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Yamaha TZR50, Owner'S Manual

The Yamaha TZR50 Owner's Manual is a comprehensive guide providing detailed instructions and essential information to maximize the potential of your motorcycle. Download this manual for free from manualshive.com and gain access to expert advice, troubleshooting tips, and maintenance techniques to ensure a flawless riding experience with your Yamaha TZR50.

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SAFETY INFORMATION.....................1-1

DESCRIPTION.....................................2-1

Left 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   6

31/07/12   10:09

Summary of Contents for TZR50

Page 1: ...TZR50 OWNER S MANUAL Read this manual carefully before operating this vehicle 1HD F819D E0 7 3 11 20 27 Página 1 2AS F819D E0 indd 1 31 07 12 10 09 ...

Page 2: ...EAU46090 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold 1HD F819D E0 7 3 11 20 27 Página 2 2AS F819D E0 indd 2 31 07 12 10 09 ...

Page 3: ...ps given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product information avai...

Page 4: ...s symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer TIP NOTICE WARNING IMPORTANT MANUAL INFORMATION 1HD F819D E0 7 3 11 20 27 Págin...

Page 5: ...rved Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited Printed in Netherlands IMPORTANT MANUAL INFORMATION 1HD F819D E0 7 3 11 20 27 Página 5 2012 by mbk inDUSTRIE 1st edition April 2012 mbk inDUSTRIE 2AS F819D E0 indd 5 31 07 12 10 09 ...

Page 6: ...ECKS 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 pane...

Page 7: ...Battery 6 32 Replacing the fuse 6 33 Replacing the headlight bulb 6 34 Replacing the tail brake light bulb 6 35 Replacing a front turn signal light bulb 6 35 Replacing a rear turn signal light bulb 6 36 Replacing the license plate light bulb 6 36 Troubleshooting 6 37 Troubleshooting charts 6 38 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER...

Page 8: ... traffic is the predominating cause of automobile motorcycle acci dents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when you are approaching and passing through intersections since intersection...

Page 9: ...y seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abra sions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Always wear protective clothing that covers your legs ankles and feet The engine or exhaust sys tem become very hot during or after...

Page 10: ...tribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability Shifting weights can create a sudden imbalance Make sure that accessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo res traints frequently Properly adjust the suspension for your load suspension adjustable models only and check the con...

Page 11: ... front fork area can create instability due to impro per weight distribution or aerodynamic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may attempt to lift the motorcycle or the motorcycle m...

Page 12: ...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 suspensio...

Page 13: ...ck lever page 3 11 3 Seat lock page 3 12 4 Grab bar page 3 12 5 Sidestand page 3 14 6 Shift pedal page 3 6 7 Coolant reservoir page 6 14 8 Front brake pads page 6 23 9 Coolant reservoir cap page 6 14 1HD F819D E0 7 3 11 20 27 Página 13 2AS F819D E0 indd 13 31 07 12 10 09 ...

Page 14: ...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 1HD F819D E0 7 3 11 20 27 Página 14 2AS F819D E0 indd 14 31 07 12 10 09 ...

Page 15: ... 4 3 Starter choke lever page 3 12 4 Tachometer page 3 4 5 Main switch steering lock page 3 1 6 Speedometer unit page 3 3 7 Right handlebar switches page 3 4 8 Throttle grip page 6 18 9 Front brake lever page 3 6 10 Fuel tank cap page 3 7 1HD F819D E0 7 3 11 20 27 Página 15 2AS F819D E0 indd 15 31 07 12 10 09 ...

Page 16: ...en the engine is started EAU10661 OFF All electrical systems are off The key can be removed EWA10061 Never turn the key to or while the vehicle is moving Other wise the electrical systems will be switched off which may result in loss of control or an accident EAU10683 LOCK The steering is locked and all electri cal systems are off The key can be removed To lock the steering 1 Push 2 Turn 1 Turn th...

Page 17: ...t 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 ...

