2006 YAMAHA TTR50 transmission

6. When going for riding, be sure to be withyour family.
Never go alone.
7. Before riding the machine, ask your par-ents to check the machine very carefully.
8. Don ’t touch the areas shown, or you ’ll get
burnt in the hand.
9. Don ’t touch rotating or moving parts.
10. Before starting the engine, be sure to shift
the transmission into neutral.

CHAPTER 4ENGINE
FRONT FENDER, SEAT ASSEMBLY
AND FUEL TANK .......................................4-1
MUFFLER ...................................................4-3
CARBURETOR ...........................................4-4
CYLINDER HEAD .....................................4-10
CAMSHAFT AND ROCKER ARMS .........4-15
VALVES AND VALVE SPRINGS .............4-18
CYLINDER AND PISTON .........................4-23
CLUTCH ....................................................4-29
SHIFT SHAFT ...........................................4-37
OIL PUMP .................................................4-39
AC MAGNETO AND
STARTER CLUTCH ..................................4-42
ENGINE REMOVAL ..................................4-47
CRANKCASE AND CRANKSHAFT .........4-51
SHIFT FORK, SHIFT CAM AND
TRANSMISSION .......................................4-54
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL ........5-1
HANDLEBAR ............................................5-10
STEERING AND
FRONT SUSPENSION .............................5-13
SWINGARM ..............................................5-17
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS AND
WIRING DIAGRAM .....................................6-1
IGNITION SYSTEM .....................................6-2
ELECTRIC STARTING SYSTEM ...............6-6
CHARGING SYSTEM ...............................6-14
CARBURETOR HEATING SYSTEM ........6-16
MAINTENANCE RECORD .......................6-20

GEN
INFO
ALLGEMEINES
FAHRZEUGBESCHREIBUNG
1 Motorstoppschalter
2 Chokehebel
3 Zündschloss
4 Handbremshebel
5 Gasdrehgriff
6 Starterschalter
7 Tankverschluss
8 Kraftstofftank
9 Fußbremshebel
0 Kraftstoffhahn
A Luftfilter
B Antriebskette
C Fußschalthebel
D Teleskopgabel
E Reflektor (Canada)
HINWEIS:
 Die Abbildungen in vorliegender Anleitung
können leicht vom eigentlichen Modell
abweichen und dienen daher lediglich zur
Bezugnahme.
 Änderungen an Design und technischen
Daten jederzeit vorbehalten.
DESCRIPTION
FAHRZEUGBESCHREIBUNG
RENSEIGNEMENTS
GENERAUX
DESCRIPTION
1 Coupe-circuit du moteur
2 Levier de starter
3 Contacteur à clé
4 Levier de frein avant
5 Poignée des gaz
6 Contacteur du démarreur
7 Bouchon du réservoir de carburant
8 Réservoir de carburant
9 Pédale de frein arrière
0 Robinet de carburant
A Filtre à air
B Chaîne de transmission
C Sélecteur
D Fourche
E Réflecteur (Canada)
N.B.:
 Votre moto diffère peut-être partiellement de
celle montrée sur ces photos.
 La conception et les caractéristiques peuvent être
modifiées sans préavis.
1 - 1
1
2
3
4
5
6

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GEN
INFO
CONTROL FUNCTIONS
EC150000
CONTROL FUNCTIONS
MAIN SWITCH
Functions of the respective switch positions
are as follows:
ON: The engine can be started only at this
position.
OFF: All electrical circuits are switched off. The key can be removed in this position.
ENGINE STOP SWITCH
Make sure that the engine stop switch 1 is
positioned to “”. The engine stop switch has
been equipped to ensure safety in an emer-
gency such when the machine is up set or
trouble takes place in the throttle system. The
engine will not start or run when the engine
stop switch is turned to “”.
START SWITCH
The start switch 1 is located on the right han-
dlebar. Push this switch to crank the engine
with the starter.
1
SHIFT PEDAL
The gear ratios of the constant-mesh 3 speed
transmission are ideally spaced. The gears
can be shifted by using the shift pedal 1 on
the left side of the engine.
WARNING
When starting out on the machine, shift the
transmission into 1st after pulling in the
front brake lever and closing the throttle
grip.
3
2
1
N
1

