Read this manual carefully before operating this vehicle. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ AUF RECYCLINGPAPIER GEDRUCKT PRINTED IN JAPAN 2012.07-0.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM Read this manual carefully before operating this vehicle.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM EAU46235 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. EC Declaration of Conformity conforming to Directive 2006/42/EC We, YAMAHA MOTOR CO., LTD.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM INTRODUCTION EAU41664 Congratulations on your purchase of the Yamaha TT-R110E/TT-R110ED. 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.
U5B685E0.book Page 2 Tuesday, July 10, 2012 5:06 PM INTRODUCTION 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. ● Weight of the rider should not exceed 60.0 kg (132 lb). AN IMPORTANT NOTE TO PARENTS: This motorcycle is not a toy.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM IMPORTANT MANUAL INFORMATION EAU10133 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING NOTICE TIP A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
U5B685E0.book Page 2 Tuesday, July 10, 2012 5:06 PM IMPORTANT MANUAL INFORMATION EAU10200 TT-R110E/TT-R110ED OWNER’S MANUAL ©2012 by Yamaha Motor Co., Ltd. 1st edition, June 2012 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM TABLE OF CONTENTS LOCATION OF IMPORTANT LABELS ............................................1-1 FOR YOUR SAFETY – PRE-OPERATION CHECKS ............. 5-1 SAFETY INFORMATION ..................2-1 OPERATION AND IMPORTANT RIDING POINTS ................................ 6-1 Starting and warming up a cold engine ......................................... 6-1 Starting a warm engine .................. 6-2 Shifting ...........................................
U5B685E0.book Page 2 Tuesday, July 10, 2012 5:06 PM TABLE OF CONTENTS Troubleshooting ............................7-32 Troubleshooting chart ...................7-33 MOTORCYCLE CARE AND STORAGE ..........................................8-1 Matte color caution .........................8-1 Care ................................................8-1 Storage ...........................................8-3 SPECIFICATIONS .............................9-1 CONSUMER INFORMATION...........10-1 Identification numbers ....
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM LOCATION OF IMPORTANT LABELS EAU48115 Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.
U5B685E0.book Page 2 Tuesday, July 10, 2012 5:06 PM LOCATION OF IMPORTANT LABELS For Canada 1 2 INFORMATION SUR LES PNEUS La pression des pneus à froid doit normalement être réglée comme suit. AVANT : 100kPa, {1.00kgf/cm2}, 15psi ARRIERE : 100kPa, {1.00kgf/cm2}, 15psi 3RV-21668-A0 4 VAC • NS ANADA • •C 506 T RA T 3 NSPO TIRE INFORMATION Cold tire normal pressure should be set as follows. FRONT : 100kPa, {1.00kgf/cm2}, 15psi REAR : 100kPa, {1.
U5B685E0.book Page 3 Tuesday, July 10, 2012 5:06 PM LOCATION OF IMPORTANT LABELS For Canada 5 6 1 3PT-2118K-A1 7 This spark ignition system meets all requirements of the Canadian Interference Causing Equipment Regulations. Ce système d’allumage par étincelle de véhicule respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada. 8 3JK-82377-00 THIS VEHICLE IS A RESTRICTED USE MOTORCYCLE AND IS NOT INTENDED FOR USE ON PUBLIC HIGHWAYS.
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U5B685E0.book Page 5 Tuesday, July 10, 2012 5:06 PM LOCATION OF IMPORTANT LABELS For Europe 1 2 EN16029 2012 1 TT-R110E 5.4 kW 72 kg 5B6-2156A-10 YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN 5B6-2817L-00 3 4 100 kPa 100 kPa 1.00 kgf/cm² 1.
U5B685E0.book Page 6 Tuesday, July 10, 2012 5:06 PM LOCATION OF IMPORTANT LABELS Familiarize yourself with the following pictograms and read the explanatory text. 1 Read the Owner’s manual. Never use on paved roads. Always use an approved helmet and protective gear. Never carry passengers. Use from 6 years old. Operation of this motorcycle by children under the age of 6 increase the risk of severe injury or death. This unit contains highpressure nitrogen gas. Mishandling can cause an explosion.
