check engine YAMAHA TZR50 2012 User Guide

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.
EAUS1560
0–500 km (0–300 mi)
Avoid prolonged operation above
4000 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 engi-
ne at one set throttle position.500–1000 km (300–600 mi)
Avoid prolonged operation above
6000 r/min.
Rev the engine freely through the
gears, but do not use full throttle
at any time.
NOTICE:After 1000
km (600 mi) of operation, the
transmission oil must be chan-
ged.
[ECA10370]
1000 km (600 mi) and beyond
The vehicle can now be operated
normally.
ECA10310
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
NOTICE
OPERATION AND IMPORTANT RIDING POINTS
5-3
5
1HD-F819D-E0 7/3/11 20:27 Página 36
2AS-F819D-E0.indd 3631/07/12 10:09

EAU46871
TIP
The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK,
a mileage-based maintenance, is performed instead.
From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi).
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
EAU46920
Periodic maintenance chart for the emission control system
PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
6
ODOMETER READING
CHECK OR ANNUAL
NO. ITEM MAINTENANCE JOB
1000 km 6000 km 12000 km 18000 km 24000 km CHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
1* Fuel line • Check fuel hoses for cracks
or damage. √ √√ √ √
2
Spark plug • Replace. √ √√ √ √
3* Carburetor • Check starter (choke) operation.
• Adjust engine idling speed. √√ √ √ √ √
• Check the air cut-off valve, reed
4* Air induction system valve, and hose for damage.
√ √√ √ √
• Replace any damaged parts
if necessary.
1HD-F819D-E0 7/3/11 20:27 Página 40
2AS-F819D-E0.indd 4031/07/12 10:09

EAUS2110
Panel B
T
o remove the panel
1. Turn the fuel cock lever to the offposition. (See page 3-11).
2. Remove the fuel cock lever screw, the fuel cock lever and the
panel screw, and then take the
panel off as shown.
1. Fuel cock lever
2. Screw 1. Panel B
2. Panel mounting bolt
To install the panel
1. Place the panel in the original
position by pushing it.
2. Install the fuel cock lever, the fuel cock lever screw and the panel
screw.
EAUS1580
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause
any spark plug to slowly erode, the
spark plug should be removed and
checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug1. Remove panel A. (See page 6-8).
2. Remove the spark plug cap.
1. Spark plug cap
PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
1HD-F819D-E0 7/3/11 20:27 Página 48
2AS-F819D-E0.indd 4831/07/12 10:09

3. Remove the spark plug asshown, using the spark plug
wrench, which is located in the
storage compartment. (See page
6-1).
1. Spark plug wrench
To check the spark plug1. Check that the porcelain insula- tor around the center electrode of
the spark plug is a medium-to-
light tan (the ideal color when the
vehicle is ridden normally).
TIP
If the spark plug shows a distinctly
different color, the engine could be
operating improperly. Do not attempt
to diagnose such problems yourself. Instead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for electro-
de erosion and excessive carbon
or other deposits, and replace it if
necessary.
To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if
necessary, adjust the gap to spe-
cification.
1. Spark plug gap
2. Clean the surface of the sparkplug gasket and its mating surfa-
ce, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the spark plug wrench, and then
tighten it to the specified torque.
TIP
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4–1/2 turn past finger tight. Howe-
ver, the spark plug should be tighte-
ned to the specified torque as soon
as possible.
4. Install the spark plug cap.
5. Install the panel.
Tightening torque:Spark plug: 22.5 Nm (2.2 m•kgf, 16.3 ft•lbf)
Spark plug gap:0.6–0.7 mm (0.024–0.028 in)
1
Specified spark plug:NGK / BR9 ES


PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
1HD-F819D-E0 7/3/11 20:27 Página 49
2AS-F819D-E0.indd 4931/07/12 10:09

