2010 YAMAHA TZR50 brake

ODOMETER READING
CHECK OR ANNUAL
NO. ITEM MAINTENANCE JOB 1000 km 6000 km 12000 km 18000 km 24000 kmCHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
9* Swingarm • Check operation and for
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
10 Drive chain • Adjust and lubricate chain with washing the motorcycle
a special O-ring chain lubricant or riding in the rain
thoroughly.
11 * Steering bearings • Check bearing play and steering
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
• Lubricate with silicone grease. √√√ √√
shaft
14 Brake pedal pivot
• Lubricate with lithium-soap-
√√√ √√
shaftbased grease.
15 Clutch lever pivot
• Lubricate with lithium-soap-
shaft based grease. √√√ √√
16 Shift pedal pivot
• Lubricate with lithium-soap-
shaft based grease. √√√ √√
17 Sidestand • Check operation.
• Lubricate. √√√ √√
18 * Sidestand switch • Check operation. √√ √ √ √ √
PERIODIC MAINTENANCE AND ADJUSTMENT
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ODOMETER READING
CHECK OR ANNUAL
NO. ITEM MAINTENANCE JOB 1000 km 6000 km 12000 km 18000 km 24000 kmCHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
19 * Front fork • Check operation and for
oil leakage. √√√ √
20 *Rear suspension
• Check operation.
√√√ √
relay arm and • Lubricate with lithium-soap-
connecting arm
based grease. √√
pivoting points
21 * Autolube pump • Check operation.
• Bleed if necessary. √√ √√
22
Transmission oil • Check oil level.
√√ √ √ √ √• Change.√√ √
23 * Front and rear brake
switches • Check operation.
√√ √ √ √ √
24 Moving parts and
cables • Lubricate.
√√√ √√
• Check operation and free play.
Throttle grip • Adjust the throttle cable free play
25 * housing if necessary. √√√ √√
and cable • Lubricate the throttle grip
housing and cable.
26 * Lights, signals and
• Check operation.
switches • Adjust headlight beam. √√ √ √ √ √
PERIODIC MAINTENANCE AND ADJUSTMENT
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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 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
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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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