2006 YAMAHA TTR50 Timing

SPEC
2 - 10
Part to be tightened Thread size Q
’ty Tightening torque
Remarks
Nm m ·kg ft ·lb
Cylinder head nut M8 × 1.25 4 22 2.2 16
Cylinder head bolt M6 × 1.0 2 10 1.0 7.2
Spark plug M10 × 1.0 1 13 1.3 9.4
Camshaft sprocket cover bolt M6 × 1.0 2 10 1.0 7.2
Tappet cover M45 × 1.5 2 18 1.8 13
Exhaust pipe stud bolt M6 × 1.0 2 7 0.7 5.1
Rotor nut M12 × 1.25 1 48 4.8 35
Timing chain guide stopper M6 × 1.0 2 10 1.0 7.2
LT
Valve clearance adjust screw locknut M5 × 0.5 2 7 0.7 5.1
Camshaft sprocket M8 × 1.25 1 26 2.6 19
Camshaft bearing retainer M6 × 1.0 1 10 1.0 7.2
LT
Timing chain tensioner cap bolt M8 × 1.25 1 8 0.8 5.8
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Oil pump assembly M6 × 1.0 2 7 0.7 5.1
LT
Engine oil drain bolt M12 × 1.5 1 20 2.0 14
Intake manifold (cylinder head side) M6 × 1.0 2 7 0.7 5.1
Intake manifold (carburetor side) M6 × 1.0 2 7 0.7 5.1
Carburetor heater M8 × 1.25 1 3 0.3 2.2
Clamp (air filter joint) M4 × 0.7 1 2 0.2 1.4
Exhaust pipe M6 × 1.0 2 7 0.7 5.1
Muffler M8 × 1.25 1 38 3.8 27
Muffler cover M6 × 1.0 4 7 0.7 5.1
Spark arrester M6 × 1.0 3 10 1.0 7.2
Crankcase M6 × 1.0 10 10 1.0 7.2
Crankcase cover (left) M6 × 1.0 8 10 1.0 7.2
Drive sprocket cover M6 × 1.0 2 7 0.7 5.1
Timing plug M14 × 1.5 1 7 0.7 5.1
Crankshaft end cover M32 × 1.5 1 7 0.7 5.1
Crankcase cover (right) M6 × 1.0 9 10 1.0 7.2
Clutch adjuster locknut M8 × 1.25 1 6 0.6 4.3
Cylinder head stud bolt M8 × 1.25 4 13 1.3 9.4
Starter clutch and rotor M6 × 1.0 3 14 1.4 10 Stake
Clutch housing nut M14 × 1.0 1 70 7.0 50
Pressure plate M5 × 0.8 3 5 0.5 3.6
Primary driven gear M14 × 1.0 1 70 7.0 50
Stopper bolt M8 × 1.25 1 23 2.3 17
LT
Shift pedal M6 × 1.0 1 10 1.0 7.2
Pickup coil M6 × 1.0 2 10 1.0 7.2
LT
Stator assembly M6 × 1.0 3 10 1.0 7.2LT
Neutral switch M10 × 1.25 1 18 1.8 13
MAINTENANCE SPECIFICATIONS

3 - 10
INSPADJIDLE SPEED ADJUSTMENT/
VALVE CLEARANCE ADJUSTMENT
IDLE SPEED ADJUSTMENT
1. Start the engine and thoroughly warm it up.
2. Attach:
Tachometer
To spark plug lead.
3. Adjust:
Idle speed
Adjustment steps:
Turn the throttle stop screw 1 until the
engine runs at the lowest possible speed.
To increase idle speed → Turn the throt-
tle stop screw 1 in
a.
To decrease idle speed → Turn the throt-
tle stop screw 1 out
b.
Engine idling speed:
1,600 ~ 1,800 r/min
1
a
b
VALVE CLEARANCE ADJUSTMENT
NOTE:
 The valve clearance should be adjusted
when the engine is cool to the touch.
 The piston must be at Top Dead Center
(T.D.C.) on compression stroke to check or
adjust the valve clearance.
1. Remove: Spark plug cap 1
 Spark plug
 Tappet cover (intake side) 2
 Tappet cover (exhaust side) 3
 Camshaft sprocket cover 4
3
4
1
2
2. Remove:
Timing plug 1
 Crankshaft end cover 2
 O-rings
1
2

3 - 13
INSPADJVALVE CLEARANCE ADJUSTMENT/
SPARK ARRESTER CLEANING (For USA)
6. Install:
Spark plug
 Spark plug cap
 Timing plug
 Crankshaft end cover
NOTE:
Apply the engine oil on the O-ring.
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
SPARK ARRESTER CLEANING (For USA)
WARNING
 Be sure the exhaust pipe and muffler are
cool before cleaning the spark arrester.
 Do not start the engine when cleaning the
exhaust system.
1. Remove: Bolts (spark arrester) 1
2. Remove:
Spark arrester 2
Pull the spark arrester out of the muffler.
3. Clean:
Spark arrester
Tap the spark arrester lightly, then use a
wire brush to remove any carbon depos-
its.
4. Install: Spark arrester
Insert the spark arrester into the muffler
and align the bolt holes.
 Bolts (spark arrester)
1
2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

