HD-F819D-E0 7/3/11 20:27 Página 1 Read this manual carefully before operating this vehicle. OWNER’S MANUAL TZR50 2AS-F819D-E0.
1HD-F819D-E0 7/3/11 20:27 Página 2 EAU46090 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. 2AS-F819D-E0.
1HD-F819D-E0 7/3/11 20:27 Página 3 INTRODUCTION EAU10102 Welcome to the Yamaha world of motorcycling! As the owner of the TZR50, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TZR50.
1HD-F819D-E0 7/3/11 20:27 Página 4 IMPORTANT MANUAL INFORMATION EAU10132 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
1HD-F819D-E0 7/3/11 20:27 Página 5 IMPORTANT MANUAL INFORMATION EAUS1172 TZR50 OWNER’S MANUAL ©2012 byby MBK INDUSTRIE ©2012 mbk inDUSTRIE 1stedition, edition,April April2012 2012 1st All rights reserved. Any reprinting or unauthorized use without the written permission of MBK mbkINDUSTRIE inDUSTRIE is expressly prohibited. Printed in Netherlands. 2AS-F819D-E0.
1HD-F819D-E0 7/3/11 20:27 Página 6 TABLE OF CONTENTS 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 ...
1HD-F819D-E0 7/3/11 20:27 Página 7 TABLE OF CONTENTS Checking and lubricating the cables ..........................................6-28 Checking and lubricating the throttle grip and cable .................6-28 Adjusting the Autolube pump.........6-28 Checking and lubricating the brake and shift pedals.................6-29 Checking and lubricating the brake and clutch levers ...............6-29 Checking and lubricating the sidestand .....................................6-30 Checking the front fork......
1HD-F819D-E0 7/3/11 20:27 Página 8 SAFETY INFORMATION EAU10289 1 Be a Responsible Owner As the vehicle’s owner, you are responsible for the safe and proper operation of your motorcycle. Motorcycles are single-track vehicles. Their safe use and operation are dependent upon the use of proper riding techniques as well as the expertise of the operator. Every operator should know the following requirements before riding this motorcycle.
1HD-F819D-E0 7/3/11 20:27 Página 9 SAFETY INFORMATION • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control. • The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle.
1HD-F819D-E0 7/3/11 20:27 Página 10 SAFETY INFORMATION 1 de can rapidly reach dangerous levels. Do not run engine in poorly ventilated or partially enclosed areas such as barns, garages, or carports. Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors. Loading Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed.
1HD-F819D-E0 7/3/11 20:27 Página 11 SAFETY INFORMATION of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha, even if sold and installed by a Yamaha dealer. Aftermarket Parts, Accessories, and Modifications While you may find aftermarket products similar in design and quality to genuine Yamaha accessories, recognize that some aftermarket accessories or modifications are not suitable because of potential safety hazards to you or others.
1HD-F819D-E0 7/3/11 20:27 Página 12 SAFETY INFORMATION 1 Transporting the Motorcycle Be sure to observe following instructions 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” position 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 prevent movement.
1HD-F819D-E0 7/3/11 20:27 Página 13 DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8. Air filter (page 6-17) Fuel cock lever (page 3-11) Seat lock (page 3-12) Grab bar (page 3-12) Sidestand (page 3-14) Shift pedal (page 3-6) Coolant reservoir (page 6-14) Front brake pads (page 6-23) 9. Coolant reservoir cap (page 6-14) 2-1 2AS-F819D-E0.
1HD-F819D-E0 7/3/11 20:27 Página 14 DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. Anti-theft device housing (page 3-13) Owner’s tool kit (page 6-1) Battery (page 6-32) Main fuse (page 6-33) 2-stroke engine oil tank cap (page 3-10) Front brake fluid reservoir (page 6-24) Radiator cap (page 6-14) Brake pedal (page 3-6) 9. Rear brake fluid reservoir (page 6-24) 10. Rear brake pads (page 6-23) 2-2 2AS-F819D-E0.
1HD-F819D-E0 7/3/11 20:27 Página 15 DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8. Clutch lever (page 3-5) Left handlebar switches (page 3-4) Starter (choke) lever (page 3-12) Tachometer (page 3-4) Main switch/steering lock (page 3-1) Speedometer unit (page 3-3) Right handlebar switches (page 3-4) Throttle grip (page 6-18) 9. Front brake lever (page 3-6) 10 . Fuel tank cap (page 3-7) 2-3 2AS-F819D-E0.
