2016 YAMAHA PW50 maintenance

Introduction
EAU41075
Congratulations on your purchase of the Yamaha PW50 / PW50G / PW50G2. This
model is the result of Yamaha’s vast experience in the production of fine sporting,
touring, and pacesetting racing machines. It represents the high degree of crafts-
manship and reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic
maintenance of this motorcycle. If you have any questions concerning the opera-
tion or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the
emissions standards for clean air applicable at the date of manufacture. Yamaha
has met these standards without reducing the performance or economy of oper-
ation of the motorcycle. To maintain these high standards, it is important that you
and your Yamaha dealer pay close attention to the recommended maintenance
schedules and operating instructions contained within this manual.
Yamaha continually seeks advancements in product design and quality. There- fore, while this manual contains the most current product information available at
the time of printing, there may be minor discrepancies between your motorcycle
and this manual. If there is any question concerning this manual, please consult a
Yamaha dealer.
WARNING
EWA10032
Please rea d this manual carefully an d completely before operating this mo-
torcycle.
WARNING
EWA14352
This motorcycle is desi gne d an d manufactured for off-road use only. It is il-
le gal to operate this motorcycle on any pu blic street, road or highway. Such
use is prohi bite d b y law. This motorcycle complies with almost all state off-
hi ghway noise level an d spark arrester laws an d re gulations. Please check
your local ri din g laws an d re gulations before operatin g this motorcycle.
AN IMPORTANT SAFETY MESSAGE:
 Read this manual carefully and completely before operating this motorcycle.
Make sure you understand all instructions.
 Pay close attention to the warning and notice labels on the motorcycle.
 Never operate a motorcycle without proper training or instruction.
 Weight of the rider should not exceed 25 kg (55 lb).
AN IMPORTANT NOTE TO PARENTS:
This motorcycle is not a toy. Before you let your child ride this motorcycle, you
should understand the instructions and warnings in this Owner’s Manual. Then be
sure your child understands and will follow them. Children differ in skills, physical
abilities, and judgment. Some children may not be able to operate a motorcycle
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Introduction
safely. Parents should supervise their child’s use of the motorcycle at all times.
Parents should permit continued use only if they determine that the child has the
ability to operate the motorcycle safely.
Your motorcycle is equipped with an adjustable speed limiter and a power reduc-
tion plate. Yamaha recommends that all beginners start off with the speed limiter
adjusting screw turned in and the power reduction plate installed in the exhaust
manifold to limit the power available while they learn. The limiter screw may be
gradually turned out to increase maximum speed as the beginner becomes more
familiar with operating the motorcycle. Parents should decide when to adjust the
motorcycle for more power as their youngster’s riding skills improve. Once the rid-
er can operate with skill at the top speed permitted by adjusting the speed limiter
alone, the power reduction plate can be removed. Since removal of this plate will
result in a significant increase in power, turn the speed limiter back in again; adjust
it out in stages as you did before.
Motorcycles are sin gle track vehicles. Their safe use an d operation are d e-
pen dent upon the use of proper ri din g techniques as well as the expertise of
the operator. Every operator shoul d know the followin g requirements before
ri din g this motorcycle.
He or she should:  Obtain thorough instructions from a competent source on all aspects of mo-
torcycle operation.
 Observe the warnings and maintenance requirements in this Owner’s Manu-
al.
 Obtain qualified training in safe and proper riding techniques.
 Obtain professional technical service as indicated in this Owner’s Manual
and/or when made necessary by mechanical conditions.
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Table of contents
Location of important la bels ........... 1-1
Safety information ............................ 2-1
Description ....................................... 3-1
Left view ......................................... 3-1
Right view ....................................... 3-2
Controls and instruments ............... 3-3
Instrument an d 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 ................................................. 4-4
Fuel tank breather hose.................. 4-6
2-stroke engine oil .......................... 4-6
Fuel cock ........................................ 4-7
Starter (choke) lever ...................... 4-7
Kickstarter ...................................... 4-8
Seat ................................................ 4-8
Cable lock (for Europe) ................... 4-9
For your safety – pre-operation
checks ............................................... 5-1
Operation an d important ri din g
points ................................................ 6-1
Starting and warming up a cold engine ......................................... 6-1
Starting a warm engine .................. 6-2
Starting off ...................................... 6-2
Acceleration and deceleration ........ 6-3
Braking ........................................... 6-3
Engine break-in .............................. 6-4
Parking ........................................... 6-4
Perio dic maintenance an d
a d justment ........................................ 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 ....... 7-10
Cleaning the spark arrester ........... 7-11
Adjusting the carburetor ............... 7-12
Adjusting the engine idling speed ......................................... 7-12
Checking the throttle grip free
play ............................................ 7-13
Tires .............................................. 7-14
Panel wheels ................................. 7-16
Adjusting the front and rear brake lever free play ............................ 7-16
Checking the front and rear brake
shoes ......................................... 7-17
Checking and lubricating the cables ........................................ 7-18
Checking and lubricating the throttle grip and cable ............... 7-19
Adjusting the Autolube pump ....... 7-19
Lubricating the front and rear
brake levers ............................... 7-20
Checking and lubricating the
centerstand ................................ 7-20
Checking the front fork ................. 7-21
Checking the steering ................... 7-21
Checking the wheel bearings ........ 7-22
Front wheel ................................... 7-22
Rear wheel .................................... 7-24
Troubleshooting ............................ 7-26
Troubleshooting chart ................... 7-27
Motorcycle care an d stora ge .......... 8-1
Matte color caution ......................... 8-1
Care................................................. 8-1
Storage............................................ 8-3
Specifications ................................... 9-1
Consumer information ................... 10-1
Identification numbers .................. 10-1
In dex .
