TTR 110 Owners Service Manual - The Motocross Life

DIC183

B51-28199-80

TT-R110ETT-R110EF

OWNER’S MANUALMANUEL DU PROPRIÉTAIRE

BEDIENUNGSANLEITUNG

Il convient de lire attentivement ce manuel avant la pre-

mière utilisation du véhicule.

Bitte lesen Sie diese Bedienungsanleitung sorgfältig

durch, bevor Sie das Fahrzeug in Betrieb nehmen.

Read this manual carefully before operating this vehicle.

PRINTED IN JAPAN2014.06-0.8×1 CR

(E,F,G)

DIC183

PRINTED ON RECYCLED PAPERIMPRIMÉ SUR PAPIER RECYCLÉAUF RECYCLINGPAPIER GEDRUCKT

Original instructionsNotice originale

Originalbetriebsanleitung

Read this manual carefully before operating this vehicle.

OWNER’S MANUAL

TT-R110ETT-R110EF

B51-28199-80-E0

UB5180E0.book Page 1 Monday, June 9, 2014 1:20 PM

EAU46238

Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.

EC Declaration of Conformityconforming to Directive 98/37/EC, 2006/42/EC

We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan,declare in sole responsibility, that the product

TT-R110E (JYACE17W000008398– )(Make, model)

2004/108/EC(Title and/or number and date of issue of the other Directives of EEC)

to which this declaration applies, conforms to the essential healthand safety requirements of Directive 98/37/EC, 2006/42/EC

(If applicable)

and to the other relevant Directives of EEC

(If applicable)

To effect correct application of the essential health and safety requirementsstated in the Directives of EEC, the following-standards and/or technicalspecifications were consulted:

(Title and/or number and date of issue of standards and/or specifications)

Authorized RepresentativeYAMAHA MOTOR EUROPE N.V.

Koolhovenlaan 101, 1119 NC Schiphol-Rijk, The Netherlands

SignatureToshiharu Shigeta

– –

Date of Issue 18 April , 2014

Division ManagerMotorcycle HeadquartersPF Development Operations


INTRODUCTION

EAU41665

Congratulations on your purchase of the Yamaha TT-R110E/TT-R110EF. This model is the result of Yamaha’s vast experi-ence in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of crafts-manship 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 youhave 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 applicableat the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operationof the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attentionto 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 andthis manual. If there is any question concerning this manual, please consult a Yamaha dealer.

WARNING

EWA10032

Please read this manual carefully and completely before operating this motorcycle.

WARNING

EWA14352

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 regulations

before operating this motorcycle.

WARNING

EWA16291

This vehicle is not suitable for novice riders. This vehicle shall only be used by trained and experienced riders.


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. 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’suse of the motorcycle at all times. Parents should permit continued use only if they determine that the child has the abilityto 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.


IMPORTANT MANUAL INFORMATION

EAU10134

Particularly important information is distinguished in this manual by the following notations:

*Product and specifications are subject to change without notice.

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.

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

WARNING

NOTICE

TIP


IMPORTANT MANUAL INFORMATION

EAU10201

TT-R110E/TT-R110EFOWNER’S MANUAL

©2014 by Yamaha Motor Co., Ltd.1st edition, May 2014

All rights reserved.Any reprinting or unauthorized use without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

Printed in Japan.


TABLE OF CONTENTS

LOCATION OF IMPORTANT

LABELS ..............................................1-1

SAFETY INFORMATION ...................2-1

DESCRIPTION ...................................3-1Left view ..........................................3-1Right view........................................3-2Controls and instruments ................3-3

INSTRUMENT AND CONTROL

FUNCTIONS.......................................4-1Main switch .....................................4-1Handlebar switches.........................4-1Shift pedal .......................................4-2Brake lever ......................................4-2Brake pedal .....................................4-3Fuel tank cap...................................4-3Fuel..................................................4-3Fuel tank breather hose...................4-6Fuel cock.........................................4-6Starter (choke) lever .......................4-7Kickstarter .......................................4-7Seat .................................................4-8Shock absorber assembly...............4-8Sidestand ........................................4-9Starting circuit cut-off system.........4-9

FOR YOUR SAFETY –

PRE-OPERATION CHECKS ............. 5-1

OPERATION AND IMPORTANT

RIDING POINTS ................................ 6-1Starting and warming up a cold

engine.......................................... 6-1Starting a warm engine................... 6-2Shifting............................................ 6-2Engine break-in............................... 6-3Parking............................................ 6-4

PERIODIC MAINTENANCE AND

ADJUSTMENT .................................. 7-1Owner’s tool kit............................... 7-2Periodic maintenance chart for the

emission control system ............. 7-3General maintenance and

lubrication chart .......................... 7-4Removing and installing panels ...... 7-7Checking the spark plug................. 7-8Engine oil ........................................ 7-9Cleaning the air filter element ....... 7-11Cleaning the spark arrester .......... 7-13Adjusting the carburetor ............... 7-14Adjusting the engine idling

speed......................................... 7-14Checking the throttle grip free

play............................................ 7-15Valve clearance............................. 7-15Tires .............................................. 7-15

Spoke wheels................................7-17Adjusting the clutch free play........7-17Adjusting the brake lever free

play ............................................7-18Adjusting the brake pedal free

play ............................................7-19Checking the shift pedal ...............7-20Checking the front and rear brake

shoes .........................................7-20Drive chain slack ...........................7-21Cleaning and lubricating the drive

chain ..........................................7-22Checking and lubricating the

cables ........................................7-23Checking and lubricating the

throttle grip and cable ...............7-23Checking and lubricating the

brake lever .................................7-23Checking and lubricating the

brake pedal ................................7-24Checking and lubricating the

sidestand ...................................7-24Lubricating the swingarm pivots ...7-24Checking the front fork .................7-25Checking the steering ...................7-25Checking the wheel bearings........7-26Battery...........................................7-26Replacing the fuse ........................7-28Supporting the motorcycle ...........7-28Front wheel ...................................7-29Rear wheel ....................................7-31


TABLE OF CONTENTS

Troubleshooting............................ 7-32Troubleshooting chart .................. 7-34

MOTORCYCLE CARE AND

STORAGE.......................................... 8-1Matte color caution ........................ 8-1Care ................................................ 8-1Storage........................................... 8-3

SPECIFICATIONS ............................. 9-1

CONSUMER INFORMATION ......... 10-1Identification numbers.................. 10-1

INDEX .............................................. 11-1


LOCATION OF IMPORTANT LABELS

1-1

1EAU48116

Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation ofyour vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacementlabel is available from your Yamaha dealer.

For Canada

1,2 3 5,6,7,84



1-2

1For Canada

•CM

VS

S

• CANADA • NSVA

C•

TRANSPORT

506

2

4

1

3

Cold tire normal pressure should be set asfollows.FRONT : 100kPa, {1.00kgf/cm2}, 15psiREAR : 100kPa, {1.00kgf/cm2}, 15psi

3RV-21668-A0

TIRE INFORMATIONLa pression des pneus à froid doit normalementêtre réglée comme suit.AVANT : 100kPa, {1.00kgf/cm2}, 15psiARRIERE : 100kPa, {1.00kgf/cm2}, 15psi

3RV-21668-B0

INFORMATION SUR LES PNEUS



1-3

1For Canada

3JK-82377-00

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.

THIS VEHICLE IS A RESTRICTED USEMOTORCYCLE AND IS NOT INTENDED FORUSE ON PUBLIC HIGHWAYS.CE VÉHICULE EST UNE MOTOCYCLETTE ÀUSAGE RESTREINT DONT L’USAGE N’EST PASDESTINÉ AUX VOIES PUBLIQUES.

3PT-2416E-10

3PT-2118K-A1

5 6

87



1-4

1For Europe

41,2 53



1-5

1For Europe

5PG-2816R-00

100 kPa1.00 kgf/cm² 15 psi

100 kPa1.00 kgf/cm² 15 psi

4AA-22259-40

5B6-2156A-10

TT-R110E5.4 kW 72 kg

5B6-2816R-00

5B6-2817L-00

YAMAHA MOTOR CO., LTD.2500 SHINGAI, IWATA, JAPAN

2014EN16029

1

5

2

43



1-6

1Familiarize yourself with the following pictograms and read the explanatory text.

Read the Owner’s manual.

Always use an approved helmet and protective gear.

Never use on paved roads.

Use from 6 years old.Operation of this motorcycle by children under the age of 6 increase the risk of severe injury or death.

Never carry passengers.

Adult supervision required for children.

This unit contains high-pressure nitrogen gas.Mishandling can cause an explosion. Do not incinerate, puncture or open.

Turn off the main switch after riding to avoid draining the battery.



1-7

1

**.* kPa*.** kgf/cm²*.* psi

**.* kPa*.** kgf/cm²*.* psi

********* kW *** kg

1

2 3

YAMAHA MOTOR CO., LTD.2500 SHINGAI, IWATA, JAPAN

****

1Use unleaded gasoline only.

Measure the tire pressure when the tires are cold.

Adjust the tire pressure.Improper tire pressure can cause loss of control.Loss of control can result in severe injury or death.

1

2

3

Model Name

Max. Power

Mass In Running Order

1 Year of construction



1-8

1For Oceania and South Africa

1 32



1-9

1For Oceania and South Africa

TIRE INFORMATIONCold tire normal pressure should be set asfollows.FRONT : 100kPa, {1.00kgf/cm2}, 15psiREAR : 100kPa, {1.00kgf/cm2}, 15psi

3RV-21668-A0

4AA-22259-40

3PT-2118K-A1

1 2

3


2-1

2

SAFETY INFORMATION

EAU4121C

Be a Responsible Owner

As the vehicle’s owner, you are re-sponsible for the safe and proper oper-ation of your motorcycle.Motorcycles are single-track vehicles.Their safe use and operation are de-pendent upon the use of proper ridingtechniques as well as the expertise ofthe operator. Every operator shouldknow the following requirements be-fore riding this motorcycle.He or she should: Obtain thorough instructions from

a competent source on all aspectsof motorcycle operation.

Observe the warnings and mainte-nance requirements in this Own-er’s Manual.

Obtain qualified training in safeand proper riding techniques.

Obtain professional technical ser-vice as indicated in this Owner’sManual and/or when made neces-sary by mechanical conditions.

Never operate a motorcycle with-out proper training or instruction.Take a training course. Beginnersshould receive training from a cer-tified instructor. Contact an autho-rized motorcycle dealer to find outabout the training courses nearestyou.

