YAMAHA PW50 2015 Workshop Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
7-10
7
5. Insert the sponge material into the
air filter case. NOTICE: Make
sure that the spon ge material is
properly seate d in the air filter
case. The en gine should never
b e operated without the spon ge
material installe d, otherwise the
piston(s) an d/or cylin der(s) may
b ecome excessively worn.
[ECA15622]
6. Install the air filter case cover by
installing the screw.
7. Install the seat.
EAU41222
Cleanin g the spark arresterThe spark arrester should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
WARNING
EWA10981
 Always let the exhaust system
cool prior to touching exhaust
components.
 Do not start the en gine when
cleanin g the exhaust system.1. Remove the tailpipe by removing
the screw, and then pulling it out
of the muffler. 2. Tap the tailpipe lightly, and then
use a wire brush to remove any
carbon deposits from the spark
arrester portion of the tailpipe and
inside of the tailpipe housing.
3. Insert the tailpipe into the muffler, and then install and tighten the
screw.
TIPMake sure to align the screw hole
when inserting the tailpipe.
Recommen ded oil:
Yamaha foam air filter oil or other
quality foam air filter oil
1. Tailpipe
2. Screw
3. Muffler1
2
3
1. Spark arrester
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-11
7
EAU39931
Adjustin g the car buretorThe carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most
carburetor adjustments should be left
to a Yamaha dealer, who has the nec-
essary professional knowledge and ex-
perience. The adjustment described in
the following section, however, may be
serviced by the owner as part of rou-
tine maintenance.NOTICE
ECA10551
The car buretor has been set an d ex-
tensively teste d at the Yamaha fac-
tory. Chang ing these settin gs
without sufficient technical knowl-
e dge may result in poor perfor-
mance of or d amage to the en gine.
EAU21363
A djustin g the eng ine idlin g
spee dThe engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.TIPA diagnostic tachometer is needed to
make this adjustment.1. Attach the tachometer to the
spark plug lead.
2. Start the engine and warm it up for several minutes at 1000–2000
r/min while occasionally revving it
to 4000–5000 r/min.TIPThe engine is warm when it quickly re-
sponds to the throttle.3. Check the engine idling speedand, if necessary, adjust it to
specification by turning the throt-
tle stop screw. To increase the en-
gine idling speed, turn the screw in direction (a). To decrease the en-
gine idling speed, turn the screw in
direction (b).
TIPIf the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.1. Throttle stop screwEn gine i dlin g spee d:
1650–1750 r/min
1 (a)
(b)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-12
7
EAU21385
Checking the throttle grip free
playThe throttle grip free play should mea-
sure 1.5–3.5 mm (0.06–0.14 in) at the
inner edge of the throttle grip. Periodi-
cally check the throttle grip free play
and, if necessary, have a Yamaha deal-
er adjust it.
EAU40916
TiresTires are the only contact between the
vehicle and the road. Safety in all con-
ditions of riding depends on a relatively
small area of road contact. Therefore, it
is essential to maintain the tires in good
condition at all times and replace them
at the appropriate time with the speci-
fied tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
WARNING
EWA15371
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or d eath from loss of
control.
The tire air pressure must be
checked and a djuste d on col d tires
(i.e., when the temperature of the
tires equals the am bient tempera-
ture).
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.
1. Throttle grip free play
1
Stan dar d tire air pressure:
Front:
100 kPa (1.00 kgf/cm², 15 psi)
Rear:
100 kPa (1.00 kgf/cm², 15 psi)
1. Tire sidewall
2. Tire tread depth
Minimum tire trea d d epth (front an d
rear): 4.0 mm (0.16 in)
12
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-13
7Tire information
This model is equipped with tube tires.
Tires age, even if they have not been
used or have only been used occasion-
ally. Cracking of the tread and sidewall
rubber, sometimes accompanied by
carcass deformation, is an evidence of
ageing. Old and aged tires shall be
checked by tire specialists to ascertain
their suitability for further use.
WARNING
EWA10462
The front an
d rear tires shoul d b e of
the same make an d d esi gn, other-
wise the han dlin g characteristics of
the vehicle may be different, which
coul d lea d to an acci dent.After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha.
WARNING
EWA15542
 Have a Yamaha dealer replace
excessively worn tires. Operat-
in g the motorcycle with exces-
sively worn tires decreases
ri din g sta bility an d can lead to
loss of control.
 The replacement of all wheel-
and b rake-relate d parts, inclu d-
in g the tires, shoul d b e left to a
Yamaha dealer, who has the
necessary professional knowl-
e dge an d experience. 
It is not recommen ded to patch
a punctured tube. If unavoi d-
a b le, however, patch the tu be
very carefully an d replace it as
soon as possi ble with a hi gh-
quality pro duct.
 Ride conservatively after
chan gin g a tire since the tire
must seat itself on the rim prop-
erly. Failure to allow proper
seatin g may cause tire failure,
which may result in damag e to
the motorcycle an d injury to the
ri der.Front tire:
Size:
2.50-10 4PR
Manufacturer/model:
BRIDGESTONE/M29
PW50 IRC/Z MARK II (ZAF)
PW50F IRC/Z MARK II
PW50F1 IRC/Z MARK II
Rear tire: Size:
2.50-10 4PR
Manufacturer/model: BRIDGESTONE/M29
PW50 IRC/Z MARK II (ZAF)
PW50F IRC/Z MARK II
PW50F1 IRC/Z MARK II
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-14
7
EAU40782
Panel wheels
WARNING
EWA10611
The wheels on this model are not
d esi gne d for use with tu beless tires.
