2003 YAMAHA TZR50 maintenance

EAU18781
Removing and installing
cowlings
1. Cowling A
2. Cowling B
The cowlings shown need to be
removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each
time a cowling needs to be removed
and installed.
EAU18880
Cowling A
1. Screws (x 7 Right side)
1. Screws (x 6 Left side)
To remove the cowling
1. Remove the cowling screws.
2. Push the cowling in lightly, and
then pull it back as shown.
ECA11200
CAUTION
Take care not to damage the tabs
on the cowling when removing and
or installing it.
To install the cowling
1. Insert the tabs on the cowling
into the slots as shown, and then
push the cowling in until it snaps
into place.
2. Install the cowling screws.
EAU18790
Cowling B
1. Screws (x 5 Rechterkant)
1. Screws (x 7 Linkerkant)
To remove the cowling
Remove the screws, and then take
the cowling off.
T
o install the cowling
Place the cowling in the original posi-
tion, and then install the screws.
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EAU19620
Checking the spark plug
1. Spark plug
The spark plug is an important engine
component, which should be chec-
ked periodically, preferably by a
Yamaha dealer. Since heat and depo-
sits will cause any spark plug to
slowly erode, it should be removed
and checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
The porcelain insulator around the
center electrode of the spark plug
should be a medium-to-light tan (the
ideal color when the vehicle is riddennormally). If the spark plug shows a
distinctly different color, the engine
could be defective. Do not attempt to
diagnose such problems yourself.
Instead, have a Yamaha dealer check
the vehicle.
If the spark plug shows signs of elec-
trode erosion and excessive carbon
or other deposits, it should be repla-
ced.
Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4~1/2 turn past finger tight. Howe-
ver, the spark plug should be tighte-
ned to the specified torque as soon
as possible.
EAUM1270
Transmission oil
1. Oil level check bolt
2. Oil drain bolt
3. Oil filler cap
Tightening torque:
Spark plug:
20 Nm (2,0 m•kgf)
Spark plug gap:
0,6 ~ 0,7 mm (0,023~0,027 in)
Specified spark plug:
BR9ES (NGK)
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The transmission oil level should be
checked before each ride. In addition,
the oil must be changed at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
To check the transmission oil level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
NOTE:
Make sure that the vehicle is positio-
ned straight up when checking the oil
level. A slight tilt to the side can result
in a false reading.
2. Remove the oil check bolt, and
then check the oil level.
NOTE:
The oil should be at the brim of the
check hole.
3. If the oil is below the brim of the
check hole, remove the oil filler
cap, add sufficient oil of the
recommended type to raise it to
the correct level, and then install
the oil filler cap.
4. Install the oil check bolt, and then
tighten it to the specified torque.
To change the transmission oil
1. Place an oil pan under the trans-
mission oil case to collect the used
oil.
2. Remove the drain bolt and the oil
check bolt to drain the oil.
3. Install the drain bolt and the
check bolt, and then tighten them to
the specified torque.4. Remove the oil filler cap, add the
specified amount of the recom-
mended transmission oil, and
then install and tighten the oil
filler cap.
ECAM1020
CAUTION
Make sure that no foreign material
enters the transmission case.
5. Start the engine and let it idle for
several minutes while checking
the transmission oil case for oil
leakage. If oil is leaking, imme-
diately turn the engine off and
check for the cause.
Recommended transmission oil:
See page 8-1.
Oil change quantity:
0,75 L (0,65 imp.qt)
Tightening torque:
Transmission oil drain bolt:
17 Nm (1,7 m•kgf)
Oil check bolt:
3 Nm (0,3 m•kgf)
Tightening torque:
Oil check bolt:
3 Nm (0,3 m•kgf)
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EAU20170
To check the coolant level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
NOTE:
The coolant level must be chec-
ked on a cold engine since the
level varies with engine tempera-
ture.
Make sure that the vehicle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
1. Panel
2. Remove panel (1). (See page 6-8.)
3. Check the coolant level in the
coolant reservoir.
NOTE:
The coolant should be between the
minimum and maximum level marks.
4. If the coolant is at or below the
minimum level mark, open the
reservoir cap, add coolant to the
maximum level mark, and then
close the reservoir cap.
ECA10470
CAUTION
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
If water has been used instead
of coolant, replace it with coo-
lant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the coo-
ling system will not be protec-
ted against frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
EWA10380
s s
WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
5. Install the panel.
Coolant reservoir capacity:
0,45 L (0.39 Imp.qt)
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NOTE:
If the engine overheats, see page 6-5
for further instructions.
EAU21300
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, all car-
buretor adjustments should be left to
a Yamaha dealer, who has the neces-
sary professional knowledge and
experience.
EAU21320
Adjusting the engine idling
speed
1. Idle aedjusting bolt
The engine idling speed must be
checked and, if necessary, adjusted
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
The engine should be warm before
making this adjustment.
NOTE:
The engine is warm when it quickly
responds to the throttle.
Check the engine idling speed and, if
necessary, adjust it to specification by
turning the throttle stop screw. To
increase the engine idling speed, turn
the screw in direction (a). To decrease
the engine idling speed, turn the
screw in direction (b).
