engine oil YAMAHA TTR50 2006 User Guide

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

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INSPADJ
MAINTENANCE INTERVALS
* : Since these items requires special tools data and technical skills, they should be serviced.
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
20 Sidestand pivot Check operation.
Apply lithium soap based grease lightly.
√

√
21 * Front fork Check operation and for grease leakage.
Replace if necessary.
√

√
22 * Shock absorber
assembly Check operation and for oil leakage.
Replace if necessary.
√

√
23 * Control cables Apply Yamaha chain and cable lube or engine oil
10W-30 thoroughly.
√

√
√
24 * Throttle grip hous-
ing and cable Check operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.
√

√
√
25 * Chassis fasteners Check all chassis fitting and fasteners.
Correct if necessary.
√

√
√
26 Battery Check terminal for looseness and corrosion. √
No. ITEM
CHECKS AND
MAINTENANCE JOBS WHICH-
EVER
COMES FIRST INITIAL EVERY
month 1 6 12
hours 30 60 120
1
2
3
4
5
6

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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

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INSPADJ
2. Clean:
Air filter element
Clean it with solvent.
NOTE:
After cleaning, remove the remaining solvent
by squeezing the element.
CAUTION:
 Do not twist the element when squeezing
the element.
 Leaving too much of solvent in the ele-
ment may result in poor starting.
3. Inspect: Air filter element
Damage → Replace.
4. Apply: Foam-air-filter oil or engine oil
To the element.
NOTE:
Squeeze out the excess oil. Element should be
wet but not dripping.
5. Install:
Air filter element
 Air filter case cover
 Air scoop (left)
 Seat assembly
ENGINE OIL LEVEL INSPECTION
1. Start the engine, warm it up for several
minutes, and then turn off the engine and
wait for five minutes.
2. Place the machine on a level place and hold it up on upright position by placing the
suitable stand under the engine.
3. Remove: Oil filler cap 1
1
AIR FILTER CLEANING/
ENGINE OIL LEVEL INSPECTION

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INSPADJ
4. Check:
Oil level
Oil level should be between maximum a
and minimum b marks.
Oil level is low → Add oil to proper level.
NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.
 When inspecting the oil level, do not screw
the dipstick into the oil tank. Insert the gauge
lightly.
(For USA and CDN)
CAUTION:
 Do not add any chemical additives.
Engine oil also lubricates the clutch and
additives could cause clutch slippage.
 Do not allow foreign material to enter the
crankcase.
(Except for USA and CDN)
CAUTION:
 Do not add any chemical additives or use
oils with a grade of CD a or higher.
 Do not use oils labeled “ENERGY CON-
SERVING II ” b or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.
 Do not allow foreign materials to enter the
crankcase.
Recommended oil:
At –10 °C (14 °F) or higher È:
Yamalube 4 (10W-30) or SAE
10W-30 type SE/SF/SG motor
oil
At 5 °C (41 °F) or higher É:
Yamalube 4 (20W-40) or SAE
20W-40 type SE/SF/SG motor
oil
Recommended oil: Refer to the following chart for
selection of oils which are suited
to the atmospheric temperatures.
Recommended engine oil classifi-
cation:
API STANDARD: API “SE/SF/SG ” or higher grade
(Designed primarily for
motorcycles)
0 10 30 50 70
90110
130
-20 -10 010
20 30 40 50
È
É
˚C
˚
F
a
b
ENGINE OIL LEVEL INSPECTION

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INSPADJENGINE OIL LEVEL INSPECTION/
ENGINE OIL REPLACEMENT
5. Install:
Oil filler cap
6. Start the engine and let it warm up for sev-
eral minutes.
7. Turn off the engine and inspect the oil level once again.
NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.
ENGINE OIL REPLACEMENT
1. Start the engine and warm it up for severalminutes, and then turn off the engine and
wait for five minutes.
2. Place the machine on a level place and hold it on upright position by placing the
suitable stand under the engine.
3. Place a suitable container under the engine.
4. Remove:
Oil filler cap 1
 Drain bolt (with gasket) 2
Drain the crankcase of its oil.
5. Install: Gasket
 Drain bolt
6. Fill: Crankcase
7. Install: Oil filler cap
8. Inspect: Engine (for oil leaks)
 Oil level
Refer to “ENGINE OIL LEVEL INSPEC-
TION ” section.
Oil quantity:
Periodic oil change: 0.8 L (0.70 Imp qt, 0.85 US qt)
1
2
New
T R..20 Nm (2.0 m · kg, 14 ft · lb)