U5B685E0.book Page 7 Tuesday, July 10, 2012 5:06 PM LOCATION OF IMPORTANT LABELS Use unleaded gasoline only. 1 1 **** YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN Measure the tire pressure when the tires are cold. **.* kPa *.** kgf/cm² *.* psi **.* kPa *.** kgf/cm² *.* psi 1 ****** *** kW *** kg 2 3 Adjust the tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or death. 1 Model Name 2 Max.
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U5B685E0.book Page 9 Tuesday, July 10, 2012 5:06 PM LOCATION OF IMPORTANT LABELS For Oceania and South Africa 1 2 TIRE INFORMATION 1 Cold tire normal pressure should be set as follows. FRONT : 100kPa, {1.00kgf/cm2}, 15psi REAR : 100kPa, {1.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM SAFETY INFORMATION EAU4121B 2 Be a Responsible Owner As the vehicle’s owner, you are responsible for the safe and proper operation of your motorcycle. 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.
U5B685E0.book Page 2 Tuesday, July 10, 2012 5:06 PM SAFETY INFORMATION ● ● ● ● Many accidents involve inexperienced operators. • Make sure that you are qualified and that you only lend your motorcycle to other qualified operators. • Know your skills and limits. Staying within your limits may help you to avoid an accident. • We recommend that you practice riding your motorcycle until you have become thoroughly familiar with the motorcycle and all of its controls.
U5B685E0.book Page 3 Tuesday, July 10, 2012 5:06 PM SAFETY INFORMATION ● 2 ● ● Do not run engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels. Do not run engine in poorly ventilated or partially enclosed areas such as barns, garages, or carports. Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors.
U5B685E0.book Page 4 Tuesday, July 10, 2012 5:06 PM SAFETY INFORMATION ucts 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 “Loading” when mounting accessories.
U5B685E0.book Page 5 Tuesday, July 10, 2012 5:06 PM SAFETY INFORMATION ● 2 cation for the straps carefully so the straps will not rub against painted surfaces during transport. The suspension should be compressed somewhat by the tiedowns, if possible, so that the motorcycle will not bounce excessively during transport.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM DESCRIPTION EAU10410 Left view 1 2 3 4 3 8 1. 2. 3. 4. 5. 6. 7. 8.
U5B685E0.book Page 2 Tuesday, July 10, 2012 5:06 PM DESCRIPTION EAU10420 Right view 1 2 3 4 3 8 1. 2. 3. 4. 5. 6. 7. 8.
U5B685E0.book Page 3 Tuesday, July 10, 2012 5:06 PM DESCRIPTION EAU10430 Controls and instruments 1 2 3 4 3 6 1. 2. 3. 4. 5. 6.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM INSTRUMENT AND CONTROL FUNCTIONS EAU40340 Main switch EWA10072 EAU1234B Handlebar switches WARNING 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 control or an accident. Left 4 The main switch controls the ignition system. The main switch positions are described below. 1.
U5B685E0.book Page 2 Tuesday, July 10, 2012 5:06 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12660 Engine stop switch “ / ” Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck. EAU39851 Shift pedal EAU12891 Brake lever 1 EAU12711 Start switch “ ” Push this switch to crank the engine with the starter. See page 6-1 for starting instructions prior to starting the engine.
U5B685E0.book Page 3 Tuesday, July 10, 2012 5:06 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal EAU13182 Fuel tank cap EAU13212 Fuel Make sure there is sufficient gasoline in the tank. EWA10881 WARNING Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions. 1 4 1. Brake pedal 1. Fuel tank cap The brake pedal is on the right side of the motorcycle.
U5B685E0.book Page 4 Tuesday, July 10, 2012 5:06 PM INSTRUMENT AND CONTROL FUNCTIONS ately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. EAU50251 For Canada 1. Fuel tank filler tube 2. Maximum fuel level 3. Wipe up any spilled fuel immediately. NOTICE: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. [ECA10071] 4.
U5B685E0.book Page 5 Tuesday, July 10, 2012 5:06 PM INSTRUMENT AND CONTROL FUNCTIONS ECA11400 NOTICE 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. 4 Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane number of 95 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel.
