2006 YAMAHA TTR50 brake

2 - 20
SPECCABLE ROUTING DIAGRAM
ÑFasten the wire harness with a plastic locking tie
as far rearward as possible on the frame. Cut off
the excess end of the plastic locking tie, and
then face the cut end of the tie upward. The cut
end of the plastic locking tie should be 5 mm
(0.20 in) or less.
Ò Do not pinch the carburetor air vent hose
between the air filter case and frame.
Ó Fasten the engine stop switch lead with the plas-
tic bands.
Ô 20 ~ 30 mm (0.79 ~ 1.18 in) Õ
Route the brake cable in front of the front fender.
Ö Route the main switch lead over the handlebar.
× Route the starter cable, engine stop switch lead,
and main switch lead in front of the upper
bracket in the order listed from front to rear.
Ø Route the throttle cable behind the front fender.
Ù Fasten the start switch lead with the plastic
bands.
2
É
BÍ
B Ñ
BÏ
F Î
LÕ
\b
8 \b
×
0
\f Ø
E
E Ò 6
\f
7
8
\b
0
\f
C
D
H
H
7
J
I
I
K 8
7
\b
C
0
\f
E H
G 345
Ê
Ì
Ð
ÙÓ
Ô
Ô
È
B
A C
C
B
A
B-B
A-A
C-C
1

2 - 21
SPECCABLE ROUTING DIAGRAM
1Cable guide
2 Brake cable
3 Throttle cable
4 Fuel tank breather hose
5 Thermo switch lead
6 Ignition coil lead terminal
7 Ground lead terminal
8 Rectifier/regulator
9 Plastic locking tie
0 Starter relay
A Battery band B
Starter motor lead
C AC magneto lead
D Fuel overflow hose
E Fuel hose
F Ignition coil
G Thermo switch
H Frame
I Wire harness
J Rectifier/regulator lead
K CDI unit lead
L Drive sprocket cover
RES
OFF
FUEL
A
EE
A
B C
C
B
G
G
D
F
È1
ÕJ
2
3
4
5
8
\f
6
Ê
\bÎ
0 Ï
\b Ò
L \b
B
C
D
E
F
G
H I
B I
H
C
NB
M B
P O
R Q
I
S
I
K
I
B
C
I
H
B
C
\f C
Ó
×
Ø
Ô
ÐÑ
Ì
Í
7 \f
É
C-C
E-EA-A
B-B
G-G
D
F

2 - 22
SPECCABLE ROUTING DIAGRAM
MNeutral switch lead
N Crankcase cover (left)
O Bottom cover
P Starter motor
Q AC magneto lead coupler (4-pin)
R AC magneto lead coupler (2-pin)
S CDI unit
È Pass the brake cable through the cable guide.
É Connect the flat terminal to the ignition coil. Ê
Install both the ignition coil lead terminal and
ignition coil to the bolt hole shown in the frame,
making sure that the ignition coil lead terminal is
installed on the right side of the ignition coil.
Ë Install the ground lead terminal on the right side
of the frame using the bolt, making sure that the
crimped side of the terminal is facing to the right.
Ì Make sure that there is no slack in the AC mag-
neto lead and wire harness in the area shown in
the illustration.
Í 20 ~ 30 mm (0.79 ~ 1.18 in)
RES
OFF
FUEL
A
EE
A
B C
C
B
G
G
D
F
È1
ÕJ
2
3
4
5
8
\f
6
Ê
\bÎ
0 Ï
\b Ò
L \b
B
C
D
E
F
G
H I
B I
H
C
NB
M B
P O
R Q
I
S
I
K
I
B
C
I
H
B
C
\f C
Ó
×
Ø
Ô
ÐÑ
Ì
Í
7 \f
É
C-C
E-EA-A
B-B
G-G
D
F

2 - 24
SPECCABLE ROUTING DIAGRAM
ÒFasten the wire harness, AC magneto lead, and
starter motor lead to the frame with a plastic
locking tie at the location shown in the illustra-
tion. Cut off the excess end of the plastic locking
tie, and then face the cut end of the tie upward.
The cut end of the plastic locking tie should be
5 mm (0.20 in) or less.
Ó Gather the slack of the AC magneto lead and
starter motor lead in the area shown in the illus-
tration, and then place the slack between the air
filter case and battery. Ô
Pass the brake cable through the guides on the
front fork guard.
Õ Do not fasten the rectifier/regulator lead.
Ö Do not pinch the starter motor lead.
× Before installing the CDI unit, connect the AC
magneto lead couplers and place them under
the wire harness in the CDI unit holder.
Ø Place the cover on the CDI unit, and then install
the CDI unit in the CDI unit holder.
RES
OFF
FUEL
A
EE
A
B C
C
B
G
G
D
F
È1
ÕJ
2
3
4
5
8
\f
6
Ê
\bÎ
0 Ï
\b Ò
L \b
B
C
D
E
F
G
H I
B I
H
C
NB
M B
P O
R Q
I
S
I
K
I
B
C
I
H
B
C
\f C
Ó
×
Ø
Ô
ÐÑ
Ì
Í
7 \f
É
C-C
E-EA-A
B-B
G-G
D
F

