2013 YAMAHA TTR110 Front fork

TABLE OF CONTENTS
LOCATION OF IMPORTANT
LABELS ............................................1-1
SAFETY INFORMATION .................. 2-1
DESCRIPTION .................................. 3-1
Left view .......................................... 3-1
Right view ........................................ 3-2
Controls and instruments ................3-3
INSTRUMENT AND CONTROL
FUNCTIONS ....................................... 4-1
Main switch ..................................... 4-1
Handlebar switches ........................ 4-1
Shift pedal ......................................4-2
Brake lever ..................................... 4-2
Brake pedal .................................... 4-3
Fuel tank cap .................................. 4-3
Fuel ................................................ 4-3
Fuel tank breather hose ................. 4-6
Fuel cock ........................................ 4-6
Starter (choke) lever ....................... 4-7
Kickstarter ......................................4-8
Seat ................................................ 4-8
Shock absorber assembly .............. 4-9
Sidestand ....................................... 4-9
Starting circuit cut-off system ......... 4-9 FOR YOUR SAFETY –
PRE-OPERATION CHECKS
............. 5-1
OPERATION AND IMPORTANT
RIDING POINTS ................................ 6-1
Starting and warming up a cold engine ......................................... 6-1
Starting a warm engine .................. 6-2
Shifting ........................................... 6-2
Engine break-in .............................. 6-3
Parking ........................................... 6-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ................................... 7-1
Owner’s tool kit .............................. 7-2
Periodic maintenance chart for the emission control system ............. 7-3
General maintenance and lubrication chart .......................... 7-4
Removing and installing panels ..... 7-7
Checking the spark plug ................ 7-8
Engine oil ....................................... 7-9
Cleaning the air filter element ...... 7-11
Cleaning the spark arrester ......... 7-13
Adjusting the carburetor ............... 7-14
Adjusting the engine idling
speed ........................................ 7-14
Checking the throttle grip free play ........................................... 7-15
Valve clearance ........................... 7-15
Tires ............................................. 7-15 Spoke wheels ............................... 7-17
Adjusting the clutch free play ....... 7-17
Adjusting the brake lever free
play ........................................... 7-18
Adjusting the brake pedal free
play ........................................... 7-19
Checking the shift pedal ............... 7-20
Checking the front and rear brake shoes ........................................ 7-20
Drive chain slack .......................... 7-21
Cleaning and lubricating the drive chain ......................................... 7-22
Checking and lubricating the cables ....................................... 7-23
Checking and lubricating the throttle grip and cable ............... 7-23
Checking and lubricating the
brake lever ................................ 7-23
Checking and lubricating the brake pedal ............................... 7-24
Checking and lubricating the sidestand .................................. 7-24
Lubricating the swingarm pivots ... 7-24
Checking the front fork ................. 7-25
Checking the steering .................. 7-25
Checking the wheel bearings ....... 7-26
Battery .......................................... 7-26
Replacing the fuse ....................... 7-27
Supporting the motorcycle ........... 7-28
Front wheel .................................. 7-29
Rear wheel ................................... 7-30
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SAFETY INFORMATION
2-3
2
●
Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
●
Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
●
Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loading
Adding accessories to your motorcycle
can adversely affect stability and han-
dling if the weight distribution of the mo-
torcycle is changed. To avoid the
possibility of an accident, use extreme
caution when adding accessories to
your motorcycle. Use extra care when
riding a motorcycle that has added ac-
cessories. Here are some general
guidelines to follow if adding accesso-
ries to your motorcycle:
Operation of an overloaded vehicle
could cause an accident.
●
The weight of the operator must
not exceed 60.0 kg (132 lb).
●
Accessory weight should be kept
as low and close to the motorcycle
as possible. Securely pack your
heaviest items as close to the cen-
ter of the vehicle as possible and
make sure to distribute the weight
as evenly as possible on both
sides of the motorcycle to mini-
mize imbalance or instability.
●
Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories are securely attached to
the motorcycle before riding.
Check accessory mounts fre-
quently. Properly adjust the suspension for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
Never attach any large or heavy items to the handlebar, front
fork, or front fender. Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail- able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection to
Yamaha manufacture parts and acces- sories or offer other modifications for
Yamaha vehicles. Yamaha is not in a position to test the products that these
aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories, and
Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accessories
or modifications are not suitable be-
cause of potential safety hazards to you
or others. Installing aftermarket prod-
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SAFETY INFORMATION
2-4
2
ucts or having other modifications per-
formed to your vehicle that change any
of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or death.
