Yamaha TZR50 '03 User manual

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

TZR50’03 / X-POWER’03
SERVICE MANUAL
© 2003 by Yamaha Motor España, S.A.
1st Edition, December 2003
All rights reserved
Any reproduction or non-authorised use of this
material
is expressly prohibited without the consent of
Yamaha Motor España, S.A.

WARNING
This 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 possible to include the full training of
a mechanic in a manual, for which reason we take it for granted that the persons who use
this manual to carry out maintenance and repair work on Yamaha /MBK motorcycles basi-
cally understand mechanical concepts and procedures inherent to motorcycle repair tech-
nology. Without such knowledge, any attempts to repair or service this model may make it
inappropriate for use and/or dangerous.
Yamaha Motor España, S.A. makes a constant effort to improve all the models that it manu-
factures. Any significant modifications and changes which are brought into the specifica-
tions or procedures will be made known to all Authorised Yamaha/MBK dealers and will
appear, where applicable, in future editions of this manual.
TECHNICAL PUBLICATIONS
AFTER-SALES SERVICE
YAMAHA MOTOR ESPAÑA, S.A
HOW TO USE THIS MANUAL
INFORMATION OF PARTICULAR IMPORTANCE
This material is distinguished by the following annotations:
sA danger symbol means: DANGER! TAKE CARE! YOUR SAFETY
IS AT RISK!
ssWARNING Failure to comply with a WARNING may lead to serious injuries
or death for the rider, a bystander or the person inspecting or
repairing the motorcycle.
CAUTION CAUTION indicates the special precautions which have to be
taken to prevent damage to the motorcycle.
NOTE: A NOTE provides key information for making procedures easier
or clearer.

MANUAL FORMAT
All the procedures included in this manual are arranged in sequential format, divided into
stages. The information presented has been grouped together in order to give the mecha-
nic a reference that is easy to read and convenient to handle, containing exhaustive expla-
nations of all the operations for dismantling, repair, assembly and inspection.
In this reviewed format, the condition of each faulty component is followed by an arrow,
which will in turn be followed by the operation required; for example:
• Bearing
• Pitting / Deterioration  Replace
EXPLODED VIEWS
Each chapter includes exploded views, before each dismantling section, to facilitate iden-
tification of the right procedures for dismantling and assembly.

SYMBOLS ILLUSTRATED
(See the ilustration)
Symbols to are designed as thumb tabs,
in order to show the number of the chapter
and index
General information
Specifications
Regular inspection and adjustments
General engine servicing
Carburation
Chassis
Electrical system
Troubleshooting - location and repair of
faults
Symbols to 
15 are used to identify the spe-
cifications appearing in the text
Filling liquid
10 Lubricant

11 Special tool

12 Tightening

13 Limit of wear or clearance

14 Engine speed

15 Ω, V, A
Symbols 
16 to 23 of the detailed diagrams
indicate the grade of lubricant and the loca-
tion of the lubrication point.
16 Apply engine oil

17 Apply gearbox oil

18 Apply molybdenum bisulphide oil

19 Apply grease for wheel bearings

20 Apply lightweight lithium soap-based
grease

21 Apply molybdenum bisulphide grease

22 Apply locking agent (LOCTITE®)

23 Use a new one
INSP/
ADJ
CHAS
TRBL
SPEC
ENG
CARB
GEN
INFO
NEW





11
13
15
16
19
22




10
12
14
23
18
21
17
20
ELEC

SPEC 2
SPECIFICATIONS
INSP
ADJ 3
REGULAR INSPECTIONS
AND ADJUSTMENTS
ENG 4
DISMANTLING THE ENGINE
COOL 5
COOLING SYSTEM
CARB 6
CARBURATION
CHAS 7
CHASSIS
INDEX
ELEC 8
ELECTRICAL SYSTEM
GENERAL INFORMATION GEN/
INFO 1

GEN/
INFO 1

GEN/
INFO
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION OF THE MOTORCYCLE …………………………………1-1
FRAME SERIAL NUMBER ……………………………………………………1-1
ENGINE SERIAL NUMBER……………………………………………………1-1
IMPORTANT INFORMATION …………………………………………………1-2
PREPARATION FOR REMOVAL AND DISMANTLING ……………………1-2
SPARES …………………………………………………………………………1-3
GASKETS, OIL SEALS AND O RINGS………………………………………1-3
WASHERS, LOCKING PLATES AND SPLIT PINS …………………………1-3
BEARINGS AND OIL SEALS …………………………………………………1-3
CIRCLIPS ………………………………………………………………………1-4
SPECIAL TOOLS …………………………………………………………………1-4
FOR TUNING …………………………………………………………………1-4
FOR ENGINE SERVICE ………………………………………………………1-4
FOR CHASSIS SERVICE ……………………………………………………1-7
FOR ELECTRICAL COMPONENTS …………………………………………1-8

GEN/
INFO
IDENTIFICATION OF THE MOTORCYCLE
1-1
GENERAL INFORMATION
IDENTIFICATION OF THE
MOTORCYCLE
FRAME SERIAL NUMBER
The chassis serial number is printed on the
right-hand side of the steering head.
ENGINE SERIAL NUMBER
The engine serial number is printed on the
left-hand side of the engine.
NOTE:
The first three figures of these numbers are for
identifying the model: the others are the
machine manufacturing number.
NOTE:
Design and characteristics subject to modifi-
cation at no prior notice.



GEN/
INFO
IMPORTANT INFORMATION
1-2
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
AND DISMANTLING
1. Before starting removal and dismantling,
remove any dirt, mud, dust and foreign
bodies.
2. Use appropriate tools and cleaning equip-
ment
See “SPECIAL TOOLS”
3. When dismantling the motorcycle, keep any
matching parts together. This refers to
gears, cylinders and pistons and other
items which work together and undergo the
same normal wear. Matching parts must be
assembled or replaced together.
4. As you dismantle the motorcycle, clean all
the parts and place them in trays, in the
same order in which these are dismantled.
This will cut down the time required for
assembly and will make it easier to install
them all together.
5. Keep any fire well away. CAREFUL ! NO
SMOKING !