Yamaha TZR50 '03 - User Manual

SERVICE MANUAL
TZR50
X-POWER
’03
5WX-AE1
’03

Summary

Chapter 1 General Information

Identification of the Motorcycle

Identifies motorcycle frame and engine serial numbers.

Important Information

Provides crucial details on preparation, spares, and handling of parts during maintenance.

Special Tools

Lists and illustrates specialized tools required for specific repair and tuning tasks.

Chapter 2 General Specifications

Specifications

Covers general specifications, dimensions, engine, chassis, and tyre details.

General Specifications of Tightening Torques;Definition of the Units

Details tightening torques for common fixings and unit conversions.

Lubrication Points and Type of Lubricant

Specifies lubrication points and recommended lubricant types for engine and chassis.

Cable Routing

Illustrates the routing of electrical cables and pipes throughout the motorcycle.

Chapter 3 Regular Inspection and Adjustments

Introduction;Regular Maintenance;Lubrication

Outlines the schedule for regular maintenance, inspections, and lubrication.

Side Covers

Instructions for dismantling and assembling motorcycle side covers.

Engine

Details procedures for adjusting engine speed, cables, and inspecting various engine components.

Chassis

Covers inspection and adjustment of brakes, steering, wheels, and suspension systems.

Electrical System

Procedures for inspecting the battery, fuses, and adjusting headlight beam.

Chapter 4 Engine

Removing the Engine

Step-by-step guide for safely removing the engine from the motorcycle.

Dismantling the Engine

Detailed instructions for disassembling engine components and sub-assemblies.

Inspection and Repair

Procedures for inspecting and repairing individual engine parts like cylinder head, piston, and crankshaft.

Assembling and Adjusting the Engine

Guidance on reassembling engine components and performing necessary adjustments.

Chapter 5 Coolant System

Changing the Coolant

Procedure for draining, flushing, and refilling the cooling system with new coolant.

Water Pump

Details on dismantling, inspecting, and assembling the water pump.

Thermostat and Radiator

Instructions for inspecting and assembling the thermostat and radiator components.

Chapter 6 Carburation

Carburetor

Procedures for removing, dismantling, inspecting, and assembling the carburetor.

Reed Valve

Steps for inspecting and assembling the reed valve system.

Chapter 7 Chassis

Front Wheel

Details on front wheel dismantling, inspection, and assembly, including tyre pressure.

Rear Wheel

Procedures for dismantling, inspecting, and assembling the rear wheel and chain.

Front Brake

Instructions for changing brake pads, dismantling caliper and pump, and inspection.

Front Fork

Guide for removing, dismantling, inspecting, and assembling the front fork assembly.

Steering Head and Handlebars

Procedures for dismantling, inspecting, and assembling the steering head and handlebars.

Rear Shock Absorber and Swingarm

Instructions for handling, dismantling, inspecting, and assembling the rear shock absorber and swingarm.

Rear Wheel Sprocket and Drive Chain

Details on dismantling, inspecting, and assembling the rear sprocket and drive chain.

Chapter 8 Electrical System

Electrical Diagram

Schematic diagram of the motorcycle's electrical system with component identification.

Electrical Components

Lists and illustrates key electrical components of the motorcycle.

Ignition and Starting System

Circuit diagram and troubleshooting for ignition and starting systems.

Electric Start System

Circuit diagram and troubleshooting guide for the electric start system.

Charging System

Circuit diagram and troubleshooting for the battery charging system.

Lighting System

Circuit diagram and troubleshooting for headlights, indicators, and instrument panel.

Signaling System

Circuit diagram and troubleshooting for indicators, brake lights, horn, and oil/neutral lights.

Cooling System

Circuit diagram and troubleshooting for the engine temperature warning light.

Yamaha TZR50 '03 Specifications

General

Displacement	49.7 cc
Fuel System	Carburetor
Ignition	CDI
Transmission	6-speed
Final Drive	Chain
Front Suspension	Telescopic fork
Rear Suspension	Swingarm
Front Brake	Single disc
Rear Brake	Single disc
Front Tire	90/80-17
Rear Tire	110/80-17
Seat Height	815 mm
Engine Type	Liquid cooled, 2-stroke, single cylinder