2008 Yamaha TT-R110, TT-R110EX Service Manual

Technical Scope of the 2008–2012 Yamaha TT-R110EX

• Covers the 2008–2012 Yamaha TT-R110 and TT-R110EX (5B61) off-road motorcycles, including specific chassis and engine configurations for the U.S. market.
• Official Yamaha publication P/N LIT-11616-21-48, first edition published August 2007.
• Contains 8 major chapters, including hundreds of technical pages with detailed exploded-view diagrams, electrical schematics, and torque specifications.
• Stored against your account so you can retrieve it after a hard-drive loss.
• OCR text layer lets you jump to a torque spec by keyword.
• This 2007 first edition is 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 TT-R110 and TT-R110EX service documentation provides exhaustive technical information regarding vehicle maintenance and system assemblies. The text spans from basic vehicle identification and periodic maintenance schedules to deep-dive engine teardowns, chassis adjustments, and electrical system diagnostics. It documents the air-cooled 4-stroke SOHC engine, the 4-speed constant-mesh transmission, and the drum-braked chassis components, offering specialized guidance for qualified mechanics.

Separate chapters detail the fuel system, wiring routing, and suspension maintenance, emphasizing proper assembly and torque values for every fastener. By summarizing wear limits for clutch components, valve clearances, and piston ring end gaps, this manual allows for precise monitoring of engine state-of-health. The documentation for periodic maintenance ensures long-term reliability through structured service intervals for oil changes, chain tensioning, and brake adjustments.

Specification Highlights

Engine compression is documented at 1300 kPa (185 psi) at 500 r/min. The valve clearance is listed at 0.05–0.09 mm for intake and 0.08–0.12 mm for exhaust. Primary clutch housing nut torque is specified at 50 Nm. Rear wheel axle nut torque is documented at 60 Nm. Drive chain slack is defined at 40.0–56.0 mm. For reference, understanding how factory workshop documentation is structured is essential for effective maintenance of these small-displacement off-roaders. Note: This page is a contents overview for the manual. It does not provide repair or diagnostic instructions. An official 100-page Yamaha OEM workshop manual covering the 2008–2012 TT-R110/TT-R110EX, documenting engine, chassis, and electrical specifications for the 5B61-series build.