2010 YAMAHA TTR50 clutch

TABLE OF CONTENTS
LOCATION OF IMPORTANT
LABELS ............................................1-1
SAFETY INFORMATION .................. 2-1
DESCRIPTION .................................. 3-1
Left view .......................................... 3-1
Right view ........................................ 3-2
Controls and instruments ................3-3
INSTRUMENT AND CONTROL
FUNCTIONS....................................... 4-1
Main switch ..................................... 4-1
Handlebar switches ........................ 4-1
Speed limiter .................................. 4-2
Shift pedal ......................................4-3
Brake lever ..................................... 4-3
Brake pedal .................................... 4-3
Fuel tank cap .................................. 4-4
Fuel ................................................ 4-4
Fuel tank breather hose ................. 4-6
Fuel cock ........................................ 4-6
Starter (choke) lever ....................... 4-7
Seat ................................................ 4-7
Sidestand ....................................... 4-8
Starting circuit cut-off system ......... 4-8FOR YOUR SAFETY –
PRE-OPERATION CHECKS............. 5-1
OPERATION AND IMPORTANT
RIDING POINTS................................ 6-1
Starting and warming up a cold
engine ......................................... 6-1
Starting a warm engine .................. 6-2
Shifting ........................................... 6-2
Engine break-in .............................. 6-3
Parking ........................................... 6-4
PERIODIC MAINTENANCE AND
ADJUSTMENT................................... 7-1
Periodic maintenance chart for the
emission control system ............. 7-2
General maintenance and
lubrication chart .......................... 7-3
Checking the spark plug ................ 7-6
Engine oil ....................................... 7-7
Cleaning the air filter element ........ 7-8
Cleaning the spark arrester ......... 7-10
Adjusting the carburetor ............... 7-11
Adjusting the engine idling
speed ........................................ 7-11
Adjusting the throttle cable free
play ........................................... 7-12
Valve clearance ........................... 7-13
Tires ............................................. 7-13
Spoke wheels .............................. 7-14
Adjusting the clutch free play ....... 7-15Adjusting the brake lever free
play ........................................... 7-16
Adjusting the brake pedal free
play ........................................... 7-16
Checking the shift pedal ............... 7-17
Checking the front and rear
brake shoes .............................. 7-17
Drive chain slack .......................... 7-18
Cleaning and lubricating the
drive chain ................................ 7-20
Checking and lubricating the
cables ....................................... 7-20
Checking and lubricating the
throttle grip and cable ............... 7-21
Checking and lubricating the
brake lever ................................ 7-21
Checking and lubricating the
brake pedal ............................... 7-21
Checking and lubricating the
sidestand .................................. 7-22
Lubricating the swingarm pivots ... 7-22
Checking the front fork ................. 7-22
Checking the steering .................. 7-23
Checking the wheel bearings ....... 7-23
Battery .......................................... 7-24
Replacing the fuse ....................... 7-25
Supporting the motorcycle ........... 7-26
Front wheel .................................. 7-27
Rear wheel ................................... 7-28
Troubleshooting ........................... 7-30
Troubleshooting chart .................. 7-31
U1P684E0.book Page 1 Tuesday, April 28, 2009 10:22 AM

DESCRIPTION
3-2
3
EAU10420
Right view
4 65 32 1
1. Seat (page 4-7)
2. Fuel tank cap (page 4-4)
3. Spark plug cap (page 7-6)
4. Brake pedal (page 4-3)
5. Clutch adjusting screw (page 7-15)
6. Engine oil filler cap (page 7-7)U1P684E0.book Page 2 Tuesday, April 28, 2009 10:22 AM

OPERATION AND IMPORTANT RIDING POINTS
6-2
6
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.TIPTo shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel.
NOTICE
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.
EAU39911
To start out and accelerate
1. Close the throttle.
2. Shift into first gear and release the
shift pedal. NOTICE: Always
close the throttle before shifting
gears, otherwise damage to the
engine and drive train may re-
sult.
[ECA15461]
1. Shift pedal
2. Neutral position
U1P684E0.book Page 2 Tuesday, April 28, 2009 10:22 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-3
7
EAU35349
General maintenance and lubrication chart TIP

From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 6 months.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
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.√√
U1P684E0.book Page 3 Tuesday, April 28, 2009 10:22 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-8
73. 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. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the engine
oil filler cap.
NOTICE
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.
EAU39834
Cleaning the air filter element The air filter element should be cleaned
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Clean or, if necessary, re-
place the air filter element more
frequently if you are riding in unusually
wet or dusty areas.
To clean the air filter element
1. Remove the air filter case cover by
removing the screws.
2. Pull the sponge material and the
air filter mesh out.
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 9-1.
Oil change quantity:
0.80 L (0.85 US qt, 0.70 Imp.qt)
1. Screw
2. Air filter case cover
U1P684E0.book Page 8 Tuesday, April 28, 2009 10:22 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-15
7


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.
EAU46251
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. Remove the clutch adjusting
screw cover by removing the
screws.
2. Loosen the locknut.
3. Slowly turn the clutch adjusting
screw in direction (a) until resis-
tance is felt, and then turn it 1/8
turn in direction (b).4. Tighten the locknut to the specified
torque.
TIPWhen tightening the locknut, hold the
clutch adjusting screw with a screwdriv-
er so that it does not turn together with
the locknut.5. Install the clutch adjusting screw
cover by installing the screws.
1. Screw
2. Clutch adjusting screw cover
1. Locknut
2. Clutch adjusting screw
Tightening torque:
Locknut:
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
U1P684E0.book Page 15 Tuesday, April 28, 2009 10:22 AM

