2015 YAMAHA PW50 brake

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
U2SA81E0.book Page 1 Monday, June 2, 2014 2:00 PM

DESCRIPTION
3-3
3
EAU10431
Controls and instruments
1
234
5
1. Rear brake lever (page 4-3)
2. Starter (choke) lever (page 4-7)
3. Engine stop switch (page 4-1)
4. Front brake lever (page 4-2)
5. Throttle grip (page 7-12)
U2SA81E0.book Page 3 Monday, June 2, 2014 2:00 PM

INSTRUMENT AND CONTROL FUNCTIONS
4-2
4
3. Tighten the locknut.
TIPThe adjusting range of the speed limit-
er screw is from the fully turned-in po-
sition to 7 mm (0.28 in) turned out.
When the screw is turned out to 7 mm (0.28 in), the throttle grip can only be
opened approximately halfway. If more
power is required, please consult a
Yamaha dealer.
WARNING
EWA14632
Improper a
djustment of the spee d
limiter coul d cause improper throttle
operation. You coul d lose control,
have an acci dent or be injured . Do
not turn the a djustin g screw out
more than 7 mm (0.28 in) before con-
sultin g a Yamaha d ealer. Always
make sure the throttle grip free play
is a djuste d to 1.5–3.5 mm (0.06–0.14
in). (See pa ge 7-12.)Power re duction plate
Once the rider can operate with skill at
the top speed permitted by adjusting
the speed limiter alone, the power re-
duction plate can be removed. (See
page 7-7.)
EAU12902
Front brake leverThe front brake lever is located on the
right side of the handlebar. To apply
the front brake, pull this lever toward
the throttle grip.
1. Locknut
2. Adjusting screw
1. No more than 7 mm (0.28 in)
1
(a) (b)2
1
1. Front brake lever
1
U2SA81E0.book Page 2 Monday, June 2, 2014 2:00 PM

INSTRUMENT AND CONTROL FUNCTIONS
4-3
4
EAU12952
Rear brake leverThe rear brake lever is located on the
left side of the handlebar. To apply the
rear brake, pull this lever toward the
handlebar grip.
EAU13183
Fuel tank capTo 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
clockwise.
WARNING
EWA11092
Make sure that the fuel tank cap is
properly close d after fillin g fuel.
Leakin g fuel is a fire hazar d.
EAU13213
FuelMake sure there is sufficient gasoline in
the tank.
WARNING
EWA10882
Gasoline an d g asoline vapors are
extremely flamma ble. To avoi d fires
an d explosions an d to re duce the
risk of injury when refuelin g, 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
U2SA81E0.book Page 3 Monday, June 2, 2014 2:00 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-1
5
EAU15598
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
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility of an acci dent or equipment damag e.
Do not operate the vehicle if you fin d any pro blem. If a pro blem cannot be corrected b y the proce dures provi ded in
this manual, have the vehicle inspecte d b y a Yamaha dealer.Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel • Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check fuel tank breather hose for obstructions, cracks or damage, and check
hose connection. 4-3, 4-5
2-stroke en gine oil • Check oil level in oil tank.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage. 4-6
Tr a n s m i s s i o n o i l • Check oil level in transmission case.
• If necessary, add recommended oil to specified level.
7-8
Mi dd le an d final g ear 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
U2SA81E0.book Page 1 Monday, June 2, 2014 2:00 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-2
5
Throttle grip • Make sure that operation is smooth.
• Check throttle grip free play.
• If necessary, have Yamaha dealer adjust throttle grip free play and lubricate ca-
ble and grip housing. 7-12, 7-16
Control ca bles • Make sure that operation is smooth.
• Lubricate if necessary.
7-16
Wheels an d tires • Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary. 7-12, 7-14
Brake levers • Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary. 7-17
Centerstan d • Make sure that operation is smooth.
• Lubricate pivot if necessary.
7-17
Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary. —
En gine stop switch • Check operation. 4-1
ITEM CHECKS PAGE
U2SA81E0.book Page 2 Monday, June 2, 2014 2:00 PM

OPERATION AND IMPORTANT RIDING POINTS
6-1
6
EAU15952
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWA10272
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which coul d cause an acci dent
or injury.
EAU4088A
Startin g an d warmin g up a
col d en gine1. Turn the fuel cock lever to “O”
(on).
2. Set the engine stop switch to “START”.
3. Turn the starter (choke) on and completely close the throttle. (See
page 4-7.)
4. While applying the front or rear brake, start the engine by pushing
the kickstarter lever down.
5. After starting the engine, move the starter (choke) back halfway.
6. When the engine is warm, turn the starter (choke) off and set the en-
gine stop switch to “RUN”.TIPThe engine is warm when it responds
quickly to the throttle with the starter
(choke) turned off.NOTICE
ECA11043
For maximum en gine life, never ac-
celerate har d when the en gine is
col d!
EAU16661
Startin g a warm en gineFollow the same procedure as for
starting a cold engine with the excep-
tion that the starter (choke) is not re-
quired when the engine is warm.
Instead, start the engine with the throt-
tle slightly open.TIPIf the engine does not start after sever-
al kicks, try again with the throttle 1/4
to 1/2 open.
U2SA81E0.book Page 1 Monday, June 2, 2014 2:00 PM

OPERATION AND IMPORTANT RIDING POINTS
6-2
6
EAU41004
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, release the rear brake lever,
and then slowly turn the throttle
grip in order to take off.
EAU16782
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)
U2SA81E0.book Page 2 Monday, June 2, 2014 2:00 PM