steering wheel 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

GEN
INFO
1 - 7
SPECIAL TOOLS
YM-34483, 90890-03079 Thickness gauge
This tool is used to measure the valve clearance. YM-34483 90890-03079
YM-34487 90890-06754 Opama pet-4000 spark checker
Ignition checker
This instrument is necessary for checking the ignition
system components. YM-34487 90890-06754
YU-33975, 90890-01403 Steering nut wrench This tool is used when tighten the steering ring nut to
specification. YU-33975 90890-01403
YS-01880-A, 90890-01701 Sheave holder This tool is used for when loosening or tightening the
flywheel magneto securing nut. YS-01880-A 90890-01701
YU-33270-B, 90890-01362 Flywheel puller This tool is used to remove the rotor. YU-33270-B 90890-01362
90890-85505 YAMAHA Bond No. 1215 This sealant (Bond) is used for crankcase mating sur-
face, etc. 90890-85505
Part number Tool name/How to use Illustration

SPEC
2 - 11
CHASSIS
Item Standard Limit
Steering system: Steering bearing type Angular bearing ----
Front suspension: Front fork travel 96 mm (3.78 in) ----
Spring rate K1 7.95 N/mm (0.81 kgf/mm, 45.39 lb/in)----
K2 10.50 N/mm (1.07 kgf/mm, 59.96 lb/in) ----
Optional spring/spacer No ----
Inner tube outer diameter 21.7 mm (0.85 in) ----
Rear suspension: Shock absorber travel 47 mm (1.85 in) ----
Spring free length 114 mm (4.49 in) ----
Fitting length 110 mm (4.33 in) ----
Spring rate, STD K = 29.0 N/mm (2.96 kg/mm, 166 lb/in)----
Optional spring No ----
Swingarm: Swingarm free play limit End ---- 1.0 mm (0.0394 in)
Side clearance ---- 0.3 mm (0.0118 in)
Wheel: Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 10 × 1.40/steel ----
Rear rim size/material 10 × 1.40/steel ----
Rim runout limit: Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain: Type/manufacturer 420/KMC ----
Number of links 79 links + joint ----
Chain slack 35 ~ 45 mm (1.38 ~ 1.77 in) ----
Chain length (15 links) ---- 194.3 mm (7.65 in)
MAINTENANCE SPECIFICATIONS

