2006 YAMAHA TTR50 wheel

4 - 43
ENGAC MAGNETO AND STARTER CLUTCH
Extent of removal Order Part name Q’ty Remarks
10 Shaft 1
11 Idler gear 1
12 Starter clutch/wheel gear 1/1
4

4 - 44
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

4 - 45
ENG
INSPECTION
Starter clutch
1. Inspect:Starter idle gear teeth a
 Starter drive gear teeth b
 Starter wheel gear teeth c
Burrs/chips/roughness/wear → Replace.
2. Check:
Starter clutch operation.
Checking steps:
 Install the starter wheel gear onto the
starter clutch and hold the starter clutch.
 When turning the starter wheel gear clock-
wise È, the starter clutch and the starter
wheel gear should be engage, otherwise
the starter clutch is faulty and must be
replaced.
 When turning the starter wheel gear coun-
terclockwise É, it should turn freely, other-
wise the starter clutch is faulty and must
be replaced.
É
È
ASSEMBLY AND INSTALLATION
Starter clutch
1. Install:Starter clutch 1
1T R..14 Nm (1.4 m · kg, 10 ft · lb)
2. Unloosen the starter clutch assembly by
using the center punch.
AC MAGNETO AND STARTER CLUTCH

4 - 46
ENGAC MAGNETO AND STARTER CLUTCH
3. Install:Spring 1
 Spring cap 2
 Pin 3
4. Install: Shim 1
 Starter wheel gear 2
 Starter idle gear 3
 Shaft 4
NOTE:
Apply the molybdenum disulfide oil on the
starter wheel gear inner circumference.
 Apply the engine oil on the starter idle gear
inner circumference and on the shaft outer
circumference.
1 2
3
12
3
5. Install:
Woodruff key 1
 Rotor 2
NOTE:
Clean the tapered portion of the crankshaft
and the rotor hub.
 When installing the rotor, make sure the
woodruff key is properly seated in the key
way of the crankshaft.
6. Tighten: Rotor nut 1
NOTE:
Tighten the rotor nut 1 while holding the
rotor 2 with a sheave holder 3.
 Do not allow the sheave holder to touch the
projection on the rotor.
7. Install: Crankcase cover (left)
NOTE:
 Pass the starter motor lead 1 and neutral
switch lead 2 into the crankcase cover
groove as shown.
 Fasten the starter motor lead with the clamp 3.
Sheave holder:
YS-01880-A/90890-01701
T R..48 Nm (4.8 m · kg, 35 ft · lb)
3
1
2

4 - 55
ENGSHIFT FORK, SHIFT CAM AND TRANSMISSION
0.8~1.3mm
(0.03~0.05 in)
New
New
New
New
M
M
1213 14
15 16
17 18
19
7
8
9
10
11
4 3
1
2
M
E
5 6
Extent of removal Order Part name Q
’ty Remarks
10 3rd pinion gear 1
11 Main axle 1
12 Circlip 1
13 Washer 1
14 1st wheel gear 1
15 3rd wheel gear 1
16 Circlip 1
17 Washer 1
18 2nd wheel gear 1
19 Drive axle 1
2
3

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ENGSHIFT FORK, SHIFT CAM AND TRANSMISSION
2. Install:Main axle assembly 1
 Drive axle assembly 2
 Shift fork 2 “R ” 3
 Shift fork 1 “L ” 4
 Shift cam 5
 Guide bar 6
NOTE:
The embossed marks on the shift forks
should face towards the right side of the
engine and be in the following sequence:
“R ”, “L ”.
 Mesh the shift fork 2 “R ” with the 3rd wheel
gear on the drive axle.
 Mesh the shift fork 1 “L ” with the 2nd pinion
gear on the main axle.
3. Check: Shifter operation
 Transmission operation
Unsmooth operation → Repair.
3
4
5 1
6
2

5 - 1
CHAS
EC500000
CHASSIS
FRONT WHEEL AND REAR WHEEL
FRONT WHEEL AND FRONT BRAKE
Extent of removal:1 Front wheel removal
2 Wheel bearing removal
3 Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q ’ty Remarks
FRONT WHEEL 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.
1 Front brake adjuster 1
2Pin 1
3Spring 1
4 Locknut 1
5 Brake cable 1 Disconnect at the lever side.
6 Front fork guard (left) 1
7 Front fork guard (right) 1
8 Wheel axle nut 1
9 Front wheel axle 1
21
FRONT WHEEL AND REAR WHEEL

5 - 2
CHAS
Extent of removal Order Part name Q’ty Remarks
10 Front wheel 1
11 Collar 1
12 Brake shoe plate assembly 1
13 Oil seal 1
14 Bearing 2 Refer to “REMOVAL POINTS ”.
15 Brake shoe spring 1
16 Brake shoe 2
17 Brake camshaft lever 1
18 Wear indicator plate 1
19 Brake camshaft 1
2
1
3
3
FRONT WHEEL AND REAR WHEEL