2009 YAMAHA PW50 seat adjustment

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

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

PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
2
3
4
5
67
8
9 very carefully and replace it as
soon as possible with a

high-quality product.
EAU40780
Panel wheels
WARNING

EWA10610
The wheels on this model are not de-
signed for use with tubeless tires.
Do not attempt to use tubeless tires
on this model.
To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified wheels.

The wheel rims should be checked
for cracks, bends, warpage or
damage before each ride. If any
damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

Ride conservatively after changinga tire since the tire must seat itself
on the rim properly. Failure to al-
low proper seating may cause tire
failure, which may result in dam-
age to the motorcycle and injury to
the rider.

PERIODIC MAINTENANCE AND ADJUSTMENT
6-20
1
2
3
4
5
6
7
8
9
8. Push down hard on the handlebar
several times to check for proper
fork operation.

EAU25080
Rear wheel
EAU41082
To remove the rear wheel
WARNING

EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.
1. Place the motorcycle on the cen-
terstand.
2. Remove the seat. (See page 3-7.)
3. Remove the muffler bolt and
washers.
WARNING! Always let
the exhaust system cool prior to
touching exhaust compo-
nents.
[EWA14581]
4. Slide the spring clamp down, and
then remove the muffler.
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

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