2014 YAMAHA PW50 engine

PERIODIC MAINTENANCE AND ADJUSTMENT
7-1
7
EAU17245
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10322
Failure to properly maintain the vehi-
cle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death durin g
service or while usin g the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha d ealer perform
service.
WARNING
EWA15123
Turn off the en gine when performin g
maintenance unless otherwise
specified .
 A runnin g en gine has movin g
parts that can catch on body
parts or clothin g an d electrical
parts that can cause shocks or
fires.
 Runnin g the en gine while ser-
vicin g can lead to eye injury,
b urns, fire, or car bon monoxi de
poisonin g – possi bly lea din g to
d eath. See pag e 2-2 for more in-
formation a bout car bon monox-
i d e.
WARNING
EWA15461
Brake discs, calipers, drums, and
linin gs can b ecome very hot d uring
use. To avoi d possi ble burns, let
b rake components cool before
touchin g them.
EAU17303
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replace-
ment, or repair of the emission control
devices and systems may be per-
formed by any repair establishment or
individual that is certified (if applicable).
Yamaha dealers are trained and equipped to perform these particular
services.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-3
7
EAU41743
Periodic maintenance chart for the emission control systemTIPItems marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.NO. ITEM CHECK OR MAINTENANCE JOB INITIAL
THEREAFTER
EVERY
1
month 3
months 6
months 6
months 12
months
1* Fuel line
Check fuel hoses for cracks or damage.Replace if necessary.
2 Spark plugCheck condition.Adjust gap and clean.Replace if necessary.
3 Air filter elementClean with solvent.Replace if necessary.
4* CarburetorCheck engine idling speed and starter operation.Adjust if necessary.Clean.
5* Cylinder head and
exhaust systemCheck for leakage.Tighten if necessary.Decarbonize if necessary.
6* Spark arresterClean.
U2SA80E0.book Page 3 Monday, June 3, 2013 5:25 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-6
7
EAU19605
Checking the spark plugThe spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic main-
tenance and lubrication chart. In addi-
tion, the condition of the spark plug
can reveal the condition of the engine.
To remove the spark plu g
1. Remove the spark plug cap.
2. Remove the spark plug as shown, with the spark plug wrench includ-
ed in the owner’s tool kit. To check the spark plu
g
1. Check that the porcelain insulator around the center electrode of the
spark plug is a medium-to-light
tan (the ideal color when the vehi-
cle is ridden normally).
TIPIf the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
stead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for electrodeerosion and excessive carbon or
other deposits, and replace it if
necessary.
3. Measure the spark plug gap with a wire thickness gauge and, if nec-
essary, adjust the gap to specifi-
cation.
1. Spark plug cap
1
1. Spark plug wrench
1
Specified spark plu g:
PW50 NGK/BP4HS (ZAF)
PW50 NGK/BPR4HS
(AUT)(BEL)(CHE)(CYP)(CZE)(DEU)
(DNK)(ESP)(FIN)(FRA)(GBR)(GRC)
(IRL)(ITA)(NLD)(NOR)(POL)(PRT)
(SVK)(SVN)(SWE)(TUR)
PW50E NGK/BPR4HS
PW50E1 NGK/BPR4HS
PW50 DENSO/W14FP-L (ZAF)
1. Spark plug gap
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-7
7To install the spark plu
g
1. Clean the surface of the spark plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
2. Install the spark plug with the spark plug wrench, and then tight-
en it to the specified torque.
TIPIf 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
specified torque as soon as possible.3. Install the spark plug cap.
EAU41104
Removin g the power re duc-
tion plateTo 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.
[EWA14582]
2. Remove the gasket.
3. Remove the power reduction plate.
TIPStore 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 and itsnew gasket by installing the bolts,
and then tighten the bolts to the
specified torque.
