Oil YAMAHA TTR50 2006 User Guide

SPEC
2 - 9
Carburetor:
I. D. mark 1P61 00 ----
Main jet (M.J) #62.5 ----
Main nozzle (N.J) E-2M ----
Main air jet (M.A.J) ø 1.4 ----
Jet needle (J.N) 4DL22-1 ----
Cutaway (C.A) 2.5 ----
Pilot outlet (P.O) ø 0.8 × 1.5 ----
Pilot jet (P.J) #12.5 ----
Valve seat size (V.S) ø 1.2 ----
Starter jet 1 (G.S.1) #20 ----
Starter jet 2 (G.S.2) ø 0.6 ----
Float height (F.H) 18.5 mm (0.73 in) ----
Fuel level (F.L) 2.0 ~ 3.0 mm (0.08 ~ 0.12 in) ----
Engine idle speed 1,600 ~ 1,800 r/min ----
Lubrication system: Oil filter type Wire mesh type ----
Oil pump type Trochoid type ----
Inner-rotor-to-outer-rotor-tip clearance 0.15 mm or less (0.0061 in or less)0.20 mm
(0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.07 mm (0.0028 in)0.15 mm
(0.0059 in)
Oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance 0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)0.17 mm
(0.0067 in)
Item Standard Limit
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

SPEC
2 - 14
EC212300
ELECTRICALItem Standard Limit
Ignition system: Advancer Digital ----
CDI: Magneto-model/manufacturer F1P6/MORIC ----
Pickup coil resistance (color) 248 ~ 372 Ω at 20 °C (68 °F)
(Red – White) ----
CDI unit model/manufacturer 1P6/SHY ----
Ignition coil: Model/manufacturer 4FP/SHY ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.32 ~ 0.48 Ω at 20 °C (68 °F) ----
Secondary winding resistance 5.68 ~ 8.52 k Ω at 20 °C (68 °F) ----
Spark plug cap: Type Resin ----
Resistance 10 k Ω at 20 °C (68 °F) ----
Charging system: System type AC magneto ----
Model/manufacturer F1P6/SHY ----
Normal output 14 V/80 W at 5,000 r/min ----
Charging coil resistance (color) 0.96 ~ 1.44 Ω at 20 °C (68 °F)
(White – Black) ----
Lighting coil resistance (color) 0.80 ~ 1.20 Ω at 20 °C (68 °F)
(Yellow – Black) ----
Rectifier/regulator: Regulator type Semiconductor short circuit ----
Model/manufacturer SH620B-12/SHINDENGEN ----
No-load regulated voltage (DC) 14.0 ~ 15.0 V ----
No-load regulated voltage (AC) 13.0 ~ 14.0 V ----
Rectifier capacity 8 A ----
Battery: Model YT4B-BS or GT4B-5 ----
Voltage capacity 12 V 2.3 Ah or 12 V 2.5 Ah ----
Electric starting system: Type Constant mesh ----
Starter motor: Model/manufacturer 1P6/SHY ----
Operation voltage 12 V ----
Output 0.25 kW ----
Armature coil resistance 0.035 ~ 0.043 Ω at 20 °C (68 °F) ----
Brush overall length 7 mm (0.28 in) 3.5 mm (0.14 in)
Brush quantity 2 pcs. ----
MAINTENANCE SPECIFICATIONS

SPEC
2 - 15
Spring force 3.92 ~ 5.88 N
(400 ~ 600 g, 14.1 ~ 21.2 oz)3.92 N
(400 g,
14.1 oz)
Commutator diameter 17.6 mm (0.69 in) 16.6 mm (0.65 in)
Mica undercut (depth) 1.35 mm (0.05 in) ----
Starter relay: Model/manufacturer ACA12115-1/NAis ----
Amperage rating 30 A ----
Coil winding resistance 72.00 ~ 88.00 Ω at 20 °C (68 °F) ----
Fuse (amperage × quantity):
Main fuse 10 A × 1 ----
Reserve fuse 10 A × 1 ----
Item Standard Limit
MAINTENANCE SPECIFICATIONS

2 - 4
SPEC
CARACTERISTIQUES D’ENTRETIEN
MOTEUR
Elément Standard Limite
Culasse: Limite de d éformation ---- 0,05 mm
(0,0020 in)
Cylindre: Alésage 35,995 à 36,015 mm
(1,4171 à 1,4179 in) 36,05 mm
(1,419 in)
Arbre à cames:
M éthode de transmission Transmission par cha îne (gauche) ----
Dimensions de came
Admission “A ” 25,428 à 25,528 mm
(1,0011 à 1,0050 in) 25,328 mm
(0,9972 in)
“ B ” 21,034 à 21,134 mm
(0,8281 à 0,8320 in) 20,934 mm
(0,8242 in)
Echappement “A ” 25,286 à 25,386 mm
(0,9955 à 0,9994 in) 25,186 mm
(0,9916 in)
“ B ” 21,047 à 21,147 mm
(0,8286 à 0,8326 in) 20,947 mm
(0,8247 in)
Limite de voile d ’arbre à cames ---- 0,03 mm
(0,0012 in)
Cha îne de came:
Type de cha îne de came/nbre de maillons 92RH2005-84M/84 ----
M éthode de r églage de la cha îne de came Automatique ----
CARACTERISTIQUES D ’ENTRETIEN

