2006 YAMAHA TTR50 engine

SPEC
2 - 16
EC220001
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
A
(Nut) B
(Bolt) TORQUE
SPECIFICATION
Nm m ·kg ft ·lb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm 6 mm
8 mm
10 mm
12 mm
14 mm
16 mm 6
15
30
55
85
130 0.6
1.5
3.0
5.5
8.5
13 4.3
11
22
40
61
94
Unit Read Definition Measure
mm
cm millimeter
centimeter 10
-3 meter
10-2 meter Length
Length
kg kilogram 10
3 gram Weight
N Newton 1 kg × m/sec
2 Force
Nm
m  kg Newton meter
Meter kilogram N
× m
m × kg Torque
Torque
Pa Pascal N/m
2Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3 Liter
Cubic centimeter
—
—Volume or capacity
Volume or capacity
r/min Revolution per minute —Engine speed
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS

2 - 17
SPECCABLE ROUTING DIAGRAM
CABLE ROUTING DIAGRAM
1 CDI unit lead
2 Lead guide
3 Carburetor heater
4 Carburetor heater lead flat terminal
5 Carburetor heater lead L-shaped terminal
6 Cable guide
7 Start switch lead
8 Main switch lead
9 Engine stop switch lead 0
Starter cable
A Throttle cable
B Plastic locking tie
C Thermo switch lead
D Spark plug lead
E Carburetor air vent hose
F Crankcase breather hose
G AC magneto leads
H Wire harness
2
É
BÍ
B Ñ
BÏ
F Î
LÕ
\b
8 \b
×
0
\f Ø
E
E Ò 6
\f
7
8
\b
0
\f
C
D
H
H
7
J
I
I
K 8
7
\b
C
0
\f
E H
G 345
Ê
Ì
Ð
ÙÓ
Ô
Ô
È
B
A C
C
B
A
B-B
A-A
C-C
1

2 - 18
SPECCABLE ROUTING DIAGRAM
IAir filter case
J Frame
K Ignition coil
L Brake cable
È Make sure that there is no slack in the wire har-
ness in the area shown in the illustration.
É Pass the wire harness, then the carburetor air
vent hose through the lead guide.
Ê The couplers of identical colors should be con-
nected. Ë
Pass the start switch lead, main switch lead,
engine stop switch lead, throttle cable, and
starter cable through the cable guide.
Ì Route the throttle cable and starter cable under
the start switch lead, main switch lead, and
engine stop switch lead.
2
É
BÍ
B Ñ
BÏ
F Î
LÕ
\b
8 \b
×
0
\f Ø
E
E Ò 6
\f
7
8
\b
0
\f
C
D
H
H
7
J
I
I
K 8
7
\b
C
0
\f
E H
G 345
Ê
Ì
Ð
ÙÓ
Ô
Ô
È
B
A C
C
B
A
B-B
A-A
C-C
1

2 - 19
SPECCABLE ROUTING DIAGRAM
ÍFasten the start switch lead, main switch lead,
engine stop switch lead, and thermo switch lead
to the frame with a plastic locking tie at the loca-
tion shown in the illustration. Face the buckle of
the plastic locking tie upward, and then cut off
the excess end of the tie.
Î When installing the crankcase breather hose,
make sure that it does not contact the muffler
and is not twisted. Ï
Fasten the wire harness to the frame with a plas-
tic locking tie at the location shown in the illustra-
tion, making sure that the plastic locking tie does
not contact the crankcase breather hose. Cut off
the excess end of the plastic locking tie, and
then face the cut end of the tie upward. The cut
end of the plastic locking tie should be 5 mm
(0.20 in) or less.
Ð Insert the wire harness holder completely into
the hole in the frame.
2
É
BÍ
B Ñ
BÏ
F Î
LÕ
\b
8 \b
×
0
\f Ø
E
E Ò 6
\f
7
8
\b
0
\f
C
D
H
H
7
J
I
I
K 8
7
\b
C
0
\f
E H
G 345
Ê
Ì
Ð
ÙÓ
Ô
Ô
È
B
A C
C
B
A
B-B
A-A
C-C
1

2 - 20
SPECCABLE ROUTING DIAGRAM
ÑFasten the wire harness with a plastic locking tie
as far rearward as possible on the frame. Cut off
the excess end of the plastic locking tie, and
then face the cut end of the tie upward. The cut
end of the plastic locking tie should be 5 mm
(0.20 in) or less.
Ò Do not pinch the carburetor air vent hose
between the air filter case and frame.
Ó Fasten the engine stop switch lead with the plas-
tic bands.
Ô 20 ~ 30 mm (0.79 ~ 1.18 in) Õ
Route the brake cable in front of the front fender.
Ö Route the main switch lead over the handlebar.
× Route the starter cable, engine stop switch lead,
and main switch lead in front of the upper
bracket in the order listed from front to rear.
Ø Route the throttle cable behind the front fender.
Ù Fasten the start switch lead with the plastic
bands.
2
É
BÍ
B Ñ
BÏ
F Î
LÕ
\b
8 \b
×
0
\f Ø
E
E Ò 6
\f
7
8
\b
0
\f
C
D
H
H
7
J
I
I
K 8
7
\b
C
0
\f
E H
G 345
Ê
Ì
Ð
ÙÓ
Ô
Ô
È
B
A C
C
B
A
B-B
A-A
C-C
1