1HD-F819D-E0 7/3/11 20:27 Página 16 INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10661 OFF All electrical systems are off. The key can be removed. To lock the steering EWA10061 WARNING Never turn the key to “ ” or “ ” while the vehicle is moving. Otherwise the electrical systems will be switched off, which may result in loss of control or an accident. 3 The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering.
1HD-F819D-E0 7/3/11 20:27 Página 17 INSTRUMENT AND CONTROL FUNCTIONS 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.
1HD-F819D-E0 7/3/11 20:27 Página 18 INSTRUMENT AND CONTROL FUNCTIONS EAU11446 3 Coolant temperature warning light “ ” This warning light comes on if the engine overheats. If this occurs, stop the engine immediately and allow the engine to cool. The electrical circuit of the warning light can be checked by turning the key to “ ”. The warning light should come on for a few seconds, and then go off.
1HD-F8199-E0 13/5/11 07:11 Página 19 INSTRUMENT AND CONTROL FUNCTIONS The speedometer unit is equipped with a speedometer and an odometer. The speedometer shows riding speed. The odometer shows the total distance traveled. EAU11851 Tachometer EAU12348 Handlebar switches Left 3 1. Tachometer 2. Tachometer red zone The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. 1. Pass switch “PASS” 2. Dimmer switch “ / ” 3.
1HD-F819D-E0 7/3/11 20:27 Página 20 INSTRUMENT AND CONTROL FUNCTIONS EAU12360 Pass switch “PASS” Press this switch to flash the headlight. EAU12400 3 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. turns or when the throttle cable is stuck. EAU31640 Clutch lever EAU12711 Start switch “ ” Push this switch to crank the engine with the starter. See page 5-1 for starting instructions prior to starting the engine.
1HD-F819D-E0 7/3/11 20:27 Página 21 INSTRUMENT AND CONTROL FUNCTIONS EAU12871 Shift pedal EAU12890 Brake lever EAU12941 Brake pedal 3 1. Shift pedal 1. Brake lever 1. Brake 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-speed constant-mesh transmission equipped on this motorcycle. The brake lever is located at the right handlebar grip.
1HD-F819D-E0 7/3/11 20:27 Página 22 INSTRUMENT AND CONTROL FUNCTIONS EAU13074 EWA11091 Fuel tank cap WARNING Make sure that the fuel tank cap is properly closed after filling fuel. Leaking fuel is a fire hazard. 3 1. Lock 1. Fuel tank cap lock cover 2. Unlock To open the fuel tank cap Open the fuel tank cap lock cover, insert the key into the lock, and then turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be opened. To close the fuel tank cap 1.
1HD-F819D-E0 7/3/11 20:27 Página 23 INSTRUMENT AND CONTROL FUNCTIONS vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. EAU13212 Fuel Make sure there is sufficient gasoline in the tank. EWA10881 WARNING Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions. 1.
1HD-F819D-E0 7/3/11 20:27 Página 24 INSTRUMENT AND CONTROL FUNCTIONS EAUB1300 Fuel tank breather/overflow hose EAU13433 Catalytic converter This model is equipped with a catalytic converter in the exhaust system. EWA10862 WARNING 3 1. Fuel tank breather hose and overflow hose Before operating the motorcycle: Check the fuel tank breather/ overflow hose connection. Check the fuel tank breather/overflow hose for cracks or damage, and replace it if damaged.
1HD-F819D-E0 7/3/11 20:27 Página 25 INSTRUMENT AND CONTROL FUNCTIONS EAUS1550 2-stroke engine oil Recommended oil: See page 8-1 Oil quantity: 1.40 L (1.48 US qt, 1.23 Imp.qt) Make sure that there is sufficient 2stroke engine oil in the oil tank. Add the recommended 2-stroke engine oil as necessary. The 2-stroke engine oil tank is located under the seat. (See page 3-12). 3 2. Install the 2-stroke engine oil tank cap by pushing it into the oil tank opening. 1. 2-stroke engine oil tank 2.
1HD-F819D-E0 7/3/11 20:27 Página 26 INSTRUMENT AND CONTROL FUNCTIONS EAU13561 Fuel cock ON 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! The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: 3 OFF 1.
