2008 YAMAHA TZR50 check engine

If necessary, add 2-stroke engine
oil, and then check the warning
light again. If the warning light does
not come on when pushing the
start switch, or if it does not go off
after starting with sufficient 2-stro-
ke engine oil, have a Yamaha dealer
check the electrical circuit.
6. After starting the engine, move
the starter (choke) back halfway.
ECA11040
CAUTION:
For maximum engine life, never
accelerate hard when the engine is
cold!
7. When the engine is warm, turn
the starter (choke) off.
NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
EAU16640
Starting a warm engine
Follow the same procedure as for
starting a cold engine with the excep-
tion that the starter (choke) is not
required when the engine is warm.
EAU16671
Shifting
1. Shift pedal
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the
illustration.
NOTE:
To shift the transmission into the neu-
tral position, press the shift pedal
down repeatedly until it reaches the
end of its travel, and then slightly rai-
se it.
6
5
4
3
2
N
1
1
5
OPERATION AND IMPORTANT RIDING POINTS
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500~1000 km (300~600 mi)
Avoid prolonged operation above
6.000 r/min.
Rev the engine freely through the
gears, but do not use full throttle at
any time.
ECA10370
CAUTION:
After 1000 km (600 mi) of operation,
the transmission oil must be chan-
ged.
1000 km (600 mi) and beyond
The vehicle can now be operated nor-
mally.
ECA10310
CAUTION:
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
EAU17180
Parking
When parking, stop the engine, remo-
ve the key from the main switch, and
then turn the fuel cock lever to “OFF”.
EWA10310
s s WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedes-
trians or children are not likely
to touch them.
Do not park on a slope or on
soft ground, otherwise the
vehicle may overturn.
ECA10380
CAUTION:
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
5
OPERATION AND IMPORTANT RIDING POINTS
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ODOMETER READING (x 1000 Km)
ANNUAL
NO ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24CHECK
• Check tread depth and for damage.
9*Tires• Replace if necessary.
√√√√ √
• Check air pressure.
• Correct if necessary.
10 *Wheel bearings• Check bearing for looseness or damage.√√√√
11 *Swingarm• Check operation and for excessive play.√√√√• Lubricate with lithium-soap-based grease. Every 24000 km
• Check chain slack, alignment and condition.
Every 500 km and after washing
12Drive chain• Adjust and lubricate chain with a special O-ring chain
lubricant thoroughly.the motorcycle or riding in the rain
13 *Steering bearings• Check bearing play and steering for roughness.√√ √ √√• Lubricate with lithium-soap-based grease. Every 50000 km
14 *Chassis fasteners• Make sure that all nuts, bolts and screws are properly
tightened.√√√√ √
15Sidestand• Check operation.
• Lubricate.√√√√ √
16 *Sidestand switch• Check operation.√√ √ √√ √
17 *Front fork• Check operation and for oil leakage.√√√√
Rear suspension relay • Check operation.√√√√
18 *arm and connecting arm
pivoting points• Lubricate with lithium-soap-based grease.√√
19 *Carburetor• Check starter (choke) operation.
• Adjust engine idling speed.√√ √ √√ √
20 *Autolube pump• Check operation.
• Bleed if necessary.√√√√
6
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU19630
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause
any spark plug to slowly erode, the
spark plug 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.
To remove the spark plug
1. Remove cowling C. (See page
6-5.)
1. Spark plug cap
2. Remove the spark plug cap.
1. Spark plug wrench
3. Remove the spark plug as
shown, with the spark plug
wrench included in the owner’s
tool kit.
To check the spark plug
1. Check that the porcelain insula-
tor around the center electrode of
the spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).
NOTE:
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 motorcy-
cle.
2. Check the spark plug for electro-
de erosion and excessive carbon
or other deposits, and replace it if
necessary.
To install the spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to spe-
cification.
2. Clean the surface of the spark
plug gasket and its mating surfa-
ce, and then wipe off any grime
from the spark plug threads.
