2006 YAMAHA TTR50 charging

CHAPTER 4ENGINE
FRONT FENDER, SEAT ASSEMBLY
AND FUEL TANK .......................................4-1
MUFFLER ...................................................4-3
CARBURETOR ...........................................4-4
CYLINDER HEAD .....................................4-10
CAMSHAFT AND ROCKER ARMS .........4-15
VALVES AND VALVE SPRINGS .............4-18
CYLINDER AND PISTON .........................4-23
CLUTCH ....................................................4-29
SHIFT SHAFT ...........................................4-37
OIL PUMP .................................................4-39
AC MAGNETO AND
STARTER CLUTCH ..................................4-42
ENGINE REMOVAL ..................................4-47
CRANKCASE AND CRANKSHAFT .........4-51
SHIFT FORK, SHIFT CAM AND
TRANSMISSION .......................................4-54
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL ........5-1
HANDLEBAR ............................................5-10
STEERING AND
FRONT SUSPENSION .............................5-13
SWINGARM ..............................................5-17
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS AND
WIRING DIAGRAM .....................................6-1
IGNITION SYSTEM .....................................6-2
ELECTRIC STARTING SYSTEM ...............6-6
CHARGING SYSTEM ...............................6-14
CARBURETOR HEATING SYSTEM ........6-16
MAINTENANCE RECORD .......................6-20

SPEC
2 - 3
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (monocross suspension)
Shock absorber:
Front shock absorber Coil spring
Rear shock absorber Coil spring/oil damper
Wheel travel: Front wheel travel 96.0 mm (3.78 in)
Rear wheel travel 71.0 mm (2.80 in)
Electrical: Ignition system CDI
Charging system AC magneto
GENERAL SPECIFICATIONS

SPEC
2 - 14
EC212300
ELECTRICALItem Standard Limit
Ignition system: Advancer Digital ----
CDI: Magneto-model/manufacturer F1P6/MORIC ----
Pickup coil resistance (color) 248 ~ 372 Ω at 20 °C (68 °F)
(Red – White) ----
CDI unit model/manufacturer 1P6/SHY ----
Ignition coil: Model/manufacturer 4FP/SHY ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.32 ~ 0.48 Ω at 20 °C (68 °F) ----
Secondary winding resistance 5.68 ~ 8.52 k Ω at 20 °C (68 °F) ----
Spark plug cap: Type Resin ----
Resistance 10 k Ω at 20 °C (68 °F) ----
Charging system: System type AC magneto ----
Model/manufacturer F1P6/SHY ----
Normal output 14 V/80 W at 5,000 r/min ----
Charging coil resistance (color) 0.96 ~ 1.44 Ω at 20 °C (68 °F)
(White – Black) ----
Lighting coil resistance (color) 0.80 ~ 1.20 Ω at 20 °C (68 °F)
(Yellow – Black) ----
Rectifier/regulator: Regulator type Semiconductor short circuit ----
Model/manufacturer SH620B-12/SHINDENGEN ----
No-load regulated voltage (DC) 14.0 ~ 15.0 V ----
No-load regulated voltage (AC) 13.0 ~ 14.0 V ----
Rectifier capacity 8 A ----
Battery: Model YT4B-BS or GT4B-5 ----
Voltage capacity 12 V 2.3 Ah or 12 V 2.5 Ah ----
Electric starting system: Type Constant mesh ----
Starter motor: Model/manufacturer 1P6/SHY ----
Operation voltage 12 V ----
Output 0.25 kW ----
Armature coil resistance 0.035 ~ 0.043 Ω at 20 °C (68 °F) ----
Brush overall length 7 mm (0.28 in) 3.5 mm (0.14 in)
Brush quantity 2 pcs. ----
MAINTENANCE SPECIFICATIONS

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INSPADJ
BATTERY INSPECTION AND CHARGING
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
 Wear protective eye gear when handling
or working near batteries.
 Charge batteries in a well-ventilated area.
 Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
 DO NOT SMOKE when charging or han-
dling batteries.
 KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
 Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
 Skin — Wash with water.
 Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
 Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
CAUTION:
Charging time, charging amperage and
charging voltage for an MF battery are dif-
ferent from those of conventional batteries.
The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
BATTERY INSPECTION AND CHARGING

