clutch YAMAHA TT-R110E 2020 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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Description
3-1
3
EAU63371
Left view
678
123 45
1. Fuel cock (page 4-6)
2. Starter (choke) lever (page 4-7)
3. Fuse (page 7-29)
4. Battery (page 7-27)
5. Clutch adjusting screw (page 7-18)
6. Engine oil drain bolt (page 7-8)
7. Shift pedal (page 4-2)
8. Throttle stop screw (page 7-14)
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Operation and important rid ing 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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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 ushes • Check bush assemblies for
looseness.
• Lubricate with molybdenum di- sulfide 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
7-9
7
4. If the engine oil is not between the
tip of the dipstick and the maxi-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Check the O-ring for damage, and replace it if necessary.
6. Insert the dipstick into the oil filler hole, and then tighten the oil filler
cap.
To chan ge the en gine oil
1. Start the engine, warm it up for several minutes, and then turn it
off.
2. Place an oil pan under the engine to collect the used oil.
3. Remove the engine oil filler cap, the engine oil drain bolt and its
gasket to drain the oil from the
crankcase.
4. Install a new gasket and the drain bolt, and then tighten the drain
bolt to the specified torque.
5. Refill with the specified amount of the recommended engine oil.
NOTICE
ECA11621
In or der to prevent clutch slip-
pa ge (since the en gine oil also
lu bricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a hi gh-
er quality than specified . In
a dd ition, do not use oils la bele d
“ENERGY CONSERVING II” or
hi gher.
 Make sure that no forei gn mate-
rial enters the crankcase.
6. Check the O-ring for damage, and replace it if necessary.
7. Install and tighten the engine oil filler cap.
8. 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.
1. Engine oil drain bolt
2. Gasket
Tightening torque:
Engine oil drain bolt: 20 N·m (2.0 kgf·m, 15 lb·ft)
12
Recommended engine oil:
See page 9-1.
Oil change quantity: 0.80 L (0.85 US qt, 0.70 Imp.qt)
1. Engine oil filler cap
2. O-ring
2
1
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Periodic maintenance an d a djustment
7-18
7
EAU44664
A djustin g 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 resis-
tance is felt, and then turn it 1/8
turn in direction (b).
3. Tighten the locknut to the speci- fied torque.
TIP
When tightening the locknut, hold the
clutch adjusting screw with a screw-
driver so that it does not turn together
with the locknut.
EAU44886
Adjustin g the brake lever free
play
Measure the brake lever free play as
shown.
Periodically check the brake lever free
play and, if necessary, adjust it as fol-
lows.
1. Slide the rubber cover back.
2. Loosen the locknut at the brake le- ver.
3. To increase the brake lever free play, turn the brake lever free play
adjusting bolt in direction (a). To
decrease the brake lever free play,
turn the adjusting bolt in direction
(b).
TIP
Skip steps 4–7 if the specified brake le-
ver free play could be obtained as de-
scribed above.
4. Fully turn the adjusting bolt at thebrake lever in direction (a) to loos-
en the brake cable.
