2006 YAMAHA TTR50 battery

3 - 27
INSPADJ
 When charging a battery, be sure to
remove it from the machine. (If charging
has to be done with the battery mounted
on the machine, disconnect the negative
battery lead from the battery terminal.)
 To reduce the chance of sparks, do not
plug in the battery charger until the bat-
tery charger leads are connected to the
battery.
 Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
 Make sure the battery charger lead clips
are in full contact with the battery termi-
nal and that they are not shorted. A cor-
roded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
 If the battery becomes hot to the touch at
any time during the charging process,
disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
 As shown in the following illustration, the
open-circuit voltage of an MF battery sta-
bilizes about 30 minutes after charging
has been completed. Therefore, wait 30
minutes after charging is completed
before measuring the open-circuit volt-
age.
BATTERY INSPECTION AND CHARGING

3 - 28
INSPADJ
BATTERY INSPECTION AND CHARGING
Charging method using a variable voltage charger
Measure the open-circuit
voltage prior to charging.
Connect a charger and
ammeter to the battery
and start charging. Is the amperage higher
than the standard charg-
ing amperage written on
the battery? NO
YES
Charger
Ammeter
Adjust the voltage to obtain
the standard charging
amperage.
Set the timer to the charging
time determined by the open-
circuit voltage.
Refer to “BATTERY INSPEC-
TION AND CHARGING ”. Adjust the charging voltage to
20 ~ 25 V.
Monitor the amperage for 3 ~
5 minutes. Is the standard
charging amperage
exceeded?
NO
YES
If the amperage does not
exceed the standard charg-
ing amperage after 5 min-
utes, replace the battery.
If the required charging time exceeds 5 hours, it is advisable to check
the charging amperage after 5 hours. If there is any change in the
amperage, readjust the voltage to obtain the standard charging
amperage.
Leave the battery unused for more than 30 minutes before measuring
its open-circuit voltage.
12.8 V
→ Charging is complete.
12.0 ~ 12.7 V
→ Recharging is required.
Under 12.0 V
→ Replace the battery.
Leave the battery unused for more
than 30 minutes before measuring its
open-circuit voltage.
Set the charging voltage to 16 ~ 17 V.
(If the charging voltage is lower, charg-
ing will be insufficient, if it is higher, the
battery will be over-charged.)
NOTE:
NOTE:

3 - 29
INSPADJ
BATTERY INSPECTION AND CHARGING
Charging method using a constant voltage charger
Measure the open-circuit
voltage prior to charging.
Connect a charger and
ammeter to the battery
and start charging.
NO
YES Is the amperage higher
than the standard
charging amperage writ-
ten on the battery?
Charge the battery until the charging
voltage reaches 15 V.
Leave the battery unused for more than
30 minutes before measuring its open-
circuit voltage.
12.8 V
→ Charging is complete.
12.0 ~ 12.7 V
→ Recharging is required.
Under 12.0 V
→ Replace the battery. This type of battery charger cannot
charge an MF battery. A variable
voltage charger is recommended.
Leave the battery unused for more
than 30 minutes before measuring
its open-circuit voltage.
Set the charging time to a maximum of 20 hours.
Constant amperage chargers are not
suitable for charging MF batteries.
Charger
Ammeter
Voltmeter
NOTE:
CAUTION:
NOTE:

3 - 30
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

3 - 31
INSPADJ
FUSE INSPECTION
3. Check:
Continuity
2 Reserve fuse
Checking steps:

Remove the fuse 1
.
 Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω × 1 ”.
Pocket tester:
YU-03112-C/90890-03112
 If the pocket tester indicates “∞ ”, replace
the fuse.
1 2
4. Replace:
Blown fuse
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rat-
ing may cause extensive damage to the
electrical system, cause the starting and
ignition systems to malfunction and could
possibly cause a fire.
5. Connect:
Battery lead coupler
(to the battery terminals)
6. Install: Battery cover
 Seat assembly
Replacement steps:

Set the main switch to “OFF ”.
 Install a new fuse of the correct amperage.
 Set on the switches to verify if the electri-
cal circuit is operational.
 If the fuse immediately blows again, check
the electrical circuit.
Items Amperage
rating Q
’ty
Main fuse 10 A 1

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

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 - 6
ELECTRIC STARTING SYSTEM
INSPECTION STEPS
If the starter motor will not operate, 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.
*3 marked: Refer to “MAIN SWITCH INSPECTION ” section.
*4 marked: Refer to “ENGINE STOP SWITCH INSPECTION ” section.
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 12 V battery in this inspection.
 Use the following special tools 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.
*3 Check main switch. Replace. *4 Check engine stop switch. Replace.
Check starter motor operation. Repair or replace.
Check starter relay. Replace.
Check neutral switch. Replace. Check start switch. Replace.
OK
OK
OK
OK
OK
OK
OK
OK
No good
No good
No good
No good
No good
No good
ELECTRIC STARTING SYSTEM
No good
No good
No good