3 - 1
INSPADJ
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
No. ITEM CHECKS AND
MAINTENANCE JOBS WHICH-
EVER
COMES
FIRST INITIAL EVERY
month 1 6 12
hours 30 60 120
1 * Fuel line Check fuel hoses for cracks or damage.
Replace if necessary.
√

√
2 Spark plug Check condition.
Adjust gap and clean.
√

√
3 * Valve clearance Check and adjust valve clearance when engine is
cold.
√

4 * Air filter element Clean with solvent.
Replace if necessary.
√

√
5 * Breather system Check ventilation hose for cracks or damage.
Replace if necessary.
√

√
√
6 * Carburetor Check engine idling speed and starter operation.
Adjust if necessary.
√

√
√
7 Exhaust system Check for leakage.
Tighten if necessary.
Replace gasket if necessary.
√

√
8 Engine oil Change (warm engine before draining). √
√
√
9 * Clutch Check operation.
Adjust if necessary.
√

√
√
10 * Front brake Check operation.
Adjust brake lever free play and replace brake shoes
if necessary.
√

√
√
11 * Rear brake Check operation.
Adjust brake pedal free play and replace brake shoes
if necessary. √

√
√
12 * Wheels Check runout, spoke tightness and for damage.
Tighten spokes if necessary.
√

√
√
13 * Tires Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
√

√
14 * Wheel bearings Check bearings for smooth operation.
Replace if necessary.
√

√
15 * Swingarm Check swingarm pivoting point for play.
Correct if necessary.
Lubricate with lithium soap based grease. √

√
√
16 Drive chain Check chain slack/alignment and condition.
Adjust and lubricate chain. Every ride
17 * Steering bearings Check bearing assemblies for looseness.
Lubricate with lithium soap based grease every
120 hours or 12 months (whichever comes first).
√

√
18 Brake lever pivot
shaft Apply lithium soap based grease lightly.
√
√
√
19 Brake pedal pivot
shaft Apply lithium soap based grease lightly.
√
√
√
3

3 - 2
INSPADJ
MAINTENANCE INTERVALS
* : Since these items requires special tools data and technical skills, they should be serviced.
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
20 Sidestand pivot Check operation.
Apply lithium soap based grease lightly.
√

√
21 * Front fork Check operation and for grease leakage.
Replace if necessary.
√

√
22 * Shock absorber
assembly Check operation and for oil leakage.
Replace if necessary.
√

√
23 * Control cables Apply Yamaha chain and cable lube or engine oil
10W-30 thoroughly.
√

√
√
24 * Throttle grip hous-
ing and cable Check operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.
√

√
√
25 * Chassis fasteners Check all chassis fitting and fasteners.
Correct if necessary.
√

√
√
26 Battery Check terminal for looseness and corrosion. √
No. ITEM
CHECKS AND
MAINTENANCE JOBS WHICH-
EVER
COMES FIRST INITIAL EVERY
month 1 6 12
hours 30 60 120
1
2
3
4
5
6

3 - 3
INSPADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel line
for leakage. P.1-11
Engine oil Check that the oil level is correct. Check the crankcase for leakage. P.3-7 ~ 9
Throttle Check for proper throttle cable operation. P.3-4 ~ 5
Brakes Check the play of front and rear brake and effect of front and rear
brake. P.3-14 ~ 15
Drive chain Check chain slack and alignment. Check that the chain is lubricated
properly. P.3-16 ~ 18
Wheels and tires Check pressure/runout/spoke tightness/bead stopper/axle nuts. P.3-19 ~ 20
Steering Check that the handlebar can be turned smoothly and have no exces-
sive play. P.3-20 ~ 21
Front forks and rear
shock absorber assembly Check that they operate smoothly and there is no oil leakage. P.3-18
Cables (wires) Check that the throttle cable move smoothly. Check that they are not
caught when the handlebars are turned. —
Muffler Check that the muffler is tightly mounted and has no cracks. P.4-3
Sprocket Check that the driven sprocket tightening nut is not loose. P.3-15
Lubrication Check for smooth operation. Lubricate if necessary. P.3-22
Spark plug Check color/condition. P.3-23
Fittings/fasteners Check all – tighten as necessary. P.2-13
Lead connectors Check that the AC magneto, CDI unit, and ignition coil are connected
tightly. P.1-5