YAMAHA TZR50 2008 Repair Manual

1. Headlight lead connectors
2. Headlight bulb holder
2. Unhook the headlight bulb hol-
der, and then remove the defecti-
ve bulb.
EWA10790
s s
WARNING
Headlight bulbs get very hot. The-
refore, keep flammable products
away from a lit headlight bulb, and
do not touch the bulb until it has
cooled down.
3. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
ECA10660
CAUTION:
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the
bulb, and the bulb life will be adver-
sely affected. Thoroughly clean off
any dirt and fingerprints on the
headlight bulb using a cloth mois-
tened with alcohol or thinner.
4. Connect the headlight lead con-
nectors, and then install the bulb
cover.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAUS1150
Replacing the license plate
light bulb
1. Remove the lens by removing the
screw.
2. Remove the defective bulb by
pulling it out.
3. Insert a new bulb into the socket.
4. Install the lens by installing the
screw.
ECA11190
CAUTION:
Do not overtighten the screw,
otherwise the lens may break.
1
2
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EAU24281
Replacing a turn signal light
bulb or the tail/brake light
bulb
1. Remove the lens by removing the
screws.
2. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screws.
ECA10680
CAUTION:
Do not overtighten the screws,
otherwise the lens may break.
EAUS1350
Replacing a front turn signal
light bulb
ECA10670
CAUTION:
It is advisable to have a Yamaha
dealer perform this job.
1. Remove the socket (together
with the bulb) by turning it coun-
terclockwise for the right turn sig-
nal and turning it clockwise for
the left turn signal.
2. Remove the defective bulb by
pulling it out.
3. Insert a new bulb into the socket.
4. Install the socket (together with
the bulb) by turning it clockwise
for the right turn signal and tur-
ning it counterclockwise for the
left turn signal.
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1. Socket
1. Bulb
EAU25870
Troubleshooting
Although Yamaha motorcycles recei-
ve a thorough inspection before ship-
ment from the factory, trouble may
occur during operation. Any problem
in the fuel, compression, or ignition
systems, for example, can cause poor
starting and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcy-
cle require any repair, take it to a
Yamaha dealer, whose skilled techni-
cians have the necessary tools, expe-
rience, and know-how to service the
motorcycle properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
1
1
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
EAU25921
Troubleshooting charts
Starting problems or poor engine performanceEWA10840
s s
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.
1. FuelThere is enough fuel.
There is no fuel.Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.
2. CompressionThere is compression.
There is no compression.Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.
3. IgnitionWipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.
4. BatteryThe engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the battery lead connections,
and charge the battery if necessary.
Dry
We tOpen the throttle halfway and operate
the electric starter.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
Engine overheatingEWA10400
s s
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the his-
sing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
Wait until the
engine has cooled.Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
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EAU26001
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.
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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.
EWA11130
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 riding at hig-
her speeds, test the motorcy-
cle’s braking performance and
cornering behavior.
ECA10800
CAUTION:
Apply spray oil and wax spa-
ringly and make sure to wipe
off any excess.
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
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Avoid using abrasive polishing
compounds as they will wear
away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
EAU37220
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. Turn the fuel cock lever to “OFF”.
3. Drain the carburetor float cham-
ber by loosening the drain bolt;
this will prevent fuel depositsfrom 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.
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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
the tires from becoming degra-
ded in one spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a
month. Do not store the battery in
an excessively cold or warm pla-
ce [less than 0 °C (30 °F) or more
than 30 °C (90 °F)]. For moreinformation on storing the bat-
tery, see page 6-27.
NOTE:
Make any necessary repairs before
storing the motorcycle.
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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
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