2006 YAMAHA TTR50 torque

CONTENTS
CHAPTER 1
GENERAL INFORMATION
DESCRIPTION ............................................1-1
MACHINE IDENTIFICATION ......................1-2
IMPORTANT INFORMATION .....................1-3
CHECKING OF CONNECTION ..................1-5
SPECIAL TOOLS .......................................1-6
CONTROL FUNCTIONS .............................1-8
FUEL .........................................................1-11
STARTING AND OPERATION .................1-12
CLEANING AND STORAGE ....................1-13
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................2-1
MAINTENANCE SPECIFICATIONS ...........2-4
GENERAL TORQUE
SPECIFICATIONS ....................................2-16
DEFINITION OF UNITS ............................2-16
CABLE ROUTING DIAGRAM ..................2-17
CHAPTER 3
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS ....................3-1
PRE-OPERATION INSPECTION AND
MAINTENANCE ..........................................3-3
ENGINE .......................................................3-4
CHASSIS ..................................................3-14
ELECTRICAL ............................................3-23

SPEC
2 - 10
Part to be tightened Thread size Q
’ty Tightening torque
Remarks
Nm m ·kg ft ·lb
Cylinder head nut M8 × 1.25 4 22 2.2 16
Cylinder head bolt M6 × 1.0 2 10 1.0 7.2
Spark plug M10 × 1.0 1 13 1.3 9.4
Camshaft sprocket cover bolt M6 × 1.0 2 10 1.0 7.2
Tappet cover M45 × 1.5 2 18 1.8 13
Exhaust pipe stud bolt M6 × 1.0 2 7 0.7 5.1
Rotor nut M12 × 1.25 1 48 4.8 35
Timing chain guide stopper M6 × 1.0 2 10 1.0 7.2
LT
Valve clearance adjust screw locknut M5 × 0.5 2 7 0.7 5.1
Camshaft sprocket M8 × 1.25 1 26 2.6 19
Camshaft bearing retainer M6 × 1.0 1 10 1.0 7.2
LT
Timing chain tensioner cap bolt M8 × 1.25 1 8 0.8 5.8
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Oil pump assembly M6 × 1.0 2 7 0.7 5.1
LT
Engine oil drain bolt M12 × 1.5 1 20 2.0 14
Intake manifold (cylinder head side) M6 × 1.0 2 7 0.7 5.1
Intake manifold (carburetor side) M6 × 1.0 2 7 0.7 5.1
Carburetor heater M8 × 1.25 1 3 0.3 2.2
Clamp (air filter joint) M4 × 0.7 1 2 0.2 1.4
Exhaust pipe M6 × 1.0 2 7 0.7 5.1
Muffler M8 × 1.25 1 38 3.8 27
Muffler cover M6 × 1.0 4 7 0.7 5.1
Spark arrester M6 × 1.0 3 10 1.0 7.2
Crankcase M6 × 1.0 10 10 1.0 7.2
Crankcase cover (left) M6 × 1.0 8 10 1.0 7.2
Drive sprocket cover M6 × 1.0 2 7 0.7 5.1
Timing plug M14 × 1.5 1 7 0.7 5.1
Crankshaft end cover M32 × 1.5 1 7 0.7 5.1
Crankcase cover (right) M6 × 1.0 9 10 1.0 7.2
Clutch adjuster locknut M8 × 1.25 1 6 0.6 4.3
Cylinder head stud bolt M8 × 1.25 4 13 1.3 9.4
Starter clutch and rotor M6 × 1.0 3 14 1.4 10 Stake
Clutch housing nut M14 × 1.0 1 70 7.0 50
Pressure plate M5 × 0.8 3 5 0.5 3.6
Primary driven gear M14 × 1.0 1 70 7.0 50
Stopper bolt M8 × 1.25 1 23 2.3 17
LT
Shift pedal M6 × 1.0 1 10 1.0 7.2
Pickup coil M6 × 1.0 2 10 1.0 7.2
LT
Stator assembly M6 × 1.0 3 10 1.0 7.2LT
Neutral switch M10 × 1.25 1 18 1.8 13
MAINTENANCE SPECIFICATIONS

