2012 YAMAHA TZR50 brake fluid

SAFETY INFORMATION .....................1-1
DESCRIPTION.....................................2-1Left view ...........................................3-1
Right view .........................................3-1
Controls and instruments .................3-1
INSTRUMENT AND CONTROL
FUNCTIONS ........................................3-1 Main switch/steering lock .................3-1
Indicator and warning lights .............3-2
Turn signal indicator light ................3-2
Neutral indicator light ......................3-2
Oil level warning light ......................3-2
Coolant temperature warning light ...............................................3-3
Engine trouble warning light ............3-3
Speedometer unit .............................3-3
Tachometer .......................................3-4
Handlebar switches ..........................3-4
Pass switch ......................................3-5
Dimmer switch .................................3-5
Turn signal switch ............................3-5
Horn switch .....................................3-5
Engine stop switch ..........................3-5
Start switch ......................................3-5
Clutch lever .......................................3-5
Shift pedal.........................................3-6
Brake lever ........................................3-6
Brake pedal.......................................3-6
Fuel tank cap ....................................3-7 Fuel ...................................................3-8
Fuel tank breather/overflow hose .....3-9
Catalytic converter............................3-9
2-stroke engine oil ..........................3-10
Fuel cock ........................................3-11
Starter (choke) lever ......................3-12
Seat.................................................3-12
Anti-theft device housing................3-13
Rear view mirrors ............................3-13
Sidestand ........................................3-14
Ignition circuit cut-off system .........3-14
FOR YOUR SAFETY –
PRE-OPERATION CHECKS ...............4-1
OPERATION AND IMPORTANT
RIDING POINTS ..................................5-1 Starting a cold engine ......................5-1
Starting a warm engine ....................5-2
Shifting ..............................................5-2
Tips for reducing fuel consumption..................................5-3
Engine break-in.................................5-3
Parking ..............................................5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ....................................6-1 Owner’s tool kit .................................6-1
Periodic maintenance chart for the emission control system .........6-3 General maintenance and
lubrication chart ............................6-4
Removing and installing cowlings and panels .....................................6-8
Checking the spark plug ................6-11
Transmission oil ..............................6-13
Coolant ...........................................6-14
Air filter element ..............................6-17
Adjusting the carburetor .................6-17
Adjusting the engine idling speed..........................................6-18
Adjusting the throttle grip free play .......................................6-18
Tires ................................................6-19
Cast wheels ....................................6-21
Adjusting the clutch lever free play .......................................6-21
Checking the front brake lever free play .......................................6-22
Adjusting the brake pedal free play .......................................6-22
Adjusting the shift pedal position ...6-22
Brake light switches .......................6-23
Checking the front and rear brake pads ..................................6-23
Checking the brake fluid level ........6-24
Changing the brake fluid ................6-25
Drive chain slack.............................6-25
Cleaning and lubricating the drive chain ............................................6-27
TABLE OF CONTENTS
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EAU10420
Right view
DESCRIPTION
2-2
2
1. Anti-theft device housing (page 3-13)
2. Owner’s tool kit (page 6-1)
3. Battery (page 6-32)
4. Main fuse (page 6-33)
5. 2-stroke engine oil tank cap (page 3-10)
6. Front brake fluid reservoir (page 6-24)
7. Radiator cap (page 6-14)
8. Brake pedal (page 3-6)9. Rear brake fluid reservoir (page 6-24)
10. Rear brake pads (page 6-23)
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the ins-
pection and maintenance procedures and schedules described in the Owner’s Manual.
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment dama-
ge. Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures pro-
vided in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
WARNING
ITEMCHECKS PAGE
• Check fuel level in fuel tank.
Fuel • Refuel if necessary. 3-8
• Check fuel line for leakage.
• Check oil level in oil tank.
2-stroke engine oil • If necessary, add recommended oil to specified level. 3-10
• Check vehicle for oil leakage.
Transmission oil • Check oil level in transmission case.
• If necessary, add recommended oil to specified level. 6-13
• Check coolant level in reservoir.
Coolant • If necessary, add recommended coolant to specified level. 6-14
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Front brake • Replace if necessary. 6-23, 6-24
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
ITEMCHECKS PAGE
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Rear brake • Replace if necessary. 6-23, 6-24
• 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.
6-21
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
Throttle grip • Check throttle grip free play.
6-18, 6-28
• If necessary, have Yamaha dealer adjust throttle grip free play and lubricate
cable and grip housing.
Control cables • Make sure that operation is smooth.
• Lubricate if necessary. 6-28
• Check chain slack.
Drive chain • Adjust if necessary.
6-25, 6-27
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
Wheels and tires • Check tire condition and tread depth.
6-19, 6-21
• Check air pressure.
• Correct if necessary.
Shift pedal • Make sure that operation is smooth.
• Correct if necessary. 6-22, 6-29
Brake pedal • Make sure that operation is smooth.
6-29
• Lubricate pedal pivoting point if necessary.
Brake and clutch levers • Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary. 6-29
Sidestand • Make sure that operation is smooth.
• Lubricate pivot if necessary. 6-30
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU17717
General maintenance and lubrication chart
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)
1*
Air filter element • Clean.
√√• Replace. √√
2 Clutch • Check operation.
• Adjust. √√ √ √ √
• Check operation, fluid level and
3* Front brake vehicle for fluid leakage. √√ √ √ √ √
• Replace brake pads.
Whenever worn to the limit
• Check operation, fluid level and
4* Rear brake vehicle for fluid leakage. √√ √ √ √ √
• Replace brake pads.
Whenever worn to the limit
• Check for cracks or damage.
5* Brake hose • Check for correct routing and
√ √√ √ √
clamping.
• Replace. Every 4 years
6*Wheels • Check runout and for damage. √ √√ √
• Check tread depth and for damage.
7* Tires • Replace if necessary. √ √√ √ √
• Check air pressure.
• Correct if necessary.
8* Wheel bearings • Check bearing for looseness or
damage. √ √√ √
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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.
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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)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-24
6
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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
6-25
6
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