2006 YAMAHA TTR50 tow

1 - 9
GEN
INFO
CONTROL FUNCTIONS
EC155001
THROTTLE GRIP
The throttle grip 1 is located on the right han-
dlebar; it accelerates or decelerates the
engine. For acceleration, turn the grip toward
you; for deceleration, turn it away from you.
1
EC156000
FRONT BRAKE LEVER
The front brake lever 1 is located on the right
handlebar. Pull it toward the handlebar to acti-
vate the front brake.
1
EC157000
REAR BRAKE PEDAL
The rear brake pedal 1 is located on the right
side of the machine. Press down on the brake
pedal to activate the rear brake.
1
FUEL COCK
The fuel cock supplies fuel from the tank to
carburetor while filtering the fuel. The fuel cock
has the three positions:
OFF: With the lever in this position, fuel will not flow. Always return the lever to this posi-
tion when the engine is not running.
ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done
with the lever in this position.
RES: This indicates reserve. If you run out of fuel while riding, move the lever to this
position. FILL THE TANK AT THE FIRST
OPPORTUNITY. BE SURE TO SET
THE LEVER TO “ON ” AFTER REFUEL-
ING.

GEN
INFO
1 - 13
CLEANING AND STORAGE
EC1B0000
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will
enhance its appearance, maintain good overall
performance, and extend the life of many com-
ponents.
1. Before washing the machine, block off the
end of the exhaust pipe to prevent water
from entering.
2. If the engine is excessively greasy, apply some degreaser to it with a paint brush. Do
not apply degreaser to the chain, sprock-
ets, or wheel axles.
3. Rinse the dirt and degreaser off with a gar- den hose; use only enough pressure to do
the job.
CAUTION:
Excessive hose pressure may cause water
seepage and contamination of wheel bear-
ings, front forks, brakes and transmission
seals. Many expensive repair bills have
resulted from improper high pressure
detergent applications such as those avail-
able in coin-operated car washers.
4. After the majority of the dirt has been hosed off, wash all surfaces with warm
water and a mild detergent. Use an old
toothbrush to clean hard-to-reach places.
5. Rinse the machine off immediately with clean water, and dry all surfaces with a soft
towel or cloth.
6. Immediately after washing, remove excess water from the chain with a paper towel
and lubricate the chain to prevent rust.
7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and
glossy.
8. Automotive wax may be applied to all
painted or chromed surfaces. Avoid combi-
nation cleaner-waxes, as they may contain
abrasives.
9. After completing the above, start the engine and allow it to idle for several min-
utes.
EC182001
STORAGE
If your machine is to be stored for 60 days or
more, some preventive measures must be
taken to avoid deterioration. After cleaning the
machine thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines, and the car-
buretor float bowl.
2. Remove the spark plug, pour a tablespoon of SAE 10W-30 motor oil in the spark plug
hole, and reinstall the plug. Set the engine
stop switch to “”, turn the engine over
several times with starter. (This will coat
the cylinder walls with oil.)
3. Remove the drive chain, clean it thoroughly with solvent, and lubricate it. Reinstall the
chain or store it in a plastic bag tied to the
frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off the ground.
6. Tie a plastic bag over the exhaust pipe out-
let to prevent moisture from entering.
7. If the machine is to be stored in a humid or salt-air environment, coat all exposed
metal surfaces with a film of light oil. Do not
apply oil to rubber parts or the seat cover.
NOTE:
Make any necessary repairs before the
machine is stored.

4 - 24
ENGCYLINDER AND PISTON
REMOVAL POINTS
Piston
1. Remove:Piston pin clips 1
 Piston pin 2
 Piston 3
NOTE:
Before removing the piston pin clip, cover the
crankcase opening with a clean towel or rag
to prevent the clip from falling into the crank-
case cavity.
 Before removing each piston pin, deburr the
clip groove and pin hole area. If the piston
pin groove is deburred and the piston pin is
still difficult to remove, use the piston pin
puller set 4.
Piston pin puller set:
YU-01304/90890-01304
Piston ring
1. Remove:
Piston rings
NOTE:
Spread the end gaps apart while at the same
time lifting the piston ring over the top of the
piston crown, as shown in the illustration.
INSPECTION
Cylinder and piston
1. Inspect:
Cylinder and piston walls
Vertical scratches → Replace cylinder
and piston.

4 - 57
ENGSHIFT FORK, SHIFT CAM AND TRANSMISSION
2. Install:Main axle assembly 1
 Drive axle assembly 2
 Shift fork 2 “R ” 3
 Shift fork 1 “L ” 4
 Shift cam 5
 Guide bar 6
NOTE:
The embossed marks on the shift forks
should face towards the right side of the
engine and be in the following sequence:
“R ”, “L ”.
 Mesh the shift fork 2 “R ” with the 3rd wheel
gear on the drive axle.
 Mesh the shift fork 1 “L ” with the 2nd pinion
gear on the main axle.
3. Check: Shifter operation
 Transmission operation
Unsmooth operation → Repair.
3
4
5 1
6
2

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