2006 YAMAHA TTR50 steering

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INSPADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
 Remove the special washer 6.
 Remove the upper ring nut 7, and rubber
washer 8.
 Loosen the lower ring nut 9 using the
steering nut wrench 0.
Steering nut wrench:
YU-33975/90890-01403
 Tighten the lower ring nut 9 using steer-
ing nut wrench 0 and turn the steering
right and left a few times.
NOTE:
Set the torque wrench to the steering nut
wrench so that they form a right angle.
Steering nut wrench: YU-33975/90890-01403
T R..
Lower ring nut (initial tightening):38 Nm (3.8 m  kg, 27 ft  lb)
 Loosen the lower ring nut completely.
 Retighten the lower ring nut using the
steering nut wrench.
WARNING
Avoid over-tightening.
T R..
Ring nut (final tightening):
4 Nm (0.4 m  kg, 2.9 ft  lb)
 Check the steering stem by turning it lock
to lock. If there is any binding, remove the
steering stem assembly and inspect the
steering bearings.
 Install the rubber washer 8, upper ring nut
7 and special washer 6.
NOTE:
Tighten the upper ring nut until it contacts
the rubber washer.
 Insert the special washer pawls a into the
slots b. If the slots are not aligned, tighten
the upper ring nut for alignment.
 Install the upper bracket, steering stem nut
and upper bracket bolts, handlebar.
T R..
Steering stem nut:
110 Nm (11.0 m  kg, 80 ft  lb)
Upper bracket bolt: 32 Nm (3.2 m  kg, 23 ft  lb)
7
8
\b
6
0
\b
0
\b
86
7
a
a
b

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CHASSTEERING AND FRONT SUSPENSION
EC560000
STEERING AND FRONT SUSPENSION
Extent of removal:1 Lower bracket removal
2 Bearing removal
3 Inner table assembly removal
Extent of removal Order Part name Q ’ty Remarks
STEERING AND FRONT SUS-
PENSION REMOVAL
WARNING
Support the machine securely so
there is no danger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL ” section.
Handlebar Refer to “HANDLEBAR ” section.
1 Cable guide 1
2 Reflector 2 For Canada
3 Steering stem nut 1
4 Upper bracket 1
5 Special washer 1 Use special tool. Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT ” section in
the CHAPTER 3.
6 Upper ring nut 1
7 Rubber washer 1
213

5 - 14
CHASSTEERING AND FRONT SUSPENSION
Extent of removal Order Part name Q’ty Remarks
8 Lower ring nut 1 Use special tool. Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT ” section in
the CHAPTER 3.
9 Front fork assembly 1
10 Bearing race cover 1
11 Upper bearing inner race 1
12 Upper bearing 1
13 Lower bearing 1
14 Lower bearing inner race 1
15 Dust seal 1
16 Upper bearing outer race 1
17 Lower bearing outer race 1
18 Circlip 2
19 Inner tube assembly (left) 1
20 Inner tube assembly (right) 1
21 Lower bracket 1
2
3

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CHAS
EC563000
REMOVAL POINTS
EC563202
Ring nut
1. Remove:Lower ring nut 1
Use the steering nut wrench 2.
WARNING
Support the steering shaft so that it may
not fall down.
Steering nut wrench:
YU-33975/90890-01403
2
1
Bearing race
1. Remove:
Bearing race 1
Remove the bearing race using long rod
2 and the hammer.
2. Remove:
Bearing race 1
Use the floor chisel 2.
CAUTION:
Take care not to damage the steering shaft
thread.
ASSEMBLY AND INSTALLATION
1. Install: Front fork assembly
NOTE:
When installing an inner tube assembly in the
lower bracket, align the projection a on the
inner tube assembly with the indentation b in
the lower bracket.
b
a
b
a
STEERING AND FRONT SUSPENSION

5 - 16
CHAS
2. Install:Lower ring nut 1
NOTE:
Be sure to install the lower ring nut 1 with the
broad side of the inner tapered section a fac-
ing down.
Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT ” section in the
CHAPTER 3.1
a
STEERING AND FRONT SUSPENSION