Do not attempt to use tub eless tires
on this mo del.To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.
 The wheel rims should be
checked for cracks, bends, warp-
age or 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.
 The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
EAU22153
Adjustin g the front an d rear
b rake lever free playThe front and rear brake lever free play
should be measured at the positions as
shown.
Front
Rear Periodically check the front and rear
brake lever free play and, if necessary,
adjust them as follows.
To increase the brake lever free play,
turn the adjusting nut at the brake shoe
plate in direction (a). To decrease the
brake lever free play, turn the adjusting
nut in direction (b).
Front1. Front brake lever free play
1. Rear brake lever free play
1
1
Front
brake lever free play:
10.0–20.0 mm (0.39–0.79 in)
Rear brake lever free play:
10.0–20.0 mm (0.39–0.79 in)
1. Front brake lever free play adjusting nut
1
(a)
(b)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-15
7Rear
WARNING
EWA10651
If proper ad
justment cannot be o b-
taine d as d escri bed , have a Yamaha
d ealer make this ad justment.
EAU41054
Checking the front an d rear
b rake shoesThe front and rear brake shoes must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.TIPThe wheels must be removed to check
brake shoe lining thickness.
 To remove the front wheel: See
page 7-19.
 To remove the rear wheel: See
page 7-20.
Front
Rear
If the lining thickness of a brake shoe is
less than 1.5 mm (0.06 in), have a
Yamaha dealer replace the brake shoes as a set.TIPBe sure to measure the brake lining at
the thinnest portion.
1. Rear brake lever free play adjusting nut
1
(a) (b)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-16
7
EAU23098
Checking an d lu bricatin g the
ca blesThe operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubri-
cated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or re-
place it. WARNING! Dama ge to the
outer housin g of cab les may result
in internal rustin g an d cause inter-
ference with ca ble movement. Re-
place damag ed cab les as soon as
possi ble to prevent unsafe con di-
tions.
[EWA10712] EAU23115
Checkin
g an d lu bricatin g the
throttle grip an d ca bleThe operation of the throttle grip
should be checked before each ride. In
addition, the cable should be lubricat-
ed by a Yamaha dealer at the intervals
specified in the periodic maintenance
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 wa-
ter entry. Therefore, use care not to
pour water directly onto the cover or
cable when washing the vehicle. If the
cable or cover becomes dirty, wipe
clean with a moist cloth.
EAU23121
A djustin g the Autolu be pumpThe Autolube pump is a vital and so-
phisticated component of the engine,
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
Recommen ded lu bricant:
Yamaha cable lubricant or other
suitable cable lubricant
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-17
7
EAU43634
Lubricatin g the front an d rear
b rake leversThe pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic main-
tenance and lubrication chart.
EAU23193
Checkin g an d lu bricatin g the
centerstan dThe operation of the centerstand
should be checked before each ride,
and the pivots and metal-to-metal con-
tact surfaces should be lubricated if
necessary.
WARNING
EWA11302
If the centerstan d d oes not move up
an d d own smoothly, have a Yamaha
d ealer check or repair it. Otherwise,
the centerstan d coul d contact the
g roun d an d d istract the operator, re-
sultin g in a possi ble loss of control.
EAU42082
Checkin g the front forkThe condition and operation of the
front fork must be checked as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
To check the con dition
Check the inner tubes for scratches
and damage.
To check the operation 1. Place the vehicle on a level surfa- ce and hold it in an upright posi-
tion. WARNING! To avoi d injury,
securely support the vehicle so
there is no dan ger of it fallin g
over.
[EWA10752]
2. While applying the front brake, push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
Recommen ded lu bricant:
Lithium-soap-based grease
Recommen ded lu bricant:
Lithium-soap-based grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-18
7
NOTICE
ECA10591
If any damag e is foun d or the front
fork does not operate smoothly,
have a Yamaha d ealer check or re-
pair it.
EAU45512
Checkin g the steerin gWorn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Place the vehicle on the center- stand. WARNING! To avoi d inju-
ry, securely support the vehicle
so there is no dan ger of it fallin g
over.
[EWA10752]
2. Hold the lower ends of the front fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
EAU23292
Checkin g the wheel bearin gsThe front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion 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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-19
7
EAU24361
Front wheel
EAU56510
To remove the front wheel
WARNING
EWA10822
To avoid injury, securely support the
vehicle so there is no dan ger of it
fallin g over.1. Place the motorcycle on the cen-
terstand.
2. Disconnect the brake cable at the wheel hub by removing the front
brake lever free play adjusting nut,
then removing the cable from the
brake camshaft lever and brake
shoe plate. 3. Remove the axle nut and washer.
4. Pull the wheel axle out, and then
remove the wheel. To install the front wheel
1. Install the brake shoe plate into the wheel hub as shown.
2. Lift the wheel up between the fork legs.
TIPMake sure that the slot in the brake
shoe plate fits over the retainer on the
fork leg.
1. Brake camshaft lever
2. Brake shoe plate
3. Washer
4. Axle nut
5. Brake cable
6. Front brake lever free play adjusting nut
1. Wheel axle
5
6
1 3
4
2
1
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