Page 18: ...cles the radiator fan s automati cally switch on or off according to the coolant temperature in the radiator If the engine overheats see page 6 39 for further instructions EAUS1540 Engine trouble warning light This warning light flashes if a problem is detected in the electrical circuit monitoring the engine If this occurs have a Yamaha dealer check the self diagnosis system The electrical circuit...

Page 19: ...s the rider to monitor the engine speed and keep it within the ideal power range ECA10031 Do not operate the engine in the tachometer red zone Red zone 10000 r min and above EAU12348 Handlebar switches Left 1 Pass switch PASS 2 Dimmer switch 3 Turn signal switch 4 Horn switch Right 1 Start switch 2 Engine stop switch NOTICE INSTRUMENT AND CONTROL FUNCTIONS 3 4 3 1HD F8199 E0 13 5 11 07 11 Página 1...

Page 20: ...h to to stop the engine in case of an emer gency such as when the vehicle over turns or when the throttle cable is stuck EAU12711 Start switch Push this switch to crank the engine with the starter See page 5 1 for star ting instructions prior to starting the engine EAU31640 Clutch lever 1 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever tow...

Page 21: ...his 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 F81...

Page 22: ...ion with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover TIP The fuel tank cap cannot be closed unless the key is in the lock In addi tion the key cannot be removed if the cap is not properly closed and loc ked EWA11091 Make sure that the fuel tank cap is properly closed after filling fuel Leaking fuel is a fire hazard W...

Page 23: ... since fuel may deteriorate painted surfa ces or plastic parts ECA10071 4 Be sure to securely close the fuel tank cap EWA15151 Gasoline is poisonous and can cau se injury or death Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin...

Page 24: ... in the exhaust system EWA10862 The exhaust system is hot after operation To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system Make sure that the exhaust system has cooled down befo re doing any maintenance work D...

Page 25: ... stroke engine oil tank cap 1 Remove the 2 stroke engine oil tank cap by pulling it off 2 Install the 2 stroke engine oil tank cap by pushing it into the oil tank opening TIP Make sure that the 2 stroke engine oil tank cap is properly installed before riding the vehicle Recommended oil See page 8 1 Oil quantity 1 40 L 1 48 US qt 1 23 Imp qt INSTRUMENT AND CONTROL FUNCTIONS 3 10 3 1HD F819D E0 7 3 ...

Page 26: ... running ON 1 Pointed end positioned over ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES 1 Pointed end positioned over RES This indicates reserve If you run out of fuel while riding move the lever to this position Fill the tank at the first opportunity Be sure to set the lever back to ON after refueling INSTRUMENT AND CONTR...

Page 27: ...remove the seat 1 Insert the key into the seat lock and then turn it as shown 1 Seat lock 2 Open 2 Pull the seat off To install the seat 1 Insert the projection on the front of the seat into the seat holder as shown 1 Projection 2 Seat holder 2 Push the rear of the seat down to lock it in place 3 Remove the key TIP Make sure that the seat is properly secured before riding INSTRUMENT AND CONTROL FU...

Page 28: ...storage com partment be sure to secure the straps to prevent losing them TIP Some U LOCKS cannot fit into the housing due to their size or shape EAU39671 Rear view mirrors The rear view mirrors of this vehicle can be folded forward or backward for parking in narrow spaces Fold the mirrors back to their original position before riding EWA14371 Be sure to fold the rear view mirrors back to their ori...

Page 29: ...y 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 u...

Page 30: ...led 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may not be working correctly The motorcycle shoul...

Page 31: ...CKS 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 ...

Page 32: ...lay 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 ...

Page 33: ...s Check operation and switches Correct if necessary Engine stop switch Check operation 3 4 Sidestand switch Check operation of ignition circuit cut off system If system is not working correctly have Yamaha dealer check vehicle 3 14 FOR YOUR SAFETY PRE OPERATION CHECKS 4 3 4 1HD F819D E0 7 3 11 20 27 Página 33 2AS F819D E0 indd 33 31 07 12 10 09 ...

Page 34: ...ion 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...

