clutch YAMAHA TTR50 2006 Betriebsanleitungen (in German)

CHAPTER 4ENGINE
FRONT FENDER, SEAT ASSEMBLY
AND FUEL TANK .......................................4-1
MUFFLER ...................................................4-3
CARBURETOR ...........................................4-4
CYLINDER HEAD .....................................4-10
CAMSHAFT AND ROCKER ARMS .........4-15
VALVES AND VALVE SPRINGS .............4-18
CYLINDER AND PISTON .........................4-23
CLUTCH ....................................................4-29
SHIFT SHAFT ...........................................4-37
OIL PUMP .................................................4-39
AC MAGNETO AND
STARTER CLUTCH ..................................4-42
ENGINE REMOVAL ..................................4-47
CRANKCASE AND CRANKSHAFT .........4-51
SHIFT FORK, SHIFT CAM AND
TRANSMISSION .......................................4-54
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL ........5-1
HANDLEBAR ............................................5-10
STEERING AND
FRONT SUSPENSION .............................5-13
SWINGARM ..............................................5-17
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS AND
WIRING DIAGRAM .....................................6-1
IGNITION SYSTEM .....................................6-2
ELECTRIC STARTING SYSTEM ...............6-6
CHARGING SYSTEM ...............................6-14
CARBURETOR HEATING SYSTEM ........6-16
MAINTENANCE RECORD .......................6-20

SPEC
2 - 2
Oil capacity:
Engine oil Periodic oil change 0.8 L (0.70 Imp qt, 0.85 US qt)
Total amount 1.0 L (0.88 Imp qt, 1.06 US qt)
Air filter: Wet element
Fuel: Type Unleaded gasoline only (USA, AUS and NZ) Regular unleaded gasoline only
(CDN, Europe and ZA)
Tank capacity 3.1 L (0.68 Imp gal, 0.82 US gal)
Reserve amount 0.4 L (0.09 Imp gal, 0.11 US gal)
Carburetor: Type VM11
Manufacturer MIKUNI
Spark plug: Type CR7HSA
Manufacturer NGK
Gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Clutch type: Wet, multiple-disc and centrifugal automatic
Transmission: Primary reduction system Spur gear
Primary reduction ratio 67/18 (3.722)
Secondary reduction system Chain drive
Secondary reduction ratio 37/13 (2.846)
Transmission type Constant mesh, 3-speed
Operation Left foot operation
Gear ratio: 1st 39/12 (3.250) 2nd 33/19 (1.736)
3rd 28/23 (1.217)
Chassis: Frame type Steel tube backbone
Caster angle 25.50 °
Trail 34.0 mm (1.34 in)
Tire: Type With tube
Size (front) 2.50-10 4PR
Size (rear) 2.50-10 4PR
Manufacturer (front and rear) CHENG SHIN
Type (front and rear) KNOBBY
Tire pressure (front and rear) 100 kPa (1.00 kgf/cm
2, 14.2 psi)
Brake: Front brake type Drum brake
Operation Right hand operation
Rear brake type Drum brake
Operation Right foot operation
GENERAL SPECIFICATIONS
1
2
3
4
5
6

SPEC
2 - 8
Oil ring
Dimensions (B × T) 1.50 × 1.60 mm
(0.059 × 0.063 in) ----
End gap (installed) 0.20 ~ 0.70 mm (0.008 ~ 0.028 in)----
Crankshaft: Crank width “A” 42.95 ~ 43.00 mm (1.691 ~ 1.693 in)----
Runout limit “C” ---- 0.03 mm (0.0012 in)
Big end side clearance “D” 0.10 ~ 0.40 mm (0.0039 ~ 0.0157 in)0.50 mm
(0.02 in)
Big end radial clearance “E” 0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in)0.05 mm
(0.002 in)
Clutch: Friction plate Thickness 2.92 ~ 3.08 mm (0.115 ~ 0.121 in)2.82 mm
(0.111 in)
Quantity 2 ----
Clutch plate 1 Thickness 1.85 ~ 2.15 mm (0.073 ~ 0.085 in)----
Quantity 1 ----
Warp limit ---- 0.2 mm (0.008 in)
Clutch plate 2 Thickness 1.95 ~ 2.05 mm (0.077 ~ 0.081 in)----
Quantity 1 ----
Warp limit ---- 0.2 mm (0.008 in)
Clutch plate 3 Thickness 1.90 ~ 2.10 mm (0.075 ~ 0.083 in)----
Quantity 1 ----
Warp limit ---- 0.2 mm (0.008 in)
Automatic centrifugal clutch: Clutch-in revolution 2,300 ~ 2,700 r/min ----
Clutch-stall revolution 3,210 ~ 3,710 r/min ----
Shifter: Shifter type Shift drum and guide bar ---- Item Standard Limit
B
T
CC
D
A
E
MAINTENANCE SPECIFICATIONS