U5B685E0.book Page 6 Tuesday, July 10, 2012 5:06 PM INSTRUMENT AND CONTROL FUNCTIONS or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10% (E10).
U5B685E0.book Page 7 Tuesday, July 10, 2012 5:06 PM INSTRUMENT AND CONTROL FUNCTIONS ON 4 This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first opportunity. Be sure to set the lever back to “ON” after refueling! EAU13590 Starter (choke) lever “ ” 1. Arrow mark positioned over “ON” 1. Starter (choke) lever “ With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.
U5B685E0.book Page 8 Tuesday, July 10, 2012 5:06 PM INSTRUMENT AND CONTROL FUNCTIONS EAU37650 Kickstarter EAU46282 1 Seat 1 To remove the seat Remove the bolts, and then slide the seat to the rear and pull upward. 2 3 1. Slot 2. Projection 3. Seat holder 1. Kickstarter lever If the engine fails to start by pushing the start switch, try to start it by using the kickstarter.
U5B685E0.book Page 9 Tuesday, July 10, 2012 5:06 PM INSTRUMENT AND CONTROL FUNCTIONS EAU46021 Shock absorber assembly EWA10221 WARNING 4 This shock absorber assembly contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber assembly. ● Do not tamper with or attempt to open the cylinder assembly. ● Do not subject the shock absorber assembly to an open flame or other high heat source.
U5B685E0.book Page 10 Tuesday, July 10, 2012 5:06 PM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Make sure that the engine stop switch is set to “ 2. Turn the key to “ON”. 3. Shift the transmission into gear. 4. Keep the front or rear brake applied. 5. Push the start switch. Does the engine start? NO WARNING ”. If a malfunction is noted, have a Yamaha dealer check the system before riding. 4 The neutral switch may not be working correctly.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM FOR YOUR SAFETY – PRE-OPERATION CHECKS EAU15596 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. EWA11151 WARNING 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.
U5B685E0.book Page 2 Tuesday, July 10, 2012 5:06 PM FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM CHECKS PAGE Control cables • Make sure that operation is smooth. • Lubricate if necessary. Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. 7-21, 7-22 Wheels and tires • • • • Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. 7-15, 7-17 Shift pedal • Make sure that operation is smooth.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM OPERATION AND IMPORTANT RIDING POINTS EAU15951 Read the Owner’s Manual carefully to become familiar with all controls. If there is a control or function you do not understand, ask your Yamaha dealer. EWA10271 WARNING Failure to familiarize yourself with the controls can lead to loss of control, which could cause an accident or injury. EAU44814 Starting and warming up a cold engine 1. Turn the fuel cock lever to “ON”. 2.
U5B685E0.book Page 2 Tuesday, July 10, 2012 5:06 PM OPERATION AND IMPORTANT RIDING POINTS EAU16640 Starting a warm engine EAU39901 Shifting Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. ECA15441 NOTICE ● 4 3 2 1 2 1 1. Shift pedal 2. Neutral position ● This motorcycle has a 4-speed transmission with a centrifugal, automatic clutch.
U5B685E0.book Page 3 Tuesday, July 10, 2012 5:06 PM OPERATION AND IMPORTANT RIDING POINTS 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. EAU16710 6 To decelerate 1. Close the throttle and apply both the front and the rear brakes to slow the motorcycle. 2.
U5B685E0.book Page 4 Tuesday, July 10, 2012 5:06 PM OPERATION AND IMPORTANT RIDING POINTS EAU17171 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. EWA10311 WARNING ● ● ● Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them and be burned.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17244 EWA15122 EAU17302 WARNING 7 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 important points of vehicle inspection, adjustment, and lubrication are explained on the following pages.
U5B685E0.book Page 2 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT 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. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.
U5B685E0.book Page 3 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU39944 Periodic 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. INITIAL No.
U5B685E0.book Page 4 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU3534C General maintenance and lubrication 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. INITIAL No.
