2006 YAMAHA TTR50 key

EC080000
HOW TO USE
THIS MANUAL
EC081000
PARTICULARLY IMPORTANT
INFORMATION
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could
result in severe injury or death to the machine
operator, a bystander, or a person inspecting
or repairing the machine.
A CAUTION indicates special precautions that
must be taken to avoid damage to the
machine.
NOTE: A NOTE provides key information to make pro-
cedures easier or clearer.
WARNING
CAUTION:
EC082000
FINDING THE REQUIRED PAGE
1. This manual consists of six chapters; “Gen-
eral Information ”, “Specifications ”, “Regular
inspection and adjustments ”, “Engine ”,
“ Chassis ” and “Electrical ”.
2. The table of contents is at the beginning of the manual. Look over the general layout of
the book before finding then required chap-
ter and item.
Bend the book at its edge, as shown, to
find the required fore edge symbol mark
and go to a page for required item and
description.

1 - 2
GEN
INFO
MACHINE IDENTIFICATION
EC120001
MACHINE IDENTIFICATION
There are two significant reasons for knowing
the serial number of your machine:
1. When ordering parts, you can give the
number to your Yamaha dealer for positive
identification of the model you own.
2. If your machine is stolen, the authorities will need the number to search for and identify
your machine.
KEY IDENTIFICATION NUMBER
The key identification number 1 is stamped
on the key as shown in the following illustra-
tion. This number can be used for ordering a
new key.
EC121001
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped on the right of the steering head pipe.
1
ENGINE SERIAL NUMBER
The engine serial number 1 is stamped into
the elevated part of the left-side of the engine.
1
EC124000
MODEL LABEL
The model label 1 is affixed to the frame
under the rider ’s seat. This information will be
needed to order spare parts.
1

1 - 8
GEN
INFO
CONTROL FUNCTIONS
EC150000
CONTROL FUNCTIONS
MAIN SWITCH
Functions of the respective switch positions
are as follows:
ON: The engine can be started only at this
position.
OFF: All electrical circuits are switched off. The key can be removed in this position.
ENGINE STOP SWITCH
Make sure that the engine stop switch 1 is
positioned to “”. The engine stop switch has
been equipped to ensure safety in an emer-
gency such when the machine is up set or
trouble takes place in the throttle system. The
engine will not start or run when the engine
stop switch is turned to “”.
START SWITCH
The start switch 1 is located on the right han-
dlebar. Push this switch to crank the engine
with the starter.
1
SHIFT PEDAL
The gear ratios of the constant-mesh 3 speed
transmission are ideally spaced. The gears
can be shifted by using the shift pedal 1 on
the left side of the engine.
WARNING
When starting out on the machine, shift the
transmission into 1st after pulling in the
front brake lever and closing the throttle
grip.
3
2
1
N
1

3 - 6
INSPADJ
 Tighten the locknut.
WARNING
Particularly for a beginner rider, the
speed limiter should be screwed in
completely. Screw it out little by little as
their riding technique improves. Never
remove the speed limiter for a begin-
ning rider.
 For proper throttle lever operation do
not turn out the adjuster more than
25.0 mm (0.98 in). Also, always adjust
the throttle lever free play to 3 ~ 5 mm
(0.12 ~ 0.20 in).
AIR FILTER CLEANING
NOTE:
Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.
CAUTION:
Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid
wear and possible engine damage.
1. Remove: Seat assembly
 Air scoop (left)
Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section in
the CHAPTER 4.
 Air filter case cover 1
 Air filter element
1
SPEED LIMITER ADJUSTMENT/AIR FILTER CLEANING

4 - 42
ENGAC MAGNETO AND STARTER CLUTCH
AC MAGNETO AND STARTER CLUTCH
È Stake
Extent of removal: 1 Crankcase cover (left) removal
2 Pickup coil/stator removal
3 Rotor removal
4 Starter clutch/wheel gear removal
Extent of removal Order Part name Q ’ty Remarks
AC MAGNETO AND STATOR
REMOVAL
Preparation for removal Seat assembly Refer to “FRONT FENDER, SEAT
ASSEMBLY AND FUEL TANK ” section.
1 Crankcase cover (left) 1
2 Dowel pin 2
3 Gasket 1
4 AC magneto coupler 2
5 Neutral switch lead 1
6 Pickup coil/stator assembly 1
7 Rotor nut 1 Use special tool.
Refer to “REMOVAL POINTS ”.
8 Rotor 1
9 Woodruff key 1
21
3
4

4 - 44
ENGAC MAGNETO AND STARTER CLUTCH
REMOVAL POINTS
Rotor
1. Remove:Rotor nut 1
 Washer 2
NOTE:
Loosen the rotor nut while holding the rotor
with sheave holder 3.
 Do not allow the sheave holder to touch the
projection on the rotor.
Sheave holder:
YS-01880-A/90890-01701
2. Remove:
Rotor 1
 Woodruff key
NOTE:
 Use the flywheel puller 2.
 Center the flywheel puller over the rotor.
Make sure after installing the holding bolts
that the clearance between the flywheel
puller and the rotor is the same everywhere.
If necessary, one holding bolt may be turned
out slightly to adjust the flywheel puller ’s
position.
CAUTION:
Cover the crankshaft end with the box
wrench for protection.
Flywheel puller: YU-33270-B/90890-01362

4 - 46
ENGAC MAGNETO AND STARTER CLUTCH
3. Install:Spring 1
 Spring cap 2
 Pin 3
4. Install: Shim 1
 Starter wheel gear 2
 Starter idle gear 3
 Shaft 4
NOTE:
Apply the molybdenum disulfide oil on the
starter wheel gear inner circumference.
 Apply the engine oil on the starter idle gear
inner circumference and on the shaft outer
circumference.
1 2
3
12
3
5. Install:
Woodruff key 1
 Rotor 2
NOTE:
Clean the tapered portion of the crankshaft
and the rotor hub.
 When installing the rotor, make sure the
woodruff key is properly seated in the key
way of the crankshaft.
6. Tighten: Rotor nut 1
NOTE:
Tighten the rotor nut 1 while holding the
rotor 2 with a sheave holder 3.
 Do not allow the sheave holder to touch the
projection on the rotor.
7. Install: Crankcase cover (left)
NOTE:
 Pass the starter motor lead 1 and neutral
switch lead 2 into the crankcase cover
groove as shown.
 Fasten the starter motor lead with the clamp 3.
Sheave holder:
YS-01880-A/90890-01701
T R..48 Nm (4.8 m · kg, 35 ft · lb)
3
1
2