2006 YAMAHA TTR50 heater

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

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

4 - 4
ENG
CARBURETOR
2
1
6
6
3
8
9 5
47
New
New
T R..7 Nm (0.7 m
•
kg, 5.1 ft • Ib)
New
T R..2 Nm (0.2 m •
kg, 1.4 ft • Ib)
Extent of removal: 1 Carburetor removal
Extent of removal Order Part name Q ’ty Remarks
CARBURETOR REMOVAL
Preparation for removal Fuel tank Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section.
1 Clamp (air filter joint) 1 Loosen the screw (air filter joint).
2 Carburetor heater lead connector 2
3 Air vent hose 1
4 Fuel hose 1
5 Carburetor assembly 1
6O-ring 2
7 Joint 1
8 Carburetor top 1
9 Starter plunger assembly 1
1
CARBURETOR

4 - 6
ENGCARBURETOR
Extent of removal Order Part name Q’ty Remarks
C Float pin 1
D Float 1
E Needle valve set 1
F Main jet 1
G Needle jet 1
H Pilot jet 1
I Throttle stop screw set 1
J Carburetor heater 1
K Fuel filter 1
1

6 - 1
–+ELEC
345
6
78
\b0
B\f
2
1
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1 Thermo switch
2 Main switch
3 Engine stop switch
4 Ignition coil
5 Ground lead
6 Fuse
7 Battery
8 CDI unit
9 Starter relay 0
Rectifier/regulator
A Neutral switch
B AC magneto
C Carburetor heater
D Start switch
E Spark plug
F Starter motorCOLOR CODE
B ...................... Black
Br .................... Brown
O ..................... Orange
R ..................... Red
Sb .................... Sky blue
W ..................... White
Y ...................... Yellow
EC612000
WIRING DIAGRAM
R
WR
W
BL /WSb B
RW
W
W
OO
B
B
Y /R
R
W
B
R
Y /RY /R
Y
ON
OFF
OFF ON
Y
B
BY
/RRB
SbY /RR B
W
B
B
RBrR
Br
R
/WBr
R /W
L /W
OFF
RUN
Sb
BrBr
Sb
WBY
/RW SbY
B
B
B
RR
RR
R
R
R
/W
L /W
RRRB
R /W
L
/WR
R
RR
B Br
BO
R
WB
\f
2 8
4
E
1
C
D
0
63
\b F
5 7
Br
L/W .................. Blue/White
R/W .................. Red/White
Y/R ................... Yellow/Red
E
F
D
C

–+ELEC
6 - 16
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

6 - 18
–+ELEC
ÈThe thermo switch circuit is open.
É The thermo switch circuit is closed.
Test step Water temperature Continuity
1 Less than 16
± 3 °C
(60.8 ± 5.4 °F) YES
2 More than 16
± 3 °C
(60.8 ± 5.4 °F) NO
3 More than 11
± 3 °C
(51.8 ± 5.4 °F) NO
4 Less than 11
± 3 °C
(51.8 ± 5.4 °F) YES
Test steps 1 & 2: Heating phase
Test steps 3 & 4: Cooling phase
WARNING

Handle the thermo switch with special
care.
 Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
 Check the thermo switch operation.
CARBURETOR HEATER INSPECTION
1. Inspect:
Carburetor heater resistance
Out of specification → Replace.
Tester (+) probe →
Carburetor heater terminal 1
Tester ( –) probe →
Carburetor heater body 2
Carburetor
heater resistance Tester selector
position
4.6 ~ 9.6 Ω at
20 °C (68 °F) Ω
× 1
CARBURETOR HEATING SYSTEM