Yamaha TZR50 '03, Service Manual

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INSP
ADJ
INTRODUCTION/REGULAR MAINTENANCE/
LUBRICATION
3-1
REGULAR INSPECTION AND ADJUSTMENT
INTRODUCTION
This chapter contains all the information required to carry out the recommended services and
adjustments. By following these preventive maintenance procedures you will ensure greater opera-
ting reliability for the vehicle and a longer useful life, considerably reducing the need for costly
repairs. This information is applicable to both vehicles already in service and ones that are being
prepared for sale. All service technicians should be completely familiar with this chapter.
KILOMETRE CLOCK READING
( x 1.000 km) ANNUAL
No ITEM CHECK OR MAINTENANCE OPERATION 1 6 12 18 24 CHECK
1 * Petrol line • Check to see if the petrol hose is cracked or damaged
√ √ √ √ √
2 Spark plug • Check its condition
• Clean and adjust space between electrodes
√ √
• Change
√ √
3 Air filter *Clean
√ √
• Change
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4 Clutch • Check operation
• Adjust
√ √ √ √ √
5 Front brake • Check operation, liquid level and to see if there are leaks on the vehicle
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• Check the brake pads Whenever these have reached the wear limit
6 Rear brake • Check operation, liquid level and to see if there are leaks on the vehicle
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• Check the brake pads Whenever these have reached the wear limit
7 Brake tubes *Check to see if these are cracked or damaged
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• Change Every 4 years
8 Wheels • Check eccentricity and whether these are damaged
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9 Tyres • Check the depth of the tread pattern and whether they are damaged
• Change if necessary
• Check the air pressure
• Correct if necessary
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10 Wheel bearings • Check to see if the bearings are weak or damaged
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11 Swinging arm • Check operation and to see if play is excessive
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• Lubricate with molybdenum bisulphide grease Every 24,000 km
12 Transmission chain • Check the chain tension
• Check that the rear wheel is properly aligned
Every 500 km and after washing
• Clean and grease the motorcycle or using in rain
13 Steering bearings • Check the bearing play and to see if the steering is stiff
√ √ √ √ √
• Lubricate with lithium soap-based grease Every 24,000 km
14 Chassis fixings • Check that all the nuts, bolts and screws are properly tightened
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15 Side stand • Check operation
• Grease
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16 Stand switch • Check operation
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17 Front fork • Check operation and whether oil is leaking
√ √ √ √
18 Shock absorber assembly • Check operation and to see if the shock absorber is leaking oil
√ √ √ √
19 Carburettor • Check the choke operation
• Adjust the engine idling speed
√ √ √ √ √ √
20 Autolube pump • Check operation
• Bleed if necessary
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21 Transmission oil • Check the oil level
√ √ √ √ √ √
• Change
√ √ √
22 Cooling system • Check the coolant level and to see if there are leaks from the vehicle
√ √ √ √ √
• Change Every 3 years
23 Brake switches • Check operation
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24 Moving parts and cables • Grease
√ √ √ √ √
25 Throttle twist grip box • Check operation and play
• Adjust the throttle cable play and to see if this is precise
• Grease the throttle twist grip box and cable
√ √ √ √ √
26 Lights, signals and switches • Check operation
• Adjust the headlight beam
√ √ √ √ √ √
* We recommend these articles being serviced by an authorised Yamaha/MBK distributor.
** Apply medium weight bearing oil
NOTE:
• The air filter requires more frequent servicing when the vehicle is used in particularly wet or dusty areas.
• Hydraulic brake servicing
•• Regularly check the brake liquid level and correct this as necessary
•• Every two years change the internal components of the brake pump and calliper, as well as the brake liquid
•• Change the brake tubes every four years and whenever these are cracked or damaged.