fuel YAMAHA TTR50 2006 Owner's Manual

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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
ENGINE/THROTTLE CABLE ADJUSTMENT
EC350000
ENGINE
THROTTLE CABLE ADJUSTMENT
1. Check:
Throttle grip free play a
Out of specification → Adjust.
Throttle grip free play
a:
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Adjust:
Throttle grip free play
Throttle grip free play adjustment steps:
Carburetor side
NOTE:
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
 Remove the seat assembly and air scoop
(right).
Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section in
the CHAPTER 4.
 Pull back the adjuster cover.
 Loosen the locknut 1 on throttle cable.
 Turn the adjuster 2 in or out until the
specified free play is obtained.
Turning in b → Free play is increased.
Turning out c → Free play is decreased.
 Tighten the locknut.
 Slide the adjuster cover to its original posi-
tion.
 Install the seat assembly and air scoop
(right).
NOTE:
If the specified throttle cable free play can-
not be obtained on the carburetor side of the
cable, use the adjusting nut on the handle-
bar side.
WARNING
After adjusting, turn the handlebar to
right and left and make sure that the
engine idling does not run faster.
c
b
1
2

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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

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INSPADJ
BATTERY INSPECTION AND CHARGING
NOTE:
Since MF batteries are sealed, it is not possi-
ble to check the charge state of the battery by
measuring the specific gravity of the electro-
lyte. Therefore, the charge of the battery has to
be checked by measuring the voltage at the
battery terminals.
1. Remove:
Seat assembly
 Battery cover
Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section in
the CHAPTER 4.
2. Disconnect:
Battery lead coupler 1
(from the battery terminals)
NOTE:
Push down on the tab a, and then remove the
battery lead coupler.
3. Remove:
Battery band
 Battery
Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section in
the CHAPTER 4.
1
a
4. Measure:
Battery charge
Measurement steps:
 Connect a pocket tester 1 to the battery
terminals.
Tester positive probe → battery positive
terminal
Tester negative probe → battery negative
terminal
NOTE:
 The charge state of an MF battery can be
checked by measuring its open-circuit volt-
age (i.e., the voltage when the positive ter-
minal is disconnected).
 No charging is necessary when the open-
circuit voltage equals or exceeds 12.8 V.
1

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INSPADJBATTERY INSPECTION AND CHARGING/
FUSE INSPECTION
6. Install:
Battery
 Battery band
7. Check: Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
8. Lubricate: Battery terminal
9. Connect: Battery lead coupler
(to the battery terminals)
10. Install:
Battery cover
 Seat assembly
Recommended lubricant:
Lithium soap base grease
FUSE INSPECTION
CAUTION:
To avoid a short circuit, always set the
main switch to “OFF ” when checking or
replacing a fuse.
1. Remove:
Seat assembly
 Battery cover
Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section in
the CHAPTER 4.
2. Disconnect: Battery lead coupler 1
(from the battery terminals)
NOTE:
Push down on the tab a, and then remove the
battery lead coupler.
1
a

4 - 1
ENGFRONT FENDER, SEAT ASSEMBLY AND FUEL TANK
EC400000
ENGINE
EC4R0000
FRONT FENDER, SEAT ASSEMBLY AND FUEL TANK
Extent of removal:1 Front fender removal
2 Seat removal
3 Battery removal
4 Fuel tank removal
5 Air filter case removal
6 Bottom cover removal
Extent of removal Order Part name Q ’ty Remarks
FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK
REMOVAL
Preparation for removal Turn the fuel cock to “OFF ”.
1 Front fender 1
2 Seat assembly 1
3 Air scoop (left and right) 2
4 Battery cover 1
5 Battery coupler 1 Disconnect.
6 Battery band 1
7 Battery rubber cover 1
8 Battery 1
9 Fitting band 1
10 Fuel hose 1 Remove on fuel tank side.
1
2
3
43
4
5
5

4 - 2
ENGFRONT FENDER, SEAT ASSEMBLY AND FUEL TANK
Extent of removal Order Part name Q’ty Remarks
11 Bolt (fuel tank) 2
12 Fuel tank 1
13 Air filter case cover 1
14 Air filter element 1
15 Air filter case 1
16 Bottom cover 1
4
5
6

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ENGMUFFLER
MUFFLER
Extent of removal: 1 Muffler removal
Extent of removal Order Part name Q ’ty Remarks
MUFFLER REMOVAL
Preparation for removal Seat assembly Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section.
1 Bolt (spark arrester) 3
2 Spark arrester 1
3 Nut (muffler) 2
4 Bolt (muffler) 1
5 Muffler 1
1

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ENG
CARBURETOR
2
1
6
6
3
8
9 5
47
New
New
T R..7 Nm (0.7 m
•
kg, 5.1 ft • Ib)
New
T R..2 Nm (0.2 m •
kg, 1.4 ft • Ib)
Extent of removal: 1 Carburetor removal
Extent of removal Order Part name Q ’ty Remarks
CARBURETOR REMOVAL
Preparation for removal Fuel tank Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section.
1 Clamp (air filter joint) 1 Loosen the screw (air filter joint).
2 Carburetor heater lead connector 2
3 Air vent hose 1
4 Fuel hose 1
5 Carburetor assembly 1
6O-ring 2
7 Joint 1
8 Carburetor top 1
9 Starter plunger assembly 1
1
CARBURETOR

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ENGCARBURETOR
EC468000
CARBURETOR DISASSEMBLY
Extent of removal:1 Carburetor disassembly
Extent of removal Order Part name Q ’ty Remarks
CARBURETOR DISASSEMBLY
1 Throttle valve 1
2 Throttle cable 1
3 Spring 1
4 Clip 1
5 Gasket 1
6 Carburetor top cover 1
7 Jet needle assembly 1
8 Starter plunger assembly 1
9 Starter cable 1
0 Carburetor overflow hose 1
A Fuel drain screw 1
B Float chamber 1
1