2008 YAMAHA TTR50 service

INTRODUCTIONMOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON
THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERA-
TOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE.
HE OR SHE SHOULD:

OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE
OPERATION.


OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.


OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.


OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN
MADE NECESSARY BY MECHANICAL CONDITIONS.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
6
EAU17231
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of
motorcycle inspection, adjustment, and
lubrication are explained on the follow-
ing pages.
Maintenance, replacement, or repair
of the emission control devices and
systems may be performed by any
repair establishment or individual
that is certified (if applicable).
WARNING
EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealerdo it for you.
EAU40350
PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE
OF YOUR VEHICLE IS IMPORTANT
IN ORDER TO ENJOY LONG, PLEA-
SURABLE SERVICE. ESPECIALLY
IMPORTANT ARE THE MAINTE-
NANCE SERVICES RELATED TO
EMISSIONS CONTROL. THESE
CONTROLS NOT ONLY FUNCTION
TO ENSURE CLEANER AIR, BUT
ARE ALSO VITAL TO PROPER EN-
GINE OPERATION AND MAXIMUM
PERFORMANCE. IN THE FOLLOW-
ING PERIODIC MAINTENANCE
CHARTS, THE SERVICES RELATED
TO EMISSIONS CONTROL ARE
GROUPED SEPARATELY. THESE
SERVICES REQUIRE SPECIALIZED
DATA, KNOWLEDGE, AND EQUIP-
MENT. YAMAHA DEALERS ARE
TRAINED AND EQUIPPED TO PER-
FORM THESE PARTICULAR SER-
VICES.
WARNING
EWA10340
Modifications not approved by
Yamaha may cause loss of perfor-
mance, excessive emissions, andrender the vehicle unsafe for use.
Consult a Yamaha dealer before at-
tempting any changes.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU40000
NOTE:The air filter needs more frequent service if you are riding in unusually wet or dusty areas.10*Chassis fastenersCheck all chassis fitting and fasteners.
Correct if necessary.√√√
11 Brake lever pivot shaftApply lithium-soap-based grease (all-purpose grease)
lightly.√√
12 Brake pedal pivot shaftApply lithium-soap-based grease (all-purpose grease)
lightly.√√
13 Sidestand pivotCheck operation.
Apply lithium-soap-based grease (all-purpose grease)
lightly.√√
14*Spark arresterClean.√
15*Front forkCheck operation and for grease leakage.
Replace if necessary.√√
16*Shock absorber assem-
blyCheck operation and for oil leakage.
Replace if necessary.√
17*Control cablesApply Yamaha chain and cable lube or engine oil 10W-30
thoroughly.√√√
18*Throttle grip housing and
cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√ 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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU23013
Cleaning and lubricating the
drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.CAUTION:
ECA10581
The drive chain must be lubricated
after washing the motorcycle andriding in the rain.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.NOTE:For a thorough cleaning, have a
Yamaha dealer remove the drive chainand soak it in solvent.
2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on both sides
and on the middle of the chain,making sure that all side plates
and rollers have been sufficiently
oiled.
EAU23091
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING
EWA10710
Damage to the outer housing of ca-
bles may result in internal rusting
and cause interference with cable
movement. Replace damaged ca-
bles as soon as possible to preventunsafe conditions.Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil SAE 10W-30
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU42020
Replacing the fuse The fuse is located inside the battery
coupler.
If the fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
2. Disconnect the battery coupler.
3. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
CAUTION:
ECA10640
Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly afire.
4. Connect the battery coupler.
5. Turn the key to “ON” and turn on
the electrical circuits to check if the
devices operate.
6. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU24350
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
1. Fuse
2. Spare fuseSpecified fuse:
10.0 A
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6 a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU24360
Front wheel
EAU39791
To remove the front wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Remove the guard from each front
fork leg by removing the bolts.
2. Disconnect the brake cable at the
wheel by removing the brake lever
free play adjusting nut at the brakecamshaft lever, then remove the
cable from the brake camshaft le-
ver.
3. Loosen the axle nut.
1. Front fork leg guard
2. Bolt
1. Brake cable
2. Brake camshaft lever
3. Brake lever free play adjusting nut
1. Axle nut
2. Washer
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6
EAU25080
Rear wheel
EAU39770
To remove the rear wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the axle nut.2. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod from the brake cam-
shaft lever.
3. Loosen the locknut and drive chain
adjusting nut on each end of the
swingarm.
4. Lift the rear wheel off the ground
according to the procedure on
page 6-25.
5. Remove the axle nut and washer,
then pull the wheel axle out.6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:The drive chain does not need to be
disassembled in order to remove andinstall the wheel.
1. Axle nut
2. Washer
3. Drive chain slack adjusting nut
4. Locknut
1
4
3
2
1. Brake pedal free play adjusting nut
2. Brake rod
3. Brake camshaft lever
1
2
3
1. Wheel axle
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
67. Remove the wheel.
EAU39781
To install the rear wheel
1. Install the drive chain onto the rear
sprocket, and then install the
wheel by inserting the wheel axle
from the right-hand side.NOTE:Make sure that the slot in the brake
shoe plate fits over the retainer on theswingarm.
2. Connect the brake rod to the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.3. Adjust the drive chain slack. (See
page 6-17.)
4. Install the washer and axle nut,
and then lower the rear wheel so
that it is on the ground.
5. Tighten the axle nut to the speci-
fied torque.
6. Adjust the brake pedal free play.
(See page 6-16.)
EAU25850
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
1. Slot
2. Retainer
Tightening torque:
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
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