4 - 10
ENGCYLINDER HEAD
CYLINDER HEAD
Extent of removal: 1 Cylinder head removal
Extent of removal Order Part name Q ’ty Remarks
CYLINDER HEAD REMOVAL
Preparation for removal Seat assembly and fuel tank Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section.
Muffler Refer to “MUFFLER ” section.
Carburetor Refer to “CARBURETOR ” section.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL ” section in the CHAPTER 5.
1 Plug cap/spark plug 1/1
2 Crankshaft end cover 1
3 Timing plug 1
4 Camshaft sprocket cover 1
5 Tappet cover 2
6 Camshaft sprocket bolt 1 Refer to “REMOVAL POINTS ”.
7 Timing chain tensioner cap bolt 1
1

4 - 11
ENGCYLINDER HEAD
Extent of removal Order Part name Q’ty Remarks
8 Timing chain tensioner 1 Refer to “REMOVAL POINTS ”.
9 Gasket 1
10 Camshaft sprocket 1
11 Intake manifold 1
12 Cylinder head 1 Refer to “REMOVAL POINTS ”.
13 Dowel pin 2
14 Gasket 1
1

4 - 12
ENGCYLINDER HEAD
REMOVAL POINTS
Cylinder head
1. Align:“I” mark
(with stationary pointer)
Checking steps:
 Turn the crankshaft counterclockwise with
a wrench.
 Align the “I” mark a on the rotor with the
stationary pointer b on the crankcase
cover. When the “I” mark is aligned with
the stationary pointer, the piston is at the
Top Dead Center (T.D.C.).
NOTE:
 In order to be sure that the piston is at Top
Dead Center, the “I” mark c on the cam-
shaft sprocket must align with the station-
ary pointer d on the cylinder head as
shown in the illustration.
 If there is no valve clearance, rotate the
crankshaft counterclockwise one turn.
b
a
c
d
2. Loosen:
Camshaft sprocket bolt 1
3. Remove:
Timing chain tensioner
 Camshaft sprocket 2
NOTE:
Fasten a safety wire to the timing chain 3 to
prevent it from falling into the crankcase.
 Remove the bolt 1 while holding the rotor
nut with a wrench.
12
3

4 - 13
ENGCYLINDER HEAD
4. Remove:Cylinder head
NOTE:
 Loosen the bolts and nuts in their proper
loosening sequence.
 Start by loosening each bolt and nut 1/2 turn
until all are loose.1
2
5
64
3
ASSEMBLY AND INSTALLATION
1. Install:
Cylinder head
2. Tighten: Nuts
 Bolts
NOTE:
 Apply the engine oil on the contact surfaces
of the nuts and copper washers.
 Apply the engine oil on the thread and con-
tact surface of the bolts.
 Follow the numerical order shown in the illus-
tration. Tighten the bolts and nuts in two
stages.
6
5
2
13
4
T R..22 Nm (2.2 m · kg, 16 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
3. Install:
Camshaft sprocket 1
Installation steps:
 Turn the crankshaft counterclockwise until
the “I” mark a on the rotor is aligned with
the stationary pointer b on the crankcase
cover.
 Align the “I” mark c on the camshaft
sprocket with the stationary pointer d on
the cylinder head.
 Fit the timing chain 2 onto camshaft
sprocket and install the camshaft sprocket
on the camshaft.
NOTE:
When installing the camshaft sprocket, keep
the timing chain as tense as possible on the
exhaust side.
b
a
1
2
c
d

4 - 14
ENGCYLINDER HEAD
CAUTION:
.Do not turn the crankshaft during instal-
lation of the camshaft. Damage or
improper valve timing will result.
 Remove the safety wire from the timing
chain.
4. Install:
Timing chain tensioner
Installation steps:
 Remove the tensioner cap bolt 1 and
spring 2.
 Release the timing chain tensioner one-
way cam 3 and push the tensioner rod 4
all the way in.
 Install the tensioner with a new gasket 5
onto the cylinder.
T R..
Timing chain tensioner bolt: 10 Nm (1.0 m  kg, 7.2 ft  lb)
 Install the spring 2 and cap bolt 1.
 Tighten the bolt (with O-ring) to the speci-
fied torque.
T R..
Cap bolt:
8 Nm (0.8 m  kg, 5.8 ft  lb)
5. Install:
Washer
 Camshaft sprocket bolt 1
NOTE:
Install the bolt 1 while holding the rotor nut
with a wrench.
6. Check:
Rotor “I” mark
Align with the crankcase cover stationary
pointer.
 Valve clearance
Out of specification → Adjust.
Refer to the “VALVE CLEARANCE
ADJUSTMENT ” section in CHAPTER 3.
1
T R..26 Nm (2.6 m · kg, 19 ft · lb)