YAMAHA TTR50 2012 Workshop Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
7-10
7 2. If dirt or water is visible, remove
the hose, clean it, and then install
it.
EAU40421
Cleaning the spark arrester The spark arrester should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
WARNING
EWA10980


Always let the exhaust system
cool prior to touching exhaust
components.


Do not start the engine when
cleaning the exhaust system.
TIPMake sure to select a well-ventilated
area free of combustible materials to
clean the spark arrester.1. Remove the tailpipe by removing
the bolts, and then pulling it out of
the muffler.2. Tap the tailpipe lightly, and then
use a wire brush to remove any
carbon deposits from the spark ar-
rester portion of the tailpipe and in-
side of the tailpipe housing.
1. Air filter check hose
1. Tailpipe bolt
2. Tailpipe
1. Spark arrester
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-11
73. Insert the tailpipe into the muffler,
and then install and tighten the
bolts to the specified torque.
TIPMake sure to align the bolt holes when
inserting the tailpipe.
EAU39930
Adjusting the carburetor The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in the
following section, however, may be ser-
viced by the owner as part of routine
maintenance.NOTICE
ECA10550
The carburetor has been set and ex-
tensively tested at the Yamaha fac-
tory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine.
EAU21362
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.TIPA diagnostic tachometer is needed to
make this adjustment.1. Attach the tachometer to the spark
plug lead.
2. Start the engine and warm it up for
several minutes at 1000–2000
r/min while occasionally revving it
to 4000–5000 r/min.TIPThe engine is warm when it quickly re-
sponds to the throttle.3. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
Tightening torque:
Tailpipe bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-12
7 rection (a). To decrease the en-
gine idling speed, turn the screw in
direction (b).
TIPIf the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
EAU21384
Checking the throttle grip free
play The throttle grip free play should mea-
sure 3.0–5.0 mm (0.12–0.20 in) at the
inner edge of the throttle grip. Periodi-
cally check the throttle grip free play
and, if necessary, have a Yamaha deal-
er adjust it.
EAU21401
Valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Throttle stop screwEngine idling speed:
1600–1800 r/min
(a)
(b)
1
1. Throttle grip free play
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-13
7
EAU39824
Tires To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING
EWA15370
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.
The tire air pressure must be
checked and adjusted on cold tires
(i.e., when the temperature of the
tires equals the ambient tempera-
ture).
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
Tire information
This motorcycle is equipped with spoke
wheels and tube tires.
WARNING
EWA10461
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, which
could lead to an accident.After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
WARNING
EWA15541


Have a Yamaha dealer replace
excessively worn tires. Operat-
ing the motorcycle with exces-
sively worn tires decreases
riding stability and can lead to
loss of control.
Standard tire air pressure:
Fr o nt :
100 kPa (1.00 kgf/cm², 15 psi)
Rear:
100 kPa (1.00 kgf/cm², 15 psi)
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
4.0 mm (0.16 in)
12
Front tire:
Size:
2.50-10 4PR
Manufacturer/model:
CHENG SHIN/C183A
Rear tire:
Size:
2.50-10 4PR
Manufacturer/model:
CHENG SHIN/C183A
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-14
7


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.


It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.


Ride conservatively after
changing a tire since the tire
must seat itself on the rim prop-
erly. Failure to allow proper
seating may cause tire failure,
which may result in damage to
the motorcycle and injury to the
rider.
EAU21943
Spoke wheels
WARNING
EWA10610
The wheels on this model are not de-
signed for use with tubeless tires.
Do not attempt to use tubeless tires
on this model.To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified wheels.

