maintenance YAMAHA PW50 2009 Owners Manual

INTRODUCTION
EAU41072
Congratulations on your purchase of the Yamaha PW50(Y). This model is the result of Yamaha’s vast experience in the pro-
duction of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reli-
ability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you
have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable
at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of
the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the
recommended maintenance schedules and operating instructions contained within this manual.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most cur-
rent product information available at the time of printing, there may be minor discrepancies between your motorcycle and this
manual. If there is any question concerning this manual, please consult a Yamaha dealer.
WARNING

EWA10031
Please read this manual carefully and completely before operating this motorcycle.
WARNING

EWA14351
This motorcycle is designed and manufactured for off-road use only. It is illegal to operate this motorcycle on any
public street, road or highway. Such use is prohibited by law. This motorcycle complies with almost all state
off-highway noise level and spark arrester laws and regulations. Please check your local riding laws and regulations
before operating this motorcycle.
AN IMPORTANT SAFETY MESSAGE:

Read this manual carefully and completely before operating this motorcycle. Make sure you understand all instructions.

Pay close attention to the warning and notice labels on the motorcycle.

Never operate a motorcycle without proper training or instruction.

Weight of the rider should not exceed 25 kg (55 lb).

INTRODUCTION
AN IMPORTANT NOTE TO PARENTS:
This motorcycle is not a toy. Before you let your child ride this motorcycle, you should understand the instructions and warn-
ings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abil-
ities, and judgment. Some children may not be able to operate a motorcycle safely. Parents should supervise their child’s
use of the motorcycle at all times. Parents should permit continued use only if they determine that the child has the ability to
operate the motorcycle safely.
Your motorcycle was delivered with an adjustable speed limiter and power reduction plate. Yamaha recommends that all
beginners start off with the speed limiter adjusting screw turned in and the power reduction plate installed in the exhaust man-
ifold to limit the power available while they learn. The limiter screw may be gradually turned out to increase maximum speed
as the beginner becomes more familiar with operating the motorcycle. Parents should decide when to adjust the motorcycle
for more power as their youngster’s riding skills improve. Once the rider can operate with skill at the top speed permitted by
adjusting the speed limiter alone, the power reduction plate can be removed. Since removal of this plate will result in a sig-
nificant increase in power, turn the speed limiter back in again; adjust it out in stages as you did before.
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.
He or she should:


Obtain thorough instructions from a competent source on all aspects of motorcycle operation.

Observe the warnings and maintenance requirements in this Owner’s Manual.

Obtain qualified training in safe and proper riding techniques.

Obtain professional technical service as indicated in this Owner’s Manual and/or when made necessary by mechanical
conditions.

TABLE OF CONTENTS
SAFETY INFORMATION
................... 1-1
DESCRIPTION
................................... 2-1
Left view ........................................... 2-1
Right view ......................................... 2-2
Controls and instruments ................. 2-3
INSTRUMENT AND CONTROL
FUNCTIONS
........................................ 3-1
Handlebar switch ............................. 3-1
Speed limiter and power reduction
plate ............................................. 3-1
Brake lever ...................................... 3-2
Rear brake lever .............................. 3-3
Fuel tank cap ................................... 3-3
Fuel ................................................. 3-3
Fuel tank breather hose .................. 3-5
2-stroke engine oil ........................... 3-5
Fuel cock ......................................... 3-6
Starter (choke) lever “
1
” ................ 3-6
Kickstarter ....................................... 3-7
Seat ................................................. 3-7
FOR YOUR SAFETY –
PRE-OPERATION CHECKS
............... 4-1
Pre-operation check list ................... 4-2
OPERATION AND IMPORTANT
RIDING POINTS
.................................. 5-1
Starting and warming up a cold
engine .......................................... 5-1Starting a warm engine ................... 5-1
Starting off ....................................... 5-2
Acceleration and deceleration ......... 5-2
Braking ............................................ 5-2
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 .............. 6-2
General maintenance and lubrication
chart ............................................. 6-3
Checking the spark plug .................. 6-5
Removing the power reduction
plate ............................................. 6-6
Transmission oil .............................. 6-7
Middle and final gear cases ............ 6-8
Cleaning the air filter element ......... 6-8
Cleaning the spark arrester ............. 6-9
Adjusting the carburetor ................ 6-10
Adjusting the engine idling
speed ......................................... 6-10
Checking the throttle cable free
play ............................................ 6-11
Tires .............................................. 6-11
Panel wheels ................................. 6-13
Adjusting the front and rear brake
lever free play ............................ 6-14Checking the front and rear brake
shoes ..........................................6-15
Checking and lubricating the
cables .........................................6-15
Checking and lubricating the throttle
grip and cable .............................6-16
Adjusting the Autolube pump .........6-16
Lubricating the front and rear brake
levers ..........................................6-16
Checking and lubricating the
centerstand .................................6-17
Checking the front fork ...................6-17
Checking the steering ....................6-18
Checking the wheel bearings .........6-18
Front wheel ....................................6-18
Rear wheel .....................................6-20
Troubleshooting .............................6-23
Troubleshooting chart ....................6-24
MOTORCYCLE CARE AND
STORAGE
...........................................7-1
Matte color caution ..........................7-1
Care .................................................7-1
Storage ............................................7-3
SPECIFICATIONS
..............................8-1
CONSUMER INFORMATION
..............9-1
Identification numbers ......................9-1

INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
2
3
4
5
6
7
8
9
3. Wipe up any spilled fuel immedi-
ately.
NOTICE:
Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteri-
orate painted surfaces or plastic
parts.

