fuel YAMAHA TZR50 2008 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 and warning lights .............3-1
Speedometer unit .............................3-2
Tachometer .......................................3-3
Handlebar switches ..........................3-3
Clutch lever .......................................3-4
Shift pedal.........................................3-4
Brake lever ........................................3-5
Brake pedal.......................................3-5
Fuel ...................................................3-5
Catalytic converter............................3-6
Fuel tank cap ....................................3-6
Fuel tank breather/overflow hose .....3-7
2-stroke engine oil ............................3-7
Fuel cock ..........................................3-8
Starter (choke) lever “
q” .................3-8
Seat...................................................3-9
Anti-theft device housing..................3-9
Rear view mirrors ..............................3-9
Sidestand ........................................3-10
Ignition circuit cut-off system .........3-10PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2
OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Starting a warm engine ....................5-2
Shifting ..............................................5-2
Tips for reducing fuel consumption..5-3
Engine break-in.................................5-3
Parking ..............................................5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR...................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and
lubrication chart ............................6-2
Removing and installing cowlings
and panels .....................................6-5
Checking the spark plug ..................6-7
Transmission oil ................................6-8
Coolant .............................................6-9
Air filter element ..............................6-12
Adjusting the carburetor .................6-12
Adjusting the throttle cable free
play ..............................................6-12
Adjusting the engine idling speed ..6-13
Tires ................................................6-14
Cast wheels ....................................6-16
Adjusting the clutch lever free
play ..............................................6-16Checking the front brake lever free
play ..............................................6-17
Adjusting the brake pedal free
play ..............................................6-17
Adjusting the shift pedal position ...6-18
Adjusting the rear brake light
switch ..........................................6-18
Checking the front and rear brake
pads.............................................6-18
Checking the brake fluid level ........6-19
Changing the brake fluid ................6-20
Drive chain slack.............................6-21
Cleaning and lubricating the drive
chain ............................................6-22
Checking and lubricating the
cables ..........................................6-23
Checking and lubricating the
throttle grip and cable .................6-23
Adjusting the Autolube pump .........6-24
Checking and lubricating the brake
and shift pedals ...........................6-24
Checking and lubricating the brake
and clutch levers .........................6-24
Checking and lubricating the
sidestand .....................................6-25
Checking the front fork ...................6-25
Checking the steering.....................6-26
Checking the wheel bearings .........6-26
Battery ............................................6-27
Replacing the fuse ..........................6-28
Replacing the headlight bulb..........6-28
TABLE OF CONTENTS
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tem, an electric failure could
result, which could cause a dan-
gerous loss of lights or engine
power.
Gasoline and exhaust gas
GASOLINE IS HIGHLY FLAMMA-
BLE:
• Always turn the engine off
when refueling.
• Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.
• Never refuel while smoking or
in the vicinity of an open flame.
Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within
a short time. Always operate your
motorcycle in an area that has
adequate ventilation.
Always turn the engine off before
leaving the motorcycle unatten-
ded and remove the key from the
main switch. When parking the
motorcycle, note the following:
• The engine and exhaust sys-
tem may be hot, therefore,park the motorcycle in a place
where pedestrians or children
are not likely to touch these hot
areas.
• Do not park the motorcycle on
a slope or soft ground, other-
wise it may fall over.
• Do not park the motorcycle
near a flammable source (e.g. a
kerosene heater, or near an
open flame), otherwise it could
catch fire.
When transporting the motorcy-
cle in another vehicle, make sure
that it is kept upright and that the
fuel cock is turned to “ON” or
“RES” (for vacuum type) / “OFF”
(for manual type). If it should lean
over, gasoline may leak out of the
carburetor or fuel tank.
If you should swallow any gasoli-
ne, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immedia-
tely. If any gasoline spills on your
skin or clothing, immediately
wash the affected area with soap
and water and change your clot-
hes.
1
SAFETY INFORMATION t
1-4
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EAU10410
Left view
2
DESCRIPTION
2-1
123
4567
8 9 10
1. Fuel tank (page 3-6)
2. Fuel cock (page 3-8)
3. Oil tank (page 3-7)
4. Seat lock (page 3-9)
5. Battery/fuse box (page 6-27)6. Owner’s tool kit (page 6-1)
7. Grab bar
8. Sidestand (page 3-10)
9. Shift pedal (page 3-4)
10. Coolant recovery (page 6-9)
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EAU10430
Controls and instruments
2
DESCRIPTION
2-3
12
34 5
6
7
8 9
1. Left rear view mirror (page 3-9)
2. Tachometer (page 3-3)
3. Main switch/Steering lock (page 3-1)
4. Speedometer/Odometer (page 3-2)
5. Right rear view mirror (page 3-9)6. Front brake lever (page 3-5)
7. Throttle grip (page 6-12)
8. Fuel tank cap (page 3-6)
9. Clutch lever (page 3-4)
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EAU12890
Brake lever
1. Brake lever
The brake lever is located at the right
handlebar grip. To apply the front bra-
ke, pull the lever toward the handle-
bar grip.
