brake YAMAHA TZR50 2011 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6
EAU18670
TIP
The air filter needs more frequent service 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 cylinders and calipers, and change th\
e bra- ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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EWA10470
●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.
EAU21960
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 or warpage
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 crac-
ked 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.
●Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for
it to develop its optimal characte-
ristics.
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).
WARNING
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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.
EAUT1221
Checking the front brake
lever free play
1. Front brake lever free play
The brake lever free play should mea-
sure 2.0–5.0 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 sys-
tem.
EWA10641
An incorrect brake lever free play
indicates a hazardous condition in
the brake system. Do not operate
the vehicle until the brake system
has been checked or repaired by a
Yamaha dealer.
EAUM1353
Adjusting the brake pedal
free play
1. Brake pedal free play
The brake pedal free play should
measure 5.0–10.0 mm (0.20–0.39 in)
as shown. Periodically check the bra-
ke pedal free play and, if necessary,
have a Yamaha dealer adjust it.
EWAM1030
An incorrect brake pedal 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.
WARNING
WARNING
PERIODIC MAINTENANCE AND ADJUSTMENT
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EAUB1100
Adjusting the shift pedal
position
1. Distance between shift pedal and footrest
The top of the shift pedal should be
positioned approximately 65 mm
(2.56 in) below the top of the footrest
as shown. Periodically check the shift
pedal position and, if necessary, have
a Yamaha dealer adjust it.
EAU22272
Adjusting the rear brake light
switch
1. Rear brake light switch adjusting nut
2. Brake light switch
The rear brake light, which is activa-
ted by the brake pedal, should come
on just before braking takes effect. If
necessary, adjust the rear brake light
switch as follows.
Turn the rear brake light switch adjus-
ting nut while holding the rear brake
light switch in place. To make the bra-
ke 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 groove
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
PERIODIC MAINTENANCE AND ADJUSTMENT
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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.
1. Brake caliper bolt1. Brake pad wear indicator groove
2. Install the brake caliper bolt, and
then tighten it to the specified
torque.
EAU22580
Checking the brake fluid
level
Front brake
1. Minimum level mark
Rear brake
1. Minimum level
Tightening torque:
Brake caliper bolt:
30 Nm (3.0 m•kgf, 21.7 ft•lbf)
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Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low bra-
ke fluid level may indicate worn brake
pads and/or brake system leakage. If
the brake fluid level is low, be sure to
check the brake pads for wear and
the brake system for leakage.
Observe these precautions:
●When checking the fluid level,
make sure that the top of the bra-
ke fluid reservoir is level.
●Use only the recommended qua-
lity brake fluid, otherwise the rub-
ber seals may deteriorate, cau-
sing leakage and poor braking
performance.
●Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performan-
ce.
●Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock.
●Brake fluid may deteriorate pain-
ted surfaces or plastic parts.
Always clean up spilled fluid
immediately.
●As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
EAU22731
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenan-
ce and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
●Oil seals: Replace every two
years.
●Brake hoses: Replace every four
years.
Recommended brake fluid:
DOT 4
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EAU23120
Adjusting the Autolube pump
The Autolube pump is a vital and sop-
histicated component of the engine,
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
EAU44271
Checking and lubricating the
brake and shift pedals
The operation of the brake and shift
pedals should be checked before
each ride, and the pedal pivots
should be lubricated if necessary.
EAU23142
Checking and lubricating the
brake and clutch levers
Brake lever
Clutch lever
Recommended lubricant:
Lithium-soap-based grease
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The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be
lubricated if necessary.EAU23202
Checking and lubricating the
sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated
if necessary.
EWA10731
If the sidestand does not move up
and down smoothly, have a Yama-
ha dealer check or repair it. Other-
wise, the sidestand could contact
the ground and distract the opera-
tor, resulting in a possible loss of
control.
EAU23272
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the perio-
dic maintenance and lubrication
chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10751]
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
Recommended lubricant:
Lithium-soap-based grease
WARNING
Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease
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3. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
4. Connect the headlight lead con-
nectors, and then install the bulb
cover.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.EAU24133
Replacing the tail/brake light
bulb
1. Remove the tail/brake light lens
by removing the screws.
1. Tail/brake light lens
2. Screw
2. Remove the burnt-out bulb by
pushing it in and turning it coun-
terclockwise.
1. Tail/brake light bulb
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. NOTICE: Do not over-
tighten the screws, otherwise
the lens may break.
[ECA10681]
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water, diluted mild detergent
with water may be used. Be
sure to rinse off any detergent
residue using plenty of water,
as it is harmful to plastic parts.
●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 abrasive
cleaning 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.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottle-
brush for hard-to-reach areas. Stub-
born dirt and insects will come off
more easily if the area is covered with
a wet cloth for a few minutes before
cleaning.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on
roads during winter are extremely
corrosive in combination with water,
carry out the following steps aftereach ride in the rain, near the sea or
on salt-sprayed roads.
TIP
Salt sprayed on roads in the winter
may remain well into spring.
1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
NOTICE: Do not use warm
water since it increases the
corrosive action of the salt.
[ECA10791]
2. Apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, surfa-
ces to prevent corrosion.
After cleaning
1. Dry the motorcycle with a cha-
mois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally indu-
ced discoloring of stainless-steel
MOTORCYCLE CARE AND STORAGE
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