2006 YAMAHA TTR50 parts

INTRODUCTION
Congratulations on your purchase of a
Yamaha TT-R50E/TT-R50EV. This model is
the culmination of Yamaha’s vast experience
in the production of pacesetting racing
machines. It represents the highest grade of
craftsmanship and reliability that have made
Yamaha a leader.
This manual explains operation, inspection
and basic maintenance of your machine. If you
have any questions about this manual or your
machine, please contact your Yamaha dealer.
NOTE:
As improvements are made on this model,
some data in this manual may become out-
dated. If you have any questions, please con-
sult your Yamaha dealer.
WARNING
READ THIS MANUAL CAREFULLY FOR
INSTRUCTIONS ON HOW TO PROPERLY
OPERATE THIS MACHINE.
 ADULT INSTRUCTION AND SUPERVI-
SION ARE REQUIRED.
 WEIGHT OF THE RIDER SHOULD NOT
EXCEED 40 kg (88 lb).
 ALWAYS WEAR A HELMET AND SUIT-
ABLE PROTECTIVE CLOTHING WHEN
RIDING.
 DO NOT TOUCH ANY MOVING PARTS OR
HEATED AREAS.
 ALWAYS PERFORM PRE-OPERATION
CHECKS. REFER TO PAGE 3-3.
 THIS MACHINE IS DESIGNED TO CARRY
THE OPERATOR ONLY. NO PASSEN-
GERS.
 THIS MACHINE IS DESIGNED OFF-ROAD
USE ONLY.
IT IS NOT SUITABLE FOR ON-ROAD USE.

6. When going for riding, be sure to be withyour family.
Never go alone.
7. Before riding the machine, ask your par-ents to check the machine very carefully.
8. Don ’t touch the areas shown, or you ’ll get
burnt in the hand.
9. Don ’t touch rotating or moving parts.
10. Before starting the engine, be sure to shift
the transmission into neutral.

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

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 - 3
GEN
INFO
IMPORTANT INFORMATION
EC130000
IMPORTANT INFORMATION
EC131002
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign
material before removal and disassembly.
When washing the machine with high pres-
sured water, cover the parts as follows.
Silencer exhaust port
2. Use proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS ” section.
3. When disassembling the machine, keep
mated parts together. They include gears,
cylinders, pistons, and other mated parts
that have been “mated ” through normal
wear. Mated parts must be reused as an
assembly or replaced.
4. During the machine disassembly, clean all parts and place them in trays in the order of
disassembly. This will speed up assembly
time and help assure that all parts are cor-
rectly reinstalled.
5. Keep away from fire.

1 - 4
GEN
INFO
IMPORTANT INFORMATION
EC132000
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.
EC133000
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings shouldbe replaced when an engine is overhauled.
All gasket surfaces, oil seal lips, and O-
rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
EC134000
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates 1 and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been
properly tightened.
EC135001
BEARINGS AND OIL SEALS
1. Install the bearing(s) 1 and oil seal(s) 2
with their manufacturer ’s marks or numbers
facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of light-weight
lithium base grease to the seal lip(s). Oil
the bearings liberally when installing.
CAUTION:
Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.

1 - 11
GEN
INFO
FUEL
Use regular gasoline. Always use fresh, name
brand gasoline.
WARNING
Do not overfill the fuel tank. Avoid spilling
fuel on the hot engine. Do not fill the fuel
tank above the bottom of the filler tube 1
as shown in the illustration or it may over-
flow when the fuel heats up later and
expands.
a Fuel level
CAUTION:
Use only unleaded gasoline. The use of
leaded gasoline will cause severe damage
to the engine internal parts such as valves,
piston rings, and exhaust system, etc.
Recommended fuel: For USA, AUS and NZ: Unleaded gasoline only
For CDN, EUROPE and ZA: Regular unleaded gasoline
only
Fuel tank capacity: Total: 3.1 L (0.68 Imp gal, 0.82 US gal)
Reserve: 0.4 L (0.09 lmp gal, 0.11 US gal)
FUEL