Yamaha TT-R 110 Owner'S Manual Download Page 10

Page: 10 / 88

TABLE OF CONTENTS

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

.......................................... 8-1

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

SPECIFICATIONS

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

CONSUMER INFORMATION

......... 10-1

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

INDEX

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

UB5180E0.book Page 2 Monday, June 9, 2014 1:20 PM

Summary of Contents for TT-R 110

Page 1: ...IÉTAIRE 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 ...

Page 2: ...PRINTED IN JAPAN 2014 06 0 8 1 CR E F G DIC183 PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ AUF RECYCLINGPAPIER GEDRUCKT Original instructions Notice originale Originalbetriebsanleitung ...

Page 3: ...Read this manual carefully before operating this vehicle OWNER S MANUAL TT R110E TT R110EF B51 28199 80 E0 UB5180E0 book Page 1 Monday June 9 2014 1 20 PM ...

Page 4: ...al health and 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 requirements stated in the Directives of EEC the following standards and or technical specifications were consulted Title and or number and date of issue of standards and or specifications Authori...

Page 5: ... attention to the recommended maintenance schedules and operating instructions contained within this manual Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur rent product information available at the time of printing there may be minor discrepancies between your motorcycle and this manual If there is any question concerning this m...

Page 6: ...torcycle safely Parents should supervise their child s use of the motorcycle at all times Parents should permit continued use only if they determine that the child has the ability to operate the motorcycle safely Motorcycles are single track vehicles Their safe use and operation are dependent upon the use of proper riding techniques as well as the expertise of the operator Every operator should kn...

Page 7: ...tential 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...

Page 8: ...WNER 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 UB5180E0 book Page 2 Monday June 9 2014 1 20 PM ...

Page 9: ...g panels 7 7 Checking the spark plug 7 8 Engine oil 7 9 Cleaning the air filter element 7 11 Cleaning the spark arrester 7 13 Adjusting the carburetor 7 14 Adjusting the engine idling speed 7 14 Checking the throttle grip free play 7 15 Valve clearance 7 15 Tires 7 15 Spoke wheels 7 17 Adjusting the clutch free play 7 17 Adjusting the brake lever free play 7 18 Adjusting the brake pedal free play ...

Page 10: ...32 Troubleshooting chart 7 34 MOTORCYCLE CARE AND STORAGE 8 1 Matte color caution 8 1 Care 8 1 Storage 8 3 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 INDEX 11 1 UB5180E0 book Page 2 Monday June 9 2014 1 20 PM ...

Page 11: ...ey contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer For Canada 1 2 3 5 6 7 8 4 UB5180E0 book Page 1 Monday June 9 2014 1 20 PM ...

Page 12: ... be set as follows FRONT 100kPa 1 00kgf cm2 15psi REAR 100kPa 1 00kgf cm2 15psi 3RV 21668 A0 TIRE INFORMATION La pression des pneus à froid doit normalement être réglée comme suit AVANT 100kPa 1 00kgf cm2 15psi ARRIERE 100kPa 1 00kgf cm2 15psi 3RV 21668 B0 INFORMATION SUR LES PNEUS UB5180E0 book Page 2 Monday June 9 2014 1 20 PM ...

Page 13: ...umage par étincelle de véhicule respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada THIS VEHICLE IS A RESTRICTED USE MOTORCYCLE AND IS NOT INTENDED FOR USE ON PUBLIC HIGHWAYS CE VÉHICULE EST UNE MOTOCYCLETTE À USAGE RESTREINT DONT L USAGE N EST PAS DESTINÉ AUX VOIES PUBLIQUES 3PT 2416E 10 3PT 2118K A1 5 6 8 7 UB5180E0 book Page 3 Monday June 9 2014 1 20 PM ...

Page 14: ...LOCATION OF IMPORTANT LABELS 1 4 1 For Europe 4 1 2 5 3 UB5180E0 book Page 4 Monday June 9 2014 1 20 PM ...

