Yamaha TZR50 '03 Service Manual

SERVICE MANUALTZR50X-POWER’035WX-AE1’03

GEN/INFOIMPORTANT INFORMATION1-2IMPORTANT INFORMATIONPREPARATION FOR REMOVALAND DISMANTLING1. Before starting removal and dismantling,remove any dirt,

ENGINSPECTION AND REPAIR4-214. Measure:• Run out of the shaftOutside specifications ChangeUse the centring tool and the compara-tor (90890 - 03097)5

ENGINSPECTION AND REPAIR4-22BEARINGS AND OIL SEALS1. Inspect:• BearingPerforated / Damaged Change• Oil seal lipsDamaged / Worn ChangeCRANKCASE1. T

ENGASSEMBLING AND ADJUSTING THE ENGINE4-23ASSEMBLING AND ADJUSTING THE ENGINECRANKSHAFT  Crankshaft  Rings 15 Balancer Con rod  Pin 16 Bearing

ENGASSEMBLING AND ADJUSTING THE ENGINE4-24CAUTIONTo protect the crankshaft from scratchingor facilitate the installation operation, applygrease to the

ENGASSEMBLING AND ADJUSTING THE ENGINE4-25 Primary 10 Secondary19 Circlip 5th gear11 1st wheel gear 20 Washer 3rd gear 12 5th wheel gear 2

ENGASSEMBLING AND ADJUSTING THE ENGINE4-26SELECTOR Shift drum  Shift fork guide bar 1 Washer 10 Shift fork guide bar 2 Neutral 11Washer Spring

ENGASSEMBLING AND ADJUSTING THE ENGINE4-27NOTE:When you install the secondary shaft on thecrankcase pay attention to the lip of the oilseal of the cra

ENGASSEMBLING AND ADJUSTING THE ENGINE4-28CAUTIONBefore installing and tightening the crank-case securing screws, do not forget tocheck if the shift w

ENGASSEMBLING AND ADJUSTING THE ENGINE4-29STARTER MOTOR Starter motor Screw Magnetic flywheel Screw Nut

ENGASSEMBLING AND ADJUSTING THE ENGINE4-30STARTER MOTOR1. Install:• Starter motor 2. Install:• Coil plate in the crankcaseCAUTIONInstall the coil hol

GEN/INFOIMPORTANT INFORMATION1-3SPARES1. Use only original Yamaha/MBK spares forall changes. Use the oils and /or greasesrecommended by Yamaha/MBK for

ENGASSEMBLING AND ADJUSTING THE ENGINE4-31CLUTCH AND PRIMARY DRIVE GEARING Primary drive gearing 10 Pressure plate 19 Tensor Bush11 Spring 20

ENGASSEMBLING AND ADJUSTING THE ENGINE4-32NOTE:To tighten the CDI magneto nut use the flyw-heel holder 90890-01235 and without relea-sing this also ti

ENG4-334. Install:• Conical spring washer • Washer • Primary drive gear • Washer • Clutch boss • Washer • Clutch boss nut 5. Tighten:• Clutch

ENG4-347. Install:• Clutch discs • Friction discs • Push rod nº 1 • Pressure plate • Washer • Nut • Clutch springs • Screws for securing the cl

ENGASSEMBLING AND ADJUSTING THE ENGINE4-358. Adjusting the clutch lever:• Loosen locknut • Tighten the screw  until it reaches theend• Loosen the sc

ENGASSEMBLING AND ADJUSTING THE ENGINE4-363. Install:• Right-hand crankcase cover • ScrewsNOTE: Tighten the securing screws of the crankcasecover fol

ENGPISTON PIN AND PISTON4-37PISTON PIN AND PISTON1. Apply:• 2 stroke engine oilTo the piston pin, bearing, piston ringslots and piston2. Install:• Con

ENG4-38CYLINDER HEAD AND CYLINDER Cylinder  Nut Spark plug10 Flat washer Water pipe 11 Cylinder  Head gasket 12 Cylinder gasket Head gask

ENGASSEMBLING AND ADJUSTING THE ENGINE4-391. Install:• Cylinder head gasket NOTE:• Make sure that the mark and manufacturernumber engraved on the rin

ENGASSEMBLING AND ADJUSTING THE ENGINE4-40ssWARNINGHandle the thermostat with special care.Never hold this tightly or drop it. If it fallsreplace it w

GEN/INFOSPECIAL TOOLS1-4CIRCLIPS1. All circlips must be carefully inspected befo-re installing these again.Always change the ones on the piston rodswh

ENGASSEMBLING AND ADJUSTING THE ENGINE4-412. Install:• Drive chain NOTE:After installing the drive chain adjust the ten-sion of the chain. See “ADJUS

ENGASSEMBLING AND ADJUSTING THE ENGINE4-426. Inspect:• Oil leaks• Coolant leaks7. Connect:• Neutral cableNOTE:Before starting the engine up, bleed the

COOL5

CHAPTER 5COOLANT SYSTEMCHANGING THE COOLANT ……………………………………………………5-1WATER PUMP ……………………………………………………………………5-3DISMANTLING …………………………………………………………………5-4INS

COOLCOOLANT5-1COOLING SYSTEMCOOLANTCHANGING THE COOLANTssWARNINGDo not remove the radiator cap while thisand the engine are hot. Boiling liquid andvap

COOLCOOLANT5-28. Fill up with:• Coolant liquid (in the radiator)CAUTIONWater with impurities is harmful for theengine. If you cannot get distilled wat