SPEC
2 - 10
Part to be tightened Thread size Q
’ty Tightening torque
Remarks
Nm m ·kg ft ·lb
Cylinder head nut M8 × 1.25 4 22 2.2 16
Cylinder head bolt M6 × 1.0 2 10 1.0 7.2
Spark plug M10 × 1.0 1 13 1.3 9.4
Camshaft sprocket cover bolt M6 × 1.0 2 10 1.0 7.2
Tappet cover M45 × 1.5 2 18 1.8 13
Exhaust pipe stud bolt M6 × 1.0 2 7 0.7 5.1
Rotor nut M12 × 1.25 1 48 4.8 35
Timing chain guide stopper M6 × 1.0 2 10 1.0 7.2
LT
Valve clearance adjust screw locknut M5 × 0.5 2 7 0.7 5.1
Camshaft sprocket M8 × 1.25 1 26 2.6 19
Camshaft bearing retainer M6 × 1.0 1 10 1.0 7.2
LT
Timing chain tensioner cap bolt M8 × 1.25 1 8 0.8 5.8
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Oil pump assembly M6 × 1.0 2 7 0.7 5.1
LT
Engine oil drain bolt M12 × 1.5 1 20 2.0 14
Intake manifold (cylinder head side) M6 × 1.0 2 7 0.7 5.1
Intake manifold (carburetor side) M6 × 1.0 2 7 0.7 5.1
Carburetor heater M8 × 1.25 1 3 0.3 2.2
Clamp (air filter joint) M4 × 0.7 1 2 0.2 1.4
Exhaust pipe M6 × 1.0 2 7 0.7 5.1
Muffler M8 × 1.25 1 38 3.8 27
Muffler cover M6 × 1.0 4 7 0.7 5.1
Spark arrester M6 × 1.0 3 10 1.0 7.2
Crankcase M6 × 1.0 10 10 1.0 7.2
Crankcase cover (left) M6 × 1.0 8 10 1.0 7.2
Drive sprocket cover M6 × 1.0 2 7 0.7 5.1
Timing plug M14 × 1.5 1 7 0.7 5.1
Crankshaft end cover M32 × 1.5 1 7 0.7 5.1
Crankcase cover (right) M6 × 1.0 9 10 1.0 7.2
Clutch adjuster locknut M8 × 1.25 1 6 0.6 4.3
Cylinder head stud bolt M8 × 1.25 4 13 1.3 9.4
Starter clutch and rotor M6 × 1.0 3 14 1.4 10 Stake
Clutch housing nut M14 × 1.0 1 70 7.0 50
Pressure plate M5 × 0.8 3 5 0.5 3.6
Primary driven gear M14 × 1.0 1 70 7.0 50
Stopper bolt M8 × 1.25 1 23 2.3 17
LT
Shift pedal M6 × 1.0 1 10 1.0 7.2
Pickup coil M6 × 1.0 2 10 1.0 7.2
LT
Stator assembly M6 × 1.0 3 10 1.0 7.2LT
Neutral switch M10 × 1.25 1 18 1.8 13
MAINTENANCE SPECIFICATIONS

3 - 1
INSPADJ
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
No. ITEM CHECKS AND
MAINTENANCE JOBS WHICH-
EVER
COMES
FIRST INITIAL EVERY
month 1 6 12
hours 30 60 120
1 * Fuel line Check fuel hoses for cracks or damage.
Replace if necessary.
√

√
2 Spark plug Check condition.
Adjust gap and clean.
√

√
3 * Valve clearance Check and adjust valve clearance when engine is
cold.
√

4 * Air filter element Clean with solvent.
Replace if necessary.
√

√
5 * Breather system Check ventilation hose for cracks or damage.
Replace if necessary.
√

√
√
6 * Carburetor Check engine idling speed and starter operation.
Adjust if necessary.
√

√
√
7 Exhaust system Check for leakage.
Tighten if necessary.
Replace gasket if necessary.
√

√
8 Engine oil Change (warm engine before draining). √
√
√
9 * Clutch Check operation.
Adjust if necessary.
√

√
√
10 * Front brake Check operation.
Adjust brake lever free play and replace brake shoes
if necessary.
√

√
√
11 * Rear brake Check operation.
Adjust brake pedal free play and replace brake shoes
if necessary. √

√
√
12 * Wheels Check runout, spoke tightness and for damage.
Tighten spokes if necessary.
√

√
√
13 * Tires Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
√

√
14 * Wheel bearings Check bearings for smooth operation.
Replace if necessary.
√

√
15 * Swingarm Check swingarm pivoting point for play.
Correct if necessary.
Lubricate with lithium soap based grease. √

√
√
16 Drive chain Check chain slack/alignment and condition.
Adjust and lubricate chain. Every ride
17 * Steering bearings Check bearing assemblies for looseness.
Lubricate with lithium soap based grease every
120 hours or 12 months (whichever comes first).
√

√
18 Brake lever pivot
shaft Apply lithium soap based grease lightly.
√
√
√
19 Brake pedal pivot
shaft Apply lithium soap based grease lightly.
√
√
√
3