SPEC
2 - 13
NOTE:
1.First, tighten the ring nut approximately 38 Nm (3.8 m · kg, 27 ft · lb) by using the lower ring nut
wrench and turn the steering right and left a few times; then loosen the lower ring nut completely.
2.Retighten the lower ring nut 4 Nm (0.4 m · kg, 2.9 ft · lb).
Part to be tightened Thread size Q
’ty Tightening torque
Nm m ·kg ft ·lb
Engine mounting: Engine and frame (front upper side) M8 × 1.25 1 30 3.0 22
Engine and frame (rear upper side) M8 × 1.25 1 30 3.0 22
Engine and frame (rear lower side) M10 × 1.25 1 48 4.8 35
Engine bracket and frame M8 × 1.25 2 30 3.0 22
Front wheel axle and front wheel axle nut M12 × 1.25 1 35 3.5 25
Front brake camshaft lever and front brake
camshaft M6
× 1.0 1 7 0.7 5.1
Front brake cable locknut M8 × 1.25 1 16 1.6 11
Front wheel nipple (spoke) —28 2 0.2 1.4
Rear wheel nipple (spoke) —28 2 0.2 1.4
Rear wheel axle and rear wheel axle nut M12 × 1.25 1 60 6.0 43
Rear brake camshaft lever and rear brake
camshaft M6
× 1.0 1 7 0.7 5.1
Rear wheel drive hub and rear wheel sprocket M8 × 1.25 4 25 2.5 18
Drive chain puller locknut M6 × 1.0 2 7 0.7 5.1
Upper bracket and handlebar M10 × 1.25 2 32 3.2 23
Steering stem nut M22 × 1.0 1 110 11.0 80
Lower ring nut M25 1 Refer to NOTE.
Upper bracket and lower bracket M10 × 1.25 2 32 3.2 23
Inner tube assembly and front fork guard M6 × 1.0 4 7 0.7 5.1
Pivot shaft and nut M10 × 1.25 1 35 3.5 25
Rear shock absorber and frame M10 × 1.25 1 30 3.0 22
Rear shock absorber and swingarm M10 × 1.25 1 30 3.0 22
Drive chain guide and swingarm M6 × 1.0 2 7 0.7 5.1
Drive chain support and swingarm M6 × 1.0 3 7 0.7 5.1
Drive chain guard and swingarm M6 × 1.0 2 7 0.7 5.1
Upper bracket and front fender M6 × 1.0 2 7 0.7 5.1
Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1
Fuel tank and frame M6 × 1.0 2 7 0.7 5.1
Air scoop and fuel tank M6 × 1.0 2 7 0.7 5.1
Seat assembly and frame M6 × 1.0 2 7 0.7 5.1
Seat and rear fender M6 × 1.0 3 7 0.7 5.1
Seat and side covers M6 × 1.0 4 7 0.7 5.1
Footrest, under cover and engine M8 × 1.25 4 30 3.0 22
Sidestand and sidestand bracket M10 × 1.25 1 40 4.0 29
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 - 3
INSPADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel line
for leakage. P.1-11
Engine oil Check that the oil level is correct. Check the crankcase for leakage. P.3-7 ~ 9
Throttle Check for proper throttle cable operation. P.3-4 ~ 5
Brakes Check the play of front and rear brake and effect of front and rear
brake. P.3-14 ~ 15
Drive chain Check chain slack and alignment. Check that the chain is lubricated
properly. P.3-16 ~ 18
Wheels and tires Check pressure/runout/spoke tightness/bead stopper/axle nuts. P.3-19 ~ 20
Steering Check that the handlebar can be turned smoothly and have no exces-
sive play. P.3-20 ~ 21
Front forks and rear
shock absorber assembly Check that they operate smoothly and there is no oil leakage. P.3-18
Cables (wires) Check that the throttle cable move smoothly. Check that they are not
caught when the handlebars are turned. —
Muffler Check that the muffler is tightly mounted and has no cracks. P.4-3
Sprocket Check that the driven sprocket tightening nut is not loose. P.3-15
Lubrication Check for smooth operation. Lubricate if necessary. P.3-22
Spark plug Check color/condition. P.3-23
Fittings/fasteners Check all – tighten as necessary. P.2-13
Lead connectors Check that the AC magneto, CDI unit, and ignition coil are connected
tightly. P.1-5

3 - 20
INSPADJWHEEL INSPECTION/
STEERING HEAD INSPECTION AND ADJUSTMENT
2. Inspect:
Bearing free play
Exist play → Replace.
STEERING HEAD INSPECTION AND
ADJUSTMENT
1. Elevate the front wheel by placing a suit-
able stand under the engine.
2. Check:
Steering head
Grasp the bottom of the forks and gently
rock the fork assembly back and forth.
Free play → Adjust the steering head.
3. Check: Steering smooth action
Turn the handlebar lock to lock.
Unsmooth action → Adjust the steering
head.
4. Adjust:
Steering head
Steering ring nut adjustment steps:
 Remove the front fender 1.
 Remove the handlebar 2, upper bracket
bolts 3, steering stem nut 4 and upper
bracket 5.
1
4
3
52

5 - 13
CHASSTEERING AND FRONT SUSPENSION
EC560000
STEERING AND FRONT SUSPENSION
Extent of removal:1 Lower bracket removal
2 Bearing removal
3 Inner table assembly removal
Extent of removal Order Part name Q ’ty Remarks
STEERING AND FRONT SUS-
PENSION 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.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL ” section.
Handlebar Refer to “HANDLEBAR ” section.
1 Cable guide 1
2 Reflector 2 For Canada
3 Steering stem nut 1
4 Upper bracket 1
5 Special washer 1 Use special tool. Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT ” section in
the CHAPTER 3.
6 Upper ring nut 1
7 Rubber washer 1
213