2009 YAMAHA TTR110 maintenance

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 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 regulationsbefore 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 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.
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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 .................. 4-2OPERATION 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 ....... 6-16Adjusting 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
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INSTRUMENT AND CONTROL FUNCTIONS
3-4
3
3. 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.
EAU41931
For CanadaNOTICE
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 research
octane number of 91 or higher. Ifknocking (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 cost.
Gasohol
There are two types of gasohol: gaso-
hol containing ethanol and that contain-
ing methanol. Gasohol containing
ethanol can be used if ethanol content
does not exceed 10% (E10). Gasohol
containing methanol is not recom-
mended by Yamaha because it can
cause damage to the fuel system or ve-
hicle performance problems.
For Europe, Oceania and South Afri-
ca
1. Fuel tank filler tube
2. Fuel level
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)
Recommended fuel:
For Europe: REGULAR UNLEADED
GASOLINE ONLY
For Oceania and South Africa: UN-
LEADED 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)
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INSTRUMENT AND CONTROL FUNCTIONS
3-5
3
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 research octane number of
91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
EAU13412
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 al-
so.
The fuel cock has three positions:
OFF
With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.
1. Fuel tank breather hose
1
1. Arrow mark positioned over “OFF”
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
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.
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 inthis manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-1
6
EAU41951
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.
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 performservice.
WARNING
EWA15121
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 1-1 for more in-
formation about carbon monox-ide.
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
6-2
6
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, havea Yamaha dealer perform it for you.
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