[ECA10071]

4. Be sure to securely close the fuel
tank cap.
WARNING

EWA15151
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gaso-
line by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline vapor, or get some gasoline inyour eyes, see your doctor immedi-
ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change
your clothes.
EAU41981
For Canada
NOTICE

ECA15590
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the piston rings as well as to
the exhaust system.
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a pump octane number
[(R+M)/2] of 86 or higher, or a research
octane number of 91 or higher. If
knocking (or pinging) occurs, use agasoline of a different brand or premi-
um unleaded fuel. Use of unleaded fuel
will extend spark plug life and reduce
maintenance cost.
Gasohol
There are two types of gasohol: gaso-
hol containing ethanol and that contain-
ing methanol. Gasohol containing
ethanol can be used if ethanol content
does not exceed 10% (E10). Gasohol
containing methanol is not recom-
mended by Yamaha because it can
cause damage to the fuel system or ve-
hicle performance problems.
Except for Canada
NOTICE

ECA15590
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
1. Fuel tank filler tube
2. Fuel level
2 1

Recommended fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
2.0 L (0.53 US gal, 0.44 Imp.gal)
Recommended fuel:
For Europe: REGULAR UNLEADED
GASOLINE ONLY
Except for Canada and Europe: UN-
LEADED GASOLINE ONLY
Fuel tank capacity:
2.0 L (0.53 US gal, 0.44 Imp.gal)

INSTRUMENT AND CONTROL FUNCTIONS
3-5
2
34
5
6
7
8
9 such as the piston rings as well as to

the exhaust system.
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
EAU13412
Fuel tank breather hose
Before operating the motorcycle:

Check the fuel tank breather hose
connection.

Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.

Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.
EAU13452
2-stroke engine oil
Make sure that there is sufficient
2-stroke engine oil in the oil tank. Add
the recommended 2-stroke engine oil
as necessary.
TIP

Make sure that the 2-stroke engine oil
tank cap is properly installed.
1. Fuel tank breather hose
1

1. 2-stroke engine oil tank cap
2. Minimum level mark
Recommended oil:
See page 8-1.
Oil quantity:
0.30 L (0.32 US qt, 0.26 Imp.qt)
21

4-1
1
2
3
4
5
6
7
8
9

FOR YOUR SAFETY – PRE-OPERATION CHECKS
EAU15595
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.
WARNING

EWA11151
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. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:

6-1
2
3
4
5
67
8
9

PERIODIC MAINTENANCE AND ADJUSTMENT
EAU41951
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
WARNING

EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING

EWA15121
Turn off the engine when performing
maintenance unless otherwise
specified.

A running engine has moving
parts that can catch on body
parts or clothing and electricalparts that can cause shocks or
fires.

Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more in-
formation about carbon monox-
ide.
EAU17311
Owner’s tool kit
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
TIP

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.

PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
1
2
3
4
5
6
7
8
9

EAU41741
Periodic maintenance chart for the emission control system
TIP


From 18 months, repeat the maintenance intervals starting from 6 months.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM CHECK OR MAINTENANCE JOBINITIALTHEREAFTER
EVERY
1
month3
months6
months6
months12
months
1*Fuel line
Check fuel hoses for cracks or damage.Replace if necessary.
2Spark plugCheck condition.Adjust gap and clean.Replace if necessary.
3Air filter elementClean with solvent.Replace if necessary.
4*CarburetorCheck engine idling speed and starter operation.Adjust if necessary.Clean.
5*Cylinder head and
exhaust systemCheck for leakage.Tighten if necessary.Decarbonize if necessary.
6*Spark arresterClean.

PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
2
3
4
5
67
8
9

EAU41753
General maintenance and lubrication chart
NO. ITEM CHECK OR MAINTENANCE JOBINITIALTHEREAFTER
EVERY
1
month3
months6
months6
months12
months
1*Front brake
Check operation.Adjust brake lever free play.Replace brake shoes. Whenever worn to the limit
2*Rear brakeCheck operation.Adjust brake lever free play.Replace brake shoes. Whenever worn to the limit
3*WheelsCheck runout and for damage.Replace if necessary.
4*TiresCheck tread depth and for damage.Replace if necessary.Check air pressure.Correct if necessary.
5*Wheel bearingsCheck bearings for smooth operation.Replace if necessary.
6*Steering bearingsCheck bearing assemblies for looseness.Moderately repack with lithium-soap-based
grease every 2 years.
7*Middle and final gear
casesCheck for grease leakage.Check gears for damage and wear.Lubricate gears with lithium-soap-based grease.Every 2 years
8*Chassis fastenersCheck all chassis fitting and fasteners.Correct if necessary.
9*Autolube pumpCheck operation.Correct if necessary.Bleed.

PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
1
2
3
4
5
6
7
8
9
TIP

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
10
*Transmission oil
Check for oil leakage .Correct if necessary.Change.
11
*Front and rear brake
lever pivot
Apply lithium-soap-based grease lightly.
12
*Centerstand pivot
Check operation.Apply lithium-soap-based grease lightly.
13
*Shock absorber
assemblies
Check operation and for oil leakage.Replace if necessary.
14
*Control cable
Apply Yamaha chain and cable lube or engine oil
10W-30 lightly.
15
*Throttle grip housing
and cable
Check operation and free play.Apply Yamaha chain and cable lube or engine oil
10W-30 lightly. NO. ITEM CHECK OR MAINTENANCE JOBINITIALTHEREAFTER
EVERY
1
month3
months6
months6
months12
months