............................................... 11-1
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Safety information
2-2
2
sic motorcycle maintenance.
Certain maintenance can only
be carried out by certified staff.
 Many accidents involve inexperi-
enced operators.
• Make sure that you are qualified and that you only lend your mo-
torcycle to other qualified oper-
ators.
• Know your skills and limits. Staying within your limits may
help you to avoid an accident.
• We recommend that you prac- tice riding your motorcycle until
you have become thoroughly
familiar with the motorcycle and
all of its controls.
 Many accidents have been
caused by error of the motorcycle
operator. A typical error made by
the operator is veering wide on a
turn due to excessive speed or un-
dercornering (insufficient lean an-
gle for the speed). Never travel
faster than warranted by condi-
tions.
 Ride cautiously in unfamiliar ar-
eas. You may encounter hidden
obstacles that could cause an ac-
cident.
 The posture of the operator is im-
portant for proper control. The op-
erator should keep both hands on
the handlebar and both feet on the
operator footrests during opera-
tion to maintain control of the mo-
torcycle.
 Never ride under the influence of
alcohol or other drugs. Protective Apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the pre-
vention or reduction of head injuries.
 Always wear an approved helmet.
 Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
 The use of a jacket, heavy boots,
trousers, gloves, etc., is effective
in preventing or reducing abra-
sions or lacerations.
 Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
 Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause
burns.
Avoi d Car bon Monoxi de Poisonin g
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing
carbon monoxide can cause head-
aches, dizziness, drowsiness, nausea,
confusion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be pres-
ent even if you do not see or smell any
engine exhaust. Deadly levels of car-
bon monoxide can collect rapidly and
you can quickly be overcome and un-
able to save yourself. Also, deadly lev-
els of carbon monoxide can linger for
hours or days in enclosed or poorly
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Instrument and control functions
4-5
4 gasoline of a different brand or premi-
um unleaded fuel. Use of unleaded fuel
will extend spark plug life and reduce
maintenance cost.
Gasohol
There are two types of gasohol: gaso-
hol containing ethanol and that con-
taining methanol. Gasohol containing
ethanol can be used if ethanol content
does not exceed 10% (E10). Gasohol
containing methanol is not recom-
mended by Yamaha because it can
cause damage to the fuel system or
vehicle performance problems.
For Europe
NOTICE
ECA15591
Use only unlea
ded g asoline. The use
of lea ded 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
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.
Recommen ded fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
2.0 L (0.5 US gal, 0.4 Imp.gal)
Recommen ded fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
2.0 L (0.5 US gal, 0.4 Imp.gal)
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For your safety – pre-operation checks
5-1
5
EAU63440
Inspect your vehicle each time you use it to make sure the vehicle is in safe oper-
ating 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 d amage. Do not operate the vehicle if you fin d
any pro blem. If a pro blem cannot be correcte d 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 CHECKSPAGE
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. 4-4, 4-6
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
Transmission oil • 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. 7-16,
7-17
Rear brake • Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary. 7-16,
7-17
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 cable and grip housing. 7-13,
7-19
Control ca bles • Make sure that operation is smooth.
• Lubricate if necessary.
7-18
Wheels an d tires •Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary. 7-14,
7-16
Brake levers • Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
7-20
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Periodic maintenance an d a djustment
7-1
7
EAU17246
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 performin g maintenance ac-
tivities incorrectly may increase
your risk of injury or d eath 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, an d
linin gs can b ecome very hot during
use. To avoi d possi ble burns, let
b rake components cool before
touchin g them.
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Periodic maintenance an d a djustment
7-2
7
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.
EAU17312
Owner’s tool kit
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
TIP
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
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