maintenance 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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EAU10251
MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE USE
AND OPERATION ARE DEPENDENT
UPON THE USE OF PROPER RIDING
TECHNIQUES AS WELL AS THE
EXPERTISE OF THE OPERATOR.
EVERY OPERATOR SHOULD KNOW
THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS MOTORCY-
CLE.
HE OR SHE SHOULD:
OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
OBSERVE THE WARNINGS AND
MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S
MANUAL.
OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDI-
TIONS.Safe riding
Always make pre-operation
checks. Careful checks may help
prevent an accident.
This motorcycle is designed to
carry the operator and a passen-
ger.
The failure of motorists to detect
and recognize motorcycles in
traffic is the predominating cause
of automobile/motorcycle acci-
dents. Many accidents have
been caused by an automobile
driver who did not see the
motorcycle. Making yourself
conspicuous appears to be very
effective in reducing the chance
of this type of accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when appro-
aching and passing through
intersections, since intersec-
tions are the most likely places
for motorcycle accidents to
occur.
• Ride where other motorists can
see you. Avoid riding in anot-
her motorist’s blind spot.
Many motorcycle accidents
involve inexperienced operators.
In fact, many operators who have
been involved in accidents do not
even have a current motorcycle
license.
• Make sure that you are quali-
fied and that you only lend your
motorcycle to other qualified
operators.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
• We recommend that you prac-
tice riding your motorcycle
where there is no traffic until
you have become thoroughly
familiar with the motorcycle
and all of its controls.
Many motorcycle accidents have
been caused by error of the
motorcycle operator. A typical
error made by the operator is
veering wide on a turn due to
EXCESSIVE SPEED or undercor-
nering (insufficient lean angle for
the speed).
• Always obey the speed limit
and never travel faster than
1
tSAFETY INFORMATION
1-1
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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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EAU17240
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. The most important
points of inspection, adjustment, and
lubrication are explained on the follo-
wing pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, DEPENDING
ON THE WEATHER, TERRAIN, GEO-
GRAPHICAL LOCATION, AND INDIVI-
DUAL USE, THE MAINTENANCE
INTERVALS MAY NEED TO BE
SHORTENED.
EWA10320
s s
WARNING
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
EAU17520
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located inside
the storage compartment under the
seat. (See page 3-9.)
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to
assist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be
necessary to perform certain mainte-
nance work correctly.
NOTE:
If you do not have the tools or expe-
rience required for a particular job,
have a Yamaha dealer perform it for
you.
EWA10350
s s
WARNING
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle
unsafe for use. Consult a Yamaha
dealer before attempting any chan-
ges.
1
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
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EAU17710
Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed
instead.
From 30000 km, repeat the maintenance intervals starting from 6000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
ODOMETER READING (x 1000 Km)
ANNUAL
NO ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24CHECK
1*Fuel line• Check fuel hoses for cracks or damage.√√√√ √
2Spark plug• Replace.√√√√ √
3*Air filter element• Clean.√√• Replace.√√
4Clutch• Check operation.
• Adjust.√√ √ √√
5*Front brake• Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √• Replace brake pads. Whenever worn to the limit
6*Rear brake• Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √• Replace brake pads. Whenever worn to the limit
7*Brake hose• Check for cracks or damage.√√√√ √• Replace. Every 4 years
8*Wheels• Check runout and for damage.√√√√
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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.√√√√
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
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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.
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EAU18712
Removing and installing
cowlings and panels
The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each
time a cowling or panel needs to be
removed and installed.
1. Cowling A (screws x 7)
2. Panel A (screw x 1)
3. Cowling B (screws x 5)1. Cowling A (screws x 6)
2. Cowling B (screws x 7)
3. Cowling C (screw x 1)
4. Panel B (screw x 1)
EAU18790
Cowling A
T
o remove the cowling
Remove the screws, and then take
the cowling off.T
o install the cowling
Place the cowling in the original posi-
tion, and then install the screws.
EAU18951
Cowling B
T
o remove the cowling
1. Remove cowling A.
2. Remove the screws, and then
pull the cowling off as shown.
T
o install the cowling
1. Place the cowling in the original
position, and then install the
screws.
NOTE:
Make sure that the projection fits into
the grommet.
2. Install cowling A.
1 2 34
13
2
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
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EAU18810
Cowling C
T
o remove the cowling
Remove the screw, and then pull the
cowling off as shown.
T
o install the cowling
Place the cowling in the original posi-
tion, and then install the screw.
EAU19272
Panel A
T
o remove the panel
Remove the screw, and then pull out-
ward on the areas shown.
T
o install the panel
Place the panel in the original posi-
tion, and then install the screw.
EAU19280
Panel B
T
o remove the panel
Remove the screw, and then pull the
panel off as shown.
T
o install the panel
Place the panel in the original posi-
tion, and then install the screw.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
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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
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
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