2013 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 ..........................4-6
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
2-4
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

FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-1
5
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:
ITEMCHECKS PAGE
Fuel Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check fuel tank breather hose for obs
tructions, cracks or damage, and check
hose connection. 4-3, 4-5
2-stroke engine oil Check oil level in oil tank.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage. 4-6
Transmission oil Check oil level in transmission case.
If necessary, add recommended oil to specified level.
7-8
Middle and final gear cases Check vehicle for grease leakage. 7-9
Front brake Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary. 7-14, 7-15
Rear brake Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
7-14, 7-15
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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
Check operation.Check throttle grip free play, and adjust if
necessary.Apply Yamaha chain and cable lube or engine oil
10W-30 lightly.
NO. ITEM CHECK OR MAINTENANCE JOB
INITIAL
THEREAFTER
EVERY
1
month 3
months 6
months 6
months 12
months
8* Chassis fastenersCorrect if necessary.
A
9* utolube pumpCheck operation.Correct if necessary. 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 idlefor 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)
1
2
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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:Curb weight:39 kg (86 lb)
Technical permissible mass (Maximum load +
curb weight): 64 kg (141 lb)Noise and vibration level:Noise level (77/311/EEC):
PW50 75.1 dB(A)@2750 r/min
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)
(FIN)(FRA)(GBR)(GRC)(IRL)(ITA)(NLD)
(NOR)(POL)(PRT)(SVN)(SWE)
Vibration on seat (EN1032, ISO5008): PW50 Will not exceed 0.5 m/s²
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)
(FIN)(FRA)(GBR)(GRC)(IRL)(ITA)(NLD)
(NOR)(POL)(PRT)(SVN)(SWE) Vibration on handlebar (EN1032, ISO5008):
PW50 Will not exceed 2.5 m/s²
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)
(FIN)(FRA)(GBR)(GRC)(IRL)(ITA)(NLD)
(NOR)(POL)(PRT)(SVN)(SWE)
Engine:Engine type:
Air cooled 2-stroke
Cylinder arrangement: 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
PW50D Unleaded gasoline only
PW50D1 Regular unleaded gasoline only
Fuel tank capacity:
2.0 L (0.53 US gal, 0.44 Imp.gal)Carburetor:Type × quantity:
VM12SC x 1Spark plug(s):Manufacturer/model: PW50 NGK/BP4HS (ZAF)
PW50 NGK/BPR4HS
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)
(FIN)(FRA)(GBR)(GRC)(IRL)(ITA)(NLD)
(NOR)(POL)(PRT)(SVN)(SWE)
PW50D NGK/BPR4HS
PW50D1 NGK/BPR4HS
Manufacturer/model: PW50 DENSO/W14FP-L (ZAF)
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:Wet, centrifugal automaticTransmission:Primary reduction ratio:1.909 (63/33)
Final drive: Shaft
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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
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