COOLWATER PUMP5-3COOLING SYSTEMWATER PUMP Impeller shaft  Gasket Oil seal 10 Screw Pin 11 Screw Washer12 Drain screw Circlip13 Gasket Im

COOLWATER PUMP5-4DISMANTLINGNOTE:There is no need to dismantle the water pumpunless anomalies have been observed, suchas excessive variations in tempe

COOLWATER PUMP5-53. Dismantle:• The cover of the water pump body • The crankcase cover CAUTIONRemove the coolant from the water pumptaking care that

GEN/INFOSPECIAL TOOLS1-52. Flywheel (rotor) holding toolRef. 90890-01235This tool is used when the securing screw forthe magnetic flywheel magneto has

COOLWATER PUMP5-62. Inspect:• The gear of the impeller shaftCracks/Wear/Damage replace3. Inspect:• The seal Wear / Damage ReplaceReplacement ste

COOLWATER PUMP5-72. Install:• The impeller shaft Turn the shaft during assemblyNOTE:Proceed with care so as not to damage the lipof the seal and so t

COOLTHERMOSTAT AND RADIATOR5-8THERMOSTAT AND RADIATOR Radiator  Protector ring Cap  Bush Stop  Protector ring Bolt  Screw Washer10 WasherB:

COOLTHERMOSTAT AND RADIATOR5-9INSPECTION1. Inspect:• The radiator coreObstruction Eliminate this with com-pressed air, blowing from the rear of the

COOLTHERMOSTAT AND RADIATOR5-10Inspection steps:• Hang the thermostat  in a recipient • Submerge a reliable thermometer in water• Heat up the water

COOLTHERMOSTAT AND RADIATOR5-114. Fill up:• The coolantSee the section on “CHANGING THECOOLANT” in CHAPTER 3.5. Inspect:• The cooling systemReduce the

CARB6

CHAPTER 6CARBURATIONCARBURETOR ……………………………………………………………………6-1REMOVAL ………………………………………………………………………6-2DISMANTLING …………………………………………………………………6-2INSPECTION……

CARBCARBURETOR6-1CARBURATIONCARBURETOR Carburetor 14 Spring Carburetor cover13 Casing Needle valve 15 Choke jet Float chamber24 Idling screw

CARBCARBURETOR6-2REMOVAL1. Remove:• Carburetor assemblySee the section on engine removalDISMANTLING1. Remove:• Idling stop screw 2. Remove:• Float ch

GEN/INFOSPECIAL TOOLS1-67. Crankcase remover toolRef. 90890-11030This tool is used for dismantling the crankshaftor removing the crankcase.8. Tools fo

CARBCARBURETOR6-33. Inspect• JetsWear / Dirt Change / Clean 4. Inspect:• Plunger • Wear/damage Replace5. Check:• Free movementDifficulty Change

CARBCARBURETOR / REED VALVE6-4Adjustment steps:• Take out the carburetor• Inspect the valve seat and the float cham-ber valve.• If either of the two p

CARBREED VALVE6-52. Measure:• Height of the valve stop Outside specifications Adjust/ chan-ge the stop of the valveNOTE:If the height is 0.4 mm gre

CARBREED VALVE6-6INSTALLATIONTo install the reed valve, follow the procedurefor removal inversely. Pay attention to the follo-wing points.1. Install:•

CHAS7

CHAPTER 7CHASSISFRONT WHEEL …………………………………………………………………7-1DISMANTLING …………………………………………………………………7-2INSPECTION……………………………………………………………………7-2ASSEMBLY ………………

CHASFRONT WHEEL7-1CHASSISFRONT WHEEL Front wheel Spacer Bearing Bearing Seal Bush AxleAIR PRESSURE IN THE TIRESBASIC WEIGHT: WITH OIL AND FULL

CHASFRONT WHEEL7-2DISMANTLINGssWARNINGSupport the motorcycle firmly to avoid anyrisk of falling over.1. Lift up the front wheel, placing an appro-pria

CHASFRONT WHEEL7-32. Get rid of any corrosion on the parts.3. Inspect:• The front axleMake the axle turn on a flat surfaceDeformations ReplacessWARN

GEN/INFOSPECIAL TOOLS1-712. Seal installer(Clutch lever)Ref. 90890-1103513. Seal installer(Clutch side of crankshaft)Ref. 90890-11036)FOR CHASSIS SERV

CHASRUEDA DELANTERA7-4CAUTIONDo not tap the inner race of the bearing.Contact should only be with the outerrace.7. Check:• The wheel balanceIf the whe

CHASFRONT WHEEL7-5INSTALLINGRepeat the dismantling procedure, inversely.Take into account the following points:1. Apply:• Lithium greaseLightly grease

CHASREAR WHEEL7-6REAR WHEEL Rear wheel10 Chain 19 Bush Spacer 11 Coupling Bearing12 Wheel axle Bearing 13 Chain tensioner Rear wheel sprocke

CHASREAR WHEEL7-7DISMANTLINGssWARNINGSupport the motorcycle firmly so it does notfall over1. Lift the rear wheel and place a suitablesupport under the

CHASREAR WHEEL7-82. Measure:• The run out of the wheelSee the section on “FRONT WHEEL -INSPECTION”3. Check:• The wheel bearings• The wheel balancingSe

CHASREAR WHEEL7-94. Install:• The pin (a new one) ssWARNINGAlways use a new pin for the wheel axle.5. Adjust:• The free play of the brake pedalSee th

