check engine light 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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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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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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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
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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
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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
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AAir filter element .......................................6-17
Anti-theft device housing .........................3-13
Autolube pump, adjusting........................6-28
BBattery......................................................6-32
Brake and clutch levers, checking andlubricating ..............................................6-29
Brake and shift pedals, checking and lubricating ..............................................6-29
Brake fluid level, checking .......................6-24
Brake fluid, changing ...............................6-25
Brake lever .................................................3-6
Brake light switches .................................6-23
Brake pedal ................................................3-6
Brake pedal free play, adjusting ..............6-22
CCables, checking and lubricating ............6-28
Carburetor, adjusting ...............................6-17
Care............................................................7-1
Catalytic converter .....................................3-9
Clutch lever ................................................3-5
Clutch lever free play, adjusting...............6-21
Coolant.....................................................6-14
Coolant temperature warning light ............3-3
Cowlings and panels, removing and installing ...................................................6-8
DDimmer switch ...........................................3-5
Drive chain slack ......................................6-25
Drive chain, cleaning and lubricating.......6-27
EEngine break-in ..........................................5-3
Engine idling speed .................................6-18 Engine oil .................................................3-10
Engine stop switch ....................................3-5
Engine trouble warning light ......................3-3
Engine, starting a warm .............................5-2
FFront and rear brake pads, checking ......6-23
Front brake lever free play, checking.......6-22
Front fork, checking .................................6-31
Fuel ............................................................3-8
Fuel cock..................................................3-11
Fuel consumption, tips for reducing ..........5-3
Fuel tank breather/overflow hose ..............3-9
Fuel tank cap .............................................3-7
Fuse, replacing.........................................6-33
HHandlebar switches ...................................3-4
Headlight bulb, replacing .........................6-34
Horn switch ................................................3-5
IIdentification numbers ...............................9-1
Ignition circuit cut-off system ..................3-14
Indicator and warning lights ......................3-2
LLicense plate light bulb, replacing ...........6-36
MMain switch/steering lock ..........................3-1
Maintenance and lubrication, periodic ......6-4
Maintenance, emission control system .....6-3
Matte color, caution ...................................7-1
Model label ................................................9-1
NNeutral indicator light.................................3-2
OOil level warning light .................................3-2
PParking .......................................................5-4
Part locations .............................................2-1
Pass switch ................................................3-5
RRear view mirrors .....................................3-13
SSafety information ......................................1-1
Seat ..........................................................3-12
Shift pedal ..................................................3-6
Shift pedal position, adjusting .................6-22
Shifting .......................................................5-2
Sidestand .................................................3-14
Sidestand, checking and lubricating .......6-30
Spark plug, checking ...............................6-11
Specifications.............................................8-1
Speedometer unit ......................................3-3
Start switch ................................................3-5
Starter (choke) lever .................................3-12
Starting a cold engine ................................5-1
Steering, checking ...................................6-31
Storage.......................................................7-3
TTachometer ................................................3-4
Tail/brake light bulb, replacing .................6-35
Throttle grip and cable, checking
and lubricating .......................................6-28
Throttle grip free play, adjusting ..............6-18
Tires .........................................................6-19
Tool kit ........................................................6-1
Transmission oil .......................................6-13
Troubleshooting .......................................6-37
Troubleshooting charts ............................6-38
Turn signal indicator light ...........................3-2
INDEX
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