Page 35: ...al 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 w...

Page 36: ... polish themsel ves to the correct operating clearan ces During this period prolonged full throttle operation or any condition that might result in engine overhea ting must be avoided EAUS1560 0 500 km 0 300 mi Avoid prolonged operation above 4000 r min After every hour of operation stop the engine and then let it cool for five to ten minutes Vary the engine speed from time to time Do not operate ...

Page 37: ... place where pedes trians or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increa sing the risk of a fuel leak and fire Do not park near grass or other flammable materials which might catch fire WARNING OPERATION AND IMPORTANT RIDING POINTS 5 4 5 1HD F819D E0 7 3 11 20 27 Página 37 2AS F819D E0 indd 37 31 07 12 10 09...

Page 38: ...ng maintenance unless otherwi se specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while servi cing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 1 1 for more information about carbon monoxide EWA15460 Brake discs calipers drums and linings c...

Page 39: ...NANCE AND ADJUSTMENT 6 2 6 TIP If you do not have the tools or expe rience required for a particular job have a Yamaha dealer perform it for you 1HD F819D E0 7 3 11 20 27 Página 39 2AS F819D E0 indd 39 31 07 12 10 09 ...

Page 40: ...0 Periodic maintenance chart for the emission control system PERIODIC MAINTENANCE AND ADJUSTMENT 6 3 6 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 Fuel line Check fuel hoses for cracks or damage 2 Spark plug Replace 3 Carburetor Check starter choke operation Adjust engine idling speed Check the...

Page 41: ...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 p...

Page 42: ...ial O ring chain lubricant thoroughly Check bearing play and steering 11 Steering bearings 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 shaft Lubricate with silicone grease 14 Brake pedal pivot Lubricate with lithium soap shaft based grease 15 Clutch lever piv...

Page 43: ...th lithium soap connecting arm pivoting points based grease 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 25 Throttle grip Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 26 Lights signals and Check operation s...

Page 44: ...as 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 1HD F819D E0 7 3 11 20 27 Página 44 2AS F819D E0 indd 44 31 07 12 10 09 ...

Page 45: ...nel needs to be removed and installed 1 Cowling A 2 Cowling C 1 Cowling B 2 Panel A 3 Panel B EAUS2080 Cowling A To remove the cowling 1 Remove the bolt and the screws 1 Screw 2 Bolt 2 Pull the cowling down slightly and then pull it outward as shown 1 Cowling A To install the cowling Insert the tabs on the cowling into the slots as shown and then install the bolt and the screws 1 Tab 1HD F819D E0 ...

Page 46: ...Insert the tabs on the cowling into the slots as shown and then install the bolt and the screws 1 Tab 2 Install cowling A EAUS2100 Cowling C To remove the cowling 1 Remove cowlings A and B See page 6 8 2 Remove the screw shown 1 Screw 3 Remove the bolts and screws shown and then take the cowling off PERIODIC MAINTENANCE AND ADJUSTMENT 6 9 6 1HD F819D E0 7 3 11 20 27 Página 46 2AS F819D E0 indd 46 ...

Page 47: ...EAU19161 Panel A To remove the panel 1 Remove the bolt 1 Panel mounting bolt 2 Pull the rear of the panel out and then slide the panel forward to release it in the front 1 Panel A To install the panel 1 Secure the front of the panel and then push the rear of the panel in 2 Install the bolt PERIODIC MAINTENANCE AND ADJUSTMENT 6 10 6 1HD F819D E0 7 3 11 20 27 Página 47 2AS F819D E0 indd 47 31 07 12 ...

Page 48: ...ew and the panel screw EAUS1580 Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart In addition the condition of the spark plug can reveal the condition of the engine To remove the...

Page 49: ...re the spark plug gap with a wire thickness gauge and if necessary adjust the gap to spe cification 1 Spark plug gap 2 Clean the surface of the spark plug gasket and its mating surfa ce and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tighten it to the specified torque TIP If a torque wrench is not available when installing a spar...