CHASFRONT BRAKE7-10FRONT BRAKE Disc brake  Drain screw Screw  Pin Complete brake caliper  Through screw Complete pistons  Seal Brake pads10

CHASFRONT BRAKE7-11CAUTIONThe components of the disk brake rarelyneed to be dismantled. Do not do so unlessthis is absolutely necessary. If any of the

CHASFRONT BRAKE7-122. Measure:• The thickness (a) of the pads:If this does not match the value specifiedreplaceNOTE:• Replace the pads as a set, if

CHASFRONT BRAKE7-137. Install:• The screws (brake caliper)8. Inspect:• The level of the brake liquidSee the section on “INSPECTING THEBRAKE LIQUID” in

GEN/INFOSPECIAL TOOLS1-8FOR ELECTRICAL COMPONENTS1. Pocket testerRef. 90890-03112This tester is an invaluable help for checkingthe electrical system.2

CHASFRONT BRAKE7-142. Dismantle:• The screws (brake caliper)• The brake padsSee the section on “CHANGING THEBRAKE PADS”3. Dismantle:• Pistons Dismantl

CHASFRONT BRAKE7-151. Dismantle:• The brake switch • The brake lever • The coupling screw • The copper washers 2. Dismantle:• The pump cover • Th

CHASFRONT BRAKE7-161. Measure:• The brake pads (thickness) (a)Out of specification replaceNOTE:• Change the pads as a set, whenever any ofthese is

CHASFRONT BRAKE7-17ASSEMBLYssWARNING• All the internal components must be clea-ned only with new brake liquid.• The internal items must be lubricated

CHASFRONT BRAKE7-184. Assemble:• The dust seal • The brake pump 5. Assemble:• The line • The copper washers • The coupling screw ssWARNINGAlways

CHASFRONT BRAKE7-197. Fill up:• Brake liquidCAUTIONThe brake liquid could erode painted surfa-ces and plastic parts. Always clean anyliquid spilt.ssWA

CHASFRONT FORK7-20FRONT FORK Rubber plug10 Tapered spindle Circlip11 Dust sealing plug Plug screw 12 Retaining clip O ring 13 Oil seal Fork s

CHASFRONT FORK7-21REMOVALssWARNINGStand the motorcycle up firmly so that thereis no risk of it falling over.1. Lift up the front wheel placing an appr

CHASFRONT FORK7-22NOTE:When the fork legs are dismantled, also remo-ve the screws  (brake line clamp) and odometer cable.7. Dismantle:• The front fo

CHASFRONT FORK7-232. Drain:• The oil out of the fork3. Remove:• The dust sealing cover • The retainer clip Use a fine screwdriver and take care nott

CHASFRONT FORK7-24INSPECTION1. Inspect:• The inner tube Scratching / Deformations ReplacessWARNINGDo not try to straighten the inner tube if thisi

CHASFRONT FORK7-25NOTE:• When putting the fork back on, make surethat you replace the following items with newones.• Guide bush• Oil seal• Dust protec

CHASFRONT FORK7-264. Install:• The guide sleeve Use the counterweight for installing fork4 seals and the adapter 5. Inner tube Outer tube5. Install

CHASFRONT FORK7-277. Measure:• The oil level (a)If this does not coincide with the valuespecified add or remove oil.NOTE:• To measure the oil level,

CHASFRONT FORK7-28INSTALLINGUse the “EXTRACTION” procedure inversely.Take into account the following points.1. Install:• The forkProvisionally tighten

CHASSTEERING HEAD AND HANDLEBARS7-29STEERING HEAD AND HANDLEBARSHANDLEBARS Handlebar (left-hand)  Set of throttle cable  Handlebar (right-hand) and

CHASSTEERING HEAD AND HANDLEBARS7-30STEERING HEAD Upper race of the bearing  Steering adjustment nut Lower race of the bearing  Upper shank of the

CHASSTEERING HEAD AND HANDLEBARS7-31DISMANTLINGssWARNINGStand the motorcycle up firmly to prevent itfrom falling over1. Lift the front wheel up instal

CHASSTEERING HEAD AND HANDLEBAR7-328. Loosen:• The clamp screws (handlebars) 9. Remove:• The screws (handlebars) 10. Dismantle:• The handlebars (lef

CHASSTEERING HEAD AND HANDLEBARS7-3318. Remove:• The ring nut Use the wrench for ring nuts WARNINGSupport the steering axle so that this can-not fal

SPEC2

CHASSTEERING HEAD AND HANDLEBARS7-34INSPECTION1. Wash the ball bearings and races with sol-vents.2. Inspect:• The ball bearings• The bearing racesPitt

CHASSTEERING HEAD AND HANDLEBARS7-352. Install:• The bearingsInstall the balls on the race and applymore grease3. Install:• The steering axlessWARNING

CHASSTEERING HEAD AND HANDLEBARS7-365. Install: • The upper crownNOTE:Provisionally tighten nut 2 of the steering axle.6. Install:• The headlight supp

CHASSTEERING HEAD AND HANDLEBARS7-37Stages in replacing the left-hand handle-bar:• Couple the lever support  to the handle-bar, as shown in the illus

CHASSTEERING HEAD AND HANDLEBARS7-38ssWARNINGLeave a space of 1 mm between the twistgrip  and the counterweight . Otherwisethe twist grip could stic

CHASSTEERING HEAD AND HANDLEBARS7-3919. Adjust:• The free play of the clutch cableSee the section on “ADJUSTING THECLUTCH” in CHAPTER 320. Install:• T

