2006 YAMAHA TTR50 warning

5 - 3
CHASFRONT WHEEL AND REAR WHEEL
REAR WHEEL AND REAR BRAKE
Extent of removal:1 Rear wheel removal
2 Wheel bearing removal
3 Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q ’ty Remarks
REAR WHEEL REMOVAL
WARNING
Support the machine securely so
there is no danger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
1 Rear brake adjuster 1
2Pin 1
3Spring 1
4 Drive chain locknut 2
5 Wheel axle nut 1
6 Rear wheel axle 1
7 Drive chain puller 2
8 Rear wheel 1
9 Collar (left) 1
10 Brake shoe plate assembly 1
2
1
3

5 - 6
CHAS
ASSEMBLY AND INSTALLATION
Brake shoe plate assembly
1. Install:Wear indicator plate 1
NOTE:
When installing the wear indicator plate to the
brake camshaft align the projection a on the
wear indicator plate with the slots b on the
brake camshaft.
2. Install:
Brake camshaft lever 1
NOTE:
Align the punch mark a on the brake camshaft
lever with the punch mark b on the brake
camshaft.
b
1
a
1a
b
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
3. Install:
Spring 1
 Brake shoes 2
NOTE:
Apply the lithium soap base grease on the
pivot pin.
WARNING
Do not apply grease to the brake shoe lin-
ings.
1
2
2
LS
New
New
FRONT WHEEL AND REAR WHEEL

5 - 11
CHAS
REMOVAL POINTS
Handlebar grip
1. Remove:Handlebar grip 1
NOTE:
Blow in air between the handlebar or tube
guide and the grip. Then remove the grip
which has become loose.
INSPECTION
Handlebar
1. Inspect:
Handlebar 1
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar.
ASSEMBLY AND INSTALLATION
Handlebar
1. Install:
Starter lever 1
NOTE:
Be sure to align the flat section a of the starter
lever 1 with the flat section b of the bracket
on the handlebar
1
a
b 1
2. Install:
Left grip 1
Apply the adhesive to the handlebar 2.
NOTE:
Before applying the adhesive, wipe off
grease or oil on the handlebar surface a
with a lacquer thinner.
 Be sure to align the projection “L ” b on the
left grip with the punch mark c on the han-
dlebar.
HANDLEBAR

5 - 12
CHAS
3. Install:Engine stop switch 1
NOTE:
Align the tab a on the engine stop switch
holder with the hole b in the handlebar.
a
b
1
4. Install:
Start switch 1
NOTE:
Align the mating surfaces a of the start switch
with the punch mark b on the handlebar.
1
b a
5. Install:
Throttle cable 1
NOTE:
After installing the throttle cable, insert the rub-
ber seal and throttle cable guide completely
into the hole in the start switch housing, mak-
ing sure that the rubber seal flange a, throttle
cable guide flange b, and housing c contact
each other.
a
c b
1
6. Install:
Screws (start switch) 1
WARNING
After tightening the screws, check that the
throttle grip 2 moves smoothly. If it does
not, retighten the screws for adjustment.
2
1
HANDLEBAR

5 - 13
CHASSTEERING AND FRONT SUSPENSION
EC560000
STEERING AND FRONT SUSPENSION
Extent of removal:1 Lower bracket removal
2 Bearing removal
3 Inner table assembly removal
Extent of removal Order Part name Q ’ty Remarks
STEERING AND FRONT SUS-
PENSION REMOVAL
WARNING
Support the machine securely so
there is no danger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL ” section.
Handlebar Refer to “HANDLEBAR ” section.
1 Cable guide 1
2 Reflector 2 For Canada
3 Steering stem nut 1
4 Upper bracket 1
5 Special washer 1 Use special tool. Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT ” section in
the CHAPTER 3.
6 Upper ring nut 1
7 Rubber washer 1
213

5 - 15
CHAS
EC563000
REMOVAL POINTS
EC563202
Ring nut
1. Remove:Lower ring nut 1
Use the steering nut wrench 2.
WARNING
Support the steering shaft so that it may
not fall down.
Steering nut wrench:
YU-33975/90890-01403
2
1
Bearing race
1. Remove:
Bearing race 1
Remove the bearing race using long rod
2 and the hammer.
2. Remove:
Bearing race 1
Use the floor chisel 2.
CAUTION:
Take care not to damage the steering shaft
thread.
ASSEMBLY AND INSTALLATION
1. Install: Front fork assembly
NOTE:
When installing an inner tube assembly in the
lower bracket, align the projection a on the
inner tube assembly with the indentation b in
the lower bracket.
b
a
b
a
STEERING AND FRONT SUSPENSION

5 - 17
CHASSWINGARM
EC570000
SWINGARM
Extent of removal:1 Swingarm removal
2 Rear shock absorber removal
Extent of removal Order Part name Q ’ty Remarks
SWINGARM REMOVAL
WARNING
Support the machine securely so
there is no danger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Seat assembly Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section
in the CHAPTER 4.
Rear wheel Refer to “FRONT WHEEL AND REAR
WHEEL ” section.
Drive chain
1 Rear shock absorber 1
2 Drive chain guard 1
3 Drive chain support 1
4 Drive chain guide 1
1
2

6 - 7
–+ELEC
EC624000
COUPLERS AND LEADS CONNECTION
INSPECTION
1. Check:
Couplers and leads connection
Rust/dust/looseness/short-circuit →
Repair or replace.
STARTER MOTOR OPERATION
1. Connect the positive battery terminal 1
and starter motor lead 2 with a jumper
lead 3.
Not operate → Repair or replace the
starter motor.
WARNING
 A wire that is used as a jumper lead must
have at least the same capacity or more
as that of the a battery lead, otherwise the
jumper lead may burn.
 This check is likely to produce sparks,
therefore make sure nothing flammable is
in the vicinity.
ELECTRIC STARTING SYSTEM