Page 15: ... 2816R 00 100 kPa 1 00 kgf cm 15 psi 100 kPa 1 00 kgf cm 15 psi 4AA 22259 40 5B6 2156A 10 TT R110E 5 4 kW 72 kg 5B6 2816R 00 5B6 2817L 00 YAMAHAMOTORCO LTD 2500SHINGAI IWATA JAPAN 2014 EN16029 1 5 2 4 3 UB5180E0 book Page 5 Monday June 9 2014 1 20 PM ...

Page 16: ...se 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 UB5180E0 book Page 6 Monday J...

Page 17: ...Use 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 UB5180E0 book Page 7 Monday June 9 2014 1 20 PM ...

Page 18: ...LOCATION OF IMPORTANT LABELS 1 8 1 For Oceania and South Africa 1 3 2 UB5180E0 book Page 8 Monday June 9 2014 1 20 PM ...

Page 19: ...ania and South Africa TIRE INFORMATION Cold tire normal pressure should be set as follows FRONT 100kPa 1 00kgf cm2 15psi REAR 100kPa 1 00kgf cm2 15psi 3RV 21668 A0 4AA 22259 40 3PT 2118K A1 1 2 3 UB5180E0 book Page 9 Monday June 9 2014 1 20 PM ...

Page 20: ...tion Failure to inspect or maintain the vehi cle properly increases the possibility of an accident or equipment damage See page 5 1 for a list of pre operation checks This motorcycle is designed for off road use only therefore it is il legal to operate it on public streets roads or highways even a dirt or gravel one Off road use on public lands may be illegal Please check local regulations be fore...

Page 21: ...nts are the result of head in juries The use of a safety helmet is the single most critical factor in the pre vention or reduction of head injuries Always wear an approved helmet Wear a face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or re...

Page 22: ...s of the motorcycle to minimize imbalance or instability Shifting weights can create a sud den imbalance Make sure that accessories are securely attached to the motorcycle before riding Check accessory mounts fre quently Properly adjust the suspension for your load suspension ad justable models only and check the condition and pres sure of your tires Never attach any large or heavy items to the ha...

Page 23: ...movement of the operator and may limit control ability therefore such accesso ries are not recommended Use caution when adding electri cal accessories If electrical ac cessories exceed the capacity of the motorcycle s electrical sys tem an electric failure could re sult which could cause a dangerous loss of lights or engine power Aftermarket Tires and Rims The tires and rims that came with your mo...

Page 24: ...y so the straps will not rub against painted 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 UB5180E0 book Page 5 Monday June 9 2014 1 20 PM ...

Page 25: ...Fuel cock page 4 6 2 Starter choke lever page 4 7 3 Fuse page 7 28 4 Battery page 7 26 5 Clutch adjusting screw page 7 17 6 Engine oil drain bolt page 7 9 7 Shift pedal page 4 2 8 Throttle stop screw page 7 14 UB5180E0 book Page 1 Monday June 9 2014 1 20 PM ...

Page 26: ...6 1 Spark arrester page 7 13 2 Seat page 4 8 3 Fuel tank cap page 4 3 4 Air filter element page 7 11 5 Spark plug cap page 7 8 6 Engine oil filler cap page 7 9 7 Brake pedal page 4 3 8 Kickstarter page 4 7 UB5180E0 book Page 2 Monday June 9 2014 1 20 PM ...

Page 27: ... EAU10431 Controls and instruments 1 2 3 4 5 1 Engine stop switch page 4 1 2 Main switch page 4 1 3 Start switch page 4 1 4 Brake lever page 4 2 5 Throttle grip page 7 15 UB5180E0 book Page 3 Monday June 9 2014 1 20 PM ...

Page 28: ...e engine can be started The key cannot be removed EAU45752 OFF All electrical systems are off The key can be removed WARNING EWA10073 Never turn the key to OFF while the vehicle is moving otherwise the electrical systems will be switched off which may result in loss of con trol or an accident EAU1234H Handlebar switches Left Right 1 Engine stop switch 1 Start switch 1 UB5180E0 book Page 1 Monday J...

