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Yamaha PW50(Z), Owner'S Manual

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Yamaha PW50(Z) Owner'S Manual Download Page 39

 

PERIODIC MAINTENANCE AND ADJUSTMENT

 

7-3

 

2

3

4

5

6

7

8

9

 

EAU41754

 

General maintenance and lubrication chart 

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 brake

Check operation.
Adjust brake lever free play.
Replace brake shoes.

Whenever worn to the limit

3

*

Wheels

Check runout and for damage.
Replace if necessary.

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.
Moderately repack with lithium-soap-based 
grease every 2 years.

7

*

Middle and final gear 
cases

Check for grease leakage.
Check gears for damage and wear.
Lubricate gears with lithium-soap-based grease.

Every 2 years

8

*

Chassis fasteners

Check all chassis fitting and fasteners.
Correct if necessary.

A

9

*

utolube pump

Check operation.
Correct if necessary.

Summary of Contents for PW50(Z)

Page 1: ...DIENUNGSANLEITUNG Read this manual carefully before operating this vehicle Il convient de lire attentivement ce manuel avant la pre mière utilisation du véhicule Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen ...

Page 2: ...YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2009 04 0 5 1 E F G D PAPER R GEDRUCKT RECYCLÉ YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2009 04 0 5 1 E F G D PAPER R GEDRUCKT RECYCLÉ ...

Page 3: ...5PG 28199 89 E0 PW50 Z OWNER S MANUAL Read this manual carefully before operating this vehicle ...

Page 4: ...forms to the essential health of Directive 98 37 EC 2006 42 EC Directives of EEC 2004 108 EC e of issue of the other Directives of EEC tion of the essential health and safety requirements of EEC the following standards and or technical ulted and date of issue of standards and or specifications e N V Schiphol Rijk The Netherlands Signature Kunihiko Miwa Division Manager Motorcycle Headquarters Prod...

Page 5: ...hedules and operating instructions contained within this manual eks advancements in product design and quality Therefore while this manual contains the most cur n available at the time of printing there may be minor discrepancies between your motorcycle and this question concerning this manual please consult a Yamaha dealer EWA10031 ual carefully and completely before operating this motorcycle EWA...

Page 6: ...radually turned out to increase maximum speed es more familiar with operating the motorcycle Parents should decide when to adjust the motorcycle youngster s riding skills improve Once the rider can operate with skill at the top speed permitted by ter alone the power reduction plate can be removed Since removal of this plate will result in a sig er turn the speed limiter back in again adjust it out...

Page 7: ...sonal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer ...

Page 8: ...200 PW50 Z OWNER S MANUAL 2009 by Yamaha Motor Co Ltd 1st edition March 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 9: ... Cleaning the spark arrester 7 9 Adjusting the carburetor 7 10 Adjusting the engine idling speed 7 10 Checking the throttle cable free play 7 11 Tires 7 11 Panel wheels 7 13 Adjusting the front and rear brake lever free play 7 13 Checking the front and rear brake shoes 7 14 Checking and lubricating the cables 7 15 Checking and lubricating the throttle grip and cable 7 15 Adjusting the Autolube pum...

Page 10: ...110 ll of the labels on your vehicle They contain important information for safe and proper operation of ove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label amaha dealer 6 3 2 4 5 ...

Page 11: ...UBLICS collision avec un autre véhicule UN CASQUE DE MOTOCYCLISTE es et des vêtements de protection follows FRONT REAR 3RV 21668 A0 Cold tire normal pressure should be set as 100 kPa 1 00 kgf cm2 15 psi 100 kPa 1 00 kgf cm2 15 psi être réglée comme suit AVANT ARRIERE 3RV 21668 B0 100 kPa 1 00 kgf cm2 15 psi 100 kPa 1 00 kgf cm2 15 psi La pression des pneus à froid doit normallement 5 This spark ig...

Page 12: ...F IMPORTANT LABELS 1 3 3 2 1 ...

Page 13: ...LOCATION OF IMPORTANT LABELS 1 4 1 2 3 4 5 6 7 8 9 3 100 1 00 15 100 1 00 15 5PG 2816R 00 G 2817L 10 1 kw NG ORDER 39 kg 5PG 2156A 00 ...

