2006 YAMAHA TTR50 Chassis

EC080000
HOW TO USE
THIS MANUAL
EC081000
PARTICULARLY IMPORTANT
INFORMATION
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could
result in severe injury or death to the machine
operator, a bystander, or a person inspecting
or repairing the machine.
A CAUTION indicates special precautions that
must be taken to avoid damage to the
machine.
NOTE: A NOTE provides key information to make pro-
cedures easier or clearer.
WARNING
CAUTION:
EC082000
FINDING THE REQUIRED PAGE
1. This manual consists of six chapters; “Gen-
eral Information ”, “Specifications ”, “Regular
inspection and adjustments ”, “Engine ”,
“ Chassis ” and “Electrical ”.
2. The table of contents is at the beginning of the manual. Look over the general layout of
the book before finding then required chap-
ter and item.
Bend the book at its edge, as shown, to
find the required fore edge symbol mark
and go to a page for required item and
description.

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1 to 6 are designed as
thumb tabs to indicate the chapter ’s number
and content.
1 General information
2 Specifications
3 Regular inspection and adjustments
4 Engine
5 Chassis
6 Electrical
Illustrated symbols
7 to D are used to identify
the specifications appearing in the text.
7 With engine mounted
8 Special tool
9 Filling fluid
0 Lubricant
A Tightening
B Specified value, Service limit
C Engine speed
D Resistance (
Ω), Voltage (V), Electric current (A)
Illustrated symbols
E to H in the exploded
diagram indicate grade of lubricant and loca-
tion of lubrication point.
E Apply engine oil
F Apply molybdenum disulfide oil
G Apply lightweight lithium-soap base grease
H Apply molybdenum disulfide grease
Illustrated symbols
I to J in the exploded
diagrams indicate where to apply a locking
agent and when to install new parts.
I Apply locking agent (LOCTITE®)
J Use new one
12
34
56
78
90
AB
CD
E

F
G
H
IJ
GEN
INFOSPEC
INSP ADJ
ENG
CHAS–+ELEC
T R..
EM
LSM
LTNew

INDEX
GENERAL INFORMATION
SPECIFICATIONS
REGULAR INSPECTION AND ADJUSTMENTS
ENGINE
CHASSIS
ELECTRICAL

INDEX
ALLGEMEINES
1
TECHNISCHE
DATEN
SPEC2
REGELMÄSSIGE
WARTUNGS- UND
EINSTELLARBEITEN
3
MOTOR
ENG4
FAHRWERK
CHAS5
ELEKTRISCHE
ANLAGE
ELEC6
GEN
INFO
INSP ADJ
–+
INDEX
RENSEIGNEMENTS
GENERAUX
CARACTERISTI-
QUES
CONTROLES ET
REGLAGES
PERIODIQUES
MOTEUR
CHASSIS
PARTIE
ELECTRIQUE

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

INHALT
KAPITEL 1
ALLGEMEINES
FAHRZEUGBESCHREIBUNG ..................1-1
FAHRZEUG-IDENTIFIZIERUNG ...............1-2
WICHTIGE INFORMATIONEN ..................1-3
KABELANSCHLÜSSE
KONTROLLIEREN ....................................1-5
SPEZIALWERKZEUGE .............................1-6
BEDIENUNGSELEMENTE UND
DEREN FUNKTION ...................................1-8
KRAFTSTOFF .........................................1-11
ANLASSEN UND INBETRIEBNAHME ...1-12
PFLEGE UND LAGERUNG .....................1-13
KAPITEL 2
TECHNISCHE DATEN
ALLGEMEINE TECHNISCHE DATEN ......2-1
WARTUNGSDATEN ..................................2-4
ALLGEMEINE ANZUGSMOMENTE .......2-16
MASSEINHEITEN ....................................2-16
KABELFÜHRUNGSDIAGRAMME ..........2-17
KAPITEL 3
REGELMÄSSIGE WAR-
TUNGS- UND EINSTELLAR-
BEITEN
WARTUNGSINTERVALLE ........................3-1
ROUTINEKONTROLLE VOR
FAHRTBEGINN .........................................3-3
MOTOR ......................................................3-4
FAHRWERK ............................................3-14
ELEKTRISCHE ANLAGE ........................3-23
TABLES DES MATIERES
CHAPITRE 1
RENSEIGNEMENTS
GENERAUX
DESCRIPTION ............................................... 1-1
IDENTIFICATION DE LA MOTO .............. 1-2
INFORMATIONS IMPORTANTES ............ 1-3
VERIFICATION DES CONNEXIONS ........ 1-5
OUTILS SPECIAUX ...................................... 1-6
FONCTIONS DES COMMANDES .............. 1-8
CARBURANT ............................................... 1-11
DEMARRAGE ET
FONCTIONNEMENT .................................. 1-12
NETTOYAGE ET REMISAGE .................. 1-13
CHAPITRE 2
CARACTERISTIQUES
CARACTERISTIQUES GENERALES ........ 2-1
CARACTERISTIQUES D’ENTRETIEN ..... 2-4
CARACTERISTIQUES GENERALES
DE COUPLE .................................................. 2-16
DEFINITION DES UNITES ........................ 2-16
CHEMINEMENT DES CABLES ................ 2-17
CHAPITRE 3
CONTROLES ET REGLAGES
PERIODIQUES
PROGRAMME D’ENTRETIEN ................... 3-1
CONTROLES ET ENTRETIENS
AVANT UTILISATION ................................. 3-3
MOTEUR ......................................................... 3-4
CHASSIS ........................................................ 3-14
PARTIE ELECTRIQUE .............................. 3-23

