This tester is an invaluable help for checking the electrical system. 2. Stroboscopic lamp Ref. 90891-03141
This tool is required for checking the ignition advance. OTHER TOOLS 1. Micrometer Ref. 90896 - 03008
2. Feeler gauge Ref. 90890-03079
CHAPTER 2 GENERAL SPECIFICATIONS
SPECIFICATIONS 2-1 GENERAL SPECIFICATIONS 2-1 MAINTENANCE SPECIFICATIONS 2-4 ENGINE 2-4 CHASSIS 2-7 TIGHTENING TORQUES 2-9 ELECTRICAL SYSTEM 2-11 GENERAL SPECIFICATIONS OF TIGHTENING TORQUES/ DEFINITION OF THE UNITS 2-13 LUBRICATION POINTS AND TYPE OF LUBRICANT 2-14 ENGINE 2-14 CHASSIS 2-15 CABLE ROUTING 2-16

GENERAL SPECIFICATIONS

SPECIFICATIONS
Model Model code number Frame serial number Yamaha MBK Dimensions: Total length Total width Total height Height of the seat Distance between axles Minimum ground clearance Basic weight: With oil and full fuel tank Minimum turning radius Engine: Type of engine Admission system Cylinder arrangement Cylinder capacity Bore x stroke Compression ratio Starting system Lubrication system Motor oil Type Capacity Transmission oil: Type Capacity: Regular oil change Total amount Capacity of coolant: Including all routes Air filter: Type 5WX

TZR50 / X-POWER

UTLRA031000000001 UTLRAmm 675 mm 1065 mm 815 mm 1330 mm 144 mm 124.2 kg. 2900 mm 2 stroke, petrol, liquid cooled Reed valve Single cylinder, slanting forwards 49.7 cm3 40.3 x 39 mm 6.85:1 Electric Independent lubrication Yamaha 2 stroke oil or oil for air-cooled 2 stroke engines 1.35 L Engine oil SAE 10W30 SE type 0.75 L 0.82 L 0.7 L Damp element
Model Fuel: Type Capacity of the fuel tank: Full Reserve Carburettor : Type / Number Manufacturer Spark plug Type / Number Manufacturer Spark plug gap Clutch: Type Transmission: Type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Action Gear reduction ratio: 1st 2nd 3rd 4th 5th 6th Chassis: Frame type Caster angle Trail Tyres: Type: Dimensions: Front Rear Maximum load* Cold tyre pressure: Up to 90 kg. (198 pounds) load* From 90 kg. (198 pounds) up to max. load
TZR50 / X-POWER Unleaded gasoline 13.8 L 2.2 L PHBN 16 NS/1 DELLORTO BR9ES/1 piece N.G.K. 0.6 ~ 0.7 mm Wet, multi disc 6 gears constant mesh Helical gear 71/20 (3,550) Drive chain 47/12 (3.916) Left foot 36/12 33/16 29/19 27/22 25/24 24/25 (3,000) (2,062) (1,526) (1,227) (1,041) (0,960)
Double cradle (Deltabox) mm Tubeless 100/80-17 52H 130/70-17 62H 183 kg. FRONT 1.8 kg/cm2 1.9 kg/cm2 REAR 2.0 kg/cm2 2.3 kg/cm2
Model Brakes: Type of front brake Front brake action Type of rear brake Rear brake action Suspension: Front suspension type Rear suspension type Damping: Front shock absorber Rear shock absorber Wheel travel: Front wheel Rear wheel Electrical system Ignition system Charging system Battery: Type Capacity Headlights: Type Bulb voltage, wattage x quantity Headlight Tail and brake light Indicators Instrument panel light Neutral indicator light NEUTRAL OIL indicator TURN indicator Coolant temperature indicator General voltage: Single disc Right hand Single disc Right foot

( x 1.000 km) No

ANNUAL 18

Petrol line Spark plug
CHECK OR MAINTENANCE OPERATION
Check to see if the petrol hose is cracked or damaged Check its condition Clean and adjust space between electrodes Change

Air filter

*Clean Change

Clutch Front brake
Check operation Adjust Check operation, liquid level and to see if there are leaks on the vehicle Check the brake pads
Whenever these have reached the wear limit

Rear brake

Check operation, liquid level and to see if there are leaks on the vehicle Check the brake pads

Brake tubes

*Check to see if these are cracked or damaged Change

Every 4 years

Wheels Tyres
Check eccentricity and whether these are damaged Check the depth of the tread pattern and whether they are damaged Change if necessary Check the air pressure Correct if necessary
Wheel bearings Swinging arm
Check to see if the bearings are weak or damaged Check operation and to see if play is excessive Lubricate with molybdenum bisulphide grease
Every 24,000 km Every 500 km and after washing the motorcycle or using in rain

Transmission chain

Check the chain tension Check that the rear wheel is properly aligned Clean and grease Check the bearing play and to see if the steering is stiff Lubricate with lithium soap-based grease