3 - 8
INSPADJ
4. Check:
Oil level
Oil level should be between maximum a
and minimum b marks.
Oil level is low → Add oil to proper level.
NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.
 When inspecting the oil level, do not screw
the dipstick into the oil tank. Insert the gauge
lightly.
(For USA and CDN)
CAUTION:
 Do not add any chemical additives.
Engine oil also lubricates the clutch and
additives could cause clutch slippage.
 Do not allow foreign material to enter the
crankcase.
(Except for USA and CDN)
CAUTION:
 Do not add any chemical additives or use
oils with a grade of CD a or higher.
 Do not use oils labeled “ENERGY CON-
SERVING II ” b or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.
 Do not allow foreign materials to enter the
crankcase.
Recommended oil:
At –10 °C (14 °F) or higher È:
Yamalube 4 (10W-30) or SAE
10W-30 type SE/SF/SG motor
oil
At 5 °C (41 °F) or higher É:
Yamalube 4 (20W-40) or SAE
20W-40 type SE/SF/SG motor
oil
Recommended oil: Refer to the following chart for
selection of oils which are suited
to the atmospheric temperatures.
Recommended engine oil classifi-
cation:
API STANDARD: API “SE/SF/SG ” or higher grade
(Designed primarily for
motorcycles)
0 10 30 50 70
90110
130
-20 -10 010
20 30 40 50
È
É
˚C
˚
F
a
b
ENGINE OIL LEVEL INSPECTION

4 - 29
ENGCLUTCH
CLUTCH
LS
E
E
E
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..6 Nm (0.6 m •
kg, 4.3 ft • Ib)
T R..70 Nm (7.0 m •
kg, 50 ft • lb)
E
New
E
E
2 3
6
7
8
7
10
9
11
1314
16
25
45
20
20
191817
2728
29
2630
21
2423
22
12 15
31
1
New
T R..5 Nm (0.5 m •
kg, 3.6 ft • Ib)
(3)
Extent of removal: 1 Friction plate and clutch plate removal
2 Clutch housing removal
3 Clutch removal
Extent of removal Order Part name Q ’ty Remarks
CLUTCH REMOVAL
Preparation for removal Brake pedal and footrest assem- bly Refer to
“ENGINE REMOVAL ” section.
1 Clutch adjuster cover 1
2 Clutch adjuster locknut 1
3 Crankcase cover (right) 1
4 Dowel pin 2
5 Gasket 1
6 Clutch adjuster 1
7 Shift guide 2
8 Pawl holder 1
9 Shift arm 1
10 Pressure plate 1
213

4 - 30
ENGCLUTCH
LS
E
E
E
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..6 Nm (0.6 m •
kg, 4.3 ft • Ib)
T R..70 Nm (7.0 m •
kg, 50 ft • lb)
E
New
E
E
2 3
6
7
8
7
10
9
11
1314
16
25
45
20
20
191817
2728
29
2630
21
2423
22
12 15
31
1
New
T R..5 Nm (0.5 m •
kg, 3.6 ft • Ib)
(3)
Extent of removal Order Part name Q ’ty Remarks
11 Bush 3
12 Absorber 3
13 Clutch housing nut 1 Use special tool.
Refer to “REMOVAL POINTS ”.
14 Washer 1
15 Guide pin 3
16 Clutch housing 1
17 Circlip 1
18 Clutch spring plate 1
19 Clutch plate 1 1
20 Friction plate 2
21 Clutch plate 2 1 Silver
22 Clutch plate 3 1 Brown
23 Clutch boss 1
24 Outer drive gear 1
2
1
3

4 - 31
ENGCLUTCH
LS
E
E
E
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..6 Nm (0.6 m •
kg, 4.3 ft • Ib)
T R..70 Nm (7.0 m •
kg, 50 ft • lb)
E
New
E
E
2 3
6
7
8
7
10
9
11
1314
16
25
45
20
20
191817
2728
29
2630
21
2423
22
12 15
31
1
New
T R..5 Nm (0.5 m •
kg, 3.6 ft • Ib)
(3)
Extent of removal Order Part name Q ’ty Remarks
25 Spring 1
26 Washer 1
27 Primary driven gear nut 1
28 Lock washer 1
29 Primary driven gear 1
30 Primary drive gear 1
31 Collar 1
3

4 - 32
ENGCLUTCH
REMOVAL POINTS
Clutch
1. Remove:Clutch housing nut 1
NOTE:
Loosen the clutch housing nut while holding
the clutch housing with the sheave holder 2.
Sheave holder:
YS-01880-A/90890-01701
1
2
Primary driven gear
1. Remove: primary driven gear nut 1
 Lock washer 2
 Primary driven gear 3
NOTE:
Straighten the lock washer tab 2.
 Place an aluminum plate 4 between the
teeth of the primary driven gear 3 and pri-
mary drive gear 5.
INSPECTION
EC484100
Clutch housing and boss
1. Inspect: Clutch housing 1
Cracks/wear/damage → Replace.
 Clutch boss 2
Scoring/wear/damage → Replace.
1
2 3
5
4
2
1