2008 Yamaha TT-R110, TT-R110EX Factory Service Manual ( P/N LIT-11616-21-48)

• Covers the 2008–2012 Yamaha TT-R110 and TT-R110EX (5B61) off-road motorcycles, detailing specific chassis and engine configurations for the U.S. market.
• Official Yamaha publication P/N LIT-11616-21-48 (first edition, August 2007).
• Contains over 100 pages of technical data, including detailed exploded-view diagrams, electrical schematics, and factory torque specifications.
• Serves as the base technical reference for the 2008 TT-R110 launch build, documenting all fundamental engine and chassis parameters for the 110cc series.

Manual Content Summary

This Yamaha service documentation provides the deep-dive technical data mechanics need to service the TT-R110 and TT-R110EX. It covers everything from basic vehicle identification to complete engine teardowns. You will find exhaustive documentation for the air-cooled 4-stroke SOHC engine, the 4-speed constant-mesh transmission, and the drum-braked chassis components. Before starting any major engine work or electrical diagnostics, always review the specific safety precautions and torque sequencing outlined in the factory literature to prevent component damage or personal injury.

The manual breaks down fuel system routing, wiring, and suspension maintenance step-by-step. It lists precise wear limits for clutch components, valve clearances, and piston ring end gaps. This allows technicians to accurately gauge engine health rather than relying on guesswork. Scheduled maintenance intervals are also fully documented, outlining the exact factory-approved procedures for oil changes, chain tensioning, and brake adjustments to ensure long-term reliability.

Specification Highlights

Quick reference points extracted from the documentation include an engine compression specification of 1300 kPa (185 psi) at 500 r/min. Valve clearances are strictly defined at 0.05–0.09 mm for the intake and 0.08–0.12 mm for the exhaust. When buttoning up the bottom end, the primary clutch housing nut requires 50 Nm of torque, while the rear wheel axle nut takes 60 Nm. Drive chain slack should be carefully maintained between 40.0 and 56.0 mm.