wheel 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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Checking and lubricating the cables ..........................................6-28
Checking and lubricating the throttle grip and cable .................6-28
Adjusting the Autolube pump .........6-28
Checking and lubricating the brake and shift pedals.................6-29
Checking and lubricating the brake and clutch levers ...............6-29
Checking and lubricating the sidestand .....................................6-30
Checking the front fork ...................6-31
Checking the steering.....................6-31
Checking the wheel bearings .........6-32
Battery ............................................6-32
Replacing the fuse ..........................6-33
Replacing the headlight bulb..........6-34
Replacing the tail/brake light bulb .............................................6-35
Replacing a front turn signal light bulb......................................6-35
Replacing a rear turn signal light bulb......................................6-36
Replacing the license plate light bulb......................................6-36
Troubleshooting ..............................6-37
Troubleshooting charts ...................6-38
MOTORCYCLE CARE AND
STORAGE ............................................7-1 Matte color caution...........................7-1 Care ..................................................7-1
Storage .............................................7-3
SPECIFICATIONS ...............................8-1
CONSUMER INFORMATION .............9-1 Identification numbers ......................9-1
Vehicle identification number............9-1
Model label .......................................9-1
TABLE OF CONTENTS
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• Always obey the speed limitand never travel faster than
warranted by road and traffic
conditions.
• Always signal before turning or changing lanes. Make sure that
other motorists can see you.
The posture of the operator and
passenger is important for proper
control.
• The operator should keep both hands on the handlebar and
both feet on the operator foo-
trests during operation to
maintain control of the
motorcycle.
• The passenger should always hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger foo-
trests. Never carry a passenger
unless he or she can firmly pla-
ce both feet on the passenger
footrests.
Never ride under the influence of
alcohol or other drugs.
This motorcycle is designed for
on-road use only. It is not suitable for off-road use.
Protective Apparel
The majority of fatalities from
motorcycle accidents are the result of
head injuries. The use of a safety hel-
met is the single most critical factor in
the prevention or reduction of head
injuries.
Always wear an approved hel-
met.
Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impair-
ment of vision that could delay
seeing a hazard.
The use of a jacket, heavy boots,
trousers, gloves, etc., is effective
in preventing or reducing abra-
sions or lacerations.
Never wear loose-fitting clothes,
otherwise they could catch on
the control levers, footrests, or
wheels and cause injury or an
accident.
Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or after operation and can cause
burns.
A passenger should also observe
the above precautions.
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing
carbon monoxide can cause heada-
ches, dizziness, drowsiness, nausea,
confusion, and eventually death.
Carbon Monoxide is a colorless,
odorless, tasteless gas which may be
present even if you do not see or
smell any engine exhaust. Deadly
levels of carbon monoxide can collect
rapidly and you can quickly be over-
come and unable to save yourself.
Also, deadly levels of carbon monoxi-
de can linger for hours or days in
enclosed or poorly ventilated areas. If
you experience any symptoms of car-
bon monoxide poisoning, leave the
area immediately, get fresh air, and
SEEK MEDICAL TREATMENT.
Do not run engine indoors. Even
if you try to ventilate engine
exhaust with fans or open win-
dows and doors, carbon monoxi-
1
SAFETY INFORMATION
1-2
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Transporting the Motorcycle
Be sure to observe following instruc-
tions before transporting the
motorcycle in another vehicle.
Remove all loose items from the
motorcycle.
Check that the fuel cock (if
equipped) is in the “OFF” posi-
tion and that there are no fuel
leaks.
Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
Shift the transmission in gear (for
models with a manual transmis-
sion).
Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the
motorcycle, such as the frame or
upper front fork triple clamp (and
not, for example, to rubber-
mounted handlebars or turn sig-
nals, or parts that could break).
Choose the location for the
straps carefully so the straps will
not rub against painted surfaces
during transport.
The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the
motorcycle will not bounce
excessively during transport.
1
SAFETY INFORMATION
1-5
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
ITEMCHECKS PAGE
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Rear 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.
• Check operation.
Clutch • Lubricate cable if necessary.
6-21
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
Throttle grip • Check throttle grip free play.
6-18, 6-28
• If necessary, have Yamaha dealer adjust throttle grip free play and lubricate
cable and grip housing.
