2015 YAMAHA TT-R110E engine

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...................4-6
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 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 ............... 7-20
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 ................................. 7-23
Checking and lubricating the brake pedal ................................ 7-24
Checking and lubricating the sidestand ................................... 7-24
Lubricating the swingarm pivots ... 7-24
Checking the front fork ................. 7-25
Checking the steering ................... 7-25
Checking the wheel bearings ........ 7-26
Battery........................................... 7-26
Replacing the fuse ........................ 7-28
Supporting the motorcycle ........... 7-28
Front wheel ................................... 7-29
Rear wheel .................................... 7-31
UB5180E0.book Page 1 Monday, June 9, 2014 1:20 PM

SAFETY INFORMATION
2-2
2

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
ventilated areas. If you experience any
symptoms of carbon monoxide poi-
UB5180E0.book Page 2 Monday, June 9, 2014 1:20 PM

SAFETY INFORMATION
2-3
2soning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
 Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
 Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
 Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loa din g
Adding accessories to your motorcycle
can adversely affect stability and han-
dling if the weight distribution of the
motorcycle is changed. To avoid the
possibility of an accident, use extreme
caution when adding accessories to
your motorcycle. Use extra care when
riding a motorcycle that has added ac-
cessories. Here are some general
guidelines to follow if adding accesso-
ries to your motorcycle: Operation of an overloa
ded vehicle
coul d cause an acci dent.
 The weight of the operator must
not exceed 60.0 kg (132 lb).
 Accessory weight should be kept
as low and close to the motorcy-
cle as possible. Securely pack
your heaviest items as close to the
center of the vehicle as possible
and make sure to distribute the
weight as evenly as possible on
both sides of the motorcycle to
minimize imbalance or instability.
 Shifting weights can create a sud-
den imbalance. Make sure that
accessories are securely attached
to the motorcycle before riding.
Check accessory mounts fre-
quently.
• Properly adjust the suspension for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
• Never attach any large or heavy items to the handlebar, front
fork, or front fender. Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail- able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection
to Yamaha manufacture parts and ac-
cessories or offer other modifications
for Yamaha vehicles. Yamaha is not in
a position to test the products that
these aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories, an d
Mo difications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accesso-
ries or modifications are not suitable
because of potential safety hazards to
you or others. Installing aftermarket
UB5180E0.book Page 3 Monday, June 9, 2014 1:20 PM

SAFETY INFORMATION
2-4
2
products or having other modifications
performed to your vehicle that change
any of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or
death. You are responsible for injuries
related to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
 Never install accessories that
would impair the performance of
your motorcycle. Carefully inspect
the accessory before using it to
make sure that it does not in any
way reduce ground clearance or
cornering clearance, limit suspen-
sion travel, steering travel or con-
trol operation.
• Accessories fitted to the han- dlebar or the front fork area can
create instability due to improp-
er weight distribution. If acces-
sories are added to the
handlebar or front fork area,
they must be as lightweight as
possible and should be kept to
a minimum. • Bulky or large accessories may
seriously affect the stability of
the motorcycle. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become
unstable in cross winds.
• Certain accessories can dis- place the operator from his or
her normal riding position. This
improper position limits the
freedom of movement of the
operator and may limit control
ability, therefore, such accesso-
ries are not recommended.
 Use caution when adding electri-
cal accessories. If electrical ac-
cessories exceed the capacity of
the motorcycle’s electrical sys-
tem, an electric failure could re-
sult, which could cause a
dangerous loss of lights or engine
power.
Aftermarket Tires an d Rims
The tires and rims that came with your
motorcycle were designed to match
the performance capabilities and to
provide the best combination of han-
dling, braking, and comfort. Other tires, rims, sizes, and combinations
may not be appropriate. Refer to page
7-15 for tire specifications and more in-
formation on replacing your tires.
Transportin
g the Motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.  Remove all loose items from the
motorcycle.
 Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.
 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
UB5180E0.book Page 4 Monday, June 9, 2014 1:20 PM

DESCRIPTION
3-1
3
EAU10411
Left view
678
123 4
5
1. Fuel cock (page 4-6)
2. Starter (choke) lever (page 4-7)
3. Fuse (page 7-28)
4. Battery (page 7-26)
5. Clutch adjusting screw (page 7-17)
6. Engine oil drain bolt (page 7-9)
7. Shift pedal (page 4-2)
8. Throttle stop screw (page 7-14)
UB5180E0.book Page 1 Monday, June 9, 2014 1:20 PM

DESCRIPTION
3-2
3
EAU10421
Right view
12 3 4
85 7
6
1. Spark arrester (page 7-13)
2. Seat (page 4-8)
3. Fuel tank cap (page 4-3)
4. Air filter element (page 7-11)
5. Spark plug cap (page 7-8)
6. Engine oil filler cap (page 7-9)
7. Brake pedal (page 4-3)
8. Kickstarter (page 4-7)UB5180E0.book Page 2 Monday, June 9, 2014 1:20 PM

DESCRIPTION
3-3
3
EAU10431
Controls and instruments
123 4
5
1. Engine stop switch (page 4-1)
2. Main switch (page 4-1)
3. Start switch (page 4-1)
4. Brake lever (page 4-2)
5. Throttle grip (page 7-15)
UB5180E0.book Page 3 Monday, June 9, 2014 1:20 PM

INSTRUMENT AND CONTROL FUNCTIONS
4-1
4
EAU40341
Main switchThe main switch controls the ignition
system. The main switch positions are
described below.
EAU10631
ON
All electrical systems are supplied with
power, and the engine can be started.
The key cannot be removed.
EAU45752
OFF
All electrical systems are off. The key
can be removed.
WARNING
EWA10073
Never turn the key to “OFF” while
the vehicle is moving, otherwise the
electrical systems will be switched
off, which may result in loss of con-
trol or an acci dent.
EAU1234H
Han dle bar switchesLeft
Ri ght 1. Engine stop switch “ / ”
1. Start switch “ ”
1
UB5180E0.book Page 1 Monday, June 9, 2014 1:20 PM