check engine YAMAHA TZR50 2012 Owners Manual

SAFETY INFORMATION .....................1-1
DESCRIPTION.....................................2-1Left view ...........................................3-1
Right view .........................................3-1
Controls and instruments .................3-1
INSTRUMENT AND CONTROL
FUNCTIONS ........................................3-1 Main switch/steering lock .................3-1
Indicator and warning lights .............3-2
Turn signal indicator light ................3-2
Neutral indicator light ......................3-2
Oil level warning light ......................3-2
Coolant temperature warning light ...............................................3-3
Engine trouble warning light ............3-3
Speedometer unit .............................3-3
Tachometer .......................................3-4
Handlebar switches ..........................3-4
Pass switch ......................................3-5
Dimmer switch .................................3-5
Turn signal switch ............................3-5
Horn switch .....................................3-5
Engine stop switch ..........................3-5
Start switch ......................................3-5
Clutch lever .......................................3-5
Shift pedal.........................................3-6
Brake lever ........................................3-6
Brake pedal.......................................3-6
Fuel tank cap ....................................3-7 Fuel ...................................................3-8
Fuel tank breather/overflow hose .....3-9
Catalytic converter............................3-9
2-stroke engine oil ..........................3-10
Fuel cock ........................................3-11
Starter (choke) lever ......................3-12
Seat.................................................3-12
Anti-theft device housing................3-13
Rear view mirrors ............................3-13
Sidestand ........................................3-14
Ignition circuit cut-off system .........3-14
FOR YOUR SAFETY –
PRE-OPERATION CHECKS ...............4-1
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
ADJUSTMENT ....................................6-1 Owner’s tool kit .................................6-1
Periodic maintenance chart for the emission control system .........6-3 General maintenance and
lubrication chart ............................6-4
Removing and installing cowlings and panels .....................................6-8
Checking the spark plug ................6-11
Transmission oil ..............................6-13
Coolant ...........................................6-14
Air filter element ..............................6-17
Adjusting the carburetor .................6-17
Adjusting the engine idling speed..........................................6-18
Adjusting the throttle grip free play .......................................6-18
Tires ................................................6-19
Cast wheels ....................................6-21
Adjusting the clutch lever free play .......................................6-21
Checking the front brake lever free play .......................................6-22
Adjusting the brake pedal free play .......................................6-22
Adjusting the shift pedal position ...6-22
Brake light switches .......................6-23
Checking the front and rear brake pads ..................................6-23
Checking the brake fluid level ........6-24
Changing the brake fluid ................6-25
Drive chain slack.............................6-25
Cleaning and lubricating the drive chain ............................................6-27
TABLE OF CONTENTS
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de can rapidly reach dangerous
levels.
Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
Do not run engine outdoors whe-
re engine exhaust can be drawn
into a building through openings
such as windows and doors.
Loading
Adding accessories or cargo to your
motorcycle can adversely affect sta-
bility and handling if the weight distri-
bution of the motorcycle is changed.
To avoid the possibility of an acci-
dent, use extreme caution when
adding cargo or accessories to your
motorcycle. Use extra care when
riding a motorcycle that has added
cargo or accessories. Here, along
with the information about accesso-
ries below, are some general guideli-
nes to follow if loading cargo to your
motorcycle:
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit. Operation of an overloaded vehicle
could cause an accident.
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.
Securely pack your heaviest
items as close to the center of
the vehicle as possible and 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.
• Properly adjust the suspension for your load (suspension-
adjustable models only), and check the condition and pres-
sure of your tires.
• Never attach any large or heavy items to the handlebar,
front fork, or front fender. The-
se items, including such cargo
as sleeping bags, duffel bags,
or tents, can create unstable
handling or a slow steering res-
ponse.
This vehicle is not designed to
pull a trailer or to be attached
to a sidecar.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avai-
lable only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection
to Yamaha manufacture parts and
accessories or offer other modifica-
tions for Yamaha vehicles. Yamaha is
not in a position to test the products
that these aftermarket companies
produce. Therefore, Yamaha can neit-
her endorse nor recommend the use
Maximum load: 196 kg (432 lb)1
SAFETY INFORMATION
1-3
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To unlock the steering
1. Push
2. Turn
Push the key in, and then turn it to
“ ” while still pushing it.
