brake light YAMAHA TZR50 2003 Owners Manual

SAFETY INFORMATION.....................1-1
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments .................2-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................3-1
Main switch/steering lock .................3-1
Indicator lights ..................................3-1
Speedometer unit .............................3-2
Tachometer .......................................3-3
Handlebar switches ..........................3-3
Clucht lever .......................................3-4
Shift pedal.........................................3-4
Brake lever ........................................3-4
Brake pedal.......................................3-5
Fuel tank cap ....................................3-5
Catalytic converter............................3-6
2-stroke engine oil ............................3-6
Fuel cock ..........................................3-6
Starter (choke) lever..........................3-7
Seat...................................................3-7
Storage compartment.......................3-7
Sidestand ..........................................3-8
Ignition circuit cut-off system ...........3-8
PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Shifting ..............................................5-2
Tips for reducing fuel consumption..5-2
Engine break-in.................................5-3
Parking ..............................................5-3
PERIODIC MAINTENANCE AND
MINOR RAPAIR...................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and lubrication
chart ..................................................6-2
Removing and installing cowlings ....6-5
Checking the spark plug ..................6-6
Transmission oil ................................6-6
To check the coolant level ................6-8
Adjusting the carburetor ...................6-9
Adjusting the engine idling speed ....6-9
Adjusting the throttle cable free play ..6-9
Tires ................................................6-10
Cast wheels ....................................6-12
Adjusting the clucth lever free play 6-12
Adjusting the brake pedal position
and free play................................6-13
Adjusting the rear brake light
switch ..........................................6-13
Front brake pads ............................6-14
Rear brake pads .............................6-14
Checking the brake fluid level ........6-14
Changing the brake fluid ................6-15Drive Chain slack ............................6-16
Checking and lubricating the
cables ..........................................6-17
Checking and lubricating the brake
and shift pedals ...........................6-17
Checking and lubricating the brake
and cluctch levers .......................6-18
Checking and lubricating the
sidestand .....................................6-18
Checking the front fork ...................6-18
Checking the steering.....................6-19
Checking the wheel bearings .........6-19
Battery ............................................6-19
Replacing the fuse ..........................6-20
Replacing the headlight bulb..........6-21
Replacing a turn signal light bulb
or the tail/brake light bulb ...........6-21
Replacing the license plate light
bulb .............................................6-22
Supporting the mortorcycle ............6-22
Troubleshooting ..............................6-23
Troubleshooting charts ...................6-24
Engine overheating .........................6-25
MOTORCYCLE CARE AND
STORAGE............................................7-1
Care ..................................................7-1
Storage ...........................................7-2
SPECIFITACIONS...............................8-1
TABLE OF CONTENTS
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ITEM CHECKS PAGE
• Make sure that operation is smooth.
Throttle grip• Check cable free play.
6-9
• If necessary, have Yamaha dealer adjust cable free play and
lubricate cable and grip housing.
Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-17
• Check chain slack.
Drive chain• Adjust if necessary.
6-16
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
Wheels and tires• Check tire condition and tread depth.
6-10
• Check air pressure.
• Correct if necessary.
Brake and clutch levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.6-18
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-18
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.3-3
Sidestand switch• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.3-8
PRE-OPERATION CHECKS
4-3
4
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adjusting nut in direction (b).
6. Tighten the locknut at the clutch
lever and the crankcase.
EAU22220
Adjusting the brake pedal
position and free play
1. Position adjusting bolt
2. Brake pedal position
EWA10670
s s
WARNING
It is advisable to have a Yamaha
dealer make these adjustments.
Brake pedal position
The top of the brake pedal should be
aligned with the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary,
adjust it as follows.1. Loosen the locknut at the brake
pedal.
2. To raise the brake pedal, turn the
adjusting bolt in direction (a). To
lower the brake pedal, turn the
adjusting bolt in direction (b).
3. Tighten the locknut.
EWA11230
s s
WARNING
After adjusting the brake pedal
position, the brake pedal free play
must be adjusted.
Brake pedal free play
1. Free play
The brake pedal free play should
measure 10~15 mm (0,39~59 in) at
the brake pedal end. Periodically
check the brake pedal free play and, if
necessary, adjust it as follows.To increase the brake pedal free play,
turn the adjusting nut at the brake rod
in direction (a). To decrease the brake
pedal free play, turn the adjusting nut
in direction (b).