Steering bearings

Every 24,000 km Every 3 years
Chassis fixings Side stand Stand switch Front fork Shock absorber assembly Carburettor Autolube pump Transmission oil
Check that all the nuts, bolts and screws are properly tightened Check operation Grease Check operation Check operation and whether oil is leaking Check operation and to see if the shock absorber is leaking oil Check the choke operation Adjust the engine idling speed Check operation Bleed if necessary Check the oil level Change

Cooling system

Check the coolant level and to see if there are leaks from the vehicle Change
Brake switches Moving parts and cables Throttle twist grip box

2. Dismantle: The fuel tank The air filter cse See the section on REMOVING THE ENGINE in CHAPTER 4.
INSPECTING THE CARBURETTOR GASKET / INSPECTING THE FUEL HOSES
3. Inspect: The carburettor joint Cracks/damage Replace See the section on CARBURETTOR DISMANTLING THE ENGINE in CHAPTER 4
4. Install: The air filter case The fuel tank 5. Install: The side covers (left and right-hand) The seat See the section on SIDE COVERS ASSEMBLY
INSPECTING THE FUEL HOSES 1. Dismantle: The seat The small left-hand side cover
2. Inspect: The fuel inlet pipe Cracks / Damage Replace 3. Install: The small left-hand side cover The seat
INSPECTING THE EXHAUST SYSTEM / INSPECTING THE LEVEL OF COOLANT
INSPECTING THE EXHAUST SYSTEM 1. Inspect: The exhaust pipe The muffler Cracks / Damage Replace gaskets Leakages of exhaust gases Replace Replacement steps: Dismantle the exhaust assembly Install a new exhaust assembly Screw : 1.5 kg m Screw : 2.3 kg m

MAX MIN

INSPECTING THE COOLANT LEVEL 1. Place the motorcycle on a level surface. 2. Inspect: The level of coolant The level of coolant is under the minimum mark Remove panel Add water (for the cooling circuit)
INSPECTING THE COOLANT LEVEL / CHANGING THE COOLANT
To check the level of coolant, place the motorcycle in a vertical position; if it leans to one side, however little this may be, the readings may be false. CAUTION Water with impurities is damaging for the engine components. You can use boiled or distilled water 3. Add: Water to the cooling circuit Until the level of liquid reaches the MAX maximum mark
Capacity of the reservoir tank: Total: 0.71 L From the MIN minimum mark to the MAX maximum mark: 0.18 L

4. Install: Panel

CHANGING THE COOLANT s WARNING Do not remove the radiator cap while this and the engine are hot. Hot vapour and liquid could emerge with consequent danger of serious injury. When the engine has cooled off, open the radiator tap as follows: place a thick cloth, for example a towel, over the cap and turn this as far as it will go, slowly, anti-clockwise. This procedure will let any residual pressure release. When the whistling sound has stopped, tighten the cap downwards making it turn at the same time anti-clockwise, and remove it.

CHANGING THE COOLANT

1. Disconnect: The breather pipe 2. Drain the coolant reservoir tank. 3. Remove: The securing screw The radiator cap
4. Remove: The drainage screw 5. Drain: The coolant NOTE:
Empty out the coolant with the motorcycle slightly tilted to the right.

REMOVING THE ENGINE / DISMANTLING THE ENGINE
4. Disconnect: Clutch cable First disconnect the cable of the crankcase side and then the end at the handlebar lever
REMOVING THE ENGINE 1. Remove: Front engine mounting screw Rear lower engine mounting screw Rear upper engine mounting screw Engine assembly
OIL PUMP 1. Remove: Oil pump cover Oil pump assembly
WATER PUMP COVER 1. Remove: Water pump cover Water pump cover gasket
RIGHT CRANKCASE COVER, OIL PUMP SHAFT AND WATER PUMP SHAFT 1. Remove: Right-hand oil pump cover

DISMANTLING THE ENGINE

2. Remove Clip Washer Water pump driven gear Pin Washer Water pump shaft Clip Oil pump driven gear Pin Washer k 10 Oil pump shaft k 11 Washer k 12 Clip k 13 Washer k) 14 Intermediate gear k 15 Washer k) 16 3. Remove: Locators Gasket
CLUTCH AND PRIMARY TRACTION GEARING 1. Remove: Securing screws for the clutch springs Clutch springs Pressure plate Push rod n 1 Friction discs Clutch discs 2. Remove: Push rod ball Push rod N 2 Shaft set of the clutch push lever
3. Loosen: Safety nut of the clutch casing Use the universal clutch holder (9089004086) to hold the clutch cone
4. Remove: Clutch boss safety nut Washer Clutch boss Washer Clutch housing Washer Conical spring washer s WARNING Pay attention to the position of the conical spring washer. Install as shown in the figure.
5. Loosen: Balancer shaft nut 6. Remove: Primary traction gear nut Primary traction gear Key Balancer shaft drive gear Balancer shaft washer and nut Balancer shaft driven gear Key
7. Remove: Washer Tachometer worm gear Washer 8. Remove: Magnetic flywheel cover Neutral switch
CDI MAGNETO 1. Remove: Left-hand crankcase cover and gasket Flywheel securing nut. Use the flywheel-holding tool 90890-01235
2. Remove: CDI flywheel Use the flywheel extractor tool 90890 - 01189 and the flywheel fixer 90890-01235 Crankshaft key Stator coils Coil holder plate NOTE: Mark the coil holder plate and the crankcase with a pointed instrument
STARTER MOTOR 1. Remove: Securing screws

a d b c

CYLINDER HEAD AND CYLINDER 1. Remove: Spark plug Nuts and washers Thermocontact NOTE: Following the order stated in the drawing (a, b, c,d), loosen each screw of a turn and then fully unscrew them. 2. Remove: Cylinder head O rings Thermostat

