ABS YAMAHA TTR110 2009 Owners Manual

TABLE OF CONTENTS
SAFETY INFORMATION .................. 1-1
DESCRIPTION .................................. 2-1
Left view .......................................... 2-1
Right view ........................................ 2-2
Controls and instruments ................2-3
INSTRUMENT AND CONTROL
FUNCTIONS....................................... 3-1
Main switch ..................................... 3-1
Handlebar switches ........................ 3-1
Shift pedal ......................................3-2
Brake lever ..................................... 3-2
Brake pedal .................................... 3-3
Fuel tank cap .................................. 3-3
Fuel ................................................ 3-3
Fuel tank breather hose ................. 3-5
Fuel cock ........................................ 3-5
Starter (choke) lever ....................... 3-6
Kickstarter ......................................3-7
Seat ................................................ 3-7
Shock absorber assembly .............. 3-8
Sidestand ....................................... 3-8
Starting circuit cut-off system ......... 3-8
FOR YOUR SAFETY –
PRE-OPERATION CHECKS.............. 4-1
Pre-operation check list .................. 4-2OPERATION AND IMPORTANT
RIDING POINTS................................ 5-1
Starting and warming up a cold
engine ......................................... 5-1
Starting a warm engine .................. 5-2
Shifting ........................................... 5-2
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT................................... 6-1
Owner’s tool kit .............................. 6-2
Periodic maintenance chart for
the emission control system ....... 6-3
General maintenance and
lubrication chart .......................... 6-4
Removing and installing panels ..... 6-6
Checking the spark plug ................ 6-7
Engine oil ....................................... 6-8
Cleaning the air filter element ...... 6-10
Cleaning the spark arrester ......... 6-12
Adjusting the carburetor ............... 6-13
Adjusting the engine idling
speed ........................................ 6-13
Checking the throttle cable free
play ........................................... 6-14
Valve clearance ........................... 6-14
Tires ............................................. 6-15
Spoke wheels .............................. 6-16
Adjusting the clutch free play ....... 6-16Adjusting the brake lever free
play ........................................... 6-17
Adjusting the brake pedal free
play ........................................... 6-18
Checking the shift pedal ............... 6-19
Checking the front and rear brake
shoes ........................................ 6-19
Drive chain slack .......................... 6-20
Cleaning and lubricating the drive
chain ......................................... 6-21
Checking and lubricating the
cables ....................................... 6-22
Checking and lubricating the
throttle grip and cable ............... 6-22
Checking and lubricating the
brake lever ................................ 6-23
Checking and lubricating the
brake pedal ............................... 6-23
Checking and lubricating the
sidestand .................................. 6-23
Lubricating the swingarm pivots ... 6-24
Checking the front fork ................. 6-24
Checking the steering .................. 6-25
Checking the wheel bearings ....... 6-25
Battery .......................................... 6-25
Replacing the fuse ....................... 6-27
Supporting the motorcycle ........... 6-27
Front wheel .................................. 6-28
Rear wheel ................................... 6-29
Troubleshooting ........................... 6-31
Troubleshooting chart .................. 6-32
U5B681E0.book Page 1 Tuesday, June 17, 2008 5:48 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-8
3
EAU46021
Shock absorber assembly
WARNING
EWA10221
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 Yamahadealer for any service.
EAU37490
Sidestand The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.
WARNING
EWA14190
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, resultingin a possible loss of control.
EAU41611
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 according
to the following procedure.TIPThis check is most reliable if performedwith a warmed-up engine.
U5B681E0.book Page 8 Tuesday, June 17, 2008 5:48 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
6
EAU40000
TIPThe air filter needs more frequent service if you are riding in unusually wet or dusty areas.10*Chassis fastenersCheck all chassis fitting and fasteners.
Correct if necessary.√√√
11 Brake lever pivot shaftApply lithium-soap-based grease lightly.√√
12 Brake pedal pivot shaftApply lithium-soap-based grease lightly.√√
13 Sidestand pivotCheck operation.
Apply lithium-soap-based grease lightly.√√
14*Spark arresterClean.√
15*Front forkCheck operation and for oil leakage.
Replace if necessary.√√
16*Shock absorber assem-
blyCheck operation and for oil leakage.
Replace if necessary.√
17*Control cablesApply Yamaha chain and cable lube or engine oil thor-
oughly.√√√
18*Throttle grip housing and
cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√ No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL ODOMETER READINGS
1000 km
(600 mi) or
1 month or
30 hours3000 km
(1800 mi) or
6 months or
90 hours5000 km
(3000 mi) or
12 months or
150 hoursU5B681E0.book Page 5 Tuesday, June 17, 2008 5:48 PM