4. Remove the oil filler cap, refillwith the specified amount of the
recommended transmission oil,
and then install and tighten the oil
filler cap. NOTICE: Make sure
that no foreign material enters
the transmission case.
[ECAM1021]
5. Start the engine and let it idle for several minutes while checking
the transmission oil case for oil
leakage. If oil is leaking, imme-
diately turn the engine off and
check for the cause.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the coo-
lant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU39087
To check the coolant level1. Place the vehicle on a level surfa- ce and hold it in an upright posi-
tion.
TIP
The coolant level must be chec-
ked on a cold engine since the
level varies with engine tempera-
ture.
Make sure that the vehicle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
2. Check the coolant level in thecoolant reservoir.
TIP
The coolant should be between the
minimum and maximum level marks.
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
3. If the coolant is at or below theminimum level mark, remove
panel A to access the coolant
reservoir. (See page 6-8).
4. Remove the coolant reservoir cap, add coolant to the maxi-
mum level mark, and then install
the reservoir cap. WARNING!
Remove only the coolant reser-
voir cap. Never attempt to
remove the radiator cap when
the engine is hot.
[EWA15161]
Recommended transmission oil: See page 8-1
Oil change quantity: 0.75 L (0.79 US qt, 0.66 Imp.qt)
Tightening torque:Transmission oil drain bolt: 17.5 Nm (1.7 m•kgf, 12.7 ft•lbf)
Oil check bolt: 6 Nm (0.6 m•kgf, 4.3 ft•lbf)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6
1HD-F819D-E0 7/3/11 20:27 Página 51
2AS-F819D-E0.indd 5131/07/12 10:09

NOTICE: If coolant is not avai-
lable, use distilled water or soft
tap water instead. Do not use
hard water or salt water since it
is harmful to the engine. If
water has been used instead of
coolant, replace it with coolant
as soon as possible, otherwise
the cooling system will not be
protected against frost and
corrosion. If water has been
added to the coolant, have a
Yamaha dealer check the anti-
freeze content of the coolant
as soon as possible, otherwise
the effectiveness of the coolant
will be reduced.
[ECA10472]
1. Coolant reservoir cap
5. Install the panel.
EAUS2070
To change the coolant 1. Place the vehicle on a level surfa- ce and let the engine cool if
necessary.
2. Remove cowlings A, B and C and panel A. (See page 6-8).
3. Place a container under the engi- ne to collect the used coolant.
4. Remove the radiator cap retai- ning bolt, radiator cap retainer
and radiator cap. WARNING!
Never attempt to remove the
radiator cap when the engine is
hot.
[EWA10381]
1. Radiator cap retaining bolt
2. Radiator cap
3. Radiator cap retainer
5. Remove the coolant drain boltand its gasket to drain the coo-
ling system.
1. Coolant drain bolt
2. Gasket
Coolant reservoir capacity (up to
the maximum level mark):0.29 L (0.31 US qt, 0.26 Imp.qt)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
6
1HD-F819D-E0 7/3/11 20:27 Página 52
2AS-F819D-E0.indd 5231/07/12 10:09

6. Remove the coolant reservoircap.
1. Coolant reservoir cap
7. Move the hose clamp in thedirection shown, and then dis-
connect the coolant reservoir
hose to drain the reservoir.
1. Hose clamp
2. Coolant reservoir hose
3. Coolant reservoir
8. After the coolant is completely
drained, thoroughly flush the
cooling system with clean tap
water.
9. Connect the coolant reservoir hose, and then move the hose
clamp back to its original posi-
tion.
10. Install the coolant drain bolt and its new gasket, and then tighten
the bolt to the specified torque.
11. Pour the recommended coolant into the reservoir to the maximum
level mark, and then install the
coolant reservoir cap.
12. Pour the recommended coolant into the radiator until it is full. 13. Install the radiator cap, start the
engine, let it idle for several minu-
tes, and then turn it off.
14. Remove the radiator cap to check the coolant level in the
radiator. If necessary, add suffi-
cient coolant until it reaches the
top of the radiator, and then ins-
tall the radiator cap, retainer and
retaining bolt.
15. Check the coolant level in the reservoir. If necessary, remove
the coolant reservoir cap, add
coolant to the maximum level
mark, and then install the cap.Antifreeze/water mixture ratio:1:1
Recommended antifreeze: High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Coolant quantity: Radiator capacity (including all
routes): 0.70 L (0.74 US qt, 0.62 Imp.qt)
Coolant reservoir capacity (up to
the maximum level mark): 0.29 L (0.31 US qt, 0.26 Imp.qt)
Tightening torque:Coolant drain bolt: 9 Nm (0.9 m•kgf, 6.5 ft•lbf)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-16
6
1HD-F819D-E0 7/3/11 20:27 Página 53
2AS-F819D-E0.indd 5331/07/12 10:09