Safe Riding

Perform the pre-operation checkseach time you use the vehicle to makesure it is in safe operating condition.Failure to inspect or maintain the vehi-cle properly increases the possibility ofan accident or equipment damage.See page 5-1 for a list of pre-operationchecks. This motorcycle is designed for

off-road use only, therefore, it is il-legal to operate it on publicstreets, roads, or highways, evena dirt or gravel one. Off-road useon public lands may be illegal.Please check local regulations be-fore riding.

This motorcycle is designed tocarry the operator only. No pas-sengers.

The failure of motorists to detectand recognize motorcycles in traf-fic is the predominating cause ofautomobile/motorcycle accidents.Many accidents have beencaused by an automobile driverwho did not see the motorcycle.Making yourself conspicuous ap-pears to be very effective in reduc-ing the chance of this type ofaccident.Therefore:

• Wear a brightly colored jacket.• Use extra caution when you are

approaching and passingthrough intersections, since in-tersections are the most likelyplaces for motorcycle accidentsto occur.

• Ride where other motorists cansee you. Avoid riding in anothermotorist’s blind spot.

• Never maintain a motorcyclewithout proper knowledge.Contact an authorized motorcy-cle dealer to inform you on ba-sic motorcycle maintenance.Certain maintenance can onlybe carried out by certified staff.


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 mayhelp you to avoid an accident.

• We recommend that you prac-tice riding your motorcycle untilyou have become thoroughlyfamiliar with the motorcycle andall of its controls.

Many accidents have beencaused by error of the motorcycleoperator. A typical error made bythe operator is veering wide on aturn due to excessive speed or un-dercornering (insufficient lean an-gle for the speed). Never travelfaster than warranted by condi-tions.

Ride cautiously in unfamiliar ar-eas. You may encounter hiddenobstacles that could cause an ac-cident.

The posture of the operator is im-portant for proper control. The op-erator should keep both hands onthe handlebar and both feet on theoperator footrests during opera-tion to maintain control of the mo-torcycle.

Never ride under the influence ofalcohol 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 thesingle 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 eyescould contribute to an impairmentof vision that could delay seeing ahazard.

The use of a jacket, heavy boots,trousers, gloves, etc., is effectivein preventing or reducing abra-sions or lacerations.

Never wear loose-fitting clothes,otherwise they could catch on thecontrol levers, footrests, or wheelsand cause injury or an accident.

Always wear protective clothingthat covers your legs, ankles, andfeet. The engine or exhaust sys-tem become very hot during or af-ter operation and can causeburns.

Avoid Carbon Monoxide Poisoning

All engine exhaust contains carbonmonoxide, a deadly gas. Breathingcarbon 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 anyengine exhaust. Deadly levels of car-bon monoxide can collect rapidly andyou can quickly be overcome and un-able to save yourself. Also, deadly lev-els of carbon monoxide can linger forhours or days in enclosed or poorlyventilated areas. If you experience anysymptoms of carbon monoxide poi-


SAFETY INFORMATION

2-3

2

soning, leave the area immediately, getfresh air, and SEEK MEDICAL TREAT-MENT. Do not run engine indoors. Even if

you try to ventilate engine exhaustwith fans or open windows anddoors, carbon monoxide can rap-idly reach dangerous levels.

Do not run engine in poorly venti-lated or partially enclosed areassuch as barns, garages, or car-ports.

Do not run engine outdoors whereengine exhaust can be drawn intoa building through openings suchas windows and doors.

Loading

Adding accessories to your motorcyclecan adversely affect stability and han-dling if the weight distribution of themotorcycle is changed. To avoid thepossibility of an accident, use extremecaution when adding accessories toyour motorcycle. Use extra care whenriding a motorcycle that has added ac-cessories. Here are some generalguidelines to follow if adding accesso-ries to your motorcycle:

Operation of an overloaded vehicle

could cause an accident.

The weight of the operator mustnot exceed 60.0 kg (132 lb).

Accessory weight should be keptas low and close to the motorcy-cle as possible. Securely packyour heaviest items as close to thecenter of the vehicle as possibleand make sure to distribute theweight as evenly as possible onboth sides of the motorcycle tominimize imbalance or instability.

Shifting weights can create a sud-den imbalance. Make sure thataccessories are securely attachedto the motorcycle before riding.Check accessory mounts fre-quently.• Properly adjust the suspension

for your load (suspension-ad-justable models only), andcheck the condition and pres-sure of your tires.

• Never attach any large or heavyitems to the handlebar, frontfork, or front fender.

Genuine Yamaha Accessories

Choosing accessories for your vehicleis an important decision. GenuineYamaha accessories, which are avail-able only from a Yamaha dealer, havebeen designed, tested, and approvedby Yamaha for use on your vehicle.Many companies with no connectionto Yamaha manufacture parts and ac-cessories or offer other modificationsfor Yamaha vehicles. Yamaha is not ina position to test the products thatthese aftermarket companies produce.Therefore, Yamaha can neither en-dorse nor recommend the use of ac-cessories not sold by Yamaha ormodifications not specifically recom-mended by Yamaha, even if sold andinstalled by a Yamaha dealer.

Aftermarket Parts, Accessories, and

Modifications

While you may find aftermarket prod-ucts similar in design and quality togenuine Yamaha accessories, recog-nize that some aftermarket accesso-ries or modifications are not suitablebecause of potential safety hazards toyou or others. Installing aftermarket


SAFETY INFORMATION

2-4

2

products or having other modificationsperformed to your vehicle that changeany of the vehicle’s design or operationcharacteristics can put you and othersat greater risk of serious injury ordeath. You are responsible for injuriesrelated 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 ofyour motorcycle. Carefully inspectthe accessory before using it tomake sure that it does not in anyway reduce ground clearance orcornering clearance, limit suspen-sion travel, steering travel or con-trol operation.• Accessories fitted to the han-

dlebar or the front fork area cancreate instability due to improp-er weight distribution. If acces-sories are added to thehandlebar or front fork area,they must be as lightweight aspossible and should be kept toa minimum.

• Bulky or large accessories mayseriously affect the stability ofthe motorcycle. Wind may at-tempt to lift the motorcycle, orthe motorcycle may becomeunstable in cross winds.

• Certain accessories can dis-place the operator from his orher normal riding position. Thisimproper position limits thefreedom of movement of theoperator and may limit controlability, therefore, such accesso-ries are not recommended.

Use caution when adding electri-cal accessories. If electrical ac-cessories exceed the capacity ofthe motorcycle’s electrical sys-tem, an electric failure could re-sult, which could cause adangerous loss of lights or enginepower.

Aftermarket Tires and Rims

The tires and rims that came with yourmotorcycle were designed to matchthe performance capabilities and toprovide the best combination of han-dling, braking, and comfort. Other

tires, rims, sizes, and combinationsmay not be appropriate. Refer to page7-15 for tire specifications and more in-formation on replacing your tires.

Transporting 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” positionand that there are no fuel leaks.

Point the front wheel straightahead on the trailer or in the truckbed, and choke it in a rail to pre-vent movement.

Shift the transmission in gear (formodels with a manual transmis-sion).

Secure the motorcycle with tie-downs or suitable straps that areattached to solid parts of the mo-torcycle, such as the frame or up-per front fork triple clamp (and not,for example, to rubber-mountedhandlebars or turn signals, orparts that could break). Choose


SAFETY INFORMATION

2-5

2

the location for the straps carefullyso the straps will not rub againstpainted 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.


DESCRIPTION

3-1

3

EAU10411

Left view

678

1 2 3 4

51. 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)


DESCRIPTION

3-2

3

EAU10421

Right view

1 2 3 4

8 57 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)


DESCRIPTION

3-3

3

EAU10431

Controls and instruments

1 2 3 4

51. 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)


INSTRUMENT AND CONTROL FUNCTIONS

4-1

4

EAU40341

Main switch

The main switch controls the ignitionsystem. The main switch positions aredescribed below.

EAU10631

ON

All electrical systems are supplied withpower, and the engine can be started.The key cannot be removed.

EAU45752

OFF

All electrical systems are off. The keycan 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 accident.

EAU1234H

Handlebar switches

Left

Right

1. Engine stop switch “ / ”

1. Start switch “ ”1



4-2

4

EAU12661

Engine stop switch “ / ”

Set this switch to “ ” before startingthe engine. Set this switch to “ ” tostop the engine in case of an emergen-cy, such as when the vehicle overturnsor when the throttle cable is stuck.

EAU12713

Start switch “ ”

Push this switch to crank the enginewith the starter. See page 6-1 for start-ing instructions prior to starting the en-gine.

EAU39852

Shift pedal

This motorcycle is equipped with aconstant-mesh 4-speed transmission.The shift pedal is located on the leftside of the motorcycle. Neutral is at thebottom position.

EAU12892

Brake lever

The brake lever is located on the rightside of the handlebar. To apply thefront brake, pull the lever toward thethrottle grip.

1. Shift pedal

1

1. Brake lever

1



4-3

4

EAU12944

Brake pedal

The brake pedal is located on the rightside of the motorcycle. To apply therear brake, press down on the brakepedal.

EAU13183

Fuel tank cap

To remove the fuel tank cap, turn itcounterclockwise, and then pull it off.To install the fuel tank cap, insert it intothe tank opening, and then turn itclockwise.

WARNING

EWA11092

Make sure that the fuel tank cap is

properly closed after filling fuel.

Leaking fuel is a fire hazard.

EAU13213

FuelMake sure there is sufficient gasoline inthe tank.

WARNING

EWA10882

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. Before refueling, turn off the en-gine and be sure that no one is sit-ting on the vehicle. Never refuelwhile smoking, or while in the vi-cinity of sparks, open flames, orother sources of ignition such asthe pilot lights of water heatersand clothes dryers.

2. Do not overfill the fuel tank. Stopfilling when the fuel reaches thebottom of the filler tube. Becausefuel expands when it heats up,heat from the engine or the suncan cause fuel to spill out of thefuel tank.

1. Brake pedal

11. Fuel tank cap



4-4

4

3. Wipe up any spilled fuel immedi-ately. NOTICE: Immediately

wipe off spilled fuel with a clean,

dry, soft cloth, since fuel may

deteriorate painted surfaces or

plastic parts. [ECA10072]

4. Be sure to securely close the fueltank cap.

WARNING

EWA15152

Gasoline is poisonous and can cau-

se injury or death. Handle gasoline

with care. Never siphon gasoline by

mouth. If you should swallow some

gasoline or inhale a lot of gasoline

vapor, or get some gasoline in your

eyes, see your doctor immediately. If

gasoline spills on your skin, wash

with soap and water. If gasoline

spills on your clothing, change your

clothes.

