2016 YAMAHA PW50 transmission

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
2-5
2
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
the location for the straps carefully
so the straps will not rub against
painted surfaces during transport.
 The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the mo-
torcycle will not bounce exces-
sively during transport.
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Description
3-2
3
EAU63391
Right view
12345
6
1. Spark arrester (page 7-11)
2. Seat (page 4-8)
3. Transmission oil filler cap (page 7-8)
4. Fuel tank cap (page 4-3)
5. 2-stroke engine oil tank cap (page 4-6)
6. Transmission oil drain bolt (page 7-8)
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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
7-4
7
EAU69202
General maintenance an d lu brication chart
TIP
Items marked with an asterisk should be performed by a Yamaha dealer as they
require special tools, data and technical skills.
4 *Tires Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
5
*Wheel bearings Check bearings for smooth operation.
Replace if necessary.
6
*Steering bearings Check bearing assemblies for
looseness.
7 *Middle and final gear
cases Check for grease leakage.
8
*Chassis fasteners Check all chassis fitting and fasteners.
9
*Autolube pump Check operation.
10
*Transmission oil Check for oil leakage.
Correct if necessary.
Change. Correct if necessary. Correct if necessary. Check gears for damage and wear.
Lubricate gears with
lithium-soap-based grease.
Moderately repack with
lithium-soap-based grease.
NO. ITEM CHECK OR MAINTENANCE JOB
1 month3 months
6 months
6 months12 months
1 *
*
*Front brake Check operation.
Adjust brake lever free play.√√√
√
√√√ √
√√√ √
√√√ √
√√√ √
√√√ √
√√√ √
√√√ √ √
√
√√√ √
Replace brake shoes.
Whenever worn to the limit.
2Rear brake Check operation.
Adjust brake lever free play.
Replace brake shoes. Whenever worn to the limit.
Every 2 years
Every 2 years
3Wheels Check runout and for damage.
Replace if necessary.
THEREAFTER
EVERYINITIAL
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Periodic maintenance an d a djustment
7-8
7
TIP
Store 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 its
new gasket by installing the bolts,
and then tighten the bolts to the
specified torque.
EAU40894
Transmission oil
The 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.
Tightening torque:
Exhaust manifold bolt: 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
1. Transmission oil filler cap
1. Transmission oil drain bolt
2. Gasket
1
12
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Periodic maintenance an d a djustment
7-9
7 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), d o
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 ddition, 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 cau-
se.
EAU41712
Middle an d final g ear cases
The middle and final gear cases must
be checked for grease leakage before
each ride. If any leakage is found, have
a Yamaha dealer check and repair the
motorcycle. In addition, have a
Yamaha dealer check and lubricate the middle and final gears at the intervals
specified in the periodic maintenance
and lubrication chart.
Ti ghtenin 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)
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Specifications
9-1
9
Dimensions:
Overall length:1245 mm (49.0 in)
Overall width:
575 mm (22.6 in)
Overall height: 715 mm (28.1 in)
Seat height: 485 mm (19.1 in)
Wheelbase:
855 mm (33.7 in)
Ground clearance: 105 mm (4.13 in)
Minimum turning radius: 1.3 m (4.27 ft)
Wei ght:
Curb weight:
39 kg (86 lb)
Technical permissible mass (Maximum load +
Curb weight):
64 kg (141 lb)
Noise an d vi bration level:
Noise level (77/311/EEC):
75.1 dB(A) at 2750 r/min
(PW50_AUT/BEL/CHE/CYP/CZE/DEU/DN
K/ESP/FIN/FRA/GBR/GRC/IRL/ITA/NLD/
NOR/POL/PRT/SVK/SVN/SWE)
Uncertainty of measurement:
3.0 dB(A)
(PW50_AUT/BEL/CHE/CYP/CZE/DEU/DN
K/ESP/FIN/FRA/GBR/GRC/IRL/ITA/NLD/
NOR/POL/PRT/SVK/SVN/SWE)
Vibration on seat (EN1032, ISO5008): Will not exceed 0.5 m/s²
(PW50_AUT/BEL/CHE/CYP/CZE/DEU/DN
K/ESP/FIN/FRA/GBR/GRC/IRL/ITA/NLD/
NOR/POL/PRT/SVK/SVN/SWE)
Vibration on handlebar (EN1032, ISO5008): Will not exceed 2.5 m/s²
(PW50_AUT/BEL/CHE/CYP/CZE/DEU/DN
K/ESP/FIN/FRA/GBR/GRC/IRL/ITA/NLD/
NOR/POL/PRT/SVK/SVN/SWE)
Engine:
Combustion cycle:
2-stroke
Cooling system: Air cooled
Number of cylinders:
Single cylinder Displacement:
49 cm³
Bore × stroke:
40.0 × 39.2 mm (1.57 × 1.54 in)
Compression ratio:
6.0 : 1
Starting system: Kickstarter
Lubrication system: Separate lubrication
Engine oil:
Engine oil:
YAMALUBE 2S or 2-stroke engine oil
(JASO FC grade or ISO EG-C [or EG-D]
grade)
Recommended brand: YAMALUBE
Engine oil quantity:
Engine oil tank capacity:0.30 L (0.32 US qt, 0.26 Imp.qt)
Transmission oil:
Type: Motor oil SAE 10W-30 type SE or higher or
Gear oil SAE 85W GL-3
Quantity: 0.30 L (0.32 US qt, 0.26 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:Regular unleaded gasoline only
Fuel tank capacity:
2.0 L (0.5 US gal, 0.4 Imp.gal)
Car buretor:
Type × quantity:
VM12SC × 1
Spark plu g(s):
Manufacturer/model:
NGK/BP4HS (PW50_ZAF)
NGK/BPR4HS
(PW50_AUT/BEL/CHE/CYP/CZE/DEU/DN
K/ESP/FIN/FRA/GBR/GRC/IRL/ITA/NLD/
NOR/POL/PRT/SVK/SVN/SWE/TUR,
PW50G, PW50G2)
Manufacturer/model:
DENSO/W14FP-L (PW50_ZAF)
Spark plug gap: 0.6–0.7 mm (0.024–0.028 in)
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