maintenance YAMAHA TTR50 2006 User Guide

SPEC
2 - 11
CHASSIS
Item Standard Limit
Steering system: Steering bearing type Angular bearing ----
Front suspension: Front fork travel 96 mm (3.78 in) ----
Spring rate 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) ----
Optional spring/spacer No ----
Inner tube outer diameter 21.7 mm (0.85 in) ----
Rear suspension: Shock absorber travel 47 mm (1.85 in) ----
Spring free length 114 mm (4.49 in) ----
Fitting length 110 mm (4.33 in) ----
Spring rate, STD K = 29.0 N/mm (2.96 kg/mm, 166 lb/in)----
Optional spring No ----
Swingarm: Swingarm free play limit End ---- 1.0 mm (0.0394 in)
Side clearance ---- 0.3 mm (0.0118 in)
Wheel: Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 10 × 1.40/steel ----
Rear rim size/material 10 × 1.40/steel ----
Rim runout limit: Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain: Type/manufacturer 420/KMC ----
Number of links 79 links + joint ----
Chain slack 35 ~ 45 mm (1.38 ~ 1.77 in) ----
Chain length (15 links) ---- 194.3 mm (7.65 in)
MAINTENANCE SPECIFICATIONS

SPEC
2 - 12
Drum brake:
Front drum brake type Leading, trailing ----
Rear drum brake type Leading, trailing ----
Front drum inside diameter 80 mm (3.15 in) 80.5 mm (3.17 in)
Rear drum inside diameter 80 mm (3.15 in) 80.5 mm (3.17 in)
Front lining thickness 3.5 mm (0.14 in) 1.5 mm (0.06 in)
Rear lining thickness 3.5 mm (0.14 in) 1.5 mm (0.06 in)
Brake lever and brake pedal: Brake lever free play (lever end) 10 ~ 20 mm (0.39 ~ 0.79 in) ----
Brake pedal free play 10 ~ 20 mm (0.39 ~ 0.79 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ---- Item Standard Limit
MAINTENANCE SPECIFICATIONS

SPEC
2 - 13
NOTE:
1.First, tighten the ring nut approximately 38 Nm (3.8 m · kg, 27 ft · lb) by using the lower ring nut
wrench and turn the steering right and left a few times; then loosen the lower ring nut completely.
2.Retighten the lower ring nut 4 Nm (0.4 m · kg, 2.9 ft · lb).
Part to be tightened Thread size Q
’ty Tightening torque
Nm m ·kg ft ·lb
Engine mounting: Engine and frame (front upper side) M8 × 1.25 1 30 3.0 22
Engine and frame (rear upper side) M8 × 1.25 1 30 3.0 22
Engine and frame (rear lower side) M10 × 1.25 1 48 4.8 35
Engine bracket and frame M8 × 1.25 2 30 3.0 22
Front wheel axle and front wheel axle nut M12 × 1.25 1 35 3.5 25
Front brake camshaft lever and front brake
camshaft M6
× 1.0 1 7 0.7 5.1
Front brake cable locknut M8 × 1.25 1 16 1.6 11
Front wheel nipple (spoke) —28 2 0.2 1.4
Rear wheel nipple (spoke) —28 2 0.2 1.4
Rear wheel axle and rear wheel axle nut M12 × 1.25 1 60 6.0 43
Rear brake camshaft lever and rear brake
camshaft M6
× 1.0 1 7 0.7 5.1
Rear wheel drive hub and rear wheel sprocket M8 × 1.25 4 25 2.5 18
Drive chain puller locknut M6 × 1.0 2 7 0.7 5.1
Upper bracket and handlebar M10 × 1.25 2 32 3.2 23
Steering stem nut M22 × 1.0 1 110 11.0 80
Lower ring nut M25 1 Refer to NOTE.
Upper bracket and lower bracket M10 × 1.25 2 32 3.2 23
Inner tube assembly and front fork guard M6 × 1.0 4 7 0.7 5.1
Pivot shaft and nut M10 × 1.25 1 35 3.5 25
Rear shock absorber and frame M10 × 1.25 1 30 3.0 22
Rear shock absorber and swingarm M10 × 1.25 1 30 3.0 22
Drive chain guide and swingarm M6 × 1.0 2 7 0.7 5.1
Drive chain support and swingarm M6 × 1.0 3 7 0.7 5.1
Drive chain guard and swingarm M6 × 1.0 2 7 0.7 5.1
Upper bracket and front fender M6 × 1.0 2 7 0.7 5.1
Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1
Fuel tank and frame M6 × 1.0 2 7 0.7 5.1
Air scoop and fuel tank M6 × 1.0 2 7 0.7 5.1
Seat assembly and frame M6 × 1.0 2 7 0.7 5.1
Seat and rear fender M6 × 1.0 3 7 0.7 5.1
Seat and side covers M6 × 1.0 4 7 0.7 5.1
Footrest, under cover and engine M8 × 1.25 4 30 3.0 22
Sidestand and sidestand bracket M10 × 1.25 1 40 4.0 29
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

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

3 - 2
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

3 - 3
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

3 - 6
INSPADJ
 Tighten the locknut.
WARNING
Particularly for a beginner rider, the
speed limiter should be screwed in
completely. Screw it out little by little as
their riding technique improves. Never
remove the speed limiter for a begin-
ning rider.
 For proper throttle lever operation do
not turn out the adjuster more than
25.0 mm (0.98 in). Also, always adjust
the throttle lever free play to 3 ~ 5 mm
(0.12 ~ 0.20 in).
AIR FILTER CLEANING
NOTE:
Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.
CAUTION:
Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid
wear and possible engine damage.
1. Remove: Seat assembly
 Air scoop (left)
Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section in
the CHAPTER 4.
 Air filter case cover 1
 Air filter element
1
SPEED LIMITER ADJUSTMENT/AIR FILTER CLEANING

–+ELEC
6 - 20
MAINTENANCE RECORD
MAINTENANCE RECORD
Copies of work orders and/or receipts for parts you purchase and install will be required to docu-
ment maintenance done in accordance with the emission warranty. The chart below is printed only
as a reminder to you that the maintenance work is required. It is not acceptable proof of mainte-
nance work.
MAINTE-NANCE
INTERVAL DATE OF
SERVICE MILEAGESERVICING DEALER
NAME AND ADDRESS REMARKS
1 Month
6 Months
12 Months
18 Months
24 Months
30 Months
36 Months
42 Months
48 Months
54 Months
60 Months
66 Months