CHASREAR SHOCK ABSORBER AND SWINGARM7-40REAR SHOCK ABSORBER AND SWINGARM Swingarm  Bush 17 Screw Roller bearing10 Flat washer 18 Washer Thru

CHASREAR SHOCK ABSORBER AND SWINGARM7-41OBSERVATIONS ON HANDLINGssWARNINGThis shock absorber contains gaseousnitrogen at high pressure. Before handlin

CHASREAR SHOCK ABSORBER AND SWINGARM7-42DISMANTLINGRear swingarmssWARNINGStand the motorcycle up firmly so that itdoes not fall over.1. Dismantle:• Th

CHASREAR SHOCK ABSORBER AND SWINGARM7-43SwingarmssWARNINGStand the motorcycle up firmly so that itdoes not fall over.1. Lift up the rear wheel, instal

SPECCHAPTER 2GENERAL SPECIFICATIONSSPECIFICATIONS ………………………………………………………………2-1GENERAL SPECIFICATIONS …………………………………………………2-1MAINTENANCE SPECIFICATIONS …

CHASREAR SHOCK ABSORBER AND SWINGARM7-44INSPECTION1. Inspect:• The shock absorberOil leaks / damage replace2. Inspect:• The swingarmDeformations / C

CHASREAR SHOCK ABSORBER AND SWINGARM7-45Rear shock absorberApply the same procedure as in “DISMAN-TLING” but inversely.Take into account the following

CHASREAR WHEEL SPROCKET AND DRIVE CHAIN7-46REAR WHEEL SPROCKET AND DRIVE CHAIN Rear sprocket Holder10 Drive chain11 Chain couplingE: USE A NEW O

CHASREAR WHEEL SPROCKET AND DRIVE CHAIN7-47NOTE:Before dismantling the sprocket, the chain andthe rear wheel sprocket, the chain sloackshould be check

CHASREAR WHEEL SPROCKET AND DRIVE CHAIN7-48INSPECTION1. Check: • The chain stretchingPull the chain to separate this from thecrown wheel.Distance betw

CHASREAR WHEEL SPROCKET AND DRIVE CHAIN7-49Replacing steps:• Straighten the tab of the locknut and takeoff the crown wheel • Install the new rear whe

CHASREAR WHEEL SPROCKET AND DRIVE CHAIN7-504. Install:• The drive chain• The coupling link of the chain• The chain clip  Rotation directionssWARNING

ELEC8

CHAPTER 8ELECTRICAL SYSTEMELECTRICAL DIAGRAM ………………………………………………………8-2ELECTRICAL COMPONENTS …………………………………………………8-4IGNITION AND STARTING SYSTEM ……………………

TZR50’03 / X-POWER’03SERVICE MANUAL© 2003 by Yamaha Motor España, S.A.1st Edition, December 2003All rights reservedAny reproduction or non-authorised

SPECGENERAL SPECIFICATIONS2-1Model TZR50 / X-POWERModel code number 5WXFrame serial numberYamaha UTLRA031000000001MBK UTLRA032000000001Dimensions:Tota

ELECELECTRICAL DIAGRAM 8-2ELECTRICAL DIAGRAM

ELECELECTRICAL DIAGRAM8-3 Magnetic flywheel 16 Front brake switch Regulator / Rectifier 17 Rear brake switch Starting relay18 Tail light Fus

ELECELECTRICAL COMPONENTS8-4 CDI 12 Battery Spark plug pipe 15 Regulator/Rectifier Neutral switch17 Main switch O ring 20 Rear brake light

ELECELECTRICAL COMPONENTS8-521 Electrical installation 29 Side stand switch23 Fuse31 Relay24 Diode 32 Indicator flasher relay27 Oil lev

ELECIGNITION AND STARTING SYSTEM8-6CIRCUIT DIAGRAMThe following circuit diagram shows the ignition and starting system

ELECIGNITION AND STARTING SYSTEM8-7NOTE:For the colour codes, please see the electrical diagram C.D.I. magneto  Starter relay Main switch C.D.I.

ELECELECTRIC START SYSTEM8-8ELECTRIC START SYSTEMCIRCUIT DIAGRAM Starter relay Fuse Main switch Diodes Engine/starter stop switch13 Neutral swi

ELECELECTRIC START SYSTEM8-9TROUBLESHOOTINGNOTE:• Use the following tools in this fault locationTHE STARTER MOTOR DOES NOT WORK1. Fuse (main)• Check t

ELECELECTRIC START SYSTEM8-106. Main switch• Place in the ON position• Separate the connections• Check the continuity between R and BrOKNOTOKRepair th

SPECGENERAL SPECIFICATIONS2-2Model TZR50 / X-POWERFuel:Type Unleaded gasolineCapacity of the fuel tank:Full 13.8 LReserve 2.2 LCarburettor :Type / Num

ELECELECTRIC START SYSTEM8-1110. Clutch switch• Press the clutch• Check the continuity between BG and LYOKNOTOKRepair the side stand switch11. Starter

ELECCHARGING SYSTEM8-12CHARGING SYSTEMCIRCUIT DIAGRAM

ELECCHARGING SYSTEM8-13NOTE:For the colour codes please see the electrical diagram C.D.I. magneto Regulator / Rectifier Fuse CDI Spark plug21 Ba

ELECCHARGING SYSTEM8-14TROUBLESHOOTINGProcedure (1)Check:1. The fuse 4. The resistance of the stator coil2. The battery 5. The cable connections (cha

