maintenance YAMAHA PW50 2014 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
7
EAU41759
General maintenance and lu brication chartTIPItems 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 cable lubricant or other suitable
cable lubricant.
15
*Throttle grip
Check operation.Check throttle grip free play, and adjust if
necessary.Apply Yamaha cable lubricant or other suitable
cable lubricant.
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
EAU19605
Checking the spark plugThe 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 main-
tenance and lubrication chart. In addi-
tion, the condition of the spark plug
can reveal the condition of the engine.
To remove the spark plu g
1. 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 plu
g
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 vehi-
cle 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 specifi-
cation.
1. Spark plug cap
1
1. Spark plug wrench
1
Specified spark plu g:
PW50 NGK/BP4HS (ZAF)
PW50 NGK/BPR4HS
(AUT)(BEL)(CHE)(CYP)(CZE)(DEU)
(DNK)(ESP)(FIN)(FRA)(GBR)(GRC)
(IRL)(ITA)(NLD)(NOR)(POL)(PRT)
(SVK)(SVN)(SWE)(TUR)
PW50E NGK/BPR4HS
PW50E1 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 plu
g
1. Clean the surface of the spark plug gasket and its mating sur-
face, 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
specified torque as soon as possible.3. Install the spark plug cap.
EAU41104
Removin g the power re duc-
tion plateTo 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.
[EWA14582]
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 plu g g ap:
0.6–0.7 mm (0.024–0.028 in)
Ti ghtenin g 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 plateTightenin g 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
EAU40894
Transmission oilThe 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 lubrica-
tion 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
ECA10453
In or der to prevent clutch slip-
pa ge (since the transmission oil
also lu bricates the clutch), do
not mix any chemical additives.
Do not use oils with a diesel
specification of “CD” or oils of a
hi gher quality than specifie d. In
a dd ition, do not use oils la bele d
“ENERGY CONSERVING II” or
hi gher.
 Make sure that no forei gn mate-
rial enters the transmission.6. Start the engine, and then let it idle for 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
Tightenin g torque:
Transmission oil drain bolt: 14 Nm (1.4 m·kgf, 10 ft·lbf)
Recommen ded transmission oil:
See page 9-1.
Oil chan ge 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
EAU41712
Middle an d final g ear casesThe 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.
EAU40904
Cleanin g the air filter elementThe 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 excess 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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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.
EAU40915
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 motorcycle is equipped with panel
wheels and 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 Motor Co., Ltd.
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:
PW50 (EUR)
BRIDGESTONE/KNOBBY
PW50 (ZAF), PW50E, PW50E1
BRIDGESTONE/KNOBBY
IRC/KNOBBY
Rear tire:
Size:2.50-10 4PR
Manufacturer/model:
PW50 (EUR)
BRIDGESTONE/KNOBBY
PW50 (ZAF), PW50E, PW50E1
BRIDGESTONE/KNOBBY
IRC/KNOBBY
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