Yamaha TZR50 manual

5WX-F8199-E1 TZR50 OWNER’S MANUAL 5WX-F8199-E1.qxd 14/12/2004 15:05 Página 1[...]

5WX-F8199-E1.qxd 14/12/2004 15:05 Página 2[...]

EAU10100 W elcome to the Y amaha world of motorcycling! As the owner of the TZR50, you are benefiting fr om Y amaha’ s vast experience and newest technology regar ding the design and manufacture of high-quality pr oducts, which have ear ned Y amaha a reputation for dependability . Please take the time to read this manual thor oughly , so as to en[...]

EAU10150 Particularly important information is distinguished in this manual by the following notations: IMPOR T ANT MANUAL INFORMA TION CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. NOTE: A NOTE provides key information to make pr ocedures easier or clearer . NOTE: ● This manual should be co[...]

EWA10030 s s WARNING PLEASE READ THIS MANUAL CAREFULL Y AND COMPLETEL Y BEFORE OPERA TING THIS MOTORCYCLE. IMPOR T ANT MANUAL INFORMA TION 5WX-F8199-E1.qxd 14/12/2004 15:05 Página 5[...]

IMPOR T ANT MANUAL INFORMA TION EAUS1171 TZR50 OWNER’S MANUAL ©2005 by Y AMAHA MOTOR SP AIN S.A. 1st edition, January 2005 All rights reserved. Any reprinting or unauthorized use without the written permission of Y AMAHA MOTOR SP AIN S.A. is expressly pr ohibited. Printed in Spain. 5WX-F8199-E1.qxd 14/12/2004 15:05 Página 6[...]

SAFETY INFORMA TION .....................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/stee[...]

CONSUMER INFORMA TION .............9-1 Identification numbers ......................9-1 Frame serial number .........................9-1 Key identification number .................9-1 Model label .......................................9-2 T ABLE OF CONTENTS 5WX-F8199-E1.qxd 14/12/2004 15:05 Página 8[...]

EAU10251 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERA TION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERA TOR. EVER Y OPERA TOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCY- CLE. HE OR SHE SHOULD: ● OBT AIN THOROUGH INSTRUC- TIONS FROM A COMPETENT SOURCE ON ALL [...]

• W e recommend that you prac- tice riding your motorcycle where ther e 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 u[...]

Modifications Modifications made to this motorcy- cle not approved by Y amaha, or the removal of original equipment, may render the motor cycle unsafe for use and may cause severe personal injury . Modifications may also make your motorcycle illegal to use. Loading and accessories Adding accessories or car go to your motorcycle can adversely af fec[...]

• Accessories fitted to the hand- lebar or the front fork ar ea can create instability due to impr o- per weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork ar ea, they must be as lightweight as possible and should be kept to a minimum. • Bulky or large accessories may seriously affect the stabil[...]

● 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 ar ea with soap and water and change your clot- hes. 1 SAFETY INFORMA TION t 1-5 5WX-F8199-E1.qxd 14/12/2004 15:05 Página [...]

EAU10410 Left view DESCRIPTION 2-1 2 1 Headlight (page 6-21) 2 Sidestand (page 3-8) 3 Fuel cock (page 3-6 ) 4 Seat lock (page 3-7) 5 Fuel tank cap (page 3-5 ) 6 Coolant recovery tank (page 6-8) 1 5 3 4 6 2 5WX-F8199-E1.qxd 14/12/2004 15:05 Página 14[...]

EAU10420 Right view DESCRIPTION 2-2 2 7 Passenger handle 8 Rear shock absorber 9 Seat (page 3-7) 10 Battery/Fuse box (page 6-19) 11 Radiator 12 Rear brake pedal (page 3-5) 7 9 10 8 12 11 5WX-F8199-E1.qxd 14/12/2004 15:05 Página 15[...]

EAU10430 Controls and instruments DESCRIPTION 2-3 2 13 Clutch lever (page 3-4) 14 Left handlebar switch (page 3-3) 15 Controls and instruments (page 3-2) 16 Main switch/Steering lock (page 3-1) 17 Front brake lever (page 3-4) 18 Right handlebar switch (page 3-3) 19 Throttle grip (page 6-9) 13 14 15 16 18 17 19 5WX-F8199-E1.qxd 14/12/2004 15:05 Pág[...]

