2007 YAMAHA PW50 brake

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
2
3
4
5
67
8
9
4. Slide the spring clamp down, and
then remove the muffler.5. Remove the exhaust chamber bolt
and washers.
6. Remove the exhaust manifold
bolts, and then remove the ex-
haust chamber.
7. Remove the right-side rear shock
absorber mounting bolt and then
tilt the rear shock absorber upward
as shown.8. Remove the axle nut while apply-
ing the rear brake.
9. Remove the rear arm by removing
the nuts and washers.

1. Muffler
2. Washer
3. Muffler bolt
4. Spring clamp
1. Exhaust chamber
2. Exhaust chamber bolt
3. Washer
3
1
24
2 1
3

1. Exhaust manifold bolt
1

1. Rear shock absorber mounting bolt
1. Axle nut
1
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
1
2
3
4
5
6
7
8
9
10. Pull the wheel to the right to sepa-
rate it from the final gear case, and
then remove the wheel.

EAU41521
To install the rear wheel
1. Apply a light coating of lithi-
um-soap-based grease to the
splines of the final gear case and
wheel hub.
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.
8. Install the exhaust chamber and
then install the exhaust manifold
bolts.
9. Install the washers and exhaust
chamber bolt.
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.
NOTE:

Make sure that the spring clamp is po-
sitioned with the projection side facing
inward.
12. Tighten the muffler bolt to the
specified torque.
1. Rear arm
2. Washer
3. Rear arm nut
1
2
3

Tightening torques:
Axle nut:
60 Nm (6.0 m·kgf, 43.4 ft·lbf)
Rear arm nut:
28.5 Nm (2.9 m·kgf, 20.6 ft·lbf)
Rear shock absorber mounting bolt:
22.5 Nm (2.3 m·kgf, 16.3 ft·lbf)
Tightening torques:
Exhaust manifold bolt:
8.5 Nm (0.9 m·kgf, 6.1 ft·lbf)
Exhaust chamber bolt:
17.5 Nm (1.8 m·kgf, 12.7 ft·lbf)
1. Exhaust chamber
2. Spring clamp
3. Muffler
Tightening torque:
Muffler bolt:
17.5 Nm (1.8 m·kgf, 12.7 ft·lbf)
1
2
3

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
2
3
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5
67
8
9
13. Adjust the brake lever free play.
(See page 6-14.)
14. Install the seat.

EAU25850
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.

7-1
2
3
4
5
6
78
9

MOTORCYCLE CARE AND STORAGE
EAU40631
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
CAUTION:

ECA10770

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
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.

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 orthinner, 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.

SPECIFICATIONS
8-2
2
3
4
5
6
7
89

Size:
2.50-10 4PR
Manufacturer/model:
BRIDGESTONE/KNOBBY
Manufacturer/model:
IRC/KNOBBY
Rear tire:
Type:
With tube
Size:
2.50-10 4PR
Manufacturer/model:
BRIDGESTONE/KNOBBY
Manufacturer/model:
IRC/KNOBBY
Tire air pressure (measured on cold
tires):
Front:
100 kPa (15 psi) (1.00 kgf/cm
2

)
Rear:
100 kPa (15 psi) (1.00 kgf/cm
2

)
Front wheel:
Wheel type:
Panel wheel
Rim size:
10x1.50
Rear wheel:
Wheel type:
Panel wheel
Rim size:
10x1.50
Front brake:
Type:
Drum brake
Operation:
Right hand operation
Rear brake:
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

INDEX
A
Acceleration and deceleration ...................5-2
Accessories and replacement parts ........6-13
Air filter element, cleaning .........................6-8
Autolube pump, adjusting ........................6-16
B
Brake lever, front .......................................3-2
Brake lever, rear ........................................3-3
Brake levers, lubricating ..........................6-16
Brake shoes, checking ............................6-15
Braking ......................................................5-2
C
Cables, checking and lubricating .............6-15
Carburetor, adjusting ...............................6-10
Care ...........................................................7-1
Centerstand, checking and lubricating ....6-17
E
Engine break-in .........................................5-3
Engine idling speed .................................6-10
Engine oil ...................................................3-5
Engine, starting a warm .............................5-1
Engine stop switch.....................................3-1
F
Front and rear brake lever free play,
adjusting ................................................6-14
Front fork, checking .................................6-17
Fuel ............................................................3-3
Fuel cock ...................................................3-5
Fuel tank breather hose.............................3-5
Fuel tank cap .............................................3-3
H
Handlebar switch .......................................3-1
I
Identification numbers ...............................9-1
K
Kickstarter ................................................. 3-6
L
Labels, location of ..................................... 1-4
M
Maintenance and lubrication, periodic ....... 6-3
Maintenance, emission control system ..... 6-2
Middle and final gear cases....................... 6-8
Model label ................................................ 9-1
P
Parking ...................................................... 5-4
Part locations............................................. 2-1
Power reduction plate, removing ............... 6-6
Pre-operation check list ............................. 4-2
S
Safety information ..................................... 1-1
Seat ........................................................... 3-7
Spark arrester, cleaning ............................ 6-9
Spark plug, checking ................................. 6-5
Specifications ............................................ 8-1
Speed limiter and power reduction plate ... 3-1
Starter (choke) lever .................................. 3-6
Starting and warming up a cold engine ..... 5-1
Starting off ................................................. 5-2
Steering, checking ................................... 6-18
Storage ...................................................... 7-3
T
Throttle cable free play, checking............ 6-11
Throttle grip and cable, checking and
lubricating .............................................. 6-16
Tires ........................................................ 6-11
Tool kit ....................................................... 6-1
Transmission oil ........................................ 6-7
Troubleshooting....................................... 6-23Troubleshooting chart ............................. 6-24
V
Vehicle identification number .................... 9-1
W
Wheel bearings, checking ....................... 6-18
Wheel (front) ........................................... 6-19
Wheel (rear) ............................................ 6-20
Wheels .................................................... 6-13