2008 YAMAHA TTR50 clutch

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
Safe riding ......................................1-1
Location of important labels ............1-4
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Main switch .....................................3-1
Handlebar switches ........................3-1
Speed limiter ...................................3-2
Shift pedal .......................................3-2
Brake lever .....................................3-3
Brake pedal ....................................3-3
Fuel tank cap ..................................3-3
Fuel .................................................3-4
Fuel tank breather hose ..................3-5
Fuel cock ........................................3-5
Starter (choke) lever .......................3-6
Seat ................................................3-7
Sidestand ........................................3-7
Starting circuit cut-off system .........3-8
PRE-OPERATION CHECKS..............4-1
Pre-operation check list ..................4-2OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting and warming up a cold
engine ......................................... 5-1
Starting a warm engine .................. 5-2
Shifting ........................................... 5-2
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
PERIODIC MAINTENANCE ........... 6-1
Periodic maintenance chart for
the emission control system ....... 6-2
General maintenance and
lubrication chart .......................... 6-3
Checking the spark plug ................. 6-5
Engine oil ....................................... 6-6
Cleaning the air filter element ........ 6-8
Cleaning the spark arrester ............ 6-9
Adjusting the carburetor ............... 6-10
Adjusting the engine idling
speed ........................................ 6-11
Adjusting the throttle cable free
play ........................................... 6-11
Valve clearance ............................ 6-12
Tires ............................................. 6-12
Spoke wheels ............................... 6-14
Accessories and replacement
parts .......................................... 6-14
Adjusting the clutch free play ....... 6-14Adjusting the brake lever free
play ........................................... 6-15
Adjusting the brake pedal free
play ........................................... 6-16
Checking the front and rear brake
shoes ........................................ 6-16
Drive chain slack .......................... 6-17
Cleaning and lubricating the
drive chain ................................ 6-19
Checking and lubricating the
cables ....................................... 6-19
Checking and lubricating the
throttle grip and cable ............... 6-20
Checking and lubricating the
brake and shift pedals .............. 6-20
Checking and lubricating the
brake lever ................................ 6-20
Checking and lubricating the
sidestand .................................. 6-21
Lubricating the swingarm
pivots ........................................ 6-21
Checking the front fork ................. 6-21
Checking the steering .................. 6-22
Checking the wheel bearings ....... 6-23
Battery ......................................... 6-23
Replacing the fuse ....................... 6-25
Supporting the motorcycle ........... 6-25
Front wheel .................................. 6-26
Rear wheel ................................... 6-28
Troubleshooting ........................... 6-29
Troubleshooting chart .................. 6-30U1P682E0.book Page 1 Wednesday, May 23, 2007 9:34 AM

DESCRIPTION
2-2
2
EAU10420
Right view
4 65 32 1
1. Seat (page 3-7)
2. Fuel tank cap (page 3-3)
3. Spark plug cap (page 6-5)
4. Brake pedal (page 3-3)
5. Clutch adjusting screw (page 6-14)
6. Engine oil filler cap (page 6-6)U1P682E0.book Page 2 Wednesday, May 23, 2007 9:34 AM

OPERATION AND IMPORTANT RIDING POINTS
5-2
5
EAU16640
Starting a warm engine Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
EAU39901
Shifting This motorcycle has a 3-speed trans-
mission with a centrifugal, automatic
clutch. Shifting gears lets you control
the amount of engine power available
for starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the il-
lustration.NOTE:To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of itstravel.
CAUTION:
ECA15441


Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.


