2016 YAMAHA PW50 brake

Periodic maintenance an d a djustment
7-22
7
EAU23292
Checkin g the wheel b earings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
EAU24361
Front wheel
EAU56510
To remove the front wheel
WARNING
EWA10822
To avoi d injury, securely support the
vehicle so there is no dan ger of it
fallin g over.
1. Place the motorcycle on the cen-
terstand.
2. Disconnect the brake cable at the wheel hub by removing the front
brake lever free play adjusting nut,
then removing the cable from the
brake camshaft lever and brake
shoe plate.
3. Remove the axle nut and washer.
4. Pull the wheel axle out, and then remove the wheel.
1. Brake camshaft lever
2. Brake shoe plate
3. Washer
4. Axle nut
5. Brake cable
6. Front brake lever free play adjusting nut
5
6
1 3
4
2
U2SA82E0.book Page 22 Monday, June 8, 2015 1:09 PM

Periodic maintenance an d a djustment
7-23
7 To install the front wheel
1. Install the brake shoe plate into the wheel hub as shown.
2. Lift the wheel up between the fork legs.
TIP
Make sure that the slot in the brake
shoe plate fits over the retainer on the
fork leg.
3. Insert the wheel axle from the rightside.
4. Install the washer and axle nut, and then tighten the axle nut to the
specified torque.
5. Connect the brake cable at the wheel hub, and then install the
brake lever free play adjusting nut.
6. Adjust the brake lever free play. (See page 7-16.)
7. Take the motorcycle off the cen- terstand so that the front wheel is
on the ground.
8. Push down hard on the handlebar several times to check for proper
fork operation.
1. Wheel axle
1. Retainer
1
1
Tightening torque:
Axle nut: 40 Nm (4.0 m·kgf, 29 ft·lbf)
U2SA82E0.book Page 23 Monday, June 8, 2015 1:09 PM

Periodic maintenance an d a djustment
7-25
7 8. Remove the axle nut while apply-
ing the rear brake.
9. Remove the rear arm by removing the nuts and washers.
10. Pull the wheel to the right to re- move it from the rear axle.
To install the rear wheel 1. Apply a light coating of lithium- soap-based grease to the splines
of the rear axle and wheel hub.
2. Install the wheel to the rear axle.
3. Install the rear arm by installing the washers and nuts.
4. Install the axle nut.
5. Install the right-side rear shock absorber by installing the mount-
ing bolt. 6. While applying the rear brake,
tighten the axle nut to the speci-
fied torque.
7. Tighten the rear arm nuts and rear shock absorber mounting bolt to
the specified torques.
8. Install the exhaust chamber by in- stalling the bolt and washers.
9. Install the power reduction plate, a new gasket, and then install the
exhaust manifold bolts.
10. Tighten the exhaust manifold bolts and exhaust chamber bolt to the
specified torques.
11. Install the muffler by sliding the spring clamp up to its original po-
sition, and then installing the
washers and muffler bolt.
TIP
Make sure that the spring clamp is po-
sitioned with the projection side facing
inward.
1. Axle nut
1. Rear arm
2. Washer
3. Rear arm nut
1
12
3
Tightening torques:
Axle nut: 60 Nm (6.0 m·kgf, 43 ft·lbf)
Rear arm nut:
29 Nm (2.9 m·kgf, 21 ft·lbf)
Rear shock absorber mounting bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf)
Ti ghtening torques:
Exhaust manifold bolt:
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Exhaust chamber bolt: 18 Nm (1.8 m·kgf, 13 ft·lbf)
U2SA82E0.book Page 25 Monday, June 8, 2015 1:09 PM

Periodic maintenance an d a djustment
7-26
7
12. Tighten the muffler bolt to the
specified torque.
13. Adjust the brake lever free play. (See page 7-16.)
14. Install the seat.
EAU25852
Trou bleshootin g
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition systems,
for example, can cause poor starting
and loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
WARNING
EWA15142
When checkin g the fuel system, do
not smoke, an d make sure there are
no open flames or sparks in the ar-
ea, inclu din g pilot li ghts from water
heaters or furnaces. Gasoline or
g asoline vapors can i gnite or ex-
plo de, causin g severe injury or prop-
erty damag e.
1. Exhaust chamber
2. Spring clamp
3. Muffler
Tightening torque:
Muffler bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
1
2
3
U2SA82E0.book Page 26 Monday, June 8, 2015 1:09 PM

