2003 YAMAHA TZR50 maintenance

SAFETY INFORMATION.....................1-1
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments .................2-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................3-1
Main switch/steering lock .................3-1
Indicator lights ..................................3-1
Speedometer unit .............................3-2
Tachometer .......................................3-3
Handlebar switches ..........................3-3
Clucht lever .......................................3-4
Shift pedal.........................................3-4
Brake lever ........................................3-4
Brake pedal.......................................3-5
Fuel tank cap ....................................3-5
Catalytic converter............................3-6
2-stroke engine oil ............................3-6
Fuel cock ..........................................3-6
Starter (choke) lever..........................3-7
Seat...................................................3-7
Storage compartment.......................3-7
Sidestand ..........................................3-8
Ignition circuit cut-off system ...........3-8
PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Shifting ..............................................5-2
Tips for reducing fuel consumption..5-2
Engine break-in.................................5-3
Parking ..............................................5-3
PERIODIC MAINTENANCE AND
MINOR RAPAIR...................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and lubrication
chart ..................................................6-2
Removing and installing cowlings ....6-5
Checking the spark plug ..................6-6
Transmission oil ................................6-6
To check the coolant level ................6-8
Adjusting the carburetor ...................6-9
Adjusting the engine idling speed ....6-9
Adjusting the throttle cable free play ..6-9
Tires ................................................6-10
Cast wheels ....................................6-12
Adjusting the clucth lever free play 6-12
Adjusting the brake pedal position
and free play................................6-13
Adjusting the rear brake light
switch ..........................................6-13
Front brake pads ............................6-14
Rear brake pads .............................6-14
Checking the brake fluid level ........6-14
Changing the brake fluid ................6-15Drive Chain slack ............................6-16
Checking and lubricating the
cables ..........................................6-17
Checking and lubricating the brake
and shift pedals ...........................6-17
Checking and lubricating the brake
and cluctch levers .......................6-18
Checking and lubricating the
sidestand .....................................6-18
Checking the front fork ...................6-18
Checking the steering.....................6-19
Checking the wheel bearings .........6-19
Battery ............................................6-19
Replacing the fuse ..........................6-20
Replacing the headlight bulb..........6-21
Replacing a turn signal light bulb
or the tail/brake light bulb ...........6-21
Replacing the license plate light
bulb .............................................6-22
Supporting the mortorcycle ............6-22
Troubleshooting ..............................6-23
Troubleshooting charts ...................6-24
Engine overheating .........................6-25
MOTORCYCLE CARE AND
STORAGE............................................7-1
Care ..................................................7-1
Storage ...........................................7-2
SPECIFITACIONS...............................8-1
TABLE OF CONTENTS
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 7

EAU10251
MOTORCYCLES 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 OPERATOR SHOULD KNOW
THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS MOTORCY-
CLE.
HE OR SHE SHOULD:
OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
OBSERVE THE WARNINGS AND
MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S
MANUAL.
OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDI-
TIONS.
Safe riding
Always make pre-operation
checks. Careful checks may help
prevent an accident.
This motorcycle is designed to
carry the operator and a passen-
ger.
The failure of motorists to detect
and recognize motorcycles in
traffic is the predominating cause
of automobile/motorcycle acci-
dents. Many accidents have
been caused by an automobile
driver who did not see the
motorcycle. Making yourself
conspicuous appears to be very
effective in reducing the chance
of this type of accident.Therefore:
• Wear a brightly colored jacket.
• Use extra caution when appro-
aching and passing through
intersections, since intersec-
tions are the most likely places
for motorcycle accidents to
occur.
• Ride where other motorists can
see you. Avoid riding in anot-
her motorist’s blind spot.
Many motorcycle accidents
involve inexperienced operators.
In fact, many operators who have
been involved in accidents do not
even have a current motorcycle
license.
• Make sure that you are quali-
fied and that you only lend your
motorcycle to other qualified
operators.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
1
SAFETY INFORMATION t
1-1
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 9

EAU12941
Brake pedal
1. Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear bra-
ke, press down on the brake pedal.
EAU13000
Fuel tank cap
1. Key over
2. Open
To remove the fuel tank cap
Insert the key into the lock and turn it
1/4 turn clockwise. The lock will be
released and the fuel tank cap can be
removed.
To install the fuel tank cap
1. Push the fuel tank cap into posi-
tion with the key inserted in the
lock.
2. Turn the key counterclockwise to
the original position, and then
remove it.
NOTE:
The fuel tank cap cannot be installed
unless the key is in the lock. In addi-
tion, the key cannot be removed if the
cap is not properly installed and loc-
ked.
EWA11140
s s
WARNING
Make sure that the fuel tank cap is
properly installed before riding.
1. Filling tube
2. Fuel level
EAU13270
Your Yamaha engine has been desig-
ned to use regular unleaded gasoline
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.
Recommended fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
13,8 L (3.03 Imp.gal)
Fuel reserve amount:
2,2 L (0.48 Imp.gal)
3
INSTRUMENT AND CONTROL FUNCTIONS
3-5
1
1 22
1
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 21