EAU50253

For Canada

NOTICEECA11401

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 researchoctane number of 91 or higher. If

knocking (or pinging) occurs, use agasoline of a different brand or premi-um unleaded fuel. Use of unleaded fuelwill extend spark plug life and reducemaintenance costs.Gasohol

There are two types of gasohol: gaso-hol containing ethanol and that con-taining methanol. Gasohol containingethanol can be used if the ethanol con-tent does not exceed 10% (E10). Gas-ohol containing methanol is notrecommended by Yamaha because itcan cause damage to the fuel systemor vehicle performance problems.

For Europe

1. Fuel tank filler tube2. Maximum fuel level

Recommended fuel:Regular unleaded gasoline (Gasohol (E10) acceptable)

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)






4-5

4

NOTICEECA11401






Your Yamaha engine has been de-signed to use regular unleaded gaso-line with a research octane number of95 or higher. If knocking (or pinging)occurs, use a gasoline of a differentbrand or premium unleaded fuel. Useof unleaded fuel will extend spark pluglife and reduce maintenance costs.Gasohol

There are two types of gasohol: gaso-hol containing ethanol and that con-taining methanol. Gasohol containingethanol can be used if the ethanol con-tent does not exceed 10% (E10). Gas-ohol containing methanol is notrecommended by Yamaha because itcan cause damage to the fuel systemor vehicle performance problems.

For Oceania and South Africa

NOTICEECA11401






Your Yamaha engine has been de-signed to use regular unleaded gaso-line with a research octane number of91 or higher. If knocking (or pinging)occurs, use a gasoline of a differentbrand or premium unleaded fuel. Useof unleaded fuel will extend spark pluglife and reduce maintenance costs.Gasohol

There are two types of gasohol: gaso-hol containing ethanol and that con-taining methanol. Gasohol containingethanol can be used if the ethanol con-

tent does not exceed 10% (E10). Gas-ohol containing methanol is notrecommended by Yamaha because itcan cause damage to the fuel systemor vehicle performance problems.






4-6

4

EAU13414

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 replaceit if necessary.

Make sure that the fuel tankbreather hose is not blocked, andclean it if necessary.

EAU13562

Fuel cockThe fuel cock supplies fuel from thetank to the carburetor while filtering italso.The fuel cock has three positions:

OFF

With the lever in this position, fuel willnot flow. Always return the lever to thisposition when the engine is not run-ning.

ON

With the lever in this position, fuel flowsto the carburetor. Normal riding is donewith the lever in this position.

RES

1. Fuel tank breather hose

1

1. Arrow mark positioned over “OFF”

1. Arrow mark positioned over “ON”

1. Arrow mark positioned over “RES”



4-7

4

This indicates reserve. If you run out offuel while riding, move the lever to thisposition. Fill the tank at the first oppor-tunity. Be sure to set the lever back to“ON” after refueling!

EAU13591

Starter (choke) lever “ ”

Starting a cold engine requires a richerair-fuel mixture, which is supplied bythe starter (choke).Move the lever in direction (a) to turn onthe starter (choke).Move the lever in direction (b) to turnoff the starter (choke).

EAU37651

Kickstarter

If the engine fails to start by pushingthe start switch, try to start it by usingthe kickstarter. To start the engine, foldout the kickstarter lever, move it downlightly with your foot until the gears en-gage, and then push it down smoothlybut forcefully.

1. Starter (choke) lever “ ” 1. Kickstarter lever

1



4-8

4

EAU46283

Seat

To remove the seat

Remove the bolts, and then slide theseat to the rear and pull upward.

To install the seat

1. Fit the slot in the seat onto the pro-jection on the fuel tank, and insertthe projection on the seat into theseat holder as shown.

2. Place the seat in the original posi-tion, and then tighten the bolts.

TIP

Make sure that the seat is properly se-cured before riding.

EAU46023

Shock absorber assembly

WARNING

EWA10222

This shock absorber assembly con-

tains highly pressurized nitrogen

gas. Read and understand the fol-

lowing information before handling

the shock absorber assembly.

Do not tamper with or attempt

to open the cylinder assembly.

Do not subject the shock ab-

sorber assembly to an open

flame or other high heat source.

This may cause the unit to ex-

plode due to excessive gas

pressure.

Do not deform or damage the

cylinder in any way. Cylinder

damage will result in poor

damping performance.

Do not dispose of a damaged or

worn-out shock absorber as-

sembly yourself. Take the shock

absorber assembly to a Yamaha

dealer for any service.

1. Bolt

1

1. Slot2. Projection3. Seat holder

21

2 3



4-9

4

EAU37491

SidestandThe sidestand is located on the leftside of the frame. Raise the sidestandor lower it with your foot while holdingthe vehicle upright.

WARNING

EWA14191

The vehicle must not be ridden with

the sidestand down, or if the side-

stand cannot be properly moved up

(or does not stay up), otherwise the

sidestand could contact the ground

and distract the operator, resulting

in a possible loss of control.

EAU41612

Starting circuit cut-off systemThe starting circuit cut-off system pre-vents starting when the transmission isin gear.Periodically check the operation of thestarting circuit cut-off system accord-ing to the following procedure.

TIP

This check is most reliable if performedwith a warmed-up engine.



4-10

4

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? The neutral switch may not be working correctly.

The motorcycle should not be ridden untilchecked by a Yamaha dealer.

6. Shift the transmission into the neutral position.7. Push the start switch.Does the engine start?

The neutral switch may not be working correctly.The motorcycle should not be ridden untilchecked by a Yamaha dealer.

YESNO

The system is OK. The motorcycle can be ridden.

YES NO

If a malfunction is noted, have a Yamahadealer check the system before riding.

WARNING


FOR YOUR SAFETY – PRE-OPERATION CHECKS

5-1

5

EAU15598

Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspectionand 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 accident or equipment damage.

Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in

this manual, have the vehicle inspected by a Yamaha dealer.

Before using this vehicle, check the following points:

ITEM CHECKS PAGE

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.

4-3, 4-6

Engine oil• Check oil level in engine.• If necessary, add recommended oil to specified level.• Check vehicle for oil leakage.

7-9

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 grip

• Make sure that operation is smooth.• Check throttle grip free play.• If necessary, have Yamaha dealer adjust throttle grip free play and lubricate ca-

ble and grip housing.

7-15, 7-23


FOR YOUR SAFETY – PRE-OPERATION CHECKS

5-2

5

Control cables• 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 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.• Correct if necessary. 7-20

Brake pedal• Make sure that operation is smooth.• Lubricate pedal pivoting point if necessary. 7-24

Brake lever• Make sure that operation is smooth.• Lubricate lever pivoting point if necessary. 7-23

Sidestand• Make sure that operation is smooth.• Lubricate pivot if necessary. 7-24

Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.• Tighten if necessary. —

Engine stop switch • Check operation. 4-1

ITEM CHECKS PAGE


OPERATION AND IMPORTANT RIDING POINTS

6-1

6

EAU15952

Read the Owner’s Manual carefully tobecome familiar with all controls. Ifthere is a control or function you do notunderstand, ask your Yamaha dealer.

WARNING

EWA10272

Failure to familiarize yourself with

the controls can lead to loss of con-

trol, which could cause an accident

or injury.

EAU44815

Starting and warming up a cold engine

1. Turn the fuel cock lever to “ON”.2. Turn the key to “ON” and make

sure that the engine stop switch isset to “ ”.

3. Shift the transmission into theneutral position.

WARNING

EWA14411

Be sure to shift the transmission

into neutral before starting the

engine.

Never ride with the sidestand

down.

4. Turn the starter (choke) on andcompletely close the throttle. (Seepage 4-7.)

5. Start the engine by pushing thestart switch or by pushing thekickstarter lever down.

6. When the engine is warm, turn thestarter (choke) off.

TIP

The engine is warm when it respondsquickly to the throttle with the starter(choke) turned off.

NOTICEECA11043

For maximum engine life, never ac-

celerate hard when the engine is

cold!



6-2

6

EAU16641

Starting a warm engineFollow the same procedure as forstarting a cold engine with the excep-tion that the starter (choke) is not re-quired when the engine is warm.

EAU39902

Shifting

This motorcycle has a 4-speed trans-mission with a centrifugal, automaticclutch. Shifting gears lets you controlthe amount of engine power availablefor starting off, accelerating, climbinghills, etc.The gear positions are shown in the il-lustration.

TIP

To shift the transmission into the neu-tral position, press the shift pedal downrepeatedly until it reaches the end of itstravel.

NOTICEECA15442

Even with the transmission in

the neutral position, do not

coast for long periods of time

with the engine off, and do not

tow the motorcycle for long dis-

tances. The transmission is

properly lubricated only when

the engine is running. Inade-

quate lubrication may damage

the transmission.

Always release the throttle grip

before changing gears to avoid

damaging the engine, transmis-

sion, and drive train, which are

not designed to withstand the

shock of shifting when the

throttle grip is open.

EAU39912

To start out and accelerate

1. Close the throttle.2. Shift into first gear and release the

shift pedal. NOTICE: Always

close the throttle before shifting

gears, otherwise damage to the

engine and drive train may re-

sult. [ECA15462]

1. Shift pedal2. Neutral position

1

21234



6-3

6

3. Open the throttle gradually.4. Once the motorcycle has reached

a speed high enough to changegears, close the throttle.

5. Shift into second gear and releasethe shift pedal.

6. Open the throttle gradually.7. Follow the same procedure when

shifting to the next higher gear.

EAU16711

To decelerate

1. Close the throttle and apply boththe front and the rear brakes toslow the motorcycle.

2. Downshift through the gears andshift the transmission into the neu-tral position when the motorcycleis almost completely stopped.

EAU39921

Engine break-inThere is never a more important periodin the life of your engine than the first 5hours of riding. It is also important toaccustom the rider to the motorcycleduring this time. Please read the fol-lowing information carefully.Since the engine is brand new, do notput an excessive load on it for the first5 hours of operation. The various partsin the engine wear and polish them-selves to the correct operating clear-ances. During this period, prolongedfull-throttle operation or any conditionthat might result in engine overheatingmust be avoided. However, momen-tary full-throttle operation under load(i.e., two to three seconds maximum)does not harm the engine. Each full-throttle acceleration should be fol-lowed with a substantial rest period forthe engine. To allow the engine to cooldown from the temporary buildup ofheat, cruise at a lower engine speed.After the first 5 hours of operation,thoroughly check the motorcycle forloose parts, oil leakage and any otherproblems. Be sure to inspect and make

adjustments thoroughly, especially ca-ble and drive chain slack and loosespokes. In addition, check all fittingsand fasteners for looseness, and tight-en if necessary.

