2014 YAMAHA TTR50 check engine

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 .........................................4-7
Starter (choke) lever .......................4-8
Seat .................................................4-8
Sidestand ........................................4-9
Starting circuit cut-off system .........4-9 FOR 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
Checking the throttle grip free
play ............................................ 7-12
Valve clearance............................. 7-12
Tires .............................................. 7-13
Spoke wheels ............................... 7-14
Adjusting the clutch free play ....... 7-15 Adjusting the brake lever free
play ............................................ 7-15
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 .......................................... 7-19
Checking and lubricating the
cables ........................................ 7-20
Checking and lubricating the throttle grip and cable ............... 7-20
Checking and lubricating the brake lever ................................. 7-20
Checking and lubricating the
brake pedal ................................ 7-21
Checking and lubricating the sidestand ................................... 7-21
Lubricating the swingarm pivots ... 7-21
Checking the front fork ................. 7-22
Checking the steering ................... 7-22
Checking the wheel bearings ........ 7-23
Battery........................................... 7-23
Replacing the fuse ........................ 7-25
Supporting the motorcycle ........... 7-26
Front wheel ................................... 7-26
Rear wheel .................................... 7-28
Troubleshooting ............................ 7-30
Troubleshooting chart ................... 7-31
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SAFETY INFORMATION
2-3
2soning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
 Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
 Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
 Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loa din g
Adding accessories to your motorcycle
can adversely affect stability and han-
dling if the weight distribution of the
motorcycle is changed. To avoid the
possibility of an accident, use extreme
caution when adding accessories to
your motorcycle. Use extra care when
riding a motorcycle that has added ac-
cessories. Here are some general
guidelines to follow if adding accesso-
ries to your motorcycle: Operation of an overloa
ded vehicle
coul d cause an acci dent.
 The weight of the operator must
not exceed 40.0 kg (88 lb).
 Accessory weight should be kept
as low and close to the motorcy-
cle as possible. Securely pack
your heaviest items as close to the
center of the vehicle as possible
and make sure to distribute the
weight as evenly as possible on
both sides of the motorcycle to
minimize imbalance or instability.
 Shifting weights can create a sud-
den imbalance. Make sure that
accessories are securely attached
to the motorcycle before riding.
Check accessory mounts fre-
quently.
• Properly adjust the suspension for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
• Never attach any large or heavy items to the handlebar, front
fork, or front fender. Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail- able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection
to Yamaha manufacture parts and ac-
cessories or offer other modifications
for Yamaha vehicles. Yamaha is not in
a position to test the products that
these aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories, an d
Mo difications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accesso-
ries or modifications are not suitable
because of potential safety hazards to
you or others. Installing aftermarket
U2CJ81E0.book Page 3 Wednesday, July 10, 2013 3:54 PM

SAFETY INFORMATION
2-4
2
products or having other modifications
performed to your vehicle that change
any of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or
death. You are responsible for injuries
related to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
 Never install accessories that
would impair the performance of
your motorcycle. Carefully inspect
the accessory before using it to
make sure that it does not in any
way reduce ground clearance or
cornering clearance, limit suspen-
sion travel, steering travel or con-
trol operation.
• Accessories fitted to the han- dlebar or the front fork area can
create instability due to improp-
er weight distribution. If acces-
sories are added to the
handlebar or front fork area,
they must be as lightweight as
possible and should be kept to
a minimum. • Bulky or large accessories may
seriously affect the stability of
the motorcycle. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become
unstable in cross winds.
• Certain accessories can dis- place the operator from his or
her normal riding position. This
improper position limits the
freedom of movement of the
operator and may limit control
ability, therefore, such accesso-
ries are not recommended.
 Use caution when adding electri-
cal accessories. If electrical ac-
cessories exceed the capacity of
the motorcycle’s electrical sys-
tem, an electric failure could re-
sult, which could cause a
dangerous loss of lights or engine
power.
Aftermarket Tires an d Rims
The tires and rims that came with your
motorcycle were designed to match
the performance capabilities and to
provide the best combination of han-
dling, braking, and comfort. Other tires, rims, sizes, and combinations
may not be appropriate. Refer to page
7-13 for tire specifications and more in-
formation on replacing your tires.
Transportin
g the Motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.  Remove all loose items from the
motorcycle.
 Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.
 Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
 Shift the transmission in gear (for
models with a manual transmis-
sion).
 Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or
parts that could break). Choose
U2CJ81E0.book Page 4 Wednesday, July 10, 2013 3:54 PM

