YAMAHA PW50 2013 Service Manual

OPERATION AND IMPORTANT RIDING POINTS
6-4
6
EAU40722
Parking When parking, stop the engine, and
then turn the fuel cock lever to “S”
(stop).
WARNING
EWA10311
●
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans 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.
●
Do not park near grass or other
flammable materials which
might catch fire.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-1
7
EAU17244
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.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
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
EWA15122
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 electrical
parts 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 2-2 for more in-
formation about carbon monox-
ide.WARNING
EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
EAU17302
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replacement,
or repair of the emission control devic-
es and systems may be performed by
any repair establishment or individual
that is certified (if applicable). Yamaha
dealers are trained and equipped to
perform these particular services.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-2
7
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.TIPIf you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-3
7
EAU41742
Periodic maintenance chart for the emission control system TIPItems 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 JOB INITIAL
THEREAFTER
EVERY
1
month 3
months 6
months 6
months 12
months
1* Fuel line
Check fuel hoses for cracks or damage.Replace if necessary.
2 Spark plugCheck condition.Adjust gap and clean.Replace if necessary.
3 Air lter 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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
7
EAU41757
General maintenance and lubrication chart TIPItems 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 JOB INITIAL
THEREAFTER
EVERY
1
month 3
months 6
months 6
months 12
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*Check for grease leakage.Check gears for damage and wear.Lubricate gears with lithium-soap-based grease. Every 2 years
Middle and final gear
cases
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-5
7
TIPThe 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 cables
Apply Yamaha chain and cable lube or engine oil
10W-30 lightly.
15
*Throttle grip
Check operation.Check throttle grip free play, and adjust if
necessary.Apply Yamaha chain and cable lube or engine oil
10W-30 lightly.
NO. ITEM CHECK OR MAINTENANCE JOB
INITIAL
THEREAFTER
EVERY
1
month 3
months 6
months 6
months 12
months
8* Chassis fastenersCorrect if necessary.
A
9* utolube pumpCheck operation.Correct if necessary. Check all chassis fitting and fasteners.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-6
7
EAU19604
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 mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug1. Remove the spark plug cap.
2. Remove the spark plug as shown, with the spark plug wrench includ-
ed in the owner’s tool kit. To check the spark plug
1. Check that the porcelain insulator around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
TIPIf the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
stead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for electrodeerosion and excessive carbon or
other deposits, and replace it if
necessary.
3. Measure the spark plug gap with a wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
1. Spark plug cap
1
1. Spark plug wrench
1
Specified spark plug:PW50 NGK/BP4HS (ZAF)
PW50 NGK/BPR4HS
(AUT)(BEL)(CHE)(DEU)(DNK)
(ESP)(FIN)(FRA)(GBR)(GRC)
(IRL)(ITA)(NLD)(NOR)(POL)
(PRT)(SVN)(SWE)
PW50D NGK/BPR4HS
PW50D1 NGK/BPR4HS
PW50 DENSO/W14FP-L (ZAF)
1. Spark plug gap
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-7
7To install the spark plug
1. Clean the surface of the spark plug gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
2. Install the spark plug with the spark plug wrench, and then tight-
en it to the specified torque.
TIPIf a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.3. Install the spark plug cap.
EAU41103
Removing the power reduc-
tion plate To obtain full engine performance ca-
pability, removing the power reduction
plate is required.1. Remove the exhaust manifold by removing the bolts. WARNING!
Always let the exhaust system
cool prior to touching exhaust
components.
[EWA14581]
2. Remove the gasket.
3. Remove the power reduction plate.
TIPStore the power reduction plate with the
Owner’s Manual so that it is readily
available whenever you want to reduce
the engine power.4. Install the exhaust manifold and itsnew gasket by installing the bolts,
and then tighten the bolts to the
specified torque.
Spark plug gap:0.6–0.7 mm (0.024–0.028 in)
Tightening torque: Spark plug:20 Nm (2.0 m·kgf, 14 ft·lbf)
1. Exhaust manifold bolt
1
1. Exhaust manifold
2. Gasket
3. Power reduction plateTightening torque:Exhaust manifold bolt:
9 Nm (0.9 m·kgf, 6.5 ft·lbf)1
23
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-8
7
EAU40893
Transmission oil The transmission oil must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the motorcycle. In
addition, the transmission oil must be
changed at the intervals specified in the
periodic maintenance and lubrication
chart.1. Place the motorcycle on the cen- terstand.
2. Place an oil pan under the trans- mission to collect the used oil.
3. Remove the transmission oil filler cap, the transmission oil drain bolt
and its gasket to drain the oil from
the transmission. 4. Install the transmission oil drain
bolt and its new gasket, and then
tighten the bolt to the specified
torque.
5. Refill with the specified amount of the recommended transmission
oil, and then install and tighten the
oil filler cap.
NOTICE
ECA10452
●
In order to prevent clutch slip-
page (since the transmission oil
also lubricates the clutch), do
not mix any chemical additives.
Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
●
Make sure that no foreign mate-
rial enters the transmission.
6. Start the engine, and then let it idlefor several minutes while checking
the transmission for oil leakage. If
oil is leaking, immediately turn the
engine off and check for the cause.
1. Transmission oil filler cap
1
1. Transmission oil drain bolt
2. Gasket
Tightening torque:Transmission oil drain bolt:14 Nm (1.4 m·kgf, 10 ft·lbf)
Recommended transmission oil: See page 9-1.
Oil change quantity:
0.30 L (0.32 US qt, 0.26 Imp.qt)
1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-9
7
EAU41711
Middle and final gear cases The middle and final gear cases must
be checked for grease leakage before
each ride. If any leakage is found, have
a Yamaha dealer check and repair the
motorcycle. In addition, have a
Yamaha dealer check and lubricate the middle and final gears at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU40903
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean or, if necessary, replace the air
filter element more frequently if you are
riding in unusually wet or dusty areas. 1. Remove the seat. (See page 4-7.)
2. Remove the air filter case cover by removing the screw.
3. Pull the sponge material out, clean it with solvent, and then squeeze
the remaining solvent out. 4. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the ex-
cess oil out.
TIPThe sponge material should be wet but
not dripping.
1. Air filter case cover
2. Screw
2
1
1. Sponge material
1
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