YAMAHA PW50 2011 Repair Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
7-22
7 5. Install the right-side rear shock ab-
sorber by installing the mounting
bolt.
6. While applying the rear brake,
tighten the axle nut to the specified
torque.
7. Tighten the rear arm nuts and rear
shock absorber mounting bolt to
the specified torques.
8. Install the exhaust chamber by in-
stalling the bolt and washers.
9. Install the power reduction plate, a
new gasket, and then install the
exhaust manifold bolts.
10. Tighten the exhaust manifold bolts
and exhaust chamber bolt to the
specified torques.11. Install the muffler by sliding the
spring clamp up to its original posi-
tion, and then installing the wash-
ers and muffler bolt.
TIPMake sure that the spring clamp is po-
sitioned with the projection side facing
inward.12. Tighten the muffler bolt to the
specified torque.13. Adjust the brake lever free play.
(See page 7-14.)
14. Install the seat.
Tightening torques:
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
Rear arm nut:
29 Nm (2.9 m·kgf, 21 ft·lbf)
Rear shock absorber mounting bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
Tightening torques:
Exhaust manifold bolt:
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Exhaust chamber bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
1. Exhaust chamber
2. Spring clamp
3. Muffler
1
2
3
Tightening torque:
Muffler bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-23
7
EAU25851
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, 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 inferi-
or, have a shorter service life and can
lead to expensive repair bills.
WARNING
EWA15141
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from waterheaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or
property damage.U5PG8AE0.book Page 23 Thursday, April 8, 2010 8:37 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-24
7
EAU25972
Troubleshooting chart
Check the fuel level in
the fuel tank.1. Fuel
There is
enough fuel.
There is
no fuel.
Supply fuel.
Operate the kickstarter.2. Compression
There is compression.
There is
no compression.Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.3. Ignition
Wet
DryWipe 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.
Open the throttle halfway and operate
the kickstarter.
Check the compression.
The engine does not start.
Check the compression.
U5PG8AE0.book Page 24 Thursday, April 8, 2010 8:37 AM

MOTORCYCLE CARE AND STORAGE
8-1
8
EAU37833
Matte color caution NOTICE
ECA15192
Some models are equipped with
matte colored finished parts. Be
sure to consult a Yamaha dealer for
advice on what products to use be-
fore 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 fin-
ished parts.
EAU40634
Care While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your mo-
torcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. 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, including the
spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-ucts onto seals, gaskets and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
NOTICE
ECA10772


Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.


Improper cleaning can damage
plastic parts (such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc.) and
the mufflers. Use only a soft,
clean cloth or sponge with wa-
ter to clean plastic. However, if
the plastic parts cannot be thor-
oughly cleaned with water, di-
luted mild detergent with water
may be used. Be sure to rinse
U5PG8AE0.book Page 1 Thursday, April 8, 2010 8:37 AM

MOTORCYCLE CARE AND STORAGE
8-2
8 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 re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.


Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.


For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.
After normal useRemove dirt with warm water, a mild
detergent, 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 or near the seaSince sea salt is extremely corrosive,
carry out the following steps after each
ride in the rain or near the sea.
1. Clean the motorcycle with cold wa-
ter and a mild detergent, after the
engine has cooled down.
NOTICE: Do not use warm water
since it increases the corrosive
action of the salt.
[ECA10791]
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean-
er to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the motorcycle dry completely
before storing or covering it.
U5PG8AE0.book Page 2 Thursday, April 8, 2010 8:37 AM

MOTORCYCLE CARE AND STORAGE
8-3
8
WARNING
EWA14501
Contaminants on the brakes or tires
can cause loss of control.

Make sure that there is no oil or
wax on the tires.


If necessary, wash the tires with
warm water and a mild deter-
gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor-
nering behavior.
NOTICE
ECA10800


Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.


Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.


Avoid using abrasive polishing
compounds as they will wear
away the paint.
TIP

Consult a Yamaha dealer for ad-
vice 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.
EAU40644
Storage Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover. Be
sure the engine and the exhaust sys-
tem are cool before covering the motor-
cycle.NOTICE
ECA10810


Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.