ELECCHARGING SYSTEM8-153. Charging voltage• Connect the engine tachometer to the spark plugcable• Connect the pocket tester (DC, 20V) to the battery(+

ELECCHARGING SYSTEM8-16• Check to see if the stator coil has the specified resis-tance.DOES NOT MATCH SPECIFICATIONReplace the stator coilMATCHES SPEC

ELECLIGHTING SYSTEM8-18LIGHTING SYSTEMCIRCUIT DIAGRAM

ELECLIGHTING SYSTEM8-19NOTE:For colour codes please see the electrical diagram Fuse Main switch11 Front headlight / indicator (LH)12 Front headl

ELECLIGHTING SYSTEM8-20TROUBLESHOOTINGProcedureCheck:1.The fuse2.The light switch “LIGHTS”3.The cable connections (lighting system)NOTE:• Dismantle th

SPECGENERAL SPECIFICATIONS2-3Model TZR50 / X-POWERBrakes:Type of front brake Single discFront brake action Right handType of rear brake Single discRea

ELECLIGHTING SYSTEM8-21(+) probe of tester Red / yellow terminal (-) probe of tester Blue terminal • Place the lights switch “LIGHTS” in positio

ELECLIGHTING SYSTEM8-223. Cable connections• Check the cable connections of the whole lightsystemSee the section on “WIRING DIAGRAM”CONNECTIONS IN BA

ELECLIGHTING SYSTEM8-231. Headlight bulb• Check the continuity between B and Y and betweenB and GTHERE IS NO CONTINUITYReplace the headlight bulb.2. V

ELECLIGHTING SYSTEM8-24• Check the headlight voltageIN BAD CONDITIONReplace the handlebar switch Headlight voltage: 12.0 VDOES NOT MATCH THE SPECIFICA

ELECLIGHTING SYSTEM8-254. Cable connections• Check the wiring connections of the whole lightingsystem.See the “ELECTRICAL DIAGRAM” section 1. Brake l

ELECLIGHTING SYSTEM8-26• Check the voltage of the tail lightVoltage of the tail light: 12.0 VDOES NOT MATCH THE SPECIFICATION3. Cable connectionsCheck

ELECLIGHTING SYSTEM8-272. Voltage• Disconnect the coupler of the instrument panel• Place the main switch in the ON position.• Connect the pocket test

ELECSIGNALING SYSTEM8-28SIGNALING SYSTEMCIRCUIT DIAGRAM

ELECSIGNALING SYSTEM8-29NOTE:For the colour codes please see the electrical diagram Fuse 17 Rear brake switch Switch 18 Tail light / Brake lig

ELECSIGNALING SYSTEM8-30TROUBLESHOOTINGProcedureCheck:1.The fuse2.The battery3.Main switch4.Wiring connections (signalling system)NOTE:• Remove the fo

SPECMAINTENANCE SPECIFICATIONS2-4Model TZR50 / X-POWERCylinder head:Max. waparge 0.03 mm* Lines indicate straightedge measurement.Cylinder:Bore size

ELECSIGNALING SYSTEM8-313. Main switch• Disconnect the connector of the main switch• Connect the pocket tester (Ω x 1) to the main switch• Place the m

ELECSIGNALING SYSTEM8-321. Indicator bulb• Remove the indicator bulb• Connect the pocket tester (Ω x 1) to the bulb(+) probe of tester Terminal (-)

ELECSIGNALING SYSTEM8-33• Check if the continuity is correct in the bulb holderbush of the indicator.CONTINUITY OK3. Turning switch “TURN”• Disconnect

ELECSIGNALING SYSTEM8-344. Voltage• Place the main switch in the “ON” position• Connect the pocket tester (DC, 20 V) to the couplerof the indicator re

ELECSIGNALING SYSTEM8-35• Remove the bulb of the tail light/ brake light• Connect the pocket tester (Ω x 1) to the bulbNO CONTINUITYReplace the tail l

ELECSIGNALING SYSTEM8-363. Voltage• Place the main switch in the ON position.• Apply the front brake• Connect the pocket tester (DC, 20V) to the front

ELECSIGNALING SYSTEM8-37• Check whether the continuity is correct in the brakeswitchSwitch In good In bad position condition conditionApplying rear br

ELECSIGNALING SYSTEM8-381. Neutral switch• Disconnect the cable of the neutral switch (light blue)of the connector• Connect the pocket tester (Ω x 1)

ELECSIGNALING SYSTEM8-392. Voltage• Disconnect the instrument panel coupler.• Place the main switch in the “ON” position• Connect the pocket tester (D

ELECSIGNALING SYSTEM8-404. The turning indicator pilot light “TURN” does notcome on1. Turning switch “TURN”• Disconnect the large coupler (yellow) fro

SPECMAINTENANCE SPECIFICATIONS2-5Model TZR50 / X-POWERCrankshaft:Crank width “A” 41.90 ~ 42.0 mmRunout limit “B” 0.03 mmSmall end free play “D” 0.20 ~

ELECSIGNALING SYSTEM8-412. Voltage• Place the main switch in the “ON” position• Connect the pocket tester (+) probe of tester Brown terminal (-) pr

ELECSIGNALING SYSTEM8-42NO CONTINUITYReplace the oil level switch.1. Oil level switch• Remove the oil level switch from the oil tank• Disconnect the s

ELECSIGNALING SYSTEM8-431. HORN switch• Disconnect the handlebar switch connector from theconnector• Connect the pocket tester (Ω x 1) to the HORNswit

