2003 YAMAHA TZR50 Owners Manual

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
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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.√√√√
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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.√√
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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.
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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.
6
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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)
6
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1
3
1
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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)
6
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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)
6
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