EAU10460 Main switch/steering lock The main switch/steering lock con- trols the ignition and lighting systems, and is used to lock the steering. The various positions are described below . EAU10640 ON All electrical circuits ar e supplied with power , and the engine can be started. The key cannot be removed. NOTE: The headlight, meter lighting and [...]

EAU11020 T urn signal indicator light “ b ” This indicator light flashes when the turn signal switch is pushed to the left or right. EAU11060 Neutral indicator light “N” This indicator light comes on when the transmission is in the neutral posi- tion. EAU11120 Oil level warning light “ z ” This warning light comes on when the engine oil[...]

EAU11880 T achometer 1. T achometer The tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. ECA10030 CAUTION Do not operate the engine in the tachometer red zone. Red zone: 10000 r/min and above EAU12343 Handlebar switches 1. Pass switch “ j ” 2. Dimmer switch “ j / k ” 3. T ur n signal switch ?[...]

EAU12690 Start switch “ST ART” Push this switch to crank the engine with the starter . ECA10050 CAUTION See page 5-1 for starting instruc- tions prior to starting the engine. EAU12820 Clutch lever 1. Clutch lever The clutch lever is located at the left handlebar grip. T o disengage the clutch, pull the lever toward the hand- lebar grip. T o eng[...]

EAU12941 Brake pedal 1. Brake pedal The brake pedal is on the right side of the motorcycle. T o apply the r ear bra- ke, press down on the brake pedal. EAU13000 Fuel tank cap 1. Key over 2. Open T o remove the fuel tank cap Insert the key into the lock and turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be removed. T[...]

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 fir e hazard or other da[...]

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[...]

When storing the owner’ s manual or other documents in the storage com- partment, be sure to wrap them in a plastic bag so that they will not get wet. When washing the motorcycle, be careful not to let any water enter the storage compartment. EAU15300 Sidestand 1. Side stand The sidestand is located on the left side of the frame. Raise the sidest[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-9 3 With the engine turned off: 1. Mov e the sidestand down. 2. Make sure that the engine stop s witch is tur ned on. 3. T urn the key on. 4. Shift the transmission into the neutral position. 5. Push the star t s witch. Does the engine start? With the engine still running: 6. Mov e the sidestand up. 7. K eep the c[...]

NOTE: This check is most reliable if performed with a warmed-up engine. INSTRUMENT AND CONTROL FUNCTIONS 3-10 3 5WX-F8199-E1.qxd 14/12/2004 15:05 Página 26[...]

EAU15591 The condition of a vehicle is the owner’ s responsibility . Vital compo- nents can start to deteriorate quickly and unexpectedly , even if the vehicle remains unused (for example, as a result of exposur e to the elements). Any damage, fluid leakage or loss of tire air pr essure could have serious consequences. Therefor e, it is very impo[...]

EAU15603 Pre-operation check list PRE-OPERA TION CHECKS 4-2 4 ITEM CHECKS P AGE • Check fuel level in fuel tank. Fuel • Refuel if necessary . 3-5 • Check fuel line for leakage. • Check oil level in oil tank. 2-stroke engine oil • If necessary , add recommended oil to specified level. 3-6 • Check vehicle for oil leakage. T ransmission oi[...]

ITEM CHECKS P AGE • Make sure that operation is smooth. Throttle grip • Check cable free play . 6-9 • If necessary , have Y amaha dealer adjust cable free play and lubricate cable and grip housing. Control cables • Make sure that operation is smooth. • Lubricate if necessary . 6-17 • Check chain slack. Drive chain • Adjust if necessar[...]

EAU16000 Starting a cold engine In order for the ignition cir cuit 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[...]

EAU16671 Shifting 1. Shifting Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration. NOTE: T o shift the transmission into the neu- tral position, press the shift pedal down repeatedly until it r eaches the end of its travel, and the[...]

EAU16830 Engine break-in There is never a mor e important period in the life of your engine than the period between 0 and 1000 km (600 mi). For this reason, you should read the following material car efully . Since the engine is brand new , do not put an excessive load on it for the first 1000 km (600 mi). The various parts in the engine wear and p[...]

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 cha[...]

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, r epeat the maintenance intervals starting from 6000 km. ● Items marked with an asterisk should be performed by a Y amaha dealer as they require special to[...]

ODOMETER READING (x 1000 Km) ANNUAL NO ITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24 CHECK Check tread depth and for damage. 9* Tires Replace if necessary . √√√ √ √ Check air pressur e. Correct if necessary . 10 * Wheel bearings Check bearing for looseness or damage. √√√ √ 11 * Swingarm Check operation and for excessive play . √√?[...]