U5B685E0.book Page 5 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL No. ITEM CHECKS AND MAINTENANCE JOBS 1000 km (600 mi) or 1 month or 30 hours 8 Drive chain • Check chain slack/alignment and condition. • Adjust and lubricate chain with Yamaha chain and cable lube thoroughly. 9 * Steering bearings • Check bearing assemblies for looseness. • Moderately repack with lithium-soap-based grease. √ 10 * Chassis fasteners • Check all chassis fitting and fasteners.
U5B685E0.book Page 6 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU40000 TIP The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
U5B685E0.book Page 7 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU18771 Removing and installing panels 1 2 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. 3 3 1 1 1. Panel B EAU41110 Panel A 7 1. Panel A To remove the panel 1. Remove the seat. (See page 4-8.) 2. Remove the bolts and the quick fastener screws, and then take the panel off. 1.
U5B685E0.book Page 8 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU19604 2 1 Checking the spark plug 3 1. Panel B 2. Bolt 3. Projection To install the panel 1. Place the panel in the original position, and then install the bolt. 2. Install the seat. The spark plug is an important engine component, which is easy to check.
U5B685E0.book Page 9 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/CR6HSA 3. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. To install the spark plug 1. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 2.
U5B685E0.book Page 10 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT 1 3. Remove the engine oil filler cap, the engine oil drain bolt and its gasket to drain the oil from the crankcase. 2 2 1 ECA11620 NOTICE ● 3 4 1. 2. 3. 4. Recommended engine oil: See page 9-1. Oil change quantity: 0.80 L (0.85 US qt, 0.70 Imp.qt) Engine oil filler cap Engine oil dipstick Maximum level mark Tip of the engine oil dipstick 4.
U5B685E0.book Page 11 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU41637 Cleaning the air filter element The air filter element should be cleaned or replaced at the intervals specified in the periodic maintenance and lubrication chart. Clean or, if necessary, replace the air filter element more frequently if you are riding in unusually wet or dusty areas. To clean the air filter element 1. Remove panel A. (See page 7-7.) 2. Remove the air filter case cover by removing the screws.
U5B685E0.book Page 12 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT 2. If dirt or water is visible, remove the hoses, clean them, and then reinstall them. mesh and the sponge material installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn. 1 [ECA15572] 2 1 1. Spark plug lead 2. Guide 9. Install the panel. 8. Install the air filter case cover by installing the screws. TIP Make sure that the spark plug lead is inserted into the guide as shown.
U5B685E0.book Page 13 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT 3. Insert the tailpipe into the muffler, and then install and tighten the bolts to the specified torque. EAU40421 Cleaning the spark arrester The spark arrester should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. EWA10980 WARNING ● ● Always let the exhaust system cool prior to touching exhaust components. Do not start the engine when cleaning the exhaust system.
U5B685E0.book Page 14 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU39930 Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment described in the following section, however, may be serviced by the owner as part of routine maintenance.
U5B685E0.book Page 15 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU21384 Checking the throttle grip free play 1 EAU21401 Tires The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. Tires are the only contact between the vehicle and the road.
U5B685E0.book Page 16 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT Standard tire air pressure: Front: 100 kPa (1.00 kgf/cm², 15 psi) Rear: 100 kPa (1.00 kgf/cm², 15 psi) Tire inspection 2 Tire information This motorcycle is equipped with spoke wheels and tube tires. Tires age, even if they have not been used or have only been used occasionally. Cracking of the tread and sidewall rubber, sometimes accompanied by carcass deformation, is an evidence of ageing.
U5B685E0.book Page 17 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT ● 7 very carefully and replace it as soon as possible with a highquality product. Ride conservatively after changing a tire since the tire must seat itself on the rim properly. Failure to allow proper seating may cause tire failure, which may result in damage to the motorcycle and injury to the rider. EAU21943 Spoke wheels EWA10610 WARNING The wheels on this model are not designed for use with tubeless tires.
U5B685E0.book Page 18 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU44884 TIP When tightening the locknut, hold the clutch adjusting screw with a screwdriver so that it does not turn together with the locknut. Adjusting the brake lever free play 1 2 3 4 (b) (a) 1. 2. 3. 4. Rubber cover Brake lever free play adjusting bolt Locknut Brake lever free play The brake lever free play should measure 10.0–20.0 mm (0.39–0.79 in) as shown.
