brake YAMAHA TTR110 2010 Owner's Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
7-29
7
EAU24360
Front wheel
EAU41813
To remove the front wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling 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 7-28.
5. Remove the axle nut and washer.
6. Pull the wheel axle out.7. Remove the brake shoe assembly
from the wheel hub by pulling it
out.
8. Remove the wheel.
EAU41693
To install the front wheel
1. Install the brake shoe assembly
into the wheel hub.
2. Lift the wheel up between the fork
legs.TIPMake sure that the slot in the brake
shoe plate fits over the retainer on the
fork leg.
1. Rubber cover
2. Brake lever free play adjusting bolt
3. Locknut
3
2
(a)
1
1. Axle nut
2. Washer
1. Wheel axle
1. Brake shoe assembly
1
U5B682E0.book Page 29 Tuesday, June 9, 2009 2:04 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-30
73. Insert the wheel axle from the
right-hand side, and then install
the washer and the axle nut.
4. Lower the front wheel so that it is
on the ground, and then put the
sidestand down.
5. Tighten the axle nut to the speci-
fied torque.
6. Adjust the brake lever free play.
(See page 7-18.)7. While applying the front brake,
push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU41644
To remove the rear wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Disconnect the brake torque rod
from the brake shoe plate by re-
moving the cotter pin, the nut and
the bolt.
1. Slot
2. RetainerTightening torque:
Axle nut:
35 Nm (3.5 m·kgf, 25 ft·lbf)
21
1. Brake torque rod
2. Cotter pin
3. Brake torque rod bolt and nut
4. Brake shoe plate
U5B682E0.book Page 30 Tuesday, June 9, 2009 2:04 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-31
7 2. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod at the brake cam-
shaft lever.
3. Loosen the locknut and the drive
chain slack adjusting nut on both
ends of the swingarm.4. Loosen the axle nut.
5. Lift the rear wheel off the ground
according to the procedure on
page 7-28.
6. Remove the axle nut, washer and
the drive chain puller at the left-
hand side, then pull the wheel axle
out together with the drive chain
puller from the right-hand side.
7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
TIPThe drive chain does not need to be
disassembled in order to remove and
install the wheel.8. Remove the wheel.
EAU41654
To install the rear wheel
1. Install the drive chain onto the rear
sprocket.
2. Lift the rear wheel off the ground,
and then install the drive chain
puller and the wheel by inserting
the wheel axle from the right-hand
side.
3. Install the drive chain puller, wash-
er and axle nut.
1. Brake rod
2. Brake pedal free play adjusting nut
3. Brake camshaft lever
4. Wheel axle
1. Axle nut
2. Washer
3. Drive chain puller
4. Drive chain slack adjusting nut
5. Locknut
1
2
3
5 4
U5B682E0.book Page 31 Tuesday, June 9, 2009 2:04 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-32
74. Lower the rear wheel so that it is
on the ground, and then put the
sidestand down.
5. Install the brake rod onto the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.
6. Connect the brake torque rod to
the brake shoe plate by installing
the bolt and nut, and then tighten
the nut to the specified torque.
7. Insert a new cotter pin.
8. Adjust the drive chain slack. (See
page 7-21.)
9. Tighten the axle nut to the speci-
fied torque.
10. Adjust the brake pedal free play.
(See page 7-19.)
EAU25851
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
WARNING
EWA15141
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from waterheaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or
property damage.
Tightening torque:
Brake torque rod nut:
26 Nm (2.6 m·kgf, 19 ft·lbf)
Tightening torque:
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
U5B682E0.book Page 32 Tuesday, June 9, 2009 2:04 PM

MOTORCYCLE CARE AND STORAGE
8-2
8 off any detergent residue using
plenty of water, as it is harmful
to plastic parts.


Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
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 is
scratched, use a quality plastic
polishing compound after
washing.
After normal useRemove 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.
U5B682E0.book Page 2 Tuesday, June 9, 2009 2:04 PM

MOTORCYCLE CARE AND STORAGE
8-3
88. Let the motorcycle dry completely
before storing or covering it.
WARNING
EWA14501
Contaminants on the brakes or tires
can cause loss of control.