Page 29: ...ne with the starter See page 6 1 for start ing instructions prior to starting the en gine EAU39852 Shift pedal This motorcycle is equipped with a constant mesh 4 speed transmission The shift pedal is located on the left side of the motorcycle Neutral is at the bottom position EAU12892 Brake lever The brake lever is located on the right side of the handlebar To apply the front brake pull the lever ...

Page 30: ... in the 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 refuel while smoking or while in the vi cinity of sparks open flames or other sources of ignition such as the pilot ...

Page 31: ... been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that con taining ...

Page 32: ...or Oceania and South Africa NOTICE ECA11401 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand...

Page 33: ...e fuel cock supplies fuel from the tank to the carburetor while filtering it also The fuel cock has three positions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not run ning ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES 1 Fuel tank breather hose 1 1 Arro...

Page 34: ...s supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke EAU37651 Kickstarter If the engine fails to start by pushing the start switch try to start it by using the kickstarter To start the engine fold out the kickstarter lever move it down lightly with your foot until the gears en gage and then push it do...

Page 35: ...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 w...

Page 36: ...rly 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 system The starting circuit cut off system pre vents starting when the transmission is in gear Periodically check the operation of the starting circuit cut off system accord ing to the following procedure TIP This chec...

Page 37: ...king correctly The motorcycle should not be ridden until checked 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 until checked by a Yamaha dealer YES NO The system is OK The motorcycle can be ridden YES NO If a malfunction is noted have a Yamaha de...

Page 38: ...cle 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 n...

Page 39: ...hift 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 screw...

Page 40: ... the engine stop switch is set to 3 Shift the transmission into the neutral 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 and completely close the throttle See page 4 7 5 Start the engine by pushing the start switch or by pushing the kickstarter lever down 6 When the engine is warm ...

Page 41: ...E ECA15442 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 driv...

Page 42: ...on it for the first 5 hours of operation The various parts in the engine wear and polish them selves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in engine overheating must 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 accel...

Page 43: ...ince 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 UB5180E0 book Page 4 Monday June 9 2014 1 20 PM ...

Page 44: ...n 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 ...

Page 45: ...e intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you UB5180E0 book Page 2 Monday June 9 2014 1 20 PM ...

Page 46: ...0 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 n...

Page 47: ...0 mi or 12 months or 150 hours 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 ...

Page 48: ...hium 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 thrott...

Page 49: ...PERIODIC MAINTENANCE AND ADJUSTMENT 7 6 7 EAU40001 TIP The air filter needs more frequent service if you are riding in unusually wet or dusty areas UB5180E0 book Page 6 Monday June 9 2014 1 20 PM ...

Page 50: ...e panel 1 Remove the seat See page 4 8 2 Remove the bolts and the quick fastener screws and then take the panel off To install the panel 1 Place the panel in the original po sition and then install the bolts and the quick fastener screws 2 Install the seat Panel B To remove the panel 1 Remove the seat See page 4 8 2 Remove the bolt and then pull the panel off as shown 1 Panel A 1 1 Panel B 1 1 Pan...

Page 51: ...veal 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 insulator around the center electrode of the spark plug is a medium to light tan the ideal color when the vehi cle is ridden normally TIP If the spark plug shows a disti...

Page 52: ... the spark plug cap EAU39846 Engine oil The engine oil level should be checked before each ride In addition the oil must be changed at the intervals spec ified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the motorcycle on a level surface and hold it in an upright position A slight tilt to the side can result in a false reading 2 Start the engine warm it ...

Page 53: ... filler cap NOTICE ECA11621 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...

Page 54: ...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 recommended type to the entire surface of the sponge material and then squeeze the excess oil out TIP The sponge m...

