Oil YAMAHA TTR50 2006 Workshop Manual

4 - 52
ENGCRANKCASE AND CRANKSHAFT
E
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
T R..10 Nm (1.0 m •
kg, 7.2 ft • Ib)
LT
4
4 3
4
4
5 6
7
9
8
8
12
5 6
4
Extent of removal: 1 Timing chain removal
2 Crankcase separation
3 Crankshaft removal
Extent of removal Order Part name Q ’ty Remarks
Oil pump drive gear, oil pump and
oil strainer Refer to
“OIL PUMP ” section.
Shift shaft Refer to “SHIFT SHAFT ” section.
Rotor and starter clutch Refer to “AC MAGNETO AND
STARTER CLUTCH ” section.
1 Timing chain 1
2 Timing chain guide (intake) 1
3 Neutral switch 1
4 Bolt [40 mm (1.6 in)] 7
5 Bolt [60 mm (2.4 in)] 2
6 Bolt [75 mm (3.0 in)] 1
7 Left crankcase 1
8 Dowel pin 2
9 Crankshaft 1
2
1
3

4 - 53
ENGCRANKCASE AND CRANKSHAFT
INSPECTION
Crankshaft
1. Measure:Runout limit a
 Connecting rod big end side clearance b
 Connecting rod big end radial clearance
c
 Crank width d
Out of specification → Replace.
Use the dial gauge and a thickness
gauge.
Standard Limit
Runout
limit —0.03 mm
(0.0012 in)
Side
clearance 0.10 ~ 0.40 mm
(0.0039 ~ 0.0157 in) 0.50 mm
(0.02 in)
Radial
clearance 0.010 ~ 0.025 mm
(0.0004 ~ 0.0010 in) 0.05 mm
(0.002 in)
Crack
width 42.95 ~ 43.00 mm
(1.691 ~ 1.693 in) —
ASSEMBLY AND INSTALLATION
Crankcase
1. Apply:
Sealant
On the left crankcase.
NOTE:
 Clean the contacting surface of crankcase
(left and right) before applying the sealant.
 DO NOT ALLOW any sealant to come in
contact with the oil gallery a.
Yamaha bond No. 1215:
90890-85505
a

5 - 2
CHAS
Extent of removal Order Part name Q’ty Remarks
10 Front wheel 1
11 Collar 1
12 Brake shoe plate assembly 1
13 Oil seal 1
14 Bearing 2 Refer to “REMOVAL POINTS ”.
15 Brake shoe spring 1
16 Brake shoe 2
17 Brake camshaft lever 1
18 Wear indicator plate 1
19 Brake camshaft 1
2
1
3
3
FRONT WHEEL AND REAR WHEEL

5 - 4
CHASFRONT WHEEL AND REAR WHEEL
Extent of removal Order Part name Q’ty Remarks
11 Bearing 2 Refer to “REMOVAL POINTS ”.
12 Brake shoe spring 1
13 Brake shoe 2
14 Brake camshaft lever 1
15 Wear indicator plate 1
16 Brake camshaft 1
17 Rear wheel sprocket 1
18 Oil seal 1
2
3

5 - 5
CHAS
POINTS DE DEPOSE
Roulement de roue (si nécessaire)
1. D époser:
 Roulement 1
N.B.:
D époser le roulement à l ’aide d ’un arrache-roule-
ment courant 2.
CONTROLE
Roue
1. Mesurer: Voile de roue
Hors sp écifications → Réparer/remplacer.
Garniture de frein
1. Contr ôler:
 Surface de la garniture de m âchoire de frein
Zones brillantes → Poncer.
Utiliser du papier de verre à gros grains.
N.B.:
Apr ès pon çage, éliminer les particules à l ’aide d ’un
chiffon.
Limite de voile de roue:
Radial 1: 2,0 mm (0,08 in)
Lat éral 2: 2,0 mm (0,08 in)
2. Mesurer:
Epaisseur de la garniture de m âchoire de frein
Hors sp écifications → Remplacer.
N.B.:
Remplacer ensemble les m âchoires de frein et les
ressorts si l ’une d ’elles est us ée à la limite.
Epaisseur de la garniture de
m âchoire de frein a:
Standard: Avant: 3,5 mm (0,14 in)
Arri ère: 3,5 mm (0,14 in)
Limite: 1,5 mm (0,06 in)
DEMONTAGE-EINZELHEITEN
Radlager (nach Bedarf)
1. Demontieren:
Lager 1
HINWEIS:
Das Lager mit einem Lageraustreiber 2 aus-
bauen.
KONTROLLE
Rad
1. Messen:
Felgenschlag
Nicht nach Vorgabe → Instand setzen,
ggf. erneuern.
Trommelbremsbelag
1. Kontrollieren: Trommelbremsbelag-Oberfl äche
Glasig → Abschleifen.
Mit grobem Schmirgelpapier.
HINWEIS: Nach der Behandlung das abgeschliffene
Material mit einem Tuch abwischen.
Max. Felgenschlag:
Höhenschlag 1: 2,0 mm (0,08 in)
Seitenschlag 2: 2,0 mm (0,08 in)
2. Messen:
Trommelbremsbelag-St ärke
Nicht nach Vorgabe → Erneuern.
HINWEIS:
Trommelbremsbel äge immer satzweise samt
Federn erneuern, auch wenn nur ein Belag die
Verschlei ßgrenze erreicht hat.
Trommelbremsbelag-St ärke a:
Sollwert: Vorn: 3,5 mm (0,14 in)
Hinten: 3,5 mm (0,14 in)
Grenzwert: 1,5 mm (0,06 in)
ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD

