2006 YAMAHA TTR50 heating

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

3 - 26
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.

–+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 - 17
–+ELECCARBURETOR HEATING SYSTEM
EC624000
COUPLERS AND LEADS CONNECTION
INSPECTION
1. Check:
Couplers and leads connection
Rust/dust/looseness/short-circuit →
Repair or replace.
THERMO SWITCH INSPECTION
1. Inspect: Thermo switch operation
Faulty operation → Replace.
Inspection steps:
 Remove the thermo switch.
 Connect the pocket tester to the thermo
switch coupler as shown.
Tester (+) lead → Black
1
Tester ( –) lead
→ Black
2
 Immerse the thermo switch in a container
filled with water 3.
 Place a thermometer 4 in the water.
 Slowly heat the water, and then let it cool
to the specified temperature as indicated
in the table.
 Check the thermo switch for continuity at
the temperatures indicated in the table.

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

6 - 19
–+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