2009 YAMAHA PW50 check engine

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
3-5
2
34
5
6
7
8
9 such as the piston rings as well as to

the exhaust system.
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
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.
TIP

Make sure that the 2-stroke engine oil
tank cap is properly installed.
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

FOR YOUR SAFETY – 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

FOR YOUR SAFETY – 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

EAU41001
Starting off
TIP

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).
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 both front and rear brakes
simultaneously while gradually in-
creasing the pressure.
(a)(b)

OPERATION AND IMPORTANT RIDING POINTS
5-3
2
3
4
56
7
8
9 Front
Rear

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.
NOTICE

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

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

EAU41741
Periodic maintenance chart for the emission control system
TIP


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.

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