Oil YAMAHA TTR50 2006 Repair Manual

6 - 4
–+ELECIGNITION SYSTEM
ENGINE STOP SWITCH INSPECTION
1. Inspect:
Engine stop switch continuity
Continuous in the “” position → Replace.
Not continuous in the “” position → Replace.
Tester (+) lead
→ Black lead
1
Tester ( –) lead
→ Black lead
2
B
1 B
2 Tester selec-
tor position
Ω
× 1B
B
1 2
EC626002
IGNITION COIL INSPECTION
1. Inspect:
Primary coil resistance
Out of specification → Replace.
2. Inspect: Secondary coil resistance
Out of specification → Replace.
NOTE:
When inspecting the secondary coil resis-
tance, remove the spark plug cap.Tester (+) lead
→ Orange lead
1
Tester ( –) lead
→ Black lead
2
Primary coil
resistance Tester selector
position
0.32 ~ 0.48 Ω at
20 °C (68 °F) Ω

× 1
Tester (+) lead → Spark plug lead
1
Tester ( –) lead
→ Orange lead
2
Secondary coil
resistance Tester selector
position
5.68 ~ 8.52 k Ω
at 20 °C (68 °F) k
Ω
× 1
1
2
1
2

6 - 5
–+ELECIGNITION SYSTEM
AC MAGNETO INSPECTION
1. Inspect:
Pickup coil resistance
Out of specification → Replace.
Tester (+) lead → Red lead
1
Tester ( –) lead
→ White lead
2
Pickup coil
resistance Tester selector
position
248 ~ 372 Ω at
20 °C (68 °F) Ω

× 100
W
R
1 2

6 - 10
–+ELEC
STARTER MOTOR
1
3
45 6
8
2
\b
1
1
LS
New
New
T R..10 Nm (1.0 m •
kg, 7.2 ft • Ib)
7
Extent of removal:1 Starter motor disassembly
Extent of removal Order Part name Q ’ty Remarks
STARTER MOTOR REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT ”
section in the CHAPTER 3.
Bottom cover Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section
in the CHAPTER 4.
1 Starter motor 1 STARTER MOTOR DISASSEM-
BLY
1 Front bracket 1
2 O-ring 1
3 Brush set 1
4 Washer 1
5 Oil seal 1
6 Bearing 1
1
ELECTRIC STARTING SYSTEM

6 - 12
–+ELEC
INSPECTION AND REPAIR
1. Inspect:
Commutator
Dirt → Clean it with #600 grit sandpaper.
2. Measure: Commutator diameter a
Out of specification → Replace the
starter motor.
3. Measure: Mica undercut a
Out of specification → Scrape the mica to
the proper value (a hacksaw blade can
be ground to fit).
NOTE:
The mica insulation of the commutator must be
undercut to ensure proper operation of com-
mutator.
Commutator wear limit: 16.6 mm (0.65 in)
Mica undercut:1.35 mm (0.05 in)
4. Measure:
Armature assembly resistance (commu-
tator and insulation)
Out of specification → Replace the
starter motor.
Measurement steps:
 Measure the armature assembly resis-
tances with the pocket tester.
Pocket tester:
YU-03112-C/90890-03112
Armature coil:Commutator resistance 1
0.035 ~ 0.043 Ω at 20 °C (68 °F)
Insulation resistance 2
Above 1 M Ω at 20 °C (68 °F)
 If any resistance is out of specification,
replace the starter motor.
ELECTRIC STARTING SYSTEM

6 - 13
–+ELEC
5. Measure:
Brush length a
Out of specification → Replace.
Brush length wear limit:
3.5 mm (0.14 in)
6. Measure:
Brush spring force
Fatigue/out of specification → Replace as
a set.
Brush spring force: 3.92 ~ 5.88 N
(400 ~ 600 g, 14.1 ~ 21.2 oz)
ASSEMBLY
1. Install:
Brush holder
2. Install:
Armature coil 1
3. Install:
Ring 1
 Starter motor yoke 2
 Front bracket 3
NOTE:
Apply molybdenum disulfide grease lightly
on to the bearings of the starter motor.
 Align the match mark on the armature
assembly with the match mark on the front
bracket.
ELECTRIC STARTING SYSTEM

–+ELEC
6 - 14
CHARGING SYSTEM
EC680000
CHARGING SYSTEM
EC681001
INSPECTION STEPS
If the battery is not charged, use the following inspection steps.
*1 marked: Refer to “FUSE INSPECTION ” section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING ” section in the CHAPTER 3.
NOTE:
 Remove the following parts before inspection.
1) Seat assembly
Refer to “FRONT FENDER, SEAT ASSEMBLY AND FUEL TANK ” section in the CHAPTER 4.
 Use the following special tool in this inspection.
Pocket tester:
YU-03112-C/90890-03112
*1 Check fuse. Replace fuse and
check wire harness.
*2 Check battery. Recharge or replace.
Check each coupler and wire connection. Repair or replace.
Check charging voltage. Charging system is
good.
Check AC magneto. Charging coil Replace.
Replace rectifier/regulator.
OK
OK
OK
No good
OK
No good
OK
No good
No good
No good

6 - 15
–+ELECCHARGING SYSTEM
EC624000
COUPLERS AND LEADS CONNECTION
INSPECTION
1. Check:
Couplers and leads connection
Rust/dust/looseness/short-circuit →
Repair or replace.
CHARGING VOLTAGE INSPECTION
1. Start the engine.
2. Inspect: Charging voltage
Out of specification → If no failure is
found in checking the charging coil resis-
tance, replace the rectifier/regulator.
Tester (+) lead → Red lead
1
Tester ( –) lead
→ Black lead
2
Charging
voltage Tester selector
position
14.0 V at
5,000 r/min DCV-20
2
1
W R
Y/R
B
AC MAGNETO INSPECTION
1. Inspect: Charging coil resistance
Out of specification → Replace.
Tester (+) lead → White lead
1
Tester ( –) lead
→ Black lead
2
Charging coil
resistance Tester selector
position
0.96 ~ 1.44 Ω at
20 °C (68 °F) Ω

× 1
WSb
B
Y 1
2

–+ELEC
6 - 16
CARBURETOR HEATING SYSTEM
CARBURETOR HEATING SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning carburetor heating system.
NOTE:
 Remove the following parts before inspection.
1) Seat
2) Fuel tank
Refer to “FRONT FENDER, SEAT ASSEMBLY AND FUEL TANK ” section in the CHAPTER 4.
 Use the following special tools in this inspection.
Pocket tester:
YU-03112-C/90890-03112
Check entire carburetor
heating system for connec- tion. Repair or replace.
Check thermo switch. Replace.
Check carburetor heater. Replace. Check AC magneto. Lighting coil Replace.
Replace rectifier/regulator.
OK
OK
OK
OK
No good
No good
No good
No good

6 - 19
–+ELECCARBURETOR HEATING SYSTEM
AC MAGNETO INSPECTION
1. Inspect:
Lighting coil resistance
Out of specification → Replace.
Tester (+) lead → Yellow lead
1
Tester ( –) lead
→ Black lead
2
Lighting coil
resistance Tester selector
position
0.8 ~ 1.20 Ω at
20 °C (68 °F) Ω

× 1
WSb
B
Y
1 2