2004 YAMAHA TZR50 check engine

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.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
1
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 51

4. Install the lens by installing the
screws.
ECA10680
CAUTION
Do not overtighten the screws,
otherwise the lens may break.
EAUM1460
Replacing the license plate
light bulb
1. Auxiliary light
1. Remove the license plate light
cover by removing the screw.
2. Remove the socket (together
with the bulb) by pulling it out.
3. Remove the defective bulb by
pulling it out.
4. Insert a new bulb into the socket.
5. Install the socket (together with
the bulb) by pushing it in.
6. Install the license plate light
cover by installing the screw.
EAU24350
Supporting the motorcycle
Since this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and
rear wheel or performing other main-
tenance requiring the motorcycle to
stand upright. Check that the
motorcycle is in a stable and level
position before starting any mainte-
nance. A strong wooden box can be
placed under the engine for added
stability.
To service the front wheel
1. Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing
a jack under the frame in front of
the rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
1
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 54

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU25921
Troubleshooting charts
Starting problems or poor engine performanceEWA10840
s s
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.
1. FuelThere is enough fuel.
There is no fuel.Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.
2. CompressionThere is compression.
There is no compression.Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.
3. IgnitionWipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.
4. BatteryThe engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the battery lead connections,
and charge the battery if necessary.
Dry
WetOpen the throttle halfway and operate
the electric starter.
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 56

Engine overheatingEWA10400
s s
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the his-
sing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6Wait until the
engine has cooled.Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 57

Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing
compounds as they will wear
away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
EAU26150
Storage
Short-term
Always store your motorcycle in a
cool, dry place and, if necessary, pro-
tect it against dust with a porous
cover.
ECA10810
CAUTION
Storing the motorcycle in a
poorly ventilated room or cove-
ring it with a tarp, while it is still
wet, will allow water and humi-
dity to seep in and cause rust.
To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)and areas where strong chemi-
cals are stored.
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” posi-
tion: Turn the fuel cock lever to
“OFF”.
3. Drain the carburetor float cham-
ber by loosening the drain bolt;
this will prevent fuel deposits
from building up. Pour the drai-
ned fuel into the fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to
protect the cylinder, piston rings,
etc. from corrosion.
a. Remove the spark plug cap and
spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit sparking
during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap from
the spark plug, and then install
the spark plug and the spark plug
cap.
EWA10950
s s
WARNING
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
6. Lubricate all control cables and
the pivoting points of all levers
and pedals as well as of the
sidestand/centerstand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alter-
natively, turn the wheels a little
every month in order to prevent
7
MOTORCYCLE CARE AND STORAGE
7-3
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 60

AAdjusting the brake pedal position and
free play .................................................6-13
Adjusting the carburetor ............................6-9
Adjusting the clucth lever free play .........6-12
Adjusting the engine idling speed .............6-9
Adjusting the rear brake light switch .......6-13
Adjusting the throttle cable free play .........6-9
BBattery......................................................6-19
Brake lever .................................................3-4
Brake pedal ................................................3-5
CCare............................................................7-1
Cast wheels .............................................6-12
Catalytic converter .....................................3-6
Clucht lever ................................................3-4
Controls and instruments ..........................2-3
Changing the brake fluid..........................6-15
Checking and lubricating the brake and
cluctch levers.........................................6-18
Checking and lubricating the brake
and shift pedals .....................................6-17
Checking and lubricating the cables .......6-17
Checking and lubricating the sidestand ..6-18
Checking the brake fluid level .................6-14
Checking the front fork ............................6-18
Checking the spark plug ............................6-6
Checking the steering ..............................6-19
Checking the wheel bearings ..................6-19
D2-stroke engine oil ........................................3-6
Drive Chain slack........................................6-16
EEngine break-in ..........................................5-3
Engine overheating ..................................6-25
FFrame serial number ..................................9-1
Front brake pads......................................6-14
Fuel cock....................................................3-6
Fuel tank cap .............................................3-5
HHandlebar switches ...................................3-3
IIdentification numbers ...............................9-1
Ignition circuit cut-off system ....................3-8
Indicator lights ...........................................3-1
KKey identification number ..........................9-1
LLeft view .....................................................2-1
MMain switch/steering lock ..........................3-1
Model label ................................................9-2
OOwner’s tool kit ..........................................6-1
PParking .......................................................5-3
Periodic maintenance and lubrication
chart .........................................................6-2
Pre-operation check list .............................4-2
RRear brake pads ......................................6-14
Removing and installing cowlings .............6-5
Replacing a turn signal light bulb or the
tail/brake light bulb ................................6-21Replacing the fuse ...................................6-20
Replacing the headlight bulb ...................6-21
Replacing the license plate light bulb......6-22
Right view ..................................................2-2
SSeat ............................................................3-7
Shift pedal ..................................................3-4
Shifting .......................................................5-2
Sidestand ...................................................3-8
Speedometer unit ......................................3-2
Starter (choke) lever ...................................3-7
Starting a cold engine ................................5-1
Storage.......................................................7-2
Storage compartment ................................3-7
Supporting the mortorcycle .....................6-22
TTachometer ................................................3-3
Tips for reducing fuel consumption ...........5-2
Tires .........................................................6-10
To check the coolant level .........................6-8
Transmission oil .........................................6-6
Troubleshooting .......................................6-23
Troubleshooting charts ............................6-24
INDEX
5WX-F8199-E1.qxd 14/12/2004 15:05 Página 66