You are responsible for injuries related
to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
●
Never install accessories that
would impair the performance of
your motorcycle. Carefully inspect
the accessory before using it to
make sure that it does not in any
way reduce ground clearance or
cornering clearance, limit suspen-
sion travel, steering travel or con-
trol operation.
Accessories fitted to the handle- bar or the front fork area can
create instability due to improper
weight distribution. If accesso-
ries are added to the handlebar
or front fork area, they must be
as lightweight as possible and
should be kept to a minimum. Bulky or large accessories may
seriously affect the stability of
the motorcycle. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds.
Certain accessories can dis- place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.
●
Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match the
performance capabilities and to provide
the best combination of handling, brak-
ing, and comfort. Other tires, rims, siz-
es, and combinations may not be appropriate. Refer to page 7-15 for tire
specifications and more information on
replacing your tires.
Transporting the Motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.
●
Remove all loose items from the
motorcycle.
●
Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.
●
Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
●
Shift the transmission in gear (for
models with a manual transmis-
sion).
●
Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or parts
that could break). Choose the lo-
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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 lit
hium-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
7-25
7
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.
NOTICE
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23283
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.1. Place a stand under the engine to raise the front wheel off the
ground. (See page 7-28 for more
information.) WARNING! To
avoid injury, securely support
the vehicle so there is no danger
of it falling over.
[EWA10751]
2. Hold the lower ends of the front fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-29
7
EAU24360
Front wheel
EAU41815
To remove the front wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Slide the rubber cover back at thebrake lever.
2. Loosen the locknut, and then turn the brake lever free play adjusting
bolt fully in direction (a).
3. Loosen the axle nut. 4. Lift the front wheel off the ground
according to the procedure in the
previous section “Supporting the
motorcycle”.
5. Remove the axle nut and washer.
6. Pull the wheel axle out. 7. Remove the brake shoe assembly
from the wheel hub by pulling it
out.
8. Remove the wheel.
EAU41693
To install the front wheel 1. Install the brake shoe assembly into the wheel hub.
2. Lift the wheel up between the fork legs.TIPMake sure that the slot in the brake
shoe plate fits over the retainer on the
fork leg.
1. Rubber cover
2. Brake lever free play adjusting bolt
3. Locknut
(a)
3
2
1
(a)
1. Axle nut
2. Washer
1. Wheel axle
1. Brake shoe assembly
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-30
7
3. Insert the wheel axle from the
right-hand side, and then install
the washer and the axle nut.
4. Lower the front wheel so that it is on the ground, and then put the
sidestand down.
5. Tighten the axle nut to the speci- fied torque.
6. Adjust the brake lever free play. (See page 7-18.) 7. While applying the front brake,
push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU41645
To remove the rear wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Disconnect the brake torque rodfrom the brake shoe plate by re-
moving the cotter pin, the nut and
the bolt.
1. Slot
2. RetainerTightening torque:Axle nut:35 Nm (3.5 m·kgf, 25 ft·lbf)
21
1. Brake torque rod
2. Cotter pin
3. Brake torque rod bolt and nut
4. Brake shoe plate
U5B685E0.book Page 30 Tuesday, July 10, 2012 5:06 PM

SPECIFICATIONS
9-2
9
Transmission type:Constant mesh 4-speed
Operation: Left foot operation
Gear ratio:
1st: 3.166 (38/12)
2nd:
1.941 (33/17)
3rd: 1.380 (29/21)
4th: 1.095 (23/21)Chassis:Frame type:Backbone
Caster angle: 26.00 °
Trail:
60 mm (2.4 in)Front tire:Type:With tube
Size:
2.50-14 4PR
Manufacturer/model: CHEN SHIN/C-803-2
Speed rating: 120 km/h (75 mph)Rear tire:Type:With tube
Size: 3.00-12 4PR Manufacturer/model:
CHEN SHIN/C-803-2
Speed rating: 120 km/h (75 mph)
Loading:Maximum rider weight:60.0 kg (132 lb)Tire air pressure (measured on cold
tires):
Front: 100 kPa (1.00 kgf/cm², 15 psi)
Rear: 100 kPa (1.00 kgf/cm², 15 psi)
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 operationRear brake:Type:Drum brake
Operation: Right foot operation
Front suspension:Type:Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel: 115.0 mm (4.53 in)Rear suspension:Type:
Swingarm
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
U5B685E0.book Page 2 Tuesday, July 10, 2012 5:06 PM