check engine YAMAHA TTR50 2013 Owners Manual

TABLE OF CONTENTS
LOCATION OF IMPORTANT
LABELS ............................................1-1
SAFETY INFORMATION .................. 2-1
DESCRIPTION .................................. 3-1
Left view .......................................... 3-1
Right view ........................................ 3-2
Controls and instruments ................3-3
INSTRUMENT AND CONTROL
FUNCTIONS ....................................... 4-1
Main switch ..................................... 4-1
Handlebar switches ........................ 4-1
Speed limiter .................................. 4-2
Shift pedal ......................................4-3
Brake lever ..................................... 4-3
Brake pedal .................................... 4-3
Fuel tank cap .................................. 4-4
Fuel ................................................ 4-4
Fuel tank breather hose ................. 4-7
Fuel cock ........................................ 4-7
Starter (choke) lever ....................... 4-8
Seat ................................................ 4-8
Sidestand ....................................... 4-9
Starting circuit cut-off system ......... 4-9 FOR YOUR SAFETY –
PRE-OPERATION CHECKS
............. 5-1
OPERATION AND IMPORTANT
RIDING POINTS ................................ 6-1
Starting and warming up a cold engine ......................................... 6-1
Starting a warm engine .................. 6-2
Shifting ........................................... 6-2
Engine break-in .............................. 6-3
Parking ........................................... 6-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ................................... 7-1
Periodic maintenance chart for the emission control system ............. 7-2
General maintenance and
lubrication chart .......................... 7-3
Checking the spark plug ................ 7-6
Engine oil ....................................... 7-7
Cleaning the air filter element ........ 7-8
Cleaning the spark arrester ......... 7-10
Adjusting the carburetor ............... 7-11
Adjusting the engine idling speed ........................................ 7-11
Checking the throttle grip free
play ........................................... 7-12
Valve clearance ........................... 7-12
Tires ............................................. 7-13
Spoke wheels .............................. 7-14
Adjusting the clutch free play ....... 7-15 Adjusting the brake lever free
play ........................................... 7-15
Adjusting the brake pedal free play ........................................... 7-16
Checking the shift pedal ............... 7-17
Checking the front and rear brake
shoes ........................................ 7-17
Drive chain slack .......................... 7-18
Cleaning and lubricating the drive
chain ......................................... 7-19
Checking and lubricating the
cables ....................................... 7-20
Checking and lubricating the throttle grip and cable ............... 7-20
Checking and lubricating the brake lever ................................ 7-20
Checking and lubricating the
brake pedal ............................... 7-21
Checking and lubricating the sidestand .................................. 7-21
Lubricating the swingarm pivots ... 7-21
Checking the front fork ................. 7-22
Checking the steering .................. 7-22
Checking the wheel bearings ....... 7-23
Battery .......................................... 7-23
Replacing the fuse ....................... 7-24
Supporting the motorcycle ........... 7-25
Front wheel .................................. 7-26
Rear wheel ................................... 7-28
Troubleshooting ........................... 7-29
Troubleshooting chart .................. 7-31
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SAFETY INFORMATION
2-3
2
●
Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
●
Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
●
Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loading
Adding accessories to your motorcycle
can adversely affect stability and han-
dling if the weight distribution of the mo-
torcycle is changed. To avoid the
possibility of an accident, use extreme
caution when adding accessories to
your motorcycle. Use extra care when
riding a motorcycle that has added ac-
cessories. Here are some general
guidelines to follow if adding accesso-
ries to your motorcycle:
Operation of an overloaded vehicle
could cause an accident.
●
The weight of the operator must
not exceed 40.0 kg (88 lb).
●
Accessory weight should be kept
as low and close to the motorcycle
as possible. Securely pack your
heaviest items as close to the cen-
ter of the vehicle as possible and
make sure to distribute the weight
as evenly as possible on both
sides of the motorcycle to mini-
mize imbalance or instability.
●
Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories are securely attached to
the motorcycle before riding.
Check accessory mounts fre-
quently. Properly adjust the suspension for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
Never attach any large or heavy items to the handlebar, front
fork, or front fender. Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail- able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection to
Yamaha manufacture parts and acces- sories or offer other modifications for
Yamaha vehicles. Yamaha is not in a position to test the products that these
aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories, and
Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accessories
or modifications are not suitable be-
cause of potential safety hazards to you
or others. Installing aftermarket prod-
U2CJ80E0.book Page 3 Tuesday, June 12, 2012 11:15 AM

