YAMAHA PW50 2020 Service Manual

Periodic maintenance an d a djustment
7-1
7
EAU17246
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained 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
EWA10322
Failure to properly maintain the vehi-
cle or performin g maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while usin g the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha d ealer perform
service.
WARNING
EWA15123
Turn off the en gine when performin g
maintenance unless otherwise
specified .
 A runnin g en gine has movin g
parts that can catch on body
parts or clothin g an d electrical
parts that can cause shocks or
fires.
 Runnin g the en gine while ser-
vicin g can lead to eye injury,
b urns, fire, or car bon monoxi de
poisonin g – possi bly lea din g to d
eath. See pag e 2-2 for more in-
formation a bout car bon monox-
i d e.
WARNING
EWA15461
Brake discs, calipers, drums, an d
linin gs can b ecome very hot durin g
use. To avoi d possi ble burns, let
b rake components cool before
touching them.
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Periodic maintenance an d a djustment
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EAU17303
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, replace-
ment, or repair of the emission control
devices and systems may be per-
formed by any repair establishment or
individual that is certified (if applicable).
Yamaha dealers are trained and equipped to perform these particular
services.
EAU17312
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.
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Periodic maintenance an d a djustment
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7
EAU69180
Perio dic maintenance chart for the emission control system
TIP
Items marked with an asterisk should be performed by a Yamaha dealer as they
require special tools, data and technical skills.
4 *Carburetor Check engine idling speed and
starter operation.
Adjust if necessary.
Clean.
5 *Cylinder head and
exhaust system Check for leakage.
√
Tighten if necessary.
Decarbonize if necessary.
6
*Spark arrester Clean.√
NO. ITEM CHECK OR MAINTENANCE JOB
1 month3 months
6 months
6 months12 months
1
*Fuel line Check fuel hoses for cracks or
damage.√√√ √
√√√ √
√√
√
√
√√
√
√
√√
√ Replace if necessary.
2Spark plug Check condition.
Adjust gap and clean.
Replace if necessary.
3Air filter element
Clean with solvent.
Replace if necessary.
THEREAFTER
EVERYINITIAL
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Periodic maintenance an d a djustment
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7
EAU69202
General maintenance and lubrication chart
TIP
Items marked with an asterisk should be performed by a Yamaha dealer as they
require special tools, data and technical skills.
4 *Tires Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
5
*Wheel bearings Check bearings for smooth operation.
Replace if necessary.
6
*Steering bearings Check bearing assemblies for
looseness.
7 *Middle and final gear
cases Check for grease leakage.
8
*Chassis fasteners Check all chassis fitting and fasteners.
9
*Autolube pump Check operation.
10
*Transmission oil Check for oil leakage.
Correct if necessary.
Change. Correct if necessary. Correct if necessary. Check gears for damage and wear.
Lubricate gears with
lithium-soap-based grease.
Moderately repack with
lithium-soap-based grease.
NO. ITEM CHECK OR MAINTENANCE JOB
1 month3 months
6 months
6 months12 months
1 *
*
*Front brake Check operation.
Adjust brake lever free play.√√√
√
√√√ √
√√√ √
√√√ √
√√√ √
√√√ √
√√√ √
√√√ √ √
√
√√√ √
Replace brake shoes.
Whenever worn to the limit.
2Rear brake Check operation.
Adjust brake lever free play.
Replace brake shoes. Whenever worn to the limit.
Every 2 years
Every 2 years
3Wheels Check runout and for damage.
Replace if necessary.
THEREAFTER
EVERYINITIAL
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Periodic maintenance an d a djustment
7-5
7TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty
areas.
11 *Front and rear brake
lever pivot Apply lithium-soap-based grease
lightly.
12 *Centerstand pivot Check operation.
13
*Shock absorber
assemblies Check operation and for oil leakage.
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.
Replace if necessary. Apply lithium-soap-based grease
lightly.
NO. ITEM CHECK OR MAINTENANCE JOB
1 month3 months
6 months
6 months12 months
√√√ √
√√√ √√√
√
√√
√
√
√√
THEREAFTER
EVERYINITIAL
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Periodic maintenance an d a djustment
7-6
7
EAU19607
Checkin g the spark plu g
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 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).
TIP
If 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. Spark plug wrench
1
1
Specified spark plu g:
NGK/BP4HS (South Africa)
NGK/BPR4HS (Canada, Europe,
Oceania)
DENSO/W14FP-L (South Africa)
1. Spark plug gap
Spark plu g g ap:
0.6–0.7 mm (0.024–0.028 in)
1
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Periodic maintenance an d a djustment
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7
To install the spark plu
g
1. Clean the surface of the spark plug gasket and its mating surfa-
ce, 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.
TIP
If 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 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.
[EWA14582]
2. Remove the gasket.
3. Remove the power reduction plate.
Tightening torque:
Spark plug: 20 N·m (2.0 kgf·m, 15 lb·ft)
1. Exhaust manifold bolt
1. Exhaust manifold
2. Gasket
3. Power reduction plate
1
1
2
3
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Periodic maintenance an d a djustment
7-8
7
TIP
Store 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 its
new gasket by installing the bolts,
and then tighten the bolts to the
specified torque.
EAU40896
Transmission oil
The transmission 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.
To chan ge the transmission oil
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.
Tightenin g torque:
Exhaust manifold bolt: 9 N·m (0.9 kgf·m, 6.6 lb·ft)
1. Transmission oil filler cap
1. Transmission oil drain bolt
2. Gasket
1
12
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Periodic maintenance an d a djustment
7-9
7
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.
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 ddition, 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. Check the O-ring for damage, and replace it if necessary. 7. Install and tighten the transmis-
sion oil filler cap.
8. 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 cau-
se.
Tightening torque:
Transmission oil drain bolt: 14 N·m (1.4 kgf·m, 10 lb·ft)
Recommen ded transmission oil:
See page 9-1.
Oil chan ge quantity:
0.30 L (0.32 US qt, 0.26 Imp.qt)
1. O-ring
1
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Periodic maintenance an d a djustment
7-10
7
EAU41712
Mi ddle an d 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.
EAU40904
Cleanin g 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 4-8.)
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.
1. Air filter case cover
2. Screw
1. Sponge material
2
1
1
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