2006 YAMAHA TTR50 light

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ENGAC MAGNETO AND STARTER CLUTCH
REMOVAL POINTS
Rotor
1. Remove:Rotor nut 1
 Washer 2
NOTE:
Loosen the rotor nut while holding the rotor
with sheave holder 3.
 Do not allow the sheave holder to touch the
projection on the rotor.
Sheave holder:
YS-01880-A/90890-01701
2. Remove:
Rotor 1
 Woodruff key
NOTE:
 Use the flywheel puller 2.
 Center the flywheel puller over the rotor.
Make sure after installing the holding bolts
that the clearance between the flywheel
puller and the rotor is the same everywhere.
If necessary, one holding bolt may be turned
out slightly to adjust the flywheel puller ’s
position.
CAUTION:
Cover the crankshaft end with the box
wrench for protection.
Flywheel puller: YU-33270-B/90890-01362

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ENGSHIFT FORK, SHIFT CAM AND TRANSMISSION
EC4H3000
REMOVAL POINTS
Shift fork, shift cam and transmission
1. Remove:Shift forks
 Shift cam
 Drive axle assembly
 Main axle assembly
NOTE:
 Remove the main axle, drive axle, shift cam
and shift forks all together by tapping lightly
on the transmission main axle and shift cam
with a soft hammer to remove.
 Remove assembly carefully. Note the posi-
tion of each part. Pay particular attention to
the location and direction of shift forks.
ASSEMBLY AND INSTALLATION
Transmission, shift cam shift fork
1. Install:
Plain washer 1
 Circlip 2
NOTE:
Be sure the circlip sharp-edged corner a is
positioned opposite side to the plain washer
and gear b.
 Be sure the circlip end c is positioned at
axle spline groove d.
New

6 - 13
–+ELEC
5. Measure:
Brush length a
Out of specification → Replace.
Brush length wear limit:
3.5 mm (0.14 in)
6. Measure:
Brush spring force
Fatigue/out of specification → Replace as
a set.
Brush spring force: 3.92 ~ 5.88 N
(400 ~ 600 g, 14.1 ~ 21.2 oz)
ASSEMBLY
1. Install:
Brush holder
2. Install:
Armature coil 1
3. Install:
Ring 1
 Starter motor yoke 2
 Front bracket 3
NOTE:
Apply molybdenum disulfide grease lightly
on to the bearings of the starter motor.
 Align the match mark on the armature
assembly with the match mark on the front
bracket.
ELECTRIC STARTING SYSTEM

–+ELEC
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CARBURETOR HEATING SYSTEM
CARBURETOR HEATING SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning carburetor heating system.
NOTE:
 Remove the following parts before inspection.
1) Seat
2) Fuel tank
Refer to “FRONT FENDER, SEAT ASSEMBLY AND FUEL TANK ” section in the CHAPTER 4.
 Use the following special tools in this inspection.
Pocket tester:
YU-03112-C/90890-03112
Check entire carburetor
heating system for connec- tion. Repair or replace.
Check thermo switch. Replace.
Check carburetor heater. Replace. Check AC magneto. Lighting coil Replace.
Replace rectifier/regulator.
OK
OK
OK
OK
No good
No good
No good
No good

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–+ELECCARBURETOR HEATING SYSTEM
AC MAGNETO INSPECTION
1. Inspect:
Lighting coil resistance
Out of specification → Replace.
Tester (+) lead → Yellow lead
1
Tester ( –) lead
→ Black lead
2
Lighting coil
resistance Tester selector
position
0.8 ~ 1.20 Ω at
20 °C (68 °F) Ω

× 1
WSb
B
Y
1 2