Yamaha 2003 TZR50 Manuals

Manuals and User Guides for Yamaha 2003 TZR50. We have 1 Yamaha 2003 TZR50 manual available for free PDF download: Service Manual

Yamaha 2003 TZR50 Service Manual

Yamaha 2003 TZR50 Service Manual (251 pages)

Brand: Yamaha | Category: Motorcycle | Size: 8.49 MB

Table of Contents

Gen/ Info Chapter 1 General Information

8
- How to Use this Manual
  3
- Table of Contents
  8
- Chapter 1 General Information
  9
- Identification of the Motorcycle
  9
  - Frame Serial Number
    9
  - Engine Serial Number
    9
- Important Information
  10
  - Preparation for Removal and Dismantling
    10
  - Spares
    11
  - Gaskets, Oil Seals and O Rings
    11
  - Bearings and Oil Seals
    11
  - Circlips
    12
- Special Tools
  12
  - For Tuning
    12
  - For Engine Service
    12
  - For Chassis Service
    15
  - For Electrical Components
    16
Spec Chapter 2 General Specifications

19
- Chapter 2 General Specifications
  20
- Specifications
  20
- Maintenance Specifications
  23
  - Engine
    23
  - Chassis
    26
  - Tightening Torques
    28
  - Electrical System
    30
  - Conversion Tables
    32
- Lubrication Points and Type of Lubricant
  33
  - Engine
    33
  - Chassis
    34
- Cable Routing
  35
Insp Adj Chapter 3 Regular Inspection and Adjustments

40
- Introduction/Regular Maintenance/Lubrication
  41
- Assembly
  42
- Chapter 3
  42
- Dismantling
  42
- Side Covers
  42
- Adjusting the Idling Speed
  43
- Adjusting the Autolube Pump Cable
  44
- Adjusting the Free Play of the Throttle Cable
  45
- Bleeding the Autolube Pump
  46
- Inspecting the Spark Plug
  47
- Inspecting the Engine Oil Level
  49
- Inspecting the Transmission Oil Level
  50
- Changing the Transmission Oil
  51
- Adjusting the Clutch
  52
- Cleaning the Air Filter
  52
- Inspecting the Carburettor Gasket
  55
- Inspecting the Fuel Hoses
  55
- Inspecting the Exhaust System
  56
- Inspecting the Level of the Coolant
  56
- Changing the Coolant Liquid
  57
- Adjusting the Rear Brake
  61
- Inspecting the Cooling System
  61
- Bleeding the Air
  62
- Inspecting the Brake Liquid
  62
- Inspecting the Brake Pads
  63
- Adjusting the Brake Light Switch
  64
- Inspecting the Brake Hoses
  64
- Adjusting the Steering
  67
- Changing the Fork Oil
  69
- Inspecting the Tyres
  71
- Inspecting the Cables
  72
- Inspecting the Wheels
  72
- Lubrication
  73
- Electrical System
  74
  - Inspecting the Battery
    74
  - Inspecting the Fuses
    76
  - Adjusting the Headlight Beam
    77
  - Changing the Headlight Bulb
    77
Eng Chapter 4 Engine

79
- Chapter 4 Removing the Engine
  83
- Coolant Pipes
  83
- Exhaust Pipe
  83
- Neutral Switch Cable
  84
- Oil Pump
  84
- Spark Plug and Thermocontact Cable
  84
- Carburettor
  85
- Dismantling the Engine
  86
  - Oil Pump
    86
  - Water Pump Cover
    86
  - Right Crankcase Cover, Oil Pump Shaft and Water Pump Shaft
    86
  - CDI Magneto
    89
  - Starter Motor
    89
  - Cylinder Head and Cylinder
    90
  - Piston Pin and Piston
    91
  - Crankcase
    91
  - Selector and Shift
    92
  - Crankshaft
    92
  - Bearings and Oil Seals
    93
- Inspection and Repair
  93
  - Cylinder Head
    93
  - Piston
    94
  - Cylinder
    95
  - Piston Rings
    96
  - Piston Pin and Bearing
    96
  - Autolube Pump
    97
  - Clutch
    97
  - Selector
    99
  - Crankshaft
    100
  - Bearings and Oil Seals
    101
  - Crankcase
    101
- Assembling and Adjusting the Engine
  102
  - Crankshaft
    102
  - Shift and Selector
    104
  - Crankcase
    106
  - Starter Motor
    108
  - CDI Magneto
    109
  - Right-Hand Crankcase Cover
    115
  - Water Pump Cover
    115
  - Oil Pump
    115
  - Piston Pin and Piston
    116
  - Cylinder Head and Cylinder
    117
  - Installing the Engine
    119
Cool Chapter 5 Coolant System

124
- Changing the Coolant
  125
  - Cooling System
    125
- Chapter 5
  125
- Water Pump
  127
  - Dismantling
    128
  - Inspection
    129
  - Assembly
    130
- Thermostat and Radiator
  132
  - Inspection
    133
  - Assembly
    134
Carb Chapter 6 Carburation

137
- Carburetor
  138
- Chapter 6
  139
- Dismantling
  139
- Inspection
  139
- Removal
  139
- Assembly
  140
- Installation
  140
- Reed Valve
  141
  - Removal
    141
  - Dismantling
    141
  - Inspection
    141
  - Assembly
    142
  - Installation
    143
Chapter 7 Chassis

146
- Front Wheel
  147
- Dismantling
  148
- Inspection
  148
- Assembly
  151
- Dismantling
  153
- Inspection
  153
- Assembly
  154
- Front Brake
  156
  - Changing the Brake Pads
    157
  - Dismantling the Caliper
    159
  - Dismantling the Brake Pump
    160
  - Assembly
    163
- Front Fork
  166
  - Removal
    167
  - Dismantling
    168
  - Inspection
    170
  - Assembly
    170
  - Installation
    173
- Steering Head and Handlebars
  175
  - Steering Head
    176
  - Dismantling
    177
  - Inspection
    180
  - Assembly
    180
- Rear Shock Absorber and Swinging Arm
  186
  - Observations on Handling
    187
  - Observations on Elimination
    187
  - Dismantling
    188
  - Inspection
    190
  - Dismantling
    193
  - Inspection
    194
  - Assembly
    195
Chapter 8 Electrical System

199
- Electrical Diagram
  202
- Electrical Components
  203
- Ignition and Starting System
  205
  - Circuit Diagram
    205
- Electric Starting System
  207
  - Troubleshooting
    208
- Charging System
  211
  - Troubleshooting
    213
- Lighting System
  217
  - Checking and Testing the Lighting System
    222
- Signaling System
  227
  - Troubleshooting
    229
  - Checking and Testing the Signaling System
    231
- Cooling System
  245
  - Troubleshooting
    247
  - Chassis
    248

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