2013 YAMAHA PW50 engine

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 ..........................4-6
Fuel cock ........................................ 4-6
Starter (choke) lever ....................... 4-7
Kickstarter ......................................4-7
Seat ................................................ 4-7
Cable lock (for Europe) .................. 4-8 FOR 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 ........................................ 7-11 Checking the throttle grip free
play ........................................... 7-12
Tires ............................................. 7-12
Panel wheels ................................ 7-14
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 ................................. 7-16
Checking and lubricating
the throttle grip and cable ......... 7-16
Adjusting the Autolube pump ....... 7-16
Lubricating the front and rear brake levers ....................... 7-17
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 .................................. 7-19
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
2-2
2
●
Many accidents involve inexperi-
enced operators. Make sure that you are qualified and that you only lend your mo-
torcycle to other qualified opera-
tors.
Know your skills and limits. Staying within your limits may
help you to avoid an accident.
We recommend that you prac- tice riding your motorcycle until
you have become thoroughly fa-
miliar with the motorcycle and all
of its controls.
●
Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
erator is veering wide on a turn
due to excessive speed or under-
cornering (insufficient lean angle
for the speed). Never travel faster
than warranted by conditions.
●
Ride cautiously in unfamiliar ar-
eas. You may encounter hidden
obstacles that could cause an ac-
cident.
●
The posture of the operator is im-
portant for proper control. The op-
erator should keep both hands on the handlebar and both feet on the
operator footrests during operation
to maintain control of the motorcy-
cle.
●
Never ride under the influence of
alcohol or other drugs.
Protective Apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the preven-
tion or reduction of head injuries.
●
Always wear an approved helmet.
●
Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
●
The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
●
Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
●
Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause burns.
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing car-
bon monoxide can cause headaches,
dizziness, drowsiness, nausea, confu-
sion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be
present even if you do not see or smell
any engine exhaust. Deadly levels of
carbon monoxide can collect rapidly
and you can quickly be overcome and
unable to save yourself. Also, deadly
levels of carbon monoxide can linger
for hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poison-
ing, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
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SAFETY INFORMATION
2-3
2
●
Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
●
Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
●
Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loading
Adding accessories to your motorcycle
can adversely affect stability and han-
dling if the weight distribution of the mo-
torcycle is changed. To avoid the
possibility of an accident, use extreme
caution when adding accessories to
your motorcycle. Use extra care when
riding a motorcycle that has added ac-
cessories. Here are some general
guidelines to follow if adding accesso-
ries to your motorcycle:
Operation of an overloaded vehicle
could cause an accident.
●
The weight of the operator must
not exceed 25 kg (55 lb).
●
Accessory weight should be kept
as low and close to the motorcycle
as possible. Securely pack your
heaviest items as close to the cen-
ter of the vehicle as possible and
make sure to distribute the weight
as evenly as possible on both
sides of the motorcycle to mini-
mize imbalance or instability.
●
Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories are securely attached to
the motorcycle before riding.
Check accessory mounts fre-
quently. Properly adjust the suspension for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
Never attach any large or heavy items to the handlebar, front
fork, or front fender. Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail- able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection to
Yamaha manufacture parts and acces- sories or offer other modifications for
Yamaha vehicles. Yamaha is not in a position to test the products that these
aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories, and
Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accessories
or modifications are not suitable be-
cause of potential safety hazards to you
or others. Installing aftermarket prod-
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SAFETY INFORMATION
2-4
2
ucts or having other modifications per-
formed to your vehicle that change any
of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or death.
You are responsible for injuries related
to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
●
Never install accessories that
would impair the performance of
your motorcycle. Carefully inspect
the accessory before using it to
make sure that it does not in any
way reduce ground clearance or
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, an
electric 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 is in the
“S” (stop) 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-
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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 4-6)
5. Transmission oil drain bolt (page 7-8)U5PG8BE0.book Page 2 Wednesday, June 27, 2012 2:53 PM

DESCRIPTION
3-3
3
EAU10430
Controls and instruments
127
345
6
1. Rear brake lever (page 4-3)
2. Starter (choke) lever (page 4-7)
3. 2-stroke engine oil tank cap (page 4-6)
4. Engine stop switch (page 4-1)
5. Front brake lever (page 4-2)
6. Throttle grip (page 7-12)
7. Fuel tank cap (page 4-3)
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INSTRUMENT AND CONTROL FUNCTIONS
4-1
4
EAU40660
Handlebar switch
EAU40674
Engine stop switch
“OFF/RUN/START”
Set this switch to “START” before start-
ing the engine. Set this switch to “RUN”
after warming up the engine or before
starting off. Set this switch to “OFF” to
stop the engine.TIP●
The engine cannot be started with
this switch set to the “RUN” posi-
tion.
●
The engine speed is limited while
this switch is set to the “START”
position, therefore the motorcycle
cannot be ridden in that switch po-
sition.
EAU41044
Speed limiter and power re-
duction plate Your motorcycle is equipped with an
adjustable speed limiter and a power
reduction plate. The speed limiter
keeps the throttle from fully opening,
even when the throttle grip is turned to
the maximum. The power reduction
plate is installed in the exhaust mani-
fold to limit the amount of power avail-
able while learning.
Speed limiter1. Loosen the locknut.
2. To increase the maximum engine power available and the maximum
speed of the motorcycle, turn the
adjusting screw in direction (a). To
decrease the maximum engine
power available and the maximum
speed of the motorcycle, turn the
adjusting screw in direction (b).
1. Engine stop switch “OFF/RUN/START”
1
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INSTRUMENT AND CONTROL FUNCTIONS
4-3
4
EAU12951
Rear brake lever The rear brake lever is located on the
left side of the handlebar. To apply the
rear brake, pull this lever toward the
handlebar 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.
EAU13212
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. 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
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