maintenance YAMAHA TZR50 2012 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 the bra- ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.
1HD-F819D-E0 7/3/11 20:27 Página 44
2AS-F819D-E0.indd 4431/07/12 10:09

PERIODIC MAINTENANCE AND ADJUSTMENT
6-8
6
EAU18712
Removing and installing
cowlings and panels
The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each
time a cowling or panel needs to be
removed and installed.
1. Cowling A
2. Cowling C1. Cowling B
2. Panel A
3. Panel B
EAUS2080
Cowling A
T
o remove the cowling
1. Remove the bolt and the screws.
1. Screw
2. Bolt
2. Pull the cowling down slightly, and
then pull it outward as shown.
1. Cowling A
To install the cowling
Insert the tabs on the cowling into the
slots as shown, and then install the
bolt and the screws.
1. Tab
1HD-F819D-E0 7/3/11 20:27 Página 45
2AS-F819D-E0.indd 4531/07/12 10:09

EAUS2090
Cowling B
T
o remove the cowling
1. Remove cowling A.
2. Remove the bolt and the screws.
1. Screw
2. Bolt
3. Pull the cowling down slightly,and then pull it outward as
shown.
1. Cowling B
To install the cowling
1. Insert the tabs on the cowlinginto the slots as shown, and then
install the bolt and the screws.
1. Tab
2. Install cowling A.
EAUS2100
Cowling C
T
o remove the cowling
1. Remove cowlings A and B. (Seepage 6-8).
2. Remove the screw shown.
1. Screw
3. Remove the bolts and screws shown, and then take the cowling
off.
PERIODIC MAINTENANCE AND ADJUSTMENT
6-9
6
1HD-F819D-E0 7/3/11 20:27 Página 46
2AS-F819D-E0.indd 4631/07/12 10:09

1. Screw
2. Bolt
To install the cowling
1. Insert the tabs on the cowlinginto the slots as shown, and then
install the bolts and screws.
1. Tab
2. Install the screw removed in step 2.
3. Install cowlings B and A.
EAU19161
Panel A
T
o remove the panel
1. Remove the bolt.
1. Panel mounting bolt
2. Pull the rear of the panel out, andthen slide the panel forward to
release it in the front.
1. Panel A
To install the panel
1. Secure the front of the panel, andthen push the rear of the panel in.
2. Install the bolt.
PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6
1HD-F819D-E0 7/3/11 20:27 Página 47
2AS-F819D-E0.indd 4731/07/12 10:09

EAUS2110
Panel B
T
o remove the panel
1. Turn the fuel cock lever to the offposition. (See page 3-11).
2. Remove the fuel cock lever screw, the fuel cock lever and the
panel screw, and then take the
panel off as shown.
1. Fuel cock lever
2. Screw 1. Panel B
2. Panel mounting bolt
To install the panel
1. Place the panel in the original
position by pushing it.
2. Install the fuel cock lever, the fuel cock lever screw and the panel
screw.
EAUS1580
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause
any spark plug to slowly erode, the
spark plug should be removed and
checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug1. Remove panel A. (See page 6-8).
2. Remove the spark plug cap.
1. Spark plug cap
PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
1HD-F819D-E0 7/3/11 20:27 Página 48
2AS-F819D-E0.indd 4831/07/12 10:09

3. Remove the spark plug asshown, using the spark plug
wrench, which is located in the
storage compartment. (See page
6-1).
1. Spark plug wrench
To check the spark plug1. Check that the porcelain insula- tor around the center electrode of
the spark plug is a medium-to-
light tan (the ideal color when the
vehicle is ridden normally).
TIP
If the spark plug shows a distinctly
different color, the engine could be
operating improperly. Do not attempt
to diagnose such problems yourself. Instead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for electro-
de erosion and excessive carbon
or other deposits, and replace it if
necessary.
To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if
necessary, adjust the gap to spe-
cification.
1. Spark plug gap
2. Clean the surface of the sparkplug gasket and its mating surfa-
ce, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the spark plug wrench, and then
tighten it to the specified torque.
TIP
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4–1/2 turn past finger tight. Howe-
ver, the spark plug should be tighte-
ned to the specified torque as soon
as possible.
4. Install the spark plug cap.
5. Install the panel.
Tightening torque:Spark plug: 22.5 Nm (2.2 m•kgf, 16.3 ft•lbf)
Spark plug gap:0.6–0.7 mm (0.024–0.028 in)
1
Specified spark plug:NGK / BR9 ES


PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
1HD-F819D-E0 7/3/11 20:27 Página 49
2AS-F819D-E0.indd 4931/07/12 10:09

EAUS1591
Transmission oil
The transmission oil level should be
checked before each ride. In addition,
the oil must be changed at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
To check the transmission oil level
1. Transmission oil filler cap
2. Transmission oil check bolt
1. Remove cowling A. (See page 6-8).
2. Place the vehicle on a level surfa- ce and hold it in an upright posi-
tion.
TIP
Make sure that the vehicle is positio-
ned straight up when checking the oil
level. A slight tilt to the side can result
in a false reading.
3. Remove the oil check bolt, andthen check the oil level.
TIP
The oil should be at the brim of the
check hole.
4. If the oil is below the brim of thecheck hole, remove the oil filler
cap, add sufficient oil of the
recommended type to raise it to
the correct level, and then install
the oil filler cap.
5. Install the oil check bolt, and then tighten it to the specified torque. To change the transmission oil
1. Transmission oil check bolt
2. Transmission oil drain bolt
3. Washer
1. Place an oil pan under the trans-
mission oil case to collect the
used oil.
2. Remove the drain bolt and the oil check bolt to drain the oil.
3. Install the drain bolt and the check bolt, and then tighten them
to the specified torques.
Tightening torque:Oil check bolt: 6 Nm (0.6 m•kgf, 4.3 ft•lbf)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6
1HD-F819D-E0 7/3/11 20:27 Página 50
2AS-F819D-E0.indd 5031/07/12 10:09

