brake YAMAHA TTR110 2012 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
7
EAU3534B
General maintenance and lubrication chart TIP

From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
No.ITEM CHECKS AND MAINTENANCE JOBS INITIAL ODOMETER READINGS
1000 km
(600 mi) or
1 month or 30 hours 3000 km
(1800 mi) or
6 months or 90 hours 5000 km
(3000 mi) or
12 months or 150 hours
1 *Clutch 
Check operation.
 Adjust if necessary. √√√
2 *Front brake 
Check operation.
 Adjust brake lever free play and replace brake shoes if
necessary. √√√
3 *Rear brake 
Check operation.
 Adjust brake pedal free play and replace brake shoes if
necessary. √√√
4 *Wheels 
Check runout, spoke tightness and for damage.
 Tighten spokes if necessary. √√√
5 *Tires 
Check tread depth and for damage.
 Replace if necessary.
 Check air pressure.
 Correct if necessary. √√
6 *Wheel bearings 
Check bearings for smooth operation.
 Replace if necessary. √√
7 *Swingarm pivot bearings 
Check bearing assemblies for looseness.
 Moderately repack with lithium-soap-based grease. √√
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-5
7
8 Drive chain
Check chain slack/alignment and condition.
 Adjust and lubricate chain with Yamaha chain and cable
lube thoroughly. Every ride
9 *Steering bearings 
Check bearing assemblies for looseness.
 Moderately repack with lithium-soap-based grease. √√
10 *Chassis fasteners 
Check all chassis fitting and fasteners.
 Correct if necessary. √√√
11 Brake lever pivot shaft Apply lithium-soap-based grease lightly. √√
12 Brake pedal pivot shaft Apply lithium-soap-based grease lightly. √√
13 Sidestand pivot 
Check operation.
 Apply lithium-soap-based grease lightly. √√
14 *Front fork 
Check operation and for oil leakage.
 Replace if necessary. √√
15 *Shock absorber assem-
bly 
Check operation and for oil leakage.
 Replace if necessary. √
16 *Control cables 
Apply Yamaha chain and cable lube or engine oil thor-
oughly. √√√
17 *Throttle grip 
Check operation.
 Check throttle grip free play, and adjust if necessary.
 Lubricate cable and grip housing. √√√
No. ITEM CHECKS AND MAINTENANCE JOBS
INITIAL ODOMETER READINGS
1000 km
(600 mi) or
1 month or 30 hours 3000 km
(1800 mi) or
6 months or 90 hours 5000 km
(3000 mi) or
12 months or 150 hours
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-16
7
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
Tire information
This motorcycle is equipped with spoke
wheels and tube tires.
WARNING
EWA10461
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, which
could lead to an accident.After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
WARNING
EWA15541


Have a Yamaha dealer replace
excessively worn tires. Operat-
ing the motorcycle with exces-
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.


Ride conservatively after
changing a tire since the tire
must seat itself on the rim prop-
erly. Failure to allow proper
seating may cause tire failure,
which may result in damage to
the motorcycle and injury to the
rider.
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear): 4.0 mm (0.16 in)
12
Front tire:Size:2.50-14 4PR
Manufacturer/model: CHEN SHIN/C-803-2
Rear tire:
Size:3.00-12 4PR
Manufacturer/model:
CHEN SHIN/C-803-2
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-18
7
EAU44884
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 brake lever free play
adjusting bolt in direction (a). To decrease the brake lever free play,
turn the adjusting bolt in direction
(b).
TIPSkip 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 the brake 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 le- ver, and then slide the rubber cov-
er to its original position.
1. Rubber cover
2. Brake lever free play adjusting bolt
3. Locknut
4. Brake lever free play
3
2
1
(b)
(a) 4
1. Locknut
2. Brake lever free play adjusting bolt
21(b)
(a)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-19
7
EAU44671
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 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
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.
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.
1. Brake pedal free play adjusting nut
2. Brake pedal free playU5B684E0.book Page 19 Monday, June 13, 2011 4:46 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-20
7
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.
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22774
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. Measure the drive chain slack as shown.
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)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-21
74. If the drive chain slack is incorrect,
adjust it as follows.
EAU40114
To adjust 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 locknut
at each end of the swingarm.
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-
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.
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
7
3. Tighten the axle nut and both lock-
nuts to the specified torques.
4. Adjust the brake pedal free play. (See page 7-19.)
5. Make sure that the drive chain pull- ers are in the same position, the
drive chain slack is correct, and
the drive chain moves smoothly.
EAU23016
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
ECA10583
The drive chain must be lubricated
after washing the motorcycle, riding
in the rain or riding in wet areas.1. Remove all dirt and mud from thedrive 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 CableLube 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.
EAU23095
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]
1. Alignment marks
2. Locknut
3. Drive chain slack adjusting nut
4. Drive chain pullerTightening 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
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-23
7
EAU23114
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 by a
Yamaha dealer at the intervals speci- fied 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 water
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.
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.
Recommended lubricant: Lithium-soap-based grease
Recommended lubricant:Lithium-soap-based grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-24
7
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.
EAUM1652
Lubricating the swingarm piv-
ots The swingarm pivots must be lubricat-
ed by a Yamaha dealer at the intervals
specified in the periodic 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 operation1. 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.
Recommended lubricant:Lithium-soap-based grease
Recommended lubricant:Lithium-soap-based grease
U5B684E0.book Page 24 Monday, June 13, 2011 4:46 PM