brake YAMAHA TTR110 2009 User Guide

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

PERIODIC MAINTENANCE AND ADJUSTMENT
6-16
6 sively worn tires decreases
riding stability and can lead to
loss of control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.


It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-quality product.
EAU21940
Spoke wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU44663
Adjusting the clutch free play The clutch free play must be checked
and, if necessary, adjusted as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Loosen the locknut.
2. Slowly turn the clutch adjusting
screw in direction (a) until resis-
tance is felt, and then turn it 1/8
turn in direction (b).
3. Tighten the locknut to the specified
torque.1. Locknut
2. Clutch adjusting screw
Tightening torque:
Locknut:
8.0 Nm (0.8 m·kgf, 5.8 ft·lbf)
12
(a)
(b)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-17
6
TIPWhen tightening the locknut, hold the
clutch adjusting screw with a screwdriv-
er so that it does not turn together withthe locknut.
EAU44881
Adjusting the brake lever free
play The brake lever free play should mea-
sure 10.0–20.0 mm (0.39–0.79 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.
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 adjusting bolt in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
bolt in direction (b).
4. If the specified brake lever free
play could be obtained as de-
scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.
5. Fully turn the adjusting bolt at the
brake lever in direction (a) to loos-
en the brake cable.
6. Loosen the locknut at the brake
shoe plate.
7. To increase the brake lever free
play, turn the adjusting bolt in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
bolt in direction (b).1. Rubber cover
2. Brake lever free play adjusting bolt
3. Locknut
4. Brake lever free play
3
2
1
(b)
(a)4
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-18
6 8. Tighten the locknut at the brake
shoe plate and at the brake lever.
9. Slide the rubber cover to its origi-
nal position.
EAU44670
Adjusting the brake pedal free
play The brake pedal free play should mea-
sure 10.0–20.0 mm (0.39–0.79 in) at
the brake pedal end as shown. Period-
ically check the brake pedal free play
and, if necessary, adjust it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).
WARNING
EWA14820


After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.


If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this ad-justment.
1. Locknut
2. Brake lever free play adjusting bolt
21(b)
(a)
1. Brake pedal free play adjusting nut
2. Brake pedal free play
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-19
6
EAU44820
Checking the shift pedal 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.
EAU22361
Checking the front and rear
brake shoes Front
RearThe 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 indicator
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 11 2
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-20
6
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.TIPWhen checking and adjusting the drive
chain slack, there should be no weighton the motorcycle.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.4. If the drive chain slack is incorrect,
adjust it as follows.
EAU40111
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut, axle nut, and locknut
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. NOTICE: Improper drive
chain slack will overload the en-
gine as well as other vital parts
of the motorcycle and can lead
to chain slippage or breakage.
To prevent this from occurring,
keep the drive chain slack with-
in the specified limits.
[ECA10571]
Drive chain slack:
40.0–56.0 mm (1.57–2.20 in)
1. Drive chain slack
1
1. Brake pedal free play adjusting nut
2. Locknut
3. Drive chain slack adjusting nut
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
6
TIPUsing the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po-sition for proper wheel alignment.
3. Tighten both locknuts and the axle
nut to the specified torques.4. Adjust the brake pedal free play.
(See page 6-18.)
EAU23013
Cleaning and lubricating the
drive 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
ECA10581
The drive chain must be lubricated
after washing the motorcycle andriding in the rain.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.TIPFor a thorough cleaning, have a
Yamaha dealer remove the drive chainand soak it in solvent.
2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on both sides
and on the middle of the chain,
1. Axle nut
2. Drive chain slack adjusting nut
3. Locknut
4. Alignment marksTightening torques:
Locknut:
7.0 Nm (0.7 m·kgf, 5.1 ft·lbf)
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
6
EAU43622
Checking and lubricating the
brake lever The operation of the brake lever should
be checked before each ride, and the
lever pivot should be lubricated if nec-
essary.
EAU23182
Checking and lubricating the
brake pedal The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
EAU23202
Checking and lubricating the
sidestand 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
EWA10731
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the sidestand could contact the
ground and distract the operator, re-sulting in a possible loss of control.
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-24
6
EAUM1650
Lubricating the swingarm piv-
ots The swingarm pivots must be lubricat-
ed at the intervals specified in the peri-
odic maintenance and lubrication chart.
EAU23272
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10751]
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
NOTICE
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
Recommended lubricant:
Lithium-soap-based grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-28
6 a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU24360
Front wheel
EAU41813
To remove the front wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of itfalling over.
1. Slide the rubber cover back.
2. Loosen the locknut at the brake le-
ver, and then turn the adjusting
bolt fully in direction (a).
3. Loosen the axle nut.4. Lift the front wheel off the ground
according to the procedure on
page 6-27.
5. Remove the axle nut and washer.
6. Pull the wheel axle out.1. Rubber cover
2. Brake lever free play adjusting bolt
3. Locknut
3
2
(a)
1
1. Axle nut
2. Washer
1. Wheel axle
U5B681E0.book Page 28 Tuesday, June 17, 2008 5:48 PM