brake light YAMAHA TZR50 2008 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 and warning lights .............3-1
Speedometer unit .............................3-2
Tachometer .......................................3-3
Handlebar switches ..........................3-3
Clutch lever .......................................3-4
Shift pedal.........................................3-4
Brake lever ........................................3-5
Brake pedal.......................................3-5
Fuel ...................................................3-5
Catalytic converter............................3-6
Fuel tank cap ....................................3-6
Fuel tank breather/overflow hose .....3-7
2-stroke engine oil ............................3-7
Fuel cock ..........................................3-8
Starter (choke) lever “
q” .................3-8
Seat...................................................3-9
Anti-theft device housing..................3-9
Rear view mirrors ..............................3-9
Sidestand ........................................3-10
Ignition circuit cut-off system .........3-10PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2
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
MINOR REPAIR...................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and
lubrication chart ............................6-2
Removing and installing cowlings
and panels .....................................6-5
Checking the spark plug ..................6-7
Transmission oil ................................6-8
Coolant .............................................6-9
Air filter element ..............................6-12
Adjusting the carburetor .................6-12
Adjusting the throttle cable free
play ..............................................6-12
Adjusting the engine idling speed ..6-13
Tires ................................................6-14
Cast wheels ....................................6-16
Adjusting the clutch lever free
play ..............................................6-16Checking the front brake lever free
play ..............................................6-17
Adjusting the brake pedal free
play ..............................................6-17
Adjusting the shift pedal position ...6-18
Adjusting the rear brake light
switch ..........................................6-18
Checking the front and rear brake
pads.............................................6-18
Checking the brake fluid level ........6-19
Changing the brake fluid ................6-20
Drive chain slack.............................6-21
Cleaning and lubricating the drive
chain ............................................6-22
Checking and lubricating the
cables ..........................................6-23
Checking and lubricating the
throttle grip and cable .................6-23
Adjusting the Autolube pump .........6-24
Checking and lubricating the brake
and shift pedals ...........................6-24
Checking and lubricating the brake
and clutch levers .........................6-24
Checking and lubricating the
sidestand .....................................6-25
Checking the front fork ...................6-25
Checking the steering.....................6-26
Checking the wheel bearings .........6-26
Battery ............................................6-27
Replacing the fuse ..........................6-28
Replacing the headlight bulb..........6-28
TABLE OF CONTENTS
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Replacing the license plate light
bulb .............................................6-29
Replacing a turn signal light bulb
or the tail/brake light bulb ...........6-30
Replacing a front turn signal light
bulb .............................................6-30
Troubleshooting ..............................6-31
Troubleshooting charts ...................6-32
MOTORCYCLE CARE AND
STORAGE............................................7-1
Care ..................................................7-1
Storage .............................................7-3
SPECIFICATIONS...............................8-1
CONSUMER INFORMATION.............9-1
Identification numbers ......................9-1
TABLE OF CONTENTS
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EAU10420
Right view
2
DESCRIPTION
2-2
123
5
6 74
1. Storage compartment (page 3-9)
2. Seat (page 3-9)
3. Air filter (page 6-12)
4. Front brake fluid reservoir (page 6-19)5. Headlight/Front turnal signal light (page 6-28)
6. Radiator (page 6-9)
7. Rear brake pedal (page 3-5)
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ITEM CHECKS PAGE
Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-23
• Check chain slack.
Drive chain• Adjust if necessary.
6-21, 6-22
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
Wheels and tires• Check tire condition and tread depth.
6-14, 6-16
• Check air pressure.
• Correct if necessary.
Brake and shift pedals• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.3-4, 3-5, 6-24
Brake and clutch levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.3-4, 3-5, 6-24
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.3-10, 6-25
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.3-10
4
PRE-OPERATION CHECKS
4-3
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ODOMETER READING (x 1000 Km)
ANNUAL
NO ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24CHECK
21Transmission oil• Check oil level.√√ √ √√ √
• Change.√√
22 *Front and rear brake
switches• Check operation.√√ √ √√ √
23Moving parts and cables• Lubricate.√√√√ √
Throttle grip housing• Check operation and free play.
24 * • Adjust the throttle cable free play if necessary.√√√√ √
and cable
• Lubricate the throttle grip housing and cable.
25 *Lights, signals and • Check operation.
switches• Adjust headlight beam.√√ √ √√ √
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
EAUM1890
NOTE:
Replace the air filter element more frequently if you are riding in unusually wet or dusty areas.
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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EAUT1220
Checking the front brake
lever free play
1. Brake lever free play
The brake lever free play should mea-
sure 2~5 mm (0.08~0.20 in) as shown.
Periodically check the brake lever free
play and, if necessary, have a Yamaha
dealer check the brake system.
EWA10640
s s
WARNING
An incorrect brake lever free play
indicates a hazardous condition in
the brake system. Do not operate
the motorcycle until the brake sys-
tem has been checked or repaired
by a Yamaha dealer.
