2008 YAMAHA TTR110 clutch

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
Safe riding ......................................1-1
Location of important labels ............1-4
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Main switch .....................................3-1
Handlebar switches ........................3-1
Shift pedal .......................................3-2
Brake lever .....................................3-2
Brake pedal ....................................3-2
Fuel tank cap ..................................3-3
Fuel .................................................3-3
Fuel tank breather hose ..................3-4
Fuel cock ........................................3-5
Starter (choke) lever .......................3-6
Kickstarter .......................................3-6
Seat ................................................3-6
Sidestand ........................................3-7
Starting circuit cut-off system .........3-7
PRE-OPERATION CHECKS..............4-1
Pre-operation check list ..................4-2OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting and warming up a cold
engine ......................................... 5-1
Starting a warm engine .................. 5-2
Shifting ........................................... 5-2
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
PERIODIC MAINTENANCE ........... 6-1
Owner’s tool kit ............................... 6-2
Periodic maintenance chart for
the emission control system ....... 6-3
General maintenance and
lubrication chart .......................... 6-4
Removing and installing panels ..... 6-6
Checking the spark plug ................. 6-7
Engine oil ....................................... 6-8
Cleaning the air filter element ...... 6-10
Cleaning the spark arrester .......... 6-12
Adjusting the carburetor ............... 6-13
Adjusting the engine idling
speed ........................................ 6-13
Checking the throttle cable free
play ........................................... 6-14
Valve clearance ............................ 6-14
Tires ............................................. 6-15
Spoke wheels ............................... 6-16Accessories and replacement
parts ......................................... 6-16
Adjusting the clutch free play ....... 6-17
Adjusting the brake lever free
play ........................................... 6-17
Adjusting the brake pedal free
play ........................................... 6-18
Checking the shift pedal .............. 6-19
Checking the front and rear brake
shoes ........................................ 6-19
Drive chain slack .......................... 6-20
Cleaning and lubricating the
drive chain ................................ 6-21
Checking and lubricating the
cables ....................................... 6-22
Checking and lubricating the
throttle grip and cable ............... 6-22
Checking and lubricating the
brake lever ................................ 6-23
Checking and lubricating the
brake pedal ............................... 6-23
Checking and lubricating the
sidestand .................................. 6-23
Lubricating the swingarm
pivots ........................................ 6-24
Checking the front fork ................. 6-24
Checking the steering .................. 6-25
Checking the wheel bearings ....... 6-25
Battery ......................................... 6-26
Replacing the fuse ....................... 6-27
Supporting the motorcycle ........... 6-28U5B680E0.book Page 1 Tuesday, July 17, 2007 9:11 AM

DESCRIPTION
2-1
2
EAU10410
Left view
6 7 8123 4
5
1. Fuel cock (page 3-5)
2. Starter (choke) lever (page 3-6)
3. Fuse (page 6-27)
4. Battery (page 6-26)
5. Clutch adjusting screw (page 6-17)
6. Engine oil drain bolt (page 6-8)
7. Shift pedal (page 3-2)
8. Throttle stop screw (page 6-13)
U5B680E0.book Page 1 Tuesday, July 17, 2007 9:11 AM

OPERATION AND IMPORTANT RIDING POINTS
5-2
5
EAU16640
Starting a warm engine Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
EAU39901
Shifting This motorcycle has a 4-speed trans-
mission with a centrifugal, automatic
clutch. Shifting gears lets you control
the amount of engine power available
for starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the il-
lustration.NOTE:To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of itstravel.
CAUTION:
ECA15441


Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.