To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your motorcycle for sev-
eral months:
1. Follow all the instructions in the
“Care” section of this chapter.
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MOTORCYCLE CARE AND STORAGE
8-4
8 2. For motorcycles equipped with a
fuel cock that has an “S” (stop) po-
sition: Turn the fuel cock lever to
“S”.
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 pro-
tect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap. WARNING! To
prevent damage or injury
from sparking, make sure to
ground the spark plug elec-
trodes while turning the en-
gine over.
[EWA10951]
6. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the center-
stand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.TIPMake any necessary repairs before
storing the motorcycle.
U5PG8AE0.book Page 4 Thursday, April 8, 2010 8:37 AM

SPECIFICATIONS
9-1
9
Dimensions:Overall length:
1245 mm (49.0 in)
Overall width:
575 mm (22.6 in)
Overall height:
715 mm (28.1 in)
Seat height:
485 mm (19.1 in)
Wheelbase:
855 mm (33.7 in)
Ground clearance:
105 mm (4.13 in)
Minimum turning radius:
1300 mm (51.2 in)Weight:With oil and fuel:
39 kg (86 lb)Noise and vibration level:Noise level (77/311/EEC):
PW50 75.1 dB(A)@2750 r/min
Vibration on seat (EN1032, ISO5008):
PW50 Will not exceed 0.5 m/s²
Vibration on handlebar (EN1032, ISO5008):
PW50 Will not exceed 2.5 m/s²Engine:Engine type:
Air cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
49 cm³
Bore × stroke:
40.0 × 39.2 mm (1.57 × 1.54 in)Compression ratio:
6.00 :1
Starting system:
Kickstarter
Lubrication system:
Separate lubrication (Yamaha autolube)
Engine oil:Type:
YAMALUBE 2S or 2-stroke engine oil
(JASO FC grade) or (ISO EG-C or EG-D
grade)
Engine oil quantity:
Quantity:
0.30 L (0.32 US qt, 0.26 Imp.qt)Transmission oil:Type:
YAMALUBE 4 (10W-40) or SAE 10W-40
Oil change quantity:
0.30 L (0.32 US qt, 0.26 Imp.qt)Air filter:Air filter element:
Wet elementFuel:Recommended fuel:
PW50 Regular unleaded gasoline only
PW50A1 Regular unleaded gasoline only
(CAN)
PW50A1 Unleaded gasoline only
(AUS)(NZL)
Fuel tank capacity:
2.0 L (0.53 US gal, 0.44 Imp.gal)Carburetor:Type × quantity:
VM12SC x 1
Spark plug(s):Manufacturer/model:
NGK/BPR4HS
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:
Wet, centrifugal automaticTransmission:Primary reduction system:
Spur gear
Primary reduction ratio:
63/33 (1.909)
Secondary reduction system:
Shaft drive
Secondary reduction ratio:
19/15 × 54/11 (6.218)Chassis:Frame type:
Steel tube backbone
Caster angle:
25.50 °
Trail:
50.0 mm (1.97 in)Front tire:Type:
With tube
Size:
2.50-10 4PR
Manufacturer/model:
BRIDGESTONE/KNOBBY
Manufacturer/model:
IRC/KNOBBY
U5PG8AE0.book Page 1 Thursday, April 8, 2010 8:37 AM

SPECIFICATIONS
9-2
9
Rear tire:Type:
With tube
Size:
2.50-10 4PR
Manufacturer/model:
BRIDGESTONE/KNOBBY
Manufacturer/model:
IRC/KNOBBYLoading:Maximum rider weight:
25.0 kg (55 lb)Tire air pressure (measured on cold
tires):
Front:
100 kPa (1.00 kgf/cm², 15 psi)
Rear:
100 kPa (1.00 kgf/cm², 15 psi)
Front wheel:Wheel type:
Panel wheel
Rim size:
10x1.50Rear wheel:Wheel type:
Panel wheel
Rim size:
10x1.50Front brake:Type:
Drum brake
Operation:
Right hand operation
Rear brake:Type:
Drum brake
Operation:
Left hand operationFront suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
60.0 mm (2.36 in)Rear suspension:Type:
Unit swing
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
50.0 mm (1.97 in)Electrical system:Ignition system:
CDI
U5PG8AE0.book Page 2 Thursday, April 8, 2010 8:37 AM

CONSUMER INFORMATION
10-1
10
EAU40791
Identification numbers Record the vehicle identification num-
ber and model label information in the
spaces provided below for assistance
when ordering spare parts from a
Yamaha dealer or for reference in case
the vehicle is stolen.
VEHICLE IDENTIFICATION
NUMBER:
MODEL LABEL INFORMATION:
EAU26400
Vehicle identification number
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro-
vided.TIPThe vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcy-
cle with the licensing authority in your
area.
EAU26480
Model label
The model label is affixed to the frame
under the seat. (See page 4-7.) Record
the information on this label in the
space provided. This information will be
needed when ordering spare parts from
a Yamaha dealer.
1. Vehicle identification number
1
1. Model label
1
U5PG8AE0.book Page 1 Thursday, April 8, 2010 8:37 AM