16. Start the engine, and then checkthe vehicle for coolant leakage. If
coolant is leaking, have a Yama-
ha dealer check the cooling sys-
tem.
17. Install the cowlings and panel.EAU40371
Air filter element
The air filter element should be clea-
ned or replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart. Have a Yamaha
dealer clean or replace the air filter
element.
EAU21280
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most
carburetor adjustments should be left
to a Yamaha dealer, who has the
necessary professional knowledge
and experience. The adjustment des-
cribed in the following section, howe-
ver, may be serviced by the owner as
part of routine maintenance.
ECA10550
The carburetor has been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical know-
ledge may result in poor perfor-
mance of or damage to the engine.
NOTICE
PERIODIC MAINTENANCE AND ADJUSTMENT
6-17
6
1HD-F819D-E0 7/3/11 20:27 Página 54
2AS-F819D-E0.indd 5431/07/12 10:09

EAU33482
Adjusting the engine idling
speed
The engine idling speed must be
checked and, if necessary, adjusted
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
The engine should be warm before
making this adjustment.1. Remove panel B. (See page 6-8).
2. Check the engine idling speed and, if necessary, adjust it to spe-
cification by turning the idle
adjusting screw. To increase the
engine idling speed, turn the
screw in direction (a). To decrea-
se the engine idling speed, turn
the screw in direction (b).
1. Idle adjusting screw
TIP
If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
3. Install the panel.
EAU21374
Adjusting the throttle grip
free play
1. Throttle grip free play
The throttle grip free play should mea-
sure 4.0-6.0 mm (0.16-0.24 in) as
shown. Periodically check the throttle
grip free play and, if necessary, adjust
it as follows.
TIP
The engine idling speed must be
correctly adjusted before checking
and adjusting the throttle grip free
play.
1. Loosen the locknut.
Engine idling speed:1250–1350 r/min
PERIODIC MAINTENANCE AND ADJUSTMENT
6-18
6
1HD-F819D-E0 7/3/11 20:27 Página 55
2AS-F819D-E0.indd 5531/07/12 10:09

3. Measure the drive chain slack asshown.
4. If the drive chain slack is inco- rrect, adjust it as follows.
TIP
When checking the drive chain slack,
the chain tensioner should not be tou-
ching the drive chain.
EAU22922
To adjust the drive chain slack
Consult a Yamaha dealer before
adjusting the drive chain slack.1. Remove the cotter pin from the axle nut, and then loosen the axle
nut.
2. Loosen the chain puller locknut at each end of the swingarm.
3. To tighten the drive chain, turn the drive chain slack adjusting
nut at each end of the swingarm
in direction (a). To loosen the dri-
ve chain, turn the adjusting nut at
each end of the swingarm in direction (b), and then push the
rear wheel forward.
NOTICE:
Improper drive chain slack will
overload the engine as well as
other vital parts of the
motorcycle and can lead to
chain slippage or breakage. To
prevent this from occurring,
keep the drive chain slack wit-
hin the specified limits.
[ECA10571]
TIP
Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same
position for proper wheel alignment.
1. Drive chain slack adjusting bolt
2. Drive chain puller locknut
3. Alignment marks
4. Tighten the locknuts, and then tighten the axle nut to the speci-
fied torque.
5. Insert a new cotter pin into the axle nut, and then bend its ends
as shown. WARNING! Always
use a new cotter pin for the
axle nut.
[EWA10701]
1. Axle nut cotter pin
2. Axle nut
3. Drive chain puller locknut
4. Drive chain slack adjusting bolt
5. Alignment marks
Tightening torque:Axle nut: 90 Nm (9.0 m•kgf, 65.1 ft•lbf)
Drive chain slack:20.0–25.0 mm (0.79–0.98 in)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-26
6
1HD-F819D-E0 7/3/11 20:27 Página 63
2AS-F819D-E0.indd 6331/07/12 10:09