GEN
INFO
1 - 12
STARTING AND OPERATION
STARTING AND OPERATION
CAUTION:
Prior to operating the machine, perform
steps listed in pre-operation check list.
WARNING
Never start your engine or let it run for any
length of time in a closed area. The exhaust
fumes are poisonous and can cause loss of
consciousness and death within a short
time. Always operate your machine in an
area with adequate ventilation.
STARTING A COLD ENGINE
WARNING
Before starting the engine, be sure to shift
the transmission into neutral.
NOTE:
 This model is equipped with an ignition cir-
cuit cut-off system. In case of electric start-
ing, the engine can be started only when the
transmission is in neutral.
 If the engine fails to start by pushing the start
switch, release the switch, wait a few sec-
onds, and then try again. Each starting
attempt should be as short as possible to
preserve the battery. Do not crank the
engine more than 10 seconds on any one
attempt.
1. Turn the fuel cock to “ON ”.
2. Turn the main switch to “ON ”.
3. Shift the transmission into neutral.
4. Operate the starter (choke) and completely close the throttle grip.
5. Slide the “engine stop ” switch to the “”.
6. Start the engine by pushing the start switch.
7. After the engine starts, warm up for one or
two minutes. Make sure the stater (choke) is
returned to the original position before riding. STARTING A WARM ENGINE
To start a warm engine, refer to the
“START-
ING A COLD ENGINE ” section. The starter
(choke) should not be used. The throttle
should be opened slightly.
CAUTION:
See “Engine break-in Section ” prior to
operating engine for the first time.
WARMING UP
To get maximum engine life, always “warm-up ”
the engine before starting off. Never accelerate
hard with a cold engine! To see whether or not
the engine is warm, see if it responds to throttle
normally with the stater (choke) turned off.
WARNING
Before starting off, be sure to turn up or
remove the side stand.
Failure to retract the side stand completely
can result in a serious accident when you
try to turn a corner.
ENGINE BREAK-IN
Break-in is important to better fit the moving
and sliding parts as well as the installed parts.
It is also important to accustom the rider to the
machine better.
Avoid full-throttle run on a new machine for the
first 5 hours.
After the trial run, check for loose parts, oil
leakage and other problems.
Make full inspection and adjustment especially of
slack cables and drive chain and loose spokes.
CAUTION:
After the break-in period, check every fit-
ting and fastener for looseness.
If any loose is found, retighten it securely.

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.