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

KAPITEL 4MOTOR
VORDERRADABDECKUNG, SITZBANK
UND KRAFTSTOFFTANK .........................4-1
SCHALLD ÄMPFER ...................................4-3
VERGASER ...............................................4-4
ZYLINDERKOPF .....................................4-10
NOCKENWELLE UND KIPPHEBEL .......4-15
VENTILE UND VENTILFEDERN .............4-18
ZYLINDER UND KOLBEN ......................4-23
KUPPLUNG .............................................4-29
SCHALTWELLE ......................................4-37
Ö LPUMPE ................................................4-39
LICHTMASCHINE UND
STARTERKUPPLUNG ............................4-42
MOTOR DEMONTIEREN ........................4-47
KURBELGEH ÄUSE UND
KURBELWELLE ......................................4-51
SCHALTGABELN, SCHALTWALZE
UND GETRIEBE ......................................4-54
KAPITEL 5
FAHRWERK
VORDER- UND HINTERRAD ....................5-1
LENKER ...................................................5-10
LENKKOPF UND
VORDERRADAUFH ÄNGUNG ................5-13
SCHWINGE ..............................................5-17
KAPITEL 6
ELEKTRISCHE ANLAGE
ELEKTRISCHE BAUTEILE UND
SCHALTPLAN ...........................................6-1
Z Ü NDSYSTEM ...........................................6-2
E-STARTER ...............................................6-6
LADESYSTEM .........................................6-14
VERGASERHEIZUNG .............................6-16
VERZEICHNIS DER
WARTUNGSARBEITEN ..........................6-20
CHAPITRE 4
MOTEUR
GARDE-BOUE AVANT, SELLE ET
RESERVOIR D ’ESSENCE ............................ 4-1
POT D ’ECHAPPEMENT .............................. 4-3
CARBURATEUR ............................................ 4-4
CULASSE ...................................................... 4-10
ARBRE A CAMES ET CULBUTEURS ..... 4-15
SOUPAPES ET RESSORTS DE
SOUPAPE ...................................................... 4-18
CYLINDRE ET PISTON ............................. 4-23
EMBRAYAGE .............................................. 4-29
AXE DE SELECTEUR ................................. 4-37
POMPE A HUILE ......................................... 4-39
ALTERNATEUR AVEC ROTOR A
ALIMENTATION PERMANENTE ET
EMBRAYAGE DU DEMARREUR ............ 4-42
DEPOSE DU MOTEUR ............................... 4-47
CARTER MOTEUR ET
VILEBREQUIN ............................................ 4-51
FOURCHETTE DE SELECTION,
TAMBOUR ET BOITE DE VITESSES ..... 4-54
CHAPITRE 5
CHASSIS
ROUE AVANT ET ROUE ARRIERE .......... 5-1
GUIDON ........................................................ 5-10
DIRECTION ET
SUSPENSION AVANT ................................. 5-13
BRAS OSCILLANT ...................................... 5-17
CHAPITRE 6
PARTIE ELECTRIQUE
COMPOSANTS ELECTRIQUES ET
SCHEMA DE CABLAGE .............................. 6-1
SYSTEME D ’ALLUMAGE ........................... 6-2
DEMARRAGE ELECTRIQUE ..................... 6-6
SYSTEME DE CHARGE ............................. 6-14
SYSTEME DE RECHAUFFAGE DU
CARBURATEUR .......................................... 6-16
FICHE D ’ENTRETIEN ............................... 6-20