Front wheel YAMAHA TTR50 2006 User Guide

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

5 - 1
CHAS
EC500000
CHASSIS
FRONT WHEEL AND REAR WHEEL
FRONT WHEEL AND FRONT BRAKE
Extent of removal:1 Front wheel removal
2 Wheel bearing removal
3 Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q ’ty Remarks
FRONT WHEEL 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.
1 Front brake adjuster 1
2Pin 1
3Spring 1
4 Locknut 1
5 Brake cable 1 Disconnect at the lever side.
6 Front fork guard (left) 1
7 Front fork guard (right) 1
8 Wheel axle nut 1
9 Front wheel axle 1
21
FRONT WHEEL AND REAR WHEEL

5 - 2
CHAS
Extent of removal Order Part name Q’ty Remarks
10 Front wheel 1
11 Collar 1
12 Brake shoe plate assembly 1
13 Oil seal 1
14 Bearing 2 Refer to “REMOVAL POINTS ”.
15 Brake shoe spring 1
16 Brake shoe 2
17 Brake camshaft lever 1
18 Wear indicator plate 1
19 Brake camshaft 1
2
1
3
3
FRONT WHEEL AND REAR WHEEL

5 - 3
CHASFRONT WHEEL AND REAR WHEEL
REAR WHEEL AND REAR BRAKE
Extent of removal:1 Rear wheel removal
2 Wheel bearing removal
3 Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q ’ty Remarks
REAR WHEEL 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.
1 Rear brake adjuster 1
2Pin 1
3Spring 1
4 Drive chain locknut 2
5 Wheel axle nut 1
6 Rear wheel axle 1
7 Drive chain puller 2
8 Rear wheel 1
9 Collar (left) 1
10 Brake shoe plate assembly 1
2
1
3

5 - 4
CHASFRONT WHEEL AND REAR WHEEL
Extent of removal Order Part name Q’ty Remarks
11 Bearing 2 Refer to “REMOVAL POINTS ”.
12 Brake shoe spring 1
13 Brake shoe 2
14 Brake camshaft lever 1
15 Wear indicator plate 1
16 Brake camshaft 1
17 Rear wheel sprocket 1
18 Oil seal 1
2
3

5 - 5
CHASFRONT WHEEL AND REAR WHEEL
EC593000
REMOVAL POINTS
EC513201
Wheel bearing (if necessary)
1. Remove:Bearing 1
NOTE:
Remove the bearing using a general bearing
puller 2.11
2
1
EC594000
INSPECTION
EC514100
Wheel
1. Measure: Wheel runout
Out of limit → Repair/replace.
Brake lining
1. Inspect: Brake shoe lining surface
Glazed areas → Polish.
Use coarse sand paper.
NOTE:
After polishing, wipe the polished particles with
a cloth.
Wheel runout limit: Radial 1: 2.0 mm (0.08 in)
Lateral 2: 2.0 mm (0.08 in)
2. Measure:
Brake shoe lining thickness
Out of specification → Replace.
NOTE:
Replace the brake shoes and springs as a set
if either is worn to the limit.
Brake shoe lining thickness
a:
Standard: Front: 3.5 mm (0.14 in)
Rear: 3.5 mm (0.14 in)
Limit: 1.5 mm (0.06 in)

5 - 6
CHAS
ASSEMBLY AND INSTALLATION
Brake shoe plate assembly
1. Install:Wear indicator plate 1
NOTE:
When installing the wear indicator plate to the
brake camshaft align the projection a on the
wear indicator plate with the slots b on the
brake camshaft.
2. Install:
Brake camshaft lever 1
NOTE:
Align the punch mark a on the brake camshaft
lever with the punch mark b on the brake
camshaft.
b
1
a
1a
b
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
3. Install:
Spring 1
 Brake shoes 2
NOTE:
Apply the lithium soap base grease on the
pivot pin.
WARNING
Do not apply grease to the brake shoe lin-
ings.
1
2
2
LS
New
New
FRONT WHEEL AND REAR WHEEL

5 - 7
CHAS
Front wheel
1. Install:Wheel bearing 1
 Spacer 2
 Wheel bearing 3
 Oil seal 4
NOTE:
Apply the lithium soap base grease on the oil
seal lip when installing.
 Use a socket that matches the outside diam-
eter of the race of the bearing.
 Left side of wheel bearing shall be installed
first.
 Install the oil seal with its manufacture ’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
New
2. Install: Front wheel
NOTE:
Make sure that the slot a on the brake shoe
plate with the stopper b on the front fork inner
tube.
b
a
3. Install: Spring 1
 Pin 2
NOTE:
Install the spring 1 with its smaller diameter
end a towards the pin 2.1
2
a
1
2
FRONT WHEEL AND REAR WHEEL

5 - 8
CHAS
Rear wheel
1. Install:Wheel bearing 1
 Spacer 2
 Wheel bearing 3
 Oil seal 4
NOTE:
Apply the lithium soap base grease on the oil
seal lip when installing.
 Install the wheel bearing with seal facing out-
ward.
 Use a socket that matches the outside diam-
eter of the race of the bearing.
 Right side of bearing shall be installed first.
 Install the oil seal with its manufacture ’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
New
2. Install: Rear wheel sprocket 1
 Bolts (rear wheel sprocket) 2
 Nuts (rear wheel sprocket) 3
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
1
2 4
1
3
2 3T R..25 Nm (2.5 m · kg, 18 ft · lb)
3. Install:
Rear wheel
NOTE:
Make sure that the slot a on the brake shoe
plate with the stopper b on the swingarm.
a
b
FRONT WHEEL AND REAR WHEEL