NOTICEECA10271

If any engine trouble should occur

during the engine break-in period,

immediately have a Yamaha dealer

check the vehicle.



6-4

6

EAU17172

ParkingWhen parking, stop the engine, re-move the key from the main switch,and then turn the fuel cock lever to“OFF”.

WARNING

EWA10312

Since the engine and exhaust

system can become very hot,

park in a place where pedestri-

ans or children are not likely to

touch them and be burned.

Do not park on a slope or on soft

ground, otherwise the vehicle

may overturn, increasing the

risk of a fuel leak and fire.

Do not park near grass or other

flammable materials which

might catch fire.


PERIODIC MAINTENANCE AND ADJUSTMENT

7-1

7

EAU17245

Periodic inspection, adjustment, andlubrication will keep your vehicle in thesafest and most efficient conditionpossible. Safety is an obligation of thevehicle owner/operator. The most im-portant points of vehicle inspection,adjustment, and lubrication are ex-plained on the following pages.The intervals given in the periodicmaintenance charts should be simplyconsidered as a general guide undernormal riding conditions. However, de-pending on the weather, terrain, geo-graphical location, and individual use,the maintenance intervals may need tobe shortened.

WARNING

EWA10322

Failure to properly maintain the vehi-

cle 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 perform

service.

WARNING

EWA15123

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 2-2 for more in-

formation about carbon monox-

ide.

WARNING

EWA15461

Brake discs, calipers, drums, and

linings can become very hot during

use. To avoid possible burns, let

brake components cool before

touching them.

EAU17303

Emission controls not only function toensure cleaner air, but are also vital toproper engine operation and maximumperformance. In the following periodicmaintenance charts, the services relat-ed to emissions control are groupedseparately. These services requirespecialized data, knowledge, andequipment. Maintenance, replace-ment, or repair of the emission controldevices and systems may be per-formed by any repair establishment orindividual that is certified (if applicable).Yamaha dealers are trained andequipped to perform these particularservices.



7-2

7

EAU17312

Owner’s tool kitThe service information included in thismanual and the tools provided in theowner’s tool kit are intended to assistyou in the performance of preventivemaintenance and minor repairs. How-ever, additional tools such as a torquewrench may be necessary to performcertain maintenance work correctly.

TIP

If you do not have the tools or experi-ence required for a particular job, havea Yamaha dealer perform it for you.



7-3

7

EAU39945

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 tech-

nical skills.

No. ITEM CHECKS AND MAINTENANCE JOBS

INITIAL ODOMETER READINGS

1000 km (600 mi) or 1 month or 30 hours

3000 km (1800 mi) or 6 months or

90 hours

5000 km (3000 mi) or

12 months or 150 hours

1 * Fuel line• Check fuel hoses for cracks or damage.• Replace if necessary. √ √

2 Spark plug• Check condition.• Adjust gap and clean. √ √

3 * Valve clearance • Check and adjust valve clearance when engine is cold. √

4 Air filter element• Clean with solvent.• Replace if necessary. √ √

5 * Crankcase breather sys-tem

• Check ventilation hose for cracks or damage and drain any deposits.

• Replace if necessary.√ √ √

6 * Carburetor• Check engine idling speed and starter operation.• Adjust if necessary. √ √ √

7 Exhaust system• Check for leakage.• Tighten if necessary.• Replace gasket(s) if necessary.

√ √

8 * Spark arrester • Clean. √

9 Engine oil • Change (warm engine before draining). √ √ √



7-4

7

EAU3534D

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 tech-

nical skills.





90 hours

5000 km (3000 mi) or


1 * Clutch• Check operation.• Adjust if necessary. √ √ √

2 * Front brake• Check operation.• Adjust brake lever free play and replace brake shoes if

necessary.√ √ √

3 * Rear brake• Check operation.• Adjust brake pedal free play and replace brake shoes if

necessary.√ √ √

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 bearings• Check bearings for smooth operation.• Replace if necessary. √ √

7 * Swingarm pivot bearings• Check bearing assemblies for looseness.• Moderately repack with lithium-soap-based grease. √ √



7-5

7

8 Drive chain• Check chain slack/alignment and condition.• Adjust and lubricate chain with Yamaha chain lubricant

or other suitable chain lubricant thoroughly.Every ride

9 * Steering bearings• Check bearing assemblies for looseness.• Moderately repack with lithium-soap-based grease. √ √

10 * Chassis fasteners• Check all chassis fitting and fasteners.• Correct if necessary. √ √ √

11 Brake lever pivot shaft • Apply lithium-soap-based grease lightly. √ √

12 Brake pedal pivot shaft • Apply lithium-soap-based grease lightly. √ √

13 Sidestand pivot• Check operation.• Apply lithium-soap-based grease lightly. √ √

14 * Front fork• Check operation and for oil leakage.• Replace if necessary. √ √

15 * Shock absorber assem-bly

• Check operation and for oil leakage.• Replace if necessary. √

16 * Control cables• Apply Yamaha cable lubricant or other suitable cable lu-

bricant thoroughly. √ √ √

17 * Throttle grip• Check operation.• Check throttle grip free play, and adjust if necessary.• Lubricate cable and grip housing.

√ √ √





90 hours

5000 km (3000 mi) or




7-6

7

EAU40001

TIP

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.



7-7

7

EAU18773

Removing and installing pan-elsThe panels shown need to be removedto perform some of the maintenancejobs described in this chapter. Refer tothis section each time a panel needs tobe removed and installed.

EAU56170

Panel A

To remove the panel1. Remove the seat. (See page 4-8.)2. Remove the bolts and the quick

fastener screws, and then take thepanel off.

To install the panel1. Place the panel in the original po-

sition, and then install the boltsand the quick fastener screws.

2. Install the seat.

Panel B

To remove the panel1. Remove the seat. (See page 4-8.)2. Remove the bolt, and then pull the

panel off as shown.

1. Panel A

11. Panel B

1

1. Panel A2. Bolt3. Quick fastener screw

3

1

2

3



7-8

7

To install the panel1. Place the panel in the original po-

sition, and then install the bolt.2. Install the seat.

EAU19605

Checking the spark plugThe spark plug is an important enginecomponent, which is easy to check.Since heat and deposits will cause anyspark plug to slowly erode, the sparkplug should be removed and checkedin accordance with the periodic main-tenance and lubrication chart. In addi-tion, the condition of the spark plugcan reveal the condition of the engine.

To remove the spark plug

1. Remove the spark plug cap.

2. Remove the spark plug as shown,with the spark plug wrench includ-ed in the owner’s tool kit.

To check the spark plug

1. Check that the porcelain insulatoraround the center electrode of thespark plug is a medium-to-lighttan (the ideal color when the vehi-cle is ridden normally).

TIP

If the spark plug shows a distinctly dif-ferent color, the engine could be oper-ating improperly. Do not attempt todiagnose such problems yourself. In-stead, have a Yamaha dealer checkthe vehicle.

1. Panel B2. Bolt3. Projection

3

12

1. Spark plug cap

1

1. Spark plug wrench

1



7-9

7

2. Check the spark plug for electrodeerosion and excessive carbon orother deposits, and replace it ifnecessary.

3. Measure the spark plug gap with awire thickness gauge and, if nec-essary, adjust the gap to specifi-cation.

To install the spark plug

1. Clean the surface of the sparkplug gasket and its mating surfa-ce, and then wipe off any grimefrom the spark plug threads.

2. Install the spark plug with thespark plug wrench, and then tight-en it to the specified torque.

TIP

If a torque wrench is not availablewhen installing a spark plug, a goodestimate of the correct torque is 1/4–1/2 turn past finger tight. However, thespark plug should be tightened to thespecified torque as soon as possible.

3. Install the spark plug cap.

EAU39846

Engine oilThe engine oil level should be checkedbefore each ride. In addition, the oilmust be changed at the intervals spec-ified in the periodic maintenance andlubrication chart.

To check the engine oil level

1. Place the motorcycle on a levelsurface and hold it in an uprightposition. A slight tilt to the side canresult in a false reading.

2. Start the engine, warm it up forseveral minutes, and then turn itoff.

3. Wait a few minutes until the oil set-tles, remove the engine oil fillercap, wipe the engine oil dipstickclean, insert it back into the oil fill-er hole (without screwing it in), andthen remove it again to check theoil level.

TIP

The engine oil should be between thetip of the dipstick and the maximumlevel mark.

Specified spark plug:NGK/CR6HSA

1. Spark plug gap

Spark plug gap:0.6–0.7 mm (0.024–0.028 in)

Tightening torque:Spark plug:

13 Nm (1.3 m·kgf, 9.4 ft·lbf)



7-10

7

4. If the engine oil is not between thetip of the dipstick and the maxi-mum level mark, add sufficient oilof the recommended type to raiseit to the correct level.

5. Insert the dipstick into the oil fillerhole, and then tighten the oil fillercap.

To change the engine oil

1. Start the engine, warm it up forseveral minutes, and then turn itoff.

2. Place an oil pan under the engineto collect the used oil.

3. Remove the engine oil filler cap,the engine oil drain bolt and itsgasket to drain the oil from thecrankcase.

4. Install a new gasket and the drainbolt, and then tighten the drainbolt to the specified torque.

5. Refill with the specified amount ofthe recommended engine oil, andthen install and tighten the oil fillercap.

NOTICEECA11621

In order to prevent clutch slip-

page (since the engine oil also

lubricates the clutch), do not

mix any chemical additives. Do

not use oils with a diesel speci-

fication of “CD” or oils of a high-

er quality than specified. In

addition, do not use oils labeled

“ENERGY CONSERVING II” or

higher.

Make sure that no foreign mate-

rial enters the crankcase.

6. Start the engine, and then let it idlefor several minutes while checkingit for oil leakage. If oil is leaking,immediately turn the engine offand check for the cause.

7. Turn the engine off, and thencheck the oil level and correct it ifnecessary.

1. Engine oil filler cap2. Engine oil dipstick3. Maximum level mark4. Tip of the engine oil dipstick

1

34

2

1. Engine oil drain bolt2. Gasket

Tightening torque:Engine oil drain bolt:

20 Nm (2.0 m·kgf, 14 ft·lbf)

12

Recommended engine oil:See page 9-1.

Oil change quantity:0.80 L (0.85 US qt, 0.70 Imp.qt)



7-11

7

EAU41638

Cleaning the air filter elementThe air filter element should be cleanedor replaced at the intervals specified inthe periodic maintenance and lubrica-tion chart. Clean or, if necessary, re-place the air filter element morefrequently if you are riding in unusuallywet 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.

