2006 YAMAHA TTR50 clutch

4 - 31
ENGCLUTCH
LS
E
E
E
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..6 Nm (0.6 m •
kg, 4.3 ft • Ib)
T R..70 Nm (7.0 m •
kg, 50 ft • lb)
E
New
E
E
2 3
6
7
8
7
10
9
11
1314
16
25
45
20
20
191817
2728
29
2630
21
2423
22
12 15
31
1
New
T R..5 Nm (0.5 m •
kg, 3.6 ft • Ib)
(3)
Extent of removal Order Part name Q ’ty Remarks
25 Spring 1
26 Washer 1
27 Primary driven gear nut 1
28 Lock washer 1
29 Primary driven gear 1
30 Primary drive gear 1
31 Collar 1
3

4 - 32
ENGCLUTCH
REMOVAL POINTS
Clutch
1. Remove:Clutch housing nut 1
NOTE:
Loosen the clutch housing nut while holding
the clutch housing with the sheave holder 2.
Sheave holder:
YS-01880-A/90890-01701
1
2
Primary driven gear
1. Remove: primary driven gear nut 1
 Lock washer 2
 Primary driven gear 3
NOTE:
Straighten the lock washer tab 2.
 Place an aluminum plate 4 between the
teeth of the primary driven gear 3 and pri-
mary drive gear 5.
INSPECTION
EC484100
Clutch housing and boss
1. Inspect: Clutch housing 1
Cracks/wear/damage → Replace.
 Clutch boss 2
Scoring/wear/damage → Replace.
1
2 3
5
4
2
1

4 - 33
ENGCLUTCH
EC484500
Friction plate
1. Measure:Friction plate thickness
Out of specification → Replace friction
plate as a set.
Measure at all four points.
Friction plate thickness:
Standard Limit
2.92 ~ 3.08 mm
(0.115 ~ 0.121 in) 2.82 mm
(0.111 in)
EC484600
Clutch plate
1. Measure:
Clutch plate warpage
Out of specification → Replace clutch
plate as a set.
Use a surface plate and thickness gauge
1 .
Warp limit:
0.2 mm (0.008 in)
Spring
1. Inspect:
Spring 1
Damage → Replace.
1

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ENGCLUTCH
ASSEMBLY AND INSTALLATION
Primary driven gear
1. Install:Primary driven gear 1
 Lock washer 2
 primary driven gear nut 3
NOTE:
Place an aluminum plate 4 between the teeth
of the primary driven gear 1 and primary drive
gear 5.
2. Bend: Lock washer tab
3
2 1
4
5
New
T R..70 Nm (7.0 m · kg, 50 ft · lb)
Clutch
1. Install:
Clutch plate 3 1
 Friction plates 2
 Clutch plate 2 3
 Clutch plate 1 4
 Clutch spring plate 5
NOTE:
Align the cutouts a in clutch plate 2 and
clutch plate 3 with the holes b in the clutch
housing.
 Install the clutch spring plate 5 as shown in
the illustration.
 Align the projections c on clutch plate 1 with
the notches d in the clutch spring plate.
1
3
a
b4
1
2
2
4
3
5
d
c
c c

4 - 35
ENG
2. Install:Clutch housing nut 1
NOTE:
Tighten the clutch housing nut while holding
the clutch housing with the sheave holder 2.
Sheave holder:
YS-01880-A/90890-01701
1
2
T R..70 Nm (7.0 m · kg, 50 ft · lb)
3. Install:
Shift arm 1
 Shift guide (inner) 2
 Pawl holder 3
 Shift guide (outer) 4
 Clutch adjuster 5
NOTE:
Align the punch mark a on the shift arm with
the punch mark b on the shift shaft.
 Install the shift guide (outer) 4 and clutch
adjuster 5 in the crankcase cover 6 as
shown in the illustration.
 When install the crankcase cover, align the
pawl holder balls with the grooves in the shift
guide (outer) 4.
1
2
3
a
b
4
5
6
CLUTCH

4 - 36
ENG
Clutch free play adjustment
1. Adjust:Clutch free play
Adjustment steps:
 Loosen the locknut 1.
 Turn the clutch adjuster 2 counterclock-
wise until it becomes slightly difficult to
turn.
 Turn the clutch adjuster 2 clockwise 1/8
turn.
 Hold the clutch adjuster 2 and tighten the
locknut 1.
T R..
Locknut:
6 Nm (0.6 m  kg, 4.3 ft  lb)
1
2
CLUTCH

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ENGSHIFT SHAFT
SHIFT SHAFT
LTLT
New
New
E
E
T R..23 Nm (2.3 m • kg, 17 ft • Ib)
E
43
6
5
7
2
1
Extent of removal: 1 Shift shaft removal
Extent of removal Order Part name Q ’ty Remarks
SHIFT SHAFT REMOVAL
Preparation for removal Clutch housing and primary driven gear Refer to
“CLUTCH ” section.
1 Shift shaft assembly 1
2 Torsion spring 1
3Shift lever 1
4 Shift shaft 1
5 Torsion spring 1
6 Stopper lever 1
7 Stopper bolt 1
1

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ENGOIL PUMP
OIL PUMP
Extent of removal: 1 Oil pump removal
2 Oil strainer removal
3 Oil pump disassembly
Extent of removal Order Part name Q ’ty Remarks
OIL PUMP REMOVAL AND DIS-
ASSEMBLY
Preparation for removal Primary drive gear and primary driven gear Refer to
“CLUTCH ” section.
Shift shaft Refer to “SHIFT SHAFT ” section.
1 Oil pump assembly 1
2 Gasket 1
3 Oil pump drive gear 1
4 Oil strainer 1
5 Circlip 1
6 Oil pump driven gear 1
7Pin 1
8 Oil pump cover 1
2
1
3