wheel YAMAHA TT-R110E 2019 Owners Manual

Table of contents
Location of important la bels ........... 1-1
Safety information ............................ 2-1
Description ....................................... 3-1
Left view ......................................... 3-1
Right view ....................................... 3-2
Controls and instruments ............... 3-3
Instrument an d 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 ................................................. 4-4
Fuel tank breather hose.................. 4-5
Fuel cock ........................................ 4-6
Starter (choke) lever ...................... 4-7
Kickstarter ..................................... 4-7
Seat ................................................ 4-8
Shock absorber assembly .............. 4-8
Sidestand ....................................... 4-9
Starting circuit cut-off system ........ 4-9
For your safety – pre-operation
checks ............................................... 5-1
Operation an d important ri din g
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
Perio dic maintenance an d
a d justment ........................................ 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...... 7-6 Checking the spark plug ................. 7-7
Engine oil......................................... 7-8
Cleaning the air filter element ....... 7-10
Cleaning the spark arrester ........... 7-12
Adjusting the carburetor ............... 7-13
Adjusting the engine idling
speed ......................................... 7-14
Checking the throttle grip free
play ............................................ 7-15
Valve clearance ............................. 7-15
Tires .............................................. 7-16
Spoke wheels ................................ 7-17
Adjusting the clutch free play........ 7-18
Adjusting the brake lever free play ............................................ 7-18
Adjusting the brake pedal free play ............................................ 7-19
Checking the shift pedal ............... 7-20
Checking the front and rear brake shoes ......................................... 7-20
Drive chain slack ........................... 7-21
Cleaning and lubricating the drive chain ................................. 7-22
Checking and lubricating the cables ........................................ 7-23
Checking and lubricating the
throttle grip and cable ............... 7-23
Checking and lubricating the brake lever ................................. 7-24
Checking and lubricating the brake pedal ................................ 7-24
Checking and lubricating the
sidestand ................................... 7-25
Lubricating the swingarm pivots ... 7-25
Checking the front fork ................. 7-26
Checking the steering ................... 7-26
Checking the wheel bearings ........ 7-27
Battery........................................... 7-27
Replacing the fuse ........................ 7-29
Supporting the motorcycle ........... 7-29
Front wheel ................................... 7-30
Rear wheel .................................... 7-31
Troubleshooting ............................ 7-33
Troubleshooting chart ................... 7-34
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Safety information
2-2
2sic motorcycle maintenance.
Certain maintenance can only
be carried out by certified staff.
 Many accidents involve inexperi-
enced operators.
• Make sure that you are qualified and that you only lend your mo-
torcycle to other qualified oper-
ators.
• Know your skills and limits. Staying within your limits may
help you to avoid an accident.
• We recommend that you prac- tice riding your motorcycle until
you have become thoroughly
familiar with the motorcycle and
all of its controls.
 Many accidents have been
caused by error of the motorcycle
operator. A typical error made by
the operator is veering wide on a
turn due to excessive speed or un-
dercornering (insufficient lean an-
gle for the speed). Never travel
faster than warranted by condi-
tions.
 Ride cautiously in unfamiliar ar-
eas. You may encounter hidden
obstacles that could cause an ac-
cident.
 The posture of the operator is im-
portant for proper control. The op-
erator should keep both hands on
the handlebar and both feet on the
operator footrests during opera-
tion to maintain control of the mo-
torcycle.
 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 motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the pre-
vention 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 abra-
sions 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 sys-
tem become very hot during or af-
ter operation and can cause
burns.
Avoi d Car bon Monoxi de Poisonin g
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing
carbon monoxide can cause head-
aches, dizziness, drowsiness, nausea,
confusion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be pres-
ent even if you do not see or smell any
engine exhaust. Deadly levels of car-
bon monoxide can collect rapidly and
you can quickly be overcome and un-
able to save yourself. Also, deadly lev-
els of carbon monoxide can linger for
hours or days in enclosed or poorly
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Safety information
2-5
2

Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
 Shift the transmission in gear (for
models with a manual transmis-
sion).
 Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or
parts that could break). Choose
the location for the straps carefully
so the straps will not rub against
painted surfaces during transport.
 The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the mo-
torcycle will not bounce exces-
sively during transport.
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For your safety – pre-operation checks
5-1
5
EAU63440
Inspect your vehicle each time you use it to make sure the vehicle is in safe oper-
ating condition. Always follow the inspection and maintenance procedures and
schedules described in the Owner’s Manual.
WARNING
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility
of an acci dent or equipment d amage. Do not operate the vehicle if you fin d
any prob lem. If a pro blem cannot be corrected b y the proce dures provi ded
in this manual, have the vehicle inspecte d b y a Yamaha d ealer.
Before using this vehicle, check the following points:
ITEM CHECKSPAGE
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. 4-4, 4-5
En gine oil • Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage. 7-8
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 g rip • 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
Control ca bles • Make sure that operation is smooth.
• Lubricate if necessary. 7-23
Drive chain • Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary. 7-21,
7-22
Wheels an d tires •Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary. 7-16,
7-17
Shift pe dal • Make sure that operation is smooth.
• Correct if necessary. 7-20
Brake ped al • Make sure that operation is smooth.
• Lubricate pedal pivoting point if necessary.
7-24
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Periodic maintenance an d a djustment
7-4
7
EAU69192
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. √√
8 Drive 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
7-17
7
WARNING
EWA10462
The front an d rear tires shoul d b e of
the same make an d d esi gn, other-
wise the han dlin g characteristics of
the vehicle may be different, which
coul d lea d to an acci dent.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha.
