2008 YAMAHA TZR50 fuel cap

SAFETY INFORMATION.....................1-1
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments .................2-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................3-1
Main switch/steering lock .................3-1
Indicator and warning lights .............3-1
Speedometer unit .............................3-2
Tachometer .......................................3-3
Handlebar switches ..........................3-3
Clutch lever .......................................3-4
Shift pedal.........................................3-4
Brake lever ........................................3-5
Brake pedal.......................................3-5
Fuel ...................................................3-5
Catalytic converter............................3-6
Fuel tank cap ....................................3-6
Fuel tank breather/overflow hose .....3-7
2-stroke engine oil ............................3-7
Fuel cock ..........................................3-8
Starter (choke) lever “
q” .................3-8
Seat...................................................3-9
Anti-theft device housing..................3-9
Rear view mirrors ..............................3-9
Sidestand ........................................3-10
Ignition circuit cut-off system .........3-10PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2
OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Starting a warm engine ....................5-2
Shifting ..............................................5-2
Tips for reducing fuel consumption..5-3
Engine break-in.................................5-3
Parking ..............................................5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR...................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and
lubrication chart ............................6-2
Removing and installing cowlings
and panels .....................................6-5
Checking the spark plug ..................6-7
Transmission oil ................................6-8
Coolant .............................................6-9
Air filter element ..............................6-12
Adjusting the carburetor .................6-12
Adjusting the throttle cable free
play ..............................................6-12
Adjusting the engine idling speed ..6-13
Tires ................................................6-14
Cast wheels ....................................6-16
Adjusting the clutch lever free
play ..............................................6-16Checking the front brake lever free
play ..............................................6-17
Adjusting the brake pedal free
play ..............................................6-17
Adjusting the shift pedal position ...6-18
Adjusting the rear brake light
switch ..........................................6-18
Checking the front and rear brake
pads.............................................6-18
Checking the brake fluid level ........6-19
Changing the brake fluid ................6-20
Drive chain slack.............................6-21
Cleaning and lubricating the drive
chain ............................................6-22
Checking and lubricating the
cables ..........................................6-23
Checking and lubricating the
throttle grip and cable .................6-23
Adjusting the Autolube pump .........6-24
Checking and lubricating the brake
and shift pedals ...........................6-24
Checking and lubricating the brake
and clutch levers .........................6-24
Checking and lubricating the
sidestand .....................................6-25
Checking the front fork ...................6-25
Checking the steering.....................6-26
Checking the wheel bearings .........6-26
Battery ............................................6-27
Replacing the fuse ..........................6-28
Replacing the headlight bulb..........6-28
TABLE OF CONTENTS
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EAU10430
Controls and instruments
2
DESCRIPTION
2-3
12
34 5
6
7
8 9
1. Left rear view mirror (page 3-9)
2. Tachometer (page 3-3)
3. Main switch/Steering lock (page 3-1)
4. Speedometer/Odometer (page 3-2)
5. Right rear view mirror (page 3-9)6. Front brake lever (page 3-5)
7. Throttle grip (page 6-12)
8. Fuel tank cap (page 3-6)
9. Clutch lever (page 3-4)
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ECA10070
CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfa-
ces or plastic parts.
EAU13270
Your Yamaha engine has been desig-
ned to use regular unleaded gasoline
with a research octane number of 91
or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark
plug life and reduce maintenance
costs.
EAU13431
Catalytic converter
This model is equipped with a cataly-
tic converter in the exhaust system.
EWA10860
s s
WARNING
The exhaust system is hot after
operation. Make sure that the
exhaust system has cooled down
before doing any maintenance
work.
ECA10700
CAUTION:
The following precautions must be
observed to prevent a fire hazard or
other damages.
Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.
Never park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
Do not allow the engine to idle
too long.
EAU13070
Fuel tank cap
1. Fuel tank cap lock cover
2. Unlock
To open the fuel tank cap
Open the fuel tank cap lock cover,
insert the key into the lock, and then
turn it 1/4 turn clockwise. The lock will
be released and the fuel tank cap can
be opened.
To close the fuel tank cap
1. Push the fuel tank cap into posi-
tion with the key inserted in the
lock.
2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
1
Recommended fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
13.8 L (3.65 US gal) (3.04 Imp gal)
Fuel reserve amount:
2.2 L (0.58 US gal) (0.48 Imp gal)
3
INSTRUMENT AND CONTROL FUNCTIONS
3-6
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NOTE:
The fuel tank cap cannot be closed
unless the key is in the lock. In addi-
tion, the key cannot be removed if the
cap is not properly closed and loc-
ked.
