2003 YAMAHA TZR50 maintenance

adjusting nut in direction (b).
6. Tighten the locknut at the clutch
lever and the crankcase.
EAU22220
Adjusting the brake pedal
position and free play
1. Position adjusting bolt
2. Brake pedal position
EWA10670
s s
WARNING
It is advisable to have a Yamaha
dealer make these adjustments.
Brake pedal position
The top of the brake pedal should be
aligned with the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary,
adjust it as follows.1. Loosen the locknut at the brake
pedal.
2. To raise the brake pedal, turn the
adjusting bolt in direction (a). To
lower the brake pedal, turn the
adjusting bolt in direction (b).
3. Tighten the locknut.
EWA11230
s s
WARNING
After adjusting the brake pedal
position, the brake pedal free play
must be adjusted.
Brake pedal free play
1. Free play
The brake pedal free play should
measure 10~15 mm (0,39~59 in) at
the brake pedal end. Periodically
check the brake pedal free play and, if
necessary, adjust it as follows.To increase the brake pedal free play,
turn the adjusting nut at the brake rod
in direction (a). To decrease the brake
pedal free play, turn the adjusting nut
in direction (b).
EWA10660
s s
WARNING
After adjusting the brake pedal free
play, check the operation of the
brake light.
EAU22270
Adjusting the rear brake light
switch
1. Switch
2. Lock nut
The rear brake light switch, which is
activated by the brake pedal, is pro-
perly adjusted when the brake light
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1
1
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comes on just before braking takes
effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding
the rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a).
To make the brake light come on later,
turn the adjusting nut in direction (b).
EAU22420
Front brake pads
Each front brake pad is provided with
a wear indicator groove, which allows
you to check the brake pad wear wit-
hout having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that thewear indicator groove has almost
disappeared, have a Yamaha dealer
replace the brake pads as a set.
EAU22480
Rear brake pads
Each rear brake pad is provided with
a wear indicator groove, which allows
you to check the brake pad wear wit-
hout having to disassemble the brake.
Check the brake pad wear as follows.
1. Remove the brake caliper bolt,
and then tilt the caliper forward to
inspect the wear indicator groo-
ve. If a brake pad has worn to the
point that the wear indicator gro-
ove has almost disappeared,
have a Yamaha dealer replace
the brake pads as a set.2. Install the brake caliper bolt, and
then tighten it to the specified
torque.
EAU22610
Checking the brake fluid
level
Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Tightening torque:
Brake caliper bolt:
30 Nm (3,0 m•kgf)
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FRONT
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Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low bra-
ke fluid level may indicate worn brake
pads and/or brake system leakage. If
the brake level is low, be sure to
check the brake pads for wear and
the brake system for leakage.
Observe these precautions:
When checking the fluid level,
make sure that the top of the
brake fluid reservoir is level by
turning the handlebars.
Use only the recommended qua-
lity brake fluid, otherwise the rub-
ber seals may deteriorate, cau-
sing leakage and poor braking
performance.
NOTE:
If DOT 4 is not available, DOT 3 can
be used for the front brake system.
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performan-
ce.
Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock.
Brake fluid may deteriorate pain-
ted surfaces or plastic parts.
Always clean up spilled fluid
immediately.
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
EAU22720
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addi-
tion, have the oil seals of the brake
master cylinder and caliper as well as
the brake hose replaced at the inter-
vals listed below or whenever they are
damaged or leaking.
Oil seals: Replace every two
years.
Brake hose: Replace every four
years.Recommended brake fluid:
DOT 4
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EAU22760
Drive chain slack
(a) Drive chain slack
The drive chain slack should be chec-
ked before each ride and adjusted if
necessary.
EAU22771
To check the drive chain slack
1. Place the motorcycle on the
sidestand.
NOTE:
When checking and adjusting the dri-
ve chain slack, there should be no
weight on the motorcycle.
2. Shift the transmission into the
neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tigh-
test portion of the drive chain,and then measure the drive chain
slack as shown.
4. If the drive chain slack is inco-
rrect, adjust it as follows.
EAU22920
To adjust the drive chain slack
1. Cotter pin
2. Axle nut
3. Lock nut
4. Chain tensioner
1. Remove the cotter pin from the axle
nut, and then loosen the axle nut.
2. Loosen the chain puller locknut
at each end of the swingarm.
3. To tighten the drive chain, turn
the adjusting nut at each end of
the swingarm in direction (a). To
loosen the drive chain, turn theadjusting nut at each end of the
swingarm in direction (b), and
then push the rear wheel forward.