INSTALLING THE ENGINE When you install the engine, follow the removal process inversely. Pay attention to the following points. 1. Install: Engine assembly screws Engine assembly screws , , : 3.0 m kg
2. Install: Drive chain NOTE:
After installing the drive chain adjust the tension of the chain. See ADJUSTING CHAIN in Chapter 6. 3. Install: Crankcase cover 2 (left) Screws for securing crankcase cover 2 0.5 m kg Output gear cover Screws for securing output gear cover 0.5 m kg Shift cam Shift cam screw. 0.6 m kg 4. Install: Oil pump cover Pump cover securing screw: 0.4 m kg Spark plug Spark plug: 2.0 m kg Exhaust pipe Screws for securing the exhaust pipe to the chassis: 2.1 m kg 3.0 m kg Springs AIS pipe Screw for the clamp of the AIS tube: 0. 4 m kg 5. Add: Transmission oil Coolant Transmission oil: total: 0.82 L Total amount of coolant: 0.7 L
6. Inspect: Oil leaks Coolant leaks 7. Connect: Neutral cable NOTE:
Before starting the engine up, bleed the lubrication system.

CHAPTER 5 COOLANT SYSTEM

CHANGING THE COOLANT 5-1 WATER PUMP 5-3 DISMANTLING 5-4 INSPECTION5-5 ASSEMBLY 5-6 THERMOSTAT AND RADIATOR 5-8 INSPECTION 5-9 ASSEMBLY 5-10

COOLANT COOLANT

COOLING SYSTEM
CHANGING THE COOLANT s WARNING Do not remove the radiator cap while this and the engine are hot. Boiling liquid and vapour could emerge with consequent danger of serious injury. When the engine has cooled off, open the radiator tap as follows: place a thick cloth, for example a towel, over the cap and turn this as far as it will go, slowly, to the left. This procedure will let any residual pressure release. When the whistling sound has stopped, tighten the cap downwards making it turn left at the same time to open it
1. Place an open recipient under the engine. 2. Wait until the radiator cools down. 3. Take off: Radiator cap 4. Remove: Drain screw 5. Drain: Coolant (completely) NOTE:
Fully wash out the cooling system with clean water. 6. Inspect: Gaskets (drain screw) Damaged Change 7. Tighten: Drain screw (water pump cover)

COOLANT

Drain screw (water pump cover): 1.4 m kg
8. Fill up with: Coolant liquid (in the radiator) Recommended coolant: High quality ethylene glycol antifreeze solution containing anticorrosive materials for aluminium alloy engines. Proportion for mixing coolant and water: 50% / 50% Total volume: 0.71 L Capacity of expansion tank: 0.42 L From LOW level to FULL level: 0.18 L CAUTION Water with impurities is harmful for the engine. If you cannot get distilled water, use boiled water. Do not mix more than one type of ethylene glycol antifreeze containing anti-corrosives for aluminium engines. 9. Install: Radiator cap 10. Start the engine up for a few minutes. 11. Inspect: Coolant level in the radiator Low level Fill up (to the top of the radiator) 12. Fill up with: Coolant Top up the coolant up to the FULL level in the expansion tank. 13. Install: Radiator cap 14. Inspect: Coolant system Leakage of coolant Repair CAUTION Before starting up the engine, always check the coolant level and see if there are any leakages of this.

WATER PUMP

Impeller shaft Oil seal Pin Washer Circlip Impeller shaft gear Cover of the water pump body Locator
k Screw 10 k Screw 11 k Drain screw 12 k Gasket 13 k Connection 14 k O ring 15 k Screw 16

Gasket

A: USE A NEW ONE 1.0 m kg

1.6 m kg

A: USE A NEW ONE

DISMANTLING NOTE:

