YAMAHA TZR50 2008 Owner's Guide

ECA10260
CAUTION:
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long
distances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
Always use the clutch while
changing gears to avoid dama-
ging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU16800
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the follo-
wing tips to reduce fuel consumption:
Turn the starter (choke) off as
soon as possible.
Shift up swiftly, and avoid high
engine speeds during accelera-
tion.
Do not rev the engine while shif-
ting down, and avoid high engine
speeds with no load on the engi-
ne.
Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at
traffic lights or at railroad cros-
sings).
EAU16830
Engine break-in
There is never a more important
period in the life of your engine than
the period between 0 and 1000 km
(600 mi). For this reason, you should
read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1000 km (600 mi). The various parts in
the engine wear and polish themsel-
ves to the correct operating clearan-
ces. During this period, prolonged
full-throttle operation or any condition
that might result in engine overhea-
ting must be avoided.
EAU17130
0~500 km (0~300 mi)
Avoid prolonged operation above
4.000 r/min.
After every hour of operation, stop the
engine, and then let it cool for five to
ten minutes.
Vary the engine speed from time to
time. Do not operate the engine at
one set throttle position.
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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.
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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.
EAU17520
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located inside
the storage compartment under the
seat. (See page 3-9.)
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.
1
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EAU17710
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.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
ODOMETER READING (x 1000 Km)
ANNUAL
NO ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24CHECK
1*Fuel line• Check fuel hoses for cracks or damage.√√√√ √
2Spark plug• Replace.√√√√ √
3*Air filter element• Clean.√√• Replace.√√
4Clutch• Check operation.
• Adjust.√√ √ √√
5*Front brake• Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √• Replace brake pads. Whenever worn to the limit
6*Rear brake• Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √• Replace brake pads. Whenever worn to the limit
7*Brake hose• Check for cracks or damage.√√√√ √• Replace. Every 4 years
8*Wheels• Check runout and for damage.√√√√
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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.√√√√
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ODOMETER READING (x 1000 Km)
ANNUAL
NO ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24CHECK
21Transmission oil• Check oil level.√√ √ √√ √
• Change.√√
22 *Front and rear brake
switches• Check operation.√√ √ √√ √
23Moving parts and cables• Lubricate.√√√√ √
Throttle grip housing• Check operation and free play.
24 * • Adjust the throttle cable free play if necessary.√√√√ √
and cable
• Lubricate the throttle grip housing and cable.
25 *Lights, signals and • Check operation.
switches• Adjust headlight beam.√√ √ √√ √
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
EAUM1890
NOTE:
Replace the air filter element more frequently 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 cylinder, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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EAU18712
Removing and installing
cowlings and panels
The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each
time a cowling or panel needs to be
removed and installed.
1. Cowling A (screws x 7)
2. Panel A (screw x 1)
3. Cowling B (screws x 5)1. Cowling A (screws x 6)
2. Cowling B (screws x 7)
3. Cowling C (screw x 1)
4. Panel B (screw x 1)
EAU18790
Cowling A
T
o 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.
EAU18951
Cowling B
T
o remove the cowling
1. Remove cowling A.
2. Remove the screws, and then
pull the cowling off as shown.
T
o install the cowling
1. Place the cowling in the original
position, and then install the
screws.
NOTE:
Make sure that the projection fits into
the grommet.
2. Install cowling A.
1 2 34
13
2
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EAU18810
Cowling C
T
o remove the cowling
Remove the screw, and then pull the
cowling off as shown.
T
o install the cowling
Place the cowling in the original posi-
tion, and then install the screw.
EAU19272
Panel A
T
o remove the panel
Remove the screw, and then pull out-
ward on the areas shown.
T
o install the panel
Place the panel in the original posi-
tion, and then install the screw.
EAU19280
Panel B
T
o remove the panel
Remove the screw, and then pull the
panel off as shown.
T
o install the panel
Place the panel in the original posi-
tion, and then install the screw.
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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
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1. Spark plug wrench
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
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.
4. Install the spark plug cap.
5. Install the cowling.EAUM1270
Transmission oil
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 surface
and hold it in an upright position.
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.
1. Oil filler cap
2. Oil check bolt
3. Transmission oil drain bolt
3
2
1
Tightening torque:
Spark plug:
22.5 Nm (2.2 m•kgf, 16.3 ft•lbf)
1
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