2008 YAMAHA PW50 check engine

TABLE OF CONTENTS
SAFETY INFORMATION
...................1-1
Safe riding ........................................1-1
Location of important labels .............1-4
DESCRIPTION
...................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS
........................................3-1
Handlebar switch .............................3-1
Speed limiter and power reduction
plate .............................................3-1
Front brake lever .............................3-2
Rear brake lever ..............................3-3
Fuel tank cap ...................................3-3
Fuel ..................................................3-3
Fuel tank breather hose ...................3-5
2-stroke engine oil ...........................3-5
Fuel cock .........................................3-5
Starter (choke) lever “
1
” .................3-6
Kickstarter ........................................3-6
Seat .................................................3-7
PRE-OPERATION CHECKS
...............4-1
Pre-operation check list ...................4-2
OPERATION AND IMPORTANT
RIDING POINTS
.................................. 5-1
Starting and warming up a cold
engine .......................................... 5-1
Starting a warm engine ................... 5-1
Starting off ....................................... 5-2
Acceleration and deceleration ......... 5-2
Braking ............................................ 5-2
Engine break-in ............................... 5-3
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR
.................................. 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance chart for the
emission control system .............. 6-2
General maintenance and lubrication
chart ............................................. 6-3
Checking the spark plug .................. 6-5
Removing the power reduction
plate ............................................. 6-6
Transmission oil .............................. 6-7
Middle and final gear cases ............ 6-8
Cleaning the air filter element ......... 6-8
Cleaning the spark arrester ............. 6-9
Adjusting the carburetor ................ 6-10
Adjusting the engine idling
speed ......................................... 6-10
Checking the throttle cable free
play ............................................ 6-11
Tires .............................................. 6-11Panel wheels ................................. 6-13
Accessories and replacement
parts ........................................... 6-13
Adjusting the front and rear brake
lever free play ............................ 6-14
Checking the front and rear brake
shoes ......................................... 6-15
Checking and lubricating the
cables ........................................ 6-15
Checking and lubricating the throttle
grip and cable ............................ 6-16
Adjusting the Autolube pump ........ 6-16
Lubricating the front and rear brake
levers ......................................... 6-16
Checking and lubricating the
centerstand ................................ 6-17
Checking the front fork .................. 6-17
Checking the steering ................... 6-18
Checking the wheel bearings ........ 6-18
Front wheel ................................... 6-19
Rear wheel .................................... 6-20
Troubleshooting ............................ 6-23
Troubleshooting chart ................... 6-24
MOTORCYCLE CARE AND
STORAGE
........................................... 7-1
Matte color caution .......................... 7-1
Care ................................................ 7-1
Storage ........................................... 7-3
SPECIFICATIONS
............................. 8-1

1-1
1
SAFETY INFORMATION
EAU40931
Safe riding

Always make pre-operation
checks. Careful checks may help
prevent an accident.

This motorcycle is designed for
off-road use only, therefore, it is il-
legal to operate it on public streets,
roads, or highways, even a dirt or
gravel one. Off-road use on public
lands may be illegal. Please check
local regulations before riding.

This motorcycle is designed to car-
ry the operator only. No passen-
gers.

Many accidents involve inexperi-
enced operators.

Make sure that the operator is
qualified and that you only lend
your motorcycle to other quali-
fied operators.

Know your skills and limits.
Staying within your limits may
help you to avoid an accident.

Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
erator is veering wide on a turn
due to EXCESSIVE SPEED or un-dercornering (insufficient lean an-
gle for the speed). Never travel
faster than warranted by condi-
tions.

Ride cautiously in unfamiliar ar-
eas. You may encounter hidden
obstacles that could cause an ac-
cident.

The posture of the operator is im-
portant for proper control. The op-
erator should keep both hands on
the handlebar and both feet on the
operator footrests during operation
to maintain control of the motorcy-
cle.

Never ride under the influence of
alcohol or other drugs.
Protective apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the preven-
tion or reduction of head injuries.

Always wear an approved helmet.

Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairmentof vision that could delay seeing a
hazard.

The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.

Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.

Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protec-
tive clothing that covers your legs,
ankles, and feet.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the re-
moval of original equipment, may ren-
der the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your mo-
torcycle illegal to use.
Loading and accessories
Adding accessories to your motorcycle

INSTRUMENT AND CONTROL FUNCTIONS
3-5
2
34
5
6
7
8
9

EAU13412
Fuel tank breather hose
Before operating the motorcycle:

Check the fuel tank breather hose
connection.

Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.

Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.
EAU13452
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.
NOTE:

Make sure that the 2-stroke engine oil
tank cap is properly installed.
EAU40701
Fuel cock
The fuel cock supplies fuel from the
tank to the carburetor while filtering it al-
so.
The fuel cock has two positions:
S (stop)
With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.
1. Fuel tank breather hose
1

1. 2-stroke engine oil tank cap
2. Minimum level mark
Recommended oil:
See page 8-1.
Oil quantity:
0.30 L (0.32 US qt) (0.26 Imp.qt)
21

1. Arrow mark pointing to “S” (stop)
1

PRE-OPERATION CHECKS
4-2
2
3
45
6
7
8
9

EAU15605
Pre-operation check list
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.3-3
2-stroke engine oil

Check oil level in oil tank.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.3-5
Middle and final gear cases

Check vehicle for grease leakage. 6-8
Front brake

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.6-14, 6-15
Rear brake

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.6-14, 6-15
Throttle grip

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-11, 6-16
Control cables

Make sure that operation is smooth.

Lubricate if necessary.6-15
Wheels and tires

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.6-11, 6-13
Brake levers

Make sure that operation is smooth.

Lubricate lever pivoting points if necessary.6-16
Centerstand

Make sure that operation is smooth.

Lubricate pivot if necessary.6-17

PRE-OPERATION CHECKS
4-3
1
2
3
4
5
6
7
8
9

Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened.

Tighten if necessary.—
Engine stop switch

Check operation.3-1
ITEM CHECKS PAGE

OPERATION AND IMPORTANT RIDING POINTS
5-2
1
2
3
4
5
6
7
8
9

EAU41000
Starting off
NOTE:

Before starting off, allow the engine to
warm up.
1. While applying the rear brake le-
ver, push the motorcycle off the
centerstand.
2. Completely close the throttle.
3. Set the engine stop switch to
“RUN”.
4. Check for oncoming off-road vehi-
cles, and then slowly turn the throt-
tle grip in order to take off.
EAU16780
Acceleration and deceleration
The speed can be adjusted by opening
and closing the throttle. To increase the
speed, turn the throttle grip in direction
(a). To reduce the speed, turn the throt-
tle grip in direction (b).
EAU41011
Braking
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually in-
creasing the pressure.
Front(a)(b)

OPERATION AND IMPORTANT RIDING POINTS
5-3
2
3
4
56
7
8
9 Rear
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.
EAU42030
Engine break-in
There is never a more important period
in the life of your engine than the first 5
hours of riding. It is also important to ac-
custom the rider to the motorcycle dur-
ing this time. Please read the following
information carefully.
Since the engine is brand new, do not
put an excessive load on it for the first 5
hours of operation. The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition 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 operation, thor-
oughly check the motorcycle for loose
parts, oil leakage and any other prob-
lems. Be sure to inspect and make ad-justments thoroughly, especially
cables. In addition, check all fittings and
fasteners for looseness, and tighten if
necessary.
CAUTION:

ECA10270
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
1
2
3
4
5
6
7
8
9

EAU41741
Periodic maintenance chart for the emission control system
NOTE:


From 18 months, repeat the maintenance intervals starting from 6 months.

Items 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 JOBINITIALTHEREAFTER
EVERY
1
month3
months6
months6
months12
months
1*Fuel line
Check fuel hoses for cracks or damage.Replace if necessary.
2Spark plugCheck condition.Adjust gap and clean.Replace if necessary.
3Air filter 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.