There is no need to dismantle the water pump unless anomalies have been observed, such as excessive variations in temperature and/or volume of the coolant liquid, its decolouring or a milky look to the transmission oil.
1. Drain: Crankcase See the section on CHANGING THE TRANSMISSION OIL in CHAPTER 3. Cooling system See the section on CHANGING THE COOLANT in CHAPTER 3.
2. Remove: The output hose
3. Dismantle: The cover of the water pump body The crankcase cover CAUTION Remove the coolant from the water pump taking care that this does not splash the autolube pump.
4. Dismantle. The circlip The gear of the impeller shaft The flat washer 6. Dismantle: The impeller shaft 7. Eliminate any deposits incrusted on the shaft and the body of the water pump 5. Dismantle: The pin The flat washer
INSPECTION 1. Inspection The impeller Cracks/wear/damage

replace

2. Inspect: The gear of the impeller shaft Cracks/Wear/Damage replace
3. Inspect: The seal Wear / Damage
Replacement steps: Remove the seal from the crankcase cover, tapping this lightly outwards. Install the new seal, with the WATER SIDE mark outwards. NOTE: Apply light lithium grease to the outside of the oil seal. Press install the seal until it comes into contact with the base
ASSEMBLY Apply the DISMANTLING procedure inversely, bearing in mind the following points: 1. Apply: Light lithium grease to the lips of the seal and to the impeller shaft
2. Install: The impeller shaft Turn the shaft during assembly NOTE: Proceed with care so as not to damage the lip of the seal and so that the spring does not come out of position
3. Install: The crankcase cover (right hand) The cover of the water pump body Screw (crankcase cover): 0.5 kg m Screw (water pump body cover): 0.5 kg m
CAUTION Always use new gaskets
4. Fill up: The transmission oil See the section on CHANGING THE TRANSMISSION OIL in CHAPTER 3. The coolant. See the section on CHANGING THE COOLANT in Chapter 3.
5. Bleed the air: Autolube pump See the section on BLEEDING THE AIR FROM THE AUTOMATIC MIXING PUMP in CHAPTER 3.

THERMOSTAT AND RADIATOR

Radiator Cap Stop Bolt Washer Protector ring Bush Protector ring Screw k Washer 10
A: OPENING PRESSURE OF THE RADIATOR CAP 0.75 ~ 1.05 KG / CM2
B: COOLANT CAPACITY Including all the conduits: 0.7 L C: THERMOSTAT OPENING TEMPERATURE: 98 C

0.8 m kg

INSPECTION 1. Inspect: The radiator core Obstruction Eliminate this with compressed air, blowing from the rear of the radiator. Squashed fins repair / replace
2. Inspect: The inlet hose Cracks / damage Output sleeve Cracks / Damage

Replace Replace

3. Measure: The opening pressure of the radiator cap
Radiator cap opening pressure: 0.75 ~ 1.05 kg/cm2
Measurement steps: Connect the tester of the cooling system and the adapter to the radiator cap. Cooling system tester: 90890 - 01325 Adapter: 90890 - 01352
Apply the specified pressure for ten seconds and make sure that this does not drop. 4. Inspect: The thermostat See the section on DISMANTLING THE ENGINE in CHAPTER 4 CYLINDER HEAD AND CYLINDER The valve does not open replace
Inspection steps: Hang the thermostat in a recipient Submerge a reliable thermometer in water Heat up the water slowly Observe the thermometer without ceasing to agitate the water NOTE: The thermostat is sealed and rating this is a job for a specialist. If you have any doubts about its accuracy, replace it. A faulty valve could cause very harmful overheating or overcooling.
Screws (of the thermostat): 2.0 kg m
ASSEMBLY Follow the same procedure as in DISMANTLING but inversely. Take into account the following points. 1. Tighten: The screws (of the thermostat)
2. Assemble: The radiator
3. Tighten: The screws (radiator) Screws (radiator): 0.6 kg m
4. Fill up: The coolant See the section on CHANGING THE COOLANT in CHAPTER 3. 5. Inspect: The cooling system Reduce the pressure (leaks) as required.

Repair

Inspection steps: Connect the cooling system tester to the radiator Cooling system tester: 90890 - 01325 Apply 1.0 kg/cm2 pressure Measure the pressure with the manometer. 6. Install: The seat

CHAPTER 6 CARBURATION

CARBURETOR 6-1 REMOVAL 6-2 DISMANTLING 6-2 INSPECTION6-2 ASSEMBLY 6-3 INSTALLATION 6-3 ADJUSTING THE PETROL LEVEL 6-3 REED VALVE 6-4 REMOVAL 6-4 DISMANTLING 6-4 INSPECTION6-4 ASSEMBLY 6-5 INSTALLATION 6-6

CARBURETOR

CARBURATION
Carburetor Carburetor cover Needle valve Float chamber Main jet Diffuser k Idling jet 10
k 14 k 13 k 15 k 24 k 27 k 26
Spring Casing Choke jet Idling screw Float pin Float
SPECIFICATIONS Main jet (M.J.) Pilot air screw (P.A.S.) Fuel level (F.L.) Idling speed # 1/~14 mm 1850 150
REMOVAL 1. Remove: Carburetor assembly See the section on engine removal
DISMANTLING 1. Remove: Idling stop screw

2. Remove: Float chamber Float pin Float Water valve Gasket Main jet Idling jet Choke jet
INSPECTION 1. Inspect: Carburetor body Dirty clean NOTE: Use a petroleum type solvent for cleaning. Clean all the holes and jets with compressed air. 2. Inspect: Valve seat / float valve Wear / Dirt Change NOTE: Always change the float chamber valve and valve seat as a set.
3. Inspect Jets Wear / Dirt

