brake YAMAHA TT-R50E 2016 User Guide

Periodic maintenance an d a djustment
7-4
7
EAU69191
General maintenance an d lu brication chart
TIP
 From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals
starting from 3000 km (1800 mi) or 6 months.
 Items marked with an asterisk should be performed by a Yamaha dealer as
they require special tools, data and technical skills.
No. ITEM 13 5
0.6 1.8 3 16 12
30 90 150
1 *Clutch • Check operation.
• Adjust if necessary.
√√ √
2 *Front brake • Check operation.
• Adjust brake lever free play and
replace brake shoes if neces-
sary. √√ √
3 *Rear brake • Check operation.
• Adjust brake pedal free play
and replace brake shoes if nec-
essary. √√ √
4 *Wheels • Check runout, spoke tightness
and for damage.
• Tighten spokes if necessary. √√ √
5 *Tires • Check tread depth and for
damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary. √√
6 *Wheel bearin gs • Check bearings for smooth op-
eration.
• Replace if necessary. √√
7 *Swin
garm pivot
b earin gs • Check bearing assemblies for
looseness.
• Moderately repack with lithium- soap-based grease. √√
8Drive chain • Check chain slack/alignment
and condition.
• Adjust and lubricate chain with Yamaha chain lubricant or other
suitable chain lubricant thor-
oughly. Every rideX 1000 km
X 1000 mi month
CHECKS AND
MAINTENANCE JOBS
hours
INITIALODOMETER READINGS
U2CJ83E0.book Page 4 Friday, June 26, 2015 10:36 AM

Periodic maintenance an d a djustment
7-5
7
EAU40001
TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty
areas.
9 *Steerin g b earin gs • Check bearing assemblies for
looseness.
• Moderately repack with lithium- soap-based grease. √√
10 *Chassis fasteners • Check all chassis fitting and
fasteners.
• Correct if necessary. √√ √
11 Brake lever pivot
shaft • Apply lithium-soap-based
grease lightly. √√
12 Brake pe
dal pivot
shaft • Apply lithium-soap-based
grease lightly. √√
13 Si destan d pivot • Check operation.
• Apply lithium-soap-based
grease lightly. √√
14 *Front fork • Check operation and for grease
leakage.
• Replace if necessary. √√
15 *Shock ab
sorber as-
sem bly • Check operation and for oil
leakage.
• Replace if necessary. √
16 *Control ca bles • Apply Yamaha cable lubricant
or other suitable cable lubricant
thoroughly. √√ √
17 *Throttle grip • Check operation.
• Check throttle grip free play,
and adjust if necessary.
• Lubricate cable and grip hous- ing. √√ √
No. ITEM
13 5
0.6 1.8 3 16 12
30 90 150
X 1000 km X 1000 mi month
CHECKS AND
MAINTENANCE JOBS
hours
INITIALODOMETER READINGS
U2CJ83E0.book Page 5 Friday, June 26, 2015 10:36 AM

Periodic maintenance an d a djustment
7-17
7
EAU22133
A djustin g the brake lever free
play
Measure the brake lever free play as
shown.
Periodically check the brake lever free
play and, if necessary, adjust it as fol-
lows.
To increase the brake lever free play,
turn the brake lever free play adjusting
nut at the brake shoe plate in direction
(a). To decrease the brake lever free
play, turn the adjusting nut in direction
(b).
WARNING
EWA10651
If proper a djustment cannot b e ob-
taine d as d escri bed , have a Yamaha
d ealer make this ad justment.
1. Brake lever free play
Brake lever free play:
10.0–20.0 mm (0.39–0.79 in)
1. Brake lever free play adjusting nut
1
1
(a) (b)
U2CJ83E0.book Page 17 Friday, June 26, 2015 10:36 AM

Periodic maintenance an d a djustment
7-18
7
EAU44673
A djustin g the brake pe dal free
play
Measure the brake pedal free play at
the brake pedal end as shown.
Periodically check the brake pedal free
play and, if necessary, adjust it as fol-
lows.
To increase the brake pedal free play,
turn the brake pedal free play adjusting
nut at the brake rod in direction (a). To
decrease the brake pedal free play,
turn the adjusting nut in direction (b).
WARNING
EWA14821
 After a djustin g the d rive chain
slack or removin g an d installin g
the rear wheel, always check
the brake ped al free play.
 If proper a djustment cannot b e
o b taine d as descri bed , have a
Yamaha dealer make this a d-
justment.
1. Brake pedal free play
Brake pe dal free play:
10.0–20.0 mm (0.39–0.79 in)
1. Brake pedal free play adjusting nut
1
(b)
(a)
1
U2CJ83E0.book Page 18 Friday, June 26, 2015 10:36 AM