Spark plu g g ap:
0.6–0.7 mm (0.024–0.028 in)
Ti ghtenin g torque:
Spark plug: 20 Nm (2.0 m·kgf, 14 ft·lbf)
1. Exhaust manifold bolt
1
1. Exhaust manifold
2. Gasket
3. Power reduction plateTightenin g torque:
Exhaust manifold bolt: 9 Nm (0.9 m·kgf, 6.5 ft·lbf)1
23
U2SA80E0.book Page 7 Monday, June 3, 2013 5:25 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-8
7
EAU40894
Transmission oilThe 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 lubrica-
tion 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
ECA10453
In or der to prevent clutch slip-
pa ge (since the transmission oil
also lu bricates the clutch), do
not mix any chemical additives.
Do not use oils with a diesel
specification of “CD” or oils of a
hi gher quality than specifie d. In
a dd ition, do not use oils la bele d
“ENERGY CONSERVING II” or
hi gher.
 Make sure that no forei gn 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
Tightenin g torque:
Transmission oil drain bolt: 14 Nm (1.4 m·kgf, 10 ft·lbf)
Recommen ded transmission oil:
See page 9-1.
Oil chan ge quantity:
0.30 L (0.32 US qt, 0.26 Imp.qt)
1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-11
7
EAU39931
Adjustin g the car buretorThe carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most
carburetor adjustments should be left
to a Yamaha dealer, who has the nec-
essary professional knowledge and ex-
perience. The adjustment described in
the following section, however, may be
serviced by the owner as part of rou-
tine maintenance.NOTICE
ECA10551
The car buretor has been set an d ex-
tensively teste d at the Yamaha fac-
tory. Chang ing these settin gs
without sufficient technical knowl-
e dge may result in poor perfor-
mance of or d amage to the en gine.
EAU21363
A djustin g the eng ine idlin g
spee dThe engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.TIPA diagnostic tachometer is needed to
make this adjustment.1. Attach the tachometer to the
spark plug lead.
2. Start the engine and warm it up for several minutes at 1000–2000
r/min while occasionally revving it
to 4000–5000 r/min.TIPThe engine is warm when it quickly re-
sponds to the throttle.3. Check the engine idling speedand, if necessary, adjust it to
specification by turning the throt-
tle stop screw. To increase the en-
gine idling speed, turn the screw in direction (a). To decrease the en-
gine idling speed, turn the screw in
direction (b).
TIPIf the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.1. Throttle stop screwEn gine i dlin g spee d:
1650–1750 r/min
1 (a)
(b)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-16
7
EAU23098
Checking an d lu bricatin g the
ca blesThe operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubri-
cated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or re-
place it. WARNING! Dama ge to the
outer housin g of cab les may result
in internal rustin g an d cause inter-
ference with ca ble movement. Re-
place damag ed cab les as soon as
possi ble to prevent unsafe con di-
tions.
[EWA10712] EAU23115
Checkin
g an d lu bricatin g the
throttle grip an d ca bleThe operation of the throttle grip
should be checked before each ride. In
addition, the cable should be lubricat-
ed by a Yamaha dealer at the intervals
specified in the periodic maintenance
chart.
The throttle cable is equipped with a
rubber cover. Make sure that the cover
is securely installed. Even though the
cover is installed correctly, it does not
completely protect the cable from wa-
ter entry. Therefore, use care not to
pour water directly onto the cover or
cable when washing the vehicle. If the
cable or cover becomes dirty, wipe
clean with a moist cloth.
EAU23121
A djustin g the Autolu be pumpThe Autolube pump is a vital and so-
phisticated component of the engine,
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
Recommen ded lu bricant:
Yamaha cable lubricant or other
suitable cable lubricant
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-24
7
EAU25975
Troubleshootin g chart
Check the fuel level in
the fuel tank.1. Fuel
There is
enough fuel.
There is
no fuel.
Supply fuel.Check the ignition.
The engine does not start.
Check the ignition.
Operate the kickstarter.3. Compression
There is compression.There is
no compression. The engine does not start.
Have a Yamaha dealer check the vehicle.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.2. Ignition
Wet
Dry Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the compression.
Open the throttle halfway and operate
the kickstarter.
U2SA80E0.book Page 24 Monday, June 3, 2013 5:25 PM