engine oil YAMAHA TTR50 2006 Notices Demploi (in French)

4 - 16
ENGCAMSHAFT AND ROCKER ARMS
REMOVAL POINTS
Rocker arm shaft
1. Remove:Rocker arm shafts
NOTE:
Use a slide hammer bolt 1 and weight 2 to
slide out the rocker arm shafts.
Slide hammer bolt:
YU-01083-1/90890-01083
Weight: YU-01083-3/90890-01084
INSPECTION
Camshaft
1. Measure:
Cam lobes length a and b
Out of specification → Replace.
Cam lobes length limit:
Intake:
a 25.328 mm (0.9972 in)
b 20.934 mm (0.8242 in)
Exhaust:
a 25.186 mm (0.9916 in)
b 20.947 mm (0.8247 in)
ASSEMBLY AND INSTALLATION
1. Apply:
Molybdenum disulfide oil
(onto the camshaft cam lobe)
 Engine oil
(onto the camshaft bearing)
2. Install: Camshaft 1

4 - 27
ENGCYLINDER AND PISTON
Piston pin
1. Inspect:Piston pin
Blue discoloration/grooves →
Replace, then inspect the lubrication sys-
tem.
2. Measure: Piston pin outside diameter
 Piston pin bore inside diameter
ASSEMBLY AND INSTALLATION
Piston
1. Install: Piston rings
(onto the piston)
NOTE:
 Be sure to install the piston rings so that the
manufacturer ’s marks or numbers are
located on the upper side of the rings.
 Lubricate the piston and piston rings liberally
with engine oil.
Measurement steps:

Measure the piston pin outside diameter
a .
If out of specification, replace the piston
pin.
Outside diameter (piston pin): 11.996 ~ 12.000 mm
(0.4723 ~ 0.4724 in)
:11.976 mm (0.4715 in)
 Measure the piston inside diameter b.
If out of specification, replace the piston.
Inside diameter (piston): 12.002 ~ 12.013 mm
(0.4725 ~ 0.4730 in)
: 12.043 mm (0.4741 in)

4 - 28
ENGCYLINDER AND PISTON
2. Position:Top ring
 2nd ring
 Oil ring
Offset the piston ring end gaps as shown.
a Top ring
b Upper oil ring rail
c Oil ring expander
d Lower oil ring rail
e 2nd ring
f 20 mm (0.79 in)
È Intake side
3. Install:
Piston 1
 Piston pin 2
 Piston pin clips 3
NOTE:
Apply engine oil onto the piston pin, piston
ring and piston.
 Be sure that the arrow mark
a on the piston
points to the exhaust side of the engine.
 Before installing the piston pin clip, cover the
crankcase with a clean rag to prevent the
piston pin clip from falling into the crankcase.
4. Lubricate: Piston
 Piston rings
 Cylinder
NOTE:
Apply a liberal coating of engine oil.
Cylinder
1. Install:
Dowel pins
 Gasket
 Cylinder 1
NOTE:
Install the cylinder with one hand while com-
pressing the piston rings with the other hand.
CAUTION:
 Be careful not to damage the timing chain
damper during installation.
 Pass the timing chain through the timing
chain cavity.
e a
ff
d cb120
˚
120 ˚ 120˚
È
New
1
New

4 - 46
ENGAC MAGNETO AND STARTER CLUTCH
3. Install:Spring 1
 Spring cap 2
 Pin 3
4. Install: Shim 1
 Starter wheel gear 2
 Starter idle gear 3
 Shaft 4
NOTE:
Apply the molybdenum disulfide oil on the
starter wheel gear inner circumference.
 Apply the engine oil on the starter idle gear
inner circumference and on the shaft outer
circumference.
1 2
3
12
3
5. Install:
Woodruff key 1
 Rotor 2
NOTE:
Clean the tapered portion of the crankshaft
and the rotor hub.
 When installing the rotor, make sure the
woodruff key is properly seated in the key
way of the crankshaft.
6. Tighten: Rotor nut 1
NOTE:
Tighten the rotor nut 1 while holding the
rotor 2 with a sheave holder 3.
 Do not allow the sheave holder to touch the
projection on the rotor.
7. Install: Crankcase cover (left)
NOTE:
 Pass the starter motor lead 1 and neutral
switch lead 2 into the crankcase cover
groove as shown.
 Fasten the starter motor lead with the clamp 3.
Sheave holder:
YS-01880-A/90890-01701
T R..48 Nm (4.8 m · kg, 35 ft · lb)
3
1
2

4 - 48
ENGENGINE 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 Order Part name Q
’ty Remarks
Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT ”
section in the CHAPTER 3.
1 Drive sprocket cover 1
2 Drive sprocket 1
3 Shift pedal 1
4 Brake pedal 1
5 Footrest 1
6 Crankcase breather hose 1
7 Engine mounting bolt (front upper side) 1
8 Engine bracket 1
1

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.

