YAMAHA TT-R110E 2016 Repair Manual

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
UB5181E0.book Page 20 Monday, April 6, 2015 9:22 AM

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
7-22
7
EAU23018
Cleanin g an d lu bricatin g the
d rive 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 lu bricate d
after washin g the motorcycle, ri din g
in the rain or ri din g in wet areas.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.
TIP
For a thorough cleaning, have a
Yamaha dealer remove the drive chain and soak it in solvent.
2. Spray Yamaha chain lubricant or other suitable chain lubricant on
the entire chain, making sure that
all side plates and rollers have
been sufficiently oiled.
EAU23098
Checkin g an d lu bricatin g the
ca bles
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubri-
cated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or re-
place it. WARNING! Dama ge to the
outer housin g of cab les may result
in internal rustin g an d cause inter-
ference with cab le movement. Re-
place damag ed cab les as soon as
possi ble to prevent unsafe con di-
tions.
[EWA10712]
Recommen ded lu bricant:
Yamaha cable lubricant or other
suitable cable lubricant
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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
7-26
7
EAU23285
Checkin g the steerin g
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. Raise the front wheel off the ground. (See page 7-29.)
WARNING! To avoi d injury, se-
curely support the vehicle so
there is no dan ger of it fallin g
over.
[EWA10752]
2. Hold the lower ends of the front fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
EAU23292
Checkin g the wheel bearin gs
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
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Periodic maintenance an d a djustment
7-27
7
EAU23397
Battery
The battery is located behind panel B.
(See page 7-6.)
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 an d
d an gerous since it contains sul-
furic aci d, which causes severe
b urns. Avoi d any contact with
skin, eyes or clothin g an d al-
ways shiel d your eyes when
workin g near b atteries. In case
of contact, ad minister the fol-
lowin g FIRST AID.
EXTERNAL: Flush with plenty of water.
INTERNAL: Drink lar ge quan-
tities of water or milk an d im-
me diately call a physician.
EYES: Flush with water for 15 minutes and seek prompt
me dical attention. 
Batteries prod uce explosive hy-
d ro gen gas. Therefore, keep
sparks, flames, ci garettes, etc.,
away from the battery an d pro-
vi de sufficient ventilation when
char gin g it in an enclose d
space.
 KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
To char ge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quick-
ly if the vehicle is equipped with op-
tional electrical accessories.
NOTICE
ECA16522
To char ge a VRLA (Valve Re gulate d
Lea d Aci d) battery, a special (con-
stant-volta ge) battery char ger is re-
quire d. Usin g a conventional battery
char ger will d amage the b attery.
To store the b attery
1. If the model will not be used for more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
NOTICE: When removin g the
b attery, be sure the key is
turne d to “OFF” b efore discon-
nectin g the coupler.
[ECA16323]
2. If the battery will be stored for
more than two months, check it at
least once a month and fully char-
ge it if necessary.
1. Battery coupler
2. Battery band
3. Battery
2 3
1
UB5181E0.book Page 27 Monday, April 6, 2015 9:22 AM