Page 55: ...he screws TIP Make sure that the spark plug lead is inserted into the guide as shown 9 Install the panel To clean the air filter check hose 1 Check the hoses at the bottom of the air filter case for accumulated dirt or water 2 If dirt or water is visible remove the hoses clean them and then reinstall them 1 Spark plug lead 2 Guide 1 Air filter check hose 1 1 2 1 UB5180E0 book Page 12 Monday June 9...

Page 56: ...terials to clean the spark arrester 1 Remove the tailpipe by removing the bolts and then pulling it out of the muffler 2 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 3 Insert the tailpipe into the muffler and then install and tighten the bolts to the specified torque TIP Make sure...

Page 57: ...peed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart TIP A diagnostic tachometer is needed to make this adjustment 1 Attach the tachometer to the spark plug lead 2 Start the engine and warm it up for several minutes at 1000 2000 r min while occasionally revving it to 4000 5000 r min TIP The engine is warm when it qui...

Page 58: ...brication chart EAU40916 Tires Tires are the only contact between the vehicle and the road Safety in all con ditions of riding depends on a relatively small area of road contact Therefore it is essential to maintain the tires in good condition at all times and replace them at the appropriate time with the speci fied tires Tire air pressure The tire air pressure should be checked and if necessary a...

Page 59: ... the vehicle may be different which could lead to an accident After extensive tests only the tires list ed below have been approved for this model 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 ...

Page 60: ...r looseness or damage before each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire l...

Page 61: ...n the brake lever free play adjusting bolt in direction a To decrease the brake lever free play turn the adjusting bolt in direction b TIP Skip steps 4 7 if the specified brake le ver free play could be obtained as de scribed above 4 Fully turn the adjusting bolt at the brake lever in direction a to loos en the brake cable 5 Loosen the locknut at the brake shoe plate 6 To increase the brake lever ...

Page 62: ...it as follows To increase the brake pedal free play turn the brake pedal free play adjusting nut at the brake rod in direction a To decrease 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...

Page 63: ...intenance and lubrication chart Each brake is provid ed with a wear indicator which allows you to check the brake shoe wear with out having to disassemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indica tor reaches the wear limit line have a Yamaha dealer replace the brake shoes as a...

Page 64: ...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 play adjusting nut axle nut and lock nut at each end of the swingarm 2 To tighten the drive chain turn the drive chain slack adjusting nut at each end of the swingarm in direc Drive chain slack 40 0 56 0 mm...

Page 65: ...the drive chain moves smoothly EAU23018 Cleaning and lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECA10584 The drive chain must be lubricated after washing the motorcycle...

Page 66: ...checked before each ride In addition the cable should be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance chart The throttle cable is equipped with a rubber cover Make sure that the cover is securely installed Even though the cover is installed correctly it does not completely protect the cable from wa ter entry Therefore use care not to pour water directly ont...

Page 67: ...d if 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 intervals specified in the periodic maintenance and ...

Page 68: ...ront fork compresses and re bounds smoothly NOTICE ECA10591 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 steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the periodic maintenance and lubrication chart 1 Place...

Page 69: ...e 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 be checked and if necessary securely fastened WARNING EWA10761 Electrolyte is poisonous and dangerous since it contains sul furic acid which...

Page 70: ...y tends to discharge more quick ly if the vehicle is equipped with op tional electrical accessories NOTICE ECA16522 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 for more than one month remove the battery fully charge it and...

Page 71: ...this model is not equipped with a centerstand follow these precautions when removing the front and rear wheel or performing other mainte nance requiring the motorcycle to stand upright Check that the motorcy cle is in a stable and level position be fore starting any maintenance A strong wooden box can be placed un der the engine for added stability To service the front wheel 1 Stabilize the rear o...

Page 72: ...alling over 1 Slide the rubber cover back at the brake lever 2 Loosen the locknut and then turn the brake lever free play adjusting bolt fully in direction a 3 Loosen the axle nut 4 Lift the front wheel off the ground according to the procedure in the previous section Supporting the motorcycle 5 Remove the axle nut and washer 6 Pull the wheel axle out 1 Rubber cover 2 Brake lever free play adjusti...

