2012 YAMAHA TZR50 check engine

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

16. Start the engine, and then checkthe vehicle for coolant leakage. If
coolant is leaking, have a Yama-
ha dealer check the cooling sys-
tem.
17. Install the cowlings and panel.EAU40371
Air filter element
The air filter element should be clea-
ned or replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart. Have a Yamaha
dealer clean or replace the air filter
element.
EAU21280
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most
carburetor adjustments should be left
to a Yamaha dealer, who has the
necessary professional knowledge
and experience. The adjustment des-
cribed in the following section, howe-
ver, may be serviced by the owner as
part of routine maintenance.
ECA10550
The carburetor has been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical know-
ledge may result in poor perfor-
mance of or damage to the engine.
NOTICE
PERIODIC MAINTENANCE AND ADJUSTMENT
6-17
6
1HD-F819D-E0 7/3/11 20:27 Página 54
2AS-F819D-E0.indd 5431/07/12 10:09

EAU33482
Adjusting the engine idling
speed
The engine idling speed must be
checked and, if necessary, adjusted
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
The engine should be warm before
making this adjustment.1. Remove panel B. (See page 6-8).
2. Check the engine idling speed and, if necessary, adjust it to spe-
cification by turning the idle
adjusting screw. To increase the
engine idling speed, turn the
screw in direction (a). To decrea-
se the engine idling speed, turn
the screw in direction (b).
1. Idle adjusting screw
TIP
If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
3. Install the panel.
EAU21374
Adjusting the throttle grip
free play
1. Throttle grip free play
The throttle grip free play should mea-
sure 4.0-6.0 mm (0.16-0.24 in) as
shown. Periodically check the throttle
grip free play and, if necessary, adjust
it as follows.
TIP
The engine idling speed must be
correctly adjusted before checking
and adjusting the throttle grip free
play.
1. Loosen the locknut.
Engine idling speed:1250–1350 r/min
PERIODIC MAINTENANCE AND ADJUSTMENT
6-18
6
1HD-F819D-E0 7/3/11 20:27 Página 55
2AS-F819D-E0.indd 5531/07/12 10:09

3. Measure the drive chain slack asshown.
4. If the drive chain slack is inco- rrect, adjust it as follows.
TIP
When checking the drive chain slack,
the chain tensioner should not be tou-
ching the drive chain.
EAU22922
To adjust the drive chain slack
Consult a Yamaha dealer before
adjusting the drive chain slack.1. Remove the cotter pin from the axle nut, and then loosen the axle
nut.
2. Loosen the chain puller locknut at each end of the swingarm.
3. To tighten the drive chain, turn the drive chain slack adjusting
nut at each end of the swingarm
in direction (a). To loosen the dri-
ve chain, turn the adjusting nut at
each end of the swingarm in direction (b), and then push the
rear wheel forward.
NOTICE:
Improper drive chain slack will
overload the engine as well as
other vital parts of the
motorcycle and can lead to
chain slippage or breakage. To
prevent this from occurring,
keep the drive chain slack wit-
hin the specified limits.
[ECA10571]
TIP
Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same
position for proper wheel alignment.
1. Drive chain slack adjusting bolt
2. Drive chain puller locknut
3. Alignment marks
4. Tighten the locknuts, and then tighten the axle nut to the speci-
fied torque.
5. Insert a new cotter pin into the axle nut, and then bend its ends
as shown. WARNING! Always
use a new cotter pin for the
axle nut.
[EWA10701]
1. Axle nut cotter pin
2. Axle nut
3. Drive chain puller locknut
4. Drive chain slack adjusting bolt
5. Alignment marks
Tightening torque:Axle nut: 90 Nm (9.0 m•kgf, 65.1 ft•lbf)
Drive chain slack:20.0–25.0 mm (0.79–0.98 in)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-26
6
1HD-F819D-E0 7/3/11 20:27 Página 63
2AS-F819D-E0.indd 6331/07/12 10:09

EAU23095
Checking and lubricating the
cables
The operation of all control cables
and the condition of the cables
should be checked before each ride,
and the cables and cable ends should
be lubricated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or repla-
ce it. WARNING! Damage to the
outer housing of cables may result
in internal rusting and cause inter-
ference with cable movement.
Replace damaged cables as soon
as possible to prevent unsafe con-
ditions.
[EWA10711]EAU23114
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip
should be checked before each ride.
In addition, the cable should be lubri-
cated by a Yamaha dealer at the inter-
vals specified in the periodic mainte-
nance chart.
The throttle cable is equipped with a
rubber cover. Make sure that the
cover is securely installed. Even
though the cover is installed correctly,
it does not completely protect the
cable from water entry. Therefore, use
care not to pour water directly onto
the cover or cable when washing the
vehicle. If the cable or cover becomes
dirty, wipe clean with a moist cloth.
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.
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil
PERIODIC MAINTENANCE AND ADJUSTMENT
6-28
6
1HD-F819D-E0 7/3/11 20:27 Página 65
2AS-F819D-E0.indd 6531/07/12 10:09

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 condition1. Check the inner tubes for scrat- ches, 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.
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU23283
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.1. Place a stand under the engine to raise the front wheel off the
ground. WARNING! To avoid
injury, securely support the
vehicle so there is no danger of
it falling over.
[EWA10751]
2. Hold the lower ends of the front fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
NOTICE
PERIODIC MAINTENANCE AND ADJUSTMENT
6-31
6
1HD-F819D-E0 7/3/11 20:27 Página 68
2AS-F819D-E0.indd 6831/07/12 10:09

EAU25924
Troubleshooting charts
Starting problems or poor engine performance
Check the fuel level in
the fuel tank.
1. FuelThere is enough fuel.There is no fuel.Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.
2. CompressionThere is compression.
There is no compression.Check the ignition. Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.
3. IgnitionWipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.
4. BatteryThe engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the battery lead connections,
and have a Yamaha dealer charge
the battery if necessary.
Dry
WetOpen the throttle halfway and operate
the electric starter.
PERIODIC MAINTENANCE AND ADJUSTMENT
6-38
6
1HD-F819D-E0 7/3/11 20:27 Página 75
2AS-F819D-E0.indd 7531/07/12 10:09

Engine overheatingEWA10400
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, a\
nd then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the his-
sing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
TIP
If coolant is not available, tap water can be temporarily used instead, \
provided that it is changed to the recommended
coolant as soon as possible.
Wait until the
engine has cooled.Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.
Add coolant. (See TIP.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
WARNING
PERIODIC MAINTENANCE AND ADJUSTMENT
6-39
6
1HD-F819D-E0 7/3/11 20:27 Página 76
2AS-F819D-E0.indd 7631/07/12 10:09