2006 YAMAHA TTR50 transmission oil

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

GEN
INFO
1 - 12
STARTING AND OPERATION
STARTING AND OPERATION
CAUTION:
Prior to operating the machine, perform
steps listed in pre-operation check list.
WARNING
Never start your engine or let it run for any
length of time in a closed area. The exhaust
fumes are poisonous and can cause loss of
consciousness and death within a short
time. Always operate your machine in an
area with adequate ventilation.
STARTING A COLD ENGINE
WARNING
Before starting the engine, be sure to shift
the transmission into neutral.
NOTE:
 This model is equipped with an ignition cir-
cuit cut-off system. In case of electric start-
ing, the engine can be started only when the
transmission is in neutral.
 If the engine fails to start by pushing the start
switch, release the switch, wait a few sec-
onds, and then try again. Each starting
attempt should be as short as possible to
preserve the battery. Do not crank the
engine more than 10 seconds on any one
attempt.
1. Turn the fuel cock to “ON ”.
2. Turn the main switch to “ON ”.
3. Shift the transmission into neutral.
4. Operate the starter (choke) and completely close the throttle grip.
5. Slide the “engine stop ” switch to the “”.
6. Start the engine by pushing the start switch.
7. After the engine starts, warm up for one or
two minutes. Make sure the stater (choke) is
returned to the original position before riding. STARTING A WARM ENGINE
To start a warm engine, refer to the
“START-
ING A COLD ENGINE ” section. The starter
(choke) should not be used. The throttle
should be opened slightly.
CAUTION:
See “Engine break-in Section ” prior to
operating engine for the first time.
WARMING UP
To get maximum engine life, always “warm-up ”
the engine before starting off. Never accelerate
hard with a cold engine! To see whether or not
the engine is warm, see if it responds to throttle
normally with the stater (choke) turned off.
WARNING
Before starting off, be sure to turn up or
remove the side stand.
Failure to retract the side stand completely
can result in a serious accident when you
try to turn a corner.
ENGINE BREAK-IN
Break-in is important to better fit the moving
and sliding parts as well as the installed parts.
It is also important to accustom the rider to the
machine better.
Avoid full-throttle run on a new machine for the
first 5 hours.
After the trial run, check for loose parts, oil
leakage and other problems.
Make full inspection and adjustment especially of
slack cables and drive chain and loose spokes.
CAUTION:
After the break-in period, check every fit-
ting and fastener for looseness.
If any loose is found, retighten it securely.

GEN
INFO
1 - 13
CLEANING AND STORAGE
EC1B0000
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will
enhance its appearance, maintain good overall
performance, and extend the life of many com-
ponents.
1. Before washing the machine, block off the
end of the exhaust pipe to prevent water
from entering.
2. If the engine is excessively greasy, apply some degreaser to it with a paint brush. Do
not apply degreaser to the chain, sprock-
ets, or wheel axles.
3. Rinse the dirt and degreaser off with a gar- den hose; use only enough pressure to do
the job.
CAUTION:
Excessive hose pressure may cause water
seepage and contamination of wheel bear-
ings, front forks, brakes and transmission
seals. Many expensive repair bills have
resulted from improper high pressure
detergent applications such as those avail-
able in coin-operated car washers.
4. After the majority of the dirt has been hosed off, wash all surfaces with warm
water and a mild detergent. Use an old
toothbrush to clean hard-to-reach places.
5. Rinse the machine off immediately with clean water, and dry all surfaces with a soft
towel or cloth.
6. Immediately after washing, remove excess water from the chain with a paper towel
and lubricate the chain to prevent rust.
7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and
glossy.
8. Automotive wax may be applied to all
painted or chromed surfaces. Avoid combi-
nation cleaner-waxes, as they may contain
abrasives.
9. After completing the above, start the engine and allow it to idle for several min-
utes.
EC182001
STORAGE
If your machine is to be stored for 60 days or
more, some preventive measures must be
taken to avoid deterioration. After cleaning the
machine thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines, and the car-
buretor float bowl.
2. Remove the spark plug, pour a tablespoon of SAE 10W-30 motor oil in the spark plug
hole, and reinstall the plug. Set the engine
stop switch to “”, turn the engine over
several times with starter. (This will coat
the cylinder walls with oil.)
3. Remove the drive chain, clean it thoroughly with solvent, and lubricate it. Reinstall the
chain or store it in a plastic bag tied to the
frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off the ground.
6. Tie a plastic bag over the exhaust pipe out-
let to prevent moisture from entering.
7. If the machine is to be stored in a humid or salt-air environment, coat all exposed
metal surfaces with a film of light oil. Do not
apply oil to rubber parts or the seat cover.
NOTE:
Make any necessary repairs before the
machine is stored.

