2006 YAMAHA TTR50 fuel

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 - 23
SPECCABLE ROUTING DIAGRAM
ÎFasten the AC magneto lead and wire harness
at the white tape with a plastic locking tie. Cut off
the excess end of the plastic locking tie, and
then face the cut end of the tie inward. The cut
end of the plastic locking tie should be 5 mm
(0.20 in) or less.
Ï Place the cover on the starter relay, install the
cover to the frame, and then connect the starter
relay coupler. Ð
Install the wire harness so that the leads that
branch off from the wire harness are routed
downward.
Ñ Make sure that the leads that branch off from the
wire harness are routed alongside the wire har-
ness in the area shown in the illustration.
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 - 4
INSPADJ
ENGINE/THROTTLE CABLE ADJUSTMENT
EC350000
ENGINE
THROTTLE CABLE ADJUSTMENT
1. Check:
Throttle grip free play a
Out of specification → Adjust.
Throttle grip free play
a:
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Adjust:
Throttle grip free play
Throttle grip free play adjustment steps:
Carburetor side
NOTE:
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
 Remove the seat assembly and air scoop
(right).
Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section in
the CHAPTER 4.
 Pull back the adjuster cover.
 Loosen the locknut 1 on throttle cable.
 Turn the adjuster 2 in or out until the
specified free play is obtained.
Turning in b → Free play is increased.
Turning out c → Free play is decreased.
 Tighten the locknut.
 Slide the adjuster cover to its original posi-
tion.
 Install the seat assembly and air scoop
(right).
NOTE:
If the specified throttle cable free play can-
not be obtained on the carburetor side of the
cable, use the adjusting nut on the handle-
bar side.
WARNING
After adjusting, turn the handlebar to
right and left and make sure that the
engine idling does not run faster.
c
b
1
2

3 - 6
INSPADJ
 Tighten the locknut.
WARNING
Particularly for a beginner rider, the
speed limiter should be screwed in
completely. Screw it out little by little as
their riding technique improves. Never
remove the speed limiter for a begin-
ning rider.
 For proper throttle lever operation do
not turn out the adjuster more than
25.0 mm (0.98 in). Also, always adjust
the throttle lever free play to 3 ~ 5 mm
(0.12 ~ 0.20 in).
AIR FILTER CLEANING
NOTE:
Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.
CAUTION:
Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid
wear and possible engine damage.
1. Remove: Seat assembly
 Air scoop (left)
Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section in
the CHAPTER 4.
 Air filter case cover 1
 Air filter element
1
SPEED LIMITER ADJUSTMENT/AIR FILTER CLEANING

3 - 25
INSPADJ
BATTERY INSPECTION AND CHARGING
NOTE:
Since MF batteries are sealed, it is not possi-
ble to check the charge state of the battery by
measuring the specific gravity of the electro-
lyte. Therefore, the charge of the battery has to
be checked by measuring the voltage at the
battery terminals.
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.
3. Remove:
Battery band
 Battery
Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section in
the CHAPTER 4.
1
a
4. Measure:
Battery charge
Measurement steps:
 Connect a pocket tester 1 to the battery
terminals.
Tester positive probe → battery positive
terminal
Tester negative probe → battery negative
terminal
NOTE:
 The charge state of an MF battery can be
checked by measuring its open-circuit volt-
age (i.e., the voltage when the positive ter-
minal is disconnected).
 No charging is necessary when the open-
circuit voltage equals or exceeds 12.8 V.
1