2006 YAMAHA TTR50 brake

5 - 5
CHASFRONT WHEEL AND REAR WHEEL
EC593000
REMOVAL POINTS
EC513201
Wheel bearing (if necessary)
1. Remove:Bearing 1
NOTE:
Remove the bearing using a general bearing
puller 2.11
2
1
EC594000
INSPECTION
EC514100
Wheel
1. Measure: Wheel runout
Out of limit → Repair/replace.
Brake lining
1. Inspect: Brake shoe lining surface
Glazed areas → Polish.
Use coarse sand paper.
NOTE:
After polishing, wipe the polished particles with
a cloth.
Wheel runout limit: Radial 1: 2.0 mm (0.08 in)
Lateral 2: 2.0 mm (0.08 in)
2. Measure:
Brake shoe lining thickness
Out of specification → Replace.
NOTE:
Replace the brake shoes and springs as a set
if either is worn to the limit.
Brake shoe lining thickness
a:
Standard: Front: 3.5 mm (0.14 in)
Rear: 3.5 mm (0.14 in)
Limit: 1.5 mm (0.06 in)

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 - 7
CHAS
Front wheel
1. Install:Wheel bearing 1
 Spacer 2
 Wheel bearing 3
 Oil seal 4
NOTE:
Apply the lithium soap base grease on the oil
seal lip when installing.
 Use a socket that matches the outside diam-
eter of the race of the bearing.
 Left side of wheel bearing shall be installed
first.
 Install the oil seal with its manufacture ’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
New
2. Install: Front wheel
NOTE:
Make sure that the slot a on the brake shoe
plate with the stopper b on the front fork inner
tube.
b
a
3. Install: Spring 1
 Pin 2
NOTE:
Install the spring 1 with its smaller diameter
end a towards the pin 2.1
2
a
1
2
FRONT WHEEL AND REAR WHEEL

5 - 8
CHAS
Rear wheel
1. Install:Wheel bearing 1
 Spacer 2
 Wheel bearing 3
 Oil seal 4
NOTE:
Apply the lithium soap base grease on the oil
seal lip when installing.
 Install the wheel bearing with seal facing out-
ward.
 Use a socket that matches the outside diam-
eter of the race of the bearing.
 Right side of bearing shall be installed first.
 Install the oil seal with its manufacture ’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
New
2. Install: Rear wheel sprocket 1
 Bolts (rear wheel sprocket) 2
 Nuts (rear wheel sprocket) 3
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
1
2 4
1
3
2 3T R..25 Nm (2.5 m · kg, 18 ft · lb)
3. Install:
Rear wheel
NOTE:
Make sure that the slot a on the brake shoe
plate with the stopper b on the swingarm.
a
b
FRONT WHEEL AND REAR WHEEL

5 - 10
CHASHANDLEBAR
HANDLEBAR
Extent of removal: 1 Handlebar removal
Extent of removal Order Part name Q ’ty Remarks
HANDLEBAR REMOVAL
1Brake lever 1
2 Brake cable 1 Disconnect at the lever side.
3 Start switch 1
4 Throttle cable 1 Disconnect at the throttle side.
5 Right grip 1
6 Tube guide 1
7 Engine stop switch 1
8Left grip 1
9Starter lever 1
10 Handlebar 1
11 Main switch 1
1