Always release the throttle grip
before changing gears to avoid
damaging the engine, transmis-
sion, and drive train, which are
not designed to withstand the
shock of shifting when the throt-tle grip is open.
EAU39910
To start out and accelerate
1. Close the throttle.
2. Shift into first gear and release the
shift pedal.
1. Shift pedal
2. Neutral position
1
2
1 2
34
U5B680E0.book Page 2 Tuesday, July 17, 2007 9:11 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU35348
General maintenance and lubrication chart No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL ODOMETER READINGS
1000 km
(600 mi) or
1 month or
30 hours3000 km
(1800 mi) or
6 months or
90 hours5000 km
(3000 mi) or
12 months or
150 hours
1*ClutchCheck operation.
Adjust if necessary.√√√
2*Front brakeCheck operation.
Adjust brake lever free play and replace brake shoes if
necessary.√√√
3*Rear brakeCheck operation.
Adjust brake pedal free play and replace brake shoes if
necessary.√√√
4*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√
5*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√
6*Wheel bearingsCheck bearings for smooth operation.
Replace if necessary.√√
7*Swingarm pivot bearingsCheck bearing assemblies for looseness.
Moderately repack with lithium-soap-based grease.√√
8 Drive chainCheck chain slack/alignment and condition.
Adjust and lubricate chain with Yamaha chain and cable
lube thoroughly.Every ride
9*Steering bearingsCheck bearing assemblies for looseness.
Moderately repack with lithium-soap-based grease.√√
U5B680E0.book Page 4 Tuesday, July 17, 2007 9:11 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
NOTE:
The engine oil should be between theminimum and maximum level marks.
4. If the engine oil is at or below the
minimum 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
and drain bolt to drain the oil from
the crankcase.
4. Install the engine oil drain bolt, and
then tighten it to the specified
torque.5. Add the specified amount of the
recommended engine oil, and then
install and tighten the engine oil fill-
er cap.
CAUTION:
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.
1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
1
3
4
2
1. Engine oil drain bolt
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
1
Recommended engine oil:
See page 8-1.
Oil change quantity:
0.80 L (0.85 US qt) (0.70 Imp.qt)
U5B680E0.book Page 9 Tuesday, July 17, 2007 9:11 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU44661
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).NOTE:Turning the clutch adjusting screw in di-
rection (a) decreases clutch free play
and turning it in direction (b) increasesclutch free play.3. Tighten the locknut to the specified
torque.
NOTE:
When tightening the locknut, hold the
clutch adjusting screw with a screwdriv-
er so that it does not turn together withthe locknut.
EAU44880
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. Loosen the locknut at the brake le-
ver.
2. To increase the brake lever free
play, turn the adjusting bolt in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
bolt in direction (b).
1. Locknut
2. Clutch adjusting screw
12
(a)
(b)
Tightening torque:
Locknut:
8.0 Nm (0.8 m·kgf, 5.8 ft·lbf)
1. Brake lever free play adjusting bolt
2. Locknut
3. Brake lever free play
2
1
(b)3
(a)
U5B680E0.book Page 17 Tuesday, July 17, 2007 9:11 AM

SPECIFICATIONS
8-1
8
Dimensions:Overall length:
1565 mm (61.6 in)
Overall width:
680 mm (26.8 in)
Overall height:
923 mm (36.3 in)
Seat height:
670 mm (26.4 in)
Wheelbase:
1080 mm (42.5 in)
Ground clearance:
180 mm (7.09 in)
Minimum turning radius:
1660 mm (65.4 in)Weight:With oil and fuel:
72.0 kg (159 lb)Engine:Engine type:
Air cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
110.0 cm³
Bore × stroke:
51.0 × 54.0 mm (2.01 × 2.13 in)
Compression ratio:
9.30 :1
Starting system:
Electric starter and kickstarter
Lubrication system:
Wet sump
Engine oil:Type:
TT-R110E SAE10W-30, SAE10W-40,
SAE15W-40, SAE20W-40 or SAE20W-50
TT-R110EX SAE10W-30, SAE10W-40,
SAE15W-40, SAE20W-40 or SAE20W-50
(AUS)
TT-R110EX YAMALUBE 4, SAE10W-30 or
SAE20W-40 (CAN)Recommended engine oil grade:
API service SG type or higher, JASO
standard MA
Engine oil quantity:
Periodic oil change:
0.80 L (0.85 US qt) (0.70 Imp.qt)
Air filter:Air filter element:
Wet elementFuel:Recommended fuel:
TT-R110E Regular unleaded gasoline only
TT-R110EX Regular unleaded gasoline
only (CAN)
TT-R110EX Unleaded gasoline only (AUS)
Fuel tank capacity:
3.8 L (1.00 US gal) (0.84 Imp.gal)
Fuel reserve amount:
0.5 L (0.13 US gal) (0.11 Imp.gal)Carburetor:Manufacturer:
MIKUNI
Type × quantity:
VM16 x 1Spark plug (s):Manufacturer/model:
NGK/CR6HSA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:
Wet, multiple-disc and centrifugal
automatic
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40SAE 10W-50
10˚30˚50˚70˚90˚110˚
0˚
130
˚F
YAMALUBE 4 (10W-30)
or SAE 10W-30
YAMALUBE 4 (20W-40)
or SAE 20W-40
–10
˚0˚10˚20˚30˚40˚
–20˚
50 ˚C
U5B680E0.book Page 1 Tuesday, July 17, 2007 9:11 AM