EAUM1352
Adjusting the brake pedal
free play
1. Brake pedal free play
The brake pedal free play should
measure 10~15 mm (0.39~0.59 in) as
shown. Periodically check the brake
pedal free play and, if necessary, have
a Yamaha dealer adjust it.
EWAM1010
s s
WARNING
You are hereby informed that any
attempt to change the engine or
any other part to increase the sco-
oter’s performance or power is
strictly forbidden by law.
Any change resulting in an
increase of the vehicle’s maxi-
mum speed or in an increase of
the engine’s capacity entails a
category classification shift
from scooter to light motorcy-
cle, with all the consequences
relating to the latter category,
compelling the owner to:
- proceed with a new certifica-
tion,
- have the vehicle registered,
- hold a driving license (pur-
suant to the new legislation).
In addition, you are informed that
such changes will bar you from
insurance coverage insofar as
insurance policies expressly stipu-
late that such technical changes
brought with a view to enhancing
performance are forbidden.
For the above-mentioned reasons,
any violation of the rules forbidding
personal or otherwise third-party
interventions is punishable by law
with penalties (including seizure of
the vehicle) to which, as the case
may be, penalties may be added
relating to the failure to wear a
1
1
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
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crash helmet, the failure to identify
the vehicle, the failure to have an
insurance, or the failure to hold a
driving license.
EAUB1100
Adjusting the shift pedal
position
1. Shift pedal
The top of the shift pedal should be
positioned approximately 65 mm
(2.5590 in) below the top of the foo-
trest as shown. Periodically check the
shift pedal position and, if necessary,
have a Yamaha dealer adjust it.
EAU22270
Adjusting the rear brake light
switch
1. Rear brake light switch
2. Rear brake light switch adjusting nut
The rear brake light switch, which is
activated by the brake pedal, is pro-
perly adjusted when the brake light
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).
EAU22390
Checking the front and rear
brake pads
The front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU22430
Front brake pads
1. Brake pad wear indicator grove
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear wit-
hout having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the
wear indicator grooves have almost
11
a
b
1 2
1
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
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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.
4. Install the lens by installing the
screws.
ECA10680
CAUTION:
Do not overtighten the screws,
otherwise the lens may break.
EAUS1350
Replacing a front turn signal
light bulb
ECA10670
CAUTION:
It is advisable to have a Yamaha
dealer perform this job.
1. Remove the socket (together
with the bulb) by turning it coun-
terclockwise for the right turn sig-
nal and turning it clockwise for
the left turn signal.
2. Remove the defective bulb by
pulling it out.
3. Insert a new bulb into the socket.
4. Install the socket (together with
the bulb) by turning it clockwise
for the right turn signal and tur-
ning it counterclockwise for the
left turn signal.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
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EAU26001
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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Front tireType
Tubeless
Size
100/80-17 52H
Manufacturer/model
Pirelli / Sport Demon
Continental/Conti-Twist SM
Rear tireType
Tubeless
Size
130/70-17 62H
Manufacturer/model
Pirelli / Sport Demon
Continental/Conti-Twist SM
LoadingMaximum load
196 kg (432.18 lb)
Load is total weight of the equipement, dri-
ver, passenger and accessories
Tire air pressure (measured on cold
tires)
Loading condition
0–90 kg (0–198 lb)
Front
180 kPa (26 psi) (1.8 kgf/cm
2)
Rear
200 kPa (28 psi) (2.0 kgf/cm
2)
Loading condition
90 kg (198 lb)–Maximum load
Front
190 kPa (27 psi) (1,9 kgf/cm
2)Rear
230 kPa (33 psi) (2,3 kgf/cm
2)
Front wheelWheel type
Cast wheel
Rim size
17 x MT2.75
Rear wheelWheel type
Cast wheel
Rim size
17 x MT3.50
Front brakeType
Single disc brake
Operation
Right hand operation
Recommended fluid
DOT 4
Rear brakeType
Single disc brake
Operation
Right foot operation
Recommended fluid
DOT 4
Front suspensionType
Telescopic fork
Spring/shock absorber type
Coil spring/oil damper
Wheel travel
108 mm (4.25 in)
Rear suspensionType
Unit swing
Spring/shock absorber type
Coil spring/oil damper
Wheel travel
89.2 mm (3.51 in)
Electrical systemIgnition system
MORIC
Charging system
Transistor
BatteryManufacturer/model
TIAJIN TONG YEE INDUSTRIAL
CO. LTD. / GS GT4L-BS
Voltage, capacity
12V-3Ah
Bulb voltage, wattage x quantityHeadlight
12 V, 25.0 W / 25.0 W x 2
Tail/brake light
12 V, 21.0 W / 5.0 W x 2
Front turn signal light
12 V, 16.0 W x 2
Rear turn signal light
12 V, 10.0 W x 2
License plate light
12 V, 5.0 W x 1
Meter lighting
LED
High beam Indicator light
LED
Turn signal indicator light
8
SPECIFICATIONS
8-2
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