Page 50: ...The oil should be at the brim of the check hole 4 If the oil is below the brim of the check hole remove the oil filler cap add sufficient oil of the recommended type to raise it to the correct level and then install the oil filler cap 5 Install the oil check bolt and then tighten it to the specified torque To change the transmission oil 1 Transmission oil check bolt 2 Transmission oil drain bolt 3...

Page 51: ...tempera ture Make sure that the vehicle is positioned straight up when checking the coolant level A slight tilt to the side can result in a false reading 2 Check the coolant level in the coolant reservoir TIP The coolant should be between the minimum and maximum level marks 1 Coolant reservoir 2 Maximum level mark 3 Minimum level mark 3 If the coolant is at or below the minimum level mark remove p...

Page 52: ...2070 To change the coolant 1 Place the vehicle on a level surfa ce and let the engine cool if necessary 2 Remove cowlings A B and C and panel A See page 6 8 3 Place a container under the engi ne to collect the used coolant 4 Remove the radiator cap retai ning bolt radiator cap retainer and radiator cap WARNING Never attempt to remove the radiator cap when the engine is hot EWA10381 1 Radiator cap ...

Page 53: ...or 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 ma...

Page 54: ...mportant 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 fa...

Page 55: ...rn 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 ad...

Page 56: ...sure must be checked and adjusted on cold tires i e when the temperatu re of the tires equals the ambient temperature The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passenger cargo and accessories appro ved for this model EWA10511 Never overload your vehicle Ope ration of an overloaded vehicle could cause an accident WARNING Tire air p...

Page 57: ... this model by Yamaha Motor Co Ltd EWA10471 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 to d...

Page 58: ... tire life 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 ...

Page 59: ...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 EAUB1100 Adjusting the shift pedal position 1 Distance between shi...

Page 60: ...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 disappeared have a Yamaha dealer replace the brake pads as a set EA...

Page 61: ... 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 flui...

Page 62: ...r 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 nec...

Page 63: ... 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...

Page 64: ... areas Service the drive chain as follows ECA10583 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 1 Clean the drive chain with kero sene and a small soft brush NOTICE To prevent damaging the O rings do not clean the drive chain with steam clea ners high pressure washers or inappropriate solvents ECA11121 2 Wipe the drive chain dry 3 Thorou...

Page 65: ... 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...

Page 66: ...ld be checked before each ride and the pedal pivots should be lubricated if necessary EAU23142 Checking and lubricating the brake and clutch levers Brake lever Clutch lever Recommended lubricant Lithium soap based grease PERIODIC MAINTENANCE AND ADJUSTMENT 6 29 6 1HD F819D E0 7 3 11 20 27 Página 66 2AS F819D E0 indd 66 31 07 12 10 09 ...

Page 67: ...hould be lubricated if necessary EWA10731 If the sidestand does not move up and down smoothly have a Yama ha dealer check or repair it Other wise the sidestand could contact the ground and distract the opera tor resulting in a possible loss of control Recommended lubricant Lithium soap based grease WARNING Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease PE...

Page 68: ...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 fro...

Page 69: ...ays shield your eyes when working near batteries In case of contact administer the following FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and immediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hydrogen gas Therefore keep sparks flames cigarettes etc away from the battery ...

Page 70: ...connect the positive lead befo re connecting the negative lead ECA16840 4 After installation make sure that the battery leads are properly connected to the battery termi nals 1 Negative battery lead black 2 Positive battery lead red ECA16530 Always keep the battery charged Storing a discharged battery can cause permanent battery damage EAU23482 Replacing the fuse 1 Main fuse 2 Spare main fuse The ...

Page 71: ...the luminosity of the bulb and the bulb life will be adversely affec ted Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thin ner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than speci fied 1 Do not touch the glass part of the bulb 1 Remove the head...

Page 72: ...t in and turning it coun terclockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws NOTICE Do not over tighten the screws otherwise the lens may break ECA10681 EAUS1352 Replacing a front turn signal light bulb ECA10670 It is advisable to have a Yamaha dealer perform this job 1 Remove the socket together with th...