6 - 1
–+ELEC
345
6
78
\b0
B\f
2
1
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1 Thermo switch
2 Main switch
3 Engine stop switch
4 Ignition coil
5 Ground lead
6 Fuse
7 Battery
8 CDI unit
9 Starter relay 0
Rectifier/regulator
A Neutral switch
B AC magneto
C Carburetor heater
D Start switch
E Spark plug
F Starter motorCOLOR CODE
B ...................... Black
Br .................... Brown
O ..................... Orange
R ..................... Red
Sb .................... Sky blue
W ..................... White
Y ...................... Yellow
EC612000
WIRING DIAGRAM
R
WR
W
BL /WSb B
RW
W
W
OO
B
B
Y /R
R
W
B
R
Y /RY /R
Y
ON
OFF
OFF ON
Y
B
BY
/RRB
SbY /RR B
W
B
B
RBrR
Br
R
/WBr
R /W
L /W
OFF
RUN
Sb
BrBr
Sb
WBY
/RW SbY
B
B
B
RR
RR
R
R
R
/W
L /W
RRRB
R /W
L
/WR
R
RR
B Br
BO
R
WB
\f
2 8
4
E
1
C
D
0
63
\b F
5 7
Br
L/W .................. Blue/White
R/W .................. Red/White
Y/R ................... Yellow/Red
E
F
D
C

–+ELEC
6 - 2
IGNITION SYSTEM
EC620000
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to
ignition system failure and for checking the spark plug which will not spark.
NOTE:
Remove the following parts before inspection.
1) Seat assembly
2) Air scoops (left and right)
3) Fuel tank
Refer to “FRONT FENDER, SEAT ASSEMBLY AND FUEL TANK ” section in the CHAPTER 4.
 Use the following special tools in this inspection.
Opama pet-4000 spark checker:
YM-34487
Ignition checker: 90890-06754Pocket tester:YU-03112-C/90890-03112
Spark gap test Clean or replace
spark plug.
Check entire ignition
system for connection. Repair or replace.
Check main switch. Replace.
Check engine stop switch. Replace.
Check ignition coil. Primary coil Replace. Secondary coil Replace.
Check AC magneto. Pickup coil Replace. Replace CDI unit.
No Spark
OK
OK
OK
OK
OK
Spark
No good
No good
No good
No good
No good
No good

6 - 4
–+ELECIGNITION SYSTEM
ENGINE STOP SWITCH INSPECTION
1. Inspect:
Engine stop switch continuity
Continuous in the “” position → Replace.
Not continuous in the “” position → Replace.
Tester (+) lead
→ Black lead
1
Tester ( –) lead
→ Black lead
2
B
1 B
2 Tester selec-
tor position
Ω
× 1B
B
1 2
EC626002
IGNITION COIL INSPECTION
1. Inspect:
Primary coil resistance
Out of specification → Replace.
2. Inspect: Secondary coil resistance
Out of specification → Replace.
NOTE:
When inspecting the secondary coil resis-
tance, remove the spark plug cap.Tester (+) lead
→ Orange lead
1
Tester ( –) lead
→ Black lead
2
Primary coil
resistance Tester selector
position
0.32 ~ 0.48 Ω at
20 °C (68 °F) Ω

× 1
Tester (+) lead → Spark plug lead
1
Tester ( –) lead
→ Orange lead
2
Secondary coil
resistance Tester selector
position
5.68 ~ 8.52 k Ω
at 20 °C (68 °F) k
Ω
× 1
1
2
1
2

6 - 10
–+ELEC
STARTER MOTOR
1
3
45 6
8
2
\b
1
1
LS
New
New
T R..10 Nm (1.0 m •
kg, 7.2 ft • Ib)
7
Extent of removal:1 Starter motor disassembly
Extent of removal Order Part name Q ’ty Remarks
STARTER MOTOR REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT ”
section in the CHAPTER 3.
Bottom cover Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section
in the CHAPTER 4.
1 Starter motor 1 STARTER MOTOR DISASSEM-
BLY
1 Front bracket 1
2 O-ring 1
3 Brush set 1
4 Washer 1
5 Oil seal 1
6 Bearing 1
1
ELECTRIC STARTING SYSTEM