3. Pull the sponge material and theair filter mesh out.

4. Clean the mesh with solvent, andthen wipe the solvent off.

5. Clean the sponge material withsolvent, and then squeeze the re-maining solvent out. WARNING!

Use only a dedicated parts

cleaning solvent. To avoid the

risk of fire or explosion, do not

use gasoline or solvents with a

low flash point. [EWA10432] NOTICE:To avoid damaging the foam

material, handle it gently and

carefully, and do not twist or

wring it. [ECA10512]

6. Apply oil of the recommendedtype to the entire surface of thesponge material, and thensqueeze the excess oil out.

TIP

The sponge material should be wet butnot dripping.

7. Insert the mesh and the spongematerial into the air filter case.NOTICE: Make sure that the

mesh and the sponge material

are properly seated in the air fil-

ter case. The engine should

never be operated without the

1. Air filter case cover2. Screw

2

1

1. Sponge material2. Air filter mesh

1

2

Recommended oil:Yamaha foam air filter oil or other quality foam air filter oil



7-12

7

mesh and the sponge material

installed, otherwise the pis-

ton(s) and/or cylinder(s) may

become excessively worn.

[ECA15573]

8. Install the air filter case cover byinstalling the screws.

TIP

Make sure that the spark plug lead isinserted into the guide as shown.

9. Install the panel.

To clean the air filter check hose1. Check the hoses at the bottom of

the air filter case for accumulateddirt or water.

2. If dirt or water is visible, removethe hoses, clean them, and thenreinstall them.

1. Spark plug lead2. Guide

1. Air filter check hose

1

1 2

1



7-13

7

EAU40422

Cleaning the spark arresterThe spark arrester should be cleanedat the intervals specified in the periodicmaintenance and lubrication chart.

WARNING

EWA10981

Always let the exhaust system

cool prior to touching exhaust

components.

Do not start the engine when

cleaning the exhaust system.

TIP

Make sure to select a well-ventilatedarea free of combustible materials toclean the spark arrester.

1. Remove the tailpipe by removingthe bolts, and then pulling it out ofthe muffler.

2. Tap the tailpipe lightly, and thenuse a wire brush to remove anycarbon deposits from the sparkarrester portion of the tailpipe andinside of the tailpipe housing.

3. Insert the tailpipe into the muffler,and then install and tighten thebolts to the specified torque.

TIP

Make sure to align the bolt holes wheninserting the tailpipe.

1. Tailpipe2. Tailpipe bolt

1. Spark arrester

2

1

1

Tightening torque:Tailpipe bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)



7-14

7

EAU39931

Adjusting the carburetorThe carburetor is an important part ofthe engine and requires very sophisti-cated adjustment. Therefore, mostcarburetor adjustments should be leftto a Yamaha dealer, who has the nec-essary professional knowledge and ex-perience. The adjustment described inthe following section, however, may beserviced by the owner as part of rou-tine maintenance.

NOTICEECA10551

The carburetor has been set and ex-

tensively tested at the Yamaha fac-

tory. Changing these settings

without sufficient technical knowl-

edge may result in poor perfor-

mance of or damage to the engine.

EAU21363

Adjusting the engine idling speedThe engine idling speed must bechecked and, if necessary, adjusted asfollows at the intervals specified in theperiodic maintenance and lubricationchart.

TIP

A diagnostic tachometer is needed tomake this adjustment.

1. Attach the tachometer to thespark plug lead.

2. Start the engine and warm it up forseveral minutes at 1000–2000r/min while occasionally revving itto 4000–5000 r/min.

TIP

The engine is warm when it quickly re-sponds to the throttle.

3. Check the engine idling speedand, if necessary, adjust it tospecification by turning the throt-tle stop screw. To increase the en-gine idling speed, turn the screw in

direction (a). To decrease the en-gine idling speed, turn the screw indirection (b).

TIP

If the specified idling speed cannot beobtained as described above, have aYamaha dealer make the adjustment.

1. Throttle stop screw

Engine idling speed:1600–1800 r/min

(a) (b)

1



7-15

7

EAU21385

Checking the throttle grip free play

The throttle grip free play should mea-sure 4.0–6.0 mm (0.16–0.24 in) at theinner edge of the throttle grip. Periodi-cally check the throttle grip free playand, if necessary, have a Yamaha deal-er adjust it.

EAU21402

Valve clearanceThe valve clearance changes with use,resulting in improper air-fuel mixtureand/or engine noise. To prevent thisfrom occurring, the valve clearancemust be adjusted by a Yamaha dealerat the intervals specified in the periodicmaintenance and lubrication chart.

EAU40916

TiresTires are the only contact between thevehicle and the road. Safety in all con-ditions of riding depends on a relativelysmall area of road contact. Therefore, itis essential to maintain the tires in goodcondition at all times and replace themat the appropriate time with the speci-fied tires.

Tire air pressure

The tire air pressure should bechecked and, if necessary, adjustedbefore each ride.

WARNING

EWA15371

Operation of this vehicle with im-

proper tire pressure may cause se-

vere injury or death from loss of

control.

The tire air pressure must be

checked and adjusted on cold tires

(i.e., when the temperature of the

tires equals the ambient tempera-

ture).

1. Throttle grip free play

1



7-16

7

Tire inspection

The tires must be checked before eachride. If the center tread depth reachesthe specified limit, if the tire has a nailor glass fragments in it, or if the side-wall is cracked, have a Yamaha dealerreplace the tire immediately.

Tire information

This model is equipped with tube tires.Tires age, even if they have not beenused or have only been used occasion-ally. Cracking of the tread and sidewallrubber, sometimes accompanied bycarcass deformation, is an evidence ofageing. Old and aged tires shall bechecked by tire specialists to ascertaintheir suitability for further use.

WARNING

EWA10462

The front and rear tires should be of

the same make and design, other-

wise the handling characteristics of

the vehicle may be different, which

could lead to an accident.

After extensive tests, only the tires list-ed below have been approved for thismodel by Yamaha.

WARNING

EWA15542

Have a Yamaha dealer replace

excessively worn tires. Operat-

ing the motorcycle with exces-

sively worn tires decreases

riding stability and can lead to

loss of control.

The replacement of all wheel-

and brake-related parts, includ-

ing the tires, should be left to a

Yamaha dealer, who has the

necessary professional knowl-

edge and experience.

It is not recommended to patch

a punctured tube. If unavoid-

able, however, patch the tube

Standard tire air pressure:Front:

100 kPa (1.00 kgf/cm², 15 psi)Rear:

100 kPa (1.00 kgf/cm², 15 psi)

1. Tire sidewall2. Tire tread depth

Minimum tire tread depth (front and rear):

4.0 mm (0.16 in)

1

2

Front tire:Size:

2.50-14 4PRManufacturer/model:

CHEN SHIN/C-803-2Rear tire:

Size:3.00-12 4PR

Manufacturer/model:CHEN SHIN/C-803-2



7-17

7

very carefully and replace it as

soon as possible with a high-

quality product.

Ride conservatively after

changing a tire since the tire

must seat itself on the rim prop-

erly. Failure to allow proper

seating may cause tire failure,

which may result in damage to

the motorcycle and injury to the

rider.

EAU21944

Spoke wheels

WARNING

EWA10611

The wheels on this model are not

designed for use with tubeless tires.

Do not attempt to use tubeless tires

on this model.

To maximize the performance, durabil-ity, and safe operation of your motor-cycle, note the following pointsregarding the specified wheels. The wheel rims should be

checked for cracks, bends, warp-age or other damage, and thespokes for looseness or damagebefore each ride. If any damage isfound, have a Yamaha dealer re-place the wheel. Do not attempteven the smallest repair to thewheel. A deformed or crackedwheel must be replaced.

The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced. Anunbalanced wheel can result inpoor performance, adverse han-dling characteristics, and a short-ened tire life.

EAU44664

Adjusting the clutch free playThe clutch free play must be checkedand, if necessary, adjusted as followsat the intervals specified in the periodicmaintenance 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 1/8turn in direction (b).

3. Tighten the locknut to the speci-fied torque.

1. Locknut2. Clutch adjusting screw

Tightening torque:Locknut:

8 Nm (0.8 m·kgf, 5.8 ft·lbf)

1

2

(a)(b)



7-18

7

TIP

When tightening the locknut, hold theclutch adjusting screw with a screw-driver so that it does not turn togetherwith the locknut.

EAU44885

Adjusting the brake lever free play

The brake lever free play should mea-sure 10.0–20.0 mm (0.39–0.79 in) asshown. Periodically check the brake le-ver free play and, if necessary, adjust itas follows.

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 playadjusting 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.

5. Loosen the locknut at the brakeshoe plate.

6. To increase the brake lever freeplay, turn the adjusting bolt at thebrake shoe plate in direction (a).To decrease the brake lever freeplay, turn the adjusting bolt in di-rection (b).

1. Rubber cover2. Brake lever free play adjusting bolt3. Locknut4. Brake lever free play

321(b)

(a)

4



7-19

7

7. Tighten the locknut at the brakeshoe plate.

8. Tighten the locknut at the brakelever, and then slide the rubbercover to its original position.

EAU44672

Adjusting the brake pedal free play

The brake pedal free play should mea-sure 10.0–20.0 mm (0.39–0.79 in) atthe brake pedal end as shown. Period-ically check the brake pedal free playand, if necessary, adjust it as follows.To increase the brake pedal free play,turn the brake pedal free play adjustingnut at the brake rod in direction (a). Todecrease the brake pedal free play,turn the adjusting nut in direction (b).

WARNING

EWA14821

After adjusting the drive chain

slack or removing and installing

the rear wheel, always check

the brake pedal free play.

If proper adjustment cannot be

obtained as described, have a

Yamaha dealer make this ad-

justment.1. Locknut2. Brake lever free play adjusting bolt

2

1

(b)

(a)

1. Brake pedal free play adjusting nut2. Brake pedal free play



7-20

7

EAU44821

Checking the shift pedalThe operation of the shift pedal shouldbe checked before each ride. If opera-tion is not smooth, have a Yamahadealer check the vehicle.

EAU22363

Checking the front and rear brake shoes

Front

Rear

The front and rear brake shoes must bechecked for wear at the intervals spec-ified in the periodic maintenance andlubrication chart. Each brake is provid-ed with a wear indicator, which allowsyou to check the brake shoe wear with-out having to disassemble the brake.To check the brake shoe wear, checkthe position of the wear indicator whileapplying the brake. If a brake shoe hasworn to the point that the wear indica-tor reaches the wear limit line, have aYamaha dealer replace the brakeshoes as a set.1. Brake shoe wear indicator

2. Brake shoe wear limit line

1. Brake shoe wear indicator2. Brake shoe wear limit line

2

1

12



7-21

7

EAU22762

Drive chain slackThe drive chain slack should bechecked before each ride and adjustedif necessary.

