2012

SERVICE MANUAL

TT-R50E(B)

1P6-F8197-E1

EAS20060

TT-R50E(B)

SERVICE MANUAL

©2011 by Yamaha Motor Co., Ltd.

First edition, July 2011

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

EAS20071

IMPORTANT

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 man-

ual. 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 vehi-

cle 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 vehi-

cle 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.

TIP

• This Service Manual contains information regarding periodic maintenance to the emission control sys-

tem. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EAS20081

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.

This is the safety alert symbol. It is used to alert you to potential per-

sonal injury hazards. Obey all safety messages that follow this symbol

to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could

result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid

damage to the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

WARNING

NOTICE

TIP

EAS20091

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

“1” is shown at the top of each page.

• Sub-section titles “2” appear in smaller print than the section title.

• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each

removal and disassembly section.

• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-

sembly step.

• Symbols “5” indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-

tially.

3

4

5

6

1

2

7

EAS20101

SYMBOLS

The following symbols are used in this manual for easier understanding.

TIP

The following symbols are not relevant to every vehicle.

SYMBOL

DEFINITION

SYMBOL

DEFINITION

Serviceable with engine mounted

Gear oil

Filling fluid

Molybdenum disulfide oil

Lubricant

Brake fluid

Special tool

Wheel bearing grease

Tightening torque

Lithium-soap-based grease

Wear limit, clearance

Molybdenum disulfide grease

Engine speed

Silicone grease

Electrical data

Apply locking agent (LOCTITE®).

Engine oil

Replace the part with a new one.

G

M

BF

B

T R

.

.

LS

M

S

LT

E

New

GENERAL INFORMATION

1

SPECIFICATIONS

2

PERIODIC CHECKS AND ADJUSTMENTS 3

CHASSIS

4

ENGINE

5

FUEL SYSTEM

6

ELECTRICAL SYSTEM

7

TROUBLESHOOTING

8

EAS20110 TABLE OF CONTENTS

1

2

3

4

5

6

7

8

9

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.....................................................................1-2

CIRCLIPS...................................................................................................1-3

BASIC SERVICE INFORMATION....................................................................1-4

QUICK FASTENERS..................................................................................1-4

ELECTRICAL SYSTEM..............................................................................1-5

SPECIAL TOOLS .............................................................................................1-9

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 1-9.

3. When disassembling, always keep mated

parts together. This includes gears, cylinders,

pistons and other parts that have been “mat-

ed” through normal wear. Mated parts must

always be reused or replaced as an assem-

bly.

4. During disassembly, clean all of the parts and

place them in trays in the order of disassem-

bly. 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.

EAS20231

BEARINGS AND OIL SEALS

Install bearings “1” and oil seals “2” so that the

manufacturer marks or numbers are visible.

1. Oil

2. Lip

3. Spring

4. Grease

IMPORTANT INFORMATION

1-3

When installing oil seals, lubricate the oil seal

lips with a light coat of lithium-soap-based

grease. Oil bearings liberally when installing, if

appropriate.

NOTICE

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.

BASIC SERVICE INFORMATION

1-4

EAS30380

BASIC SERVICE INFORMATION

EAS30390

QUICK FASTENERS

Rivet type

1. Remove:

• Quick fastener

TIP

To remove the quick fastener, push its pin with a

screwdriver, then pull the fastener out.

2. Install:

• Quick fastener

TIP

To install the quick fastener, push its pin so that

it protrudes from the fastener head, then insert

the fastener into the part to be secured and push

the pin in with a screwdriver. Make sure that the

pin is flush with the fastener’s head.

Screw type

1. Remove:

• Quick fastener

TIP

To remove the quick fastener, loosen the screw

with a screwdriver, then pull the fastener out.

2. Install:

• Quick fastener

TIP

To install the quick fastener, insert the fastener

into the part to be secured and tighten the screw.

BASIC SERVICE INFORMATION

1-5

EAS30402

ELECTRICAL SYSTEM

Electrical parts handling

NOTICE

ECA16600

Never disconnect a battery lead while the en-

gine is running; otherwise, the electrical

components could be damaged.

NOTICE

ECA16751

When disconnecting the battery leads from

the battery, be sure to disconnect the nega-

tive battery lead first, then the positive bat-

tery lead. If the positive battery lead is

disconnected first and a tool or similar item

contacts the vehicle, a spark could be gener-

ated, which is extremely dangerous.

TIP

If a battery lead is difficult to disconnect due to

rust on the battery terminal, remove the rust us-

ing hot water.

NOTICE

ECA16760

Be sure to connect the battery leads to the

correct battery terminals. Reversing the bat-

tery lead connections could damage the

electrical components.

NOTICE

ECA16771

When connecting the battery leads to the

battery, be sure to connect the positive bat-

tery lead first, then the negative battery lead.

If the negative battery lead is connected first

and a tool or similar item contacts the vehi-

cle while the positive battery lead is being

connected, a spark could be generated,

which is extremely dangerous.

NOTICE

ECA16610

Turn the main switch to “OFF” before dis-

connecting or connecting an electrical com-

ponent.

BASIC SERVICE INFORMATION

1-6

NOTICE

ECA16620

Handle electrical components with special

care, and do not subject them to strong

shocks.

NOTICE

ECA16630

Electrical components are very sensitive to

and can be damaged by static electricity.

Therefore, never touch the terminals and be

sure to keep the contacts clean.

TIP

When resetting the ECU by turning the main

switch to “OFF”, be sure to wait approximately 5

seconds before turning the main switch back to

“ON”.

Checking the electrical system

TIP

Before checking the electrical system, make

sure that the battery voltage is at least 12 V.

NOTICE

ECA14371

Never insert the tester probes into the cou-

pler terminal slots. Always insert the probes

from the opposite end “a” of the coupler, tak-

ing care not to loosen or damage the leads.

NOTICE

ECA16640

For waterproof couplers, never insert the

tester probes directly into the coupler. When

performing any checks using a waterproof

coupler, use the specified test harness or a

suitable commercially available test har-

ness.

a