3 - 1
INSPADJ
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
No. ITEM CHECKS AND
MAINTENANCE JOBS WHICH-
EVER
COMES
FIRST INITIAL EVERY
month 1 6 12
hours 30 60 120
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 * Breather system Check ventilation hose for cracks or damage.
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 if necessary.
√

√
8 Engine oil Change (warm engine before draining). √
√
√
9 * Clutch Check operation.
Adjust if necessary.
√

√
√
10 * Front brake Check operation.
Adjust brake lever free play and replace brake shoes
if necessary.
√

√
√
11 * Rear brake Check operation.
Adjust brake pedal free play and replace brake shoes
if necessary. √

√
√
12 * Wheels Check runout, spoke tightness and for damage.
Tighten spokes if necessary.
√

√
√
13 * Tires Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
√

√
14 * Wheel bearings Check bearings for smooth operation.
Replace if necessary.
√

√
15 * Swingarm Check swingarm pivoting point for play.
Correct if necessary.
Lubricate with lithium soap based grease. √

√
√
16 Drive chain Check chain slack/alignment and condition.
Adjust and lubricate chain. Every ride
17 * Steering bearings Check bearing assemblies for looseness.
Lubricate with lithium soap based grease every
120 hours or 12 months (whichever comes first).
√

√
18 Brake lever pivot
shaft Apply lithium soap based grease lightly.
√
√
√
19 Brake pedal pivot
shaft Apply lithium soap based grease lightly.
√
√
√
3

3 - 3
INSPADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel line
for leakage. P.1-11
Engine oil Check that the oil level is correct. Check the crankcase for leakage. P.3-7 ~ 9
Throttle Check for proper throttle cable operation. P.3-4 ~ 5
Brakes Check the play of front and rear brake and effect of front and rear
brake. P.3-14 ~ 15
Drive chain Check chain slack and alignment. Check that the chain is lubricated
properly. P.3-16 ~ 18
Wheels and tires Check pressure/runout/spoke tightness/bead stopper/axle nuts. P.3-19 ~ 20
Steering Check that the handlebar can be turned smoothly and have no exces-
sive play. P.3-20 ~ 21
Front forks and rear
shock absorber assembly Check that they operate smoothly and there is no oil leakage. P.3-18
Cables (wires) Check that the throttle cable move smoothly. Check that they are not
caught when the handlebars are turned. —
Muffler Check that the muffler is tightly mounted and has no cracks. P.4-3
Sprocket Check that the driven sprocket tightening nut is not loose. P.3-15
Lubrication Check for smooth operation. Lubricate if necessary. P.3-22
Spark plug Check color/condition. P.3-23
Fittings/fasteners Check all – tighten as necessary. P.2-13
Lead connectors Check that the AC magneto, CDI unit, and ignition coil are connected
tightly. P.1-5

3 - 14
INSPADJCHASSIS/FRONT BRAKE ADJUSTMENT/
REAR BRAKE ADJUSTMENT
CHASSIS
FRONT BRAKE ADJUSTMENT
1. Check:Brake lever free play a
Out of specification → Adjust.
Free play (brake lever):
10 ~ 20 mm (0.39 ~ 0.79 in)
(at brake lever end)
a
2. Adjust:
Brake lever free play
REAR BRAKE ADJUSTMENT
1. Check: Brake pedal free play a
Out of specification → Adjust.
2. Adjust: Brake pedal free play
Adjustment steps:

Turn the adjusters 1 in or out until the
specified free play is obtained.
Turning in b → Free play is decreased.
Turning out c → Free play is increased.
CAUTION:
Make sure that there is no brake drag
after adjusting the front brake lever free
play.
Free play: 10 ~ 20 mm (0.39 ~ 0.79 in)
Adjustment steps:
 Turn the adjuster 1 in or out until the
specified free play is obtained.
Turning in b → Free play is decreased.
Turning out c → Free play is increased.
CAUTION:
Make sure that the brake does not drag
after adjusting it.
1
c b
ab
c
1

3 - 15
INSPADJ
FRONT BRAKE SHOE INSPECTION
1. Inspect:
Brake shoe lining wear limit
Brake shoe lining wear limit checking
steps:
 Fully pull in the brake lever and hold it in
position.
 Then check the brake shoe wear indicator
1 is within the wear limit a.
Outside the limit → Replace the brake
shoes.
Refer to “FRONT WHEEL AND REAR
WHEEL ” section in the CHAPTER 5.
a
1
REAR BRAKE SHOE INSPECTION
1. Inspect:
Brake shoe lining wear limit
Brake shoe lining wear limit checking
steps:
 Fully push down the brake pedal and hold
it in position.
 Then check the brake shoe wear indicator
1 is within the wear limit a.
Outside the limit → Replace the brake
shoes.
Refer to “FRONT WHEEL AND REAR
WHEEL ” section in the CHAPTER 5.
a 1
SPROCKETS INSPECTION
1. Inspect:
Sprocket teeth a
Excessive wear → Replace.
NOTE:
Replace the drive, driven sprockets and drive
chain as a set.
FRONT BRAKE SHOE INSPECTION/
REAR BRAKE SHOE INSPECTION/SPROCKETS INSPECTION