check engine YAMAHA TZR50 2008 User Guide

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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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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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
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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
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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)
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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
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throttle cable free play, turn the
adjusting nut in direction (b).EAU33481
Adjusting the engine idling
speed
The engine idling speed must be
checked and, if necessary, adjusted
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
The engine should be warm before
making this adjustment.
NOTE:
The engine is warm when it quickly
responds to the throttle.
1. Remove panel B. (See page 6-5.)
1. Idle adjusting screw
2. Check the engine idling speed
and, if necessary, adjust it to spe-
cification by turning the idle
adjusting screw. To increase the
engine idling speed, turn the
screw in direction (a). To decrea-
se the engine idling speed, turn
the screw in direction (b).
NOTE:
If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
3. Install the panel.
Engine idling speed:
1.600 ~ 1.900 r/min
1(a)
(b)
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EAUT1220
Checking the front brake
lever free play
1. Brake lever free play
The brake lever free play should mea-
sure 2~5 mm (0.08~0.20 in) as shown.
Periodically check the brake lever free
play and, if necessary, have a Yamaha
dealer check the brake system.
EWA10640
s s
WARNING
An incorrect brake lever free play
indicates a hazardous condition in
the brake system. Do not operate
the motorcycle until the brake sys-
tem has been checked or repaired
by a Yamaha dealer.
EAUM1352
Adjusting the brake pedal
free play
1. Brake pedal free play
The brake pedal free play should
measure 10~15 mm (0.39~0.59 in) as
shown. Periodically check the brake
pedal free play and, if necessary, have
a Yamaha dealer adjust it.
EWAM1010
s s
WARNING
You are hereby informed that any
attempt to change the engine or
any other part to increase the sco-
oter’s performance or power is
strictly forbidden by law.
Any change resulting in an
increase of the vehicle’s maxi-
mum speed or in an increase of
the engine’s capacity entails a
category classification shift
from scooter to light motorcy-
cle, with all the consequences
relating to the latter category,
compelling the owner to:
- proceed with a new certifica-
tion,
- have the vehicle registered,
- hold a driving license (pur-
suant to the new legislation).
In addition, you are informed that
such changes will bar you from
insurance coverage insofar as
insurance policies expressly stipu-
late that such technical changes
brought with a view to enhancing
performance are forbidden.
For the above-mentioned reasons,
any violation of the rules forbidding
personal or otherwise third-party
interventions is punishable by law
with penalties (including seizure of
the vehicle) to which, as the case
may be, penalties may be added
relating to the failure to wear a
1
1
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ECA11110
CAUTION:
Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
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.
EAU23111
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip
should be checked before each ride.
In addition, the cable should be lubri-
cated at the intervals specified in the
periodic maintenance chart.
Recommended lubricant:
Engine oil
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EAU23120
Adjusting the Autolube pump
The Autolube pump is a vital and sop-
histicated component of the engine,
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
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.
EAU23140
Checking and lubricating the
brake and clutch levers
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be
lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease (all-
purpose grease)
j
kj
q
Recommended lubricant:
Lithium-soap-based grease (all-
purpose grease)
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