EAU22775

To check the drive chain slack

1. Place the motorcycle on the side-stand.

TIP

When checking and adjusting the drivechain slack, there should be no weighton the motorcycle.

2. Shift the transmission into theneutral position.

3. Measure the drive chain slack asshown.

4. If the drive chain slack is incorrect,adjust it as follows.

EAU40115

To adjust the drive chain slack

Consult a Yamaha dealer before ad-justing the drive chain slack.

1. Loosen the brake pedal free playadjusting nut, axle nut, and lock-nut at each end of the swingarm.

2. To tighten the drive chain, turn thedrive chain slack adjusting nut ateach end of the swingarm in direc-

Drive chain slack:40.0–56.0 mm (1.57–2.20 in)

1. Drive chain slack

1

1. Brake pedal free play adjusting nut2. Locknut3. Drive chain slack adjusting nut

1. Axle nut2. Locknut3. Drive chain slack adjusting nut

3 2

1



7-22

7

tion (a). To loosen the drive chain,turn the adjusting nut at each endof the swingarm in direction (b),and then push the rear wheel for-ward. NOTICE: Improper drive

chain slack will overload the en-

gine 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 with-

in the specified limits. [ECA10572]

TIP

Using the alignment marks on eachside of the swingarm, make sure thatboth drive chain pullers are in the sameposition for proper wheel alignment.

3. Tighten the axle nut and bothlocknuts to the specified torques.

4. Adjust the brake pedal free play.(See page 7-19.)

5. Make sure that the drive chainpullers are in the same position,the drive chain slack is correct,and the drive chain movessmoothly.

EAU23018

Cleaning and lubricating the drive chainThe drive chain must be cleaned andlubricated at the intervals specified inthe periodic maintenance and lubrica-tion chart, otherwise it will quickly wearout, especially when riding in dusty orwet areas. Service the drive chain asfollows.

NOTICEECA10584

The drive chain must be lubricated

after washing the motorcycle, riding

in the rain or riding in wet areas.

1. Remove all dirt and mud from thedrive chain with a brush or cloth.

TIP

For a thorough cleaning, have aYamaha dealer remove the drive chainand soak it in solvent.

2. Spray Yamaha chain lubricant orother suitable chain lubricant onthe entire chain, making sure thatall side plates and rollers havebeen sufficiently oiled.

1. Alignment marks2. Locknut3. Drive chain slack adjusting nut4. Drive chain puller

Tightening torques:Axle nut:

60 Nm (6.0 m·kgf, 43 ft·lbf)Locknut:

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

(a)

(b)4 3 2

1



7-23

7

EAU23098

Checking and lubricating the cablesThe operation of all control cables andthe condition of the cables should bechecked before each ride, and the ca-bles and cable ends should be lubri-cated if necessary. If a cable isdamaged or does not move smoothly,have a Yamaha dealer check or re-place it. WARNING! Damage to the

outer housing of cables may result

in internal rusting and cause inter-

ference with cable movement. Re-

place damaged cables as soon as

possible to prevent unsafe condi-

tions. [EWA10712]

EAU23115

Checking and lubricating the throttle grip and cableThe operation of the throttle gripshould be checked before each ride. Inaddition, the cable should be lubricat-ed by a Yamaha dealer at the intervalsspecified in the periodic maintenancechart.The throttle cable is equipped with arubber cover. Make sure that the coveris securely installed. Even though thecover is installed correctly, it does notcompletely protect the cable from wa-ter entry. Therefore, use care not topour water directly onto the cover orcable when washing the vehicle. If thecable or cover becomes dirty, wipeclean with a moist cloth.

EAU43623

Checking and lubricating the brake lever

The operation of the brake lever shouldbe checked before each ride, and thelever pivot should be lubricated if nec-essary.

Recommended lubricant:Yamaha cable lubricant or other suitable cable lubricant

Recommended lubricant:Lithium-soap-based grease



7-24

7

EAU23185

Checking and lubricating the brake pedalThe operation of the brake pedalshould be checked before each ride,and the pedal pivot should be lubricat-ed if necessary.

EAU23203

Checking and lubricating the sidestand

The operation of the sidestand shouldbe checked before each ride, and thesidestand pivot and metal-to-metalcontact surfaces should be lubricatedif necessary.

WARNING

EWA10732

If the sidestand does not move up

and down smoothly, have a Yamaha

dealer check or repair it. Otherwise,

the sidestand could contact the

ground and distract the operator, re-

sulting in a possible loss of control.

EAUM1653

Lubricating the swingarm piv-ots

The swingarm pivots must be lubricat-ed by a Yamaha dealer at the intervalsspecified in the periodic maintenanceand lubrication chart.






7-25

7

EAU23273

Checking the front forkThe condition and operation of thefront fork must be checked as followsat the intervals specified in the periodicmaintenance and lubrication chart.

To check the condition

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 avoid injury,

securely support the vehicle so

there is no danger of it falling

over. [EWA10752]

2. While applying the front brake,push down hard on the handle-bars several times to check if thefront fork compresses and re-bounds smoothly.

NOTICEECA10591

If any damage is found or the front

fork does not operate smoothly,

have a Yamaha dealer check or re-

pair it.

EAU23284

Checking the steeringWorn or loose steering bearings maycause danger. Therefore, the operationof the steering must be checked as fol-lows at the intervals specified in theperiodic maintenance and lubricationchart.

1. Place a stand under the engine toraise the front wheel off theground. (See page 7-28 for moreinformation.) WARNING! To

avoid injury, securely support

the vehicle so there is no danger

of it falling over. [EWA10752]

2. Hold the lower ends of the frontfork legs and try to move them for-ward and backward. If any freeplay can be felt, have a Yamahadealer check or repair the steer-ing.



7-26

7

EAU23292

Checking the wheel bearings

The front and rear wheel bearings mustbe checked at the intervals specified inthe periodic maintenance and lubrica-tion chart. If there is play in the wheelhub or if the wheel does not turnsmoothly, have a Yamaha dealercheck the wheel bearings.

EAU23397

Battery

The battery is located behind panel B.(See page 7-7.)This model is equipped with a VRLA(Valve Regulated Lead Acid) battery.There is no need to check the electro-lyte or to add distilled water. However,the battery coupler needs to bechecked and, if necessary, securelyfastened.

WARNING

EWA10761

Electrolyte is poisonous and

dangerous since it contains sul-

furic acid, which causes severe

1. Battery coupler2. Battery band3. Battery

2 31



7-27

7

burns. Avoid any contact with

skin, eyes or clothing and al-

ways shield your eyes when

working near batteries. In case

of contact, administer the fol-

lowing FIRST AID.

• EXTERNAL: Flush with plenty

of water.

• INTERNAL: Drink large quan-

tities of water or milk and im-

mediately call a physician.

• EYES: Flush with water for 15

minutes and seek prompt

medical attention.

Batteries produce explosive hy-

drogen gas. Therefore, keep

sparks, flames, cigarettes, etc.,

away from the battery and pro-

vide sufficient ventilation when

charging it in an enclosed

space.

KEEP THIS AND ALL BATTER-

IES OUT OF THE REACH OF

CHILDREN.

To charge the battery

Have a Yamaha dealer charge the bat-tery as soon as possible if it seems tohave discharged. Keep in mind that the

battery tends to discharge more quick-ly if the vehicle is equipped with op-tional electrical accessories.

NOTICEECA16522

To charge a VRLA (Valve Regulated

Lead Acid) battery, a special (con-

stant-voltage) battery charger is re-

quired. Using a conventional battery

charger will damage the battery.

To store the battery

1. If the model will not be used formore than one month, remove thebattery, fully charge it, and thenplace it in a cool, dry place.NOTICE: When removing the

battery, be sure the key is

turned to “OFF” before discon-

necting the coupler. [ECA16323]

2. If the battery will be stored formore than two months, check it atleast once a month and fully char-ge it if necessary.

3. Fully charge the battery beforeinstallation. NOTICE: When in-

stalling the battery, be sure the

key is turned to “OFF” before

connecting the coupler. [ECA16931]

NOTICEECA16531

Always keep the battery charged.

Storing a discharged battery can

cause permanent battery damage.



7-28

7

EAU50431

Replacing the fuseThe fuse is located inside the batterycoupler. (See page 7-26.)

If the fuse is blown, replace it as fol-lows.

1. Turn the key to “OFF” and turn offall electrical circuits.

2. Disconnect the battery coupler.3. Remove the blown fuse, and then

install a new fuse of the specifiedamperage. WARNING! Do not

use a fuse of a higher amperage

rating than recommended to

avoid causing extensive dam-

age to the electrical system and

possibly a fire. [EWA15132]

4. Connect the battery coupler.5. Turn the key to “ON”.6. If the fuse immediately blows

again, have a Yamaha dealercheck the electrical system.

EAU24351

Supporting the motorcycleSince this model is not equipped with acenterstand, follow these precautionswhen removing the front and rearwheel or performing other mainte-nance requiring the motorcycle tostand upright. Check that the motorcy-cle is in a stable and level position be-fore starting any maintenance. Astrong wooden box can be placed un-der the engine for added stability.

To service the front wheel

1. Stabilize the rear of the motorcy-cle by using a motorcycle standor, if an additional motorcyclestand is not available, by placing ajack under the frame in front of therear wheel.

2. Raise the front wheel off theground by using a motorcyclestand.

To service the rear wheel

Raise the rear wheel off the ground byusing a motorcycle stand or, if a motor-cycle stand is not available, by placing

1. Battery coupler2. Fuse3. Spare fuse

13

2

Specified fuse:10.0 A



7-29

7

a jack either under each side of theframe in front of the rear wheel or undereach side of the swingarm.

EAU24361

Front wheel

EAU56490

To remove the front wheel

WARNING

EWA10822

To avoid injury, securely support the

vehicle so there is no danger of it

falling over.

1. Slide the rubber cover back at thebrake lever.

2. Loosen the locknut, and then turnthe brake lever free play adjustingbolt fully in direction (a).

3. Loosen the axle nut.

4. Lift the front wheel off the groundaccording to the procedure in theprevious section “Supporting themotorcycle”.

5. Remove the axle nut and washer.6. Pull the wheel axle out.

1. Rubber cover2. Brake lever free play adjusting bolt3. Locknut

(a)

321

(a)

1. Axle nut2. Washer



7-30

7

7. Remove the brake shoe assemblyfrom the wheel hub by pulling itout.

8. Remove the wheel.

To install the front wheel

1. Install the brake shoe assemblyinto the wheel hub.

2. Lift the wheel up between the forklegs.

TIP

Make sure that the slot in the brakeshoe plate fits over the retainer on thefork leg.

