2014 YAMAHA PW50 check 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
2-3
2soning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
 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.
Loa din g
Adding accessories to your motorcycle
can adversely affect stability and han-
dling if the weight distribution of the
motorcycle 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 overloa
ded vehicle
coul d cause an acci dent.
 The weight of the operator must
not exceed 25 kg (55 lb).
 Accessory weight should be kept
as low and close to the motorcy-
cle as possible. Securely pack
your heaviest items as close to the
center of the vehicle as possible
and make sure to distribute the
weight as evenly as possible on
both sides of the motorcycle to
minimize imbalance or instability.
 Shifting weights can create a sud-
den imbalance. Make sure that
accessories 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 ac-
cessories 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, an d
Mo difications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accesso-
ries or modifications are not suitable
because of potential safety hazards to
you or others. Installing aftermarket
U2SA80E0.book Page 3 Monday, June 3, 2013 5:25 PM

SAFETY INFORMATION
2-4
2
products or having other modifications
performed 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 han- dlebar or the front fork area can
create instability due to improp-
er weight distribution. If acces-
sories 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
unstable in cross winds.
• Certain accessories can dis- place the operator from his or
her normal riding position. This
improper position limits the
freedom of movement of the
operator and may limit control
ability, therefore, such accesso-
ries are not recommended.
 Use caution when adding electri-
cal accessories. If electrical ac-
cessories exceed the capacity of
the motorcycle’s electrical sys-
tem, an electric failure could re-
sult, which could cause a
dangerous loss of lights or engine
power.
Aftermarket Tires an d Rims
The tires and rims that came with your
motorcycle were designed to match
the performance capabilities and to
provide the best combination of han-
dling, braking, and comfort. Other tires, rims, sizes, and combinations
may not be appropriate. Refer to page
7-12 for tire specifications and more in-
formation on replacing your tires.
Transportin
g 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
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INSTRUMENT AND CONTROL FUNCTIONS
4-5
4Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
95 or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark plug
life and reduce maintenance costs.
For Oceania an
d South Africa
NOTICE
ECA15591
Use only unlea ded g asoline. The use
of lead ed g asoline will cause severe
d amag e to internal en gine parts,
such as the piston rin gs as well as to
the exhaust system.Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging)
occurs, use a gasoline of a different brand or premium unleaded fuel. Use
of unleaded fuel will extend spark plug
life and reduce maintenance costs.
EAU13414
Fuel tank
breather hoseBefore operating the motorcycle:
 Check the fuel tank breather hose
connection.
 Check the fuel tank breather hose
for cracks or damage, and replace
it if necessary.
 Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.
Recommen ded fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
2.0 L (0.53 US gal, 0.44 Imp.gal)
1. Fuel tank breather hose
1
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OPERATION AND IMPORTANT RIDING POINTS
6-2
6
EAU41003
Starting off1. While applying the rear brake le-
ver, push the motorcycle off the
centerstand.
2. Completely close the throttle.
3. Set the engine stop switch to “RUN”.
4. Check for oncoming off-road vehi- cles, and then slowly turn the
throttle grip in order to take off.
EAU16781
Acceleration an d d ecelerationThe speed can be adjusted by opening
and closing the throttle. To increase
the speed, turn the throttle grip in di-
rection (a). To reduce the speed, turn
the throttle grip in direction (b).
EAU41013
Brakin g
WARNING
EWA14572
Avoi d b rakin g har d or su ddenly
(especially when leanin g over to
one si de), otherwise the motor-
cycle may ski d or overturn.
 Keep in min d that brakin g on
wet surfaces is much more diffi-
cult.
 Ride slowly d own a hill, as brak-
in g d ownhill can be very diffi-
cult.1. Close the throttle completely.
2. Apply both front and rear brakes simultaneously while gradually in-
creasing the pressure.
(a) (b)
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OPERATION AND IMPORTANT RIDING POINTS
6-3
6Front
Rear
EAU42031
En
gine break-inThere is never a more important period
in the life of your engine than the first 5
hours of riding. It is also important to
accustom the rider to the motorcycle
during this time. Please read the fol-
lowing information carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
5 hours of operation. The various parts
in the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheating
must be avoided. However, momen-
tary full-throttle operation under load
(i.e., two to three seconds maximum)
does not harm the engine. Each full-
throttle acceleration should be fol-
lowed with a substantial rest period for
the engine. To allow the engine to cool
down from the temporary buildup of
heat, cruise at a lower engine speed.
After the first 5 hours of operation,
thoroughly check the motorcycle for
loose parts, oil leakage and any other
problems. Be sure to inspect and make adjustments thoroughly, especially ca-
bles. In addition, check all fittings and
fasteners for looseness, and tighten if
necessary.
NOTICE
ECA10271
If any en
gine trou ble shoul d occur
d urin g the en gine break-in perio d,
imme diately have a Yamaha dealer
check the vehicle.
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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.
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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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