engine oil YAMAHA TZR50 2004 Owners Manual

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 lights ..................................3-1
Speedometer unit .............................3-2
Tachometer .......................................3-3
Handlebar switches ..........................3-3
Clucht lever .......................................3-4
Shift pedal.........................................3-4
Brake lever ........................................3-4
Brake pedal.......................................3-5
Fuel tank cap ....................................3-5
Catalytic converter............................3-6
2-stroke engine oil ............................3-6
Fuel cock ..........................................3-6
Starter (choke) lever..........................3-7
Seat...................................................3-7
Storage compartment.......................3-7
Sidestand ..........................................3-8
Ignition circuit cut-off system ...........3-8
PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Shifting ..............................................5-2
Tips for reducing fuel consumption..5-2
Engine break-in.................................5-3
Parking ..............................................5-3
PERIODIC MAINTENANCE AND
MINOR RAPAIR...................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and lubrication
chart ..................................................6-2
Removing and installing cowlings ....6-5
Checking the spark plug ..................6-6
Transmission oil ................................6-6
To check the coolant level ................6-8
Adjusting the carburetor ...................6-9
Adjusting the engine idling speed ....6-9
Adjusting the throttle cable free play ..6-9
Tires ................................................6-10
Cast wheels ....................................6-12
Adjusting the clucth lever free play 6-12
Adjusting the brake pedal position
and free play................................6-13
Adjusting the rear brake light
switch ..........................................6-13
Front brake pads ............................6-14
Rear brake pads .............................6-14
Checking the brake fluid level ........6-14
Changing the brake fluid ................6-15Drive Chain slack ............................6-16
Checking and lubricating the
cables ..........................................6-17
Checking and lubricating the brake
and shift pedals ...........................6-17
Checking and lubricating the brake
and cluctch levers .......................6-18
Checking and lubricating the
sidestand .....................................6-18
Checking the front fork ...................6-18
Checking the steering.....................6-19
Checking the wheel bearings .........6-19
Battery ............................................6-19
Replacing the fuse ..........................6-20
Replacing the headlight bulb..........6-21
Replacing a turn signal light bulb
or the tail/brake light bulb ...........6-21
Replacing the license plate light
bulb .............................................6-22
Supporting the mortorcycle ............6-22
Troubleshooting ..............................6-23
Troubleshooting charts ...................6-24
Engine overheating .........................6-25
MOTORCYCLE CARE AND
STORAGE............................................7-1
Care ..................................................7-1
Storage ...........................................7-2
SPECIFITACIONS...............................8-1
TABLE OF CONTENTS
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EAU10460
Main switch/steering lock
The main switch/steering lock con-
trols the ignition and lighting systems,
and is used to lock the steering. The
various positions are described
below.
EAU10640
ON
All electrical circuits are supplied with
power, and the engine can be started.
The key cannot be removed.
NOTE:
The headlight, meter lighting and tai-
llight come on automatically when the
engine is started.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10670
“f”
The 2-stroke engine oil level warning
light should come on. (See page 3-2.)
EAUM1020
“f”
The coolant temperature warning light
should come on when the key is tur-
ned to “
f”. (See page 3-2.)
EAU10680
LOCK
The steering is locked, and all electri-
cal systems are off. The key can be
removed.
T
o lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF”
position, and then turn it to
“LOCK” while still pushing it.
3. Remove the key.T
o unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
EWA10060
s s
WARNING
Never turn the key to “OFF” or
“LOCK” while the vehicle is
moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the vehi-
cle is stopped before turning the
key to “OFF” or “LOCK”.
EAU10980
Indicator lights
1. Turn signal indicator light “b”
2. Neutral indicator light “N”
3. Oil level warning light “z”
4. Coolant temperature warning light “y”
3
INSTRUMENT AND CONTROL FUNCTIONS
3-1
2 3
41
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EAU11020
Turn signal indicator light “b”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
EAU11060
Neutral indicator light “N”
This indicator light comes on when
the transmission is in the neutral posi-
tion.
EAU11120
Oil level warning light “z”
This warning light comes on when the
engine oil level is low.
The electrical circuit of the warning
light can be checked by turning the
key to “ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical
circuit.
NOTE:
Even if the oil level is sufficient, the
warning light may flicker when riding
on a slope or during sudden accelera-
tion or deceleration, but this is not a
malfunction.
EAU11440
Coolant temperature warning light
“y”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and
allow the engine to cool.
The electrical circuit of the warning
light can be checked by turning the
key to “ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical
circuit.
ECA10020
CAUTION
Do not operate the engine if it is
overheated.
EAU11620
Speedometer unit
1. Speedometer/Odometer
The speedometer unit is equipped
with a speedometer and an odometer.
The speedometer shows riding spe-
ed. The odometer shows the total dis-
tance traveled.
3
INSTRUMENT AND CONTROL FUNCTIONS
3-2
1
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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.
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.
EAU13560
Fuel cock
1. Fuel reserve switch
The fuel cock supplies fuel from the
tank to the carburetor while filtering it
also.
The fuel cock has three positions:
OFF
With the lever in this position, fuel will
not flow. Always return the lever to
this position when the engine is not
running.
