2006-2009 Yamaha TTR50 TT R50E TT R50EW Service & Repair Manual

SERVICE MANUAL TT-R50EW LIT-11616-20-20 1P6-F8197-10

EAS20050 TT-R50EW SERVICE MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. First edition, May 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-20-20

EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig- nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: • This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. • Designs and specifications are subject to change without notice. EAS20080 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the vehicle operator, a bystander or a person checking or repairing the vehicle. A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle. A NOTE provides key information to make procedures easier or clearer. WARNING CAUTION: NOTE:

EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • The manual is divided into chapters and each chapter is divided into sections. The current section title is shown at the top of each page “1”. • Sub-section titles appear in smaller print than the section title “2”. • To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section “3”. • Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step “4”. • Symbols indicate parts to be lubricated or replaced “5”. Refer to “SYMBOLS”. • A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. “6”. • Jobs requiring more information (such as special tools and technical data) are described sequentially “7”. 3 4 5 6 1 2 7

EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. G M E B LS M 9 10 11 12 13 14 15 16 LT New T R . . 1 2 3 4 5 6 7 8 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6. Wear limit, clearance 7. Engine speed 8. Electrical data 9. Engine oil 10. Gear oil 11.Molybdenum-disulfide oil 12. Wheel-bearing grease 13.Lithium-soap-based grease 14.Molybdenum-disulfide grease 15.Apply locking agent (LOCTITE ® ) 16. Replace the part

EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 FUEL SYSTEM 6 ELECTRICAL SYSTEM 7 TROUBLESHOOTING 8

1 GENERAL INFORMATION IDENTIFICATION ............................................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER..................................................... 1-1 MODEL LABEL ......................................................................................... 1-1 IMPORTANT INFORMATION ......................................................................... 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY .......................... 1-2 REPLACEMENT PARTS .......................................................................... 1-2 GASKETS, OIL SEALS AND O-RINGS .................................................... 1-2 LOCK WASHERS/PLATES AND COTTER PINS..................................... 1-2 BEARINGS AND OIL SEALS.................................................................... 1-3 CIRCLIPS.................................................................................................. 1-3 CHECKING THE CONNECTIONS .................................................................. 1-4 SPECIAL TOOLS ............................................................................................ 1-5

IDENTIFICATION 1-1 EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts. 1 1

IMPORTANT INFORMATION 1-2 EAS20180 IMPORTANT INFORMATION EAS20190 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equip- ment. Refer to “SPECIAL TOOLS” on page 1-5. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. EAS20210 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfac- es, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease. EAS20220 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates “1” and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. 1. Oil 2. Lip 3. Spring 4. Grease

IMPORTANT INFORMATION 1-3 EAS20230 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals “1”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropri- ate. CAUTION: ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac- es. EAS20240 CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Al- ways replace piston pin clips after one use. When installing a circlip “1”, make sure the sharp-edged corner “2” is positioned opposite the thrust “3” that the circlip receives.

2006-2009 Yamaha TTR50 TT R50E TT R50EW Service & Repair Manual

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