lights YAMAHA TZR50 2008 Owners Manual

SAFETY INFORMATION.....................1-1
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments .................2-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................3-1
Main switch/steering lock .................3-1
Indicator and warning lights .............3-1
Speedometer unit .............................3-2
Tachometer .......................................3-3
Handlebar switches ..........................3-3
Clutch lever .......................................3-4
Shift pedal.........................................3-4
Brake lever ........................................3-5
Brake pedal.......................................3-5
Fuel ...................................................3-5
Catalytic converter............................3-6
Fuel tank cap ....................................3-6
Fuel tank breather/overflow hose .....3-7
2-stroke engine oil ............................3-7
Fuel cock ..........................................3-8
Starter (choke) lever “
q” .................3-8
Seat...................................................3-9
Anti-theft device housing..................3-9
Rear view mirrors ..............................3-9
Sidestand ........................................3-10
Ignition circuit cut-off system .........3-10PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2
OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Starting a warm engine ....................5-2
Shifting ..............................................5-2
Tips for reducing fuel consumption..5-3
Engine break-in.................................5-3
Parking ..............................................5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR...................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and
lubrication chart ............................6-2
Removing and installing cowlings
and panels .....................................6-5
Checking the spark plug ..................6-7
Transmission oil ................................6-8
Coolant .............................................6-9
Air filter element ..............................6-12
Adjusting the carburetor .................6-12
Adjusting the throttle cable free
play ..............................................6-12
Adjusting the engine idling speed ..6-13
Tires ................................................6-14
Cast wheels ....................................6-16
Adjusting the clutch lever free
play ..............................................6-16Checking the front brake lever free
play ..............................................6-17
Adjusting the brake pedal free
play ..............................................6-17
Adjusting the shift pedal position ...6-18
Adjusting the rear brake light
switch ..........................................6-18
Checking the front and rear brake
pads.............................................6-18
Checking the brake fluid level ........6-19
Changing the brake fluid ................6-20
Drive chain slack.............................6-21
Cleaning and lubricating the drive
chain ............................................6-22
Checking and lubricating the
cables ..........................................6-23
Checking and lubricating the
throttle grip and cable .................6-23
Adjusting the Autolube pump .........6-24
Checking and lubricating the brake
and shift pedals ...........................6-24
Checking and lubricating the brake
and clutch levers .........................6-24
Checking and lubricating the
sidestand .....................................6-25
Checking the front fork ...................6-25
Checking the steering.....................6-26
Checking the wheel bearings .........6-26
Battery ............................................6-27
Replacing the fuse ..........................6-28
Replacing the headlight bulb..........6-28
TABLE OF CONTENTS
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senger, accessories and cargo must
not exceed the maximum load limit.
When loading within this weight limit,
keep the following in mind:
Cargo and accessory weight
should be kept as low and close
to the motorcycle as possible.
Make sure to distribute the
weight as evenly as possible on
both sides of the motorcycle to
minimize imbalance or instability.
Shifting weights can create a
sudden imbalance. Make sure
that accessories and cargo are
securely attached to the
motorcycle before riding. Check
accessory mounts and cargo res-
traints frequently.
Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items,
including such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or slow
steering response.Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha can-
not test all other accessories that may
be available, you must personally be
responsible for the proper selection,
installation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any
accessories.
Keep the following guidelines in mind,
as well as those provided under “Loa-
ding” when mounting accessories.
Never install accessories or carry
cargo that would impair the per-
formance of your motorcycle.
Carefully inspect the accessory
before using it to make sure that
it does not in any way reduce
ground clearance or cornering
clearance, limit suspension tra-
vel, steering travel or control ope-
ration, or obscure lights or reflec-
tors.
• Accessories fitted to the hand-
lebar or the front fork area can
create instability due to impro-
per weight distribution oraerodynamic changes. If
accessories are added to the
handlebar or front fork area,
they must be as lightweight as
possible and should be kept to
a minimum.
• Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may
attempt to lift the motorcycle,
or the motorcycle may become
unstable in cross winds. These
accessories may also cause
instability when passing or
being passed by large vehicles.
• Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the fre-
edom of movement of the ope-
rator and may limit control abi-
lity, therefore, such
accessories are not recom-
mended.
Use caution when adding electri-
cal accessories. If electrical
accessories exceed the capacity
of the motorcycle’s electrical sys-
Maximum load:
196 kg (432.18 lb)1
tSAFETY INFORMATION
1-3
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tem, an electric failure could
result, which could cause a dan-
gerous loss of lights or engine
power.
