2006 YAMAHA TTR50 light

3 - 8
INSPADJ
4. Check:
Oil level
Oil level should be between maximum a
and minimum b marks.
Oil level is low → Add oil to proper level.
NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.
 When inspecting the oil level, do not screw
the dipstick into the oil tank. Insert the gauge
lightly.
(For USA and CDN)
CAUTION:
 Do not add any chemical additives.
Engine oil also lubricates the clutch and
additives could cause clutch slippage.
 Do not allow foreign material to enter the
crankcase.
(Except for USA and CDN)
CAUTION:
 Do not add any chemical additives or use
oils with a grade of CD a or higher.
 Do not use oils labeled “ENERGY CON-
SERVING II ” b or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.
 Do not allow foreign materials to enter the
crankcase.
Recommended oil:
At –10 °C (14 °F) or higher È:
Yamalube 4 (10W-30) or SAE
10W-30 type SE/SF/SG motor
oil
At 5 °C (41 °F) or higher É:
Yamalube 4 (20W-40) or SAE
20W-40 type SE/SF/SG motor
oil
Recommended oil: Refer to the following chart for
selection of oils which are suited
to the atmospheric temperatures.
Recommended engine oil classifi-
cation:
API STANDARD: API “SE/SF/SG ” or higher grade
(Designed primarily for
motorcycles)
0 10 30 50 70
90110
130
-20 -10 010
20 30 40 50
È
É
˚C
˚
F
a
b
ENGINE OIL LEVEL INSPECTION

3 - 13
INSPADJVALVE CLEARANCE ADJUSTMENT/
SPARK ARRESTER CLEANING (For USA)
6. Install:
Spark plug
 Spark plug cap
 Timing plug
 Crankshaft end cover
NOTE:
Apply the engine oil on the O-ring.
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
SPARK ARRESTER CLEANING (For USA)
WARNING
 Be sure the exhaust pipe and muffler are
cool before cleaning the spark arrester.
 Do not start the engine when cleaning the
exhaust system.
1. Remove: Bolts (spark arrester) 1
2. Remove:
Spark arrester 2
Pull the spark arrester out of the muffler.
3. Clean:
Spark arrester
Tap the spark arrester lightly, then use a
wire brush to remove any carbon depos-
its.
4. Install: Spark arrester
Insert the spark arrester into the muffler
and align the bolt holes.
 Bolts (spark arrester)
1
2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

3 - 22
INSPADJ
LUBRICATION
LUBRICATION
To ensure smooth operation of all compo-
nents, lubricate your machine during setup,
after break-in, and after every race.
1 All control cable
2 Brake lever pivot
3 Shift pedal pivot
4 Footrest pivot
5 Throttle-to-handlebar contact
6 Drive chain
7 Tube guide cable winding portion
8 Throttle cable end
9 Brake cable end È
Use Yamaha cable lube or equivalent on these
areas.
É Use SAE 10W-30 motor oil or suitable chain
lubricants.
Ê Lubricate the following areas with high quality,
lightweight lithium-soap base grease.
AAA
AAB
CC
7 8

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INSPADJ
ELECTRICAL/SPARK PLUG INSPECTION
EC370000
ELECTRICAL
EC371001
SPARK PLUG INSPECTION
1. Remove:
Spark plug
2. Inspect: Electrode 1
Wear/damage → Replace.
 Insulator color 2
Normal condition is a medium to light tan
color.
Distinctly different color → Check the
engine condition.
NOTE:
When the engine runs for many hours at low
speeds, the spark plug insulator will become
sooty, even if the engine and carburetor are in
good operating condition.
3. Measure: Plug gap a
Use a wire gauge or thickness gauge.
Out of specification → Regap.
4. Clean the plug with a spark plug cleaner if necessary.
5. Tighten: Spark plug
NOTE:
 Before installing a spark plug, clean the gas-
ket surface and plug surface.
 Finger-tighten a the spark plug before torqu-
ing to specification b.
Spark plug gap:
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Standard spark plug: CR7HSA (NGK)
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)

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INSPADJ
BATTERY INSPECTION AND CHARGING
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
 Wear protective eye gear when handling
or working near batteries.
 Charge batteries in a well-ventilated area.
 Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
 DO NOT SMOKE when charging or han-
dling batteries.
 KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
 Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
 Skin — Wash with water.
 Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
 Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
CAUTION:
Charging time, charging amperage and
charging voltage for an MF battery are dif-
ferent from those of conventional batteries.
The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
BATTERY INSPECTION AND CHARGING

4 - 21
ENGVALVES AND VALVE SPRINGS
2. Lap:Valve face
 Valve seat
NOTE:
After refacing the valve seat or replacing the
valve and valve guide, the valve seat and
valve face should be lapped.
Lapping steps:
 Apply a coarse lapping compound to the
valve face.
CAUTION:
Do not let the compound enter the gap
between the valve stem and the guide.
 Apply molybdenum disulfide oil to the
valve stem.
 Install the valve into the cylinder head.
 Turn the valve until the valve face and
valve seat are evenly polished, then clean
off all of the compound.
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hands.
Apply a fine lapping compound to the
valve face and repeat the above steps.
NOTE:
After every lapping operation be sure to
clean off all of the compound from the valve
face and valve seat.
Apply Mechanic ’s blueing dye (Dykem) to
the valve face.
 Install the valve into the cylinder head.
 Press the valve through the valve guide
and onto the valve seat to make a clear
pattern.
 Measure the valve seat width again. If the
valve seat width is out of specification,
reface and relap the valve seat.

4 - 22
ENGVALVES AND VALVE SPRINGS
ASSEMBLY AND INSTALLATION
1. Apply:Molybdenum disulfide oil
(onto the valve stem and valve stem seal)
2. Install: Valve stem seats
 Valves
 Valve springs
 Valve spring retainers
NOTE:
Install the valve springs with the larger pitch a
facing upwards.
bSmaller pitch
New
3. Install:
Valve cotters
NOTE:
While compressing the valve spring with a
valve spring compressor and attachment 1
install the valve cotters.
Valve spring compressor:
YM-04019/90890-04019
Valve spring compressor attach-
ment: YM-04108/90890-04108
4. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a piece of
wood.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.

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