1HD-F819D-E0 7/3/11 20:27 Página 27 INSTRUMENT AND CONTROL FUNCTIONS EAU13590 Starter (choke) lever “ ” EAU13900 Seat To remove the seat 1. Insert the key into the seat lock, and then turn it as shown. 3 1. Projection 2. Seat holder 1. Starter (choke) lever Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the lever in direction (a) to turn on the starter (choke). Move the lever in direction (b) to turn off the starter (choke). 2.
1HD-F819D-E0 7/3/11 20:27 Página 28 INSTRUMENT AND CONTROL FUNCTIONS EAUM1941 Anti-theft device housing 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. 3 1.
1HD-F819D-E0 7/3/11 20:27 Página 29 INSTRUMENT AND CONTROL FUNCTIONS 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. EWA10241 WARNING The vehicle must not be ridden with the sidestand down, or if the sidestand 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.
1HD-F819D-E0 7/3/11 20:27 Página 30 INSTRUMENT AND CONTROL FUNCTIONS 3 With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “ 3. Turn the key “ ”. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES WARNING If a malfunction is noted, have a Yamaha dealer check the system before riding. ”. NO The neutral switch may not be working correctly.
1HD-F819D-E0 7/3/11 20:27 Página 31 FOR YOUR SAFETY – PRE-OPERATION CHECKS EAU15596 Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. EWA11151 WARNING Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. Do not operate the vehicle if you find any problem.
1HD-F819D-E0 7/3/11 20:27 Página 32 FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM Rear brake Clutch 4 Throttle grip Control cables Drive chain Wheels and tires Shift pedal Brake pedal Brake and clutch levers Sidestand • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • CHECKS Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear. Replace if necessary. Check fluid level in reservoir.
1HD-F819D-E0 7/3/11 20:27 Página 33 FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM Chassis fasteners Instruments, lights, signals and switches Engine stop switch Sidestand switch CHECKS • Make sure that all nuts, bolts and screws are properly tightened. • Tighten if necessary. • Check operation. • Correct if necessary. • Check operation. • Check operation of ignition circuit cut-off system. • If system is not working correctly, have Yamaha dealer check vehicle. PAGE — — 3-4 3-14 4 4-3 2AS-F819D-E0.
1HD-F819D-E0 7/3/11 20:27 Página 34 OPERATION AND IMPORTANT RIDING POINTS 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 WARNING Failure to familiarize yourself with the controls can lead to loss of control, which could cause an accident or injury.
1HD-F819D-E0 7/3/11 20:27 Página 35 OPERATION AND IMPORTANT RIDING POINTS EAU16640 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception 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.
1HD-F819D-E0 7/3/11 20:27 Página 36 OPERATION AND IMPORTANT RIDING POINTS EAU16800 Tips for reducing fuel consumption 5 Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption: Turn the starter (choke) off as soon as possible. Shift up swiftly, and avoid high engine speeds during acceleration. Do not rev the engine while shifting down, and avoid high engine speeds with no load on the engine.
1HD-F819D-E0 7/3/11 20:27 Página 37 OPERATION AND IMPORTANT RIDING POINTS EAU17171 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. EWA10311 WARNING Since the engine and exhaust system can become very hot, park in a place where pedestrians 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, increasing the risk of a fuel leak and fire.
1HD-F819D-E0 7/3/11 20:27 Página 38 PERIODIC MAINTENANCE AND ADJUSTMENT EAU17244 6 Periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection, adjustment, and lubrication are explained on the following pages.
1HD-F819D-E0 7/3/11 20:27 Página 39 PERIODIC MAINTENANCE AND ADJUSTMENT TIP If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. 6 6-2 2AS-F819D-E0.
1HD-F819D-E0 7/3/11 20:27 Página 40 PERIODIC MAINTENANCE AND ADJUSTMENT EAU46871 TIP The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a mileage-based maintenance, is performed instead. From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi). Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
1HD-F819D-E0 7/3/11 20:27 Página 41 PERIODIC MAINTENANCE AND ADJUSTMENT EAU17717 General maintenance and lubrication chart NO. ITEM 1 * Air filter element 2 Clutch 3 * Front brake CHECK OR MAINTENANCE JOB ODOMETER READING 1000 km (600 mi) • Clean. 6000 km (3500 mi) √ • Replace. 24000 km (14000 mi) ANNUAL CHECK √ √ • Check operation. • Adjust. √ √ √ √ √ • Check operation, fluid level and vehicle for fluid leakage.