ODOMETER READING (x 1000 Km) ANNUAL NO ITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24 CHECK 22 * Cooling system Check coolant level and vehicle for coolant leakage. √√√ √ √ Change. Every 3 years 23 * Air filter element Clean. √√ Replace. √√ PERIODIC MAINTENANCE AND MINOR REP AIR 6-4 6 EAU18670 NOTE: ● The air filter needs more fr equ[...]

EAU18781 Removing and installing cowlings 1. Cowling A 2. Cowling B The cowlings shown need to be removed to perform some of the maintenance jobs described in this chapter . Refer to this section each time a cowling needs to be removed and installed. EAU18880 Cowling A 1. Screws (x 7 Right side) 1. Screws (x 6 Left side) T o r emove the cowling 1. [...]

EAU19620 Checking the spark plug 1. Spark plug The spark plug is an important engine component, which should be chec- ked periodically , preferably by a Y amaha dealer . Since heat and depo- sits will cause any spark plug to slowly erode, it should be r emoved and checked in accordance with the periodic maintenance and lubrication chart. In additio[...]

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. T o check the transmission oil level 1. Place the vehicle on a level surfa- ce and hold it in an upright posi- tion. NOTE: Make sure that the vehicle is positio- ned st[...]

EAU20170 T o check the coolant level 1. Place the vehicle on a level surfa- ce and hold it in an upright posi- tion. 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 [...]

NOTE: If the engine overheats, see page 6-5 for further instructions. EAU21300 Adjusting the carburetor The carburetor is an important part of the engine and requir es very sophisti- cated adjustment. Therefor e, all car- buretor adjustments should be left to a Y amaha dealer , who has the neces- sary professional knowledge and experience. EAU21320[...]

1. Loosen the locknut. 2. T o increase the thr ottle cable free play , tur n the adjusting nut in direction (a). T o decr ease the throttle cable fr ee play , turn the adjusting nut in direction (b). 3. Tighten the locknut. EAU21500 Tires T o maximize the performance, durabi- lity , and safe operation of your motorcycle, note the following points r[...]

1. Depth 2. Side face Tire inspection The tires must be checked befor e each ride. If the center tread depth reaches the specified limit, if the tir e has a nail or glass fragments in it, or if the sidewall is cracked, have a Y ama- ha dealer replace the tir e immediately . NOTE: The tire tr ead depth limits may differ from country to country . Alw[...]

● Brand-new tires can have a relatively poor grip on certain road surfaces until they have been “broken in”. Ther efore, it is advisable before doing any high-speed riding to ride con- servatively for approximately 100 km (60 mi) after installing a new tire. ● The tires must be warmed up before a high-speed run. ● Always adjust the tire a[...]

adjusting nut in direction (b). 6. Tighten the locknut at the clutch lever and the crankcase. EAU22220 Adjusting the brake pedal position and free play 1. Position adjusting bolt 2. Brake pedal position EWA10670 s s WARNING It is advisable to have a Y amaha dealer make these adjustments. Brake pedal position The top of the brake pedal should be ali[...]

comes on just before braking takes effect. If necessary , adjust the brake light switch as follows. T urn the adjusting nut while holding the rear brake light switch in place. T o make the brake light come on earlier , turn the adjusting nut in direction (a). T o make the brake light come on later , turn the adjusting nut in direction (b). EAU22420[...]

Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary . A low bra- ke fluid level may indicate worn brake pads and/or brake system leakage. If the brake level is low , be sure to check the brake pads for wear and the brake system for leakage. Observe these precautions: ● When checking the fluid level[...]

EAU22760 Drive chain slack (a) Drive chain slack The drive chain slack should be chec- ked before each ride and adjusted if necessary . EAU22771 T o check the 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 i[...]

NOTE: Make sure that two notches in the axle nut are aligned with the hole through the wheel axle, other wise further tighten the axle nut until they are. EWA10700 s s WARNING Always use a new cotter pin for the axle nut. EAU23012 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic m[...]

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 . EAU23200 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-t[...]

2. While applying the fr ont brake, push down hard on the handle- bars several times to check if the front fork compr esses and rebounds smoothly . ECA10590 CAUTION If any damage is found or the front fork does not operate smoothly , have a Y amaha dealer check or repair it. EAU23280 Checking the steering W orn or loose steering bearings may cause [...]