Control cables • Make sure that operation is smooth.
• Lubricate if necessary. 6-28
• Check chain slack.
Drive chain • Adjust if necessary.
6-25, 6-27
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
Wheels and tires • Check tire condition and tread depth.
6-19, 6-21
• Check air pressure.
• Correct if necessary.
Shift pedal • Make sure that operation is smooth.
• Correct if necessary. 6-22, 6-29
Brake pedal • Make sure that operation is smooth.
6-29
• Lubricate pedal pivoting point if necessary.
Brake and clutch levers • Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary. 6-29
Sidestand • Make sure that operation is smooth.
• Lubricate pivot if necessary. 6-30
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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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Tire inspection
1. Tire tread depth
2. Tire sidewall
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or if
the sidewall is cracked, have a Yama-
ha dealer replace the tire immediately.
TIP
The tire tread depth limits may differ
from country to country. Always
comply with the local regulations.
Tire information
This motorcycle is equipped with
tubeless tires, tire air valves and cast
wheels.
EWA10461
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, which
could lead to an accident.
After extensive tests, only the tires lis-
ted below have been approved for
this model by Yamaha Motor Co., Ltd.
EWA10471
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
vehicle with excessively worn
tires decreases riding stability
and can lead to loss of control.
The replacement of all wheel
and brake-related parts, inclu-
ding the tires, should be left to
a Yamaha dealer, who has the
necessary professional know-
ledge and experience to do so.
Ride at moderate speeds after
changing a tire since the tire
surface must first be “broken
in” for it to develop its optimal
characteristics.
WARNING
Front tire:Size: 100/80 17 (52H)
Manufacturer/model: Pirelli / Sport Demon
Continental/Conti-Twist SM
Rear tire: Size: 130/70 17 (62H)
Manufacturer/model: Pirelli / Sport Demon
Continental/Conti-Twist SM
WARNING
Minimum tire tread depth (front
and rear):1.6 mm (0.06 in)
1
2
ZAUM0054
PERIODIC MAINTENANCE AND ADJUSTMENT
6-20
6
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EAU21962
Cast wheels
To maximize the performance, durabi-
lity, and safe operation of your vehi-
cle, note the following points regar-
ding the specified wheels.
The wheel rims should be chec-
ked for cracks, bends, warpage
or other damage before each
ride. If any damage is found,
have a Yamaha dealer replace
the wheel. Do not attempt even
the smallest repair to the wheel.
A deformed or cracked wheel
must be replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
EAU22020
Adjusting the clutch lever
free play
1. Clutch lever free play
2. Locknut
3. Clutch lever free play adjusting bolt
The clutch lever free play should mea-
sure 10.0-15.0 mm (0.39-0.59 in) as
shown. Periodically check the clutch
lever free play and, if necessary,
adjust it as follows.1. Loosen the locknut at the clutch lever.
2. To increase the clutch lever free play, turn the adjusting bolt in
direction (a). To decrease the
clutch lever free play, turn the
adjusting bolt in direction (b). 3. Tighten the locknut.
TIP
If the specified free play cannot be
obtained as described above or if the
clutch does not operate correctly,
have a Yamaha dealer check the
internal clutch mechanism.
PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
6
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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
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TIP
Make sure that two notches in the
axle nut are aligned with the hole
through the wheel axle, otherwise
further tighten the axle nut until they
are.
6. Make sure that the drive chainpullers are in the same position,
the drive chain slack is correct,
and the drive chain moves smo-
othly.
EAU23025
Cleaning and lubricating the
drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
ECA10583
The drive chain must be lubricated
after washing the motorcycle,
riding in the rain or riding in wet
areas.
1. Clean the drive chain with kero-sene and a small soft brush.
NOTICE: To prevent damaging
the O-rings, do not clean the
drive chain with steam clea-
ners, high-pressure washers or
inappropriate solvents.
[ECA11121]
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain with a special O-ring chain
lubricant. NOTICE: Do not use
engine oil or any other lubri-
cants for the drive chain, as they may contain substances
that could damage the O-rings.
[ECA11111]
NOTICE
PERIODIC MAINTENANCE AND ADJUSTMENT
6-27
6
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