EAU11004
Indicator and warning lights
1. Coolant temperature warning light “ ”
2. Oil level warning light “ ”
3. Turn signal indicator light “ ”
4. Neutral indicator light “ ”
5. Engine trouble warning light “ ”
EAU11020
Turn signal indicator light “ ”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
EAU11060
Neutral indicator light “ ”
This indicator light comes on when
the transmission is in the neutral posi-
tion.
EAUM1062
Oil level warning light “ ”
This warning light comes on when the
key is in the “ ” position or if the oil
level in the 2-stroke engine oil tank is
low during operation. If the warning
light comes on during operation, stop
immediately and fill the oil tank with
2-stroke engine oil of either JASO
grade “FC” or ISO grades “EG-C” or
“EG-D”. The warning light should go
off after the 2-stroke engine oil tank
has been refilled.
TIP
If the warning light does not come on
when the key is in the “ ” position or
does not go off after the 2-stroke
engine oil tank has been refilled, have
an Yamaha dealer check the electrical
circuit.
ECA16291
Do not operate the vehicle until you
know that the engine oil level is suf-
ficient.
NOTICE
INSTRUMENT AND CONTROL FUNCTIONS
3-2
3
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EAU11446
Coolant temperature warning light
“”
This warning light comes on if the
engine overheats. If this occurs, stop
the engine immediately and allow the
engine to cool.
The electrical circuit of the warning
light can be checked by turning the
key to “ ”. The warning light should
come on for a few seconds, and then
go off.
If the warning light does not come
on initially when the key is turned to
“ ”, or if the warning light remains
on, have a Yamaha dealer check the
electrical circuit.
ECA10021
Do not continue to operate the
engine if it is overheating.
TIP
For radiator-fan-equipped vehi-
cles, the radiator fan(s) automati-
cally switch on or off according to
the coolant temperature in the
radiator.
If the engine overheats, see page
6-39 for further instructions.
EAUS1540
Engine trouble warning light “ ”
This warning light flashes if a problem
is detected in the electrical circuit
monitoring the engine. If this occurs,
have a Yamaha dealer check the self-
diagnosis system.
The electrical circuit of the warning
light can be checked by turning the
key to “ ”. If the warning light does
not come on for a few seconds, then
go off, have a Yamaha dealer check
the electrical circuit.
EAU11621
Speedometer unit
1. Speedometer
2. Odometer
UK ONLY
1. Speedometer
2. Odometer
NOTICE
INSTRUMENT AND CONTROL FUNCTIONS
3-3
3
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EAUB1300
Fuel tank breather/overflow
hose
1. Fuel tank breather hose and overflow hose
Before operating the motorcycle:
Check the fuel tank breather/
overflow hose connection.
Check the fuel tank
breather/overflow hose for
cracks or damage, and replace it
if damaged.
Make sure that the end of the fuel
tank breather/overflow hose is
not blocked, and clean it if
necessary.
Make sure that the end of the fuel
tank breather/overflow hose is
positioned inside of the clamp.
EAU13433
Catalytic converter
This model is equipped with a cataly-
tic converter in the exhaust system.
EWA10862
The exhaust system is hot after
operation. To prevent a fire hazard
or burns:
Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
Make sure that the exhaust
system has cooled down befo-
re doing any maintenance
work.
Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
ECA10701
Use only unleaded gasoline. The
use of leaded gasoline will cause
unrepairable damage to the cataly-
tic converter.
NOTICE
WARNING
INSTRUMENT AND CONTROL FUNCTIONS
3-9
3
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EAU15305
Sidestand
1. Sidestand
The sidestand is located on the left
side of the frame. Raise the sidestand
or lower it with your foot while holding
the vehicle upright.
TIP
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain
situations. (See the following section
for an explanation of the ignition cir-
cuit cut-off system.)
