YAMAHA TTR110 2012 Workshop Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
7-10
7
4. If the engine oil is not between the
tip of the dipstick and the maxi-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Insert the dipstick into the oil filler hole, and then tighten the oil filler
cap.
To change the engine oil 1. Start the engine, warm it up for several minutes, and then turn it
off.
2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap,
the engine oil drain bolt and its
gasket to drain the oil from the
crankcase.
4. Install a new gasket and the drain bolt, and then tighten the drain bolt
to the specified torque.
5. Refill with the specified amount of the recommended engine oil, and
then install and tighten the oil filler
cap.
NOTICE
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ ENERGY CONSERVING II ” or
higher.


Make sure that no foreign mate-
rial enters the crankcase.
6. Start the engine, and then let it idle for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
7. Turn the engine off, and then check the oil level and correct it if
necessary.
1. Engine oil filler cap
2. Engine oil dipstick
3. Maximum level mark
4. Tip of the engine oil dipstick
1
3
4
2
1. Engine oil drain bolt
2. Gasket
Tightening torque: Engine oil drain bolt:20 Nm (2.0 m ·kgf, 14 ft ·lbf)
1
1
2
Recommended engine oil:See page 9-1.
Oil change quantity: 0.80 L (0.85 US qt, 0.70 Imp.qt)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-11
7
EAU41636
Cleaning the air filter element The air filter element should be cleaned
or replaced at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Clean or, if necessary, re-
place the air filter element more
frequently if you are riding in unusually
wet or dusty areas.
To clean the air filter element1. Remove panel A. (See page 7-7.)
2. Remove the air filter case cover by removing the screws.
3. Pull the sponge material and the mesh out. 4. Clean the mesh with solvent, and
then wipe the solvent off.
5. Clean the sponge material with solvent, and then squeeze the re-
maining solvent out. WARNING!
Use only a dedicated parts
cleaning solvent. To avoid the
risk of fire or explosion, do not
use gasoline or solvents with a
low flash point.
[EWA10431]
NOTICE:
To avoid damaging the foam
material, handle it gently and
carefully, and do not twist or
wring it.
[ECA10511]
6. Apply oil of the recommended type to the entire surface of the sponge
material, and then squeeze the ex-
cess oil out.TIPThe sponge material should be wet but
not dripping.7. Insert the mesh and the spongematerial into the air filter case.
NOTICE: Make sure that the
mesh and the sponge material
are properly seated in the air fil-
ter case. The engine should
never be operated without the
1. Air filter case cover
2. Screw
2
1
1. Sponge material
2. Air filter mesh
1
2
Recommended oil:
Yamaha foam air filter oil or other
quality foam air filter oil
U5B684E0.book Page 11 Monday, June 13, 2011 4:46 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-12
7
mesh and the sponge material
installed, otherwise the pis-
ton(s) and/or cylinder(s) may
become excessively worn.
[ECA15572]
8. Install the air filter case cover by in-
stalling the screws.TIPMake sure that the spark plug lead is in-
serted into the guide as shown.
9. Install the panel.
To clean the air filter check hose1. Check the hoses at the bottom of the air filter case for accumulated
dirt or water. 2. If dirt or water is visible, remove
the hoses, clean them, and then
reinstall them.1. Spark plug lead
2. Guide
1. Air filter check hose
11
2
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-13
7
EAU40421
Cleaning the spark arrester The spark arrester should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
WARNING
EWA10980


Always let the exhaust system
cool prior to touching exhaust
components.


Do not start the engine when
cleaning the exhaust system.
TIPMake sure to select a well-ventilated
area free of combustible materials to
clean the spark arrester.1. Remove the tailpipe by removingthe bolts, and then pulling it out of
the muffler. 2. Tap the tailpipe lightly, and then
use a wire brush to remove any
carbon deposits from the spark ar-
rester portion of the tailpipe and in-
side of the tailpipe housing. 3. Insert the tailpipe into the muffler,
and then install and tighten the
bolts to the specified torque.
TIPMake sure to align the bolt holes when
inserting the tailpipe.
1. Tailpipe
2. Tailpipe bolt
1. Spark arrester
21
1
Tightening torque:
Tailpipe bolt:10 Nm (1.0 m ·kgf, 7.2 ft· lbf)
U5B684E0.book Page 13 Monday, June 13, 2011 4:46 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-14
7
EAU39930
Adjusting the carburetor The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces- sary professional knowledge and expe-
rience. The adjustment described in the
following section, however, may be ser-
viced by the owner as part of routine
maintenance.NOTICE
ECA10550
The carburetor has been set and ex-
tensively tested at the Yamaha fac-
tory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine.
EAU21362
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.TIPA diagnostic tachometer is needed to
make this adjustment.1. Attach the tachometer to the spark plug lead.
2. Start the engine and warm it up for several minutes at 1000 –2000
r/min while occasionally revving it
to 4000 –5000 r/min.TIPThe engine is warm when it quickly re-
sponds to the throttle.3. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di- rection (a). To decrease the en-
gine idling speed, turn the screw in
direction (b).
TIPIf the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.1. Throttle stop screw
Engine idling speed:
1600– 1800 r/min
1 (a) (b)
1
U5B684E0.book Page 14 Monday, June 13, 2011 4:46 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-15
7
EAU21384
Checking the throttle grip free
play The throttle grip free play should mea-
sure 4.0–6.0 mm (0.16 –0.24 in) at the
inner edge of the throttle grip. Periodi-
cally check the throttle grip free play
and, if necessary, have a Yamaha deal-
er adjust it.
EAU21401
Valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU39824
Tires To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING
EWA15370
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.
The tire air pressure must be
checked and adjusted on cold tires
(i.e., when the temperature of the
tires equals the ambient tempera-
ture).
1. Throttle grip free play
1
Standard tire air pressure: Fr o nt :100 kPa (1.00 kgf/cm ², 15 psi)
Rear:
100 kPa (1.00 kgf/cm ², 15 psi)
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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
7-17
7
EAU21943
Spoke wheels
WARNING
EWA10610
The wheels on this model are not de-
signed for use with tubeless tires.
Do not attempt to use tubeless tires
on this model.To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified wheels.

The wheel rims should be checked
for cracks, bends, warpage or oth-
er damage, and the spokes for
looseness or damage before each
ride. If any damage is found, have
a Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A de-
formed 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.
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.
TIPWhen tightening the locknut, hold the
clutch adjusting screw with a screwdriv-
er so that it does not turn together with
the locknut.
1. Locknut
2. Clutch adjusting screwTightening torque:Locknut:
8 Nm (0.8 m ·kgf, 5.8 ft ·lbf)
1 2
(a)
(b)
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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