3. Insert the wheel axle from theright-hand side, and then installthe washer and the axle nut.

4. Lower the front wheel so that it ison the ground, and then put thesidestand down.

5. Tighten the axle nut to the speci-fied torque.

6. Adjust the brake lever free play.(See page 7-18.)

7. While applying the front brake,push down hard on the handlebarseveral times to check for properfork operation.

1. Wheel axle

1. Brake shoe assembly

1

1. Slot2. Retainer

2

1

Tightening torque:Axle nut:

35 Nm (3.5 m·kgf, 25 ft·lbf)



7-31

7

EAU25081

Rear wheel

EAU56800

To remove the rear wheel

WARNING

EWA10822

To avoid injury, securely support the

vehicle so there is no danger of it

falling over.

1. Disconnect the brake torque rodfrom the brake shoe plate by re-moving the cotter pin, the nut andthe bolt.

2. Remove the brake pedal free playadjusting nut, and then discon-nect the brake rod at the brakecamshaft lever.

3. Fully loosen the locknut and thedrive chain slack adjusting nut onboth ends of the swingarm.

4. Loosen the axle nut.5. Lift the rear wheel off the ground

according to the procedure onpage 7-28.

6. Remove the axle nut, washer andthe drive chain puller at the left-hand side, then pull the wheel axleout together with the drive chainpuller from the right-hand side.

7. Push the wheel forward, and thenremove the drive chain from therear sprocket.

1. Brake torque rod2. Cotter pin3. Brake torque rod bolt and nut4. Brake shoe plate

1. Brake rod2. Brake pedal free play adjusting nut3. Brake camshaft lever4. Wheel axle

1. Axle nut2. Washer3. Drive chain puller4. Drive chain slack adjusting nut5. Locknut

1 2 3 5

4



7-32

7

TIP

The drive chain does not need to bedisassembled in order to remove andinstall the wheel.

8. Remove the wheel.

To install the rear wheel

1. Install the drive chain onto the rearsprocket.

2. Lift the rear wheel off the ground,and then install the drive chainpuller and the wheel by insertingthe wheel axle from the right-handside.

3. Install the drive chain puller, wash-er and axle nut.

4. Lower the rear wheel so that it ison the ground, and then put thesidestand down.

5. Install the brake rod onto thebrake camshaft lever, and then in-stall the brake pedal free play ad-justing nut onto the brake rod.

6. Connect the brake torque rod tothe brake shoe plate by installingthe bolt and nut, and then tightenthe nut to the specified torque.

7. Insert a new cotter pin.8. Adjust the drive chain slack. (See

page 7-21.)9. Tighten the axle nut to the speci-

fied torque.

10. Adjust the brake pedal free play.(See page 7-19.)

EAU25852

TroubleshootingAlthough Yamaha motorcycles receivea thorough inspection before shipmentfrom the factory, trouble may occurduring operation. Any problem in thefuel, compression, or ignition systems,for example, can cause poor startingand loss of power.The following troubleshooting chartrepresents a quick and easy procedurefor checking these vital systems your-self. However, should your motorcyclerequire any repair, take it to a Yamahadealer, whose skilled technicians havethe necessary tools, experience, andknow-how to service the motorcycleproperly.Use only genuine Yamaha replace-ment parts. Imitation parts may looklike Yamaha parts, but they are ofteninferior, have a shorter service life andcan lead to expensive repair bills.

WARNING

EWA15142

When checking the fuel system, do

not smoke, and make sure there are

no open flames or sparks in the ar-

ea, including pilot lights from water

Tightening torque:Brake torque rod nut:

26 Nm (2.6 m·kgf, 19 ft·lbf)

Tightening torque:Axle nut:

60 Nm (6.0 m·kgf, 43 ft·lbf)



7-33

7

heaters or furnaces. Gasoline or

gasoline vapors can ignite or ex-

plode, causing severe injury or prop-

erty damage.



7-34

7

EAU25905

Troubleshooting chart

Check the fuel level inthe fuel tank.

1. FuelThere is enough fuel.

There is no fuel.

Check the battery.

Supply fuel. The engine does not start. Check the battery.

The engine does not start. Have a Yamaha dealer check the vehicle.

Operate the electric starter.

4. CompressionThere is compression.

There is no compression.

Remove the spark plugand check the electrodes.

3. Ignition Wipe off with a dry cloth and correct thespark plug gap, or replace the spark plug.

Have a Yamaha dealer check the vehicle.

Have a Yamaha dealer check the vehicle.

The engine does not start.Check the compression.

The engine does not start. Check the ignition.

Operate the electric starter.

2. Battery The engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the battery lead connections,and have a Yamaha dealer charge the battery if necessary.

Dry

WetOpen the throttle halfway and operatethe electric starter.


MOTORCYCLE CARE AND STORAGE

8-1

8

EAU37834

Matte color caution

NOTICEECA15193

Some models are equipped with

matte colored finished parts. Be

sure to consult a Yamaha dealer for

advice on what products to use be-

fore cleaning the vehicle. Using a

brush, harsh chemical products or

cleaning compounds when cleaning

these parts will scratch or damage

their surface. Wax also should not

be applied to any matte colored fin-

ished parts.

EAU40466

CareWhile the open design of a motorcyclereveals the attractiveness of the tech-nology, it also makes it more vulnera-ble. Rust and corrosion can developeven if high-quality components areused. A rusty exhaust pipe may go un-noticed on a car, however, it detractsfrom the overall appearance of a mo-torcycle. Frequent and proper caredoes not only comply with the terms ofthe warranty, but it will also keep yourmotorcycle looking good, extend itslife and optimize its performance.

Before cleaning

1. Cover the muffler outlet with aplastic bag after the engine hascooled down.

2. Make sure that all caps and cov-ers as well as all electrical cou-plers and connectors, includingthe spark plug cap, are tightly in-stalled.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply such prod-

ucts onto seals, gaskets, sprock-ets, the drive chain and wheelaxles. Always rinse the dirt anddegreaser off with water.

Cleaning

NOTICEECA10773

Avoid using strong acidic wheel

cleaners, especially on spoked

wheels. If such products are

used on hard-to-remove dirt, do

not leave the cleaner on the af-

fected area any longer than in-

structed. Also, thoroughly rinse

the area off with water, immedi-

ately dry it, and then apply a cor-

rosion protection spray.

Improper cleaning can damage

plastic parts (such as cowlings,

panels, windshields, headlight

lenses, meter lenses, etc.) and

the mufflers. Use only a soft,

clean cloth or sponge with wa-

ter to clean plastic. However, if

the plastic parts cannot be thor-

oughly cleaned with water, di-

luted mild detergent with water

may be used. Be sure to rinse



8-2

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 re-

movers or inhibitors, brake fluid,

antifreeze or electrolyte.

Do not use high-pressure wash-

ers or steam-jet cleaners since

they cause water seepage and

deterioration in the following ar-

eas: seals (of wheel and swing-

arm bearings, fork and brakes),

electric components (couplers,

connectors, instruments,

switches and lights), breather

hoses and vents.

For motorcycles equipped with

a windshield: Do not use strong

cleaners or hard sponges as

they will cause dulling or

scratching. Some cleaning

compounds for plastic may

leave scratches on the wind-

shield. Test the product on a

small hidden part of the wind-

shield to make sure that it does

not leave any marks. If the wind-

shield is scratched, use a quality

plastic polishing compound af-

ter washing.

After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottlebrushfor hard-to-reach areas. Stubborn dirtand insects will come off more easily ifthe area is covered with a wet cloth fora few minutes before cleaning.

After riding in the rain or near the seaSince sea salt is extremely corrosive,carry out the following steps after eachride in the rain or near the sea.

1. Clean the motorcycle with coldwater and a mild detergent, afterthe engine has cooled down.NOTICE: Do not use warm wa-

ter since it increases the corro-

sive action of the salt. [ECA10792]

2. Apply a corrosion protection sprayon all metal, including chrome-and nickel-plated, surfaces to pre-vent corrosion.

After cleaning

1. Dry the motorcycle with a chamoisor an absorbing cloth.

2. Immediately dry the drive chainand lubricate it to prevent it fromrusting.

3. Use a chrome polish to shinechrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even the thermally in-duced discoloring of stainless-steel exhaust systems can be re-moved through polishing.)

4. To prevent corrosion, it is recom-mended to apply a corrosion pro-tection spray on all metal,including chrome- and nickel-plat-ed, surfaces.

5. Use spray oil as a universal clean-er to remove any remaining dirt.

6. Touch up minor paint damagecaused by stones, etc.

7. Wax all painted surfaces.



8-3

8

8. Let the motorcycle dry completelybefore storing or covering it.

WARNING

EWA14502

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 deter-

gent. Before riding at higher

speeds, test the motorcycle’s

braking performance and cor-

nering behavior.

NOTICEECA10801

Apply spray oil and wax spar-

ingly and make sure to wipe off

any excess.

Never apply oil or wax to any

rubber and plastic parts, but

treat them with a suitable care

product.

Avoid using abrasive polishing

compounds as they will wear

away the paint.

TIP

Consult a Yamaha dealer for advice onwhat products to use.

EAU26153

Storage

Short-term

Always store your motorcycle in a cool,dry place and, if necessary, protect itagainst dust with a porous cover. Besure the engine and the exhaust sys-tem are cool before covering the mo-torcycle.

NOTICEECA10811

Storing the motorcycle in a

poorly ventilated room or cover-

ing it with a tarp, while it is still

wet, will allow water and humid-

ity to seep in and cause rust.

To prevent corrosion, avoid

damp cellars, stables (because

of the presence of ammonia)

and areas where strong chemi-

cals are stored.

Long-term

Before storing your motorcycle for sev-eral months:

1. Follow all the instructions in the“Care” section of this chapter.



8-4

8

2. For motorcycles equipped with afuel cock that has an “OFF” posi-tion: Turn the fuel cock lever to“OFF”.

3. Drain the carburetor float chamberby loosening the drain bolt; thiswill prevent fuel deposits frombuilding up. Pour the drained fuelinto the fuel tank.

4. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting and thefuel from deteriorating.

5. Perform the following steps toprotect the cylinder, piston rings,etc. from corrosion.a. Remove the spark plug cap

and spark plug.b. Pour a teaspoonful of engine

oil into the spark plug bore.c. Install the spark plug cap onto

the spark plug, and then placethe spark plug on the cylinderhead so that the electrodes aregrounded. (This will limit spark-ing during the next step.)

d. Turn the engine over severaltimes with the starter. (This willcoat the cylinder wall with oil.)

