fuel tank removal 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

4 - 1
ENGFRONT FENDER, SEAT ASSEMBLY AND FUEL TANK
EC400000
ENGINE
EC4R0000
FRONT FENDER, SEAT ASSEMBLY AND FUEL TANK
Extent of removal:1 Front fender removal
2 Seat removal
3 Battery removal
4 Fuel tank removal
5 Air filter case removal
6 Bottom cover removal
Extent of removal Order Part name Q ’ty Remarks
FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK
REMOVAL
Preparation for removal Turn the fuel cock to “OFF ”.
1 Front fender 1
2 Seat assembly 1
3 Air scoop (left and right) 2
4 Battery cover 1
5 Battery coupler 1 Disconnect.
6 Battery band 1
7 Battery rubber cover 1
8 Battery 1
9 Fitting band 1
10 Fuel hose 1 Remove on fuel tank side.
1
2
3
43
4
5
5

4 - 2
ENGFRONT FENDER, SEAT ASSEMBLY AND FUEL TANK
Extent of removal Order Part name Q’ty Remarks
11 Bolt (fuel tank) 2
12 Fuel tank 1
13 Air filter case cover 1
14 Air filter element 1
15 Air filter case 1
16 Bottom cover 1
4
5
6

4 - 3
ENGMUFFLER
MUFFLER
Extent of removal: 1 Muffler removal
Extent of removal Order Part name Q ’ty Remarks
MUFFLER REMOVAL
Preparation for removal Seat assembly Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section.
1 Bolt (spark arrester) 3
2 Spark arrester 1
3 Nut (muffler) 2
4 Bolt (muffler) 1
5 Muffler 1
1

4 - 4
ENG
CARBURETOR
2
1
6
6
3
8
9 5
47
New
New
T R..7 Nm (0.7 m
•
kg, 5.1 ft • Ib)
New
T R..2 Nm (0.2 m •
kg, 1.4 ft • Ib)
Extent of removal: 1 Carburetor removal
Extent of removal Order Part name Q ’ty Remarks
CARBURETOR REMOVAL
Preparation for removal Fuel tank Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section.
1 Clamp (air filter joint) 1 Loosen the screw (air filter joint).
2 Carburetor heater lead connector 2
3 Air vent hose 1
4 Fuel hose 1
5 Carburetor assembly 1
6O-ring 2
7 Joint 1
8 Carburetor top 1
9 Starter plunger assembly 1
1
CARBURETOR

4 - 10
ENGCYLINDER HEAD
CYLINDER HEAD
Extent of removal: 1 Cylinder head removal
Extent of removal Order Part name Q ’ty Remarks
CYLINDER HEAD REMOVAL
Preparation for removal Seat assembly and fuel tank Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section.
Muffler Refer to “MUFFLER ” section.
Carburetor Refer to “CARBURETOR ” section.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL ” section in the CHAPTER 5.
1 Plug cap/spark plug 1/1
2 Crankshaft end cover 1
3 Timing plug 1
4 Camshaft sprocket cover 1
5 Tappet cover 2
6 Camshaft sprocket bolt 1 Refer to “REMOVAL POINTS ”.
7 Timing chain tensioner cap bolt 1
1

4 - 42
ENGAC MAGNETO AND STARTER CLUTCH
AC MAGNETO AND STARTER CLUTCH
È Stake
Extent of removal: 1 Crankcase cover (left) removal
2 Pickup coil/stator removal
3 Rotor removal
4 Starter clutch/wheel gear removal
Extent of removal Order Part name Q ’ty Remarks
AC MAGNETO AND STATOR
REMOVAL
Preparation for removal Seat assembly Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section.
1 Crankcase cover (left) 1
2 Dowel pin 2
3 Gasket 1
4 AC magneto coupler 2
5 Neutral switch lead 1
6 Pickup coil/stator assembly 1
7 Rotor nut 1 Use special tool.
Refer to “REMOVAL POINTS ”.
8 Rotor 1
9 Woodruff key 1
21
3
4

4 - 47
ENGENGINE REMOVAL
ENGINE REMOVAL
(4)
NewNew
LS
T R..30 Nm (3.0 m • kg, 22 ft • Ib)
T R..30 Nm (3.0 m •
kg, 22 ft • Ib)
T R..30 Nm (3.0 m •
kg, 22 ft • Ib)
T R..30 Nm (3.0 m •
kg, 22 ft • Ib)
T R..48 Nm (4.8 m •
kg, 35 ft • Ib)
T R..7 Nm (0.7 m •
kg, 5.1 ft • Ib)
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
(3)
10
4
1 6
2
9
3
11
7
5 8
Extent of removal:
1 Engine removal
Extent of removal Order Part name Q ’ty Remarks
ENGINE REMOVAL
Preparation for removal Hold the machine by placing the suitable stand under the frame.
Seat assembly, fuel tank air filter
case cover and air filter case Refer to
“FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section.
Carburetor Refer to “CARBURETOR ” section.
Muffler Refer to “MUFFLER ” section.
Spark plug cap
Disconnect the AC magneto cou-
plers.
Disconnect the neutral switch
lead.
Starter motor Refer to “ELECTRIC STARTING SYS-
TEM ” section in the CHAPTER 6.

4 - 51
ENGCRANKCASE AND CRANKSHAFT
CRANKCASE AND CRANKSHAFT
E
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
T R..10 Nm (1.0 m •
kg, 7.2 ft • Ib)
LT
4
4 3
4
4
5 6
7
9
8
8
12
5 6
4
Extent of removal Order Part name Q ’ty Remarks
CRANKCASE SEPARATION
AND CRANKSHAFT REMOVAL
Preparation for removal Seat assembly and fuel tank
Exhaust pipe
Air filter case and bottom cover Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section.
Carburetor Refer to “CARBURETOR ” section.
Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT ”
section in the CHAPTER 3.
Drive sprocket Refer to “ENGINE REMOVAL ”.
Cylinder head Refer to “CYLINDER HEAD ” section.
Cylinder and piston Refer to “CYLINDER AND PISTON ” sec-
tion.
Primary driven gear Refer to “CLUTCH ” section.

5 - 17
CHASSWINGARM
EC570000
SWINGARM
Extent of removal:1 Swingarm removal
2 Rear shock absorber removal
Extent of removal Order Part name Q ’ty Remarks
SWINGARM REMOVAL
WARNING
Support the machine securely so
there is no danger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Seat assembly Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section
in the CHAPTER 4.
Rear wheel Refer to “FRONT WHEEL AND REAR
WHEEL ” section.
Drive chain
1 Rear shock absorber 1
2 Drive chain guard 1
3 Drive chain support 1
4 Drive chain guide 1
1
2