GEN
INFO
NETTOYAGE ET REMISAGE
NETTOYAGE ET REMISAGE
NETTOYAGE
Un nettoyage fr équent de la moto pr éservera son
apparence, maintiendra ses bonnes performances et
augmentera la dur ée de vie de nombre de ses com-
posants.
1. Avant de nettoyer la moto, couvrir la sortie du
tube d ’échappement pour éviter toute p én étra-
tion d ’eau.
2. Si le moteur est fortement encrass é, appliquer
un peu de d égraissant à l ’aide d ’un pinceau.
Eviter tout contact avec la cha îne, les pignons
ou les axes de roue.
3. Rincer la salet é et le d égraissant au tuyau
d ’arrosage, en utilisant juste la pression n éces-
saire.
ATTENTION:
Une pression excessive risque de causer des infil-
trations d ’eau dans les roulements des roues, la
fourche avant, les freins et les joints de la trans-
mission. L ’emploi abusif de d étergents sous
forte pression, tels que ceux utilis és dans les por-
tiques de lavage automatique, est nuisible à la
moto et peut entra îner des r éparations on éreu-
ses.
4. Apr ès avoir élimin é le plus gros de la salet é au
tuyau d ’arrosage, laver toutes les surfaces à
l ’ eau chaude savonneuse (employer un d éter-
gent doux). Une vieille brosse à dents convient
parfaitement pour nettoyer les parties difficiles
d ’acc ès.
5. Rincer imm édiatement la moto à l ’eau claire et
s é cher toutes les surfaces à l ’aide d ’une peau de
chamois, d ’une serviette ou d ’un chiffon doux
absorbant.
6. S écher imm édiatement la cha îne à l ’aide d ’une
serviette en papier et la graisser afin de la prot é-
ger contre la rouille.
7. Nettoyer la selle à l ’aide d ’un produit de net-
toyage pour similicuir afin de conserver intacts
la souplesse et le lustre de la housse.
8. Une cire pour carrosserie peut être utilis ée pour
toutes les surfaces peintes et chrom ées. Ne pas
employer de cires d étergentes car elles contien-
nent souvent des abrasifs.
9. Lorsque le nettoyage est termin é, mettre le
moteur en marche et le laisser tourner au ralenti
pendant plusieurs minutes. REMISAGE
Si la moto doit
être remis ée pour 60 jours ou plus, il
convient de prendre certaines pr écautions pour évi-
ter tout endommagement. Apr ès un nettoyage com-
plet de la moto, la pr éparer comme suit pour le
remisage:
1. Vidanger le r éservoir de carburant, le circuit de
carburant et la cuve à niveau constant du carbu-
rateur.
2. D époser la bougie, verser une cuill ère à soupe
d ’huile moteur SAE 10W-30 dans le trou de
bougie et replacer la bougie. Placer le coupe-
circuit du moteur sur “”, mettre le moteur en
marche plusieurs fois à l ’aide du d émarreur.
(Ceci tapissera d ’huile les parois du cylindre.)
3. D époser la cha îne de transmission, la nettoyer
soigneusement à l ’aide d ’un solvant puis la
graisser. Remettre en place la cha îne ou la con-
server dans un sachet en plastique (attach é au
cadre pour éviter de l ’égarer).
4. Lubrifier tous les c âbles de commande.
5. Placer un support sous le cadre afin de sur éle-
ver les deux roues.
6. Couvrir la sortie du tuyau d ’échappement d ’un
sachet en plastique pour emp êcher la p én étra-
tion d ’humidit é.
7. Si la moto doit être remis ée dans un lieu tr ès
humide ou expos é à l ’air marin, enduire toutes
les surfaces m étalliques ext érieures d ’une fine
couche d ’huile. Ne pas enduire d ’huile les par-
ties en caoutchouc et la housse de selle.
N.B.:
Effectuer toutes les r éparations n écessaires avant de
remiser la moto.
1 - 13

SPEC
2 - 2
Oil capacity:
Engine oil Periodic oil change 0.8 L (0.70 Imp qt, 0.85 US qt)
Total amount 1.0 L (0.88 Imp qt, 1.06 US qt)
Air filter: Wet element
Fuel: Type Unleaded gasoline only (USA, AUS and NZ) Regular unleaded gasoline only
(CDN, Europe and ZA)
Tank capacity 3.1 L (0.68 Imp gal, 0.82 US gal)
Reserve amount 0.4 L (0.09 Imp gal, 0.11 US gal)
Carburetor: Type VM11
Manufacturer MIKUNI
Spark plug: Type CR7HSA
Manufacturer NGK
Gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Clutch type: Wet, multiple-disc and centrifugal automatic
Transmission: Primary reduction system Spur gear
Primary reduction ratio 67/18 (3.722)
Secondary reduction system Chain drive
Secondary reduction ratio 37/13 (2.846)
Transmission type Constant mesh, 3-speed
Operation Left foot operation
Gear ratio: 1st 39/12 (3.250) 2nd 33/19 (1.736)
3rd 28/23 (1.217)
Chassis: Frame type Steel tube backbone
Caster angle 25.50 °
Trail 34.0 mm (1.34 in)
Tire: Type With tube
Size (front) 2.50-10 4PR
Size (rear) 2.50-10 4PR
Manufacturer (front and rear) CHENG SHIN
Type (front and rear) KNOBBY
Tire pressure (front and rear) 100 kPa (1.00 kgf/cm
2, 14.2 psi)
Brake: Front brake type Drum brake
Operation Right hand operation
Rear brake type Drum brake
Operation Right foot operation
GENERAL SPECIFICATIONS
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