ELECSIGNALING SYSTEM8-444. Horn• Disconnect the pink cable from the horn terminal• Connect a bridge cable  to the horn terminal andlead this to groun

ELECCOOLING SYSTEM8-46COOLING SYSTEMCIRCUIT DIAGRAM

ELECCOOLING SYSTEM8-47NOTE:For the colour codes please see the electrical diagram Fuse Main switch19 Instrument panel21 Battery26 Thermocontac

ELECCOOLING SYSTEM8-48TROUBLESHOOTINGProcedureCheck:1.The seat2.The tank3.The front fairingNOTE:• Remove the following items before locating the fault

ELECCOOLING SYSTEM8-493. Main switch• Disconnect the coupler from the main switch• Connect the pocket tester (Ω x 1) to the main switch(+) probe of te

ELECCOOLING SYSTEM8-506. Thermosensor• Remove the thermosensor from its housing.• Connect the pocket tester (Ω x 1) to the thermosensor• Submerge the

SPECMAINTENANCE SPECIFICATIONS2-6Model TZR50 / X-POWERCarburettor:Identification mark PHBN12HS/DellortoMain jet (M.J.) # 88Air screw turns 2-1/8Fuel l

ELECTRICAL DIAGRAM TZR50 Magnetic flywheel Regulator/ rectifier Starter relay Fuse Main switch CDI Diode x 2 Spark plug Handlebar switch (RH)

SPECMAINTENANCE SPECIFICATIONS2-7Model TZR50 / X-POWERSteering system:Steering type Ball bearingsSize of the balls (number):Upper 1/4 inch (19 units)

SPECMAINTENANCE SPECIFICATIONS2-8Model TZR50 / X-POWERRear wheel:Type CastWheel size MT3.50 x 17Wheel material AluminiumRunout limitVertical 1.0 mmLa

SPECMAINTENANCE SPECIFICATIONS2-9Items to tighen Number Thread pitch Tightening ObservationstorqueNm m•kgSpark plug 1 M14 x 1.25 23 2.3Cylinder headNu

SPECMAINTENANCE SPECIFICATIONS2-10Items to tighten Number Thread pitch Tightening ObservationstorqueNm m•kgUpper bracket and forksAllen screw 2 M8 x 1

WARNINGThis manual has been issued by Yamaha Motor España, S.A., mainly for its use by Yamaha/MBK dealers and their qualified mechanics. It is not pos

SPECMAINTENANCE SPECIFICATIONS2-11Model TZR50 / X-POWERVoltage: 12 VIgnition systemIgnition data:Type of advance arrangement: ElectronicIgnition: 14º/

SPECMAINTENANCE SPECIFICATIONS2-12Model TZR50 / X-POWERCharge system: Flywheel magnetoVoltage regulator:Model / manufacturer SH 671 - 12/SHIN DEN GENB

SPECCONVERSION TABLES2-13A: Distance between sidesB: Outer thread diameterUnit Denomination Definition Dimensionmm Milimeter 10-3meters Lengthcm Centi

SPECLUBRICATION POINTS AND TYPE OF LUBRICANT2-14Lubrication point (name of the part) Type of lubricantOil seal lips (all)“O” rings (all)Bearing sealsC

SPECLUBRICATION POINTS AND TYPE OF LUBRICANT2-15Lubrication point (name of the part) Type of lubricantBall bearings (steering column)Lips of the oil s

SPECCABLE ROUTING2-16CABLE ROUTING DC-CDI Regulator-rectifier Battery Starter relay Fuse box Horn Flasher relay Neutral relayA Thread the hor

SPECCABLE ROUTING2-17 Speedometer connector Connector for headlight and front indicatorlights Connector for the speedometer sensor Ground cable E

SPECCABLE ROUTING2-18A Thread the oil pipe through the frame clampsB Clamp the starter motor cable to the frameC Clamp the cable of the speedomet

INSPADJ3

MANUAL FORMATAll the procedures included in this manual are arranged in sequential format, divided intostages. The information presented has been grou

CHAPTER 3REGULAR INSPECTION AND ADJUSTMENTSINTRODUCTION/REGULAR MAINTENANCE/LUBRICATION ……………3-1SIDE COVERS ……………………………………………………………………3-2DISMANTLING …

INSPADJINTRODUCTION/REGULAR MAINTENANCE/LUBRICATION3-1REGULAR INSPECTION AND ADJUSTMENTINTRODUCTIONThis chapter contains all the information required

INSPADJSIDE COVERS3-2SIDE COVERSDISMANTLING1. Take off:• The seatNOTE:To open the seat lock, insert the key into thisand turn clockwise2. Dismantle:•

INSPADJADJUSTING THE IDLING SPEED3-3ADJUSTING THE IDLING SPEED1. Tighten• The air screw Tighten the screw until it gently abuts theend of its travel2

INSPADJADJUSTING THE AUTOLUBE PUMP CABLE3-4ADJUSTING THE AUTOLUBE PUMPCABLENOTE:Before adjusting the automatic mixture pumpcable, you must first adjus

INSPADJADJUST THE FREE PLAY OF THE THROTTLE CABLE3-56. Adjust:• The engine idling speed .ADJUSTING THE FREE PLAY OF THETHROTTLE CABLE1. Check:• The f

INSPADJBLEEDING THE AUTOLUBE PUMP3-6BLEEDING THE AUTOLUBE PUMPNOTE:The automatic mixing pump and its hosesmust be bled in the following cases:• When t

INSPADJADJUSTING THE FREE PLAY OF THE CHOKE CABLE /INSPECTING THE SPARK PLUG3-7ADJUSTING THE FREE PLAY OF THECHOKE CABLE / INSPECTING THE SPARKPLUG 1.

