2009 YAMAHA PW50 brake

PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
2
3
4
5
67
8
9
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.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-
1. Exhaust manifold bolt
1

1. Rear shock absorber mounting bolt
1. Axle nut
1
1
1. Rear arm
2. Washer
3. Rear arm nut
1
2
3

PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
1
2
3
4
5
6
7
8
9
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.
TIP

Make sure that the spring clamp is po-
sitioned with the projection side facing
inward.
12. Tighten the muffler bolt to the
specified torque.13. Adjust the brake lever free play.
(See page 6-14.)
14. Install the seat.
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

MOTORCYCLE CARE AND STORAGE
7-2
1
2
3
4
5
6
7
8
9cleaning products, solvent or
thinner, 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.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain or near the seaSince 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- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.2. Use a chrome polish to shine
chrome, aluminum and stain-
less-steel parts, including the ex-
haust system. (Even the thermally
induced discoloring of stain-
less-steel exhaust systems can be
removed through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean-
er to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the motorcycle dry completely
before storing or covering it.
WARNING

EWA14501
Contaminants on the brakes or tires
can cause loss of control.

Make sure that there is no oil or
wax on the tires.

If necessary, wash the tires with
warm water and a mild deter-
gent. Before riding at higher
speeds, test the motorcycle’s

SPECIFICATIONS
8-2
1
2
3
4
5
6
7
8
9Transmission:

Primary reduction system:
Spur gear
Primary reduction ratio:
63/33 (1.909)
Secondary reduction system:
Shaft drive
Secondary reduction ratio:
19/15
×
54/11 (6.218)
Chassis:
Frame type:
Steel tube backbone
Caster angle:
25.50 °
Trail:
50.0 mm (1.97 in)
Front tire:
Type:
With tube
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/KNOBBYManufacturer/model:
IRC/KNOBBY
Loading:
Maximum rider weight:
25.0 kg (55 lb)
* (Total weight of rider, cargo and
accessories)
Tire air pressure (measured on cold
tires):
Front:
100 kPa (1.00 kgf/cm
2

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

, 15 psi)
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
Air filter element, cleaning......................... 6-8
Autolube pump, adjusting ....................... 6-16
B
Brake lever ................................................ 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................................................... 3-6
Fuel tank breather hose ............................ 3-5
Fuel tank cap ............................................ 3-3
H
Handlebar switch ...................................... 3-1
I
Identification numbers ............................... 9-1
K
Kickstarter ..................................................3-7
M
Maintenance and lubrication, periodic .......6-3
Maintenance, emission control system ......6-2
Matte color, caution ...................................7-1
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)............................................ 6-18
Wheel (rear) ............................................ 6-20
Wheels .................................................... 6-13