SPEC
2 - 2
Oil capacity:
Engine oil Periodic oil change 0.8 L (0.70 Imp qt, 0.85 US qt)
Total amount 1.0 L (0.88 Imp qt, 1.06 US qt)
Air filter: Wet element
Fuel: Type Unleaded gasoline only (USA, AUS and NZ) Regular unleaded gasoline only
(CDN, Europe and ZA)
Tank capacity 3.1 L (0.68 Imp gal, 0.82 US gal)
Reserve amount 0.4 L (0.09 Imp gal, 0.11 US gal)
Carburetor: Type VM11
Manufacturer MIKUNI
Spark plug: Type CR7HSA
Manufacturer NGK
Gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Clutch type: Wet, multiple-disc and centrifugal automatic
Transmission: Primary reduction system Spur gear
Primary reduction ratio 67/18 (3.722)
Secondary reduction system Chain drive
Secondary reduction ratio 37/13 (2.846)
Transmission type Constant mesh, 3-speed
Operation Left foot operation
Gear ratio: 1st 39/12 (3.250) 2nd 33/19 (1.736)
3rd 28/23 (1.217)
Chassis: Frame type Steel tube backbone
Caster angle 25.50 °
Trail 34.0 mm (1.34 in)
Tire: Type With tube
Size (front) 2.50-10 4PR
Size (rear) 2.50-10 4PR
Manufacturer (front and rear) CHENG SHIN
Type (front and rear) KNOBBY
Tire pressure (front and rear) 100 kPa (1.00 kgf/cm
2, 14.2 psi)
Brake: Front brake type Drum brake
Operation Right hand operation
Rear brake type Drum brake
Operation Right foot operation
GENERAL SPECIFICATIONS
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3
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5
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2 - 4
SPEC
CARACTERISTIQUES D’ENTRETIEN
MOTEUR
Elément Standard Limite
Culasse: Limite de d éformation ---- 0,05 mm
(0,0020 in)
Cylindre: Alésage 35,995 à 36,015 mm
(1,4171 à 1,4179 in) 36,05 mm
(1,419 in)
Arbre à cames:
M éthode de transmission Transmission par cha îne (gauche) ----
Dimensions de came
Admission “A ” 25,428 à 25,528 mm
(1,0011 à 1,0050 in) 25,328 mm
(0,9972 in)
“ B ” 21,034 à 21,134 mm
(0,8281 à 0,8320 in) 20,934 mm
(0,8242 in)
Echappement “A ” 25,286 à 25,386 mm
(0,9955 à 0,9994 in) 25,186 mm
(0,9916 in)
“ B ” 21,047 à 21,147 mm
(0,8286 à 0,8326 in) 20,947 mm
(0,8247 in)
Limite de voile d ’arbre à cames ---- 0,03 mm
(0,0012 in)
Cha îne de came:
Type de cha îne de came/nbre de maillons 92RH2005-84M/84 ----
M éthode de r églage de la cha îne de came Automatique ----
CARACTERISTIQUES D ’ENTRETIEN