5 - 7
CHAS
Front wheel
1. Install:Wheel bearing 1
 Spacer 2
 Wheel bearing 3
 Oil seal 4
NOTE:
Apply the lithium soap base grease on the oil
seal lip when installing.
 Use a socket that matches the outside diam-
eter of the race of the bearing.
 Left side of wheel bearing shall be installed
first.
 Install the oil seal with its manufacture ’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
New
2. Install: Front wheel
NOTE:
Make sure that the slot a on the brake shoe
plate with the stopper b on the front fork inner
tube.
b
a
3. Install: Spring 1
 Pin 2
NOTE:
Install the spring 1 with its smaller diameter
end a towards the pin 2.1
2
a
1
2
FRONT WHEEL AND REAR WHEEL

5 - 8
CHAS
Rear wheel
1. Install:Wheel bearing 1
 Spacer 2
 Wheel bearing 3
 Oil seal 4
NOTE:
Apply the lithium soap base grease on the oil
seal lip when installing.
 Install the wheel bearing with seal facing out-
ward.
 Use a socket that matches the outside diam-
eter of the race of the bearing.
 Right side of bearing shall be installed first.
 Install the oil seal with its manufacture ’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
New
2. Install: Rear wheel sprocket 1
 Bolts (rear wheel sprocket) 2
 Nuts (rear wheel sprocket) 3
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
1
2 4
1
3
2 3T R..25 Nm (2.5 m · kg, 18 ft · lb)
3. Install:
Rear wheel
NOTE:
Make sure that the slot a on the brake shoe
plate with the stopper b on the swingarm.
a
b
FRONT WHEEL AND REAR WHEEL

5 - 11
CHAS
REMOVAL POINTS
Handlebar grip
1. Remove:Handlebar grip 1
NOTE:
Blow in air between the handlebar or tube
guide and the grip. Then remove the grip
which has become loose.
INSPECTION
Handlebar
1. Inspect:
Handlebar 1
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar.
ASSEMBLY AND INSTALLATION
Handlebar
1. Install:
Starter lever 1
NOTE:
Be sure to align the flat section a of the starter
lever 1 with the flat section b of the bracket
on the handlebar
1
a
b 1
2. Install:
Left grip 1
Apply the adhesive to the handlebar 2.
NOTE:
Before applying the adhesive, wipe off
grease or oil on the handlebar surface a
with a lacquer thinner.
 Be sure to align the projection “L ” b on the
left grip with the punch mark c on the han-
dlebar.
HANDLEBAR

6 - 1
–+ELEC
345
6
78
\b0
B\f
2
1
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1 Thermo switch
2 Main switch
3 Engine stop switch
4 Ignition coil
5 Ground lead
6 Fuse
7 Battery
8 CDI unit
9 Starter relay 0
Rectifier/regulator
A Neutral switch
B AC magneto
C Carburetor heater
D Start switch
E Spark plug
F Starter motorCOLOR CODE
B ...................... Black
Br .................... Brown
O ..................... Orange
R ..................... Red
Sb .................... Sky blue
W ..................... White
Y ...................... Yellow
EC612000
WIRING DIAGRAM
R
WR
W
BL /WSb B
RW
W
W
OO
B
B
Y /R
R
W
B
R
Y /RY /R
Y
ON
OFF
OFF ON
Y
B
BY
/RRB
SbY /RR B
W
B
B
RBrR
Br
R
/WBr
R /W
L /W
OFF
RUN
Sb
BrBr
Sb
WBY
/RW SbY
B
B
B
RR
RR
R
R
R
/W
L /W
RRRB
R /W
L
/WR
R
RR
B Br
BO
R
WB
\f
2 8
4
E
1
C
D
0
63
\b F
5 7
Br
L/W .................. Blue/White
R/W .................. Red/White
Y/R ................... Yellow/Red
E
F
D
C

–+ELEC
6 - 2
IGNITION SYSTEM
EC620000
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to
ignition system failure and for checking the spark plug which will not spark.
NOTE:
Remove the following parts before inspection.
1) Seat assembly
2) Air scoops (left and right)
3) Fuel tank
Refer to “FRONT FENDER, SEAT ASSEMBLY AND FUEL TANK ” section in the CHAPTER 4.
 Use the following special tools in this inspection.
Opama pet-4000 spark checker:
YM-34487
Ignition checker: 90890-06754Pocket tester:YU-03112-C/90890-03112
Spark gap test Clean or replace
spark plug.
Check entire ignition
system for connection. Repair or replace.
Check main switch. Replace.
Check engine stop switch. Replace.
Check ignition coil. Primary coil Replace. Secondary coil Replace.
Check AC magneto. Pickup coil Replace. Replace CDI unit.
No Spark
OK
OK
OK
OK
OK
Spark
No good
No good
No good
No good
No good
No good