Change / Clean

4. Inspect: Plunger Wear/damage Replace 5. Check: Free movement Difficulty Change Insert the plunger into the carburetor body.
6. Inspect Float Damaged O ring Damaged

Change Change

ASSEMBLY 1. Install: Follow the dismantling procedure inversely INSTALLATION 1. Install: Carburetor assembly Apply the removal procedure inversely ADJUSTING THE FUEL LEVEL 1. Measure: Float height Outside specifications Service Float height (FH) : 13 -14 mm

CARBURETOR / REED VALVE

Adjustment steps: Take out the carburetor Inspect the valve seat and the float chamber valve. If either of the two parts is worn, change both. Check the petrol level again

REED VALVE

REMOVAL 1. Remove: Reed valve assembly See the engine removal section DISMANTLING 1. Remove: Reed valve stop Reed valve
INSPECTION 1. Inspect: Rubber gasket Deteriorated Change Reed valve Ageing / cracks Change Inspection steps: Visually inspect the reed valve NOTE A proper reed valve should install in aligned or almost aligned with the neoprene base. In the event of any doubt about sealing apply suction to the part in the carburetor mounting Any leaks must be moderate
2. Measure: Height of the valve stop Outside specifications Adjust/ change the stop of the valve Height of the valve stop: 6.28 mm NOTE: If the height is 0.4 mm greater or lower than what is specified, change the valve stop. 3. Measure: Curve limit of the reed valve Outside specifications Change Curve limit of the reed valve: 0.4 0.3 mm
ASSEMBLY When the reed valve is fitted, apply the dismantling procedure inversely. 1. Install: The reed valve The reed valve stop. NOTE: Pay attention to the cut at the lower corner of the reed and the reed stop. 2. Tighten: Safety screws of the reed valve Safety screws of the reed valve: 0.1 m kg LOCTITE
NOTE: Tighten each screw gradually to prevent deformations
INSTALLATION To install the reed valve, follow the procedure for removal inversely. Pay attention to the following points. 1. Install: A new gasket 2. Tighten: Safety screws of the reed valve body.

2. Get rid of any corrosion on the parts. 3. Inspect: The front axle Make the axle turn on a flat surface Deformations Replace s WARNING Do not attempt to straighten the axle if this is deformed
4. Inspect: The wheel Cracks/Deformations/Warping Replace
5. Measure: The run out of the wheel This does not coincide with what is specified Check the play of the wheel and bearing. Run out limit of the wheel: Radial : 2.0 mm Lateral : 2.0 mm
6. Check The wheel bearings The bearings have some play at the wheel hub or are hard to turn Replace
Replacing steps: Clean the outside of the wheel hub Dismantle the bearing with a universal extractor Install the new bearing NOTE: Use a socket wrench the right size for the outer diameter of the bearing race.

RUEDA DELANTERA

Do not tap the inner race of the bearing. Contact should only be with the outer race.
7. Check: The wheel balance If the wheel stops at the same point again, after several light turns, the static balance is not correct. Wheel unbalanced. Install the relevant balancing counterweights at the lightest part (top). NOTE: Balance the wheel with the brake disc fitted. s WARNING After installing a tire, drive carefully until it adapts to the wheel properly. If this is not done there could be an accident possibly damaging the motorcycle and injuring the rider. After repairing or replacing a tire, tighten the locknut of the valve to the specified torque Valve locknut: 0.15 kg m
INSTALLING Repeat the dismantling procedure, inversely. Take into account the following points: 1. Apply: Lithium grease Lightly grease the oil seal and the gearing unit
2. Assemble: The speedometer sensor. NOTE: Make sure that the projections on the inside of the sensor coincide with the flat sides of the wheel hub.
3. Assemble: The front wheel assembly NOTE: Make sure that the projection of the fork cylinder fits in correctly with the sensor positioning slot.
4. Tighten: The wheel axle The pressure bolt The screws (brake caliper) Wheel axle: 6.5 m kg Pressure bolt: 2.3 km kg Screws (brake caliper): 3.5 m kg

REAR WHEEL

REAR WHEEL Rear wheel Spacer Bearing Bearing Rear wheel sprocket Washer Screw Seal Seal
A: TIRE SIZE: 130 / 70 - 17 B: WHEEL SIZE: 3.50 MT X 17 C: RUN OUT LIMIT OF THE WHEEL E: VERTICAL: 2.0 mm (0.08 inch) F: LATERAL: 2.0 mm (0.08 inch)
k 10 k 11 k 12 k 13 k 14 k 15 k 16 k 17 k 18

