2004 YAMAHA TZR50 brake

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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Right view
DESCRIPTION
2-2
2
7 Passenger handle
8 Rear shock absorber
9 Seat (page 3-7)10 Battery/Fuse box (page 6-19)
11 Radiator
12 Rear brake pedal (page 3-5)
7910 8
12
11
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Controls and instruments
DESCRIPTION
2-3
2
13 Clutch lever (page 3-4)
14 Left handlebar switch (page 3-3)
15 Controls and instruments (page 3-2)
16 Main switch/Steering lock (page 3-1)17 Front brake lever (page 3-4)
18 Right handlebar switch (page 3-3)
19 Throttle grip (page 6-9)
13
14
15
16
1817
19
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Start switch “START”
Push this switch to crank the engine
with the starter.
ECA10050
CAUTION
See page 5-1 for starting instruc-
tions prior to starting the engine.
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Clutch lever
1. Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the hand-
lebar grip. To engage the clutch, rele-
ase the lever. The lever should be
pulled rapidly and released slowly for
smooth clutch operation.The clutch lever is equipped with a
clutch switch, which is part of the
ignition circuit cut-off system. (See
page 3-8.)
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Shift pedal
1. Shift pedal
The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 6-speed
constant-mesh transmission equip-
ped on this motorcycle.
EAU12890
Brake lever
1. Brake lever
The brake lever is located at the right
handlebar grip. To apply the front bra-
ke, pull the lever toward the handle-
bar grip.
3
INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
1
1
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Brake pedal
1. Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear bra-
ke, press down on the brake pedal.
EAU13000
Fuel tank cap
1. Key over
2. Open
To remove the fuel tank cap
Insert the key into the lock and turn it
1/4 turn clockwise. The lock will be
released and the fuel tank cap can be
removed.
To install the fuel tank cap
1. Push the fuel tank cap into posi-
tion with the key inserted in the
lock.
2. Turn the key counterclockwise to
the original position, and then
remove it.
NOTE:
The fuel tank cap cannot be installed
unless the key is in the lock. In addi-
tion, the key cannot be removed if the
cap is not properly installed and loc-
ked.
EWA11140
s s
WARNING
Make sure that the fuel tank cap is
properly installed before riding.
1. Filling tube
2. Fuel level
EAU13270
Your Yamaha engine has been desig-
ned to use regular unleaded gasoline
with a research octane number of 91
or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark plug
life and reduce maintenance costs.
Recommended fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
13,8 L (3.03 Imp.gal)
Fuel reserve amount:
2,2 L (0.48 Imp.gal)
3
INSTRUMENT AND CONTROL FUNCTIONS
3-5
1
1 22
1
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Pre-operation check list
PRE-OPERATION CHECKS
4-2
4
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary.3-5
• Check fuel line for leakage.
• Check oil level in oil tank.
2-stroke engine oil• If necessary, add recommended oil to specified level. 3-6
• Check vehicle for oil leakage.
Transmission oil• Check oil level in transmission case.
• If necessary, add recommended oil to specified level.6-6
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-8
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check lever free play.
• Adjust if necessary.
Front brake• Check brake pads for wear. 6-14
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Rear brake• Replace if necessary. 6-14
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
Clutch• Lubricate cable if necessary.
6-12
• Check lever free play.
• Adjust if necessary.
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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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Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed
instead.
From 30000 km, repeat the maintenance intervals starting from 6000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
ODOMETER READING (x 1000 Km) ANNUAL
NOITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24CHECK
1*Fuel lineCheck fuel and vacuum hoses for cracks or damage.√√√√ √
2Spark plugReplace.√√√√ √
3Air filter elementClean.√√Replace.√√
4ClutchCheck operation.
Adjust.√√ √ √√
5*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√ √ √√ √Replace brake pads. Whenever worn to the limit
6*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.√√ √ √√ √Replace brake pads. Whenever worn to the limit
7*Brake hoseCheck for cracks or damage.√√√√ √Replace.Every 4 years
8*WheelsCheck runout and for damage.√√√√
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