clutch YAMAHA TTR50 2006 User Guide

4 - 33
ENGCLUTCH
EC484500
Friction plate
1. Measure:Friction plate thickness
Out of specification → Replace friction
plate as a set.
Measure at all four points.
Friction plate thickness:
Standard Limit
2.92 ~ 3.08 mm
(0.115 ~ 0.121 in) 2.82 mm
(0.111 in)
EC484600
Clutch plate
1. Measure:
Clutch plate warpage
Out of specification → Replace clutch
plate as a set.
Use a surface plate and thickness gauge
1 .
Warp limit:
0.2 mm (0.008 in)
Spring
1. Inspect:
Spring 1
Damage → Replace.
1

4 - 34
ENGCLUTCH
ASSEMBLY AND INSTALLATION
Primary driven gear
1. Install:Primary driven gear 1
 Lock washer 2
 primary driven gear nut 3
NOTE:
Place an aluminum plate 4 between the teeth
of the primary driven gear 1 and primary drive
gear 5.
2. Bend: Lock washer tab
3
2 1
4
5
New
T R..70 Nm (7.0 m · kg, 50 ft · lb)
Clutch
1. Install:
Clutch plate 3 1
 Friction plates 2
 Clutch plate 2 3
 Clutch plate 1 4
 Clutch spring plate 5
NOTE:
Align the cutouts a in clutch plate 2 and
clutch plate 3 with the holes b in the clutch
housing.
 Install the clutch spring plate 5 as shown in
the illustration.
 Align the projections c on clutch plate 1 with
the notches d in the clutch spring plate.
1
3
a
b4
1
2
2
4
3
5
d
c
c c

4 - 35
ENG
2. Install:Clutch housing nut 1
NOTE:
Tighten the clutch housing nut while holding
the clutch housing with the sheave holder 2.
Sheave holder:
YS-01880-A/90890-01701
1
2
T R..70 Nm (7.0 m · kg, 50 ft · lb)
3. Install:
Shift arm 1
 Shift guide (inner) 2
 Pawl holder 3
 Shift guide (outer) 4
 Clutch adjuster 5
NOTE:
Align the punch mark a on the shift arm with
the punch mark b on the shift shaft.
 Install the shift guide (outer) 4 and clutch
adjuster 5 in the crankcase cover 6 as
shown in the illustration.
 When install the crankcase cover, align the
pawl holder balls with the grooves in the shift
guide (outer) 4.
1
2
3
a
b
4
5
6
CLUTCH

4 - 36
ENG
Clutch free play adjustment
1. Adjust:Clutch free play
Adjustment steps:
 Loosen the locknut 1.
 Turn the clutch adjuster 2 counterclock-
wise until it becomes slightly difficult to
turn.
 Turn the clutch adjuster 2 clockwise 1/8
turn.
 Hold the clutch adjuster 2 and tighten the
locknut 1.
T R..
Locknut:
6 Nm (0.6 m  kg, 4.3 ft  lb)
1
2
CLUTCH

4 - 37
ENGSHIFT SHAFT
SHIFT SHAFT
LTLT
New
New
E
E
T R..23 Nm (2.3 m • kg, 17 ft • Ib)
E
43
6
5
7
2
1
Extent of removal: 1 Shift shaft removal
Extent of removal Order Part name Q ’ty Remarks
SHIFT SHAFT REMOVAL
Preparation for removal Clutch housing and primary driven gear Refer to
“CLUTCH ” section.
1 Shift shaft assembly 1
2 Torsion spring 1
3Shift lever 1
4 Shift shaft 1
5 Torsion spring 1
6 Stopper lever 1
7 Stopper bolt 1
1

4 - 39
ENGOIL PUMP
OIL PUMP
Extent of removal: 1 Oil pump removal
2 Oil strainer removal
3 Oil pump disassembly
Extent of removal Order Part name Q ’ty Remarks
OIL PUMP REMOVAL AND DIS-
ASSEMBLY
Preparation for removal Primary drive gear and primary driven gear Refer to
“CLUTCH ” section.
Shift shaft Refer to “SHIFT SHAFT ” section.
1 Oil pump assembly 1
2 Gasket 1
3 Oil pump drive gear 1
4 Oil strainer 1
5 Circlip 1
6 Oil pump driven gear 1
7Pin 1
8 Oil pump cover 1
2
1
3

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 - 43
ENGAC MAGNETO AND STARTER CLUTCH
Extent of removal Order Part name Q’ty Remarks
10 Shaft 1
11 Idler gear 1
12 Starter clutch/wheel gear 1/1
4

4 - 44
ENGAC MAGNETO AND STARTER CLUTCH
REMOVAL POINTS
Rotor
1. Remove:Rotor nut 1
 Washer 2
NOTE:
Loosen the rotor nut while holding the rotor
with sheave holder 3.
 Do not allow the sheave holder to touch the
projection on the rotor.
Sheave holder:
YS-01880-A/90890-01701
2. Remove:
Rotor 1
 Woodruff key
NOTE:
 Use the flywheel puller 2.
 Center the flywheel puller over the rotor.
Make sure after installing the holding bolts
that the clearance between the flywheel
puller and the rotor is the same everywhere.
If necessary, one holding bolt may be turned
out slightly to adjust the flywheel puller ’s
position.
CAUTION:
Cover the crankshaft end with the box
wrench for protection.
Flywheel puller: YU-33270-B/90890-01362

4 - 45
ENG
INSPECTION
Starter clutch
1. Inspect:Starter idle gear teeth a
 Starter drive gear teeth b
 Starter wheel gear teeth c
Burrs/chips/roughness/wear → Replace.
2. Check:
Starter clutch operation.
Checking steps:
 Install the starter wheel gear onto the
starter clutch and hold the starter clutch.
 When turning the starter wheel gear clock-
wise È, the starter clutch and the starter
wheel gear should be engage, otherwise
the starter clutch is faulty and must be
replaced.
 When turning the starter wheel gear coun-
terclockwise É, it should turn freely, other-
wise the starter clutch is faulty and must
be replaced.
É
È
ASSEMBLY AND INSTALLATION
Starter clutch
1. Install:Starter clutch 1
1T R..14 Nm (1.4 m · kg, 10 ft · lb)
2. Unloosen the starter clutch assembly by
using the center punch.
AC MAGNETO AND STARTER CLUTCH