6. Dismantle: The covers of the swingarm axle The swingarm axle 7. Dismantle: The swingarm
INSPECTION 1. Inspect: The shock absorber Oil leaks / damage replace
2. Inspect: The swingarm Deformations / Cracks / damage replace
3. Inspect: The oil seals Damage Replace The thrust covers Damage Replace The bushes Scratches / Damage Replace The bushes Pitting / Damage Replace
INSTALLING Swingarm Apply the same procedure as for DISMANTLING but inversely. Take into account the following points: 1. Apply: Lithium soap grease to the oil seals, the bushes and the inside of the thrust covers. 2. Install: The swingarm Swingarm axle: 7.4 kg m
Rear shock absorber Apply the same procedure as in DISMANTLING but inversely. Take into account the following points: 1. Apply: Lithium soap grease to the oil seals and bush
2. Install: The rear shock absorber Rear shock absorber - upper: 6.0 kg m Rear shock absorber- lower: 6.0 kg m
3. Install: The rear wheel See the section on REAR WHEEL - FITTING Nut (wheel axle): 9.0 kg m
4. Adjust: The tension of the drive chain. See the section on TIGHTENING THE TRANSMISSION CHAIN in CHAPTER 3. Tension of drive chain 20 ~ 25 mm
REAR WHEEL SPROCKET AND DRIVE CHAIN
Rear sprocket Holder k Drive chain 10 k Chain coupling 11
Before dismantling the sprocket, the chain and the rear wheel sprocket, the chain sloack should be checked.
DISMANTLING 1. Dismantle: The cover of the output sprocket
2. Dismantle The circlip The sprocket
3. Dismantle: The retaining clip The coupling plate 4. Dismantle: The drive chain 5. Dismantle: The rear wheel See the section on REAR WHEEL - DISMANTLING
INSPECTION 1. Check: The chain stretching Pull the chain to separate this from the crown wheel. Distance between chain/crown wheel greater than half the tooth replace the chain.
2. Clean: The drive chain Submerge this in solvent and use a brush to clean off as much dirt as possible. Then take the chain out of the solvent and dry it.
3. Inspect: The clip (Drive chain) Damage Replace the drive chain The rollers The side plates Damage / Wear Replace the drive chain
4. Check: Chain sticking Clean and grease the chain and hold this as shown in the illustration. Sticking Replace the chain
5. Inspect: The sprocket and rear wheel sprocket Wear / damage replace

k Battery 12 k Regulator/Rectifier 15 k Main switch 17 k Rear brake light switch 20
STARTER COIL PRIMARY COIL RESISTANCE: 0.23 W + 20C SECONDARY COIL RESISTANCE: 7.9 K W
k Electrical installation 21 k Fuse 23 k Diode 24 k Oil level switch 27

k 29 k 31 k 32 k 33

Side stand switch Relay Indicator flasher relay Horn
BATTERY: CAPACITY: 12 V 3AH NO MAINTENANCE
IGNITION AND STARTING SYSTEM

CIRCUIT DIAGRAM

The following circuit diagram shows the ignition and starting system
NOTE: For the colour codes, please see the electrical diagram C.D.I. magneto Starter relay Main switch C.D.I. Spark plug Handlebar switch (RH) k Battery 21 k Coil 28 k Starter motor 29

ELECTRIC START SYSTEM

k 13 k 20 k 21 k 24 k 25 k 29
Starter relay Fuse Main switch Diodes Engine/starter stop switch Neutral switch Neutral relay Battery Clutch switch Side stand switch Starter motor
TROUBLESHOOTING THE STARTER MOTOR DOES NOT WORK NOTE: Use the following tools in this fault location Pocket tester: 90890 -03112 4. Neutral relay Remove the relay
1. Fuse (main) Check the condition of the fuse. See INSPECTING THE FUSE in CHAPTER 3. OK NOT OK
Use the battery to supply terminals Br and Sb. Then check the continuity between GB and BW
OK Change the fuse 2. Battery Check the condition of the battery. See INSPECTING THE BATTERY in CHAPTER 3. OK NOT OK Charge or change the battery 3. Starter motor

NOT OK

Change the neutral relay
5. Starter relay Remove the relay
Use the battery to supply terminals Br and WG. Check the continuity between R and R
OK Connect a bridge Check the operation of the starter motor OK NOT OK Repair or change the starter motor
NOT OK Change the starter relay
6. Main switch Place in the ON position 8. Neutral switch
Separate the connections Check the continuity between R and Br NOT OK Repair the main switch Check the continuity: Light blue ground OK NOT OK Change the neutral switch
7. Engine kill switch Place in RUN position (not pressed)
9. Side stand switch Separate the blue connection Fold up the side stand
Separate connections Check the continuity between BW and B. OK NOT OK Repair the handlebar switch (Right)
Check the continuity between B and B OK NOT OK Repair the side stand switch
10. Clutch switch Separate the yellow connection

2. Battery Check the condition of the battery See the section on INSPECTING THE BATTERY in CHAPTER 3. INCORRECT
Fill the battery up with liquid Clean the terminals Recharge or replace the battery
3. Main switch Disconnect the connector of the main switch Connect the pocket tester ( x 1) to the main switch Place the main switch in positions ON and OFF successively. Check if the continuity is correct between the red and brown cables only in the ON position.

IN BAD CONDITION

IN GOOD CONDITION

Replace the main switch.

