YAMAHA TTR110 2010 Repair Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
7-21
7
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 weight
on 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.
EAU40112
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-
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
1. Axle nut
2. Locknut
3. Drive chain slack adjusting nut
32 1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-22
7tion (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]
TIPUsing 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 both locknuts and the axle
nut to the specified torques.
4. Adjust the brake pedal free play.
(See page 7-19.)
EAU23015
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
ECA10582
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain or wet areas.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 chain
and soak it in solvent.2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on the entire
chain, making sure that all side
plates and rollers have been suffi-
ciently oiled.
1. Alignment marks
2. Locknut
3. Drive chain slack adjusting nut
4. Drive chain pullerTightening torques:
Locknut:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
(a)
(b) 4321
U5B682E0.book Page 22 Tuesday, June 9, 2009 2:04 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-23
7
EAU23093
Checking and lubricating the
cables 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 lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
housing of cables may result in in-
ternal rusting and cause interfer-
ence with cable movement. Replace
damaged cables as soon as possi-
ble to prevent unsafe conditions.[EWA10711]EAU23111
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
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.
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil
Recommended lubricant:
Lithium-soap-based grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-24
7
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.
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.
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
U5B682E0.book Page 24 Tuesday, June 9, 2009 2:04 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-25
7
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.
EAU23283
Checking the steering 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 pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground. (See page 7-28 for more
information.) WARNING! To
avoid injury, securely support
the vehicle so there is no danger
of it falling over.
[EWA10751]
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 steering.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-26
7
EAU23291
Checking the wheel bearings 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.
EAU23395
Battery The battery is located behind panel B.
(See page 7-7.)
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
EWA10760


Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severeburns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
EXTERNAL: Flush with plenty
of water.
INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
EYES: Flush with water for 15
minutes and seek prompt
medical attention.


Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.


KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
To charge 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
1. Battery coupler
2. Battery band
3. Battery
2
3
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-27
7 battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.
NOTICE
ECA16520
To charge a VRLA (Valve Regulated
Lead Acid) battery, a special (con-
stant-voltage) battery charger is re-
quired. Using a conventional battery
charger will damage the battery. If
you do not have access to a con-
stant-voltage battery charger, have a
Yamaha dealer charge your battery.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 removing the
battery, be sure the key is
turned to “OFF” before discon-
necting the coupler.
[ECA16322]
2. If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
necessary.
3. Fully charge the battery before in-
stallation.
NOTICE
ECA16530
Always keep the battery charged.
Storing a discharged battery can
cause permanent battery damage.
EAU42023
Replacing the fuse The fuse is located inside the battery
coupler. (See page 7-26.)
If the fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
2. Disconnect the battery coupler.
3. Remove the blown fuse, and then
install a new fuse of the specified
amperage. WARNING! Do not
use a fuse of a higher amperage
rating than recommended to
avoid causing extensive dam-
age to the electrical system and
possibly a fire.
[EWA15131]
1. Fuse
2. Spare fuse
1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-28
74. Connect the battery coupler.
5. Turn the key to “ON”.
6. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU24350
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der 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 placinga jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
Specified fuse:
10.0 A
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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
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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