SPECIFICATIONS
9-1
9
Dimensions:Overall length:
1305 mm (51.4 in)
Overall width:
595 mm (23.4 in)
Overall height:
775 mm (30.5 in)
Seat height:
555 mm (21.9 in)
Wheelbase:
925 mm (36.4 in)
Ground clearance:
135 mm (5.31 in)
Minimum turning radius:
1400 mm (55.1 in)Weight:With oil and fuel:
57.0 kg (126 lb)Noise and vibration level:Noise level (77/311/EEC):
TT-R50E 76.7 dB(A)
Vibration on seat (EN1032, ISO5008):
TT-R50E Will not exceed 0.5 m/s²
Vibration on handlebar (EN1032, ISO5008):
TT-R50E Will not exceed 2.5 m/s²Engine:Engine type:
Air cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
49 cm³
Bore × stroke:
36.0 × 48.6 mm (1.42 × 1.91 in)Compression ratio:
9.50 :1
Starting system:
Electric starter
Lubrication system:
Wet sump
Engine oil:Recommended brand:
YAMALUBE
Type:
SAE 10W-30, 10W-40, 10W-50, 15W-40,
20W-40 or 20W-50
Recommended engine oil grade:
API service SG type or higher, JASO
standard MA
Engine oil quantity:
Periodic oil change:
0.80 L (0.85 US qt, 0.70 Imp.qt)Air filter:Air filter element:
Wet element
Fuel:Recommended fuel:
TT-R50E Regular unleaded gasoline only
TT-R50EZ Regular unleaded gasoline only
(CAN)
TT-R50EZ Unleaded gasoline only
(AUS)(NZL)
Fuel tank capacity:
3.1 L (0.82 US gal, 0.68 Imp.gal)
Fuel reserve amount:
0.4 L (0.11 US gal, 0.09 Imp.gal)Carburetor:Type × quantity:
VM11 x 1Spark plug (s):Manufacturer/model:
NGK/CR7HSA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)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
–20–10 0
1020 30 40 50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40SAE 10W-50
10 30 50 70 90 110 0 130 ˚F
U1P684E0.book Page 1 Tuesday, April 28, 2009 10:22 AM

INDEXAAir filter element, cleaning....................... 7-8BBattery................................................... 7-24
Brake lever .............................................. 4-3
Brake lever, checking and lubricating ... 7-21
Brake lever free play, adjusting............. 7-16
Brake pedal ............................................. 4-3
Brake pedal, checking and
lubricating ........................................... 7-21
Brake pedal free play, adjusting............ 7-16
Brake shoes, checking .......................... 7-17CCables, checking and lubricating .......... 7-20
Carburetor, adjusting ............................ 7-11
Care ........................................................ 8-1
Clutch free play, adjusting..................... 7-15DDrive chain, cleaning and lubricating .... 7-20
Drive chain slack ................................... 7-18EEngine break-in ....................................... 6-3
Engine idling speed............................... 7-11
Engine oil ................................................ 7-7
Engine, starting a warm .......................... 6-2
Engine stop switch .................................. 4-2FFront fork, checking .............................. 7-22
Fuel ......................................................... 4-4
Fuel cock................................................. 4-6
Fuel tank breather hose .......................... 4-6
Fuel tank cap .......................................... 4-4
Fuse, replacing ..................................... 7-25
HHandlebar switches ................................ 4-1IIdentification numbers .......................... 10-1KKey identification number ..................... 10-1LLabels, location....................................... 1-1MMain switch ............................................. 4-1
Maintenance and lubrication, periodic .... 7-3
Maintenance, emission control system... 7-2
Matte color, caution ................................ 8-1
Model label ........................................... 10-2PParking ................................................... 6-4
Part locations .......................................... 3-1SSafety information................................... 2-1
Seat ........................................................ 4-7
Shifting.................................................... 6-2
Shift pedal............................................... 4-3
Shift pedal, checking ............................ 7-17
Sidestand................................................ 4-8
Sidestand, checking and lubricating ..... 7-22
Spark arrester, cleaning ....................... 7-10
Spark plug, checking .............................. 7-6
Specifications ......................................... 9-1
Speed limiter........................................... 4-2
Starter (choke) lever ............................... 4-7
Starting and warming up a cold
engine .................................................. 6-1
Starting circuit cut-off system ................. 4-8
Start switch ............................................. 4-2Steering, checking................................. 7-23
Storage.................................................... 8-3
Supporting the motorcycle .................... 7-26
Swingarm pivots, lubricating ................. 7-22
TThrottle cable free play, adjusting ......... 7-12
Throttle grip and cable, checking and
lubricating ........................................... 7-21
Tires ...................................................... 7-13
Troubleshooting .................................... 7-30
Troubleshooting chart ........................... 7-31VValve clearance..................................... 7-13
Vehicle Emission Control Information
label (For Canada) .............................. 10-2
Vehicle identification number ................ 10-1WWheel bearings, checking ..................... 7-23
Wheel (front) ......................................... 7-27
Wheel (rear) .......................................... 7-28
Wheels .................................................. 7-14
U1P684E0.book Page 1 Tuesday, April 28, 2009 10:22 AM