maintenance 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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EAU13212
Fuel
Make sure there is sufficient gasoline
in the tank.
EWA10881
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.
1. Before refueling, turn off the engi-ne and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the
vicinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters
and clothes dryers.
2. Do not overfill the fuel tank. Stop filling when the fuel reaches the
bottom of the filler tube. Because
fuel expands when it heats up,
heat from the engine or the sun
can cause fuel to spill out of the
fuel tank.
1. Fuel tank filler tube
2. Maximum fuel level
3. Wipe up any spilled fuel imme-diately. NOTICE: Immediately
wipe off spilled fuel with a cle-
an, dry, soft cloth, since fuel
may deteriorate painted surfa-
ces or plastic parts.
[ECA10071]
4. Be sure to securely close the fuel tank cap.
EWA15151
Gasoline is poisonous and can cau-
se injury or death. Handle gasoline
with care. Never siphon gasoline by
mouth. If you should swallow some
gasoline or inhale a lot of gasoline vapor, or get some gasoline in your
eyes, see your doctor immediately.
If gasoline spills on your skin, wash
with soap and water. If gasoline
spills on your clothing, change your
clothes.
EAU13270
Your Yamaha engine has been desig-
ned to use regular unleaded gasoline
with a research octane number of 91
or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark
plug life and reduce maintenance
costs.
Recommended fuel:
REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity: 13.8 L (3.65 US gal, 3.04 Imp.gal)
Fuel reserve amount: 2.2 L (0.58 US gal, 0.48 Imp.gal)
WARNING
WARNING
INSTRUMENT AND CONTROL FUNCTIONS
3-8
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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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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EAU17244
Periodic inspection, adjustment, and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. Safety is an obligation
of the vehicle owner/operator. The
most important points of vehicle ins-
pection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However,
depending on the weather, terrain,
geographical location, and individual
use, the maintenance intervals may
need to be shortened.
EWA10321
Failure to properly maintain the
vehicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
EWA15122
Turn off the engine when perfor-
ming maintenance unless otherwi-
se specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
Running the engine while servi-
cing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more
information about carbon
monoxide.
EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before tou-
ching them.
EAU17521
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located inside
the storage compartment under the
seat. (See page 3-12).
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to
assist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be
necessary to perform certain mainte-
nance work correctly.
WARNING
WARNING
WARNING
PERIODIC MAINTENANCE AND ADJUSTMENT
6-1
6
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
6
TIP
If you do not have the tools or expe-
rience required for a particular job,
have a Yamaha dealer perform it for
you.
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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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU17717
General maintenance and lubrication chart
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*
Air filter element • Clean.
√√• Replace. √√
2 Clutch • Check operation.
• Adjust. √√ √ √ √
• Check operation, fluid level and
3* Front brake vehicle for fluid leakage. √√ √ √ √ √
• Replace brake pads.
Whenever worn to the limit
• Check operation, fluid level and
4* Rear brake vehicle for fluid leakage. √√ √ √ √ √
• Replace brake pads.
Whenever worn to the limit
• Check for cracks or damage.
5* Brake hose • Check for correct routing and
√ √√ √ √
clamping.
• Replace. Every 4 years
6*Wheels • Check runout and for damage. √ √√ √
• Check tread depth and for damage.
7* Tires • Replace if necessary. √ √√ √ √
• Check air pressure.
• Correct if necessary.
8* Wheel bearings • Check bearing for looseness or
damage. √ √√ √
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
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)
• Check operation and for
9* Swingarm excessive play. √ √√ √
• Lubricate with lithium-soap-
based grease. Every 24000 km (14000 mi)
• Check chain slack, alignment and condition. Every 500 km (300 mi) and after washing
10 Drive chain • Adjust and lubricate chain with
the motorcycle, riding in the rain or riding in wet areas
a special O-ring chain lubricant
thoroughly.
• Check bearing play and steering
11 * Steering bearings for roughness. √√ √ √ √
• Lubricate with lithium-soap-
based grease. Every 50000 km (30000 mi)
12 * Chassis fasteners • Make sure that all nuts, bolts and
screws are properly tightened. √ √√ √ √
13 Brake lever pivot
shaft • Lubricate with silicone grease.
√ √√ √ √
14 Brake pedal pivot
• Lubricate with lithium-soap-
shaft based grease. √ √√ √ √
15 Clutch lever pivot
• Lubricate with lithium-soap-
shaft based grease. √ √√ √ √
16 Shift pedal pivot
• Lubricate with lithium-soap-
shaft based grease. √ √√ √ √
• Check operation.
17 Sidestand • Lubricate with lithium-soap- √ √√ √ √
based grease.
18 * Sidestand switch • Check operation. √√ √ √ √ √
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-6
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)
19 * Front fork • Check operation and for oil
leakage. √ √√ √
Rear suspension
• Check operation.
√ √√ √
20 * relay arm and
• Lubricate with lithium-soap-
connecting arm
pivoting points based grease.
√√
21 * Autolube pump • Check operation.
• Bleed if necessary. √
√ √√
22Transmission oil • Check oil level.
√√ √ √ √ √• Change.√√ √
23 * Front and rear brake
switches • Check operation.
√√ √ √ √ √
24 Moving parts and
cables • Lubricate.
√ √√ √ √
• Check operation.
25 * Throttle grip • Check throttle grip free play, and
√ √√ √ √
adjust if necessary.
• Lubricate cable and grip housing.
26 * Lights, signals and
• Check operation.
switches • Adjust headlight beam. √√ √ √ √ √
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