Yamaha_TZR_50__03_-Service_Manual.pdf
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TZR50
’03
X-POWER
’03
5WX-AE1
SERVICE MANUAL
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:
s
A danger symbol means: DANGER! TAKE CARE! YOUR SAFETY
IS AT RISK!
s
WARNING
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.
GEN
INFO
SPEC
SYMBOLS ILLUSTRATED
(See the ilustration)
are designed as thumb tabs,
in order to show the number of the chapter
and index
to
INSP/
ADJ
ENG
General information
Specifications
Regular inspection and adjustments
CARB
CHAS
General engine servicing
Carburation
Chassis
Electrical system
ELEC
TRBL
Troubleshooting - location and repair of
faults
10
15
are used to identify the spe-
cifications appearing in the text
to
11
12
Filling liquid
10
Lubricant
11
Special tool
12
Tightening
13
Limit of wear or clearance
13
14
14
Engine speed
15
Ω
, V, A
15
23
of the detailed diagrams
indicate the grade of lubricant and the loca-
tion of the lubrication point.
16
to
16
17
18
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
19
20
21
21
Apply molybdenum bisulphide grease
23
Use a new one
22
23
NEW
Symbols
Symbols
Symbols
22
Apply locking agent (LOCTITE®)
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