2009 YAMAHA PW50 air filter

TABLE OF CONTENTS
SAFETY INFORMATION
................... 1-1
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
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 ......................................... 3-6
Starter (choke) lever “
1
” ................ 3-6
Kickstarter ....................................... 3-7
Seat ................................................. 3-7
FOR YOUR SAFETY –
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 .......................................... 5-1Starting 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
ADJUSTMENT
.................................... 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 .............................................. 6-11
Panel wheels ................................. 6-13
Adjusting the front and rear brake
lever free play ............................ 6-14Checking 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 ....................................6-18
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
CONSUMER INFORMATION
..............9-1
Identification numbers ......................9-1

INSTRUMENT AND CONTROL FUNCTIONS
3-6
1
2
3
4
5
6
7
8
9

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.
O (on)
With the lever in this position, 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).
1. Arrow mark pointing to “S” (stop)
1

1. Arrow mark pointing to “O” (on)
1

1. Starter (choke) lever “ ”
1 (a)
(b)

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

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
10
*Transmission oil
Check for oil leakage .Correct if necessary.Change.
11
*Front and rear brake
lever pivot
Apply lithium-soap-based grease lightly.
12
*Centerstand pivot
Check operation.Apply lithium-soap-based grease lightly.
13
*Shock absorber
assemblies
Check operation and for oil leakage.Replace if necessary.
14
*Control cable
Apply Yamaha chain and cable lube or engine oil
10W-30 lightly.
15
*Throttle grip housing
and cable
Check operation and free play.Apply Yamaha chain and cable lube or engine oil
10W-30 lightly. NO. ITEM CHECK OR MAINTENANCE JOBINITIALTHEREAFTER
EVERY
1
month3
months6
months6
months12
months

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

EAU41711
Middle and 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.
EAU40902
Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication 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 3-7.)
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 oil out.
TIP

The sponge material should be wet but
1. Air filter case cover
2. Screw
2 1

1. Sponge material
1

PERIODIC MAINTENANCE AND ADJUSTMENT
6-9
2
3
4
5
67
8
9

not dripping.
5. Insert the sponge material into the
air filter case.
NOTICE:
Make sure
that the sponge material is prop-
erly seated in the air filter case.
The engine should never be op-
erated without the sponge mate-
rial installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
[ECA15621]

6. Install the air filter case cover by in-
stalling the screw.
7. Install the seat.
EAU41220
Cleaning the spark arrester
The spark arrester should be cleaned
at the intervals specified 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.
TIP

Make sure to select a well-ventilated
area free of combustible materials to
clean the spark arrester.
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 of the tailpipe and in-
side of the tailpipe housing.
Recommended oil:
Yamaha foam air filter oil or other
quality foam air filter oil
1. Tailpipe
2. Screw
3. Muffler
1
2
3

8-1
2
3
4
5
6
7
89

SPECIFICATIONS
EAU2633P
Dimensions:
Overall length:
1245 mm (49.0 in)
Overall width:
575 mm (22.6 in)
Overall height:
715 mm (28.1 in)
Seat height:
485 mm (19.1 in)
Wheelbase:
855 mm (33.7 in)
Ground clearance:
105 mm (4.13 in)
Minimum turning radius:
1300 mm (51.2 in)
Weight:
With oil and fuel:
39.0 kg (86 lb)
Noise and vibration level:
Noise level (77/311/EEC):
75.1 dB(A)
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)
Vibration on seat (EN1032, ISO5008):
Will not exceed 0.5 m/s
2


(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)Vibration on handlebar (EN1032, ISO5008):
Will not exceed 2.5 m/s
2


(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)
Engine:
Engine type:
Air cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
49.0 cm
3

Bore
×
stroke:
40.0
×
39.2 mm (1.57
×
1.54 in)
Compression ratio:
6.00 :1
Starting system:
Kickstarter
Lubrication system:
Separate lubrication (Yamaha autolube)

Engine oil:
Type:
YAMALUBE 2 or 2-stroke engine oil (JASO
FC grade) or (ISO EG-C or EG-D grade)
Engine oil quantity:
Quantity:
0.30 L (0.32 US qt, 0.26 Imp.qt)
Transmission oil:
Type:
YAMALUBE 4 (10W-40) or SAE 10W-40
Oil change quantity:
0.30 L (0.32 US qt, 0.26 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Regular unleaded gasoline only
(AUT)(BEL)(CAN)(CHE)(DEU)(DNK)
(ESP)(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)
(NOR)(PRT)(SWE)(ZAF)
Unleaded gasoline only (AUS)(NZL)
Fuel tank capacity:
2.0 L (0.53 US gal, 0.44 Imp.gal)
Carburetor:
Manufacturer:
MIKUNI
Type
×
quantity:
VM12SC x 1
Spark plug (s):
Manufacturer/model:
NGK/BP4HS (AUS)(NZL)
NGK/BPR4HS
(AUT)(BEL)(CAN)(CHE)(DEU)(DNK)
(ESP)(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)
(NOR)(PRT)(SWE)(ZAF)
Manufacturer/model:
DENSO/W14FPL (AUS)(NZL)
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, centrifugal automatic

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