Page 14: ...high pressure nitrogen gas Mishandling can cause explosion Do not incinerate puncture or open Turn off the main switch after riding to avoid draining the battery Use unleaded gasoline only Measure tire pressure when tires are cold Adjust tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death ...

Page 15: ...LOCATION OF IMPORTANT LABELS 1 6 1 2 3 4 5 6 7 8 9 h Africa 1 2 ...

Page 16: ...he owner s manual 5PA 21568 01 ggete il manuale di istruzioni e avant d utiliser ce véhicule leitung bevor Sie dieses Fahrzeug fahren culo lea el Manual del Propietario 3RV 21668 A0 sure should be set as 1 00 kgf cm2 15 psi 1 00 kgf cm2 15 psi ...

Page 17: ...nly No passen gers The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra cau...

Page 18: ...y gas Breathing car bon monoxide can cause headaches dizziness drowsiness nausea confu sion and eventually death Carbon Monoxide is a colorless odor less tasteless gas which may be present even if you do not see or smell any engine exhaust Deadly levels of carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself Also deadly levels of carbon monoxide can linge...

Page 19: ...arket companies produce Therefore Yamaha can neither en dorse nor recommend the use of ac cessories not sold by Yamaha or modifications not specifically recom mended by Yamaha even if sold and installed by a Yamaha dealer Aftermarket Parts Accessories and Modifications While you may find aftermarket prod ucts similar in design and quality to genuine Yamaha accessories recog nize that some aftermar...

Page 20: ... ability accessories are d adding electri lectrical acces capacity of the cal system an d result which gerous loss of lights or engine power Aftermarket Tires and Rims The tires and rims that came with your motorcycle were designed to match the performance capabilities and to provide the best combination of handling brak ing and comfort Other tires rims siz es and combinations may not be appropria...

Page 21: ...3 1 2 3 4 5 6 7 8 9 DESCRIPTION EAU10410 1 2 3 4 5 e 7 10 7 8 ...

Page 22: ...N 3 2 EAU10420 3 1 2 4 page 7 7 page 4 5 ...

Page 23: ...DESCRIPTION 3 3 2 3 4 5 6 7 8 9 EAU10430 uments 1 2 7 3 4 5 6 4 3 ge 4 6 cap page 4 5 4 1 4 2 ...

Page 24: ... reduction plate The speed limiter keeps the throttle from fully opening even when the throttle grip is turned to the maximum The power reduction plate is installed in the exhaust mani fold to limit the amount of power avail able while they learn Speed limiter 1 Loosen the locknut 2 To increase the maximum engine power available and the maximum speed of the motorcycle turn the adjusting screw in d...

Page 25: ...trol have an accident or be injured Do not turn the adjusting screw out more than 7 mm 0 28 in before con sulting a Yamaha dealer Always make sure the throttle cable free play is adjusted to 1 5 3 5 mm 0 06 0 14 in See page 7 11 Power reduction plate Once the rider can operate with skill at the top speed permitted by adjusting the speed limiter alone the power re duction plate can be removed See p...

Page 26: ...s are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling follow these instructions 1 Before refueling turn off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or while in the vi cinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overf...

Page 27: ...rch octane number of 91 or higher If knocking or pinging occurs use a gasoline 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 ...

Page 28: ...damage and replace it if damaged Make sure that the fuel tank breather hose is not blocked and clean it if necessary EAU13453 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 NOTICE ECA16670 Make sure that the 2 stroke engine oil tank cap is properly installed 1 Fuel tank breather hose 1 1 2 stroke engin...

Page 29: ...n fuel flows to the carburetor Normal riding is done with the lever in this position EAU13590 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke S stop 1 1 Arrow mark pointing to O on 1 1 Starter choke lever 1 a b ...

Page 30: ...ng the bolts and washers 2 Pull the seat off To install the seat 1 Insert the projection on the front of the seat into the seat holder as shown 2 Place the seat in the original posi tion 3 Install the mudguard by installing the washers and bolts TIP Make sure that the seat is properly se cured before riding 1 1 Bolt 2 Mudguard 1 2 1 Seat holder 2 Projection 1 2 ...

Page 31: ...ng points CHECKS PAGE Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 3 Check oil level in oil tank If necessary add recommended oil to specified level Check vehicle for oil leakage 4 5 es Check vehicle for grease leakage 7 8 Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 7 13 7 14 Check operation Lubricate cable if necessary ...