1HD-F819D-E0 7/3/11 20:27 Página 42 PERIODIC MAINTENANCE AND ADJUSTMENT NO. ITEM 9 * Swingarm 10 6 Drive chain 11 * Steering bearings 12 * Chassis fasteners CHECK OR MAINTENANCE JOB ODOMETER READING 1000 km (600 mi) • Check operation and for excessive play. 6000 km (3500 mi) 12000 km (7000 mi) 18000 km (10500 mi) 24000 km (14000 mi) √ √ √ √ • Lubricate with lithium-soapbased grease. Every 24000 km (14000 mi) • Check chain slack, alignment and condition.
1HD-F819D-E0 7/3/11 20:27 Página 43 PERIODIC MAINTENANCE AND ADJUSTMENT NO. ITEM 19 * Front fork Rear suspension relay arm and 20 * connecting arm pivoting points 21 * Autolube pump 22 Transmission oil CHECK OR MAINTENANCE JOB ODOMETER READING 1000 km (600 mi) 6000 km (3500 mi) 12000 km (7000 mi) 18000 km (10500 mi) 24000 km (14000 mi) • Check operation and for oil leakage. √ √ √ √ • Check operation. √ √ √ √ • Lubricate with lithium-soapbased grease. • Check operation.
1HD-F819D-E0 7/3/11 20:27 Página 44 PERIODIC MAINTENANCE AND ADJUSTMENT 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 brake fluid. • Replace the brake hoses every four years and if cracked or damaged. 6 6-7 2AS-F819D-E0.
1HD-F819D-E0 7/3/11 20:27 Página 45 PERIODIC MAINTENANCE AND ADJUSTMENT 2. Pull the cowling down slightly, and then pull it outward as shown. EAU18712 Removing and installing cowlings and panels The cowlings and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed. 1. Cowling B 2. Panel A 3. Panel B 1. Cowling A EAUS2080 Cowling A To remove the cowling 1.
1HD-F819D-E0 7/3/11 20:27 Página 46 PERIODIC MAINTENANCE AND ADJUSTMENT EAUS2090 EAUS2100 Cowling B To remove the cowling 1. Remove cowling A. 2. Remove the bolt and the screws. Cowling C To remove the cowling 1. Remove cowlings A and B. (See page 6-8). 2. Remove the screw shown. 1. Cowling B 6 1. Screw 2. Bolt To install the cowling 1. Insert the tabs on the cowling into the slots as shown, and then install the bolt and the screws. 1. Screw 3.
1HD-F819D-E0 7/3/11 20:27 Página 47 PERIODIC MAINTENANCE AND ADJUSTMENT 2. Install the screw removed in step 2. 3. Install cowlings B and A. EAU19161 Panel A To remove the panel 1. Remove the bolt. 1. Screw 2. Bolt 1. Panel A To install the panel 1. Secure the front of the panel, and then push the rear of the panel in. To install the cowling 1. Insert the tabs on the cowling into the slots as shown, and then install the bolts and screws. 6 1. Panel mounting bolt 2.
1HD-F819D-E0 7/3/11 20:27 Página 48 PERIODIC MAINTENANCE AND ADJUSTMENT EAUS2110 EAUS1580 Panel B To remove the panel 1. Turn the fuel cock lever to the off position. (See page 3-11). 2. Remove the fuel cock lever screw, the fuel cock lever and the panel screw, and then take the panel off as shown. Checking the spark plug 1. Panel B 2. Panel mounting bolt 6 1. Fuel cock lever 2. Screw To install the panel 1. Place the panel in the original position by pushing it. 2.
1HD-F819D-E0 7/3/11 20:27 Página 49 PERIODIC MAINTENANCE AND ADJUSTMENT 3. Remove the spark plug as shown, using the spark plug wrench, which is located in the storage compartment. (See page 6-1). Instead, have a Yamaha dealer check the vehicle. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK / BR9 ES 1. Spark plug wrench To check the spark plug 1.
1HD-F819D-E0 7/3/11 20:27 Página 50 PERIODIC MAINTENANCE AND ADJUSTMENT EAUS1591 Transmission oil The transmission oil level should be checked before each ride. In addition, the oil must be changed at the intervals specified in the periodic maintenance and lubrication chart. To check the transmission oil level 6 1. Transmission oil filler cap 2. Transmission oil check bolt 1. Remove cowling A. (See page 6-8). 2. Place the vehicle on a level surface and hold it in an upright position.