4. Cable connections Check the connections of the full signalling system See the section on WIRING DIAGRAM CONNECTIONS INCORRECT
See the section on CHECKING AND TESTING THE SIGNALLING SYSTEM
CHECKING AND TESTING THE SIGNALING SYSTEM 1. The indicators do not flash
1. Indicator bulb Remove the indicator bulb Connect the pocket tester ( x 1) to the bulb (+) probe of tester Terminal (-) probe of tester Terminal
Check whether the continuity is correct in the headlight bulb CONTINUITY OK
Replace the indicator bulb.
2. Bulb holder bush of the indicator Place the bulb in the holder Disconnect the indicator wires (chocolate and black) or (dark green and black). Connect the pocket tester ( x 1) to the indicator cables To check the right indicator: (+) probe of tester Dark green cable (-) probe of tester Black cable To check the left-hand indicator: (+) probe of tester Chocolate cable (-) probe of tester Black cable
Check/replace the indicator.
Check if the continuity is correct in the bulb holder bush of the indicator. CONTINUITY OK
3. Turning switch TURN Disconnect the large coupler (yellow) from the lefthand switch on the handlebars Connect the pocket tester ( x 1) to the turning switch TURN With the turn switch in position : (+) probe of tester Brown/white terminal (-) probe of tester Dark green terminal With the turn switch in position : (+) probe of tester Brown/white terminal (-) probe of tester Chocolate terminal Place the TURN switch in positions d and c successively Check if the continuity is correct in the TURN switch. Switch position d (right) c (left) : Continuity In good condition X In bad condition X X X IN BAD CONDITION
X : There is no continuity
Replace the handlebar switch.
4. Voltage Place the main switch in the ON position Connect the pocket tester (DC, 20 V) to the coupler of the indicator relay. (+) probe of tester brown terminal (-) probe of tester to ground

6. Thermosensor Remove the thermosensor from its housing. Connect the pocket tester ( x 1) to the thermosensor Submerge the thermosensor in water Measure the resistances. Take note of the temperatures while the water is heated up with the thermosensor in 3. Up to 115C No continuity From 115C Continuity s WARNING
Handle the thermostat with special care. Never let this receive any impacts or fall. If it does accidentally fall, replace it.

UNDER 115 C

OVER 115 C
Replace the thermosensor. CAUTION THE RESISTANCES MATCH SPECIFICATIONS 7. Cable connections Check the connections of the whole cooling system See the ELECTRICAL DIAGRAM section BAD CONNECTIONS After replacing the thermosensor, check the level of the coolant liquid in the radiator and see if there are any leaks.

Correct.

ELECTRICAL DIAGRAM TZR50
COLOUR CODE B R L G O Y P Br Ch Sb Dg W B/Br B/Y Black Red Blue Green Orange Yellow Pink Brown Chocolate Sky blue Dark green White Black/brown Black/yellow B/R B/W G/R G/Y Br/W W/R W/B W/G Y/L Y/R L/B L/R L/W L/Y Black/red Black/white Green/red Green/yellow Brown/white White/red White/black White/green Yellow/blue Yellow/red Blue/Black Blue/red Blue/white Blue/yellow
k 10 k 11 k 12 k 13 k 14 k 15 k 16 k 17 k 18 k 19 k 20 k 21 k 22 k 23 k 24 k 25 k 26 k 27 k 28 k 29 k 30
Magnetic flywheel Regulator/ rectifier Starter relay Fuse Main switch CDI Diode x 2 Spark plug Handlebar switch (RH) Handlebar switch (LH) Front headlight/Flasher turn signal indicator light (LH) Front headlight/Flasher turn signal indicator right (RH) Neutral switch Rear Flasher (LH) Rear Flasher (RH) Front brake switch Rear brake switch Tail light Instrument panel Neutral relay Battery Horn Flasher relay turn signal indicator light Clutch switch Side stand switch Thermocontact Oil level switch Coil Starter motor Speedometer sensor

TZR50 Accessories Overview

www.yamaha-motor-acc.com

Model year: 2005-2011 Sport Screen TZR50

Screen for added style

Gives your bike the extra sporty look Easy installation, specifically designed to fit the unit Available in three variations: Smoke, dark red and dark blue
Article number: 5WX-W0717-00-00 Smoked 5WX-W0717-20-00 Dark Red 5WX-W0717-40-00 Dark Blue

Specications

Material Certified conformity (CE/TV/WVTA) Mouting hardware 3 mm hard-coated acrylic N/A Included in package

City Tankbag

Tank-mounted bag for Yamaha street motorcycles
Soft tankbag with flexible bottom and easy fixation 12L volume Includes pocket for small items such as your wallet and mobile phone Two map holders Reflective striping, rain cover included Suitable for most Yamaha street motorcycles; XJR1300, FZ1, FZ8, FZ6, XJ6, TDM900, MT-01, MT-03, etc.
Article number: YME-W0750-20-00
Certified conformity (CE/TV/WVTA) N/A