WARNING! To prevent dam-

age or injury from sparking,

make sure to ground the

spark plug electrodes while

turning the engine over.

[EWA10952]

e. Remove the spark plug capfrom the spark plug, and theninstall the spark plug and thespark plug cap.

6. Lubricate all control cables andthe pivoting points of all levers andpedals as well as of the side-stand/centerstand.

7. Check and, if necessary, correctthe tire air pressure, and then liftthe motorcycle so that both of itswheels are off the ground. Alterna-tively, turn the wheels a little everymonth in order to prevent the tiresfrom becoming degraded in onespot.

8. Cover the muffler outlet with aplastic bag to prevent moisturefrom entering it.

9. Remove the battery and fully char-ge it. Store it in a cool, dry placeand charge it once a month. Donot store the battery in an exces-

sively cold or warm place [lessthan 0 °C (30 °F) or more than 30°C (90 °F)]. For more informationon storing the battery, see page7-26.

TIP

Make any necessary repairs beforestoring the motorcycle.


SPECIFICATIONS

9-1

9

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:

1700 mm (66.9 in)Weight:

Curb weight:72 kg (159 lb)

Technical permissible mass (Maximum load + Curb weight):

132 kg (291 lb)Noise and vibration level:

Noise level (77/311/EEC):TT-R110E 78.9 dB(A) (AUT)(BEL)(CHE)(CYP)(CZE)(DEU)(DNK)(ESP)(FIN)(FRA)(GBR)(GRC)(IRL)(ITA)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(SWE)(TUR)(ZAF)

Vibration on seat (EN1032, ISO5008):TT-R110E Will not exceed 0.5 m/s² (AUT)(BEL)(CHE)(CYP)(CZE)(DEU)(DNK)(ESP)(FIN)(FRA)(GBR)(GRC)(IRL)(ITA)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(SWE)(TUR)(ZAF)

Vibration on handlebar (EN1032, ISO5008):TT-R110E Will not exceed 2.5 m/s² (AUT)(BEL)(CHE)(CYP)(CZE)(DEU)(DNK)(ESP)(FIN)(FRA)(GBR)(GRC)(IRL)(ITA)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(SWE)(TUR)(ZAF)

Engine:Engine type:

Air cooled 4-stroke, SOHCCylinder arrangement:

Single cylinderDisplacement:

110 cm³Bore × stroke:

51.0 × 54.0 mm (2.01 × 2.13 in)Compression ratio:

9.3 : 1Starting system:

Electric starter and kickstarterLubrication system:

Wet sumpEngine oil:

Recommended brand:YAMALUBE

Type:SAE 10W-30, 10W-40, 10W-50, 15W-40, 20W-40 or 20W-50

Recommended engine oil grade:API service SG type or higher, JASO standard MA

Engine oil quantity:Periodic oil change:

0.80 L (0.85 US qt, 0.70 Imp.qt)Air filter:

Air filter element:Wet element

Fuel:Recommended fuel:

Regular unleaded gasoline (Gasohol (E10) acceptable)



Carburetor:Type × quantity:

VM16 x 1

–20 –10 0 10 20 30 40 50 ˚C

10 30 50 70 90 1100 130 ˚F

SAE 10W-30

SAE 15W-40

SAE 20W-40

SAE 20W-50

SAE 10W-40

SAE 10W-50


SPECIFICATIONS

9-2

9

Spark plug(s):Manufacturer/model:

NGK/CR6HSASpark plug gap:

0.6–0.7 mm (0.024–0.028 in)Clutch:

Clutch type:Wet, multiple-disc and centrifugal automatic

Transmission:Primary reduction ratio:

3.722 (67/18)Final drive:

ChainSecondary reduction ratio:

2.500 (35/14)Transmission type:

Constant mesh 4-speedOperation:

Left foot operationGear ratio:

1st:3.166 (38/12)

2nd:1.941 (33/17)

3rd:1.380 (29/21)

4th:1.095 (23/21)

Chassis:Frame type:

BackboneCaster angle:

26.00 °

Trail:60 mm (2.4 in)

Front tire:Type:

With tubeSize:

2.50-14 4PRManufacturer/model:

CHEN SHIN/C-803-2Speed rating:

120 km/h (75 mph)Rear tire:

Type:With tube

Size:3.00-12 4PR

Manufacturer/model:CHEN SHIN/C-803-2

Speed rating:120 km/h (75 mph)

Loading:Maximum rider weight:

60.0 kg (132 lb)Tire air pressure (measured on cold

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:14x1.40

Rear wheel:Wheel type:

Spoke wheelRim size:

12x1.60Front brake:

Type:Drum brake

Operation:Right hand operation

Rear brake:Type:

Drum brakeOperation:

Right foot operationFront suspension:

Type:Telescopic fork

Spring/shock absorber type:Coil spring/oil damper

Wheel travel:115 mm (4.5 in)

Rear suspension:Type:

SwingarmSpring/shock absorber type:

Coil spring/gas-oil damperWheel travel:

110 mm (4.3 in)Electrical system:

Ignition system:DC CDI

Charging system:AC magneto


SPECIFICATIONS

9-3

9

Battery:Model:

GT4B-5Voltage, capacity:

12 V, 2.5 AhFuse:

Fuse:10.0 A

EAU51132

For Europe only

The figures quoted are emission levelsand are not necessarily safe workinglevels. Whilst there is a correlation be-tween the emission and exposure lev-els, this cannot be used reliably todetermine whether or not further pre-cautions are required. Factors that in-fluence the actual level of exposure ofwork-force include the characteristicsof the work room, the other sources ofnoise, etc. i.e. the number of machinesand other adjacent processes, and thelength of time for which an operator isexposed to the noise. Also the permis-sible exposure level can vary fromcountry. This information, however, willenable the user of the machine to makea better evaluation of the hazard andrisk.


CONSUMER INFORMATION

10-1

10

EAU53562

Identification numbersRecord the vehicle identification num-ber, engine serial number, and themodel label information in the spacesprovided below. These identificationnumbers are needed when registeringthe vehicle with the authorities in yourarea and when ordering spare partsfrom a Yamaha dealer.

VEHICLE IDENTIFICATION NUMBER:

ENGINE SERIAL NUMBER:

MODEL LABEL INFORMATION:

EAU26401

Vehicle identification number

The vehicle identification number isstamped into the steering head pipe.Record this number in the space pro-vided.

TIP

The vehicle identification number isused to identify your motorcycle andmay be used to register your motorcy-cle with the licensing authority in yourarea.

EAU26441

Engine serial number

The engine serial number is stampedinto the crankcase.

EAU36981

Model label

1. Vehicle identification number

1

1. Engine serial number

1. Model label

1

1


CONSUMER INFORMATION

10-2

10

The model label is affixed to the framebehind panel B. (See page 7-7.) Re-cord the information on this label in thespace provided. This information willbe needed when ordering spare partsfrom a Yamaha dealer.

EAU48121

Vehicle Emission Control Informa-

tion label (For Canada)

The Vehicle Emission Control Informa-tion label is affixed at the location in theillustration. This label shows specifica-tions related to exhaust emissions asrequired by federal law, state law andEnvironment Canada.

1. Vehicle Emission Control Information label

1


11-1

11

INDEX

AAir filter element, cleaning .................... 7-11

BBattery .................................................. 7-26Brake lever.............................................. 4-2Brake lever, checking and

lubricating........................................... 7-23Brake lever free play, adjusting ............ 7-18Brake pedal ............................................ 4-3Brake pedal, checking and

lubricating........................................... 7-24Brake pedal free play, adjusting........... 7-19Brake shoes, checking ......................... 7-20

CCables, checking and lubricating ......... 7-23Carburetor, adjusting............................ 7-14Care ........................................................ 8-1Clutch free play, adjusting.................... 7-17

DDrive chain, cleaning and lubricating ... 7-22Drive chain slack .................................. 7-21

EEngine break-in ...................................... 6-3Engine idling speed .............................. 7-14Engine oil ................................................ 7-9Engine serial number............................ 10-1Engine, starting a warm.......................... 6-2Engine stop switch ................................. 4-2

FFront fork, checking ............................. 7-25Fuel......................................................... 4-3Fuel cock ................................................ 4-6Fuel tank breather hose.......................... 4-6Fuel tank cap.......................................... 4-3

Fuse, replacing..................................... 7-28H

Handlebar switches ............................... 4-1I

Identification numbers ......................... 10-1K

Kickstarter .............................................. 4-7L

Labels, location ...................................... 1-1M

Main switch ............................................ 4-1Maintenance and lubrication, periodic... 7-4Maintenance, emission control

system ................................................. 7-3Matte color, caution ............................... 8-1Model label........................................... 10-1

PPanels, removing and installing ............. 7-7Parking ................................................... 6-4Part locations ......................................... 3-1

SSafety information .................................. 2-1Seat ........................................................ 4-8Shifting ................................................... 6-2Shift pedal .............................................. 4-2Shift pedal, checking ........................... 7-20Shock absorber assembly ..................... 4-8Sidestand ............................................... 4-9Sidestand, checking and lubricating.... 7-24Spark arrester, cleaning ....................... 7-13Spark plug, checking ............................. 7-8Specifications......................................... 9-1Starter (choke) lever ............................... 4-7

Starting and warming up a cold engine...................................................6-1

Starting circuit cut-off system ................4-9Start switch.............................................4-2Steering, checking ................................7-25Storage ...................................................8-3Supporting the motorcycle ...................7-28Swingarm pivots, lubricating ................7-24

TThrottle grip and cable, checking and

lubricating...........................................7-23Throttle grip free play, checking ...........7-15Tires ......................................................7-15Tool kit ....................................................7-2Troubleshooting....................................7-32Troubleshooting chart...........................7-34

VValve clearance.....................................7-15Vehicle Emission Control Information

label (For Canada) ..............................10-2Vehicle identification number ...............10-1

WWheel bearings, checking ....................7-26Wheel (front)..........................................7-29Wheel (rear)...........................................7-31Wheels ..................................................7-17


EAU53772

WARNING

ALWAYS:• use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns.• avoid paved surfaces—pavement may seriously affect handling and control.

Improper motorcycle use can result in SEVERE INJURY or DEATH.

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR

NEVER USEON PAVED

ROADS

NEVER CARRY PASSENGERS

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.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN2014.06-0.8×1 CR

(E)


TTR 110 Owners Service Manual - The Motocross Life

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Transcript of TTR 110 Owners Service Manual - The Motocross Life