1HD-F819D-E0 7/3/11 20:27 Página 51 PERIODIC MAINTENANCE AND ADJUSTMENT Tightening torque: Transmission oil drain bolt: 17.5 Nm (1.7 m•kgf, 12.7 ft•lbf) Oil check bolt: 6 Nm (0.6 m•kgf, 4.3 ft•lbf) 4. Remove the oil filler cap, refill with the specified amount of the recommended transmission oil, and then install and tighten the oil filler cap. NOTICE: Make sure that no foreign material enters the transmission case. [ECAM1021] Recommended transmission oil: See page 8-1 Oil change quantity: 0.75 L (0.
1HD-F819D-E0 7/3/11 20:27 Página 52 PERIODIC MAINTENANCE AND ADJUSTMENT 6 NOTICE: If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine. If water has been used instead of coolant, replace it with coolant as soon as possible, otherwise the cooling system will not be protected against frost and corrosion.
1HD-F819D-E0 7/3/11 20:27 Página 53 PERIODIC MAINTENANCE AND ADJUSTMENT 6. Remove the coolant reservoir cap. 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 position. 10. Install the coolant drain bolt and its new gasket, and then tighten the bolt to the specified torque. 1. Coolant reservoir cap 7.
1HD-F819D-E0 7/3/11 20:27 Página 54 PERIODIC MAINTENANCE AND ADJUSTMENT 16. Start the engine, and then check the vehicle for coolant leakage. If coolant is leaking, have a Yamaha dealer check the cooling system. 17. Install the cowlings and panel. EAU40371 Air filter element The air filter element should be cleaned or replaced at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer clean or replace the air filter element.
1HD-F819D-E0 7/3/11 20:27 Página 55 PERIODIC MAINTENANCE AND ADJUSTMENT EAU33482 EAU21374 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 lubrication 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 specification by turning the idle adjusting screw.
1HD-F819D-E0 7/3/11 20:27 Página 56 PERIODIC MAINTENANCE AND ADJUSTMENT 2. To increase the throttle grip free play, turn the throttle grip free play adjusting nut in direction (a). To decrease the throttle grip free play, turn the adjusting nut in direction (b). EAU21565 Tires To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires.
1HD-F819D-E0 7/3/11 20:27 Página 57 PERIODIC MAINTENANCE AND ADJUSTMENT Tire inspection 1 Tire information This motorcycle is equipped with tubeless tires, tire air valves and cast wheels. EWA10471 WARNING EWA10461 WARNING 2 ZAUM0054 1. Tire tread depth 2. Tire sidewall The tires must be checked before each ride.
1HD-F819D-E0 7/3/11 20:27 Página 58 PERIODIC MAINTENANCE AND ADJUSTMENT EAU21962 Cast wheels 6 To maximize the performance, durability, and safe operation of your vehicle, note the following points regarding the specified wheels. The wheel rims should be checked for cracks, bends, warpage or other damage 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 cracked wheel must be replaced.
1HD-F819D-E0 7/3/11 20:27 Página 59 PERIODIC MAINTENANCE AND ADJUSTMENT EAUT1221 EAUM1353 EAUB1100 Checking the front brake lever free play Adjusting the brake pedal free play Adjusting the shift pedal position 1. Front brake lever free play 1. Brake pedal free play 1. Distance between shift pedal and footrest The brake lever free play should measure 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 system.
1HD-F819D-E0 7/3/11 20:27 Página 60 PERIODIC MAINTENANCE AND ADJUSTMENT EAU22273 Brake light switches EAU22392 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. Rear brake light switch adjusting nut 2. Brake light switch 6 The brake light, which is activated by the brake pedal and brake lever, should come on just before braking takes effect.
1HD-F819D-E0 7/3/11 20:27 Página 61 PERIODIC MAINTENANCE AND ADJUSTMENT EAU22580 Checking the brake fluid level Front brake 1. Brake pad wear indicator groove 2. Install the brake caliper bolt, and then tighten it to the specified torque. 1. Minimum level mark Tightening torque: Brake caliper bolt: 30 Nm (3.0 m•kgf, 21.7 ft•lbf) Rear brake Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective.
1HD-F819D-E0 7/3/11 20:27 Página 62 PERIODIC MAINTENANCE AND ADJUSTMENT 6 Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. As the brake pads wear, it is normal for the brake fluid level to gradually go down.