MOTORCYCLE CARE AND STORAGE
7-2
7 contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, 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 com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield isscratched, use a quality plastic
polishing compound after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse 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 seaSince 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 wa-
ter and a mild detergent, after the
engine has cooled down.
NOTICE: Do not use warm water
since it increases the corrosive
action of the salt.
[ECA10791]
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (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 damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
WARNING
EWA14501
Contaminants on the brakes or tires
can cause loss of control.
U5B681E0.book Page 2 Tuesday, June 17, 2008 5:48 PM

SPECIFICATIONS
8-2
8
Type × quantity:
VM16 x 1Spark plug (s):Manufacturer/model:
NGK/CR6HSA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:
Wet, multiple-disc and centrifugal
automaticTransmission:Primary reduction system:
Spur gear
Primary reduction ratio:
67/18 (3.722)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
35/14 (2.500)
Transmission type:
Constant mesh 4-speed
Operation:
Left foot operation
Gear ratio:
1st:
38/12 (3.166)
2nd:
33/17 (1.941)
3rd:
29/21 (1.380)
4th:
23/21 (1.095)
Chassis:Frame type:
Steel tube backbone
Caster angle:
26.00 °
Trail:
60.0 mm (2.36 in)Front tire:Type:
With tube
Size:
2.50-14 4PR
Manufacturer/model:
CHEN SHIN/C-803-2Rear tire:Type:
With tube
Size:
3.00-12 4PR
Manufacturer/model:
CHEN SHIN/C-803-2Loading: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 wheelRim size:
14x1.40
Rear wheel:Wheel type:
Spoke wheel
Rim size:
12x1.60Front brake:Type:
Drum brake
Operation:
Right hand operationRear brake:Type:
Drum brake
Operation:
Right foot operationFront suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
115.0 mm (4.53 in)Rear suspension:Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
110.0 mm (4.33 in)Electrical system:Ignition system:
DC. CDI
U5B681E0.book Page 2 Tuesday, June 17, 2008 5:48 PM

INDEX
AAir filter element, cleaning .................... 6-10BBattery .................................................. 6-25
Brake lever ............................................. 3-2
Brake lever, checking and lubricating ... 6-23
Brake lever free play, adjusting ............ 6-17
Brake pedal ............................................ 3-3
Brake pedal, checking and
lubricating ........................................... 6-23
Brake pedal free play, adjusting ........... 6-18
Brake shoes, checking ......................... 6-19CCables, checking and lubricating .......... 6-22
Carburetor, adjusting ............................ 6-13
Care ........................................................ 7-1
Clutch free play, adjusting .................... 6-16DDrive chain, cleaning and lubricating .... 6-21
Drive chain slack .................................. 6-20EEngine break-in ...................................... 5-3
Engine idling speed .............................. 6-13
Engine oil ................................................ 6-8
Engine, starting a warm .......................... 5-2
Engine stop switch.................................. 3-2FFront fork, checking .............................. 6-24
Fuel......................................................... 3-3
Fuel cock ................................................ 3-5
Fuel tank breather hose.......................... 3-5
Fuel tank cap .......................................... 3-3
Fuse, replacing ..................................... 6-27
HHandlebar switches ................................. 3-1IIdentification numbers ............................. 9-1KKey identification number ........................ 9-1
Kickstarter ............................................... 3-7MMain switch ............................................. 3-1
Maintenance and lubrication, periodic..... 6-4
Maintenance, emission control system ... 6-3
Matte color, caution .................................7-1
Model label .............................................. 9-2PPanels, removing and installing .............. 6-6
Parking ....................................................5-4
Part locations .......................................... 2-1
Pre-operation check list........................... 4-2SSafety information ...................................1-1
Seat ......................................................... 3-7
Shifting ....................................................5-2
Shift pedal ............................................... 3-2
Shift pedal, checking ............................. 6-19
Shock absorber assembly ....................... 3-8
Sidestand ................................................ 3-8
Sidestand, checking and lubricating...... 6-23
Spark arrester, cleaning ........................ 6-12
Spark plug, checking ...............................6-7
Specifications .......................................... 8-1
Starter (choke) lever................................ 3-6
Starting and warming up a cold engine ... 5-1
Starting circuit cut-off system .................. 3-8
Start switch.............................................. 3-2Steering, checking ................................ 6-25
Storage ................................................... 7-3
Supporting the motorcycle .................... 6-27
Swingarm pivots, lubricating ................. 6-24
TThrottle cable free play, checking ......... 6-14
Throttle grip and cable, checking and
lubricating ........................................... 6-22
Tires ...................................................... 6-15
Tool kit .................................................... 6-2
Troubleshooting .................................... 6-31
Troubleshooting chart ........................... 6-32VValve clearance .................................... 6-14
Vehicle identification number .................. 9-1WWheel bearings, checking..................... 6-25
Wheel (front) ......................................... 6-28
Wheel (rear) .......................................... 6-29
Wheels .................................................. 6-16
U5B681E0.book Page 1 Tuesday, June 17, 2008 5:48 PM