ON
RES OFFFUEL
Recommended oil:
Yamalube 2 or equivalent 2-stroke
engine oil (JASO grade “FC”, or
ISO grades “EG-C” or “EG-D”)
Oil quantity:
1,35 L (1,18 Imp.qt)
3
INSTRUMENT AND CONTROL FUNCTIONS
3-6
12
1
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EAU15603
Pre-operation check list
PRE-OPERATION CHECKS
4-2
4
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary.3-5
• Check fuel line for leakage.
• Check oil level in oil tank.
2-stroke engine oil• If necessary, add recommended oil to specified level. 3-6
• Check vehicle for oil leakage.
Transmission oil• Check oil level in transmission case.
• If necessary, add recommended oil to specified level.6-6
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-8
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check lever free play.
• Adjust if necessary.
Front brake• Check brake pads for wear. 6-14
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Rear brake• Replace if necessary. 6-14
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
Clutch• Lubricate cable if necessary.
6-12
• Check lever free play.
• Adjust if necessary.
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EAU16000
Starting a cold engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EWA10290
s s
WARNING
Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-9.
Never ride with the sidestand
down.
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch
is set to “f”.
3. Shift the transmission into the
neutral position.
NOTE:
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.
4. Turn the starter (choke) on and
completely close the throttle.
(See page 3-7.)
5. Start the engine by pushing the
start switch.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the
engine more than 10 seconds on any
one attempt.
ECA11160
CAUTION
If the oil level warning light flickers
or remains on after starting, imme-
diately stop the engine, and then
check the engine oil level and the
vehicle for oil leakage. If necessary,
add engine oil, and then check thewarning light again. If the warning
light does not go off after starting
with sufficient 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.
5
OPERATION AND IMPORTANT RIDING POINTS
5-1
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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.
EAU16860
0~150 km (0~90 mi)
Avoid prolonged operation above 1/3
throttle.
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.150~500 km (90~300 mi)
Avoid prolonged operation above 1/2
throttle.
500~1000 km (300~600 mi)
Avoid prolonged operation above 3/4
throttle.
ECA10280
CAUTION
After 1000 km (600 mi) of operation,
the engine oil must be changed.
1000 km (600 mi) and beyond
Avoid prolonged full-throttle opera-
tion. Vary the speed occasionally.
ECA10270
CAUTION
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
EAU17170
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.
5
OPERATION AND IMPORTANT RIDING POINTS
5-3
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ODOMETER READING (x 1000 Km) ANNUAL
NOITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24CHECK
Check tread depth and for damage.
9*TiresReplace if necessary.
√√√√ √
Check air pressure.
Correct if necessary.
10 *Wheel bearingsCheck bearing for looseness or damage.√√√√
11 *SwingarmCheck operation and for excessive play.√√√√Lubricate with lithium-soap-based grease. Every 24000 km
12Drive chainCheck chain slack, alignment and condition. Every 500 km and after washing
Adjust and thoroughly lubricate chain with engine oil. the motorcycle or riding in the rain
13 *Steering bearingsCheck bearing play and steering for roughness.√√ √ √√Lubricate with lithium-soap-based grease. Every 24000 km
14 *Chassis fastenersMake sure that all nuts, bolts and screws are
√√√√ √
properly tightened.
15SidestandCheck operation.
Lubricate.√√√√ √
16 *Sidestand switchCheck operation.√√ √ √√ √
17 *Front forkCheck operation and for oil leakage.√√√√
18 *Shock absorber Check operation and shock absorber for oil leakage.
√√√√
assembly
19 *CarburetorCheck starter (choke) operation.
Adjust engine idling speed.√√ √ √√ √
20 *Autolube pumpCheck operation.
Bleed if necessary.√√√√
21Transmission oilCheck oil level.√√ √ √√ √
Change.√√
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
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EAU19620
Checking the spark plug
1. Spark plug
The spark plug is an important engine
component, which should be chec-
ked periodically, preferably by a
Yamaha dealer. Since heat and depo-
sits will cause any spark plug to
slowly erode, it 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.
The porcelain insulator around the
center electrode of the spark plug
should be a medium-to-light tan (the
ideal color when the vehicle is riddennormally). 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 vehicle.
If the spark plug shows signs of elec-
trode erosion and excessive carbon
or other deposits, it should be repla-
ced.
Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
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.
EAUM1270
Transmission oil
1. Oil level check bolt
2. Oil drain bolt
3. Oil filler cap
Tightening torque:
Spark plug:
20 Nm (2,0 m•kgf)
Spark plug gap:
0,6 ~ 0,7 mm (0,023~0,027 in)
Specified spark plug:
BR9ES (NGK)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
1
3
1
2
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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 surfa-
ce and hold it in an upright posi-
tion.
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.
2. Remove the oil check bolt, and
then 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 the
check 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.
Recommended transmission oil:
See page 8-1.
Oil change quantity:
0,75 L (0,65 imp.qt)
Tightening torque:
Transmission oil drain bolt:
17 Nm (1,7 m•kgf)
Oil check bolt:
3 Nm (0,3 m•kgf)
Tightening torque:
Oil check bolt:
3 Nm (0,3 m•kgf)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
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