Gasoline and exhaust gas
GASOLINE IS HIGHLY FLAMMA-
BLE:
• Always turn the engine off
when refueling.
• Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.
• Never refuel while smoking or
in the vicinity of an open flame.
Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within
a short time. Always operate your
motorcycle in an area that has
adequate ventilation.
Always turn the engine off before
leaving the motorcycle unatten-
ded and remove the key from the
main switch. When parking the
motorcycle, note the following:
• The engine and exhaust sys-
tem may be hot, therefore,park the motorcycle in a place
where pedestrians or children
are not likely to touch these hot
areas.
• Do not park the motorcycle on
a slope or soft ground, other-
wise it may fall over.
• Do not park the motorcycle
near a flammable source (e.g. a
kerosene heater, or near an
open flame), otherwise it could
catch fire.
When transporting the motorcy-
cle in another vehicle, make sure
that it is kept upright and that the
fuel cock is turned to “ON” or
“RES” (for vacuum type) / “OFF”
(for manual type). If it should lean
over, gasoline may leak out of the
carburetor or fuel tank.
If you should swallow any gasoli-
ne, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immedia-
tely. If any gasoline spills on your
skin or clothing, immediately
wash the affected area with soap
and water and change your clot-
hes.
1
SAFETY INFORMATION t
1-4
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EAU10460
Main switch/steering lock
The main switch/steering lock con-
trols the ignition and lighting systems,
and is used to lock the steering. The
various positions are described
below.
EAU10640
f
All electrical circuits are supplied with
power, and the engine can be started.
The key cannot be removed.
NOTE:
The headlight, meter lighting and tai-
llight come on automatically when the
engine is started.
EAU10660
e
All electrical systems are off. The key
can be removed.
EAU10680
m
The steering is locked, and all electri-
cal systems are off. The key can be
removed.
T
o lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “
e”
position, and then turn it to “
m”
while still pushing it.
3. Remove the key.
T
o unlock the steering
Push the key in, and then turn it to
“
e” while still pushing it.EWA10060
s s
WARNING
Never turn the key to “
e” or “m”
while the vehicle is moving, other-
wise the electrical systems will be
switched off, which may result in
loss of control or an accident.
Make sure that the vehicle is stop-
ped before turning the key to “
e”
or “
m”.
EAU11003
Indicator and warning lights
1. Coolant temperature warning light “y”
2. Oil level warning light “z”
3. Neutral indicator light “N”
4. Engine trouble warning light “ ”
5. Turn signal indicator light “
b”
EAU11020
Turn signal indicator light “cd”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
EAU11060
Neutral indicator light “N”
This indicator light comes on when
the transmission is in the neutral posi-
tion.
3
INSTRUMENT AND CONTROL FUNCTIONS
3-1
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EAU11851
Tachometer
1. Tachometer
The electric tachometer allows the
rider to monitor the engine speed and
keep it within the ideal power range.
ECA10031
CAUTION:
Do not operate the engine in the
tachometer red zone.
Red zone: 10.000 r/min and above
EAU12345
Handlebar switches
1. Pass switch “j”
2. Dimmer switch “j/k”
3. Turn signal switch “c/d”
4. Horn switch“a”
1. Engine stop switch “
f/e”
2. Start switch “f”
EAU12380
Pass switch “j”
Press this switch to flash the head-
lights.
EAU12400
Dimmer switch “j/k”
Set this switch to “
j” for the high
beam and to “
k” for the low beam.
EAU12460
Turn signal switch “c/d”
To signal a right-hand turn, push this
switch to “
d”. To signal a left-hand
turn, push this switch to “
c”. When
released, the switch returns to the
center position. To cancel the turn
signal lights, push the switch in after it
has returned to the center position.
EAU12500
Horn switch “a”
Press this switch to sound the horn.
EAU12660
Engine stop switch “f/e”
Set this switch to “
f” before starting
the engine. Set this switch to “
e” to
stop the engine in case of an emer-
gency, such as when the motorcycle
overturns or when the throttle cable is
stuck.
1
2
j
k
1
2
43
3
INSTRUMENT AND CONTROL FUNCTIONS
3-3
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ITEM CHECKS PAGE
Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-23
• Check chain slack.
Drive chain• Adjust if necessary.
6-21, 6-22
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
Wheels and tires• Check tire condition and tread depth.
6-14, 6-16
• Check air pressure.
• Correct if necessary.
Brake and shift pedals• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.3-4, 3-5, 6-24
Brake and clutch levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.3-4, 3-5, 6-24
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.3-10, 6-25
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.—
Instruments, lights, signals • Check operation.
and switches• Correct if necessary.—
Engine stop switch• Check operation.3-3
Sidestand switch• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.3-10
4
PRE-OPERATION CHECKS
4-3
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EAU15950
EWA10270
s s
WARNING
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or func-
tion that you do not thoroughly
understand.