4. Remove the oil filler cap, refillwith the specified amount of the
recommended transmission oil,
and then install and tighten the oil
filler cap. NOTICE: Make sure
that no foreign material enters
the transmission case.
[ECAM1021]
5. Start the engine and let it idle for several minutes while checking
the transmission oil case for oil
leakage. If oil is leaking, imme-
diately turn the engine off and
check for the cause.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the coo-
lant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU39087
To check the coolant level1. Place the vehicle on a level surfa- ce and hold it in an upright posi-
tion.
TIP
The coolant level must be chec-
ked on a cold engine since the
level varies with engine tempera-
ture.
Make sure that the vehicle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
2. Check the coolant level in thecoolant reservoir.
TIP
The coolant should be between the
minimum and maximum level marks.
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
3. If the coolant is at or below theminimum level mark, remove
panel A to access the coolant
reservoir. (See page 6-8).
4. Remove the coolant reservoir cap, add coolant to the maxi-
mum level mark, and then install
the reservoir cap. WARNING!
Remove only the coolant reser-
voir cap. Never attempt to
remove the radiator cap when
the engine is hot.
[EWA15161]
Recommended transmission oil: See page 8-1
Oil change quantity: 0.75 L (0.79 US qt, 0.66 Imp.qt)
Tightening torque:Transmission oil drain bolt: 17.5 Nm (1.7 m•kgf, 12.7 ft•lbf)
Oil check bolt: 6 Nm (0.6 m•kgf, 4.3 ft•lbf)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6
1HD-F819D-E0 7/3/11 20:27 Página 51
2AS-F819D-E0.indd 5131/07/12 10:09

NOTICE: If coolant is not avai-
lable, use distilled water or soft
tap water instead. Do not use
hard water or salt water since it
is harmful to the engine. If
water has been used instead of
coolant, replace it with coolant
as soon as possible, otherwise
the cooling system will not be
protected against frost and
corrosion. If water has been
added to the coolant, have a
Yamaha dealer check the anti-
freeze content of the coolant
as soon as possible, otherwise
the effectiveness of the coolant
will be reduced.
[ECA10472]
1. Coolant reservoir cap
5. Install the panel.
EAUS2070
To change the coolant 1. Place the vehicle on a level surfa- ce and let the engine cool if
necessary.
2. Remove cowlings A, B and C and panel A. (See page 6-8).
3. Place a container under the engi- ne to collect the used coolant.
4. Remove the radiator cap retai- ning bolt, radiator cap retainer
and radiator cap. WARNING!
Never attempt to remove the
radiator cap when the engine is
hot.
[EWA10381]
1. Radiator cap retaining bolt
2. Radiator cap
3. Radiator cap retainer
5. Remove the coolant drain boltand its gasket to drain the coo-
ling system.
1. Coolant drain bolt
2. Gasket
Coolant reservoir capacity (up to
the maximum level mark):0.29 L (0.31 US qt, 0.26 Imp.qt)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
6
1HD-F819D-E0 7/3/11 20:27 Página 52
2AS-F819D-E0.indd 5231/07/12 10:09

6. Remove the coolant reservoircap.
1. Coolant reservoir cap
7. Move the hose clamp in thedirection shown, and then dis-
connect the coolant reservoir
hose to drain the reservoir.
1. Hose clamp
2. Coolant reservoir hose
3. Coolant reservoir
8. After the coolant is completely
drained, thoroughly flush the
cooling system with clean tap
water.
9. Connect the coolant reservoir hose, and then move the hose
clamp back to its original posi-
tion.
10. Install the coolant drain bolt and its new gasket, and then tighten
the bolt to the specified torque.
11. Pour the recommended coolant into the reservoir to the maximum
level mark, and then install the
coolant reservoir cap.
12. Pour the recommended coolant into the radiator until it is full. 13. Install the radiator cap, start the
engine, let it idle for several minu-
tes, and then turn it off.
14. Remove the radiator cap to check the coolant level in the
radiator. If necessary, add suffi-
cient coolant until it reaches the
top of the radiator, and then ins-
tall the radiator cap, retainer and
retaining bolt.
15. Check the coolant level in the reservoir. If necessary, remove
the coolant reservoir cap, add
coolant to the maximum level
mark, and then install the cap.Antifreeze/water mixture ratio:1:1
Recommended antifreeze: High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Coolant quantity: Radiator capacity (including all
routes): 0.70 L (0.74 US qt, 0.62 Imp.qt)
Coolant reservoir capacity (up to
the maximum level mark): 0.29 L (0.31 US qt, 0.26 Imp.qt)
Tightening torque:Coolant drain bolt: 9 Nm (0.9 m•kgf, 6.5 ft•lbf)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-16
6
1HD-F819D-E0 7/3/11 20:27 Página 53
2AS-F819D-E0.indd 5331/07/12 10:09