EWA10241
The vehicle must not be ridden with
the sidestand down, or if the sides-
tand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control. Yama-
ha’s ignition circuit cut-off system
has been designed to assist the
operator in fulfilling the responsibi-
lity of raising the sidestand before
starting off. Therefore, check this
system regularly and have a Yama-
ha dealer repair it if it does not
function properly.
EAU15314
Ignition circuit cut-off
system
The ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch
lever is not pulled.
It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the
sidestand is still down.
It cuts the running engine when
the transmission is in gear and
the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
TIP
This check is most reliable if perfor-
med with a warmed-up engine.
WARNING
INSTRUMENT AND CONTROL FUNCTIONS
3-14
3
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With the engine tu\srned off:
1. Move the sidest\fnd down.
2. M\fke sure th\ft the eng\sine sto\b switch is set to “
3. Turn the key “ ”.
4. Shift the tr\fnsmission into the \sneutr\fl \bosition.
5. Push the st\frt switch.
Does the engine start?
With the engine sti\sll running:
6. Move the sidest\fnd u\b.
7. Kee\b the clutch lever \bulled.
8. Shift the tr\fnsmission into ge\fr.
9. Move the sidest\fnd down.
Does the engine stall?
After the engine h\s\fs st\flled:
10. Move the sidest\fnd u\b.
11. Kee\b the clutch lever \bulled.
12. Push the st\frt switch.
Does the engine start?
The system is OK. The motorcycle can be ridden. The neutr\fl switch m\fy not be working correctly.
The motorcycle should not be ridden
until
checked by \f Y\fm\fh\f de\fler.
The sidest\fnd switch m\fy not be working correctly.
The motorcycle should not be ridden until
checked by \f Y\fm\fh\f de\fler.
The clutch switch m\fy not be working correctly.
The motorcycle should not be ridden until
checked by \f Y\fm\fh\f de\fler.
YES NO YES NO YES NO
If a malfunction is noted, have a Yamaha
dealer check the system before riding.
WARNING
”.
INSTRUMENT AND CONTROL FUNCTIONS
3-15
3
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the ins-
pection and maintenance procedures and schedules described in the Owner’s Manual.
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment dama-
ge. Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures pro-
vided in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
WARNING
ITEMCHECKS PAGE
• Check fuel level in fuel tank.
Fuel • Refuel if necessary. 3-8
• Check fuel line for leakage.
• Check oil level in oil tank.
2-stroke engine oil • If necessary, add recommended oil to specified level. 3-10
• Check vehicle for oil leakage.
Transmission oil • Check oil level in transmission case.
• If necessary, add recommended oil to specified level. 6-13
• Check coolant level in reservoir.
Coolant • If necessary, add recommended coolant to specified level. 6-14
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Front brake • Replace if necessary. 6-23, 6-24
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
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ITEMCHECKS PAGE
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. 3-4
Sidestand switch • Check operation of ignition circuit cut-off system.
• If system is not working correctly, have Yamaha dealer check vehicle. 3-14
FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-3
4
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EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do
not understand, ask your Yamaha
dealer.
EWA10271
Failure to familiarize yourself with
the controls can lead to loss of
control, which could cause an acci-
dent or injury.
EAU16055
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.
See page 3-14 for more information. 1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ ” and make sure that the engine stop switch
is set to “ ”.
3. Shift the transmission into the neutral position. The neutral indi-
cator light should come on. If not,
ask a Yamaha dealer to check the
electrical circuit.
4. Turn the starter (choke) on and completely close the throttle.
(See page 3-12).
5. Start the engine by pushing the start switch.
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 preserve
the battery. Do not crank the
engine more than 10 seconds on
any one attempt.
6. After starting the engine, move the starter (choke) back halfway.
7. When the engine is warm, turn the starter (choke) off.
TIP
The engine is warm when it responds
quickly to the throttle with the starter
(choke) turned off.
ECA11042
For maximum engine life, never
accelerate hard when the engine is
cold!
NOTICE
WARNING
OPERATION AND IMPORTANT RIDING POINTS
5-1
5
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