2009 YAMAHA TTR110 brake

TABLE OF CONTENTS
SAFETY INFORMATION .................. 1-1
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 .................................... 3-3
Fuel tank cap .................................. 3-3
Fuel ................................................ 3-3
Fuel tank breather hose ................. 3-5
Fuel cock ........................................ 3-5
Starter (choke) lever ....................... 3-6
Kickstarter ......................................3-7
Seat ................................................ 3-7
Shock absorber assembly .............. 3-8
Sidestand ....................................... 3-8
Starting circuit cut-off system ......... 3-8
FOR YOUR SAFETY –
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
ADJUSTMENT................................... 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 .............................. 6-16
Adjusting the clutch free play ....... 6-16Adjusting 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 .......................................... 6-25
Replacing the fuse ....................... 6-27
Supporting the motorcycle ........... 6-27
Front wheel .................................. 6-28
Rear wheel ................................... 6-29
Troubleshooting ........................... 6-31
Troubleshooting chart .................. 6-32
U5B681E0.book Page 1 Tuesday, June 17, 2008 5:48 PM

DESCRIPTION
2-2
2
EAU10420
Right view
12 3 4
857
6
1. Spark arrester (page 6-12)
2. Seat (page 3-7)
3. Fuel tank (page 3-3)
4. Air filter element (page 6-10)
5. Spark plug cap (page 6-7)
6. Engine oil filler cap (page 6-8)
7. Brake pedal (page 3-3)
8. Kickstarter (page 3-7)U5B681E0.book Page 2 Tuesday, June 17, 2008 5:48 PM

DESCRIPTION
2-3
2
EAU10430
Controls and instruments
1234
5 6
1. Left handlebar switch (page 3-1)
2. Main switch (page 3-1)
3. Right handlebar switch (page 3-1)
4. Brake lever (page 3-2)
5. Throttle grip (page 6-14)
6. Fuel tank cap (page 3-3)
U5B681E0.book Page 3 Tuesday, June 17, 2008 5:48 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-2
3
EAU12660
Engine stop switch“/”
Set this switch to“” before starting
the engine. Set this switch to“” to
stop the engine in case of an emergen-
cy, such as when the vehicle overturns
or when the throttle cable is stuck.
EAU12711
Start switch“”
Push this switch to crank the engine
with the starter. See page 5-1 for start-
ing instructions prior to starting the en-
gine.
EAU39850
Shift pedal This motorcycle is equipped with a con-
stant-mesh 4-speed transmission. The
shift pedal is located on the left side of
the engine. Neutral is at the bottom po-
sition.
EAU12890
Brake lever The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
1. Shift pedal
1
1. Brake lever
1
U5B681E0.book Page 2 Tuesday, June 17, 2008 5:48 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-3
3
EAU12941
Brake pedal The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
EAU13182
Fuel tank cap To remove the fuel tank cap, turn it
counterclockwise, and then pull it off.
To install the fuel tank cap, insert it into
the tank opening, and then turn it clock-
wise.
WARNING
EWA11091
Make sure that the fuel tank cap is
properly closed after filling fuel.Leaking fuel is a fire hazard.
EAU13212
Fuel Make sure there is sufficient gasoline in
the tank.
WARNING
EWA10881
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, followthese instructions.
1. Before refueling, turn off the en-
gine and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the vi-
cinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters and
clothes dryers.
2. Do not overfill the fuel tank. Stop
filling when the fuel reaches the
bottom of the filler tube. Because
fuel expands when it heats up,
heat from the engine or the sun
can cause fuel to spill out of the
fuel tank.
1. Brake pedal
1
1. Fuel tank cap
U5B681E0.book Page 3 Tuesday, June 17, 2008 5:48 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-9
3
With the engine turned off:
1. Make sure that the engine stop switch is set to “
”.
2. Turn the key to “ON”.
3. Shift the transmission into gear.
4. Keep the front or rear brake applied.
5. Push the start switch.
Does the engine start?
The neutral switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
6. Shift the transmission into the neutral position.
7. Push the start switch.
Does the engine start?
The neutral switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES NO
The system is OK. The motorcycle can be ridden.
YES
NO
If a malfunction is noted, have a Yamaha
dealer check the system before riding.
WARNING
U5B681E0.book Page 9 Tuesday, June 17, 2008 5:48 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-3
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-8
Front brakeCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-17, 6-19
Rear brakeCheck operation.
Check pedal free play.
Adjust if necessary.6-18, 6-19
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-14, 6-22
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-22
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-20, 6-21
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-15, 6-16
Shift pedalMake sure that operation is smooth.
Correct if necessary.6-19
U5B681E0.book Page 2 Tuesday, June 17, 2008 5:48 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-3
4
Brake pedalMake sure that operation is smooth.
Lubricate pedal pivoting point if necessary.6-23
Brake leverMake sure that operation is smooth.
Lubricate lever pivoting point if necessary.6-23
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-23
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Engine stop switchCheck operation.3-1 ITEM CHECKS PAGE
U5B681E0.book Page 3 Tuesday, June 17, 2008 5:48 PM