SAFETY INFORMATION
2-4
2
ucts or having other modifications per-
formed to your vehicle that change any
of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or death.
You are responsible for injuries related
to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
●
Never install accessories that
would impair the performance of
your motorcycle. Carefully inspect
the accessory before using it to
make sure that it does not in any
way reduce ground clearance or
cornering clearance, limit suspen-
sion travel, steering travel or con-
trol operation.
Accessories fitted to the handle- bar or the front fork area can
create instability due to improper
weight distribution. If accesso-
ries are added to the handlebar
or front fork area, they must be
as lightweight as possible and
should be kept to a minimum. Bulky or large accessories may
seriously affect the stability of
the motorcycle. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds.
Certain accessories can dis- place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.
●
Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match the
performance capabilities and to provide
the best combination of handling, brak-
ing, and comfort. Other tires, rims, siz-
es, and combinations may not be appropriate. Refer to page 7-13 for tire
specifications and more information on
replacing your tires.
Transporting the Motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.
●
Remove all loose items from the
motorcycle.
●
Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.
●
Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
●
Shift the transmission in gear (for
models with a manual transmis-
sion).
●
Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or parts
that could break). Choose the lo-
U2CJ80E0.book Page 4 Tuesday, June 12, 2012 11:15 AM

INSTRUMENT AND CONTROL FUNCTIONS
4-7
4
EAU13412
Fuel tank breather hose Before operating the motorcycle:●
Check the fuel tank breather hose
connection.
●
Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.
●
Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.
EAU13561
Fuel cock The fuel cock supplies fuel from the
tank to the carburetor while filtering it al-
so.
The fuel cock has three positions:
OFF
With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.ON
With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
RES
1. Fuel tank breather hose
1. Arrow mark positioned over “OFF”
1. Arrow mark positioned over “ON”
1. Arrow mark positioned over “RES”
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INSTRUMENT AND CONTROL FUNCTIONS
4-9
42. Place the seat in the original posi-tion, and then tighten the bolts.
TIPMake sure that the seat is properly se-
cured before riding.
EAU37490
Sidestand The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.
WARNING
EWA14190
The vehicle must not be ridden with
the sidestand down, or if the side-
stand cannot be properly moved up (or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
EAU41611
Starting circuit cut-off system The starting circuit cut-off system pre-
vents starting when the transmission is
in gear.
Periodically check the operation of the
starting circuit cut-off system according
to the following procedure.TIPThis check is most reliable if performed
with a warmed-up engine.
1. Projection
2. Seat holderU2CJ80E0.book Page 9 Tuesday, June 12, 2012 11:15 AM

INSTRUMENT AND CONTROL FUNCTIONS
4-10
4
With the engine turned off:
1. Make sure that the engine stop switch is set to “”.
2. Turn the key to “ON”.
3. Shift the transmission into gear.
4. Keep the front or rear brake applied.
5. Push the start switch.
Does the engine start?
The neutral switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
6. Shift the transmission into the neutral position.
7. Push the start switch.
Does the engine start?
The neutral switch may not be working correctly.
The motorcycle should not be ridden
until
checked by a Yamaha dealer.
YES
NO
The system is OK. The motorcycle can be ridden.
YES
NO
If a malfunction is noted, have a Yamaha
dealer check the system before riding.
WARNING
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-1
5
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEMCHECKS PAGE
Fuel Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check fuel tank breather hose for obs
tructions, cracks or damage, and check
hose connection. 4-4, 4-7
Engine oil Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage. 7-7
Front brake Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
7-15, 7-17
Rear brake Check operation.
Check pedal free play.
Adjust if necessary. 7-16, 7-17
Throttle grip Make sure that operation is smooth.
Check throttle grip free play.
If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable
and grip housing. 7-12, 7-20
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-2
5
Control cables Make sure that operation is smooth.
Lubricate if necessary. 7-20
Drive chain Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.
7-18, 7-19
Wheels and tires Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary. 7-13, 7-14
Shift pedal Make sure that operation is smooth.
Correct if necessary. 7-17
Brake pedal Make sure that operation is smooth.
Lubricate pedal pivoting point if necessary.
7-21
Brake lever Make sure that operation is smooth.
Lubricate lever pivoting point if necessary. 7-20
Sidestand Make sure that operation is smooth.
Lubricate pivot if necessary. 7-21
Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.
—
Engine stop switch Check operation. 4-1
ITEM CHECKS PAGE
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OPERATION AND IMPORTANT RIDING POINTS
6-3
63. 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 decelerate1. 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.
NOTICE
ECA10270
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-2
7
EAU39944
Periodic maintenance chart for the emission control system TIP●
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 technical
skills.
No.ITEM CHECKS AND MAINTENANCE JOBS INITIAL ODOMETER READINGS
1000 km
(600 mi) or
1 month or 30 hours 3000 km
(1800 mi) or
6 months or 90 hours 5000 km
(3000 mi) or
12 months or 150 hours
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 *Crankcase breather sys-
tem Check ventilation hose for cracks or damage and drain
any deposits.
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(s) if necessary. √√
8 *Spark arrester Clean. √
9 Engine oil Change (warm engine before draining). √√√
U2CJ80E0.book Page 2 Tuesday, June 12, 2012 11:15 AM