Yamaha TZR50 '03 Service Manual Page 61
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INSP
ADJ
INSPECTING THE COOLING SYSTEM / ADJUSTING
THE REAR BRAKE / INSPECTING THE BRAKE LIQUID
3-21
INSPECTING THE COOLING SYSTEM
1. Inspect:
• The radiator
• The inlet hose
• The outlet hose
Cracks / Damage
Replace
See the section on “COOLING SYSTEM”
in CHAPTER 5
ADJUSTING THE REAR BRAKE
Adjusting the free play of the rear brake
pedal
1. Check:
• The free play of the brake pedal (a)
Out of specification
Adjust
2. Adjust
• Free play of the rear brake pedal
INSPECTING THE BRAKE LIQUID
1. Place the motorcycle on a flat surface
2. Check:
3. Brake liquid level
• The level is under the “MIN” mark
fill
up
Adjustment steps
• Turn the adjustment device located in the
lever pusher by means of the nut and lock-
nut system
Tighten
Increases the free play of
the pedal
Loosen
Reduces the free play of the
pedal
Free play of the brake pedal:
10 ~ 15 mm
Brake liquid recommended:
DOT nº 4
MIN.
a
- SERVICE MANUAL 1
- TZR50’03 / X-POWER’03 2
- HOW TO USE THIS MANUAL 3
- MANUAL FORMAT 4
- EXPLODED VIEWS 4
- SYMBOLS ILLUSTRATED 5
- CHAPTER 1 8
- GENERAL INFORMATION 8
- IMPORTANT INFORMATION 10
- SPECIAL TOOLS 12
- CHAPTER 2 19
- GENERAL SPECIFICATIONS 19
- SPECIFICATIONS 20
- MAINTENANCE SPECIFICATIONS 23
- TIGHTENING TORQUES 28
- CONVERSION TABLES 32
- GENERAL CHARACTERISTICS 32
- OF TIGHTENING TORQUES 32
- CABLE ROUTING 35
- CHAPTER 3 40
- LUBRICATION 41
- INTRODUCTION 41
- SIDE COVERS 42
- ADJUSTING THE IDLING SPEED 43
- BLEEDING THE AUTOLUBE PUMP 46
- INSPECTING THE SPARK PLUG 47
- “OIL” level indicator 49
- ADJUSTING THE CLUTCH 51
- ADJUSTING THE CLUTCH / 52
- CLEANING THE AIR FILTER 52
- BURETTOR GASKET 54
- INSPECTING THE FUEL HOSES 55
- THE LEVEL OF COOLANT 56
- CHANGING THE COOLANT 57
- BLEEDING THE AIR 62
- INSPECTING THE BRAKE HOSES 64
- ADJUSTING THE STEERING 67
- CHANGING THE FORK OIL 69
- INSPECTING THE TYRES 71
- INSPECTING WHEELS / 72
- INSPECTING CABLES 72
- INSPECTING THE BATTERY 75
- INSPECTING THE FUSES 76
- CHANGING A HEADLIGHT BULB 77
- CHAPTER 4 79
- REMOVING THE ENGINE 80
- REMOVING THE ENGINE / 86
- DISMANTLING THE ENGINE 86
- DISMANTLING THE ENGINE / 93
- C: Internal cylinder diameter 96
- P: External piston diameter 96
- INSPECTION AND REPAIR 100
- CRANKSHAFT 102
- SHIFT AND SELECTOR 104
- SELECTOR 105
- STARTER MOTOR 108
- PISTON PIN AND PISTON 116
- CYLINDER HEAD AND CYLINDER 117
- CHAPTER 5 124
- COOLANT SYSTEM 124
- COOLING SYSTEM 125
- WATER PUMP 128
- THERMOSTAT AND RADIATOR 132
- CHAPTER 6 137
- CARBURATION 137
- CARBURETOR 139
- CARBURETOR / REED VALVE 141
- REED VALVE 141
- CHAPTER 7 146
- FRONT WHEEL 147
- RUEDA DELANTERA 150
- REAR WHEEL 152
- FRONT BRAKE 156
- FRONT FORK 166
- STEERING HEAD AND HANDLEBARS 175
- STEERING HEAD 176
- STEERING HEAD AND HANDLEBAR 178
- 6.0 m • kg 186
- 4.0 m • kg 186
- E: USE A NEW ONE 192
- 1/4 tooth 194
- Correct 194
- Roller 194
- Rear wheel sprocket 194
- Rotation direction 196
- CHAPTER 8 199
- ELECTRICAL SYSTEM 199
- ELECTRICAL DIAGRAM 201
- ELECTRICAL COMPONENTS (1) 203
- BATTERY: 204
- CAPACITY: 204
- 12 V 3AH 204
- NO MAINTENANCE 204
- CIRCUIT DIAGRAM 205
- IGNITION AND STARTING SYSTEM 206
- ELECTRIC START SYSTEM 207
- CHARGING SYSTEM 211
- TROUBLESHOOTING 213
- LIGHTING SYSTEM 217
- SIGNALING SYSTEM 227
- ELECTRICAL DIAGRAM TZR50 251
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