2010 YAMAHA PW50 brake

TABLE OF CONTENTS
LOCATION OF IMPORTANT
LABELS
............................................. 1-1
SAFETY INFORMATION
.................. 2-1
DESCRIPTION
.................................. 3-1
Left view .......................................... 3-1
Right view ........................................ 3-2
Controls and instruments ................ 3-3
INSTRUMENT AND CONTROL
FUNCTIONS
....................................... 4-1
Handlebar switch ............................ 4-1
Speed limiter and power
reduction plate ............................ 4-1
Front brake lever ............................ 4-2
Rear brake lever ............................. 4-3
Fuel tank cap .................................. 4-3
Fuel ................................................ 4-3
Fuel tank breather hose ................. 4-5
2-stroke engine oil .......................... 4-5
Fuel cock ........................................ 4-6
Starter (choke) lever “ ” ............... 4-6
Kickstarter ...................................... 4-7
Seat ................................................ 4-7
FOR YOUR SAFETY –
PRE-OPERATION CHECKS
.............. 5-1
OPERATION AND IMPORTANT
RIDING POINTS
................................. 6-1Starting and warming up a cold
engine ......................................... 6-1
Starting a warm engine .................. 6-1
Starting off ...................................... 6-2
Acceleration and deceleration ........ 6-2
Braking ........................................... 6-2
Engine break-in .............................. 6-3
Parking ........................................... 6-4
PERIODIC MAINTENANCE AND
ADJUSTMENT
................................... 7-1
Owner’s tool kit ............................... 7-1
Periodic maintenance chart for
the emission control system ....... 7-2
General maintenance and
lubrication chart .......................... 7-3
Checking the spark plug ................. 7-5
Removing the power reduction
plate ............................................ 7-6
Transmission oil ............................. 7-7
Middle and final gear cases ........... 7-8
Cleaning the air filter element ........ 7-8
Cleaning the spark arrester ............ 7-9
Adjusting the carburetor ............... 7-10
Adjusting the engine idling
speed ........................................ 7-10
Checking the throttle cable free
play ........................................... 7-11
Tires ............................................. 7-11
Panel wheels ................................ 7-13Adjusting the front and rear
brake lever free play .................. 7-13
Checking the front and rear
brake shoes ............................... 7-14
Checking and lubricating the
cables ........................................ 7-15
Checking and lubricating the
throttle grip and cable ................ 7-15
Adjusting the Autolube pump ........ 7-16
Lubricating the front and rear
brake levers ............................... 7-16
Checking and lubricating the
centerstand ................................ 7-16
Checking the front fork .................. 7-17
Checking the steering ................... 7-17
Checking the wheel bearings ........ 7-18
Front wheel ................................... 7-18
Rear wheel .................................... 7-20
Troubleshooting ............................ 7-22
Troubleshooting chart ................... 7-24
MOTORCYCLE CARE AND
STORAGE
.......................................... 8-1
Matte color caution ......................... 8-1
Care ................................................ 8-1
Storage ........................................... 8-3
SPECIFICATIONS
............................. 9-1
CONSUMER INFORMATION
........... 10-1
Identification numbers ................... 10-1

DESCRIPTION
3-3
2
34
5
6
7
8
9

EAU10430
Controls and instruments
12
7 345
6

1. Rear brake lever (page 4-3)
2. Starter (choke) lever (page 4-6)
3. 2-stroke engine oil tank cap (page 4-5)
4. Handlebar switch (page 4-1)
5. Front brake lever (page 4-2)
6. Throttle grip (page 7-11)
7. Fuel tank cap (page 4-3)

INSTRUMENT AND CONTROL FUNCTIONS
4-2
2
3
45
6
7
8
9
3. Tighten the locknut.
TIP

The adjusting range of the speed limiter
screw is from the fully turned-in positionto 7 mm (0.28 in) turned out. When the
screw is turned out to 7 mm (0.28 in),
the throttle grip can only be opened ap-
proximately halfway. If more power is
required, please consult a Yamaha
dealer.
WARNING

EWA14630
Improper adjustment of the speed
limiter could cause improper throttle
operation. You could lose control,
have an accident or be injured. Do
not turn the adjusting screw out
more than 7 mm (0.28 in) before con-
sulting a Yamaha dealer. Always
make sure the throttle cable free
play is adjusted to 1.5–3.5 mm
(0.06–0.14 in). (See page 7-11.)
Power reduction plate
Once the rider can operate with skill at
the top speed permitted by adjusting
the speed limiter alone, the power re-
duction plate can be removed. (See
page 7-6.)
EAU12900
Front brake lever
The front brake lever is located on the
right handlebar grip. To apply the front
brake, pull this lever toward the handle-
bar grip.
1. Locknut
2. Adjusting screw
1. No more than 7 mm (0.28 in)
1
(a)(b)2
1

1. Front brake lever
1

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

EAU12950
Rear brake lever
The rear brake lever is located on the
left handlebar grip. To apply the rear
brake, pull this lever toward the handle-
bar grip.
EAU13182
Fuel tank cap
To remove the fuel tank cap, turn it
counterclockwise, and then pull it off.
To install the fuel tank cap, insert it into
the tank opening, and then turn it clock-
wise.
WARNING

EWA11091
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.
EAU13221
Fuel
Make sure there is sufficient gasoline in
the tank.
WARNING

EWA10881
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.
1. Before refueling, turn off the en-
gine and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the vi-
cinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters and
clothes dryers.
2. Do not overfill the fuel tank. When
refueling, be sure to insert the
pump nozzle into the fuel tank filler
hole. Stop filling when the fuel
reaches the bottom of the filler
tube. Because fuel expands when
it heats up, heat from the engine or
the sun can cause fuel to spill out
of the fuel tank.
1. Rear brake lever
1

1. Fuel tank cap
1

5-1
2
3
4
56
7
8
9

FOR YOUR SAFETY – PRE-OPERATION CHECKS
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING

EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.4-3
2-stroke engine oil

Check oil level in oil tank.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.4-5
Middle and final gear cases

Check vehicle for grease leakage. 7-8
Front brake

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.7-13, 7-14
Rear brake

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.7-13, 7-14
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.7-11, 7-15
Control cables

Make sure that operation is smooth.

Lubricate if necessary.7-15

FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-2
1
2
3
4
5
6
7
8
9

Wheels and tires

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.7-11, 7-13
Brake levers

Make sure that operation is smooth.

Lubricate lever pivoting points if necessary.7-16
Centerstand

Make sure that operation is smooth.

Lubricate pivot if necessary.7-16
Chassis fasteners

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

Tighten if necessary.—
Engine stop switch

Check operation.4-1
ITEM CHECKS PAGE

6-1
2
3
4
5
67
8
9

OPERATION AND IMPORTANT RIDING POINTS
EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING

EWA10271
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU40887
Starting and warming up a
cold engine
1. Turn the fuel cock lever to “O” (on).
2. Set the engine stop switch to
“START”.
3. Turn the starter (choke) on and
completely close the throttle. (See
page 4-6.)
4. While applying the front or rear
brake, start the engine by pushing
the kickstarter lever down.
5. After starting the engine, move the
starter (choke) back halfway.
NOTICE:
For maximum engine
life, never accelerate hard when
the engine is cold!
[ECA11041]

6. When the engine is warm, turn the
starter (choke) off and set the en-
gine stop switch to “RUN”.
TIP

The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
EAU16660
Starting a warm engine
Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm. Instead, start
the engine with the throttle slightly
open.
TIP

If the engine does not start after several
kicks, try again with the throttle 1/4 to
1/2 open.

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

EAU41002
Starting off
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.
Front
(a)(b)