2 - 11
SPEC
CHASSISElément Standard Limite
Syst ème de direction:
Type de roulement de direction Roulement oblique ----
Suspension avant: Débattement de fourche 96 mm (3,78 in) ----
Raideur de ressort 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) ----
Ressort/entretoise en option Non ----
Diam ètre ext érieur du tube plongeur 21,7 mm (0,85 in) ----
Suspension arri ère:
D ébattement d ’amortisseur 47 mm (1,85 in) ----
Longueur de ressort libre 114 mm (4,49 in) ----
Longueur mont é 110 mm (4,33 in) ----
Raideur de ressort, standard K = 29,0 N/mm (2,96 kgf/mm, 166 lb/in)----
Ressort en option Non ----
Bras oscillant: Limite de jeu du bras oscillant A l ’extr émit é ---- 1,0 mm (0,0394 in)
Jeu lat éral ---- 0,3 mm (0,0118 in)
Roue: Type de roue avant Roue à rayons ----
Type de roue arri ère Roue à rayons ----
Taille/mat ériau de la jante avant 10 × 1,40/acier ----
Taille/mat ériau de la jante arri ère 10 × 1,40/acier ----
Limite de voile de la jante: Radial ---- 2,0 mm (0,08 in)
Lat éral ---- 2,0 mm (0,08 in)
Cha îne de transmission:
Type/fabricant 420/KMC ----
Nombre de maillons 79 maillons + attache ----
Fl èche de la cha îne 35 à 45 mm (1,38 à 1,77 in) ----
Longueur de la cha îne (15 maillons) ---- 194,3 mm
(7,65 in)
CARACTERISTIQUES D’ENTRETIEN

2 - 18
SPECCABLE ROUTING DIAGRAM
IAir filter case
J Frame
K Ignition coil
L Brake cable
È Make sure that there is no slack in the wire har-
ness in the area shown in the illustration.
É Pass the wire harness, then the carburetor air
vent hose through the lead guide.
Ê The couplers of identical colors should be con-
nected. Ë
Pass the start switch lead, main switch lead,
engine stop switch lead, throttle cable, and
starter cable through the cable guide.
Ì Route the throttle cable and starter cable under
the start switch lead, main switch lead, and
engine stop switch lead.
2
É
BÍ
B Ñ
BÏ
F Î
LÕ
\b
8 \b
×
0
\f Ø
E
E Ò 6
\f
7
8
\b
0
\f
C
D
H
H
7
J
I
I
K 8
7
\b
C
0
\f
E H
G 345
Ê
Ì
Ð
ÙÓ
Ô
Ô
È
B
A C
C
B
A
B-B
A-A
C-C
1

2 - 21
SPECCABLE ROUTING DIAGRAM
1Cable guide
2 Brake cable
3 Throttle cable
4 Fuel tank breather hose
5 Thermo switch lead
6 Ignition coil lead terminal
7 Ground lead terminal
8 Rectifier/regulator
9 Plastic locking tie
0 Starter relay
A Battery band B
Starter motor lead
C AC magneto lead
D Fuel overflow hose
E Fuel hose
F Ignition coil
G Thermo switch
H Frame
I Wire harness
J Rectifier/regulator lead
K CDI unit lead
L Drive sprocket cover
RES
OFF
FUEL
A
EE
A
B C
C
B
G
G
D
F
È1
ÕJ
2
3
4
5
8
\f
6
Ê
\bÎ
0 Ï
\b Ò
L \b
B
C
D
E
F
G
H I
B I
H
C
NB
M B
P O
R Q
I
S
I
K
I
B
C
I
H
B
C
\f C
Ó
×
Ø
Ô
ÐÑ
Ì
Í
7 \f
É
C-C
E-EA-A
B-B
G-G
D
F

2 - 22
SPECCABLE ROUTING DIAGRAM
MNeutral switch lead
N Crankcase cover (left)
O Bottom cover
P Starter motor
Q AC magneto lead coupler (4-pin)
R AC magneto lead coupler (2-pin)
S CDI unit
È Pass the brake cable through the cable guide.
É Connect the flat terminal to the ignition coil. Ê
Install both the ignition coil lead terminal and
ignition coil to the bolt hole shown in the frame,
making sure that the ignition coil lead terminal is
installed on the right side of the ignition coil.
Ë Install the ground lead terminal on the right side
of the frame using the bolt, making sure that the
crimped side of the terminal is facing to the right.
Ì Make sure that there is no slack in the AC mag-
neto lead and wire harness in the area shown in
the illustration.
Í 20 ~ 30 mm (0.79 ~ 1.18 in)
RES
OFF
FUEL
A
EE
A
B C
C
B
G
G
D
F
È1
ÕJ
2
3
4
5
8
\f
6
Ê
\bÎ
0 Ï
\b Ò
L \b
B
C
D
E
F
G
H I
B I
H
C
NB
M B
P O
R Q
I
S
I
K
I
B
C
I
H
B
C
\f C
Ó
×
Ø
Ô
ÐÑ
Ì
Í
7 \f
É
C-C
E-EA-A
B-B
G-G
D
F

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