YAMAHA TTR50 2008 Repair Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6 4. Disconnect the battery coupler.
To install the battery
1. Connect the battery coupler.
2. Place the battery in the original po-
sition, and then hook the battery
band onto the holder.
3. Install the battery cover by install-
ing the bolts.
4. Install the seat.
To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that thebattery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.
To store the battery
1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
2. If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
necessary.
3. Fully charge the battery before in-
stallation.
CAUTION:
ECA10630


Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.


To charge a sealed-type (MF)
battery, a special (constant-volt-
age) battery charger is required.
Using a conventional battery
charger will damage the battery.
If you do not have access to asealed-type (MF) battery charg-
er, have a Yamaha dealer
charge your battery.
1. Battery
2. Battery band
3. Battery coupler
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU42020
Replacing the fuse The fuse is located inside the battery
coupler.
If the fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
2. Disconnect the battery coupler.
3. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
CAUTION:
ECA10640
Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly afire.
4. Connect the battery coupler.
5. Turn the key to “ON” and turn on
the electrical circuits to check if the
devices operate.
6. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
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 placing
1. Fuse
2. Spare fuseSpecified fuse:
10.0 A
U1P682E0.book Page 25 Wednesday, May 23, 2007 9:34 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6 a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU24360
Front wheel
EAU39791
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. Remove the guard from each front
fork leg by removing the bolts.
2. Disconnect the brake cable at the
wheel by removing the brake lever
free play adjusting nut at the brakecamshaft lever, then remove the
cable from the brake camshaft le-
ver.
3. Loosen the axle nut.
1. Front fork leg guard
2. Bolt
1. Brake cable
2. Brake camshaft lever
3. Brake lever free play adjusting nut
1. Axle nut
2. Washer
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
64. Lift the front wheel off the ground
according to the procedure on
page 6-25.
5. Remove the axle nut and washer.
6. Pull the wheel axle out, and then
remove the wheel.
EAU39801
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. Connect the brake cable to the
brake camshaft lever, and then in-
stall the brake cable free play ad-
justing nut on the brake cable.
6. Adjust the brake lever free play.
(See page 6-15.)7. While applying the front brake,
push down hard on the handlebar
several times to check for proper
fork operation.
8. Install each front fork leg guard by
installing the bolts.1. Wheel axle
1. Slot
2. RetainerTightening torque:
Axle nut:
35 Nm (3.5 m·kgf, 25 ft·lbf)
1
2
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6
EAU25080
Rear wheel
EAU39770
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. Loosen the axle nut.2. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod from the brake cam-
shaft lever.
3. Loosen the locknut and drive chain
adjusting nut on each end of the
swingarm.
4. Lift the rear wheel off the ground
according to the procedure on
page 6-25.
5. Remove the axle nut and washer,
then pull the wheel axle out.6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:The drive chain does not need to be
disassembled in order to remove andinstall the wheel.
1. Axle nut
2. Washer
3. Drive chain slack adjusting nut
4. Locknut
1
4
3
2
1. Brake pedal free play adjusting nut
2. Brake rod
3. Brake camshaft lever
1
2
3
1. Wheel axle
U1P682E0.book Page 28 Wednesday, May 23, 2007 9:34 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
67. Remove the wheel.
EAU39781
To install the rear wheel
1. Install the drive chain onto the rear
sprocket, and then install the
wheel by inserting the wheel axle
from the right-hand side.NOTE:Make sure that the slot in the brake
shoe plate fits over the retainer on theswingarm.
2. Connect the brake rod to the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.3. Adjust the drive chain slack. (See
page 6-17.)
4. Install the washer and axle nut,
and then lower the rear wheel so
that it is on the ground.
5. Tighten the axle nut to the speci-
fied torque.
6. Adjust the brake pedal free play.
(See page 6-16.)
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.
1. Slot
2. Retainer
Tightening torque:
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
U1P682E0.book Page 29 Wednesday, May 23, 2007 9:34 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
EAU25901
Troubleshooting chart
WARNING
EWA10840
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
U1P682E0.book Page 30 Wednesday, May 23, 2007 9:34 AM

MOTORCYCLE CARE AND STORAGE
7-1
7
EAU37833
Matte color caution CAUTION:
ECA15192
Some models are equipped with
matte colored finished parts. Be
sure to consult a Yamaha dealer for
advice on what products to use be-
fore cleaning the vehicle. Using a
brush, harsh chemical products or
cleaning compounds when cleaning
these parts will scratch or damage
their surface. Wax also should not
be applied to any matte colored fin-ished parts.
EAU40462
Care While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
CAUTION:
ECA10771


Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.


Improper cleaning can damage
plastic parts such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.


Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
U1P682E0.book Page 1 Wednesday, May 23, 2007 9:34 AM

MOTORCYCLE CARE AND STORAGE
7-2
7 contact 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.
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MOTORCYCLE CARE AND STORAGE
7-3
7


If necessary, wash the tires with
warm water and a mild deter-
gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor-nering behavior.
CAUTION:
ECA10800


Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.


Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.


Avoid using abrasive polishing
compounds as they will wearaway the paint.
NOTE:Consult a Yamaha dealer for advice onwhat products to use.
EAU26150
Storage Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.CAUTION:
ECA10810


Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.


To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-cals are stored.
Long-term
Before storing your motorcycle for sev-
eral months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” posi-
tion: Turn the fuel cock lever to
“OFF”.3. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to pro-
tect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap.
U1P682E0.book Page 3 Wednesday, May 23, 2007 9:34 AM