2010 YAMAHA PW50 torque

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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU41951
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
WARNING

EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING

EWA15121
Turn off the engine when performing
maintenance unless otherwise
specified.

A running engine has moving
parts that can catch on body
parts or clothing and electricalparts that can cause shocks or
fires.

Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 2-1 for more in-
formation about carbon monox-
ide.
EAU17311
Owner’s tool kit
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
TIP

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.

PERIODIC MAINTENANCE AND ADJUSTMENT
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2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
TIP

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
4. Install the spark plug cap.
EAU41102
Removing the power
reduction plate
To obtain full engine performance ca-
pability, removing the power reduction
plate is required.
1. Remove the exhaust manifold by
removing the bolts.
WARNING!
Always let the exhaust system
cool prior to touching exhaust
components.
[EWA14581]

2. Remove the gasket.
3. Remove the power reduction
plate.
TIP

Store the power reduction plate with the
Owner’s Manual so that it is readily
available whenever you want to reduce
the engine power.
4. Install the exhaust manifold by in-
stalling the bolts.
Tightening torque:
Spark plug:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
1. Exhaust manifold bolt
1

1. Exhaust manifold
2. Gasket
3. Power reduction plate
Tightening torque:
Exhaust manifold bolt:
8.5 Nm (0.9 m·kgf, 6.1 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU40892
Transmission oil
The transmission oil must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the motorcycle. In
addition, the transmission oil must be
changed at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Place the motorcycle on the cen-
terstand.
2. Place an oil pan under the trans-
mission to collect the used oil.
3. Remove the oil filler cap and drain
bolt to drain the oil from the trans-
mission.4. Install the transmission oil drain
bolt, and then tighten it to the spec-
ified torque.
5. Refill with the specified amount of
the recommended transmission
oil, and then install and tighten the
oil filler cap.
NOTICE

ECA10452

In order to prevent clutch slip-
page (since the transmission oil
also lubricates the clutch), do
not mix any chemical additives.
Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

Make sure that no foreign mate-
rial enters the transmission.
6. Start the engine, and then let it idle
for several minutes while checking
the transmission for oil leakage. If
oil is leaking, immediately turn the
engine off and check for the cause.
1. Transmission oil filler cap
1

1. Transmission oil drain bolt
Tightening torque:
Transmission oil drain bolt:
14 Nm (1.4 m·kgf, 10.1 ft·lbf)
Recommended transmission oil:
See page 9-1.
Oil change quantity:
0.30 L (0.32 US qt, 0.26 Imp.qt)
1

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EAU41031
To install the front wheel
1. Install the brake shoe plate into the
wheel hub as shown.
2. Lift the wheel up between the fork
legs.
TIP

Make sure that the slot in the brake
shoe plate fits over the retainer on the
fork leg.
3. Insert the wheel axle from the right
side.
4. Install the washer and axle nut,
and then tighten the axle nut to the
specified torque.
5. Connect the brake cable at the
wheel hub, and then install the
brake cable free play adjusting nut.6. Adjust the brake lever free play.
(See page 7-13.)
7. Take the motorcycle off the center-
stand so that the front wheel is on
the ground.
8. Push down hard on the handlebar
several times to check for proper
fork operation.
1. Wheel axle
1

1. Retainer
Tightening torque:
Axle nut:
40 Nm (4.0 m·kgf, 28.9 ft·lbf)
1

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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, andthen 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-
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.
1. Exhaust manifold bolt
1. Rear shock absorber mounting bolt
1
1

1. Axle nut
1. Rear arm
2. Washer
3. Rear arm nut1
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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)

PERIODIC MAINTENANCE AND ADJUSTMENT
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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 7-13.)
14. Install the seat.
EAU25851
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
WARNING

EWA15141
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from water
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)
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