Never start the engine or ope-
rate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of cons-
ciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised comple-
tely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU16050
Starting a cold engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EWA10290
s s
WARNING
Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-11.
Never ride with the sidestand
down.
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “
f” and make
sure that the engine stop switch
is set to “
f”.
3. Shift the transmission into the
neutral position.
NOTE:
When the transmission is in the neu-
tral position, the neutral indicator lightshould be on, otherwise have a
Yamaha dealer check the electrical
circuit.
4. Turn the starter (choke) on and
completely close the throttle.
(See page 3-8.)
5. Start the engine by pushing the
start switch.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the
engine more than 10 seconds on any
one attempt.
ECA11410
CAUTION:
The 2-stroke engine oil level war-
ning light should come on when the
start switch is pushed, and it
should go off when the start switch
is released. If the warning light flic-
kers or remains on after starting,
immediately stop the engine, and
then check the 2-stroke engine oil
level and the vehicle for oil leakage.
5
OPERATION AND IMPORTANT RIDING POINTS
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ECA10260
CAUTION:
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long
distances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
Always use the clutch while
changing gears to avoid dama-
ging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU16800
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the follo-
wing tips to reduce fuel consumption:
Turn the starter (choke) off as
soon as possible.
Shift up swiftly, and avoid high
engine speeds during accelera-
tion.
Do not rev the engine while shif-
ting down, and avoid high engine
speeds with no load on the engi-
ne.
Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at
traffic lights or at railroad cros-
sings).
EAU16830
Engine break-in
There is never a more important
period in the life of your engine than
the period between 0 and 1000 km
(600 mi). For this reason, you should
read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1000 km (600 mi). The various parts in
the engine wear and polish themsel-
ves to the correct operating clearan-
ces. During this period, prolonged
full-throttle operation or any condition
that might result in engine overhea-
ting must be avoided.
EAU17130
0~500 km (0~300 mi)
Avoid prolonged operation above
4.000 r/min.
After every hour of operation, stop the
engine, and then let it cool for five to
ten minutes.
Vary the engine speed from time to
time. Do not operate the engine at
one set throttle position.
5
OPERATION AND IMPORTANT RIDING POINTS
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ODOMETER READING (x 1000 Km)
ANNUAL
NO ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24CHECK
21Transmission oil• Check oil level.√√ √ √√ √
• Change.√√
22 *Front and rear brake
switches• Check operation.√√ √ √√ √
23Moving parts and cables• Lubricate.√√√√ √
Throttle grip housing• Check operation and free play.
24 * • Adjust the throttle cable free play if necessary.√√√√ √
and cable
• Lubricate the throttle grip housing and cable.
25 *Lights, signals and • Check operation.
switches• Adjust headlight beam.√√ √ √√ √
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
EAUM1890
NOTE:
Replace the air filter element more frequently if you are riding in unusually wet or dusty areas.
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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EAU26001
Care
While the open design of a motorcy-
cle reveals the attractiveness of the
technology, it also makes it more vul-
nerable. Rust and corrosion can
develop even if high-quality compo-
nents are used. A rusty exhaust pipe
may go unnoticed on a car, however,
it detracts from the overall appearan-
ce of a motorcycle. Frequent and pro-
per care does not only comply with
the terms of the warranty, but it will
also keep your motorcycle looking
good, extend its life and optimize its
performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and
covers as well as all electrical
couplers and connectors, inclu-
ding the spark plug cap, are
tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such pro-ducts onto seals, gaskets, sproc-
kets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.
Cleaning
ECA10770
CAUTION:
Avoid using strong acidic whe-
el cleaners, especially on spo-
ked wheels. If such products
are used on hard-to-remove
dirt, do not leave the cleaner on
the affected area any longer
than instructed. Also, tho-
roughly rinse the area off with
water, immediately dry it, and
then apply a corrosion protec-
tion spray.
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or spon-
ge with mild detergent and
water to clean plastic.
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasivecleaning products, solvent or
thinner, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
Do not use high-pressure was-
hers or steam-jet cleaners sin-
ce they cause water seepage
and deterioration in the follo-
wing areas: seals (of wheel and
swingarm bearings, fork and
brakes), electric components
(couplers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or scrat-
ching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not lea-
ve any marks. If the windshield
is scratched, use a quality
plastic polishing compound
after washing.
7
MOTORCYCLE CARE AND STORAGE
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