brake YAMAHA TT-R110E 2016 User Guide

Periodic maintenance an d a djustment
7-4
7
EAU69191
General maintenance an d lu brication 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 technical skills.
No. ITEM 13 5
0.6 1.8 3 16 12
30 90 150
1 *Clutch • Check operation.
• Adjust if necessary.
√√ √
2 *Front brake • Check operation.
• Adjust brake lever free play and
replace brake shoes if neces-
sary. √√ √
3 *Rear brake • Check operation.
• Adjust brake pedal free play
and replace brake shoes if nec-
essary. √√ √
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 bearin gs • Check bearings for smooth op-
eration.
• Replace if necessary. √√
7 *Swin
garm pivot
b earin gs • Check bearing assemblies for
looseness.
• Moderately repack with lithium- soap-based grease. √√
8Drive chain • Check chain slack/alignment
and condition.
• Adjust and lubricate chain with Yamaha chain lubricant or other
suitable chain lubricant thor-
oughly. Every rideX 1000 km
X 1000 mi month
CHECKS AND
MAINTENANCE JOBS
hours
INITIALODOMETER READINGS
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Periodic maintenance an d a djustment
7-5
7
EAU40001
TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty
areas.
9 *Steerin g b earin gs • 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 pe
dal pivot
shaft • Apply lithium-soap-based
grease lightly. √√
13 Si destan d pivot • Check operation.
• Apply lithium-soap-based
grease lightly. √√
14 *Front fork • Check operation and for oil
leakage.
• Replace if necessary. √√
15 *Shock ab
sorber as-
sem bly • Check operation and for oil
leakage.
• Replace if necessary. √
16 *Control ca bles • Apply Yamaha cable lubricant
or other suitable cable lubricant
thoroughly. √√ √
17 *Throttle grip • Check operation.
• Check throttle grip free play,
and adjust if necessary.
• Lubricate cable and grip hous- ing. √√ √
No. ITEM
13 5
0.6 1.8 3 16 12
30 90 150
X 1000 km X 1000 mi month
CHECKS AND
MAINTENANCE JOBS
hours
INITIALODOMETER READINGS
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Periodic maintenance an d a djustment
7-18
7
EAU44886
A djustin g the brake lever free
play
Measure the brake lever free play as
shown.
Periodically check the brake lever free
play and, if necessary, adjust it as fol-
lows.
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 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 thebrake 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 free play, turn the adjusting bolt at the
brake shoe plate in direction (a).
To decrease the brake lever free
play, turn the adjusting bolt in di-
rection (b).
7. Tighten the locknut at the brake shoe plate.
8. Tighten the locknut at the brake lever, and then slide the rubber
cover to its original position.
1. Rubber cover
2. Brake lever free play adjusting bolt
3. Locknut
4. Brake lever free play
Brake lever free play:10.0–20.0 mm (0.39–0.79 in)
3
21
(b)
(a) 4
1. Locknut
2. Brake lever free play adjusting bolt
2
1
(b)
(a)
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Periodic maintenance an d a djustment
7-19
7
EAU44673
A djustin g the brake pe dal free
play
Measure the brake pedal free play at
the brake pedal end as shown.
Periodically check the brake pedal free
play and, if necessary, adjust it as fol-
lows.
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 a djustin g the drive chain
slack or removin g an d installin g
the rear wheel, always check
the brake pe dal free play.
 If proper a djustment cannot b e
o btaine d as descri bed , have a
Yamaha dealer make this a d-
justment.
EAU44821
Checkin g the shift pe dal
The operation of the shift pedal should
be checked before each ride. If opera-
tion is not smooth, have a Yamaha
dealer check the vehicle.
1. Brake pedal free play adjusting nut
2. Brake pedal free play
Brake ped al free play:
10.0–20.0 mm (0.39–0.79 in)
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Periodic maintenance an d a djustment
7-20
7
EAU22363
Checkin g the front an d rear
b rake shoes
Front
Rear
The front and rear brake shoes must be
checked for wear at the intervals spec-
ified in the periodic maintenance 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 set.