INSPADJINSPECTING THE SPARK PLUG3-86. Tighten:• The spark plug Before installing a spark plug, clean thesurfaces of the gasket and of the sparkplug it

INSPADJCHECKING THE ENGINE OIL LEVEL3-9INSPECTING THE ENGINE OIL LEVEL(MIXTURE)1. Check:• The oil levelOil level low top up with sufficient oil.Reco

SYMBOLS ILLUSTRATED(See the ilustration)Symbols  to  are designed as thumb tabs,in order to show the number of the chapterand index General informa

INSPADJINSPECTING THE OIL LEVEL OF THE TRANSMIS-SION/CHANGING THE TRANSMISSION OIL3-10INSPECTING THE OIL LEVEL OF THETRANSMISSION1. Heat up the engine

INSPADJCHANGING THE TRANSMISSION OIL/ADJUSTING THE CLUTCH3-115. Inspect:• The O ring (of the oil filling cap) Damage replace6. Install:• The draina

INSPADJADJUSTING THE CLUTCH / CLEANING THE AIR FILTER3-12NOTE:Normally, after properly adjusting the regulatorfor the length of the clutch cable (cran

INSPADJCLEANING THE AIR FILTER3-133. Remove:• The cover of the air filter case 4. Take out:• The filter element CAUTIONNever let the engine run with

INSPADJCLEANING THE AIR FILTER / INSPECTING THE CAR-BURETTOR GASKET3-14• Apply SAE 10 W30 engine oil • Drain off any excess oilNOTE:The element shoul

INSPADJINSPECTING THE CARBURETTOR GASKET /INSPECTING THE FUEL HOSES3-153. Inspect:• The carburettor joint Cracks/damage ReplaceSee the section on “

INSPADJINSPECTING THE EXHAUST SYSTEM / INSPECTINGTHE LEVEL OF COOLANT3-16INSPECTING THE EXHAUST SYSTEM1. Inspect:• The exhaust pipe• The mufflerCracks

INSPADJINSPECTING THE COOLANT LEVEL /CHANGING THE COOLANT3-17NOTE:To check the level of coolant, place themotorcycle in a vertical position; if it lea

INSPADJCHANGING THE COOLANT3-181. Disconnect:• The breather pipe 2. Drain the coolant reservoir tank.3. Remove:• The securing screw • The radiator c

INSPADJCHANGING THE COOLANT3-19CAUTION• Water with minerals is damaging for theengine components: use boiled or disti-lled water.• Do not use water co

SPEC2SPECIFICATIONSINSPADJ3REGULAR INSPECTIONSAND ADJUSTMENTSENG4DISMANTLING THE ENGINECOOL5COOLING SYSTEMCARB6CARBURATIONCHAS7CHASSISINDEXELEC8ELECTR

INSPADJCHANGING THE COOLANT3-208. Install:• The panel Stages in filling with coolant:• Remove the screw of the radiator cap• Pour the coolant into t

INSPADJINSPECTING THE COOLING SYSTEM / ADJUSTINGTHE REAR BRAKE / INSPECTING THE BRAKE LIQUID3-21INSPECTING THE COOLING SYSTEM1. Inspect:• The radiator

INSPADJINSPECTING THE BRAKE LIQUID / BLEEDING THE AIR3-22NOTE:• Place the motorcycle vertically to check thelevel of the brake liquid• When checking t

INSPADJBLEEDING THE AIR / INSPECTING THE BRAKE PADS3-23Bleeding air steps:a. Add brake liquid of the appropriatetype to the tankb. Install the diaphra

INSPADJADJUSTING THE BRAKE LIGHT SWITCH /INSPECTING THE BRAKE HOSES3-24ADJUSTING THE BRAKE LIGHT SWITCHNOTE:The brake light switch is activated by the

INSPADJADJUSTING THE DRIVE CHAIN SLACK3-25ADJUSTING THE DRIVE CHAIN SLACKNOTE:Before checking and/or adjusting the chain,make the rear wheel turn seve

INSPADJADJUSTING THE DRIVE CHAIN SLACK3-26• Tighten the axle nut NOTE:Tighten the axle nut while keeping the chaintaut with your hand so as to keep t

INSPADJLUBRICATING THE DRIVE CHAIN / ADJUSTING THE STEERING3-27LUBRICATING THE DRIVE CHAINThe chain consists of a large number of partsthat work in co

INSPADJADJUSTING THE STEERING3-28Adjusting the steering head1. Adjust:• The steering headAdjustment steps:• Loosen the screw  of the handlebarclamp,

INSPADJCHANGING THE FORK OIL3-29CHANGING THE FORK OILssWARNING• Leaks of oil from the fork may give rise todrops in stability and reduce drivingsafety

GEN/INFO1

INSPADJCHANGING THE FORK OIL3-307. After removing most of the oil, pump upand down with the fork to get any remai-ning oil out.8. Inspect:• The O ring

INSPADJINSPECTING THE TYRES3-31INSPECTING THE TIRE1. Measure:• The air pressureOut of specification AdjustBasic weight: With oil and fuel tank full

INSPADJINSPECTING WHEELS /INSPECTING CABLES3-32INSPECTING WHEELS1. Inspect:• The wheelsDamage / deformations ReplaceNOTE:After changing the tire or