EWA11090
s s
WARNING
Make sure that the fuel tank cap is
properly closed before riding.
EAUB1300
Fuel tank breather/overflow
hose
1. Fuel tank breather/overflow hose
Before operating the motorcycle:
Check the fuel tank breather/over-
flow hose connection.
Check the fuel tank
breather/overflow hose for
cracks or damage, and replace it
if damaged.
Make sure that the end of the fuel
tank breather/overflow hose is
not blocked, and clean it if
necessary.
Make sure that the end of the fuel
tank breather/overflow hose is
positioned inside of the clamp.
EAU13460
2-stroke engine oil
1. 2-stroke engine oil tank
2. 2-stroke engine oil tank cap
Make sure that there is sufficient oil in
the 2-stroke engine oil tank. Add the
recommended 2-stroke engine oil if
necessary.
NOTE:
Make sure that the 2-stroke engine oil
tank cap is properly installed.
Recommended oil:
Yamalube 2 or equivalent 2-stroke
engine oil (JASO grade “FC”, or
ISO grades “EG-C” or “EG-D”)
Oil quantity:
1.4 L (1.48 US qt) (1.23 Imp qt)
12
1
3
INSTRUMENT AND CONTROL FUNCTIONS
3-7
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EAU26001
Care
While the open design of a motorcy-
cle reveals the attractiveness of the
technology, it also makes it more vul-
nerable. Rust and corrosion can
develop even if high-quality compo-
nents are used. A rusty exhaust pipe
may go unnoticed on a car, however,
it detracts from the overall appearan-
ce of a motorcycle. Frequent and pro-
per care does not only comply with
the terms of the warranty, but it will
also keep your motorcycle looking
good, extend its life and optimize its
performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and
covers as well as all electrical
couplers and connectors, inclu-
ding the spark plug cap, are
tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such pro-ducts onto seals, gaskets, sproc-
kets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.
Cleaning
ECA10770
CAUTION:
Avoid using strong acidic whe-
el cleaners, especially on spo-
ked wheels. If such products
are used on hard-to-remove
dirt, do not leave the cleaner on
the affected area any longer
than instructed. Also, tho-
roughly rinse the area off with
water, immediately dry it, and
then apply a corrosion protec-
tion spray.
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or spon-
ge with mild detergent and
water to clean plastic.
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasivecleaning products, solvent or
thinner, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
Do not use high-pressure was-
hers or steam-jet cleaners sin-
ce they cause water seepage
and deterioration in the follo-
wing areas: seals (of wheel and
swingarm bearings, fork and
brakes), electric components
(couplers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or scrat-
ching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not lea-
ve any marks. If the windshield
is scratched, use a quality
plastic polishing compound
after washing.
7
MOTORCYCLE CARE AND STORAGE
7-1
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Avoid using abrasive polishing
compounds as they will wear
away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
EAU37220
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. Turn the fuel cock lever to “OFF”.
3. Drain the carburetor float cham-
ber by loosening the drain bolt;
this will prevent fuel depositsfrom 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.