1. Locknut
2. Clutch adjusting screw
Tightenin g torque:
Locknut:
8 N·m (0.8 kgf·m, 5.9 lb·ft)
1 2
(a)(b)1. Rubber cover
2. Brake lever free play adjusting bolt
3. Locknut
4. Brake lever free play
Brake lever free play:
10.0–20.0 mm (0.39–0.79 in)
3
21
(b)
(a) 4
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Specifications
9-2
9
Spark plug(s):
Manufacturer/model:
NGK/CR6HSA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:Wet, centrifugal, shoe + multiple-disc
Drivetrain:
Primary reduction ratio:3.722 (67/18)
Final drive: Chain
Secondary reduction ratio:
2.500 (35/14)
Transmission type:
Constant mesh 4-speed
Gear ratio: 1st:
3.167 (38/12)
2nd: 1.941 (33/17)
3rd: 1.381 (29/21)
4th:
1.095 (23/21)
Chassis:
Frame type:Backbone
Caster angle:
26.0 °
Trail: 60 mm (2.4 in)
Front tire:
Type:
With tube
Size: 2.50-14 4PR
Manufacturer/model: CHENG SHIN/C-803
Speed rating:
120 km/h (75 mph)
Rear tire:
Type:With tube
Size:
3.00-12 4PR
Manufacturer/model: CHENG SHIN/C-803 Speed rating:
120 km/h (75 mph)
Tire air pressure (measure d on col d
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
Rim size: 14 x 1.40
Rear wheel:
Wheel type:
Spoke wheel
Rim size: 12 x 1.60
Front brake:
Type:
Mechanical leading trailing drum brake
Rear brake:
Type:
Mechanical leading trailing drum brake
Front suspension:
Type:Telescopic fork
Spring: Coil spring
Shock absorber:
Hydraulic damper
Wheel travel: 115 mm (4.5 in)
Rear suspension:
Type:
Swingarm
Spring: Coil spring
Shock absorber: Gas-hydraulic damper
Wheel travel:
110 mm (4.3 in)
Electrical system:
System voltage:12 V
Ignition system:
CDI
Charging system: AC magneto
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11-1
11
Index
A
Air filter element, cleaning .................... 7-10
B
Battery .................................................. 7-27
Brake lever ............................................. 4-2
Brake lever, checking and
lubricating .......................................... 7-24
Brake lever free play, adjusting ............ 7-18
Brake pedal ............................................ 4-3
Brake pedal, checking and lubricating .......................................... 7-24
Brake pedal free play, adjusting........... 7-19
Brake shoes, checking ......................... 7-20
C
Cables, checking and lubricating ......... 7-23
Carburetor, adjusting ........................... 7-13
Care ........................................................ 8-1
Clutch free play, adjusting ................... 7-18
D
Drive chain, cleaning and lubricating ... 7-22
Drive chain slack .................................. 7-21
E
Engine break-in ...................................... 6-3
Engine idling speed .............................. 7-14
Engine oil ................................................ 7-8
Engine serial number............................ 10-1
Engine, starting a warm ......................... 6-2
Engine stop switch ................................. 4-1
F
Front fork, checking ............................. 7-26
Fuel......................................................... 4-4
Fuel cock ................................................ 4-6
Fuel tank breather hose ......................... 4-5
Fuel tank cap.......................................... 4-3
Fuse, replacing ..................................... 7-29
H
Handlebar switches................................ 4-1
I
Identification numbers.......................... 10-1
K
Kickstarter .............................................. 4-7
L
Labels, location ...................................... 1-1
M
Main switch ............................................ 4-1
Maintenance and lubrication, periodic ... 7-4
Maintenance, emission control
system.................................................. 7-3
Matte color, caution ............................... 8-1
Model label ........................................... 10-1
P
Panels, removing and installing .............. 7-6
Parking .................................................... 6-4
Part locations .......................................... 3-1
S
Safety information................................... 2-1
Seat......................................................... 4-8
Shifting .................................................... 6-2
Shift pedal............................................... 4-2
Shift pedal, checking ............................ 7-20
Shock absorber assembly ...................... 4-8
Sidestand ................................................ 4-9
Sidestand, checking and lubricating .... 7-25
Spark arrester, cleaning ........................ 7-12
Spark plug, checking .............................. 7-7
Specifications ......................................... 9-1
Starter (choke) lever ................................ 4-7
Starting and warming up a cold engine ................................................... 6-1
Starting circuit cut-off system ................ 4-9
Start switch ............................................. 4-1
Steering, checking ................................ 7-26
Storage ................................................... 8-4
Supporting the motorcycle ................... 7-29
Swingarm pivots, lubricating ................ 7-25
T
Throttle grip and cable, checking and lubricating ........................................... 7-23
Throttle grip free play, checking ........... 7-15
Tires ...................................................... 7-16
Tool kit .................................................... 7-2
Troubleshooting .................................... 7-33
Troubleshooting chart........................... 7-34
V
Valve clearance..................................... 7-15
Vehicle Emission Control Information label (For Canada) .............................. 10-2
Vehicle identification number ............... 10-1
W
Wheel bearings, checking..................... 7-27
Wheel (front).......................................... 7-30
Wheel (rear) ........................................... 7-31
Wheels .................................................. 7-17
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