Page 73: ...shing it in and turning it coun terclockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw NOTICE Do not over tighten the screw otherwise the lens may break ECA11191 EAUM1461 Replacing the license plate light bulb 1 Remove the license plate light cover by removing the screw 1 Screw 2 License plate light cover 3 ...

Page 74: ...al systems your self However should your motorcy cle require any repair take it to a Yamaha dealer whose skilled techni cians have the necessary tools expe rience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills EWA15141...

Page 75: ...s 3 Ignition Wipe 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 Battery The engine turns over quickly The engine turns over slowly The battery is good Check the battery lead connections and...

Page 76: ...g 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 check and r...

Page 77: ...Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors inclu ding the spark plug cap are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such pro ducts onto seals gaskets sproc kets the drive chain and ...

Page 78: ...gent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in co...

Page 79: ...itable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for advice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAU37222 Storage Short term Always store your motorcycle in a cool dry ...

Page 80: ...l the spark plug and the spark plug cap WARNING To prevent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10951 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 7 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its w...

Page 81: ...oling system Coolant reservoir capacity up to the maxi mum level mark 0 29 L 0 31 US qt 0 26 Imp qt Radiator capacity including all routes 0 70 L 0 74 US qt 0 62 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 13 8 L 3 65 US gal 3 04 Imp gal Fuel reserve amount 2 2 L 0 58 US gal 0 48 Imp gal Carburetor Manufacturer DELL ORTO ...

Page 82: ... Front wheel Wheel type Cast wheel Rim size 17M C x MT2 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Front brake Type Single disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 108 ...

Page 83: ...1 Meter lighting LED Neutral indicator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED Fuses Main fuse 10 0 A Spare fuse 10 0 A SPECIFICATIONS 8 3 8 1HD F819D E0 7 3 11 20 27 Página 83 2AS F819D E0 indd 83 31 07 12 10 09 ...

Page 84: ...n number is stamped into the steering head pipe Record this number in the space pro vided TIP The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing autho rity in your area EAU26480 Model label 1 Model label The model label is affixed to the frame under the seat See page 3 12 Record the information on this label in the s...

Page 85: ...er overflow hose 3 9 Fuel tank cap 3 7 Fuse replacing 6 33 H Handlebar switches 3 4 Headlight bulb replacing 6 34 Horn switch 3 5 I Identification numbers 9 1 Ignition circuit cut off system 3 14 Indicator and warning lights 3 2 L License plate light bulb replacing 6 36 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Matte color caut...

Page 86: ...lacing 6 35 Turn signal light bulb rear replacing 6 36 Turn signal switch 3 5 V Vehicle identification number 9 1 W Wheel bearings checking 6 32 Wheels 6 21 INDEX 1HD F819D E0 7 3 11 20 27 Página 86 2AS F819D E0 indd 86 31 07 12 10 09 ...

Page 87: ...1HD F819D E0 7 3 11 20 27 Página 87 2AS F819D E0 indd 87 31 07 12 10 09 ...

Page 88: ...1HD F819D E0 7 3 11 20 27 Página 88 2AS F819D E0 indd 88 31 07 12 10 09 ...

Page 89: ...1HD F819D E0 7 3 11 20 27 Página 89 2AS F819D E0 indd 89 31 07 12 10 09 ...

Page 90: ...1HD F819D E0 7 3 11 20 27 Página 90 2AS F819D E0 indd 90 31 07 12 10 09 ...

Page 91: ...1HD F819D E0 7 3 11 20 27 Página 91 2AS F819D E0 indd 91 31 07 12 10 09 ...

Page 92: ...09 E MBK Industrie Z I de Rouvroy 02100 Saint Quentin Société Anonyme au capital de 45 000 000 e R C St Quentin B 329 035 422 PRINTED IN THE NETHERLANDS 2012 04 E Verso couv type YAMAH NL E indd 1 19 07 12 10 50 2AS F819D E0 indd 92 31 07 12 10 09 ...

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