NOTE:
Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same
position for proper wheel alignment.
ECA10570
CAUTION
Improper drive chain slack will
overload the engine as well as
other vital parts of the motorcycle
and can lead to chain slippage or
breakage. To prevent this from
occurring, keep the drive chain
slack within the specified limits.
4. Tighten the locknuts, and then
tighten the axle nut to the speci-
fied torque.
5. Insert a new cotter pin into the
axle nut, and then bend its ends
as shown.
Tightening torque:
Axle nut:
90 Nm (9,0 m•kgf)
Drive chain slack:
40~50 mm (1,5 ~1,9 in)
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a
a
b
2
1
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NOTE:
Make sure that two notches in the
axle nut are aligned with the hole
through the wheel axle, otherwise
further tighten the axle nut until they
are.
EWA10700
s s
WARNING
Always use a new cotter pin for the
axle nut.
EAU23012
Lubricating the drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
ECA10581
CAUTION
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.
NOTE:
For a thorough cleaning, have a
Yamaha dealer remove the drive
chain and soak it in solvent.
2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on both
sides and on the middle of the
chain, making sure that all side
plates and rollers have been suf-
ficiently oiled.
EAU23100
Checking and lubricating the
cables
The operation of all control cables
and the condition of the cables
should be checked before each ride,
and the cables and cable ends should
be lubricated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or repla-
ce it.
EWA10720
s s
WARNING
Damage to the outer sheath may
interfere with proper cable opera-
tion and will cause the inner cable
to rust. Replace a damaged cable
as soon as possible to prevent
unsafe conditions.
EAU23131
Checking and lubricating the
brake and shift pedals
The operation of the brake and shift
pedals should be checked before
each ride, and the pedal pivots
should be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease (all-
purpose grease)
Recommended lubricant:
Engine oil
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EAU23140
Checking and lubricating the
brake and clutch levers
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be
lubricated if necessary.
EAU23200
Checking and lubricating the
sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated
if necessary.
EWA10730
s s
WARNING
If the sidestand does not move up
and down smoothly, have a Yama-
ha dealer check or repair it.
EAU23271
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the perio-
dic maintenance and lubrication
chart.
To check the condition
EWA10750
s s
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.Recommended lubricant:
Lithium-soap-based grease (all-
purpose grease)
Recommended lubricant:
Lithium-soap-based grease (all-
purpose grease)
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2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
ECA10590
CAUTION
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.1. Place a stand under the engine to
raise the front wheel off the
ground.
EWA10750
s s
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the stee-
ring.
EAU23290
Checking the wheel bearings
The front and rear wheel bearings
must be checked at the intervals spe-
cified in the periodic maintenance and
lubrication chart. If there is play in the
wheel hub or if the wheel does not
turn smoothly, have a Yamaha dealer
check the wheel bearings.
EAU23440
Battery
1. Battery
This motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is
no need to check the electrolyte or to
add distilled water.
To charge the battery
Have a Yamaha dealer charge the
battery as soon as possible if it seems
to have discharged. Keep in mind that
the battery tends to discharge more
quickly if the motorcycle is equipped
with optional electrical accessories.
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EWA10760
s s
WARNING
Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any con-
tact with skin, eyes or clothing
and always shield your eyes
when working near batteries.
In case of contact, administer
the following FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quan-
tities of water or milk and
immediately call a physician.
• EYES: Flush with water for 15
minutes and seek prompt
medical attention.
Batteries produce explosive
hydrogen gas. Therefore,
keep sparks, flames, cigaret-
tes, etc., away from the bat-
tery and provide sufficient
ventilation when charging it in
an enclosed space.
KEEP THIS AND ALL BATTE-
RIES OUT OF THE REACH OF
CHILDREN.
To store the battery
1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check it
at least once a month and fully
charge it if necessary.
3. Fully charge the battery before
installation.
4. After installation, make sure that
the battery leads are properly
connected to the battery termi-
nals.
ECA10630
CAUTION
Always keep the battery char-
ged. Storing a discharged bat-
tery can cause permanent bat-
tery damage.
To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is
required. Using a conventional
battery charger will damage
the battery. If you do not have
access to a sealed-type (MF)
battery charger, have a Yamaha
dealer charge your battery.
EAU23480
Replacing the fuse
1. Fuse
The fuse box is located under the
seat. (See page 3-7.)
If the fuse is blown, replace it as
follows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
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