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INSPADJ
BATTERY INSPECTION AND CHARGING
NOTE:
Since MF batteries are sealed, it is not possi-
ble to check the charge state of the battery by
measuring the specific gravity of the electro-
lyte. Therefore, the charge of the battery has to
be checked by measuring the voltage at the
battery terminals.
1. Remove:
Seat assembly
 Battery cover
Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section in
the CHAPTER 4.
2. Disconnect:
Battery lead coupler 1
(from the battery terminals)
NOTE:
Push down on the tab a, and then remove the
battery lead coupler.
3. Remove:
Battery band
 Battery
Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section in
the CHAPTER 4.
1
a
4. Measure:
Battery charge
Measurement steps:
 Connect a pocket tester 1 to the battery
terminals.
Tester positive probe → battery positive
terminal
Tester negative probe → battery negative
terminal
NOTE:
 The charge state of an MF battery can be
checked by measuring its open-circuit volt-
age (i.e., the voltage when the positive ter-
minal is disconnected).
 No charging is necessary when the open-
circuit voltage equals or exceeds 12.8 V.
1

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INSPADJ
BATTERY INSPECTION AND CHARGING
È Relationship between the open-circuit voltage
and the charging time at 20
°C (68 °F)
(These values vary with the temperature, the
condition of the battery plates, and the electro-
lyte level.)
É Open-circuit voltage
Ê Charging time (hours)
Ë Time (minutes)
Ì Charging condition of the battery
Í Ambient temperature 20
°C (68 °F)
a Charging
b Check the open-circuit voltage.

Check the charge of the battery, as shown
in the charts and the following example.
Example:
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20 ~ 30% È
5. Charge: Battery
(refer to the appropriate charging method
illustration)
WARNING
Do not quick charge a battery.
CAUTION:
 Never remove the MF battery sealing
caps.
 Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause
battery overheating and battery plate
damage.
 If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.

3 - 27
INSPADJ
 When charging a battery, be sure to
remove it from the machine. (If charging
has to be done with the battery mounted
on the machine, disconnect the negative
battery lead from the battery terminal.)
 To reduce the chance of sparks, do not
plug in the battery charger until the bat-
tery charger leads are connected to the
battery.
 Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
 Make sure the battery charger lead clips
are in full contact with the battery termi-
nal and that they are not shorted. A cor-
roded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
 If the battery becomes hot to the touch at
any time during the charging process,
disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
 As shown in the following illustration, the
open-circuit voltage of an MF battery sta-
bilizes about 30 minutes after charging
has been completed. Therefore, wait 30
minutes after charging is completed
before measuring the open-circuit volt-
age.
BATTERY INSPECTION AND CHARGING

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INSPADJ
BATTERY INSPECTION AND CHARGING
Charging method using a variable voltage charger
Measure the open-circuit
voltage prior to charging.
Connect a charger and
ammeter to the battery
and start charging. Is the amperage higher
than the standard charg-
ing amperage written on
the battery? NO
YES
Charger
Ammeter
Adjust the voltage to obtain
the standard charging
amperage.
Set the timer to the charging
time determined by the open-
circuit voltage.
Refer to “BATTERY INSPEC-
TION AND CHARGING ”. Adjust the charging voltage to
20 ~ 25 V.
Monitor the amperage for 3 ~
5 minutes. Is the standard
charging amperage
exceeded?
NO
YES
If the amperage does not
exceed the standard charg-
ing amperage after 5 min-
utes, replace the battery.
If the required charging time exceeds 5 hours, it is advisable to check
the charging amperage after 5 hours. If there is any change in the
amperage, readjust the voltage to obtain the standard charging
amperage.
Leave the battery unused for more than 30 minutes before measuring
its open-circuit voltage.
12.8 V
→ Charging is complete.
12.0 ~ 12.7 V
→ Recharging is required.
Under 12.0 V
→ Replace the battery.
Leave the battery unused for more
than 30 minutes before measuring its
open-circuit voltage.
Set the charging voltage to 16 ~ 17 V.
(If the charging voltage is lower, charg-
ing will be insufficient, if it is higher, the
battery will be over-charged.)
NOTE:
NOTE: