oil YAMAHA TTR50 2007 Owners Manual

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
Location of important labels ............1-4
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Main switch .....................................3-1
Handlebar switches ........................3-1
Speed limiter ...................................3-2
Shift pedal .......................................3-2
Brake lever .....................................3-3
Brake pedal ....................................3-3
Fuel tank cap ..................................3-3
Fuel .................................................3-4
Fuel tank breather hose ..................3-5
Fuel cock ........................................3-5
Starter (choke) lever .......................3-6
Seat ................................................3-7
Sidestand ........................................3-7
Starting circuit cut-off system .........3-8
PRE-OPERATION CHECKS..............4-1
Pre-operation check list ..................4-2OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting and warming up a cold
engine ......................................... 5-1
Starting a warm engine .................. 5-2
Shifting ........................................... 5-2
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
PERIODIC MAINTENANCE ........... 6-1
Periodic maintenance chart for the
emission control system ............. 6-2
General maintenance and
lubrication chart .......................... 6-3
Checking the spark plug ................. 6-5
Engine oil ....................................... 6-6
Cleaning the air filter element ........ 6-8
Cleaning the spark arrester ............ 6-9
Adjusting the carburetor ............... 6-10
Adjusting the engine idling
speed ........................................ 6-11
Adjusting the throttle cable free
play ........................................... 6-11
Valve clearance ............................ 6-12
Tires ............................................. 6-12
Spoke wheels ............................... 6-14
Accessories and replacement
parts .......................................... 6-14Adjusting the brake lever free
play ........................................... 6-14
Adjusting the brake pedal free
play ........................................... 6-15
Checking the front and rear
brake shoes .............................. 6-16
Drive chain slack .......................... 6-16
Cleaning and lubricating the
drive chain ................................ 6-18
Checking and lubricating the
cables ....................................... 6-19
Checking and lubricating the
throttle grip and cable ............... 6-19
Checking and lubricating the
brake and shift pedals .............. 6-19
Checking and lubricating the
brake lever ................................ 6-20
Checking and lubricating the
sidestand .................................. 6-20
Lubricating the swingarm
pivots ........................................ 6-20
Checking the front fork ................. 6-21
Checking the steering .................. 6-21
Checking the wheel bearings ....... 6-22
Battery ......................................... 6-22
Replacing the fuse ....................... 6-24
Supporting the motorcycle ........... 6-25
Front wheel .................................. 6-25
Rear wheel ................................... 6-27
Troubleshooting ........................... 6-29
Troubleshooting chart .................. 6-30U1P681E0.book Page 1 Tuesday, April 18, 2006 2:38 PM

DESCRIPTION
2-1
2
EAU10410
Left view
12 34 5
76
1. Fuel cock (page 3-5)
2. Throttle stop screw (page 6-11)
3. Air filter element (page 6-8)
4. Fuse (page 6-24)
5. Battery (page 6-22)
6. Engine oil drain bolt (page 6-6)
7. Shift pedal (page 3-2)
U1P681E0.book Page 1 Tuesday, April 18, 2006 2:38 PM

DESCRIPTION
2-2
2
EAU10420
Right view
4 532 1
1. Seat (page 3-7)
2. Fuel tank cap (page 3-3)
3. Spark plug cap (page 6-5)
4. Brake pedal (page 3-3)
5. Engine oil filler cap (page 6-6)U1P681E0.book Page 2 Tuesday, April 18, 2006 2:38 PM

PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-4
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-6
Front brakeCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-14, 6-16
Rear brakeCheck operation.
Check pedal free play.
Adjust if necessary.6-15, 6-16
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-11, 6-19
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-19
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-16, 6-18
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-12, 6-14
Shift pedalMake sure that operation is smooth.
Correct if necessary.6-19
U1P681E0.book Page 2 Tuesday, April 18, 2006 2:38 PM

OPERATION AND IMPORTANT RIDING POINTS
5-3
5
CAUTION:
ECA15460
Always close the throttle before
shifting gears, otherwise damage to
the engine and drive train may re-sult.
3. Open the throttle gradually.
4. Once the motorcycle has reached
a speed high enough to change
gears, close the throttle.
5. Shift into second gear and release
the shift pedal.
6. Open the throttle gradually.
7. Follow the same procedure when
shifting to the next higher gear.
EAU16710
To decelerate
1. Close the throttle and apply both
the front and the rear brakes to
slow the motorcycle.
2. Downshift through the gears and
shift the transmission into the neu-
tral position when the motorcycle
is almost completely stopped.
EAU39920
Engine break-in There is never a more important period
in the life of your engine than the first 5
hours of riding. It is also important to ac-
custom the rider to the motorcycle dur-
ing this time. Please read the following
information carefully.
Since the engine is brand new, do not
put an excessive load on it for the first 5
hours of operation. The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided. However, momentary full-
throttle operation under load (i.e., two
to three seconds maximum) does not
harm the engine. Each full-throttle ac-
celeration should be followed with a
substantial rest period for the engine.
To allow the engine to cool down from
the temporary buildup of heat, cruise at
a lower engine speed.
After the first 5 hours of operation, thor-
oughly check the motorcycle for loose
parts, oil leakage and any other prob-
lems. Be sure to inspect and make ad-justments thoroughly, especially cable
and drive chain slack and loose
spokes. In addition, check all fittings
and fasteners for looseness, and tight-
en if necessary.
CAUTION:
ECA10270
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealercheck the vehicle.
U1P681E0.book Page 3 Tuesday, April 18, 2006 2:38 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU39943
Periodic maintenance chart for the emission control system NOTE:

From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL ODOMETER READINGS
1000 km
(600 mi) or
1 month or
30 hours3000 km
(1800 mi) or
6 months or
90 hours5000 km
(3000 mi) or
12 months or
150 hours
1*Fuel lineCheck fuel hoses for cracks or damage.
Replace if necessary.√√
2 Spark plugCheck condition.
Adjust gap and clean.√√
3*Valve clearanceCheck and adjust valve clearance when engine is cold.√
4*Air filter elementClean with solvent.
Replace if necessary.√√
5*Crankcase breather sys-
temCheck ventilation hose for cracks or damage and drain
any deposits.
Replace if necessary.√√√
6*CarburetorCheck engine idling speed and starter operation.
Adjust if necessary.√√√
7 Exhaust systemCheck for leakage.
Tighten if necessary.
Replace gasket(s) if necessary.√√
8 Engine oilChange (warm engine before draining).√√√
U1P681E0.book Page 2 Tuesday, April 18, 2006 2:38 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU40000
NOTE:The air filter needs more frequent service if you are riding in unusually wet or dusty areas.10*Chassis fastenersCheck all chassis fitting and fasteners.
Correct if necessary.√√√
11 Brake lever pivot shaftApply lithium-soap-based grease (all-purpose grease)
lightly.√√
12 Brake pedal pivot shaftApply lithium-soap-based grease (all-purpose grease)
lightly.√√
13 Sidestand pivotCheck operation.
Apply lithium-soap-based grease (all-purpose grease)
lightly.√√
14*Spark arresterClean.√
15*Front forkCheck operation and for grease leakage.
Replace if necessary.√√
16*Shock absorber assem-
blyCheck operation and for oil leakage.
Replace if necessary.√
17*Control cablesApply Yamaha chain and cable lube or engine oil 10W-30
thoroughly.√√√
18*Throttle grip housing and
cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√ No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL ODOMETER READINGS
1000 km
(600 mi) or
1 month or
30 hours3000 km
(1800 mi) or
6 months or
90 hours5000 km
(3000 mi) or
12 months or
150 hours
U1P681E0.book Page 4 Tuesday, April 18, 2006 2:38 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6 2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.
4. Install the spark plug cap.
EAU39840
Engine oil The engine oil level should be checked
before each ride. In addition, the oil
must be changed at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright po-
sition.NOTE:Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result ina false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
NOTE:
The engine oil should be between theminimum and maximum level marks.
4. If the engine oil is at or below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
U1P681E0.book Page 6 Tuesday, April 18, 2006 2:38 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6To change the engine oil
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
4. Install the engine oil drain bolt, and
then tighten it to the specified
torque.5. Add the specified amount of the
recommended engine oil, and then
install and tighten the engine oil fill-
er cap.
CAUTION:
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-rial enters the crankcase.
6. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.7. Turn the engine off, and then
check the oil level and correct it if
necessary.
1. Engine oil drain boltTightening torque:
Engine oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
1
Recommended engine oil:
See page 8-1.
Oil change quantity:
0.80 L (0.85 US qt) (0.70 Imp.qt)
U1P681E0.book Page 7 Tuesday, April 18, 2006 2:38 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
EAU39831
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
To clean the air filter element
1. Remove the air filter case cover by
removing the screws.
2. Pull the sponge material and the
mesh out.3. Clean the mesh with solvent, and
then wipe the solvent off.
4. Clean the sponge material with
solvent, and then squeeze the re-
maining solvent out.
WARNING
EWA10430
Use only a dedicated parts cleaning
solvent. To avoid the risk of fire or
explosion, do not use gasoline orsolvents with a low flash point.CAUTION:
ECA10510
To avoid damaging the foam materi-
al, handle it gently and carefully, anddo not twist or wring it.
5. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the ex-
cess oil out.
1. Screw
2. Air filter case cover
1. Sponge material
1. Air filter mesh
U1P681E0.book Page 8 Tuesday, April 18, 2006 2:38 PM