U5B685E0.book Page 19 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU44671 Adjusting the brake pedal free play (a) (b) EWA14820 WARNING ● 2 1 ● 1. Locknut 2. Brake lever free play adjusting bolt 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. 7 1. Brake pedal free play adjusting nut 2. Brake pedal free play The brake pedal free play should measure 10.0–20.0 mm (0.39–0.
U5B685E0.book Page 20 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU44820 Checking the shift pedal The operation of the shift pedal should be checked before each ride. If operation is not smooth, have a Yamaha dealer check the vehicle. EAU22361 Checking the front and rear brake shoes Front 1 2 1. Brake shoe wear indicator 2.
U5B685E0.book Page 21 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. EAU22774 To check the drive chain slack 1. Place the motorcycle on the sidestand. TIP When checking and adjusting the drive chain slack, there should be no weight on the motorcycle. 7 2. Shift the transmission into the neutral position. 3. Measure the drive chain slack as shown. Drive chain slack: 40.0–56.
U5B685E0.book Page 22 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT 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 forward. NOTICE: Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits.
U5B685E0.book Page 23 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23114 EAU23095 Checking and lubricating the cables Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.
U5B685E0.book Page 24 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23183 Checking and lubricating the brake pedal EAU23202 EAUM1652 Checking and lubricating the sidestand Lubricating the swingarm pivots The operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-to-metal contact surfaces should be lubricated if necessary.
U5B685E0.book Page 25 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23272 EAU23283 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1.
U5B685E0.book Page 26 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23291 Checking the wheel bearings EAU23396 Battery 2 3 1 The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 1. Battery coupler 2. Battery band 3. Battery The battery is located behind panel B. (See page 7-7.
U5B685E0.book Page 27 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories. ECA16521 NOTICE ECA16530 Replacing the fuse Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. The fuse is located inside the battery coupler. (See page 7-26.
U5B685E0.book Page 28 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT avoid causing extensive damage to the electrical system and possibly a fire. [EWA15131] Specified fuse: 10.0 A 4. Connect the battery coupler. 5. Turn the key to “ON”. 6. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.
U5B685E0.book Page 29 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT 7. Remove the brake shoe assembly from the wheel hub by pulling it out. EAU24360 Front wheel EAU41815 To remove the front wheel 1 EWA10821 WARNING To avoid injury, securely support the vehicle so there is no danger of it falling over. 1. Slide the rubber cover back at the brake lever. 2. Loosen the locknut, and then turn the brake lever free play adjusting bolt fully in direction (a). 7 1 2 3 1. Axle nut 2.
U5B685E0.book Page 30 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT 2 7. While applying the front brake, push down hard on the handlebar several times to check for proper fork operation. EAU25080 Rear wheel EAU41645 To remove the rear wheel EWA10821 WARNING 1 To avoid injury, securely support the vehicle so there is no danger of it falling over. 1. Slot 2. Retainer 1. Disconnect the brake torque rod from the brake shoe plate by removing the cotter pin, the nut and the bolt.
U5B685E0.book Page 31 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT 2. Remove the brake pedal free play adjusting nut, and then disconnect the brake rod at the brake camshaft lever. 1. 2. 3. 4. 7 Brake rod Brake pedal free play adjusting nut Brake camshaft lever Wheel axle 3. Fully loosen the locknut and the drive chain slack adjusting nut on both ends of the swingarm. 4 1 1. 2. 3. 4. 5. 2 3 5 Axle nut Washer Drive chain puller Drive chain slack adjusting nut Locknut 4.
U5B685E0.book Page 32 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT 4. Lower the rear wheel so that it is on the ground, and then put the sidestand down. 5. Install the brake rod onto the brake camshaft lever, and then install the brake pedal free play adjusting nut onto the brake rod. 6. Connect the brake torque rod to the brake shoe plate by installing the bolt and nut, and then tighten the nut to the specified torque. Tightening torque: Brake torque rod nut: 26 Nm (2.
U5B685E0.book Page 33 Tuesday, July 10, 2012 5:06 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU25903 Troubleshooting chart 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start. Check the compression. 2. Compression Operate the electric starter. 3.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. EAU40465 Care ECA15192 NOTICE Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use before cleaning the vehicle.
