
7
EAU18773
Removin g an d installin g pan-
els
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.
EAU56170
Panel A
To remove the panel
1. Remove the seat. (See page 4-9.)
2. Remove the bolts and the quick
fastener screws, and then take the
panel off. To install the panel
1. Place the panel in the original po-
sition, and then install the bolts
and the quick fastener screws.
2. Install the seat.
Panel B
To remove the panel
1. Remove the seat. (See page 4-9.)
2. Remove the bolt, and then pull the panel off as shown.
To install the panel
1. Place the panel in the original po- sition, and then install the bolt.
2. Install the seat.
1. Panel A
1. Panel B
1
1
1. Panel A
2. Bolt
3. Quick fastener screw
1. Panel B
2. Bolt
3. Projection
3
1
2
3
3
1
2
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Periodic maintenance an d a djustment
7-7
7
EAU19605
Checkin g the spark plu g
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 main-
tenance and lubrication chart. In addi-
tion, the condition of the spark plug
can reveal the condition of the engine.
To remove the spark plu g
1. Remove the spark plug cap.
2. Remove the spark plug as shown, with the spark plug wrench includ-
ed in the owner’s tool kit. To check the spark plu
g
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 vehi-
cle is ridden normally).
TIP
If the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
stead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for electrodeerosion and excessive carbon or
other deposits, and replace it if
necessary.
3. Measure the spark plug gap with a wire thickness gauge and, if nec-
essary, adjust the gap to specifi-
cation.
1. Spark plug cap
1. Spark plug wrench
1
1
Specified spark plu g:
NGK/CR6HSA
1. Spark plug gap
Spark plu g g ap:
0.6–0.7 mm (0.024–0.028 in)
UB5181E0.book Page 7 Monday, April 6, 2015 9:22 AM