Always release the throttle grip
before changing gears to avoid
damaging the engine, transmis-
sion, and drive train, which are
not designed to withstand the
shock of shifting when the throt-tle grip is open.
EAU39910
To start out and accelerate
1. Close the throttle.
2. Shift into first gear and release the
shift pedal.
1. Shift pedal
2. Neutral position
U1P682E0.book Page 2 Wednesday, May 23, 2007 9:34 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
EAU35348
General maintenance and lubrication chart No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL ODOMETER READINGS
1000 km
(600 mi) or
1 month or
30 hours3000 km
(1800 mi) or
6 months or
90 hours5000 km
(3000 mi) or
12 months or
150 hours
1*ClutchCheck operation.
Adjust if necessary.√√√
2*Front brakeCheck operation.
Adjust brake lever free play and replace brake shoes if
necessary.√√√
3*Rear brakeCheck operation.
Adjust brake pedal free play and replace brake shoes if
necessary.√√√
4*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√
5*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√
6*Wheel bearingsCheck bearings for smooth operation.
Replace if necessary.√√
7*Swingarm pivot bearingsCheck bearing assemblies for looseness.
Moderately repack with lithium-soap-based grease.√√
8 Drive chainCheck chain slack/alignment and condition.
Adjust and lubricate chain with Yamaha chain and cable
lube thoroughly.Every ride
9*Steering bearingsCheck bearing assemblies for looseness.
Moderately repack with lithium-soap-based grease.√√
U1P682E0.book Page 3 Wednesday, May 23, 2007 9:34 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6To change the engine oil
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
4. Install the engine oil drain bolt, and
then tighten it to the specified
torque.5. Add the specified amount of the
recommended engine oil, and then
install and tighten the engine oil fill-
er cap.
CAUTION:
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-rial enters the crankcase.
6. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.7. Turn the engine off, and then
check the oil level and correct it if
necessary.
1. Engine oil drain boltTightening torque:
Engine oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
1
Recommended engine oil:
See page 8-1.
Oil change quantity:
0.80 L (0.85 US qt) (0.70 Imp.qt)
U1P682E0.book Page 7 Wednesday, May 23, 2007 9:34 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6
EAU21940
Spoke wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU40431
Accessories and replacement
parts
WARNING
EWA14481
The accessories or replacement
parts you choose for your vehicle
should be designed specifically for
this model, and they must be se-
curely mounted to maintain the in-
herent stability of the original
design. Genuine Yamaha Parts and
Accessories are designed and test-
ed to be compatible with your vehi-
cle. Yamaha recommends the use of
Genuine Yamaha Parts and Acces-
sories before making a purchase.
Use of non-Yamaha-approved ac-
cessories or replacement parts may
cause loss of handling stability and
riding safety. Since Yamaha cannot
control the quality of accessories or
parts manufactured by other compa-
nies, Yamaha cannot be held liable
for any consequences caused by
the use of items which have notbeen approved by Yamaha.
EAU44661
Adjusting the clutch free play The clutch free play must be checked
and, if necessary, adjusted as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Loosen the locknut.
2. Slowly turn the clutch adjusting
screw in direction (a) until resis-
tance is felt, and then turn it 1/8
turn in direction (b).NOTE:Turning the clutch adjusting screw in di-
rection (a) decreases clutch free play
and turning it in direction (b) increasesclutch free play.1. Locknut
2. Clutch adjusting screw
U1P682E0.book Page 14 Wednesday, May 23, 2007 9:34 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
63. Tighten the locknut to the specified
torque.
NOTE:
When tightening the locknut, hold the
clutch adjusting screw with a screwdriv-
er so that it does not turn together withthe locknut.
EAU22130
Adjusting the brake lever free
play The brake lever free play should mea-
sure 10.0–20.0 mm (0.39–0.79 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.
To increase the brake lever free play,
turn the adjusting nut at the brake shoe
plate in direction (a). To decrease the
brake lever free play, turn the adjusting
nut in direction (b).
WARNING
EWA10650
If proper adjustment cannot be ob-
tained as described, have a Yamahadealer make this adjustment.
Tightening torque:
Locknut:
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
1. Brake lever free play
1
1. Brake lever free play adjusting nut
1
(a)
(b)
U1P682E0.book Page 15 Wednesday, May 23, 2007 9:34 AM

SPECIFICATIONS
8-2
8
Clutch:Clutch type:
Wet, multiple-disc and centrifugal
automaticTransmission: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)Front tire:Type:
With tubeSize:
2.50-10 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY
Rear tire:Type:
With tube
Size:
2.50-10 4PR
Manufacturer/model:
CHENG SHIN/KNOBBYLoading:Maximum rider weight:
40.0 kg (88 lb)Tire air pressure (measured on cold
tires):
Front:
100 kPa (15 psi) (1.00 kgf/cm²)
Rear:
100 kPa (15 psi) (1.00 kgf/cm²)
Front wheel:Wheel type:
Spoke wheel
Rim size:
10x1.40Rear wheel:Wheel type:
Spoke wheel
Rim size:
10x1.40Front brake:Type:
Drum brakeOperation:
Right hand operation
Rear brake:Type:
Drum brake
Operation:
Right foot operationFront suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring
Wheel travel:
96.0 mm (3.78 in)Rear suspension:Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
71.0 mm (2.80 in)Electrical system:Ignition system:
CDI
Charging system:
AC magnetoBattery:Model:
GT4B-5
Voltage, capacity:
12 V, 2.5 AhFuse:Fuse:
10.0 A
U1P682E0.book Page 2 Wednesday, May 23, 2007 9:34 AM