engine oil YAMAHA TZR50 2003 User Guide

NOTE:
Make sure that two notches in the
axle nut are aligned with the hole
through the wheel axle, otherwise
further tighten the axle nut until they
are.
EWA10700
s s
WARNING
Always use a new cotter pin for the
axle nut.
EAU23012
Lubricating the drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
ECA10581
CAUTION
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.
NOTE:
For a thorough cleaning, have a
Yamaha dealer remove the drive
chain and soak it in solvent.
2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on both
sides and on the middle of the
chain, making sure that all side
plates and rollers have been suf-
ficiently oiled.
EAU23100
Checking and lubricating the
cables
The operation of all control cables
and the condition of the cables
should be checked before each ride,
and the cables and cable ends should
be lubricated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or repla-
ce it.
EWA10720
s s
WARNING
Damage to the outer sheath may
interfere with proper cable opera-
tion and will cause the inner cable
to rust. Replace a damaged cable
as soon as possible to prevent
unsafe conditions.
EAU23131
Checking and lubricating the
brake and shift pedals
The operation of the brake and shift
pedals should be checked before
each ride, and the pedal pivots
should be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease (all-
purpose grease)
Recommended lubricant:
Engine oil
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
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EAU26000
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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After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottle-
brush for hard-to-reach areas. Stub-
born dirt and insects will come off
more easily if the area is covered with
a wet cloth for a few minutes before
cleaning.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on
roads during winter are extremely
corrosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads.
NOTE:
Salt sprayed on roads in the winter
may remain well into spring.
1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA10790
CAUTION
Do not use warm water since it
increases the corrosive action of
the salt.
2. Apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, surfa-
ces to prevent corrosion.
After cleaning
1. Dry the motorcycle with a cha-
mois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally indu-
ced discoloring of stainless-steel
exhaust systems can be removed
through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, inclu-
ding chrome- and nickel-plated,
surfaces.5. Use spray oil as a universal clea-
ner to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry comple-
tely before storing or covering it.
EWA10930
s s
WARNING
Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent.
Before operating the motorcy-
cle test its braking performan-
ce and cornering behavior.
ECA10800
CAUTION
Apply spray oil and wax spa-
ringly and make sure to wipe
off any excess.
7
MOTORCYCLE CARE AND STORAGE
7-2
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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
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EAU26339
Dimensions
Overall length
2007 mm
Overall width
675 mm
Overall height
1065 mm
Seat height
815 mm
Wheelbase
1330 mm
Ground clearance
144 mm
Minimum turning radius
2900 mm
Weight
With oil and fuel
124.2 kg
Engine
Engine type
Liquid cooled 2-stroke
Cylinder arrangement
Forward-inclined single cylinder
Displacement
49.7 cm
3
Bore x stroke
40.3 x 39.0 mm
Compression ratio
6.85 :1
Starting system
Electric starter
Lubrication system
Separate lubrication (Yamaha autolube)
Transmission oil
Oil change quantity
0.75 L
Coolant reservoir capacity (up to the maxi-
mum level mark)
0.71 L
Radiator capacity (including all routes)
0.70 L
Air filter element
Wet element
Fuel
Fuel tank capacity
13.8 L
Fuel reserve amount
2.2 L
Carburetor
Manufacturer
Dell’Orto
Type x quantity
PHBN 16 NS / 1
Spark plug (s)
Manufacturer/model
NGK/BR9ES
Spark plug gap
0.6-0.7 mm
Clutch type
Wet, multiple-disc
Transmission
Primary reduction system
Helical gear
Primary reduction ratio
71 x 20 (3.550)
Secondary reduction system
Chain driveSecondary reduction ratio
47 x 11 (4.270)
Transmission type
Constant mesh 6-speed
Gear ratio
1st
36 x 12 (3.000)
2nd
33 x 16 (2.062)
3rd
29 x 19 (1.526)
4th
27 x 22 (1.227)
5th
25 x 24 (1.041)
6th
24 x 25 (0.960)
Chassis
Frame type
Double cradle
Caster angle
25.00 degree
Trail
92.0 mm
Front tire
Type
Tubeless
Size
100/80-17 52H
Manufacturer/model
PIRELLI
Rear tire
Type
Tubeless
8
SPECIFICATIONS
8-1
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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
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