3 - 13
INSPADJVALVE CLEARANCE ADJUSTMENT/
SPARK ARRESTER CLEANING (For USA)
6. Install:
Spark plug
 Spark plug cap
 Timing plug
 Crankshaft end cover
NOTE:
Apply the engine oil on the O-ring.
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
SPARK ARRESTER CLEANING (For USA)
WARNING
 Be sure the exhaust pipe and muffler are
cool before cleaning the spark arrester.
 Do not start the engine when cleaning the
exhaust system.
1. Remove: Bolts (spark arrester) 1
2. Remove:
Spark arrester 2
Pull the spark arrester out of the muffler.
3. Clean:
Spark arrester
Tap the spark arrester lightly, then use a
wire brush to remove any carbon depos-
its.
4. Install: Spark arrester
Insert the spark arrester into the muffler
and align the bolt holes.
 Bolts (spark arrester)
1
2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

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INSPADJ
6. Lubricate:
Drive chain
Drive chain lubricant:
SAE 10W-30 motor oil or
suitable chain lubricants
DRIVE CHAIN SLACK ADJUSTMENT
1. Elevate the rear wheel by placing the suit-
able stand under the engine.
2. Check: Drive chain slack a
In the center between the drive axle and
rear wheel axle.
Out of specification → Adjust.
NOTE:
Before checking and/or adjusting, rotate the
rear wheel through several revolutions and
check the slack several times to find the tight-
est point. Check and/or adjust chain slack with
rear wheel in this “tight chain ” position.
Drive chain slack:
35 ~ 45 mm (1.38 ~ 1.77 in)
3. Adjust:
Drive chain slack
Drive chain slack adjustment steps:
 Loosen the wheel axle nut 1 and locknuts
2 .
 Adjust chain slack by turning the adjusters
3 .
To tighten → Turn adjuster 3 clockwise a.
To loosen → Turn adjuster 3 counter-
clockwise b and push wheel forward.
 Turn each adjuster exactly the same
amount to maintain correct axle alignment.
(There are marks c on each side of chain
puller alignment.)
1 b
c
a
23
DRIVE CHAIN INSPECTION/
DRIVE CHAIN SLACK ADJUSTMENT

3 - 18
INSPADJDRIVE CHAIN SLACK ADJUSTMENT/
FRONT FORK INSPECTION/REAR SHOCK ABSORBER INSPECTION
NOTE:
Turn the adjuster so that the chain is in line
with the sprocket, as viewed from the rear.
CAUTION:
Too small chain slack will overload the
engine and other vital parts; keep the
slack within the specified limits.
 Tighten the wheel axle nut while pushing
down the drive chain.
T R..
Axle nut:
60 Nm (6.0 m  kg, 43 ft  lb)
 Tighten the locknuts.
T R..
Locknut:
7 Nm (0.7 m  kg, 5.1 ft  lb)
EC36C000
FRONT FORK INSPECTION
1. Inspect:
Front fork smooth action
Operate the front brake and stroke the
front fork.
Unsmooth action → Repair or replace.
EC36K000
REAR SHOCK ABSORBER INSPECTION
1. Inspect:
Swingarm smooth action
Abnormal noise/unsmooth action →
Grease the pivoting points or repair the
pivoting points.
Damage/oil leakage → Replace.

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ENGCYLINDER HEAD
4. Remove:Cylinder head
NOTE:
 Loosen the bolts and nuts in their proper
loosening sequence.
 Start by loosening each bolt and nut 1/2 turn
until all are loose.1
2
5
64
3
ASSEMBLY AND INSTALLATION
1. Install:
Cylinder head
2. Tighten: Nuts
 Bolts
NOTE:
 Apply the engine oil on the contact surfaces
of the nuts and copper washers.
 Apply the engine oil on the thread and con-
tact surface of the bolts.
 Follow the numerical order shown in the illus-
tration. Tighten the bolts and nuts in two
stages.
6
5
2
13
4
T R..22 Nm (2.2 m · kg, 16 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
3. Install:
Camshaft sprocket 1
Installation steps:
 Turn the crankshaft counterclockwise until
the “I” mark a on the rotor is aligned with
the stationary pointer b on the crankcase
cover.
 Align the “I” mark c on the camshaft
sprocket with the stationary pointer d on
the cylinder head.
 Fit the timing chain 2 onto camshaft
sprocket and install the camshaft sprocket
on the camshaft.
NOTE:
When installing the camshaft sprocket, keep
the timing chain as tense as possible on the
exhaust side.
b
a
1
2
c
d