U5B685E0.book Page 2 Tuesday, July 10, 2012 5:06 PM MOTORCYCLE CARE AND STORAGE ● ● 8 ● off any detergent residue using plenty of water, as it is harmful to plastic parts. Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
U5B685E0.book Page 3 Tuesday, July 10, 2012 5:06 PM MOTORCYCLE CARE AND STORAGE 8. Let the motorcycle dry completely before storing or covering it. EWA14501 WARNING EAU26152 TIP Consult a Yamaha dealer for advice on what products to use. Contaminants on the brakes or tires can cause loss of control. ● Make sure that there is no oil or wax on the tires. ● If necessary, wash the tires with warm water and a mild detergent.
U5B685E0.book Page 4 Tuesday, July 10, 2012 5:06 PM MOTORCYCLE CARE AND STORAGE 8 2. For motorcycles equipped with a fuel cock that has an “OFF” position: Turn the fuel cock lever to “OFF”. 3. Drain the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank. 4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating. 5.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM SPECIFICATIONS Dimensions: Overall length: 1565 mm (61.6 in) Overall width: 680 mm (26.8 in) Overall height: 923 mm (36.3 in) Seat height: 670 mm (26.4 in) Wheelbase: 1080 mm (42.5 in) Ground clearance: 180 mm (7.09 in) Minimum turning radius: 1660 mm (65.4 in) Weight: Curb weight: 72 kg (159 lb) Technical permissible mass (Maximum load + curb weight): 132 kg (291 lb) Displacement: 110 cm³ Bore × stroke: 51.0 × 54.0 mm (2.01 × 2.
U5B685E0.book Page 2 Tuesday, July 10, 2012 5:06 PM SPECIFICATIONS Transmission type: Constant mesh 4-speed Operation: Left foot operation Gear ratio: 1st: 3.166 (38/12) 2nd: 1.941 (33/17) 3rd: 1.380 (29/21) 4th: 1.095 (23/21) Chassis: Frame type: Backbone Caster angle: 26.00 ° Trail: 60 mm (2.4 in) Front tire: 9 Type: With tube Size: 2.50-14 4PR Manufacturer/model: CHEN SHIN/C-803-2 Speed rating: 120 km/h (75 mph) Rear tire: Type: With tube Size: 3.
U5B685E0.book Page 3 Tuesday, July 10, 2012 5:06 PM SPECIFICATIONS EAU51131 For Europe only The figures quoted are emission levels and are not necessarily safe working levels. Whilst there is a correlation between the emission and exposure levels, this cannot be used reliably to determine whether or not further precautions are required. Factors that influence the actual level of exposure of work-force include the characteristics of the work room, the other sources of noise, etc. i.e.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM CONSUMER INFORMATION EAU40792 Identification numbers EAU26400 Vehicle identification number Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. EAU36980 Model label 1 1 VEHICLE IDENTIFICATION NUMBER: MODEL LABEL INFORMATION: 1. Vehicle identification number 1.
U5B685E0.book Page 2 Tuesday, July 10, 2012 5:06 PM CONSUMER INFORMATION EAU48120 Vehicle Emission Control Information label (For Canada) 1 1. Vehicle Emission Control Information label The Vehicle Emission Control Information label is affixed at the location in the illustration. This label shows specifications related to exhaust emissions as required by federal law, state law and Environment Canada.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM INDEX A H Air filter element, cleaning..................... 7-11 B Battery................................................... 7-26 Brake lever.............................................. 4-2 Brake lever, checking and lubricating ... 7-23 Brake lever free play, adjusting............. 7-18 Brake pedal............................................. 4-3 Brake pedal, checking and lubricating ...........................................
U5B685E0.
U5B685E0.book Page 1 Tuesday, July 10, 2012 5:06 PM EAU53771 WARNING Improper motorcycle use can result in SEVERE INJURY or DEATH. ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PAVED ROADS NEVER operate: • without proper training or instruction. • at speeds too fast for your skills or the conditions. • on public roads—a collision can occur with another vehicle. • with a passenger—passengers affect balance and steering and increase risk of losing control.