Make sure that there is no oil or
wax on the tires.


If necessary, wash the tires with
warm water and a mild deter-
gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor-
nering behavior.
NOTICE
ECA10800


Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.


Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.


Avoid using abrasive polishing
compounds as they will wear
away the paint.
TIPConsult a Yamaha dealer for advice on
what products to use.
EAU26151
Storage Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.NOTICE
ECA10810


Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.


To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your motorcycle for sev-
eral months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” posi-
tion: Turn the fuel cock lever to
“OFF”.
U5B682E0.book Page 3 Tuesday, June 9, 2009 2:04 PM

SPECIFICATIONS
9-2
9
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-803-2
Loading: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 wheel
Rim size:
14x1.40Rear 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 damperWheel 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
Charging system:
AC magnetoBattery:Model:
GT4B-5
Voltage, capacity:
12 V, 2.5 AhFuse:Fuse:
10.0 A
U5B682E0.book Page 2 Tuesday, June 9, 2009 2:04 PM

INDEXAAir filter element, cleaning..................... 7-11BBattery................................................... 7-26
Brake lever .............................................. 4-2
Brake lever, checking and lubricating ... 7-23
Brake lever free play, adjusting............. 7-18
Brake pedal ............................................. 4-3
Brake pedal, checking and
lubricating ........................................... 7-24
Brake pedal free play, adjusting............ 7-19
Brake shoes, checking .......................... 7-20CCables, checking and lubricating .......... 7-23
Carburetor, adjusting ............................ 7-14
Care ........................................................ 8-1
Clutch free play, adjusting..................... 7-17DDrive chain, cleaning and lubricating .... 7-22
Drive chain slack ................................... 7-21EEngine break-in ....................................... 6-3
Engine idling speed............................... 7-14
Engine oil ................................................ 7-9
Engine, starting a warm .......................... 6-2
Engine stop switch .................................. 4-2FFront fork, checking .............................. 7-25
Fuel ......................................................... 4-3
Fuel cock................................................. 4-5
Fuel tank breather hose .......................... 4-5
Fuel tank cap .......................................... 4-3
Fuse, replacing ..................................... 7-27
HHandlebar switches ................................ 4-1IIdentification numbers .......................... 10-1KKey identification number ..................... 10-1
Kickstarter............................................... 4-7LLabels, location....................................... 1-1MMain switch ............................................. 4-1
Maintenance and lubrication, periodic .... 7-4
Maintenance, emission control
system .................................................. 7-3
Matte color, caution ................................ 8-1
Model label ........................................... 10-2PPanels, removing and installing .............. 7-7
Parking ................................................... 6-4
Part locations .......................................... 3-1SSafety information................................... 2-1
Seat ........................................................ 4-7
Shifting.................................................... 6-2
Shift pedal............................................... 4-2
Shift pedal, checking ............................ 7-20
Shock absorber assembly ...................... 4-8
Sidestand................................................ 4-8
Sidestand, checking and lubricating ..... 7-24
Spark arrester, cleaning ....................... 7-13
Spark plug, checking .............................. 7-8
Specifications ......................................... 9-1
Starter (choke) lever ............................... 4-6Starting and warming up
a cold engine ........................................ 6-1
Starting circuit cut-off system .................. 4-8
Start switch.............................................. 4-2
Steering, checking................................. 7-25
Storage.................................................... 8-3
Supporting the motorcycle .................... 7-28
Swingarm pivots, lubricating ................. 7-24
TThrottle cable free play, checking ......... 7-15
Throttle grip and cable, checking and
lubricating ........................................... 7-23
Tires ...................................................... 7-15
Tool kit..................................................... 7-2
Troubleshooting .................................... 7-32
Troubleshooting chart ........................... 7-33VValve clearance..................................... 7-15
Vehicle Emission Control Information
label (For Canada) .............................. 10-2
Vehicle identification number ................ 10-1WWheel bearings, checking ..................... 7-26
Wheel (front) ......................................... 7-29
Wheel (rear) .......................................... 7-30
Wheels .................................................. 7-17
U5B682E0.book Page 1 Tuesday, June 9, 2009 2:04 PM