EAU13431
Catalytic converter
This model is equipped with a cataly-
tic converter in the exhaust system.
EWA10860
s s
WARNING
The exhaust system is hot after
operation. Make sure that the
exhaust system has cooled down
before doing any maintenance
work.
ECA10700
CAUTION
The following precautions must be
observed to prevent a fire hazard or
other damages.
Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.
Never park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
Do not allow the engine to idle
too long.
EAU13460
2-stroke engine oil
1. 2-stroke engine oil tank
2. 2-stroke engine oil tank cap
Make sure that there is sufficient oil in
the 2-stroke engine oil tank. Add the
recommended 2-stroke engine oil if
necessary.
NOTE:
Make sure that the 2-stroke engine oil
tank cap is properly installed.
EAU13560
Fuel cock
1. Fuel reserve switch
The fuel cock supplies fuel from the
tank to the carburetor while filtering it
also.
The fuel cock has three positions:
OFF
With the lever in this position, fuel will
not flow. Always return the lever to
this position when the engine is not
running.
ON
RES OFFFUEL
Recommended oil:
Yamalube 2 or equivalent 2-stroke
engine oil (JASO grade “FC”, or
ISO grades “EG-C” or “EG-D”)
Oil quantity:
1,35 L (1,18 Imp.qt)
3
INSTRUMENT AND CONTROL FUNCTIONS
3-6
12
1
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 22

EAU17240
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. The most important
points of inspection, adjustment, and
lubrication are explained on the follo-
wing pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, DEPENDING
ON THE WEATHER, TERRAIN, GEO-
GRAPHICAL LOCATION, AND INDIVI-
DUAL USE, THE MAINTENANCE
INTERVALS MAY NEED TO BE
SHORTENED.
EWA10320
s s
WARNING
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
EAU17380
Owner’s tool kit
1. Owner’s took kit
The owner’s tool kit is located under
the seat. (See page 3-7 for.)
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to
assist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be
necessary to perform certain mainte-
nance work correctly.
NOTE:
If you do not have the tools or expe-
rience required for a particular job,
have a Yamaha dealer perform it for
you.
EWA10350
s s
WARNING
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle
unsafe for use. Consult a Yamaha
dealer before attempting any chan-
ges.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
1
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 33

EAU17710
Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed
instead.
From 30000 km, repeat the maintenance intervals starting from 6000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
ODOMETER READING (x 1000 Km) ANNUAL
NOITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24CHECK
1*Fuel lineCheck fuel and vacuum hoses for cracks or damage.√√√√ √
2Spark plugReplace.√√√√ √
3Air filter elementClean.√√Replace.√√
4ClutchCheck operation.
Adjust.√√ √ √√
5*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√ √ √√ √Replace brake pads. Whenever worn to the limit
6*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.√√ √ √√ √Replace brake pads. Whenever worn to the limit
7*Brake hoseCheck for cracks or damage.√√√√ √Replace.Every 4 years
8*WheelsCheck runout and for damage.√√√√
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 34

ODOMETER READING (x 1000 Km) ANNUAL
NOITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24CHECK
Check tread depth and for damage.
9*TiresReplace if necessary.
√√√√ √
Check air pressure.
Correct if necessary.
10 *Wheel bearingsCheck bearing for looseness or damage.√√√√
11 *SwingarmCheck operation and for excessive play.√√√√Lubricate with lithium-soap-based grease. Every 24000 km
12Drive chainCheck chain slack, alignment and condition. Every 500 km and after washing
Adjust and thoroughly lubricate chain with engine oil. the motorcycle or riding in the rain
13 *Steering bearingsCheck bearing play and steering for roughness.√√ √ √√Lubricate with lithium-soap-based grease. Every 24000 km
14 *Chassis fastenersMake sure that all nuts, bolts and screws are
√√√√ √
properly tightened.
15SidestandCheck operation.
Lubricate.√√√√ √
16 *Sidestand switchCheck operation.√√ √ √√ √
17 *Front forkCheck operation and for oil leakage.√√√√
18 *Shock absorber Check operation and shock absorber for oil leakage.
√√√√
assembly
19 *CarburetorCheck starter (choke) operation.
Adjust engine idling speed.√√ √ √√ √
20 *Autolube pumpCheck operation.
Bleed if necessary.√√√√
21Transmission oilCheck oil level.√√ √ √√ √
Change.√√
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 35

ODOMETER READING (x 1000 Km) ANNUAL
NOITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24CHECK
22 *Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √Change.Every 3 years
23 *Air filter elementClean.√√
Replace.√√
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU18670
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and change the bra-
ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 36