EWA10660
s s
WARNING
After adjusting the brake pedal free
play, check the operation of the
brake light.
EAU22270
Adjusting the rear brake light
switch
1. Switch
2. Lock nut
The rear brake light switch, which is
activated by the brake pedal, is pro-
perly adjusted when the brake light
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
21
1
1
2a
b
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comes on just before braking takes
effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding
the rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a).
To make the brake light come on later,
turn the adjusting nut in direction (b).
EAU22420
Front brake pads
Each front brake pad is provided with
a wear indicator groove, which allows
you to check the brake pad wear wit-
hout having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that thewear indicator groove has almost
disappeared, have a Yamaha dealer
replace the brake pads as a set.
EAU22480
Rear brake pads
Each rear brake pad is provided with
a wear indicator groove, which allows
you to check the brake pad wear wit-
hout having to disassemble the brake.
Check the brake pad wear as follows.
1. Remove the brake caliper bolt,
and then tilt the caliper forward to
inspect the wear indicator groo-
ve. If a brake pad has worn to the
point that the wear indicator gro-
ove has almost disappeared,
have a Yamaha dealer replace
the brake pads as a set.2. Install the brake caliper bolt, and
then tighten it to the specified
torque.
EAU22610
Checking the brake fluid
level
Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Tightening torque:
Brake caliper bolt:
30 Nm (3,0 m•kgf)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
FRONT
mín.
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2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
ECA10640
CAUTION
Do not use a fuse of a higher ampe-
rage rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.
3. Turn the key to “ON” and turn on
the electrical circuits to check if the
devices operate.
4. If the fuse immediately blows
again, have a Yamaha dealer check
the electrical system.
EAU23800
Replacing the headlight bulb
This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.
1. Remove the headlight bulb cover,
and then disconnect the head-
light lead connectors.
2. Unhook the headlight bulb hol-der, and then remove the defecti-
ve bulb.
EWA10790
s s
WARNING
Headlight bulbs get very hot. The-
refore, keep flammable products
away from a lit headlight bulb, and
do not touch the bulb until it has
cooled down.
3. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
ECA10660
CAUTION
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the
bulb, and the bulb life will be adver-
sely affected. Thoroughly clean off
any dirt and fingerprints on the
headlight bulb using a cloth mois-
tened with alcohol or thinner.
4. Connect the headlight lead con-
nectors, and then install the bulb
cover.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU24281
Replacing a turn signal light
bulb or the tail/brake light
bulb
1. Remove the lens by removing the
screws.
2. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
Specified fuse:
10 A
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
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EAU26000
Care
While the open design of a motorcy-
cle reveals the attractiveness of the
technology, it also makes it more vul-
nerable. Rust and corrosion can
develop even if high-quality compo-
nents are used. A rusty exhaust pipe
may go unnoticed on a car, however,
it detracts from the overall appearan-
ce of a motorcycle. Frequent and pro-
per care does not only comply with
the terms of the warranty, but it will
also keep your motorcycle looking
good, extend its life and optimize its
performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and
covers as well as all electrical
couplers and connectors, inclu-
ding the spark plug cap, are
tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such pro-ducts onto seals, gaskets, sproc-
kets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.
Cleaning
ECA10770
CAUTION
Avoid using strong acidic whe-
el cleaners, especially on spo-
ked wheels. If such products
are used on hard-to-remove
dirt, do not leave the cleaner on
the affected area any longer
than instructed. Also, tho-
roughly rinse the area off with
water, immediately dry it, and
then apply a corrosion protec-
tion spray.
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or spon-
ge with mild detergent and
water to clean plastic.
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasivecleaning products, solvent or
thinner, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
Do not use high-pressure was-
hers or steam-jet cleaners sin-
ce they cause water seepage
and deterioration in the follo-
wing areas: seals (of wheel and
swingarm bearings, fork and
brakes), electric components
(couplers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or scrat-
ching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not lea-
ve any marks. If the windshield
is scratched, use a quality
plastic polishing compound
after washing.