Page 32: ...e Correct if necessary 7 11 7 13 Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 16 Make sure that operation is smooth Lubricate pivot if necessary 7 16 Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Check operation 4 1 CHECKS PAGE ...

Page 33: ... down 5 After starting the engine move the starter choke back halfway NOTICE For maximum engine life never accelerate hard when the engine is cold ECA11041 6 When the engine is warm turn the starter choke off and set the en gine stop switch to RUN TIP The engine is warm when it responds normally to the throttle with the starter choke turned off EAU16660 Starting a warm engine Follow the same proce...

Page 34: ...direction a To reduce the speed turn the throt tle grip in direction b EAU41012 Braking WARNING EWA14571 Avoid braking hard or suddenly especially when leaning over to one side otherwise the motor cycle may skid or overturn Keep in mind that braking on wet surfaces is much more diffi cult Ride slowly down a hill as brak ing downhill can be very diffi cult 1 Close the throttle completely 2 Apply bo...

Page 35: ...n that might result in engine overheating must be avoided However momentary full throttle operation under load i e two to three seconds maximum does not harm the engine Each full throttle acceleration should be followed with a substantial rest period for the engine To allow the engine to cool down from the temporary buildup of heat cruise at a lower engine speed After the first 5 hours of operatio...

Page 36: ...TANT RIDING POINTS 6 4 EAU40722 e engine and k lever to S EWA10311 and exhaust ome very hot here pedestri e not likely to e burned lope or on soft e the vehicle ncreasing the and fire grass or other erials which ...

Page 37: ... the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 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 addi...

Page 38: ...s data and technical CHECK OR MAINTENANCE JOB INITIAL THEREAFTER EVERY 1 month 3 months 6 months 6 months 12 months Check fuel hoses for cracks or damage Replace if necessary Check condition Adjust gap and clean Replace if necessary Clean with solvent Replace if necessary Check engine idling speed and starter operation Adjust if necessary Clean Check for leakage Tighten if necessary Decarbonize if...

Page 39: ...ever worn to the limit Check runout and for damage Replace if necessary Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary Check bearings for smooth operation Replace if necessary s Check bearing assemblies for looseness Moderately repack with lithium soap based grease every 2 years gear Check for grease leakage Check gears for damage and wear Lubricate g...

Page 40: ...ease lightly Check operation Apply lithium soap based grease lightly Check operation and for oil leakage Replace if necessary Apply Yamaha chain and cable lube or engine oil 10W 30 lightly ing Check operation and free play Apply Yamaha chain and cable lube or engine oil 10W 30 lightly CHECK OR MAINTENANCE JOB INITIAL THEREAFTER EVERY 1 month 3 months 6 months 6 months 12 months ...

Page 41: ...vehicle 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 electrode erosion and excessive carbon or other deposits and replace it if necessary To install the spark plug 1 Measure the spark plug gap with a w...

Page 42: ...ve 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 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 by in stalling the bolts 14 5 ft lbf 1 Exh...

Page 43: ...h 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 idle for several minutes while checking the t...

Page 44: ...tion chart Clean the air filter element more fre quently 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...

Page 45: ...ified in the periodic maintenance and lubrication chart WARNING EWA10980 Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning 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 ar rester portion...

Page 46: ... sufficient technical knowl edge may result in poor perfor mance of or damage to the engine EAU21362 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart TIP A diagnostic tachometer is needed to make this adjustment 1 Attach the tachometer to the spark plug lead 2 ...

Page 47: ...safe operation of your motorcy cle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA14381 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The tire air pressure must be checked and adjusted on cold tires i e when the tem...

Page 48: ...390 Have a Yamaha dealer replace excessively worn tires Operat ing the motorcycle with exces sively worn tires decreases riding stability and can lead to loss of control The replacement of all wheel and brake related parts including the tires should be left to a Yamaha dealer who has the necessary professional knowledge and experience It is not recommended to patch a punctured tube If unavoid able...

Page 49: ...ed laced d be balanced he tire or wheel or replaced An l can result in adverse han cs and a short y after changing a tire since the tire must seat itself on the rim properly Failure to al low proper seating may cause tire failure which may result in dam age to the motorcycle and injury to the rider EAU22151 Adjusting the front and rear brake lever free play Front Rear The front and rear brake leve...