The wheel rims should be checked
for cracks, bends, warpage or oth-
er damage, and the spokes for
looseness or damage before each
ride. If any damage is found, have
a Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A de-
formed or cracked wheel must be
replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
EAU46251
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. Remove the clutch adjusting
screw cover by removing the
screws.
2. Loosen the locknut.
3. Slowly turn the clutch adjusting
screw in direction (a) until resis-
tance is felt, and then turn it 1/8
turn in direction (b).1. Screw
2. Clutch adjusting screw cover
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-15
74. Tighten the locknut to the specified
torque.
TIPWhen tightening the locknut, hold the
clutch adjusting screw with a screwdriv-
er so that it does not turn together with
the locknut.5. Install the clutch adjusting screw
cover by installing the screws.
EAU22130
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.
To increase the brake lever free play,
turn the adjusting nut at the brake shoe
plate in direction (a). To decrease the
brake lever free play, turn the adjusting
nut in direction (b).
WARNING
EWA10650
If proper adjustment cannot be ob-
tained as described, have a Yamaha
dealer make this adjustment.
1. Locknut
2. Clutch adjusting screwTightening torque:
Locknut:
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
1. Brake lever free play
1
1. Brake lever free play adjusting nut
1
(a)
(b)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-16
7
EAU44670
Adjusting the brake pedal free
play The brake pedal free play should mea-
sure 10.0–20.0 mm (0.39–0.79 in) at
the brake pedal end as shown. Period-
ically check the brake pedal free play
and, if necessary, adjust it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).
WARNING
EWA14820


After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.


If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this ad-
justment.
EAU44820
Checking the shift pedal The operation of the shift pedal should
be checked before each ride. If opera-
tion is not smooth, have a Yamaha
dealer check the vehicle.
1. Brake pedal free play
1
1. Brake pedal free play adjusting nut
(b) (a)
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-17
7
EAU22361
Checking the front and rear
brake shoes Front
RearThe front and rear brake shoes must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart. Each brake is provid-
ed with a wear indicator, which allows
you to check the brake shoe wear with-
out having to disassemble the brake.
To check the brake shoe wear, check
the position of the wear indicator while
applying the brake. If a brake shoe has
worn to the point that the wear indicator
reaches the wear limit line, have a
Yamaha dealer replace the brake
shoes as a set.
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22774
To check the drive chain slack
1. Place the motorcycle on the side-
stand.TIPWhen checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.2. Shift the transmission into the neu-
tral position.
3. Measure the drive chain slack as
shown.
1. Brake shoe wear indicator
2. Brake shoe wear limit line
1. Brake shoe wear indicator
2. Brake shoe wear limit line
2
1
21
Drive chain slack:
35.0–45.0 mm (1.38–1.77 in)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-18
7 4. If the drive chain slack is incorrect,
adjust it as follows.
EAU40113
To adjust the drive chain slack
Consult a Yamaha dealer before ad-
justing the drive chain slack.
1. Loosen the brake pedal free play
adjusting nut, axle nut, and locknut
at each end of the swingarm.
2. To tighten the drive chain, turn the
drive chain slack adjusting nut at
each end of the swingarm in direc-tion (a). To loosen the drive chain,
turn the adjusting nut at each end
of the swingarm in direction (b),
and then push the rear wheel for-
ward. NOTICE: Improper drive
chain slack will overload the en-
gine as well as other vital parts
of the motorcycle and can lead
to chain slippage or breakage.
To prevent this from occurring,
keep the drive chain slack with-
in the specified limits.
[ECA10571]
TIPUsing the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the same
position for proper wheel alignment.
1. Drive chain slack
1. Brake pedal free play adjusting nut
2. Drive chain slack adjusting nut
3. Locknut
1. Axle nut
2. Drive chain slack adjusting nut
3. Locknut
1
2
3
2
3
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-19
73. Tighten both locknuts and the axle
nut to the specified torques.
4. Adjust the brake pedal free play.
(See page 7-16.)
5. Make sure that the drive chain pull-
ers are in the same position, the
drive chain slack is correct, and
the drive chain moves smoothly.
EAU23016
Cleaning and lubricating the
drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.NOTICE
ECA10583
The drive chain must be lubricated
after washing the motorcycle, riding
in the rain or riding in wet areas.1. Remove all dirt and mud from the
drive chain with a brush or cloth.TIPFor a thorough cleaning, have a
Yamaha dealer remove the drive chain
and soak it in solvent.2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on the entire
chain, making sure that all side
plates and rollers have been suffi-
ciently oiled.
EAU23095
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
housing of cables may result in in-
ternal rusting and cause interfer-
ence with cable movement. Replace
damaged cables as soon as possi-
ble to prevent unsafe conditions.[EWA10711]
1. Alignment marks
2. Drive chain puller
3. Drive chain slack adjusting nutTightening torques:
Locknut:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
(b)(a)3
2
1
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil
U1P686E0.book Page 19 Thursday, April 14, 2011 1:20 PM