WARNING
EWA14391
 Have a Yamaha dealer replace
excessively worn tires. Operat-
in g the motorcycle with exces-
sively worn tires decreases
ri din g sta bility an d can lead to
loss of control.
 The replacement of all wheel-
and b rake-related parts, includ-
in g the tires, shoul d b e left to a
Yamaha dealer, who has the
necessary professional knowl-
e dge an d experience.
 It is not recommen ded to patch
a puncture d tu be. If unavoid -
a b le, however, patch the tu be
very carefully an d replace it as
soon as possi ble with a hi gh-
quality prod uct.
EAU21944
Spoke wheels
WARNING
EWA10611
The wheels on this mod el are not
d esi gne d for use with tu beless tires.
Do not attempt to use tu beless tires
on this mo del.
To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.
 The wheel rims should be
checked for cracks, bends, warp-
age or other damage, and the
spokes for looseness or damage
before each ride. If any damage is
found, have a Yamaha dealer re-
place 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 han-
dling characteristics, and a short-
ened tire life.
Front tire:
Size:
2.50-14 4PR
Manufacturer/model: CHENG SHIN/C-803
Rear tire: Size:3.00-12 4PR
Manufacturer/model: CHENG SHIN/C-803
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Periodic maintenance an d a djustment
7-19
7
5. Loosen the locknut at the brake
shoe plate.
6. To increase the brake lever free play, turn the adjusting bolt at the
brake shoe plate in direction (a).
To decrease the brake lever free
play, turn the adjusting bolt in di-
rection (b).
7. Tighten the locknut at the brake shoe plate.
8. Tighten the locknut at the brake lever, and then slide the rubber
cover to its original position.
EAU44673
Adjustin g the brake pe dal free
play
Measure the brake pedal free play at
the brake pedal end as shown.
Periodically check the brake pedal free
play and, if necessary, adjust it as fol-
lows.
To increase the brake pedal free play,
turn the brake pedal free play adjusting
nut at the brake rod in direction (a). To
decrease the brake pedal free play,
turn the adjusting nut in direction (b).
WARNING
EWA14821
 After a djustin g the d rive chain
slack or removin g an d installin g
the rear wheel, always check
the brake ped al free play.
 If proper a djustment cannot b e
o b taine d as descri bed , have a
Yamaha dealer make this a d-
justment.
1. Locknut
2. Brake lever free play adjusting bolt
2
1
(b)
(a)
1. Brake pedal free play adjusting nut
2. Brake pedal free play
Brake pe dal free play:
10.0–20.0 mm (0.39–0.79 in)
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Periodic maintenance an d a djustment
7-21
7
EAU22762
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU74251To check the drive chain slack
1. Place the motorcycle on the side- stand.
TIP
When checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.
2. Shift the transmission into theneutral position.
3. Measure the drive chain slack as shown.
4. If the drive chain slack is incorrect, adjust it as follows. NOTICE: Im-
proper drive chain slack will
overloa d the en gine as well as
other vital parts of the motorcy-
cle an d can lead to chain slip-
pa ge or b reakag e. To prevent
this from occurrin g, keep the
d rive chain slack within the
specified limits.
[ECA10572] EAU40116
To a
djust the drive chain slack
Consult a Yamaha dealer before ad-
justing the drive chain slack. 1. Loosen the brake pedal free play adjusting nut, axle nut, and lock-
nut at each end of the swingarm.
2. To tighten the drive chain, turn the drive chain slack adjusting nut at
each end of the swingarm in direc-
tion (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 for-
ward.
1. Drive chain slack
Drive chain slack:40.0–56.0 mm (1.57–2.20 in)
1
1. Brake pedal free play adjusting nut
2. Locknut
3. Drive chain slack adjusting nut
1. Axle nut
2. Locknut
3. Drive chain slack adjusting nut
32
1
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Periodic maintenance an d a djustment
7-22
7
TIP
Using the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the same
position for proper wheel alignment.
3. Tighten the axle nut and both
locknuts to the specified torques.
4. Adjust the brake pedal free play. (See page 7-19.)
5. Make sure that the drive chain pullers are in the same position,
the drive chain slack is correct,
and the drive chain moves
smoothly.
EAU23018
Cleanin g an d lu bricatin g the
d rive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
NOTICE
ECA10584
The drive chain must be lu bricate d
after washin g the motorcycle, ri din g
in the rain or ri din g in wet areas.
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 lubricant or other suitable chain lubricant on
the entire chain, making sure that
all side plates and rollers have
been sufficiently oiled.
1. Alignment marks
2. Locknut
3. Drive chain slack adjusting nut
4. Drive chain puller
Tightenin g torques:
Axle nut:
60 N·m (6.0 kgf·m, 44 lb·ft)
Locknut: 7 N·m (0.7 kgf·m, 5.2 lb·ft)
(a)
(b)
432 1
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Periodic maintenance an d a djustment
7-26
7
EAU23273
Checkin g 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 con dition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation 1. Place the vehicle on a level surfa- ce and hold it in an upright posi-
tion. WARNING! To avoi d injury,
securely support the vehicle so
there is no dan ger of it fallin g
over.
[EWA10752]
2. While applying the front brake, push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
NOTICE
ECA10591
If any d amage is foun d or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23285
Checkin g the steerin g
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Raise the front wheel off the ground. (See page 7-29.)
WARNING! To avoi d injury, se-
curely support the vehicle so
there is no dan ger of it fallin g
over.
[EWA10752]
2. Hold the lower ends of the front fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
UB5183E0.book Page 26 Friday, June 9, 2017 8:32 AM