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Yamaha · European two-stroke single (DKW, Jawa, CZ, MZ, Puch, Bultaco, Montesa, Ossa)

TZR 50

Library entry covers 2003-2016

36 factory 41 guideline

Published source

Yamaha TZR50 2010 Owner's Manual 5WX-F8199-E3 (UK, English), periodic maintenance chart for the emission control system p.6-3 and general maintenance and lubrication chart pp.6-4 to 6-7

Factory owner's handbook. Covers TZR50 2010 UK owner's manual 5WX-F8199-E3, English. Chart columns 1000/6000/12000/18000/24000 km (600/3500/7000/10500/14000 mi) plus annual check; from 30000 km (17500 mi) repeat the intervals starting from 6000 km (3500 mi); annual checks every year unless a kilometer-based (UK: mileage-based) maintenance is performed instead. Two-stroke with Autolube oil injection and chain final drive: no engine oil, oil filter or valve rows.

Open the source

77 items for a 2007 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Two-stroke
Engine lubrication: Two-stroke premix (oil in fuel)
Oil filtration: None (no filter)
Valve gear: None (two-stroke porting)
Ignition: Magneto (incl. magdyno, flywheel magneto)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Drum (or band / stirrup)
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

2007 Yamaha TZR 50

On the road: every 150 mi

1 item

Check two-stroke oil tank / carry premix oil

Pre-ride / on the road

Guideline

Running a two-stroke out of oil seizes it. Injection bikes: check the tank. Premix: carry oil and a measure.

On the road: every 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 300 mi

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Factory

Manual: Drive chain (check chain slack, alignment and condition; adjust and lubricate chain with a special O-ring chain lubricant thoroughly). Factory: Every 500 km (300 mi) and after washing the motorcycle or riding in the rain, printed as text (p.6-5)

Every 1,000 mi or 6 months

2 items

Adjust front drum brake

Brakes

Guideline
Adjust rear drum brake and rod / cable linkage

Brakes

Guideline

Every 2,000 mi or 12 months

1 item

Replace spark plugs (two-stroke)

Engine

Guideline

Every 3,000 mi or 12 months

7 items

Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Check / set ignition timing

Ignition and electrics

Guideline
Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Guideline
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline

Every 3,000 mi or 2 years

1 item

Decarbonize exhaust ports, pipes and baffles

Engine

Guideline

Two-strokes coke up the exhaust port and muffler baffles; power falls off gradually.

Every 3,500 mi or 12 months

18 items

Air induction system (check air cut-off valve, reed valve and hose for damage, replace damaged parts if necessary)

Engine

Factory

Factory: Emission control chart. Marked 6000-24000 km; not at 1000 km; annual check; dealer item (p.6-3)
Chassis fasteners (make sure all nuts, bolts and screws are properly tightened)

Engine

Factory

Factory: Marked 6000-24000 km; annual check; dealer item (p.6-5)
Lights, signals and switches (check operation, adjust headlight beam)

Engine

Factory

Factory: Every column incl. 1000 km initial; annual check; dealer item (p.6-6)
Replace spark plugs

Engine

Factory

Manual: Spark plug (replace). Factory: Emission control chart. Replace marked at 6000, 12000, 18000, 24000 km (3500-14000 mi); not at 1000 km; annual check marked; no separate inspect row (p.6-3)
Shift pedal pivot shaft (lubricate with lithium-soap-based grease)

Engine

Factory

Factory: Marked 6000-24000 km; annual check (p.6-5)
Carburetor (check starter (choke) operation, adjust engine idling speed)

Fuel and air

Factory

Factory: Emission control chart. Every column incl. 1000 km (600 mi) initial; annual check; dealer item (p.6-3)
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle grip housing and cable (check operation and free play, adjust throttle cable free play if necessary, lubricate grip housing and cable). Factory: Marked 6000-24000 km; annual check; dealer item (p.6-6)
Replace fuel lines

Fuel and air

Factory

Manual: Fuel line (check fuel hoses for cracks or damage). Factory: Emission control chart. Marked 6000-24000 km (3500-14000 mi); not at 1000 km; annual check; dealer item (p.6-3)
Clutch lever pivot shaft (lubricate with lithium-soap-based grease)

Primary and gearbox

Factory

Factory: Marked 6000-24000 km; annual check (p.6-5)
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Sidestand (check operation, lubricate). Factory: Marked 6000-24000 km; annual check (p.6-5)
Sidestand switch (check operation)

Rear suspension and frame

Factory

Factory: Every column incl. 1000 km initial; annual check; dealer item (p.6-5)
Brake lever pivot shaft (lubricate with silicone grease)

Brakes

Factory

Factory: Marked 6000-24000 km; annual check (p.6-5)
Brake pedal pivot shaft (lubricate with lithium-soap-based grease)

Brakes

Factory

Factory: Marked 6000-24000 km; annual check (p.6-5)
Check brake pads and discs

Brakes

Factory

Manual: Front brake (check operation, fluid level and vehicle for fluid leakage; replace brake pads whenever worn to the limit). Factory: Hydraulic disc. Check every column incl. 1000 km initial; annual check; pads replaced whenever worn to the limit; dealer item (p.6-4)
Front and rear brake switches (check operation)

