2012 YAMAHA TZR50 transmission

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
1HD-F819D-E0 7/3/11 20:27 Página 6
2AS-F819D-E0.indd 631/07/12 10:09

Transporting the Motorcycle
Be sure to observe following instruc-
tions before transporting the
motorcycle in another vehicle.
Remove all loose items from the
motorcycle.
Check that the fuel cock (if
equipped) is in the “OFF” posi-
tion and that there are no fuel
leaks.
Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
Shift the transmission in gear (for
models with a manual transmis-
sion).
Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the
motorcycle, such as the frame or
upper front fork triple clamp (and
not, for example, to rubber-
mounted handlebars or turn sig-
nals, or parts that could break).
Choose the location for the
straps carefully so the straps will
not rub against painted surfaces
during transport.
The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the
motorcycle will not bounce
excessively during transport.
1
SAFETY INFORMATION
1-5
1HD-F819D-E0 7/3/11 20:27 Página 12
2AS-F819D-E0.indd 1231/07/12 10:09

To unlock the steering
1. Push
2. Turn
Push the key in, and then turn it to
“ ” while still pushing it.
EAU11004
Indicator and warning lights
1. Coolant temperature warning light “ ”
2. Oil level warning light “ ”
3. Turn signal indicator light “ ”
4. Neutral indicator light “ ”
5. Engine trouble warning light “ ”
EAU11020
Turn signal indicator light “ ”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
EAU11060
Neutral indicator light “ ”
This indicator light comes on when
the transmission is in the neutral posi-
tion.
EAUM1062
Oil level warning light “ ”
This warning light comes on when the
key is in the “ ” position or if the oil
level in the 2-stroke engine oil tank is
low during operation. If the warning
light comes on during operation, stop
immediately and fill the oil tank with
2-stroke engine oil of either JASO
grade “FC” or ISO grades “EG-C” or
“EG-D”. The warning light should go
off after the 2-stroke engine oil tank
has been refilled.
TIP
If the warning light does not come on
when the key is in the “ ” position or
does not go off after the 2-stroke
engine oil tank has been refilled, have
an Yamaha dealer check the electrical
circuit.
ECA16291
Do not operate the vehicle until you
know that the engine oil level is suf-
ficient.
NOTICE
INSTRUMENT AND CONTROL FUNCTIONS
3-2
3
1HD-F819D-E0 7/3/11 20:27 Página 17
2AS-F819D-E0.indd 1731/07/12 10:09

EAU12871
Shift pedal
1. Shift pedal
The shift pedal is located on the left
side of the motorcycle and is used in
combination with the clutch lever
when shifting the gears of the 6-spe-
ed constant-mesh transmission
equipped 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.
EAU12941
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.
INSTRUMENT AND CONTROL FUNCTIONS
3-6
3
1HD-F819D-E0 7/3/11 20:27 Página 21
2AS-F819D-E0.indd 2131/07/12 10:09

EAU15305
Sidestand
1. Sidestand
The sidestand is located on the left
side of the frame. Raise the sidestand
or lower it with your foot while holding
the vehicle upright.
TIP
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain
situations. (See the following section
for an explanation of the ignition cir-
cuit cut-off system.)
EWA10241
The vehicle must not be ridden with
the sidestand down, or if the sides-
tand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control. Yama-
ha’s ignition circuit cut-off system
has been designed to assist the
operator in fulfilling the responsibi-
lity of raising the sidestand before
starting off. Therefore, check this
system regularly and have a Yama-
ha dealer repair it if it does not
function properly.
EAU15314
Ignition circuit cut-off
system
The ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch
lever is not pulled.
It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the
sidestand is still down.
It cuts the running engine when
the transmission is in gear and
the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
TIP
This check is most reliable if perfor-
med with a warmed-up engine.
WARNING
INSTRUMENT AND CONTROL FUNCTIONS
3-14
3
1HD-F819D-E0 7/3/11 20:27 Página 29
2AS-F819D-E0.indd 2931/07/12 10:09

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.
1HD-F819D-E0 7/3/11 20:27 Página 31
2AS-F819D-E0.indd 3131/07/12 10:09

EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do
not understand, ask your Yamaha
dealer.
EWA10271
Failure to familiarize yourself with
the controls can lead to loss of
control, which could cause an acci-
dent or injury.
EAU16055
Starting a cold engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the
sidestand up.
See page 3-14 for more information. 1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ ” and make sure that the engine stop switch
is set to “ ”.
3. Shift the transmission into the neutral position. The neutral indi-
cator light should come on. If not,
ask a Yamaha dealer to check the
electrical circuit.
4. Turn the starter (choke) on and completely close the throttle.
(See page 3-12).
5. Start the engine by pushing the start switch.
If the engine fails to start, release
the start switch, wait a few
seconds, and then try again.
Each starting attempt should be as short as possible to preserve
the battery. Do not crank the
engine more than 10 seconds on
any one attempt.
6. After starting the engine, move the starter (choke) back halfway.
7. When the engine is warm, turn the starter (choke) off.
TIP
The engine is warm when it responds
quickly to the throttle with the starter
(choke) turned off.
ECA11042
For maximum engine life, never
accelerate hard when the engine is
cold!
NOTICE
WARNING
OPERATION AND IMPORTANT RIDING POINTS
5-1
5
1HD-F819D-E0 7/3/11 20:27 Página 34
2AS-F819D-E0.indd 3431/07/12 10:09

EAU16640
Starting a warm engine
Follow the same procedure as for
starting a cold engine with the excep-
tion that the starter (choke) is not
required when the engine is warm.
EAU16671
Shifting
1. Neutral position
2. Shift pedal
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the
illustration.
TIP
To shift the transmission into the neu-
tral position, press the shift pedal
down repeatedly until it reaches the
end of its travel, and then slightly rai-
se it.
ECA10260
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long
distances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
Always use the clutch while
changing gears to avoid dama-
ging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
NOTICE
OPERATION AND IMPORTANT RIDING POINTS
5-2
5
1HD-F819D-E0 7/3/11 20:27 Página 35
2AS-F819D-E0.indd 3531/07/12 10:09