EAU12941
Brake pedal
1. Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear bra-
ke, press down on the brake pedal.
EAU13210
Fuel
1. Fuel tank filler tube
2. Fuel level
Make sure that there is sufficient fuel
in the tank. Fill the fuel tank to the
bottom of the filler tube as shown.
EWA10880
s s
WARNING
Do not overfill the fuel tank,
otherwise it may overflow
when the fuel warms up and
expands.
Avoid spilling fuel on the hot
engine.
1
1
3
INSTRUMENT AND CONTROL FUNCTIONS
3-5
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ECA10070
CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfa-
ces or plastic parts.
EAU13270
Your Yamaha engine has been desig-
ned to use regular unleaded gasoline
with a research octane number of 91
or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark
plug life and reduce maintenance
costs.
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.
EAU13070
Fuel tank cap
1. Fuel tank cap lock cover
2. Unlock
To open the fuel tank cap
Open the fuel tank cap lock cover,
insert the key into the lock, and then
turn it 1/4 turn clockwise. The lock will
be released and the fuel tank cap can
be opened.
To close the fuel tank cap
1. Push the fuel tank cap into posi-
tion with the key inserted in the
lock.
2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
1
Recommended fuel:
REGULAR UNLEADED GASOLINE
ONLY
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)
3
INSTRUMENT AND CONTROL FUNCTIONS
3-6
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NOTE:
The fuel tank cap cannot be closed
unless the key is in the lock. In addi-
tion, the key cannot be removed if the
cap is not properly closed and loc-
ked.
EWA11090
s s
WARNING
Make sure that the fuel tank cap is
properly closed before riding.
EAUB1300
Fuel tank breather/overflow
hose
1. Fuel tank breather/overflow hose
Before operating the motorcycle:
Check the fuel tank breather/over-
flow hose connection.
Check the fuel tank
breather/overflow hose for
cracks or damage, and replace it
if damaged.
Make sure that the end of the fuel
tank breather/overflow hose is
not blocked, and clean it if
necessary.
Make sure that the end of the fuel
tank breather/overflow hose is
positioned inside of the clamp.
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.
Recommended oil:
Yamalube 2 or equivalent 2-stroke
engine oil (JASO grade “FC”, or
ISO grades “EG-C” or “EG-D”)
Oil quantity:
1.4 L (1.48 US qt) (1.23 Imp qt)
12
1
3
INSTRUMENT AND CONTROL FUNCTIONS
3-7
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EAU13561
Fuel cock
1. Fuel cock
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
With the lever in this position, fuel
flows to the carburetor. Normal riding
is done with the lever in this position.RES
This indicates reserve. If you run out
of fuel while riding, move the lever to
this position. Fill the tank at the first
opportunity. Be sure to set the lever
back to “ON” after refueling!
EAU13590
Starter (choke) lever “q”
1. Starter (choke) lever
Starting a cold engine requires a
richer air-fuel mixture, which is sup-
plied by the starter (choke).
Move the lever in direction (a) to turn
on the starter (choke).
Move the lever in direction (b) to turn
off the starter (choke).
j
k1(b)
(a)1
ON
RES OFFFUEL
3
INSTRUMENT AND CONTROL FUNCTIONS
3-8
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EAU15603
Pre-operation check list
4
PRE-OPERATION CHECKS
4-2
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary. 3-5, 3-6, 3-7
• Check fuel line for leakage.
• Check oil level in oil tank.
2-stroke engine oil• If necessary, add recommended oil to specified level. 3-7
• Check vehicle for oil leakage.
Transmission oil• Check oil level in transmission case.
• If necessary, add recommended oil to specified level.6-8
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-9
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Front brake• Replace if necessary. 3-5, 6-17 ~ 6-20
• 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. 3-5, 6-17 ~ 6-20
• 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.
3-4, 6-16, 6-24
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
Throttle grip• Check cable free play.
6-12, 6-23
• If necessary, have Yamaha dealer adjust cable free play and lubricate
cable and grip housing.
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EAU15950
EWA10270
s s
WARNING
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or func-
tion that you do not thoroughly
understand.
Never start the engine or ope-
rate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of cons-
ciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised comple-
tely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU16050
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 3-11.
Never ride with the sidestand
down.
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “
f” 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 lightshould be on, otherwise have a
Yamaha dealer check the electrical
circuit.
4. Turn the starter (choke) on and
completely close the throttle.
(See page 3-8.)
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.
ECA11410
CAUTION:
The 2-stroke engine oil level war-
ning light should come on when the
start switch is pushed, and it
should go off when the start switch
is released. If the warning light flic-
kers or remains on after starting,
immediately stop the engine, and
then check the 2-stroke engine oil
level and the vehicle for oil leakage.
5
OPERATION AND IMPORTANT RIDING POINTS
5-1
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