2011 YAMAHA PW50 transmission

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 ................................................ 4-7FOR YOUR SAFETY –
PRE-OPERATION CHECKS............. 5-1
OPERATION AND IMPORTANT
RIDING POINTS................................ 6-1
Starting 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 .............................. 7-2
Periodic maintenance chart for the
emission control system ............. 7-3
General maintenance and
lubrication chart .......................... 7-4
Checking the spark plug ................ 7-6
Removing the power reduction
plate ............................................ 7-7
Transmission oil ............................. 7-8
Middle and final gear cases ........... 7-9
Cleaning the air filter element ........ 7-9
Cleaning the spark arrester ......... 7-10
Adjusting the carburetor ............... 7-11
Adjusting the engine idling
speed ........................................ 7-11Checking the throttle cable free
play ........................................... 7-12
Tires ............................................. 7-12
Panel wheels ................................ 7-13
Adjusting the front and rear brake
lever free play ........................... 7-14
Checking the front and rear brake
shoes ........................................ 7-15
Checking and lubricating the
cables ....................................... 7-15
Checking and lubricating the
throttle grip and cable ............... 7-16
Adjusting the Autolube pump ....... 7-16
Lubricating the front and rear
brake levers .............................. 7-16
Checking and lubricating the
centerstand ............................... 7-17
Checking the front fork ................. 7-17
Checking the steering .................. 7-18
Checking the wheel bearings ....... 7-18
Front wheel .................................. 7-18
Rear wheel ................................... 7-20
Troubleshooting ........................... 7-23
Troubleshooting chart .................. 7-24
MOTORCYCLE CARE AND
STORAGE.......................................... 8-1
Matte color caution ......................... 8-1
Care ............................................... 8-1
Storage ........................................... 8-3
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SAFETY INFORMATION
2-4
2 cornering clearance, limit suspen-
sion travel, steering travel or con-
trol operation.
Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution. If accesso-
ries are added to the handlebar
or front fork area, they must be
as lightweight as possible and
should be kept to a minimum.
Bulky or large accessories may
seriously affect the stability of
the motorcycle. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds.
Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.


Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, anelectric failure could result, which
could cause a dangerous loss of
lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match the
performance capabilities and to provide
the best combination of handling, brak-
ing, and comfort. Other tires, rims, siz-
es, and combinations may not be
appropriate. Refer to page 7-12 for tire
specifications and more information on
replacing your tires.
Transporting the motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.


Remove all loose items from the
motorcycle.


Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.


Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.


Shift the transmission in gear (for
models with a manual transmis-
sion).


Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or parts
that could break). Choose the lo-
cation for the straps carefully so
the straps will not rub against
painted surfaces during transport.