Page 50: ...ake this adjustment EAU41052 Checking the front and rear brake shoes The front and rear brake shoes must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart TIP The wheels must be removed to check brake shoe lining thickness To remove the front wheel See page 7 18 To remove the rear wheel See page 7 20 Front play 0 79 in play 0 79 in usting nut 1 1 Bra...

Page 51: ...ove smoothly have a Yamaha dealer check or replace it WARNING Damage to the outer housing of cables may result in in ternal rusting and cause interfer ence with cable movement Replace damaged cables as soon as possi ble to prevent unsafe condi tions EWA10711 EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi t...

Page 52: ...rt EAU23192 Checking and lubricating the centerstand The operation of the centerstand should be checked before each ride and the pivots and metal to metal con tact surfaces should be lubricated if necessary WARNING EWA11301 If the centerstand does not move up and down smoothly have a Yamaha dealer check or repair it Otherwise the centerstand could contact the ground and distract the operator re su...

Page 53: ... have a Yamaha dealer check or re pair it EAU45511 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place the vehicle on the center stand WARNING To avoid inju ry securely support the vehicle so there is no danger of it falling ov...

Page 54: ...he vehicle so there is no danger of it falling over 1 Place the motorcycle on the cen terstand 2 Disconnect the brake cable at the wheel by removing the brake lever free play adjusting nut then re moving the cable from the brake camshaft lever and brake shoe plate 3 Remove the axle nut and washer 4 Pull the wheel axle out and then remove the wheel 1 Brake lever free play adjusting nut 2 Brake cams...

Page 55: ... washer and axle nut and then tighten the axle nut to the specified torque 5 Connect the brake cable at the wheel hub and then install the brake cable free play adjusting nut 6 Adjust the brake lever free play See page 7 13 7 Take the motorcycle off the center stand so that the front wheel is on the ground 8 Push down hard on the handlebar several times to check for proper fork operation 1 Retaine...

Page 56: ...page 4 7 ffler bolt and G Always let m cool prior to ust compo amp down and uffler 5 Remove the exhaust chamber bolt and washers 6 Remove the exhaust manifold bolts and then remove the ex haust chamber 1 Muffler 2 Washer 3 Muffler bolt 4 Spring clamp 3 1 2 4 1 Exhaust chamber 2 Exhaust chamber bolt 3 Washer 2 1 3 ...

Page 57: ...2 Install the wheel by inserting it into the wheel hub 3 Install the rear arm by installing the washers and nuts 4 Install the axle nut 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 ounting bolt 1 1 1...

Page 58: ...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 o...

Page 59: ...PERIODIC MAINTENANCE AND ADJUSTMENT 7 23 2 3 4 5 6 7 8 9 Gasoline or ignite or ex ere injury or ...

Page 60: ...n Have a Yamaha dealer check the vehicle Wet Dry Wipe 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 ...

Page 61: ...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 ...

Page 62: ...riding in the rain or near the sea Since 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 an...

Page 63: ...U40643 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover 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 are...

Page 64: ...nt 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 littl...

Page 65: ...ement Wet element Fuel Recommended fuel PW50 Regular unleaded gasoline only PW50Z Regular unleaded gasoline only CAN PW50Z 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 PW50 NGK BPR4HS PW50Z NGK BPR4HS DENSO W14FPL Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet centrifugal automa...

Page 66: ... Type Drum brake Operation Left hand operation Front 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 ...

Page 67: ...this number in the space pro vided TIP The 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 part...

Page 68: ... EAU48120 trol Informa Control Informa e location in the illustration This label shows specifica tions related to exhaust emissions as required by federal law state law and Environment Canada Information Information 1 ...

Page 69: ...ty information 2 1 Seat 4 7 Spark arrester cleaning 7 9 Spark plug checking 7 5 Specifications 9 1 Speed limiter and power reduction plate 4 1 Starter choke lever 4 6 Starting and warming up a cold engine 6 1 Starting off 6 2 Steering checking 7 17 Storage 8 3 T Throttle cable free play checking 7 11 Throttle grip and cable checking and lubricating 7 15 Tires 7 11 Tool kit 7 1 Transmission oil 7 7...

Page 70: ...ED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2009 04 0 5 1 E ...

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