Periodic maintenance an d a djustment
7-19
7
EAU44821
Checkin g the shift pe dal
The operation of the shift pedal should
be checked before each ride. If opera-
tion is not smooth, have a Yamaha
dealer check the vehicle.
EAU22363
Checkin g the front an d rear
b rake shoes
Front
Rear
The front and rear brake shoes must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart. Each brake is provid-
ed with a wear indicator, which allows
you to check the brake shoe wear with-
out having to disassemble the brake.
To check the brake shoe wear, check
the position of the wear indicator while
applying the brake. If a brake shoe has
worn to the point that the wear indica-
tor reaches the wear limit line, have a
Yamaha dealer replace the brake shoes as a set.
1. Brake shoe wear indicator
2. Brake shoe wear limit line
1. Brake shoe wear indicator
2. Brake shoe wear limit line
2
1
2 1
U2CJ83E0.book Page 19 Friday, June 26, 2015 10:36 AM

Periodic maintenance an d a djustment
7-20
7
EAU22762
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22777To check the drive chain slack
1. Place the motorcycle on the side- stand.
TIP
When checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.
2. Shift the transmission into theneutral position.
3. Measure the drive chain slack as shown.
4. If the drive chain slack is incorrect, adjust it as follows.
EAU40115To a djust the d rive chain slack
Consult a Yamaha dealer before ad-
justing the drive chain slack. 1. Loosen the brake pedal free play adjusting nut, axle nut, and lock-
nut at each end of the swingarm. 2. To tighten the drive chain, turn the
drive chain slack adjusting nut at
each end of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting nut at each end
of the swingarm in direction (b),
and then push the rear wheel for-
ward. NOTICE: Improper drive
chain slack will overloa d the en-
g ine as well as other vital parts
of the motorcycle an d can lead
to chain slippa ge or breakag e.
To prevent this from occurrin g,
keep the d rive chain slack with-
in the specifie d limits.
[ECA10572]
Drive chain slack:
35.0–45.0 mm (1.38–1.77 in)
1. Drive chain slack
1. Brake pedal free play adjusting nut
2. Drive chain slack adjusting nut
3. Locknut
1. Axle nut
2. Drive chain slack adjusting nut
3. Locknut
1
2
3
231
U2CJ83E0.book Page 20 Friday, June 26, 2015 10:36 AM

Periodic maintenance an d a djustment
7-21
7
TIP
Using the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the same
position for proper wheel alignment.
3. Tighten the axle nut and both
locknuts to the specified torques.
4. Adjust the brake pedal free play. (See page 7-18.)
5. Make sure that the drive chain pullers are in the same position,
the drive chain slack is correct,
and the drive chain moves
smoothly.
EAU23018
Cleanin g an d lu bricatin g the
d rive 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.
NOTICE
ECA10584
The drive chain must be lu bricate d
after washin g the motorcycle, ri din g
in the rain or ri din g in wet areas.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.
TIP
For a thorough cleaning, have a
Yamaha dealer remove the drive chain and soak it in solvent.
2. Spray Yamaha chain lubricant or other suitable chain lubricant on
the entire chain, making sure that
all side plates and rollers have
been sufficiently oiled.
1. Alignment marks
2. Drive chain puller
3. Drive chain slack adjusting nut
Tightenin g torques:
Axle nut: 60 Nm (6.0 m·kgf, 43 ft·lbf)
Locknut:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
(b)(a)
321
U2CJ83E0.book Page 21 Friday, June 26, 2015 10:36 AM

Periodic maintenance an d a djustment
7-23
7
EAU43623
Checkin g an d lu bricatin g the
b rake lever
The operation of the brake lever should
be checked before each ride, and the
lever pivot should be lubricated if nec-
essary.
EAU23185
Checkin g an d lu bricatin g the
b rake pe dal
The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
Recommen ded lu bricant:
Lithium-soap-based greaseRecommen ded lu bricant:
Lithium-soap-based grease
U2CJ83E0.book Page 23 Friday, June 26, 2015 10:36 AM

Periodic maintenance an d a djustment
7-25
7
EAU42082
Checkin g the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
To check the con dition
Check the inner tubes for scratches
and damage.
To check the operation 1. Place the vehicle on a level surfa- ce and hold it in an upright posi-
tion. WARNING! To avoi d injury,
securely support the vehicle so
there is no dan ger of it fallin g
over.
[EWA10752]
2. While applying the front brake, push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
NOTICE
ECA10591
If any d amage is foun d or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23285
Checkin g the steerin g
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Raise the front wheel off the ground. (See page 7-29.)
WARNING! To avoi d injury, se-
curely support the vehicle so
there is no dan ger of it fallin g
over.
[EWA10752]
2. Hold the lower ends of the front fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
U2CJ83E0.book Page 25 Friday, June 26, 2015 10:36 AM

Periodic maintenance an d a djustment
7-29
7
EAU24351
Supportin g the motorcycle
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motorcy-
cle is in a stable and level position be-
fore starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy- cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing a
jack under the frame in front of the
rear wheel.
2. Raise the front wheel off the ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU24361
Front wheel
EAU56364
To remove the front wheel
WARNING
EWA10822
To avoi d injury, securely support the
vehicle so there is no dan ger of it
fallin g over.
1. Remove the front fork leg guard
from each front fork leg by remov-
ing the bolts.
2. Disconnect the brake cable at the wheel by removing the brake lever
free play adjusting nut at the brake
camshaft lever, then remove the
cable from the brake camshaft le-
ver.
1. Front fork leg guard
2. Bolt
U2CJ83E0.book Page 29 Friday, June 26, 2015 10:36 AM