7
MOTORCYCLE CARE AND STORAGE
7-3
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DimensionsOverall length
2202 mm (86.7 in)
Overall width
689 mm (27.1 in)
Overall height
1175 mm (46.3 in)
Seat height
820 mm (32.3 in)
Wheelbase
1341 mm (52.8 in)
Ground clearance
151 mm (5.94 in)
Minimum turning radius
2900 mm (114.2 in)
WeightWith oil and fuel
124 kg (273 lb)
EngineEngine type
Liquid cooled 2-stroke
Cylinder arrangement
Forward-inclined single cylinder
Displacement
49.7 cm
3(3.03 cu*in)
Bore x stroke
40.3 x 39.0 mm (1.58 x 1.53 in)
Compression ratio
11.5:1
Starting system
Electric starter
Lubrication system
Separate lubrication (Yamaha autolube)
Oil type or gradeRecommended engine oil grade
SAE10W30 type SE motor oil
Cooling systemRadiator capacity (including all routes)
0.70 L (0.74 US qt) (0.62 Imp qt)
Coolant reservoir capacity (up to the maxi-
mum level mark)
0.29L (0.31 US qt) ( 0.26 Imp qt)
Air filterAir filter element
Wet element
Recommended fuelRecommended fuel
Unleaded fuel
Fuel tank capacity
13.8 L (3.65 US gal) (3.04 Imp gal)
Fuel reserve amount
2.2 L (0.58 US gal) (0.48 Imp gal)
CarburetorManufacturer
Dell’Orto
Type x quantity
PHBN 16 x 1
Spark plug (s)Manufacturer/model
NGK/BR 9 ES
Spark plug gap
0.6 ~ 0.7 mm (0.023 ~ 0.027 in)
ClutchClutch type
Wet, multiple-disc
TransmissionPrimary reduction system
Helical gear
Primary reduction ratio
71 x 20 (3.55)
Secondary reduction system
Chain drive
Secondary reduction ratio
60 x 11 (5.45)
Transmission type
Constant mesh 6-speed
Operation
Left foot operation
Gear ratio1-
36 x 12 (3.00)
2-
33 x 16 (2.062)
3-
29 x 19 (1.526)
4-
27 x 22 (1.227)
5-
25 x 24 (1.041)
6-
24 x 25 (0.960)
ChassisFrame type
Double cradle
Caster angle
25 º
Trail
90 mm (3.54 in)
8
SPECIFICATIONS
8-1
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2-stroke engine oil .....................................3-7
AAir filter element .......................................6-12
Anti-theft device housing ...........................3-9
Autolube pump, adjusting........................6-24
BBattery......................................................6-27
Brake and clutch levers, checking and
lubricating ..............................................6-24
Brake and shift pedals, checking and
lubricating ..............................................6-24
Brake fluid level, checking .......................6-19
Brake fluid, changing ...............................6-20
Brake lever .................................................3-5
Brake pedal ................................................3-5
Brake pedal free play, adjusting ..............6-17
CCables, checking and lubricating ............6-23
Carburetor, adjusting ...............................6-12
Care............................................................7-1
Catalytic converter .....................................3-6
Clutch lever ................................................3-4
Clutch lever free play, adjusting...............6-16
Coolant.......................................................6-9
Coolant temperature warning light ............3-2
Cowlings and panels, removing and
installing ...................................................6-5
DDimmer switch ...........................................3-3
Drive chain slack ......................................6-21
Drive chain, cleaning and lubricating.......6-22
EEngine break-in ..........................................5-3
Engine idling speed .................................6-13Engine stop switch ....................................3-3
Engine trouble warning light ......................3-2
Engine, starting a warm .............................5-2
FFront and rear brake pads, checking ......6-18
Front brake lever free play, checking.......6-17
Front fork, checking .................................6-25
Fuel ............................................................3-5
Fuel cock....................................................3-8
Fuel consumption, tips for reducing ..........5-3
Fuel tank breather/overflow hose ..............3-7
Fuel tank cap .............................................3-6
Fuse, replacing.........................................6-28
HHandlebar switches ...................................3-3
Headlight bulb, replacing .........................6-28
Horn switch ................................................3-3
IIdentification numbers ...............................9-1
Ignition circuit cut-off system ..................3-10
Indicator and warning lights ......................3-1
KKey identification number ..........................9-1
LLicense plate light bulb, replacing ...........6-29
MMain switch/steering lock ..........................3-1
Model label ................................................9-2
NNeutral indicator light.................................3-1
OOil level warning light .................................3-2
PParking .......................................................5-4
Part locations .............................................2-1
Pass switch ................................................3-3
Periodic maintenance and lubrication
chart .........................................................6-2
Pre-operation check list .............................4-2
RRear brake light switch, adjusting ...........6-18
Rear view mirrors .......................................3-9
SSafety information ......................................1-1
Seat ............................................................3-9
Shift pedal ..................................................3-4
Shift pedal position, adjusting .................6-18
Shifting .......................................................5-2
Sidestand .................................................3-10
Sidestand, checking and lubricating .......6-25
Spark plug, checking .................................6-7
Specifications.............................................8-1
Speedometer unit ......................................3-2
Start switch ................................................3-4
Starter (choke) lever ...................................3-8
Starting a cold engine ................................5-1
Steering, checking ...................................6-26
Storage.......................................................7-3
TTachometer ................................................3-3
Throttle cable free play, adjusting ............6-12
Throttle grip and cable, checking and
lubricating ..............................................6-23
Tires .........................................................6-14
Tool kit ........................................................6-1
Transmission oil .........................................6-8
INDEX
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