INSTRUMENT AND CONTROL FUNCTIONS
4-6
4
For Oceania an
d South Africa
NOTICE
ECA11401
Use only unlea ded g asoline. The use
of lead ed g asoline will cause severe
d amag e to internal en gine parts,
such as the valves an d piston rin gs,
as well as to the exhaust system.Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark plug
life and reduce maintenance costs.
Gasohol
There are two types of gasohol: gaso-
hol containing ethanol and that con-
taining methanol. Gasohol containing
ethanol can be used if the ethanol con- tent does not exceed 10% (E10). Gas-
ohol containing methanol is not
recommended by Yamaha because it
can cause damage to the fuel system
or vehicle performance problems.
EAU13414
Fuel tank
breather hoseBefore operating the motorcycle:
 Check the fuel tank breather hose
connection.
 Check the fuel tank breather hose
for cracks or damage, and replace
it if necessary.
 Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.
Recommen ded fuel:
Regular unleaded gasoline (Gasohol
(E10) acceptable)
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)
1. Fuel tank breather hose
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INSTRUMENT AND CONTROL FUNCTIONS
4-9
4
EAU37491
Sidestan dThe sidestand is located on the left
side of the frame. Raise the sidestand
or lower it with your foot while holding
the vehicle upright.
WARNING
EWA14191
The vehicle must not be ri dden with
the si destan d d own, or if the si de-
stan d cannot b e properly move d up
(or does not stay up), otherwise the
si destan d coul d contact the groun d
an d d istract the operator, resultin g
in a possi ble loss of control.
EAU41612
Startin g circuit cut-off systemThe starting circuit cut-off system pre-
vents starting when the transmission is
in gear.
Periodically check the operation of the
starting circuit cut-off system accord-
ing to the following procedure.TIPThis check is most reliable if performed
with a warmed-up engine.
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INSTRUMENT AND CONTROL FUNCTIONS
4-10
4
With the engine turned off:
1. Make sure that the engine stop switch is set to “”.
2. Turn the key to “ON”.
3. Shift the transmission into gear.
4. Keep the front or rear brake applied.
5. Push the start switch.
Does the engine start?
The neutral switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
6. Shift the transmission into the neutral position.
7. Push the start switch.
Does the engine start?
The neutral switch may not be working correctly.
The motorcycle should not be ridden
until
checked by a Yamaha dealer.
YES
NO
The system is OK. The motorcycle can be ridden.
YES
NO
If a malfunction is noted, have a Yamaha
dealer check the system before riding.
WARNING
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-1
5
EAU15598
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility of an acci dent or equipment damag e.
Do not operate the vehicle if you fin d any pro blem. If a pro blem cannot be corrected b y the proce dures provi ded in
this manual, have the vehicle inspecte d b y a Yamaha dealer.Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel • Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check fuel tank breather hose for obstructions, cracks or damage, and check
hose connection. 4-4, 4-6
En gine oil • Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage. 7-7
Front brake • Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.
7-15, 7-17
Rear brake • Check operation.
• Check pedal free play.
• Adjust if necessary. 7-16, 7-17
Throttle g rip • Make sure that operation is smooth.
• Check throttle grip free play.
• If necessary, have Yamaha dealer adjust throttle grip free play and lubricate ca-
ble and grip housing. 7-12, 7-20
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OPERATION AND IMPORTANT RIDING POINTS
6-3
63. Open the throttle gradually.
4. Once the motorcycle has reached
a speed high enough to change
gears, close the throttle.
5. Shift into second gear and release the shift pedal.
6. Open the throttle gradually.
7. Follow the same procedure when shifting to the next higher gear.
EAU16711
To decelerate
1. Close the throttle and apply both the front and the rear brakes to
slow the motorcycle.
2. Downshift through the gears and shift the transmission into the neu-
tral position when the motorcycle
is almost completely stopped.
EAU39921
Engine break-inThere is never a more important period
in the life of your engine than the first 5
hours of riding. It is also important to
accustom the rider to the motorcycle
during this time. Please read the fol-
lowing information carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
5 hours of operation. The various parts
in the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheating
must be avoided. However, momen-
tary full-throttle operation under load
(i.e., two to three seconds maximum)
does not harm the engine. Each full-
throttle acceleration should be fol-
lowed with a substantial rest period for
the engine. To allow the engine to cool
down from the temporary buildup of
heat, cruise at a lower engine speed.
After the first 5 hours of operation,
thoroughly check the motorcycle for
loose parts, oil leakage and any other
problems. Be sure to inspect and make adjustments thoroughly, especially ca-
ble and drive chain slack and loose
spokes. In addition, check all fittings
and fasteners for looseness, and tight-
en if necessary.
NOTICE
ECA10271
If any en
gine trou ble shoul d occur
d urin g the en gine break-in perio d,
imme diately have a Yamaha dealer
check the vehicle.
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