YAMAHA TT-R110E 2019 Repair Manual

Periodic maintenance an d a djustment
7-19
7
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.
EAU44673
Adjustin 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 d rive chain
slack or removin g an d installin g
the rear wheel, always check
the brake ped al free play.
 If proper a djustment cannot b e
o b taine d as descri bed , have a
Yamaha dealer make this a d-
justment.
1. Locknut
2. Brake lever free play adjusting bolt
2
1
(b)
(a)
1. Brake pedal free play adjusting nut
2. Brake pedal free play
Brake pe dal 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
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.
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.
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
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Periodic maintenance an d a djustment
7-21
7
EAU22762
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU74251To check the drive 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 theneutral position.
3. Measure the drive chain slack as shown.
4. If the drive chain slack is incorrect, adjust it as follows. NOTICE: Im-
proper drive chain slack will
overloa d the en gine as well as
other vital parts of the motorcy-
cle an d can lead to chain slip-
pa ge or b reakag e. To prevent
this from occurrin g, keep the
d rive chain slack within the
specified limits.
[ECA10572] EAU40116
To 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.
2. To tighten the drive chain, turn the drive 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.
1. Drive chain slack
Drive chain slack:40.0–56.0 mm (1.57–2.20 in)
1
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
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Periodic maintenance an d a djustment
7-22
7
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.
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.
1. Alignment marks
2. Locknut
3. Drive chain slack adjusting nut
4. Drive chain puller
Tightenin g torques:
Axle nut:
60 N·m (6.0 kgf·m, 44 lb·ft)
Locknut: 7 N·m (0.7 kgf·m, 5.2 lb·ft)
(a)
(b)
432 1
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Periodic maintenance an d a djustment
7-23
7
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 dama ged cab les as soon as
possi ble to prevent unsafe con di-
tions.
[EWA10712] 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.
Recommen ded lu bricant:
Yamaha cable lubricant or other
suitable cable lubricant
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Periodic maintenance an d a djustment
7-24
7
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.
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.
Recommen ded lu bricant:
Lithium-soap-based greaseRecommen ded lu bricant:
Lithium-soap-based grease
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Periodic maintenance an d a djustment
7-25
7
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 possi ble loss of control.
EAUM1653
Lu bricatin 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.
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
7-26
7
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 d amage is foun d or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
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.
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Periodic maintenance an d a djustment
7-27
7
EAU23292
Checkin g the wheel b earings
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.
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.
1. Battery coupler
2. Battery band
3. Battery
2
3
1
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Periodic maintenance an d a djustment
7-28
7 
Batteries pro duce 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. Using a conventional battery
char ger will dama ge the b attery.
To store the battery
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” before 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. 3. Fully charge the battery before
installation. NOTICE: When in-
stallin g the b attery, be sure the
key is turned to “OFF” before
connectin g the coupler.
[ECA16931]
NOTICE
ECA16531
Always keep the b attery charged .
Storin g a d ischar ged battery can
cause permanent b attery damag e.
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