Page 73: ... Insert the wheel axle from the right hand side and then install the washer and the axle nut 4 Lower the front wheel so that it is on the ground and then put the sidestand 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 handlebar several times to check for proper fork operation 1 Wheel axle...

Page 74: ...on both ends of the swingarm 4 Loosen the axle nut 5 Lift the rear wheel off the ground according to the procedure on page 7 28 6 Remove the axle nut washer and the drive chain puller at the left hand side then pull the wheel axle out together with the drive chain puller from the right hand side 7 Push the wheel forward and then remove the drive chain from the rear sprocket 1 Brake torque rod 2 Co...

Page 75: ... the brake pedal free play See page 7 19 EAU25852 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital...

Page 76: ...ERIODIC MAINTENANCE AND ADJUSTMENT 7 33 7 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or prop erty damage UB5180E0 book Page 33 Monday June 9 2014 1 20 PM ...

Page 77: ...check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark 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 g...

Page 78: ... outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and cov ers as well as all electrical cou plers and connectors including the spark plug cap are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Alw...

Page 79: ...thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain or near the sea Since sea salt is extremely corrosive carry out the following steps after each ride in the rain or near the sea 1 Clean the motorcycle with cold wate...

Page 80: ...ing compounds as they will wear away the paint TIP Consult a Yamaha dealer for advice on what products to use EAU26153 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover Be sure the engine and the exhaust sys tem are cool before covering the mo torcycle NOTICE ECA10811 Storing the motorcycle in a poorly ventilated room o...

Page 81: ...r 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 cap from the spark plug and then install the spark plug and the spark plug cap 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 7 Check and if necessary...

Page 82: ...DNK ESP FIN FRA GBR GRC IRL ITA NLD NOR POL PRT SVK SVN SWE TUR ZAF Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder Displacement 110 cm Bore stroke 51 0 54 0 mm 2 01 2 13 in Compression ratio 9 3 1 Starting system Electric starter and kickstarter Lubrication system Wet sump Engine oil Recommended brand YAMALUBE Type SAE 10W 30 10W 40 10W 50 15W 40 20W 40 or 20W 50 ...

Page 83: ...pe 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 cm 15 psi Rear 100 kPa 1 00 kgf cm 15 psi Front wheel Wheel type Spoke wheel Rim size 14x1 40 Rear wheel Wheel type Spoke wheel Rim size 12x1 60 Front brake Type Drum brake Operation Right hand op...

Page 84: ...not further pre cautions are required Factors that in fluence the actual level of exposure of work force include the characteristics of the work room the other sources of noise etc i e the number of machines and other adjacent processes and the length of time for which an operator is exposed to the noise Also the permis sible exposure level can vary from country This information however will enabl...

Page 85: ...RIAL NUMBER MODEL LABEL INFORMATION EAU26401 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided TIP The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area EAU26441 Engine serial number The engine serial n...

Page 86: ...are parts from 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 the illustration This label shows specifica tions related to exhaust emissions as required by federal law state law and Environment Canada 1 Vehicle Emission Control Information label 1 UB5180E0 book Page 2 Monday June 9 2014 1...

Page 87: ...brication periodic 7 4 Maintenance emission control system 7 3 Matte color caution 8 1 Model label 10 1 P Panels removing and installing 7 7 Parking 6 4 Part locations 3 1 S Safety information 2 1 Seat 4 8 Shifting 6 2 Shift pedal 4 2 Shift pedal checking 7 20 Shock absorber assembly 4 8 Sidestand 4 9 Sidestand checking and lubricating 7 24 Spark arrester cleaning 7 13 Spark plug checking 7 8 Spec...

Page 88: ...CTIVE GEAR NEVER USE ON 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 RECYC...

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