1HD-F819D-E0 7/3/11 20:27 Página 63 PERIODIC MAINTENANCE AND ADJUSTMENT 3. Measure the drive chain slack as shown. Drive chain slack: 20.0–25.0 mm (0.79–0.98 in) 4. If the drive chain slack is incorrect, adjust it as follows. TIP When checking the drive chain slack, the chain tensioner should not be touching 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.
1HD-F819D-E0 7/3/11 20:27 Página 64 PERIODIC MAINTENANCE AND ADJUSTMENT TIP Make sure that two notches in the axle nut are aligned with the hole through the wheel axle, otherwise further tighten the axle nut until they are. 6. Make sure that the drive chain pullers are in the same position, the drive chain slack is correct, and the drive chain moves smoothly. 6 EAU23025 Cleaning and lubricating the drive chain they may contain substances that could damage the O-rings.
1HD-F819D-E0 7/3/11 20:27 Página 65 PERIODIC MAINTENANCE AND ADJUSTMENT 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 replace it. WARNING! Damage to the outer housing of cables may result in internal rusting and cause interference with cable movement.
1HD-F819D-E0 7/3/11 20:27 Página 66 PERIODIC MAINTENANCE AND ADJUSTMENT EAU44272 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. Brake pedal EAU23142 Checking and lubricating the brake and clutch levers Brake lever Recommended lubricant: Lithium-soap-based grease 6 Shift pedal Clutch lever 6-29 2AS-F819D-E0.
1HD-F819D-E0 7/3/11 20:27 Página 67 PERIODIC MAINTENANCE AND ADJUSTMENT The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
1HD-F819D-E0 7/3/11 20:27 Página 68 PERIODIC MAINTENANCE AND ADJUSTMENT EAU23272 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly. To check the condition 1. Check the inner tubes for scratches, damage and excessive oil leakage.
1HD-F819D-E0 7/3/11 20:27 Página 69 PERIODIC MAINTENANCE AND ADJUSTMENT EAU23291 EAU23445 Checking the wheel bearings Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 1. Battery This model is equipped with a VRLA (Valve Regulated Lead Acid) battery.
1HD-F819D-E0 7/3/11 20:27 Página 70 PERIODIC MAINTENANCE AND ADJUSTMENT ECA16521 NOTICE To charge a VRLA (Valve Regulated Lead Acid) battery, a special (constant-voltage) battery charger is required. Using a conventional battery charger will damage the battery. 6 To store the battery 1. If the vehicle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place.
1HD-F819D-E0 7/3/11 20:27 Página 71 PERIODIC MAINTENANCE AND ADJUSTMENT EAU23804 Specified fuse: 10.0 A 3. Turn the key to “ ” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. Replacing the headlight bulb This model is equipped with a halogen bulb headlight. If the headlight bulb burns out, replace it as follows.
1HD-F819D-E0 7/3/11 20:27 Página 72 PERIODIC MAINTENANCE AND ADJUSTMENT EAU24133 Replacing the tail/brake light bulb 1. Remove the tail/brake light lens by removing the screws. 6 ECA10670 NOTICE It is advisable to have a Yamaha dealer perform this job. 1. Remove the socket (together with the bulb) by turning it counterclockwise for the right turn signal and turning it clockwise for the left turn signal. 1. Unhook the headlight bulb holder 2. Take the headlight bulb holder off 3.
1HD-F819D-E0 7/3/11 20:27 Página 73 PERIODIC MAINTENANCE AND ADJUSTMENT EAUS1610 EAUM1461 Replacing a rear turn signal light bulb Replacing the license plate light bulb 1. Screw 2. Turn signal light bulb 3. Turn signal light lens 1. Screw 2. License plate light cover 3. License plate light bulb socket 1. Remove the turn signal lens by removing the screw. 1. Remove the license plate light cover by removing the screw. 1. Turn signal light bulb 3. Insert a new bulb into the socket. 4.
1HD-F819D-E0 7/3/11 20:27 Página 74 PERIODIC MAINTENANCE AND ADJUSTMENT EAU25871 Troubleshooting 1. Bulb 6 3. Remove the burnt out bulb by pulling it out. 4. Insert a new bulb into the socket. 5. Install the socket (together with the bulb) by pushing it in. 6. Install the license plate light cover by installing the screw. Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation.
