transmission YAMAHA TZR50 2008 User Guide

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.√√ √ √√ √
6
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.
5WX-F8199-E2.qxd 29/05/2006 14:23 Página 4

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
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
5WX-F8199-E2.qxd 29/05/2006 14:23 Página 8

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
PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
5WX-F8199-E2.qxd 31/05/2006 10:23 Página 9

EAU22760
Drive chain slack
The drive chain slack should be chec-
ked before each ride and adjusted if
necessary.
EAU22781
To check the drive chain slack
1. Drive chain slack
1. Place the motorcycle on the
sidestand.
NOTE:
When checking and adjusting the dri-
ve chain slack, there should be no
weight on the motorcycle.
2. Shift the transmission into the
neutral position.3. Move the rear wheel by pushing
the motorcycle to locate the tigh-
test portion of the drive chain,
and then measure the drive chain
slack as shown.
4. If the drive chain slack is inco-
rrect, adjust it as follows.
NOTE:
When checking the drive chain slack,
the chain tensioner should not be tou-
ching the drive chain.
EAU22920
To adjust the drive chain slack
1. Cotter pin
2. Axle nut
3. Locknut
4. Drive chain slack adjusting bolt
5. Alignment marks
1. Axle nut
2. Locknut
3. Drive chain slack adjusting bolt
4. Alignment marks
1
2
4 3
b
a
12
3
4
5a
b
Drive chain slack:
20 ~ 25 mm (0.787 ~ 0.984 in)
16
PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
5WX-F8199-E2.qxd 29/05/2006 14:23 Página 21

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
5WX-F8199-E2.qxd 29/05/2006 14:23 Página 38

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
5WX-F8199-E2.qxd 29/05/2006 14:23 Página 43