The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the mo-
torcycle will not bounce excessive-
ly during transport.
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DESCRIPTION
3-2
3
EAU10420
Right view
1
2
3
4
5
1. Spark arrester (page 7-10)
2. Seat (page 4-7)
3. Transmission oil filler cap (page 7-8)
4. 2-stroke engine oil tank (page 4-5)
5. Transmission oil drain bolt (page 7-8)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-5
7
TIPThe 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 cables
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
7*Check for grease leakage.Check gears for damage and wear.Lubricate gears with lithium-soap-based grease.Every 2 years
8*Chassis fastenersCorrect if necessary.
A 9*utolube pumpCheck operation.Correct if necessary. Middle and final gear
cases
Check all chassis fitting and fasteners.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-8
7
EAU40893
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 transmission oil filler
cap, the transmission oil drain bolt
and its gasket to drain the oil from
the transmission.4. Install the transmission oil drain
bolt and its new gasket, and then
tighten the bolt to the specified
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
2. Gasket
Tightening torque:
Transmission oil drain bolt:
14 Nm (1.4 m·kgf, 10 ft·lbf)
Recommended transmission oil:
See page 9-1.
Oil change quantity:
0.30 L (0.32 US qt, 0.26 Imp.qt)
12
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SPECIFICATIONS
9-1
9
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 kg (86 lb)Noise and vibration level:Noise level (77/311/EEC):
PW50 75.1 dB(A)@2750 r/min
Vibration on seat (EN1032, ISO5008):
PW50 Will not exceed 0.5 m/s²
Vibration on handlebar (EN1032, ISO5008):
PW50 Will not exceed 2.5 m/s²Engine:Engine type:
Air cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
49 cm³
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 2S 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 elementFuel:Recommended fuel:
PW50 Regular unleaded gasoline only
PW50A1 Regular unleaded gasoline only
(CAN)
PW50A1 Unleaded gasoline only
(AUS)(NZL)
Fuel tank capacity:
2.0 L (0.53 US gal, 0.44 Imp.gal)Carburetor:Type × quantity:
VM12SC x 1
Spark plug(s):Manufacturer/model:
NGK/BPR4HS
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:
Wet, centrifugal automaticTransmission:Primary reduction system:
Spur gear
Primary reduction ratio:
63/33 (1.909)
Secondary reduction system:
Shaft drive
Secondary reduction ratio:
19/15 × 54/11 (6.218)Chassis:Frame type:
Steel tube backbone
Caster angle:
25.50 °
Trail:
50.0 mm (1.97 in)Front tire:Type:
With tube
Size:
2.50-10 4PR
Manufacturer/model:
BRIDGESTONE/KNOBBY
Manufacturer/model:
IRC/KNOBBY
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INDEXAAcceleration and deceleration................. 6-2
Air filter element, cleaning....................... 7-9
Autolube pump, adjusting ..................... 7-16BBrake lever, front..................................... 4-2
Brake lever, rear ..................................... 4-3
Brake levers, lubricating........................ 7-16
Brake shoes, checking .......................... 7-15
Braking .................................................... 6-2CCables, checking and lubricating .......... 7-15
Carburetor, adjusting ............................ 7-11
Care ........................................................ 8-1
Centerstand, checking and
lubricating ........................................... 7-17EEngine break-in ....................................... 6-3
Engine idling speed............................... 7-11
Engine oil ................................................ 4-5
Engine, starting a warm .......................... 6-1
Engine stop switch .................................. 4-1FFront and rear brake lever free play,
adjusting ............................................. 7-14
Front fork, checking .............................. 7-17
Fuel ......................................................... 4-3
Fuel cock................................................. 4-6
Fuel tank breather hose .......................... 4-5
Fuel tank cap .......................................... 4-3HHandlebar switch .................................... 4-1IIdentification numbers ........................... 10-1
KKickstarter............................................... 4-7LLabels, location....................................... 1-1MMaintenance and lubrication, periodic .... 7-4
Maintenance, emission control system... 7-3
Matte color, caution ................................ 8-1
Middle and final gear cases .................... 7-9
Model label ........................................... 10-1PParking ................................................... 6-4
Part locations .......................................... 3-1
Power reduction plate, removing ............ 7-7SSafety information................................... 2-1
Seat ........................................................ 4-7
Spark arrester, cleaning ....................... 7-10
Spark plug, checking .............................. 7-6
Specifications ......................................... 9-1
Speed limiter and power reduction
plate ..................................................... 4-1
Starter (choke) lever ............................... 4-6
Starting and warming up a cold
engine .................................................. 6-1
Starting off .............................................. 6-2
Steering, checking ................................ 7-18
Storage ................................................... 8-3TThrottle cable free play, checking ......... 7-12
Throttle grip and cable, checking and
lubricating ........................................... 7-16
Tires...................................................... 7-12
Tool kit .................................................... 7-2Transmission oil ...................................... 7-8
Troubleshooting .................................... 7-23
Troubleshooting chart ........................... 7-24
VVehicle Emission Control Information
label (For Canada) .............................. 10-2
Vehicle identification number ................ 10-1WWheel bearings, checking ..................... 7-18
Wheel (front) ......................................... 7-18
Wheel (rear) .......................................... 7-20
Wheels .................................................. 7-13
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