2006 YAMAHA TTR50 oil

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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

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CHARGING SYSTEM
EC680000
CHARGING SYSTEM
EC681001
INSPECTION STEPS
If the battery is not charged, use the following inspection steps.
*1 marked: Refer to “FUSE INSPECTION ” section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING ” section in the CHAPTER 3.
NOTE:
 Remove the following parts before inspection.
1) Seat assembly
Refer to “FRONT FENDER, SEAT ASSEMBLY AND FUEL TANK ” section in the CHAPTER 4.
 Use the following special tool in this inspection.
Pocket tester:
YU-03112-C/90890-03112
*1 Check fuse. Replace fuse and
check wire harness.
*2 Check battery. Recharge or replace.
Check each coupler and wire connection. Repair or replace.
Check charging voltage. Charging system is
good.
Check AC magneto. Charging coil Replace.
Replace rectifier/regulator.
OK
OK
OK
No good
OK
No good
OK
No good
No good
No good

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–+ELECCHARGING SYSTEM
EC624000
COUPLERS AND LEADS CONNECTION
INSPECTION
1. Check:
Couplers and leads connection
Rust/dust/looseness/short-circuit →
Repair or replace.
CHARGING VOLTAGE INSPECTION
1. Start the engine.
2. Inspect: Charging voltage
Out of specification → If no failure is
found in checking the charging coil resis-
tance, replace the rectifier/regulator.
Tester (+) lead → Red lead
1
Tester ( –) lead
→ Black lead
2
Charging
voltage Tester selector
position
14.0 V at
5,000 r/min DCV-20
2
1
W R
Y/R
B
AC MAGNETO INSPECTION
1. Inspect: Charging coil resistance
Out of specification → Replace.
Tester (+) lead → White lead
1
Tester ( –) lead
→ Black lead
2
Charging coil
resistance Tester selector
position
0.96 ~ 1.44 Ω at
20 °C (68 °F) Ω

× 1
WSb
B
Y 1
2

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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