INSPADJLUBRICATION3-33LUBRICATIONLubrication of cablesLubricating steps:• Keep the cable in vertical position• Apply lubricant to the upper end of the

INSPADJELECTRICAL SYSTEM3-34ELECTRICAL SYSTEMINSPECTING THE BATTERY1. Remove:• The seat2. Inspect:• The battery terminalsDirty terminals Clean with

INSPADJINSPECTING THE BATTERY3-35ssWARNINGThe electrolyte in the battery is dangerous:it contains sulphuric acid and is conse-quently poisonous and ve

INSPADJINSPECTING THE FUSES3-36INSPECTING THE FUSES1. Remove:• The seat2. Remove: • The fuse 3. Inspect:• The fuseStages in inspection• Connect the p

INSPADJADJUSTING THE HEADLIGHT BEAM / CHANGING A HEADLIGHT BULB3-37ADJUSTING THE RIGHT-HANDHEADLIGHT BEAM1. Adjust :• The headlight beam (vertical)To

ENG4

CHAPTER 4ENGINEREMOVING THE ENGINE ………………………………………………………4-1PREPARING FOR REMOVAL…………………………………………………4-1PETROL TANK …………………………………………………………………4-2AIR FILT

GEN/INFOCHAPTER 1GENERAL INFORMATIONIDENTIFICATION OF THE MOTORCYCLE …………………………………1-1FRAME SERIAL NUMBER ……………………………………………………1-1ENGINE SERIAL NUMBER……

ENGREMOVING THE ENGINE4-1ENGINEREMOVING THE ENGINENOTE:It is not necessary to remove the engine totake out the following components:• Cylinder head• C

ENGREMOVING THE ENGINE4-2PETROL TANK1. Remove:• Seat• Grip strap• Side covers (left  / right)2. Remove the fuel tank cap3. Remove the bolts of the fu

ENGREMOVING THE ENGINE4-3AIR FILTER 1. Remove:• Securing screw 2. Take out:• Clip3. Disconnect:• Rubber pipe4. Remove• Filter casing◗

ENGREMOVING THE ENGINE4-4EXHAUST PIPE1. Remove:• Springs • Clamp of the AIS system 2. Remove:• Exhaust pipe screws  and • Exhaust pipeCOOLANT PIPE

ENGREMOVING THE ENGINE4-5SPARK PLUG AND THERMOCONTACTCABLE1. Disconnect• Spark plug cable • Thermocontact cable 2. Loosen:• Spark plug CDI CABLE1.

ENGREMOVING THE ENGINE4-6CARBURETTOR1. Loosen:• Carburettor securing screw 2. Remove:• Upper carburettor cover • Throttle cable • Tube for supplyin

ENGREMOVING THE ENGINE /DISMANTLING THE ENGINE4-74. Disconnect:• Clutch cable First disconnect the cable of the crank-case side and then the end at t

ENGDISMANTLING THE ENGINE4-82. Remove• Clip • Washer • Water pump driven gear • Pin • Washer • Water pump shaft • Clip • Oil pump driven gear 

ENGREMOVING THE ENGINE4-94. Remove:• Clutch boss safety nut • Washer • Clutch boss • Washer • Clutch housing • Washer • Conical spring washer s

ENGREMOVING THE ENGINE4-10CDI MAGNETO1. Remove:• Left-hand crankcase cover and gasket• Flywheel securing nut.2. Remove:• CDI flywheel• Crankshaft key•

GEN/INFOIDENTIFICATION OF THE MOTORCYCLE1-1GENERAL INFORMATIONIDENTIFICATION OF THEMOTORCYCLEFRAME SERIAL NUMBERThe chassis serial number  is printed

ENGDISMANTLING THE ENGINE4-11CYLINDER HEAD AND CYLINDER 1. Remove:• Spark plug• Nuts and washers• Thermocontact NOTE:Following the order stated in th

ENGDISMANTLING THE ENGINE4-12PISTON PIN AND PISTON1. Take out:• Piston pin clip NOTE:Before removing the pin clip from the piston,cover the crankcase

ENGDISMANTLING THE ENGINE4-13CAUTIONUse a soft hammer to hit the crankcaselightly. Only tap the reinforced parts. Do nottap the closing surface. Work

ENGDISMANTLING THE ENGINE /INSPECTION AND REPAIR4-14BEARINGS AND OIL SEALSNOTE:• It is not necessary to take out the bearingsand oil seals unless thes

ENGINSPECTION AND REPAIR4-15Measuring warping and steps for sandingthe surface:• Put a straightedge and a thickness gaugeon the cylinder head• Measure

ENGINSPECTION AND REPAIR4-16CYLINDER1. Eliminate:• Any carbon depositsUse a rounded scrap 2. Inspect:• The cylinderMineral deposited / rust Remove

ENGINSPECTION AND REPAIR4-175. Measure• Piston free play:Outside specifications Grind thecylinder or replace the pistonC: Internal cylinder diameter

ENGINSPECTION AND REPAIR4-183. Check:• Free playThere should not be any considerableplayFree play exists check to see if thecon rod is worn / change

ENGINSPECTION AND REPAIR4-192. Measure:• Thickness of the friction discOut of specifications Change the fullset of friction discs.Measure at 4 point

ENGINSPECTION AND REPAIR4-207. Inspect:• Slots in the clutch drumCracks / wear / damaged removedeburr or change• Bearing of the clutch drumScraping