EWA10760 s s WARNING ● Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any con- tact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. • EXTERNAL: Flush with plenty of water . • INTERNAL: Drink la[...]

2. Remove the blown fuse, and then install a new fuse of the specified amperage. ECA10640 CAUTION Do not use a fuse of a higher ampe- rage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. 3. T ur n the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If th[...]

4. Install the lens by installing the screws. ECA10680 CAUTION Do not overtighten the screws, otherwise the lens may break. EAUM1460 Replacing the license plate light bulb 1. Auxiliary light 1. Remove the license plate light cover by removing the scr ew . 2. Remove the socket (together with the bulb) by pulling it out. 3. Remove the defective bulb [...]

T o service the rear wheel Raise the rear wheel of f the ground by using a motorcycle stand or , if a motorcycle stand is not available, by placing a jack either under each side of the frame in front of the r ear wheel or under each side of the swingarm. EAU25870 T roubleshooting Although Y amaha motorcycles r ecei- ve a thorough inspection befor e[...]

PERIODIC MAINTENANCE AND MINOR REP AIR 6-24 6 EAU25921 T roubleshooting charts Starting problems or poor engine performance EWA10840 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. Fuel There is enough fuel. There is no fuel. Check the compression. Supply fue[...]

Engine overheating EWA10400 s s WARNING ● Do not remove the radiator cap when the engine and radiator ar e hot. Scalding hot fluid and steam may be blown out under pressur e, which could cause serious injury . Be sure to wait until the engine has cooled. ● After removing the radiator cap r etaining bolt, place a thick rag, like a towel, over th[...]

EAU26000 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. Fr equent and pro- p[...]

After nor mal use Remove dirt with warm water , a mild deter gent, and a soft, clean sponge, and then rinse thoroughly with clean water . Use a toothbrush or bottle- brush for hard-to-r each areas. Stub- born dirt and insects will come off more easily if the ar ea is covered with a wet cloth for a few minutes before cleaning. After riding in the ra[...]

● Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable car e product. ● Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consult a Y amaha dealer for advice on what products to use. EAU26150 Storage Short-term Always store your motor cycle in a cool, dry place and, if necessary ,[...]

the tires fr om becoming degra- ded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moistur e from entering it. 9. Remove the battery and fully char ge 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[...]

EAU26339 Dimensions Overall length 2007 mm Overall width 675 mm Overall height 1065 mm Seat height 815 mm Wheelbase 1330 mm Ground clearance 144 mm Minimum turning radius 2900 mm W eight With oil and fuel 124.2 kg Engine Engine type Liquid cooled 2-stroke Cylinder arrangement Forward-inclined single cylinder Displacement 49.7 cm 3 Bore x str oke 40[...]

Size 130/70-17 62H Manufacturer/model PIRELLI Maximum load 195 kg Tire air pr essure (measur ed on cold tires) Loading condition 0-90 kg Front 180 kPa Rear 200 kPa Loading condition 90-180 kg Front 190 kPa Rear 230 kPa Front wheel Wheel type Cast wheel Rim size MT 2.75x17” Rear wheel Wheel type Cast wheel Rim size MT 3.50x17” Front brake T ype [...]

EAU26351 Identification numbers Record the key identification number , vehicle identification number and model label information in the spaces provided below for assistance when ordering spar e parts from a Y amaha dealer or for refer ence in case the vehicle is stolen. KEY IDENTIFICA TION NUMBER: VEHICLE IDENTIFICA TION NUMBER: MODEL LABEL INFORMA[...]

EAU26480 Model label 1. Model label The model label is affixed to the frame under the seat. (See page 3-7.) Record the information on this label in the space provided. This information will be needed when ordering spar e parts from a Y amaha dealer . 9 CONSUMER INFORMA TION 9-2 1 5WX-F8199-E1.qxd 14/12/2004 15:05 Página 65[...]

A Adjusting the brake pedal position and free play .................................................6-13 Adjusting the carburetor ............................6-9 Adjusting the clucth lever free play .........6-12 Adjusting the engine idling speed .............6-9 Adjusting the rear brake light switch .......6-13 Adjusting the throttle cable fr ee p[...]

Y AMAHA MO T OR ESP AÑA, S.A. PRINTED IN SP AIN 2005.1-Bengar Gràfiques, S.L. (E) 5WX-F8199-E1.qxd 14/12/2004 15:05 Página 67[...]