7
MOTORCYCLE CARE AND STORAGE
7-1
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Size
130/70-17 62H
Manufacturer/model
PIRELLI
Maximum load
195 kg
Tire air pressure (measured on cold
tires)
Loading condition
0-90 kg
Front
180 kPa
Rear
200 kPa
Loading condition
90-180 kg
Front
190 kPa
Rear
230 kPa
Front wheelWheel type
Cast wheel
Rim size
MT 2.75x17”
Rear wheelWheel type
Cast wheel
Rim size
MT 3.50x17”
Front brakeType
Single disc brakeRecommended fluid
DOT 4
Rear brakeType
Single disc brake
Recommended fluid
DOT 4
Front suspensionType
Telescopic fork
Spring/shock absorber type
Coil spring/oil damper
Wheel travel
130.0 mm
Rear suspension
Type
Swingarm
Spring/shock absorber type
Coil-gas spring/oil damper
Wheel travel
102.0 mm
Electrical systemIgnition system
DC. CDI
Charging system
CDI magneto
Model
YT4L-BS
Voltage, capacity
12 V, 3.0 Ah
Bulb type
Incandescence
Bulb voltage, wattage x quantityHeadlight
12 V, 25 W/25.0 W x 2
Tail/brake light
12 V, 5.0 W/21.0 W x 1
Front turn signal light
12 V, 16.0 W
Rear turn signal light
12 V, 10.0 W x 2
Neutral indicator light
LED
Oil level warning light
LED
Turn signal indicator light
LED
Coolant temperature warning light
LED
Main fuse
10.0 A
8
SPECIFICATIONS
8-2
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AAdjusting the brake pedal position and
free play .................................................6-13
Adjusting the carburetor ............................6-9
Adjusting the clucth lever free play .........6-12
Adjusting the engine idling speed .............6-9
Adjusting the rear brake light switch .......6-13
Adjusting the throttle cable free play .........6-9
BBattery......................................................6-19
Brake lever .................................................3-4
Brake pedal ................................................3-5
CCare............................................................7-1
Cast wheels .............................................6-12
Catalytic converter .....................................3-6
Clucht lever ................................................3-4
Controls and instruments ..........................2-3
Changing the brake fluid..........................6-15
Checking and lubricating the brake and
cluctch levers.........................................6-18
Checking and lubricating the brake
and shift pedals .....................................6-17
Checking and lubricating the cables .......6-17
Checking and lubricating the sidestand ..6-18
Checking the brake fluid level .................6-14
Checking the front fork ............................6-18
Checking the spark plug ............................6-6
Checking the steering ..............................6-19
Checking the wheel bearings ..................6-19
D2-stroke engine oil ........................................3-6
Drive Chain slack........................................6-16
EEngine break-in ..........................................5-3
Engine overheating ..................................6-25
FFrame serial number ..................................9-1
Front brake pads......................................6-14
Fuel cock....................................................3-6
Fuel tank cap .............................................3-5
HHandlebar switches ...................................3-3
IIdentification numbers ...............................9-1
Ignition circuit cut-off system ....................3-8
Indicator lights ...........................................3-1
KKey identification number ..........................9-1
LLeft view .....................................................2-1
MMain switch/steering lock ..........................3-1
Model label ................................................9-2
OOwner’s tool kit ..........................................6-1
PParking .......................................................5-3
Periodic maintenance and lubrication
chart .........................................................6-2
Pre-operation check list .............................4-2
RRear brake pads ......................................6-14
Removing and installing cowlings .............6-5
Replacing a turn signal light bulb or the
tail/brake light bulb ................................6-21Replacing the fuse ...................................6-20
Replacing the headlight bulb ...................6-21
Replacing the license plate light bulb......6-22
Right view ..................................................2-2
SSeat ............................................................3-7
Shift pedal ..................................................3-4
Shifting .......................................................5-2
Sidestand ...................................................3-8
Speedometer unit ......................................3-2
Starter (choke) lever ...................................3-7
Starting a cold engine ................................5-1
Storage.......................................................7-2
Storage compartment ................................3-7
Supporting the mortorcycle .....................6-22
TTachometer ................................................3-3
Tips for reducing fuel consumption ...........5-2
Tires .........................................................6-10
To check the coolant level .........................6-8
Transmission oil .........................................6-6
Troubleshooting .......................................6-23
Troubleshooting charts ............................6-24
INDEX
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