NOTE:
If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
EAU21370
Adjusting the throttle cable
free play
(a) Throttle cable free play
The throttle cable free play should
measure 2~5 mm (0,08~0,2 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, adjust it as follows.
NOTE:
The engine idling speed must be
correctly adjusted before checking
and adjusting the throttle cable free
play.
Engine idling speed:
1700 ~ 2000 tpm
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1. Loosen the locknut.
2. To increase the throttle cable free
play, turn the adjusting nut in
direction (a). To decrease the
throttle cable free play, turn the
adjusting nut in direction (b).
3. Tighten the locknut.
EAU21500
Tires
To maximize the performance, durabi-
lity, and safe operation of your
motorcycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be chec-
ked and, if necessary, adjusted befo-
re each ride.
EWA10440
s s
WARNING
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperatu-re of the tires equals the
ambient temperature).
The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, cargo, and
accessories approved for this
model.
EWA10450
s s
WARNING
Because loading has an enormous
impact on the handling, braking,
performance and safety characte-
ristics of your vehicle, you should
keep the following precautions in
mind.
NEVER OVERLOAD THE VEHI-
CLE! Operation of an overloa-
ded vehicle may result in tire
damage, loss of control, or
severe injury. Make sure that
the total weight of rider, cargo,
and accessories does not
exceed the specified maximum
load for the vehicle.
Do not carry along loosely pac-
ked items, which can shift
during a ride.
Securely pack the heaviest
items close to the center of the
vehicle and distribute the
weight evenly on both sides.
Adjust the suspension and tire
air pressure with regard to the
load.
Check the tire condition and air
pressure before each ride.
Tire air pressure (measured on cold
tires):
Up to 90 kg (198 lb):
Front:
180 kPa (25,6 psi) (1,8 kgf/cm
2)
Rear:
200 kPa (28,4 psi) (2,0 kgf/cm
2)
90 kg (198 lb) to maximum load:
Front:
190 kPa (27 psi) (1,9 kgf/cm
2)
Rear:
230 kPa (32,7 psi) (2,3 kgf/cm
2)
High-speed riding:
Front:
190 kPa (27 psi) (1,9 kgf/cm
2)
Rear:
230 kPa (32,7 psi) (2,3 kgf/cm
2)
Maximum load*:
195 kg (429,9 lb)
* Total weight of rider, cargo and
accessories
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1. Depth
2. Side face
Tire inspection
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or if
the sidewall is cracked, have a Yama-
ha dealer replace the tire immediately.
NOTE:
The tire tread depth limits may differ
from country to country. Always
comply with the local regulations.
EWA10470
s s
WARNING
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
vehicle with excessively worn
tires decreases riding stability
and can lead to loss of control.
The replacement of all wheel
and brake related parts, inclu-
ding the tires, should be left to
a Yamaha dealer, who has the
necessary professional know-
ledge and experience.
Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
EWA10480
s s
WARNING
The front and rear tires should
be of the same make and
design, otherwise the handling
characteristics of the motorcy-
cle cannot be guaranteed.
After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor España, S.A.
Always make sure that the val-
ve caps are securely installed
to prevent air pressure leaka-
ge.
Use only the tire valves and val-
ve cores listed below to avoid
tire deflation during a high-
speed ride.
EWA10600
s s
WARNING
This motorcycle is fitted with
super-high-speed tires. Note the
following points in order to make
the most efficient use of these tires.
Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at super
high speeds.
Front tire:
Size:
100/80-17
Manufacturer/model:
PIRELLI
Rear tire:
Size:
130/70-17
Manufacturer/model:
PIRELLI
Minimum tire tread depth (front
and rear):
1.6 mm (0.06 in)
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Brand-new tires can have a
relatively poor grip on certain
road surfaces until they have
been “broken in”. Therefore, it
is advisable before doing any
high-speed riding to ride con-
servatively for approximately
100 km (60 mi) after installing a
new tire.
The tires must be warmed up
before a high-speed run.
Always adjust the tire air pres-
sure according to the opera-
ting conditions.
EAU21960
Cast wheels
To maximize the performance, durabi-
lity, and safe operation of your
motorcycle, note the following points
regarding the specified wheels.
The wheel rims should be chec-
ked for cracks, bends or warpage
before each ride. If any damage
is found, have a Yamaha dealer
replace the wheel. Do not
attempt even the smallest repair
to the wheel. A deformed or crac-
ked wheel must be replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for
it to develop its optimal characte-
ristics.
EAU22041
Adjusting the clutch lever
free play
1. Free play
The clutch lever free play should mea-
sure 2~5 mm (0,08~0,2 in) as shown.
Periodically check the clutch lever free
play and, if necessary, adjust it as
follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in
direction (a). To decrease the
clutch lever free play, turn the
adjusting bolt in direction (b).
NOTE:
If the specified clutch lever free play
could be obtained as described abo-
ve, tighten the locknut and skip the
rest of the procedure, otherwise pro-
ceed as follows.
3. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loo-
sen the clutch cable.
4. Loosen the locknut at the crank-
case.
5. To increase the clutch lever free
play, turn the adjusting nut in
direction (a). To decrease the
clutch lever free play, turn the
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