SPEC
2 - 13
NOTE:
1.First, tighten the ring nut approximately 38 Nm (3.8 m · kg, 27 ft · lb) by using the lower ring nut
wrench and turn the steering right and left a few times; then loosen the lower ring nut completely.
2.Retighten the lower ring nut 4 Nm (0.4 m · kg, 2.9 ft · lb).
Part to be tightened Thread size Q
’ty Tightening torque
Nm m ·kg ft ·lb
Engine mounting: Engine and frame (front upper side) M8 × 1.25 1 30 3.0 22
Engine and frame (rear upper side) M8 × 1.25 1 30 3.0 22
Engine and frame (rear lower side) M10 × 1.25 1 48 4.8 35
Engine bracket and frame M8 × 1.25 2 30 3.0 22
Front wheel axle and front wheel axle nut M12 × 1.25 1 35 3.5 25
Front brake camshaft lever and front brake
camshaft M6
× 1.0 1 7 0.7 5.1
Front brake cable locknut M8 × 1.25 1 16 1.6 11
Front wheel nipple (spoke) —28 2 0.2 1.4
Rear wheel nipple (spoke) —28 2 0.2 1.4
Rear wheel axle and rear wheel axle nut M12 × 1.25 1 60 6.0 43
Rear brake camshaft lever and rear brake
camshaft M6
× 1.0 1 7 0.7 5.1
Rear wheel drive hub and rear wheel sprocket M8 × 1.25 4 25 2.5 18
Drive chain puller locknut M6 × 1.0 2 7 0.7 5.1
Upper bracket and handlebar M10 × 1.25 2 32 3.2 23
Steering stem nut M22 × 1.0 1 110 11.0 80
Lower ring nut M25 1 Refer to NOTE.
Upper bracket and lower bracket M10 × 1.25 2 32 3.2 23
Inner tube assembly and front fork guard M6 × 1.0 4 7 0.7 5.1
Pivot shaft and nut M10 × 1.25 1 35 3.5 25
Rear shock absorber and frame M10 × 1.25 1 30 3.0 22
Rear shock absorber and swingarm M10 × 1.25 1 30 3.0 22
Drive chain guide and swingarm M6 × 1.0 2 7 0.7 5.1
Drive chain support and swingarm M6 × 1.0 3 7 0.7 5.1
Drive chain guard and swingarm M6 × 1.0 2 7 0.7 5.1
Upper bracket and front fender M6 × 1.0 2 7 0.7 5.1
Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1
Fuel tank and frame M6 × 1.0 2 7 0.7 5.1
Air scoop and fuel tank M6 × 1.0 2 7 0.7 5.1
Seat assembly and frame M6 × 1.0 2 7 0.7 5.1
Seat and rear fender M6 × 1.0 3 7 0.7 5.1
Seat and side covers M6 × 1.0 4 7 0.7 5.1
Footrest, under cover and engine M8 × 1.25 4 30 3.0 22
Sidestand and sidestand bracket M10 × 1.25 1 40 4.0 29
MAINTENANCE SPECIFICATIONS

SPEC
2 - 16
EC220001
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
A
(Nut) B
(Bolt) TORQUE
SPECIFICATION
Nm m ·kg ft ·lb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm 6 mm
8 mm
10 mm
12 mm
14 mm
16 mm 6
15
30
55
85
130 0.6
1.5
3.0
5.5
8.5
13 4.3
11
22
40
61
94
Unit Read Definition Measure
mm
cm millimeter
centimeter 10
-3 meter
10-2 meter Length
Length
kg kilogram 10
3 gram Weight
N Newton 1 kg × m/sec
2 Force
Nm
m  kg Newton meter
Meter kilogram N
× m
m × kg Torque
Torque
Pa Pascal N/m
2Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3 Liter
Cubic centimeter
—
—Volume or capacity
Volume or capacity
r/min Revolution per minute —Engine speed
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS

3 - 21
INSPADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
 Remove the special washer 6.
 Remove the upper ring nut 7, and rubber
washer 8.
 Loosen the lower ring nut 9 using the
steering nut wrench 0.
Steering nut wrench:
YU-33975/90890-01403
 Tighten the lower ring nut 9 using steer-
ing nut wrench 0 and turn the steering
right and left a few times.
NOTE:
Set the torque wrench to the steering nut
wrench so that they form a right angle.
Steering nut wrench: YU-33975/90890-01403
T R..
Lower ring nut (initial tightening):38 Nm (3.8 m  kg, 27 ft  lb)
 Loosen the lower ring nut completely.
 Retighten the lower ring nut using the
steering nut wrench.
WARNING
Avoid over-tightening.
T R..
Ring nut (final tightening):
4 Nm (0.4 m  kg, 2.9 ft  lb)
 Check the steering stem by turning it lock
to lock. If there is any binding, remove the
steering stem assembly and inspect the
steering bearings.
 Install the rubber washer 8, upper ring nut
7 and special washer 6.
NOTE:
Tighten the upper ring nut until it contacts
the rubber washer.
 Insert the special washer pawls a into the
slots b. If the slots are not aligned, tighten
the upper ring nut for alignment.
 Install the upper bracket, steering stem nut
and upper bracket bolts, handlebar.
T R..
Steering stem nut:
110 Nm (11.0 m  kg, 80 ft  lb)
Upper bracket bolt: 32 Nm (3.2 m  kg, 23 ft  lb)
7
8
\b
6
0
\b
0
\b
86
7
a
a
b

4 - 14
ENGCYLINDER HEAD
CAUTION:
.Do not turn the crankshaft during instal-
lation of the camshaft. Damage or
improper valve timing will result.
 Remove the safety wire from the timing
chain.
4. Install:
Timing chain tensioner
Installation steps:
 Remove the tensioner cap bolt 1 and
spring 2.
 Release the timing chain tensioner one-
way cam 3 and push the tensioner rod 4
all the way in.
 Install the tensioner with a new gasket 5
onto the cylinder.
T R..
Timing chain tensioner bolt: 10 Nm (1.0 m  kg, 7.2 ft  lb)
 Install the spring 2 and cap bolt 1.
 Tighten the bolt (with O-ring) to the speci-
fied torque.
T R..
Cap bolt:
8 Nm (0.8 m  kg, 5.8 ft  lb)
5. Install:
Washer
 Camshaft sprocket bolt 1
NOTE:
Install the bolt 1 while holding the rotor nut
with a wrench.
6. Check:
Rotor “I” mark
Align with the crankcase cover stationary
pointer.
 Valve clearance
Out of specification → Adjust.
Refer to the “VALVE CLEARANCE
ADJUSTMENT ” section in CHAPTER 3.
1
T R..26 Nm (2.6 m · kg, 19 ft · lb)