Motorcycle care and stora ge
8-2
8 structe
d. Also, thorou ghly rinse
the area off with water, imme di-
ately dry it, an d then apply a cor-
rosion protection spray.
 Improper cleanin g can d amage
plastic parts (such as cowlin gs,
panels, etc.) an d the mufflers.
Use only a soft, clean cloth or
spon ge with water to clean
plastic. However, if the plastic
parts cannot be thorou ghly
cleaned with water, dilute d mil d
d eter gent with water may b e
use d. Be sure to rinse off any
d eter gent resi due using plenty
of water, as it is harmful to plas-
tic parts.
 Do not use any harsh chemical
prod ucts on plastic parts. Be
sure to avoi d using cloths or
spon ges which have been in
contact with stron g or a brasive
cleanin g prod ucts, solvent or
thinner, fuel (g asoline), rust re-
movers or inhi bitors, brake flui d,
antifreeze or electrolyte.
 Do not use hi
gh-pr
essure wash-
ers or steam-jet cleaners since
they cause water seepa ge an d
d eterioration in the followin g ar-
eas: seals (of wheel an d swin g-
arm bearin gs, fork an d b rakes),
electric components (couplers,
connectors, an d switches),
b reather hoses an d vents.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain or near the sea
Since sea salt is extremely corrosive,
carry out the following steps after each
ride in the rain or near the sea.
1. Clean the motorcycle with cold water and a mild detergent, after
the engine has cooled down.
NOTICE: Do not use warm wa-
ter since it increases the corro-
sive action of the salt.
[ECA10792]
2. Apply a corrosion protection spray on all metal, including chrome-
and nickel-plated, surfaces to pre-
vent corrosion.
After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth.
2. Use a chrome polish to shine chrome, aluminum and stainless-
steel parts.
3. To prevent corrosion, it is recom- mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean- er to remove any remaining dirt.
5. Touch up minor paint damage caused by stones, etc.
6. Wax all painted surfaces.
7. Let the motorcycle dry completely before storing or covering it.
WARNING
EWA14502
Contaminants on the brakes or tires
can cause loss of control.
U2SA82E0.book Page 2 Monday, June 8, 2015 1:09 PM

Specifications
9-2
9
Clutch:
Clutch type:Wet, centrifugal, shoe
Drivetrain:
Primary reduction ratio:1.909 (63/33)
Final drive: Shaft
Secondary reduction ratio:
6.218 (19/15 x 54/11)
Chassis:
Frame type:Backbone
Caster angle:
25.50 °
Trail:
50 mm (2.0 in)
Front tire:
Type:With tube
Size:
2.50-10 4PR
Manufacturer/model: BRIDGESTONE/M29
Manufacturer/model: IRC/Z MARK II (PW50_ZAF, PW50G,
PW50G2)
Speed rating: 100 km/h (62 mph)
Rear tire:
Type:With tube
Size: 2.50-10 4PR
Manufacturer/model:
BRIDGESTONE/M29
Manufacturer/model: IRC/Z MARK II (PW50_ZAF, PW50G,
PW50G2)
Speed rating: 100 km/h (62 mph)
Loa din g:
Maximum rider weight:
25.0 kg (55 lb)
Tire air pressure (measure d on col d
tires):
Front:
100 kPa (1.00 kgf/cm², 15 psi)
Rear: 100 kPa (1.00 kgf/cm², 15 psi)
Front wheel:
Wheel type:Panel wheel
Rim size:
10x1.50
Rear wheel:
Wheel type:Panel wheel
Rim size:
10x1.50
Front brake:
Type:
Mechanical leading trailing drum brake
Rear brake:
Type:
Mechanical leading trailing drum brake
Front suspension:
Type:Telescopic fork
Spring:
Coil spring
Shock absorber: Hydraulic damper
Wheel travel: 60 mm (2.4 in)
Rear suspension:
Type:Unit swing
Spring: Coil spring
Shock absorber:
Hydraulic damper
Wheel travel: 50 mm (2.0 in)
Electrical system:
Ignition system:
CDI
U2SA82E0.book Page 2 Monday, June 8, 2015 1:09 PM

11-1
11
Index
A
Acceleration and deceleration ................ 6-3
Air filter element, cleaning .................... 7-10
Autolube pump, adjusting..................... 7-19
B
Brake lever, front .................................... 4-2
Brake lever, rear...................................... 4-3
Brake levers, lubricating ....................... 7-20
Brake shoes, checking ......................... 7-17
Braking.................................................... 6-3
C
Cable lock (for Europe) ........................... 4-9
Cables, checking and lubricating ......... 7-18
Carburetor, adjusting ............................ 7-12
Care ........................................................ 8-1
Centerstand, checking and
lubricating ........................................... 7-20
E
Engine break-in....................................... 6-4
Engine idling speed .............................. 7-12
Engine oil ................................................ 4-6
Engine serial number ............................ 10-1
Engine, starting a warm .......................... 6-2
Engine stop switch ................................. 4-1
F
Front and rear brake lever free play, adjusting ............................................. 7-16
Front fork, checking .............................. 7-21
Fuel ......................................................... 4-4
Fuel cock ................................................ 4-7
Fuel tank breather hose .......................... 4-6
Fuel tank cap .......................................... 4-3
H
Handlebar switch .................................... 4-1
I
Identification numbers .......................... 10-1
K
Kickstarter............................................... 4-8
L
Labels, location....................................... 1-1
M
Maintenance 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 ........................................... 10-1
P
Parking .................................................... 6-4
Part locations .......................................... 3-1 Power reduction plate, removing ........... 7-7
S
Safety information .................................. 2-1
Seat ........................................................ 4-8
Spark arrester, cleaning ....................... 7-11
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................................ 7-21
Storage ................................................... 8-3
T
Throttle grip and cable, checking and
lubricating .......................................... 7-19
Throttle grip free play, checking........... 7-13
Tires ...................................................... 7-14
Tool kit.................................................... 7-2
Transmission oil ..................................... 7-8
Troubleshooting ................................... 7-26
Troubleshooting chart .......................... 7-27
V
Vehicle Emission Control Information label (For Canada) .............................. 10-2
Vehicle identification number ............... 10-1
W
Wheel bearings, checking .................... 7-22
Wheel (front) ......................................... 7-22
Wheel (rear) .......................................... 7-24
Wheels .................................................. 7-16
U2SA82E0.book Page 1 Monday, June 8, 2015 1:09 PM