2008 YAMAHA TTR110 brake

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU43621
Checking and lubricating the
brake lever The operation of the brake lever should
be checked before each ride, and the
lever pivots 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.
EAU23201
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
EWA10730
If the sidestand does not move up
and down smoothly, have a Yamahadealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
U5B680E0.book Page 23 Tuesday, July 17, 2007 9:11 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
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.
EAU23271
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
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
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.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:
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
U5B680E0.book Page 24 Tuesday, July 17, 2007 9:11 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6
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.
EAU24360
Front wheel
EAU41810
To remove the front wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the locknut at the brake le-
ver, and then turn the adjusting
bolt fully in direction (a).
2. Loosen the axle nut.
1. Brake lever free play adjusting bolt
2. Locknut
2
1
(a)
U5B680E0.book Page 28 Tuesday, July 17, 2007 9:11 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6 3. Lift the front wheel off the ground
according to the procedure on
page 6-28.
4. Remove the axle nut and washer.
5. Pull the wheel axle out, and then
remove the wheel.
EAU41691
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle from the
right-hand side.NOTE:Make sure that the slot in the brake
shoe plate fits over the retainer on thefork leg.
3. Lower the front wheel so that it is
on the ground.
4. Install the washer and axle nut,
and then tighten the axle nut to the
specified torque.5. Adjust the brake lever free play.
(See page 6-17.)
6. While applying the front brake,
push down hard on the handlebar
several times to check for proper
fork operation.
1. Axle nut
2. Washer
1. Wheel axle
1. Slot
2. Retainer
21
Tightening torque:
Axle nut:
35 Nm (3.5 m·kgf, 25 ft·lbf)
U5B680E0.book Page 29 Tuesday, July 17, 2007 9:11 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
EAU25080
Rear wheel
EAU41642
To remove the rear wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof 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.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 6-28.
6. Remove the axle nut and washer,
and then pull the wheel axle out.
7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
1. Brake torque rod
2. Cotter pin
3. Brake torque rod bolt and nut
4. Brake shoe plate
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 slack adjusting nut
4. Locknut
1
2
4 3
U5B680E0.book Page 30 Tuesday, July 17, 2007 9:11 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
NOTE:The drive chain does not need to be
disassembled in order to remove andinstall the wheel.
8. Remove the wheel.
EAU41652
To install the rear wheel
1. Install the drive chain onto the rear
sprocket.
2. Insert the wheel axle from the
right-hand side.
3. Adjust the drive chain slack. (See
page 6-20.)
4. Lower the rear wheel so that it is
on the ground.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. Tighten the axle nut to the speci-
fied torque.
9. Adjust the brake pedal free play.
(See page 6-18.)
EAU25850
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.
Tightening torques:
Brake torque rod nut:
26 Nm (2.6 m·kgf, 19 ft·lbf)
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
U5B680E0.book Page 31 Tuesday, July 17, 2007 9:11 AM

MOTORCYCLE CARE AND STORAGE
7-2
7contact 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 isscratched, use a quality plastic
polishing compound after
washing.
After normal use
Remove 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.CAUTION:
ECA10790
Do not use warm water since it in-
creases the corrosive action of thesalt.
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.
8. Let the motorcycle dry completely
before storing or covering it.
WARNING
EWA14500


Make sure that there is no oil or
wax on the tires.
U5B680E0.book Page 2 Tuesday, July 17, 2007 9:11 AM

SPECIFICATIONS
8-2
8
Transmission:Primary reduction system:
Spur gear
Primary reduction ratio:
67/18 (3.722)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
35/14 (2.500)
Transmission type:
Constant mesh 4-speed
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 4PRManufacturer/model:
CHEN SHIN/C-803
Rear tire:Type:
With tube
Size:
3.00-12 4PR
Manufacturer/model:
CHEN SHIN/C-803Loading:Maximum rider weight:
60.0 kg (132 lb)Tire air pressure (measured on cold
tires):
Front:
100 kPa (15 psi) (1.00 kgf/cm²)
Rear:
100 kPa (15 psi) (1.00 kgf/cm²)
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 operation
Rear brake:Type:
Drum brake
Operation:
Right foot operationFront suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel 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
U5B680E0.book Page 2 Tuesday, July 17, 2007 9:11 AM