Brakes

Factory

Factory: Every column incl. 1000 km initial; annual check; dealer item (p.6-6)
Rear brake (check operation, fluid level and vehicle for fluid leakage; replace brake pads whenever worn to the limit)

Brakes

Factory

Factory: Hydraulic disc. Check every column incl. 1000 km initial; annual check; pads replaced whenever worn to the limit; dealer item (p.6-4)
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tires (check tread depth and for damage, replace if necessary, check and correct air pressure). Factory: Marked 6000-24000 km; annual check; dealer item (p.6-4)
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Moving parts and cables (lubricate). Factory: Marked 6000-24000 km; annual check (p.6-6)

Every 3,500 mi

7 items

Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch (check operation, adjust). Factory: Every column incl. 1000 km (600 mi) initial; no annual check (p.6-4)
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings (check bearing play and steering for roughness). Factory: Every column incl. 1000 km (600 mi) initial; no annual check; dealer item (p.6-5)
Front fork (check operation and for oil leakage)

Front end

Factory

Factory: Marked 6000-24000 km; no annual check; no fork oil change interval printed; dealer item (p.6-6)
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Rear suspension relay arm and connecting arm pivoting points (check operation). Factory: Marked 6000-24000 km; no annual check; dealer item. No separate rear shock absorber row in this chart (p.6-6)
Swingarm (check operation and for excessive play)

Rear suspension and frame

Factory

Factory: Marked 6000-24000 km; no annual check; dealer item (p.6-5)
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings (check bearing for looseness or damage). Factory: Marked 6000-24000 km; no annual check; dealer item (p.6-4)
Wheels (check runout and for damage)

Wheels and tires

Factory

Factory: Marked 6000-24000 km; no annual check; dealer item (p.6-4)

Every 4,000 mi or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 6,000 mi or 12 months

5 items

Inspect coolant hoses and clamps

Engine

Guideline
Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,000 mi or 2 years

2 items

Lubricate and check automatic advance unit

Ignition and electrics

Guideline
Magneto: clean slip ring and pickup brush, check HT lead

Ignition and electrics

Guideline

Every 7,000 mi or 12 months

1 item

Autolube pump (check operation, bleed if necessary)

Engine

Factory

Factory: Two-stroke oil injection pump. Marked at 1000, 12000 and 24000 km (not 6000 or 18000 km); annual check; dealer item (p.6-6)

Every 7,000 mi

4 items

Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter element (clean). Factory: Clean marked at 6000 and 18000 km (3500/10500 mi) only, alternating with replace; with the repeat-from-6000 km rule this is every 12000 km offset by 6000 km; no annual check; dealer item. TIP: more frequent service in unusually wet or dusty areas (pp.6-4, 6-7)
Replace air filter element

Fuel and air

Factory

Manual: Air filter element (replace). Factory: Replace marked at 12000 and 24000 km (7000/14000 mi); no annual check; dealer item; more frequent service in wet or dusty areas (pp.6-4, 6-7)
Change gearbox oil

Primary and gearbox

Factory

Manual: Transmission oil (change). Factory: Gearbox oil of this two-stroke (engine is lubricated by Autolube injection; there is no engine oil row). Change marked at 1000 km (600 mi) initial, 12000 and 24000 km (7000/14000 mi); no annual check on the change row. Check oil level marked every column incl. 1000 km and annually (p.6-6)
Clean and grease rear suspension linkage

Rear suspension and frame

Factory

Manual: Rear suspension relay arm and connecting arm pivoting points (lubricate with lithium-soap-based grease). Factory: Marked at 12000 and 24000 km (7000/14000 mi); no annual check; dealer item (p.6-6)

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,000 mi or 3 years

1 item

Replace points and condenser

Ignition and electrics

Guideline

Every 14,000 mi

1 item

Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Swingarm (lubricate with lithium-soap-based grease). Factory: Every 24000 km (14000 mi), printed as text; dealer item (p.6-5)

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 25,000 mi or 10 years

1 item

Magneto overhaul / re-magnetize, replace capacitor

Ignition and electrics

Guideline

Weak spark when hot is the classic symptom. Old capacitors fail with age, not miles.

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 30,000 mi

1 item

Repack / replace steering head bearings

Front end

Factory

Manual: Steering bearings (lubricate with lithium-soap-based grease). Factory: Every 50000 km (30000 mi), printed as text; dealer item (p.6-5)

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

5 items

Replace coolant

Engine

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Brake master cylinder and caliper internal components (replace)

Brakes

Factory

Factory: From the TIP under the chart: every two years replace the internal components of the brake master cylinders and calipers; not a chart row (p.6-7)
Replace brake fluid

Brakes

Factory

Manual: Brake fluid (change). Factory: From the hydraulic brake service TIP under the chart: every two years change the brake fluid; regularly check and correct fluid level; not a chart row (p.6-7)

Every 4 years

1 item

Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hoses (replace). Factory: Every 4 years (TIP also: and if cracked or damaged); check for cracks or damage marked 6000-24000 km and annually; dealer item (pp.6-4, 6-7)

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.