INDEX
AAccessories and replacement parts ..... 6-16
Air filter element, cleaning .................... 6-10BBattery .................................................. 6-26
Brake lever ............................................. 3-2
Brake lever, checking and lubricating ... 6-23
Brake lever free play, adjusting ............ 6-17
Brake pedal ............................................ 3-2
Brake pedal, checking and
lubricating ........................................... 6-23
Brake pedal free play, adjusting ........... 6-18
Brake shoes, checking ......................... 6-19CCables, checking and lubricating .......... 6-22
Carburetor, adjusting ............................ 6-13
Care ........................................................ 7-1
Clutch free play, adjusting .................... 6-17DDrive chain, cleaning and lubricating .... 6-21
Drive chain slack .................................. 6-20EEngine break-in ...................................... 5-3
Engine idling speed .............................. 6-13
Engine oil ................................................ 6-8
Engine, starting a warm .......................... 5-2
Engine stop switch.................................. 3-1FFront fork, checking .............................. 6-24
Fuel......................................................... 3-3
Fuel cock ................................................ 3-5
Fuel tank breather hose.......................... 3-4
Fuel tank cap .......................................... 3-3
Fuse, replacing ..................................... 6-27
HHandlebar switches ................................. 3-1IIdentification numbers ............................. 9-1KKey identification number ........................ 9-1
Kickstarter ............................................... 3-6LLabels, location of ...................................1-4MMain switch ............................................. 3-1
Maintenance and lubrication, periodic..... 6-4
Maintenance, emission control system ... 6-3
Maintenance, periodic ............................. 6-1
Matte color, caution .................................7-1
Model label .............................................. 9-2PPanels, removing and installing .............. 6-6
Parking ....................................................5-4
Part locations .......................................... 2-1
Pre-operation check list........................... 4-2SSafety information ...................................1-1
Seat ......................................................... 3-6
Shifting ....................................................5-2
Shift pedal ............................................... 3-2
Shift pedal, checking ............................. 6-19
Sidestand ................................................ 3-7
Sidestand, checking and lubricating...... 6-23
Spark arrester, cleaning ........................ 6-12
Spark plug, checking ...............................6-7
Specifications .......................................... 8-1
Starter (choke) lever................................ 3-6Starting and warming up a cold
engine ................................................... 5-1
Starting circuit cut-off system.................. 3-7
Start switch ............................................. 3-1
Steering, checking ................................ 6-25
Storage ................................................... 7-3
Supporting the motorcycle .................... 6-28
Swingarm pivots, lubricating ................. 6-24
TThrottle cable free play, checking ......... 6-14
Throttle grip and cable, checking and
lubricating ........................................... 6-22
Tires ...................................................... 6-15
Tool kit .................................................... 6-2
Troubleshooting .................................... 6-31
Troubleshooting chart ........................... 6-32VValve clearance .................................... 6-14
Vehicle identification number .................. 9-1WWheel bearings, checking..................... 6-25
Wheel (front) ......................................... 6-28
Wheel (rear) .......................................... 6-30
Wheels .................................................. 6-16
U5B680E0.book Page 1 Tuesday, July 17, 2007 9:11 AM