2013 YAMAHA PW50 brake

PERIODIC MAINTENANCE AND ADJUSTMENT
7-20
7
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 lever free play adjusting nut.
6. Adjust the brake lever free play. (See page 7-14.)
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.
EAU25080
Rear wheel
EAU41084
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 4-7.)
3. Remove the muffler bolt and wash- ers. WARNING! Always let the
exhaust system cool prior to
touching exhaust components.
[EWA14581]
4. Slide the spring clamp down, and then remove the muffler.
1. RetainerTightening torque:Axle nut:40 Nm (4.0 m·kgf, 29 ft·lbf)
1
U5PG8BE0.book Page 20 Wednesday, June 27, 2012 2:53 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-21
75. Remove the exhaust chamber bolt
and washers. 6. Remove the exhaust manifold
bolts, and then remove the ex-
haust chamber, the power reduc-
tion plate and the gasket.
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.
1. Muffler
2. Washer
3. Muffler bolt
4. Spring clamp
1. Exhaust chamber
2. Exhaust chamber bolt
3. Washer
3
1
2 4
2
1
3
1. Exhaust manifold bolt
1
1. Rear shock absorber mounting bolt
1. Axle nut
1
1
U5PG8BE0.book Page 21 Wednesday, June 27, 2012 2:53 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-22
7
10. Pull the wheel to the right to sepa-
rate it from the final gear case, and
then remove the wheel.
EAU41523
To install the rear wheel1. Apply a light coating of lithium- 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.
8. Install the exhaust chamber by in- stalling the bolt and washers.
9. Install the power reduction plate, a new gasket, and then install the
exhaust manifold bolts.
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.
TIPMake sure that the spring clamp is po-
sitioned with the projection side facing
inward.12. Tighten the muffler bolt to thespecified torque.
1. Rear arm
2. Washer
3. Rear arm nut
12
3
Tightening torques:
Axle nut:60 Nm (6.0 m·kgf, 43 ft·lbf)
Rear arm nut:
29 Nm (2.9 m·kgf, 21 ft·lbf)
Rear shock absorber mounting bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf)
Tightening torques:Exhaust manifold bolt:
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Exhaust chamber bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
1. Exhaust chamber
2. Spring clamp
3. Muffler
1
2
3
U5PG8BE0.book Page 22 Wednesday, June 27, 2012 2:53 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-23
713. Adjust the brake lever free play.
(See page 7-14.)
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 heaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or
property damage.
Tightening torque:
Muffler bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
U5PG8BE0.book Page 23 Wednesday, June 27, 2012 2:53 PM

MOTORCYCLE CARE AND STORAGE
8-2
8
●
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
●
Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, and switches),
breather hoses and vents.
After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.After riding in the rain or near the sea
Since sea salt is extremely corrosive,
carry out the following steps after each
ride in the rain or near the sea.
1. Clean the motorcycle with cold wa- ter and a mild detergent, after the
engine has cooled down.
NOTICE: Do not use warm water
since it increases the corrosive
action of the salt.
[ECA10791]
2. Apply a corrosion protection spray on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth.
2. Use a chrome polish to shine chrome, aluminum and stainless-
steel parts.
3. To prevent corrosion, it is recom- mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean- er to remove any remaining dirt. 5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the motorcycle dry completely before storing or covering it.
WARNING
EWA14501
Contaminants on the brakes or tires
can cause loss of control.●
Make sure that there is no oil or
wax on the tires.
●
If necessary, wash the tires with
warm water and a mild deter-
gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor-
nering behavior.
NOTICE
ECA10800
●
Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.
●
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
U5PG8BE0.book Page 2 Wednesday, June 27, 2012 2:53 PM

SPECIFICATIONS
9-2
9
Secondary reduction ratio:6.218 (19/15 x 54/11)Chassis:Frame type:
Backbone
Caster angle: 25.50 °
Trail: 50 mm (2.0 in)Front tire:Type:With tube
Size: 2.50-10 4PR
Manufacturer/model:
PW50 (EUR)
BRIDGESTONE/KNOBBY PW50 (ZAF), PW50D, PW50D1
BRIDGESTONE/KNOBBY IRC/KNOBBY
Speed rating:
100 km/h (62 mph)Rear tire:Type:With tube
Size:
2.50-10 4PR
Manufacturer/model: PW50 (EUR)
BRIDGESTONE/KNOBBY PW50 (ZAF), PW50D, PW50D1
BRIDGESTONE/KNOBBY
IRC/KNOBBY Speed rating:
100 km/h (62 mph)
Loading:Maximum rider weight:
25.0 kg (55 lb)Tire air pressure (measured on cold
tires):
Front:100 kPa (1.00 kgf/cm², 15 psi)
Rear: 100 kPa (1.00 kgf/cm², 15 psi)
Front wheel:Wheel type:
Panel wheel
Rim size: 10x1.50Rear wheel:Wheel type:
Panel wheel
Rim size: 10x1.50Front brake:Type:
Drum brake
Operation: Right hand operationRear brake:Type:
Drum brake
Operation: Left hand operationFront suspension:Type:
Telescopic fork Spring/shock absorber type:
Coil spring/oil damper
Wheel travel: 60.0 mm (2.36 in)
Rear suspension:Type:Unit swing
Spring/shock absorber type: Coil spring/oil damper
Wheel travel:
50.0 mm (1.97 in)Electrical system:Ignition system:CDI
U5PG8BE0.book Page 2 Wednesday, June 27, 2012 2:53 PM

INDEX
AAcceleration 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 ....................... 7-17
Brake shoes, checking ......................... 7-15
Braking ................................................... 6-2CCable lock (for Europe)........................... 4-8
Cables, checking and lubricating .......... 7-16
Carburetor, adjusting ............................ 7-11
Care ........................................................ 8-1
Centerstand, checking and lubricating ..................... 7-17EEngine break-in ...................................... 6-3
Engine idling speed .............................. 7-11
Engine oil ................................................ 4-6
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 .................................... 4-1
IIdentification numbers ........................... 10-1KKickstarter ............................................... 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................................ 4-7
Starting and warming up a cold engine ... 6-1
Starting off ............................................... 6-2
Steering, checking.................................7-18
Storage....................................................8-3TThrottle grip and cable,
checking and lubricating ..................... 7-16
Throttle grip free play, checking ............7-12
Tires ......................................................7-12 Tool kit .................................................... 7-2
Transmission 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) ......................................... 7-19
Wheel (rear) .......................................... 7-20
Wheels .................................................. 7-14
U5PG8BE0.book Page 1 Wednesday, June 27, 2012 2:53 PM