2006 YAMAHA TTR50 clutch

4 - 42
ENGAC MAGNETO AND STARTER CLUTCH
AC MAGNETO AND STARTER CLUTCH
È Stake
Extent of removal: 1 Crankcase cover (left) removal
2 Pickup coil/stator removal
3 Rotor removal
4 Starter clutch/wheel gear removal
Extent of removal Order Part name Q ’ty Remarks
AC MAGNETO AND STATOR
REMOVAL
Preparation for removal Seat assembly Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section.
1 Crankcase cover (left) 1
2 Dowel pin 2
3 Gasket 1
4 AC magneto coupler 2
5 Neutral switch lead 1
6 Pickup coil/stator assembly 1
7 Rotor nut 1 Use special tool.
Refer to “REMOVAL POINTS ”.
8 Rotor 1
9 Woodruff key 1
21
3
4

4 - 43
ENGAC MAGNETO AND STARTER CLUTCH
Extent of removal Order Part name Q’ty Remarks
10 Shaft 1
11 Idler gear 1
12 Starter clutch/wheel gear 1/1
4

4 - 44
ENGAC MAGNETO AND STARTER CLUTCH
REMOVAL POINTS
Rotor
1. Remove:Rotor nut 1
 Washer 2
NOTE:
Loosen the rotor nut while holding the rotor
with sheave holder 3.
 Do not allow the sheave holder to touch the
projection on the rotor.
Sheave holder:
YS-01880-A/90890-01701
2. Remove:
Rotor 1
 Woodruff key
NOTE:
 Use the flywheel puller 2.
 Center the flywheel puller over the rotor.
Make sure after installing the holding bolts
that the clearance between the flywheel
puller and the rotor is the same everywhere.
If necessary, one holding bolt may be turned
out slightly to adjust the flywheel puller ’s
position.
CAUTION:
Cover the crankshaft end with the box
wrench for protection.
Flywheel puller: YU-33270-B/90890-01362

4 - 45
ENG
INSPECTION
Starter clutch
1. Inspect:Starter idle gear teeth a
 Starter drive gear teeth b
 Starter wheel gear teeth c
Burrs/chips/roughness/wear → Replace.
2. Check:
Starter clutch operation.
Checking steps:
 Install the starter wheel gear onto the
starter clutch and hold the starter clutch.
 When turning the starter wheel gear clock-
wise È, the starter clutch and the starter
wheel gear should be engage, otherwise
the starter clutch is faulty and must be
replaced.
 When turning the starter wheel gear coun-
terclockwise É, it should turn freely, other-
wise the starter clutch is faulty and must
be replaced.
É
È
ASSEMBLY AND INSTALLATION
Starter clutch
1. Install:Starter clutch 1
1T R..14 Nm (1.4 m · kg, 10 ft · lb)
2. Unloosen the starter clutch assembly by
using the center punch.
AC MAGNETO AND STARTER CLUTCH

4 - 46
ENGAC MAGNETO AND STARTER CLUTCH
3. Install:Spring 1
 Spring cap 2
 Pin 3
4. Install: Shim 1
 Starter wheel gear 2
 Starter idle gear 3
 Shaft 4
NOTE:
Apply the molybdenum disulfide oil on the
starter wheel gear inner circumference.
 Apply the engine oil on the starter idle gear
inner circumference and on the shaft outer
circumference.
1 2
3
12
3
5. Install:
Woodruff key 1
 Rotor 2
NOTE:
Clean the tapered portion of the crankshaft
and the rotor hub.
 When installing the rotor, make sure the
woodruff key is properly seated in the key
way of the crankshaft.
6. Tighten: Rotor nut 1
NOTE:
Tighten the rotor nut 1 while holding the
rotor 2 with a sheave holder 3.
 Do not allow the sheave holder to touch the
projection on the rotor.
7. Install: Crankcase cover (left)
NOTE:
 Pass the starter motor lead 1 and neutral
switch lead 2 into the crankcase cover
groove as shown.
 Fasten the starter motor lead with the clamp 3.
Sheave holder:
YS-01880-A/90890-01701
T R..48 Nm (4.8 m · kg, 35 ft · lb)
3
1
2

4 - 51
ENGCRANKCASE AND CRANKSHAFT
CRANKCASE AND CRANKSHAFT
E
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
T R..10 Nm (1.0 m •
kg, 7.2 ft • Ib)
LT
4
4 3
4
4
5 6
7
9
8
8
12
5 6
4
Extent of removal Order Part name Q ’ty Remarks
CRANKCASE SEPARATION
AND CRANKSHAFT REMOVAL
Preparation for removal Seat assembly and fuel tank
Exhaust pipe
Air filter case and bottom cover Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section.
Carburetor Refer to “CARBURETOR ” section.
Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT ”
section in the CHAPTER 3.
Drive sprocket Refer to “ENGINE REMOVAL ”.
Cylinder head Refer to “CYLINDER HEAD ” section.
Cylinder and piston Refer to “CYLINDER AND PISTON ” sec-
tion.
Primary driven gear Refer to “CLUTCH ” section.

4 - 52
ENGCRANKCASE AND CRANKSHAFT
E
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
T R..10 Nm (1.0 m •
kg, 7.2 ft • Ib)
LT
4
4 3
4
4
5 6
7
9
8
8
12
5 6
4
Extent of removal: 1 Timing chain removal
2 Crankcase separation
3 Crankshaft removal
Extent of removal Order Part name Q ’ty Remarks
Oil pump drive gear, oil pump and
oil strainer Refer to
“OIL PUMP ” section.
Shift shaft Refer to “SHIFT SHAFT ” section.
Rotor and starter clutch Refer to “AC MAGNETO AND
STARTER CLUTCH ” section.
1 Timing chain 1
2 Timing chain guide (intake) 1
3 Neutral switch 1
4 Bolt [40 mm (1.6 in)] 7
5 Bolt [60 mm (2.4 in)] 2
6 Bolt [75 mm (3.0 in)] 1
7 Left crankcase 1
8 Dowel pin 2
9 Crankshaft 1
2
1
3