Rim Sticker Set

Sticker set for the rims of 17" wheels
Embellishes your bike into a more sportier look Specifically designed for Yamaha Available in 4 colour variations featuring the Yamaha logo and 1 colour variation featuring the Yamaha Iwata graphics One sticker set contains stickers for 1 wheel (2 sides, 4 parts per side) Suitable for 17" wheels only Fits most Yamaha motorcycles with 17" wheels
Article number: YME-W0790-RS-BL YME-W0790-RS-RD YME-W0790-RS-WH YME-W0790-RS-YE YME-W0790-RS-IW
Blue Red White Yellow Iwata
Material Certified conformity (CE/TV/WVTA) Mounting hardware Solid resin N/A Not required. Application instructions included in package

YEC-40 Battery Charger

Charger that can charge the battery of your Yamaha motorcycle, scooter, ATV, SMB and/or marine products
Article number: YME-YEC40-EU-00 EU-plug YME-YEC40-UK-00 UK-plug
Contains unique battery charging technology. Fully automatic switch mode charger that analyses the state of the battery, charges and automatically switches to maintenance charging when ready Designed for safety: spark-free, protected from reverse polarity connections and short-circuit proof Light and compact; handy and easy to store Specially tested and approved by Yamaha service engineers to fit our range of motorcycles, scooters, ATV, SMB and other products Patented method for desulphation; extends life of the battery Also separately available: 1) indicator plug with long cable and traffic-light style battery indicator 2) built-in panel plug with extra long cable to mount in the dashboard of your Yamaha 3) Indicator panel 150, a combination of the indicator plug and built-in panel plug with long cable
Type Dimensions Weight Certified conformity (CE/TV/WVTA) Battery charge capacity 8 step, fully automatic switch model with pulse maintenance 168 x 65 x 38 mm 0,6 kg CE-approved 1.2-90 Ah

YEC-8 Battery Charger

Charger that can charge the battery of your Yamaha motorcycle, scooter, ATV, SMB and/or Marine products
Article number: YME-YEC08-EU-00 EU-plug YME-YEC08-UK-00 UK-plug
Type Dimensions Weight Certified conformity (CE/TV/WVTA) Battery charge capacity 4 step, fully automatic switch model with pulse maintenance 140 x 50 x 38 mm 0,6 kg CE-approved 1.2-32Ah

YEC Indicator Panel 150

Combines a battery charger built-in plug and a battery charge indicator into one
Connects to the battery chargers YEC-8 and YEC-40 Allows a neat, solid connection point rather than a flying lead connection Traffic light style LED indication: green, orange, red 1.5 m extra long cable to allow installation of connector to almost anywhere on your bike Rubber grommet to keep dirt out of connector Equipped with an inline fuse for extra safety
Article number: YME-YECIP-15-00
Dimensions Weight Certified conformity (CE/TV/WVTA) Mounting hardware 42 x 23 x 55 mm ~100 gr N/A Not required. Instructions for use included in package
YEC Battery Charger Built-in Panel Plug
Smart and easy plug for connection from panel mount socket at the dashboard to the YEC-8 or YEC-40 battery chargers
Allows a neat, solid connection point rather than a flying lead connection 1.5 m extra long cable to allow installation of connector to almost anywhere on your bike Rubber grommet to keep dirt out of connector Equipped with an inline fuse for extra safety
Article number: YME-YECPA-15-00
YEC Battery Charger Indicator
Gives instant and clear indication of the charge condition of your vehicles battery
Connects to the battery chargers YEC-8 and YEC-40 Traffic light style LED indication: green, orange, red 0.5 m long cable Rubber grommet to keep dirt out of connector Equipped with an inline fuse for extra safety
Article number: YME-YECPL-05-00
Dimensions Weight Certified conformity (CE/TV/WVTA) Mounting hardware 55 x 20 x 15 mm ~80 gr N/A Not required. Instructions for use included in package
The Yamaha Chain of Quality
Yamaha technicians are fully trained and equipped to offer the best service and advice for your Yamaha product. For this reason, Yamaha strongly recommends visiting an official Yamaha dealer for all your service requirements. Yamaha Genuine Parts & Accessories are especially developed, designed and tested for our Yamaha product range. Yamaha also recommends the use of Yamalube and BYE helmets*. Yamalube is our own range of high-tech lubricants, the lifeblood of Yamaha engines. They are developed to carry on working effectively, no matter where you ride. Besides functional and style accessories, Yamaha offers a range of high quality, innovative riding gear designed to keep you comfortable and protected, both on- and off-road. An extensive range of casual wear is also available. For more information go to: www.yamaha-motor-acc.com

Always wear a helmet, eye protection and protective clothing when riding any type of powered vehicle. Yamaha encourages you to ride safely and respect fellow riders and the environment. All information in this brochure/catalogue is given for general guidance. Specifications and appearance of Yamaha products are subject to change without prior notice. Yamaha does not guarantee the availability of the displayed products in local markets. The product range may be limited in some countries and Yamaha has the right to discontinue products without prior notice. Where applicable, prices of Yamaha products may vary according to local requirements and conditions. Sizes of the apparel displayed are indicative - Yamaha recommends you to visit your local Yamaha dealer for the best fit. For further details and availability, please consult your local Yamaha dealer. * BYE helmets are sold in most European countries, available exclusively through Yamahas official dealer network. Visit www.byehelmets.com.