Spark plug gap:
0.6 ~ 0.7 mm (0.023 ~ 0.027 in)
Specified spark plug:
NGK BR9 ES
1
1
6
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2. Remove the oil check bolt, andthen 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 thecheck 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.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the coo-
lant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU33030
Changing the coolantEWA10380
s s WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
The coolant must be changed at the
intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer change the
coolant.
EAU20080
To check the coolant level 1. Place the vehicle on a level surfa- ce and hold it in an upright posi-
tion.
Recommended transmission oil:See page 8-1.
Oil change quantity: 0.82 L (0.87 US qt) (0.72 Imp.qt)
Tightening torque:Transmission oil drain bolt:17.5 Nm (1.7 m•kgf, 12.7 ft•lbf)
Oil check bolt: 6 Nm (0.6 m•kgf, 4.3 ft•lbf)
Tightening torque:Oil check bolt: 6 Nm (0.6 m•kgf, 4.3 ft•lbf)6
PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
2. Check the coolant level in the
coolant reservoir.
NOTE:
The coolant should be between the
minimum and maximum level marks.
3. If the coolant is at or below the
minimum level mark, open thereservoir cap, add coolant to the
maximum level mark, and then
close the reservoir cap.
EWA10380
s s
WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
NOTE:
If the engine overheats, see page
6-33 for further instructions.
EAU20431
To change the coolant
1. Place the vehicle on the centers-
tand and let the engine cool if
necessary.
2. Remove cowlings A and B. (See
page 6-5.)
3. Place a container under the engi-
ne to collect the used coolant.
1. Radiator cap
2. Coolant drain bolt
4. Remove the radiator cap.EWA10380
s s
WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
5. Remove the coolant drain bolt to
drain the cooling system.
6. After the coolant is completely
drained, thoroughly flush the
cooling system with clean tap
water.
7. Install the coolant drain bolt, and
then tighten it to the specified
torque.
1
2
MAX
MIN
6
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NOTE:
Check the washer for damage and
replace it if necessary.
8. Pour the recommended coolant
into the radiator until it is full.
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 possi-
ble, otherwise the effective-
ness of the coolant will be
reduced.
9. Install the radiator cap, start the
engine, let it idle for several minu-
tes, and then turn it off.
10. Remove the radiator cap to
check the coolant level in the
radiator. If necessary, add suffi-
cient coolant until it reaches the
top of the radiator, and then ins-
tall the radiator cap.
11. Check the coolant level in the
reservoir. If necessary, remove
the coolant reservoir cap, add
coolant to the maximum level
mark, and then install the cap.12. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yama-
ha dealer check the cooling sys-
tem.
13. Install the cowlings.
Recommended antifreeze:
High-quality ethylene glycol anti-
freeze containing corrosion inhibi-
tors for aluminum engines
Antifreeze/water mixture ratio:
1:1
Coolant quantity:
Radiator capacity (including all
routes):
0.70 L (0.74 US qt) (0.62 Imp qt)
Coolant reservoir capacity:
0.29L (0.31 US qt) ( 0.26 Imp qt)
Tightening torque:
Coolant drain bolt:
9 Nm (0.9 m•kgf, 6.5 ft•lbf)
6
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EAU40370
Air filter element
The air filter element must be cleaned
and replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart. Have a Yamaha dealer
clean and replace the air filter ele-
ment.
EAU21280
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most
carburetor adjustments should be left
to a Yamaha dealer, who has the
necessary professional knowledge
and experience. The adjustment des-
cribed in the following section, howe-
ver, may be serviced by the owner as
part of routine maintenance.
ECA10550
CAUTION:
The carburetor has been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical know-
ledge may result in poor perfor-
mance of or damage to the engine.
EAU21370
Adjusting the throttle cable
free play
The throttle cable free play should
measure 4 ~ 6 mm (0.15 ~ 0.23 in) at
the throttle grip. Periodically check
the throttle cable free play and, if
necessary, adjust it as follows.
1. Throttle cable free play
NOTE:
The engine idling speed must be
correctly adjusted before checking
and adjusting the throttle cable free
play.
1. To increase the throttle cable free
play, turn the adjusting nut in
direction (a). To decrease the
ef
g(a)
(b)1
6
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