1HD-F819D-E0 7/3/11 20:27 Página 75 PERIODIC MAINTENANCE AND ADJUSTMENT EAU25924 Troubleshooting charts Starting problems or poor engine performance 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start. Check the compression. 2. Compression Operate the electric starter. 6 3.
1HD-F819D-E0 7/3/11 20:27 Página 76 PERIODIC MAINTENANCE AND ADJUSTMENT Engine overheating EWA10400 WARNING 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.
1HD-F819D-E0 7/3/11 20:27 Página 77 MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution EAU26004 Care ECA15192 NOTICE Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use before cleaning the vehicle. Using a brush, harsh chemical products or cleaning compounds when cleaning these parts will scratch or damage their surface. Wax also should not be applied to any matte colored finished parts.
1HD-F819D-E0 7/3/11 20:27 Página 78 MOTORCYCLE CARE AND STORAGE 7 water, diluted mild detergent with water may be used. Be sure to rinse off any detergent residue using plenty of water, as it is harmful to plastic parts. Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
1HD-F819D-E0 7/3/11 20:27 Página 79 MOTORCYCLE CARE AND STORAGE 4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces. 5. Use spray oil as a universal cleaner to remove any remaining dirt. 6. Touch up minor paint damage caused by stones, etc. 7. Wax all painted surfaces. 8. Let the motorcycle dry completely before storing or covering it. EWA11131 WARNING Contaminants on the brakes or tires can cause loss of control.
1HD-F819D-E0 7/3/11 20:27 Página 80 MOTORCYCLE CARE AND STORAGE 7 2. Turn the fuel cock lever to “OFF”. 3. Drain the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank. 4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating. 5. Perform the following steps to protect the cylinder, piston rings, etc. from corrosion. a.
1HD-F819D-E0 7/3/11 20:27 Página 81 SPECIFICATIONS Dimensions: Overall length: 2202 mm (86.7 in) Overall width: 689 mm (27.1 in) Overall height: 1175 mm (46.3 in) Seat height: 820 mm (32.3 in) Wheelbase: 1341 mm (52.8 in) Ground clearance: 151 mm (5.94 in) Minimum turning radius: 2900 mm (114.2 in) Weight: Curb weight: 124 kg (273 lb) Engine: Engine type: Liquid cooled 2-stroke Cylinder arrangement: Single cylinder Displacement: 49 cm3 Bore x stroke: 40.3 x 39.0 mm (1.59 x 1.
1HD-F819D-E0 7/3/11 20:27 Página 82 SPECIFICATIONS Caster angle: 25.00 º Trail: 90 mm (3.5 in) Front tire: Type: Tubeless Size: 100/80 17 (52H) Manufacturer/model: Pirelli / Sport Demon Manufacturer/model: Continental/Conti-Twist SM Rear tire: 8 Type: Tubeless Size: 130/70 17 (62H) Manufacturer/model: Pirelli / Sport Demon Manufacturer/model: Continental/Conti-Twist SM Maximum load: 196 kg (432 lb) Tire air pressure (measured on cold tires): Loading condition: 0–90 kg (0–198 lb) Front: 180 kPa (1.
1HD-F819D-E0 7/3/11 20:27 Página 83 SPECIFICATIONS Front turn signal light: 12 V, 16.0 W x 2 Rear turn signal light: 12 V, 10.0 W x 2 License plate light: 12 V, 5.0 W x 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 8 8-3 2AS-F819D-E0.
1HD-F819D-E0 7/3/11 20:27 Página 84 CONSUMER INFORMATION EAU48612 Identification numbers EAU26400 EAU26480 Vehicle identification number Model label 1. Vehicle identification number 1. Model label The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided. The model label is affixed to the frame under the seat. (See page 3-12). Record the information on this label in the space provided.
1HD-F819D-E0 7/3/11 20:27 Página 85 INDEX A Air filter element .......................................6-17 Anti-theft device housing.........................3-13 Autolube pump, adjusting........................6-28 B Battery......................................................6-32 Brake and clutch levers, checking and lubricating ..............................................6-29 Brake and shift pedals, checking and lubricating ..............................................
1HD-F819D-E0 7/3/11 20:27 Página 86 INDEX Turn signal light bulb (front), replacing ....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 2AS-F819D-E0.
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YAMAHA ESPAÑA, S.A. MBK MOTOR 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 2AS-F819D-E0.indd 92 NL (E).indd 1 Verso couv type YAMAH PRINTED IN SPAIN 2010.