EAU22762
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22776To check the d rive chain slack
1. Place the motorcycle on the side- stand.
TIP
When checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.
2. Shift the transmission into the neutral position.
3. Measure the drive chain slack as shown.
4. If the drive chain slack is incorrect, adjust it as follows.
EAU40115To a djust 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.
1. Brake shoe wear indicator
2. Brake shoe wear limit line
1. Brake shoe wear indicator
2. Brake shoe wear limit line
2
1
12
Drive chain slack:
40.0–56.0 mm (1.57–2.20 in)
1. Drive chain slack
1
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Periodic maintenance an d a djustment
7-21
7
2. To tighten the drive chain, turn thedrive chain slack adjusting nut at
each end of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting nut at each end
of the swingarm in direction (b),
and then push the rear wheel for-
ward. NOTICE: Improper drive
chain slack will overload the en-
g ine as well as other vital parts
of the motorcycle an d can lead
to chain slippa ge or breakag e.
To prevent this from occurrin g,
keep the d rive chain slack with-
in the specifie d limits.
[ECA10572]
TIP
Using the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the same
position for proper wheel alignment.
3. Tighten the axle nut and both
locknuts to the specified torques.
4. Adjust the brake pedal free play. (See page 7-19.)
5. Make sure that the drive chain pullers are in the same position,
the drive chain slack is correct,
and the drive chain moves
smoothly.
1. Brake pedal free play adjusting nut
2. Locknut
3. Drive chain slack adjusting nut
1. Axle nut
2. Locknut
3. Drive chain slack adjusting nut
32
1
1. Alignment marks
2. Locknut
3. Drive chain slack adjusting nut
4. Drive chain puller
Ti
ghtening 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)
432 1
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Periodic maintenance an d a djustment
7-23
7
EAU23115
Checkin g an d lu bricatin g the
throttle grip an d ca ble
The operation of the throttle grip
should be 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 onto the cover or
cable when washing the vehicle. If the
cable or cover becomes dirty, wipe
clean with a moist cloth.
EAU43623
Checkin g an d lu bricatin g the
b rake lever
The operation of the brake lever should
be checked before each ride, and the
lever pivot should be lubricated if nec-
essary.
Recommen ded lu bricant:
Lithium-soap-based grease
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Periodic maintenance an d a djustment
7-24
7
EAU23185
Checkin g an d lu bricatin g the
b rake pe dal
The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
EAU23203
Checkin g an d lu bricatin g the
si destan d
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated
if necessary.
WARNING
EWA10732
If the si destan d d oes not move up
an d d own smoothly, have a Yamaha
d ealer check or repair it. Otherwise,
the si destan d coul d contact the
g roun d an d d istract the operator, re-
sultin g in a possib le loss of control.
Recommen ded lu bricant:
Lithium-soap-based grease
Recommen ded lu bricant:
Lithium-soap-based grease
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Periodic maintenance an d a djustment
7-25
7
EAUM1653
Lub ricatin g the swin garm piv-
ots
The swingarm pivots must be lubricat-
ed by a Yamaha dealer at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU23273
Checkin g the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
To check the con dition
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 avoi d injury,
securely support the vehicle so
there is no dan ger of it fallin g
over.
[EWA10752]
2. While applying the front brake, push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
NOTICE
ECA10591
If any damag e is foun d or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
Recommen ded lu bricant:
Lithium-soap-based grease
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Periodic maintenance an d a djustment
7-29
7
EAU24351
Supportin g the motorcycle
Since 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 of the motorcy- cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing a
jack under the frame in front of the
rear wheel.
2. Raise the front wheel off the ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU24361
Front wheel
EAU56491
To remove the front wheel
WARNING
EWA10822
To avoi d injury, securely support the
vehicle so there is no dan ger of it
fallin g 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.
1. Rubber cover
2. Brake lever free play adjusting bolt
3. Locknut
1. Axle nut
2. Washer
(a)
3
21
(a)
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