brake YAMAHA TZR50 2012 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
6
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)
• Check operation and for
9* Swingarm excessive play. √ √√ √
• Lubricate with lithium-soap-
based grease. Every 24000 km (14000 mi)
• Check chain slack, alignment and condition. Every 500 km (300 mi) and after washing
10 Drive chain • Adjust and lubricate chain with
the motorcycle, riding in the rain or riding in wet areas
a special O-ring chain lubricant
thoroughly.
• Check bearing play and steering
11 * Steering bearings for roughness. √√ √ √ √
• Lubricate with lithium-soap-
based grease. Every 50000 km (30000 mi)
12 * Chassis fasteners • Make sure that all nuts, bolts and
screws are properly tightened. √ √√ √ √
13 Brake lever pivot
shaft • Lubricate with silicone grease.
√ √√ √ √
14 Brake pedal pivot
• Lubricate with lithium-soap-
shaft based grease. √ √√ √ √
15 Clutch lever pivot
• Lubricate with lithium-soap-
shaft based grease. √ √√ √ √
16 Shift pedal pivot
• Lubricate with lithium-soap-
shaft based grease. √ √√ √ √
• Check operation.
17 Sidestand • Lubricate with lithium-soap- √ √√ √ √
based grease.
18 * Sidestand switch • Check operation. √√ √ √ √ √
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PERIODIC MAINTENANCE AND ADJUSTMENT
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6
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)
19 * Front fork • Check operation and for oil
leakage. √ √√ √
Rear suspension
• Check operation.
√ √√ √
20 * relay arm and
• Lubricate with lithium-soap-
connecting arm
pivoting points based grease.
√√
21 * Autolube pump • Check operation.
• Bleed if necessary. √
√ √√
22Transmission oil • Check oil level.
√√ √ √ √ √• Change.√√ √
23 * Front and rear brake
switches • Check operation.
√√ √ √ √ √
24 Moving parts and
cables • Lubricate.
√ √√ √ √
• Check operation.
25 * Throttle grip • Check throttle grip free play, and
√ √√ √ √
adjust if necessary.
• Lubricate cable and grip housing.
26 * Lights, signals and
• Check operation.
switches • Adjust headlight beam. √√ √ √ √ √
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PERIODIC MAINTENANCE AND ADJUSTMENT
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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 the bra- ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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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
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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.
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.
WARNINGWARNING
PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU22273
Brake light switches
1. Rear brake light switch adjusting nut
2. Brake light switch
The brake light, which is activated by
the brake pedal and brake lever,
should come on just before braking
takes effect. If necessary, adjust the
rear brake light switch as follows, but
the front brake light switch should be
adjusted by a Yamaha dealer.
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).
EAU22392
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 almostdisappeared, 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 bolt
PERIODIC MAINTENANCE AND ADJUSTMENT
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1. Brake pad wear indicator groove
2. Install the brake caliper bolt, andthen tighten it to the specified
torque.
EAU22580
Checking the brake fluid
level
Front brake
1. Minimum level mark
Rear brake
1. Minimum level mark
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.
Recommended brake fluid:DOT 4
Tightening torque:Brake caliper bolt: 30 Nm (3.0 m•kgf, 21.7 ft•lbf)
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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.
EAU22760
Drive chain slack
The drive chain slack should be chec-
ked before each ride and adjusted if
necessary.
EAU22784
To check the drive chain slack
1. Drive chain slack
1. Place the motorcycle on thesidestand.
TIP
When checking and adjusting the dri-
ve chain slack, there should be no
weight on the motorcycle.
2. Shift the transmission into theneutral position.
PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU44272
Checking and lubricating the
brake and shift pedals
Brake pedal
Shift pedalThe 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.
Recommended lubricant:Lithium-soap-based grease
WARNING
Recommended lubricants:Brake lever: Silicone grease
Clutch lever: Lithium-soap-based grease
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