2 - 11
SPEC
CHASSISElément Standard Limite
Syst ème de direction:
Type de roulement de direction Roulement oblique ----
Suspension avant: Débattement de fourche 96 mm (3,78 in) ----
Raideur de ressort K1 7,95 N/mm (0,81 kgf/mm, 45,39 lb/in)----
K2 10,50 N/mm (1,07 kgf/mm, 59,96 lb/in) ----
Ressort/entretoise en option Non ----
Diam ètre ext érieur du tube plongeur 21,7 mm (0,85 in) ----
Suspension arri ère:
D ébattement d ’amortisseur 47 mm (1,85 in) ----
Longueur de ressort libre 114 mm (4,49 in) ----
Longueur mont é 110 mm (4,33 in) ----
Raideur de ressort, standard K = 29,0 N/mm (2,96 kgf/mm, 166 lb/in)----
Ressort en option Non ----
Bras oscillant: Limite de jeu du bras oscillant A l ’extr émit é ---- 1,0 mm (0,0394 in)
Jeu lat éral ---- 0,3 mm (0,0118 in)
Roue: Type de roue avant Roue à rayons ----
Type de roue arri ère Roue à rayons ----
Taille/mat ériau de la jante avant 10 × 1,40/acier ----
Taille/mat ériau de la jante arri ère 10 × 1,40/acier ----
Limite de voile de la jante: Radial ---- 2,0 mm (0,08 in)
Lat éral ---- 2,0 mm (0,08 in)
Cha îne de transmission:
Type/fabricant 420/KMC ----
Nombre de maillons 79 maillons + attache ----
Fl èche de la cha îne 35 à 45 mm (1,38 à 1,77 in) ----
Longueur de la cha îne (15 maillons) ---- 194,3 mm
(7,65 in)
CARACTERISTIQUES D’ENTRETIEN

INSPADJ

CONTROLES ET ENTRETIENS AVANT UTILISATION
CONTROLES ET ENTRETIENS AVANT UTILISATION
Avant d ’entamer le rodage de la moto, un entra înement ou une course, s ’assurer que la moto est en bon état de
marche.
Contr ôler les points suivants avant d ’utiliser cette moto.
CONTROLES ET ENTRETIENS GENERAUX
El ément Travail Page
Carburant Faire le plein du r
éservoir de carburant à l ’aide d ’essence fra îche. Contr ôler
que la canalisation de carburant ne pr ésente aucune fuite. P. 1-11
Huile moteur Contr
ôler que le niveau d ’huile est correct. V érifier que le carter moteur ne
pr ésente aucune fuite. P. 3-7
à 9
Acc élé rateur Contr ôler le bon fonctionnement du c âble des gaz. P. 3-4 à 5
Freins Contr ôler le jeu et l ’efficacit é des freins avant et arri ère. P. 3-14 à 15
Cha îne de transmission Contr
ôler le jeu et l ’alignement de la cha îne. Contr ôler que la cha îne est cor-
rectement lubrifi ée. P. 3-16
à 18
Roues et pneus Contr
ôler la pression de gonflage, le voile, le serrage des rayons, la but ée de
talon et les écrous d ’axe. P. 3-19
à 20
Direction Contr
ôler que le mouvement du guidon s ’effectue en douceur et ne pr ésente
pas de jeu excessif. P. 3-20
à 21
Fourche avant et combin é
ressort-amortisseur arri ère Contr
ôler qu ’ils fonctionnent en douceur et ne pr ésentent pas de fuite d ’huile. P. 3-18
C âbles (fils) Contr
ôler que le c âble des gaz coulisse librement. V érifier qu ’il ne se coince
pas lorsque l ’on tourne le guidon. —
Pot d ’échappement Contr
ôler que le pot d ’échappement est bien fix é et ne pr ésente pas de fissu-
res. P.4-3
Pignon Contr
ôler que l ’écrou de serrage du pignon de sortie de bo îte n ’est pas des-
serr é. P. 3-15
Lubrification Contr ôler le bon fonctionnement. Lubrifier si n écessaire. P. 3-22
Bougie Contr ôler la couleur et l ’état. P. 3-23
Visserie Contr ôler tout – resserrer si n écessaire. P.2-13
Connecteurs Contr
ôler que l ’alternateur à rotor à aimantation permanente, le bo îtier CDI
et la bobine d ’allumage sont bien connect és. P. 1-5
3 - 3