2006 YAMAHA TTR50 diagram

EC083000
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been complied to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol, e.g.
Bearings
Pitting/damage →
Replace.
EC084002
HOW TO READ DESCRIPTIONS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 1
is provided for removal and disassembly jobs.
2. Numbers 2
are given in the order of the jobs in the exploded diagram. A number that is
enclosed by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol
marks 3
. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 4
accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. Extent of removal 5
is provided in the job instruction chart to save the trouble of an unneces-
sary removal job.
6. For jobs requiring more information, the step-by-step format supplements 6
are given in addi-
tion to the exploded diagram and job instruction chart.

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1 to 6 are designed as
thumb tabs to indicate the chapter ’s number
and content.
1 General information
2 Specifications
3 Regular inspection and adjustments
4 Engine
5 Chassis
6 Electrical
Illustrated symbols
7 to D are used to identify
the specifications appearing in the text.
7 With engine mounted
8 Special tool
9 Filling fluid
0 Lubricant
A Tightening
B Specified value, Service limit
C Engine speed
D Resistance (
Ω), Voltage (V), Electric current (A)
Illustrated symbols
E to H in the exploded
diagram indicate grade of lubricant and loca-
tion of lubrication point.
E Apply engine oil
F Apply molybdenum disulfide oil
G Apply lightweight lithium-soap base grease
H Apply molybdenum disulfide grease
Illustrated symbols
I to J in the exploded
diagrams indicate where to apply a locking
agent and when to install new parts.
I Apply locking agent (LOCTITE®)
J Use new one
12
34
56
78
90
AB
CD
E

F
G
H
IJ
GEN
INFOSPEC
INSP ADJ
ENG
CHAS–+ELEC
T R..
EM
LSM
LTNew

CONTENTS
CHAPTER 1
GENERAL INFORMATION
DESCRIPTION ............................................1-1
MACHINE IDENTIFICATION ......................1-2
IMPORTANT INFORMATION .....................1-3
CHECKING OF CONNECTION ..................1-5
SPECIAL TOOLS .......................................1-6
CONTROL FUNCTIONS .............................1-8
FUEL .........................................................1-11
STARTING AND OPERATION .................1-12
CLEANING AND STORAGE ....................1-13
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................2-1
MAINTENANCE SPECIFICATIONS ...........2-4
GENERAL TORQUE
SPECIFICATIONS ....................................2-16
DEFINITION OF UNITS ............................2-16
CABLE ROUTING DIAGRAM ..................2-17
CHAPTER 3
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS ....................3-1
PRE-OPERATION INSPECTION AND
MAINTENANCE ..........................................3-3
ENGINE .......................................................3-4
CHASSIS ..................................................3-14
ELECTRICAL ............................................3-23

INHALT
KAPITEL 1
ALLGEMEINES
FAHRZEUGBESCHREIBUNG ..................1-1
FAHRZEUG-IDENTIFIZIERUNG ...............1-2
WICHTIGE INFORMATIONEN ..................1-3
KABELANSCHLÜSSE
KONTROLLIEREN ....................................1-5
SPEZIALWERKZEUGE .............................1-6
BEDIENUNGSELEMENTE UND
DEREN FUNKTION ...................................1-8
KRAFTSTOFF .........................................1-11
ANLASSEN UND INBETRIEBNAHME ...1-12
PFLEGE UND LAGERUNG .....................1-13
KAPITEL 2
TECHNISCHE DATEN
ALLGEMEINE TECHNISCHE DATEN ......2-1
WARTUNGSDATEN ..................................2-4
ALLGEMEINE ANZUGSMOMENTE .......2-16
MASSEINHEITEN ....................................2-16
KABELFÜHRUNGSDIAGRAMME ..........2-17
KAPITEL 3
REGELMÄSSIGE WAR-
TUNGS- UND EINSTELLAR-
BEITEN
WARTUNGSINTERVALLE ........................3-1
ROUTINEKONTROLLE VOR
FAHRTBEGINN .........................................3-3
MOTOR ......................................................3-4
FAHRWERK ............................................3-14
ELEKTRISCHE ANLAGE ........................3-23
TABLES DES MATIERES
CHAPITRE 1
RENSEIGNEMENTS
GENERAUX
DESCRIPTION ............................................... 1-1
IDENTIFICATION DE LA MOTO .............. 1-2
INFORMATIONS IMPORTANTES ............ 1-3
VERIFICATION DES CONNEXIONS ........ 1-5
OUTILS SPECIAUX ...................................... 1-6
FONCTIONS DES COMMANDES .............. 1-8
CARBURANT ............................................... 1-11
DEMARRAGE ET
FONCTIONNEMENT .................................. 1-12
NETTOYAGE ET REMISAGE .................. 1-13
CHAPITRE 2
CARACTERISTIQUES
CARACTERISTIQUES GENERALES ........ 2-1
CARACTERISTIQUES D’ENTRETIEN ..... 2-4
CARACTERISTIQUES GENERALES
DE COUPLE .................................................. 2-16
DEFINITION DES UNITES ........................ 2-16
CHEMINEMENT DES CABLES ................ 2-17
CHAPITRE 3
CONTROLES ET REGLAGES
PERIODIQUES
PROGRAMME D’ENTRETIEN ................... 3-1
CONTROLES ET ENTRETIENS
AVANT UTILISATION ................................. 3-3
MOTEUR ......................................................... 3-4
CHASSIS ........................................................ 3-14
PARTIE ELECTRIQUE .............................. 3-23

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

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 - 17
SPEC
KABELFÜHRUNGSDIAGRAMME
1 Z
ündbox-Kabel
2 Kabelf
ührung
3 Vergaserheizung
4 Vergaserheizungs-Anschlussklemme (flach)
5 Vergaserheizungs-Anschlussklemme (L-f
örmig)
6 Kabelf
ührung
7 Starterschalter-Kabel
8 Z
ündschloss-Kabel
9 Motorstoppschalter-Kabel
0 Chokezug
A Gaszug
B Kabelbinder
C Thermoschalter-Kabel
D Z
ündkabel
E Vergaser-Bel
üftungsschlauch
F Kurbelgeh
äuse-Entl üftungsschlauch
G Lichtmaschinen-Kabel
H Kabelbaum
CHEMINEMENT DES CABLES
KABELF ÜHRUNGSDIAGRAMME
CHEMINEMENT DES CABLES
1 Fil du bo îtier CDI
2 Guide-fil
3 Réchauffeur de carburateur
4 Borne plate du fil du r échauffeur de carburateur
5 Borne en L du fil du r échauffeur de carburateur
6 Guide-c âble
7 Fil du contacteur du d émarreur
8 Fil du contacteur à cl é
9 Fil du coupe-circuit du moteur
0 Câble de starter
A Câble des gaz
B Collier en plastique
C Fil du contacteur thermique
D Fil de bougie
E Durit de ventilation du carburateur
F Durit de mise à l ’air du carter moteur
G Fils de l ’alternateur avec rotor à aimantation perma-
nente
H Faisceau de fils

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