Home

User Manual PDF

1. DIC183 Downloaded from y n manuals search engine YAMAHA PRINTED ON RECYCLED PAPER IMPRIME SUR PAPIER RECYCLE AUF RECYCLINGPAPIER GEDRUCKT Downloaded from www Manualslib com manuals search engine PRINTED IN JAPAN 2012 07 0 6x1 CR E F G DIC183 U5PG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM EAU48173 AN Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold EC Declaration of Conformity conforming to Directive 2006 42 EC We YAMAHA MOTOR CO LTD 2500 Shingai Iwata Japan declare in sole responsibility that the product PW50 JYA3PT00000428377 Make model to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC If applicable and to the other relevant Directives of EEC 2004 108 EC Title and or number and date of issue of the other Directives of EEC If applicable To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted EN16029 Title and or number and date of issue of standards and or specifications Authorized Representative YAMAHA MOTOR EUROPE N V Koolhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature i Hiroki amoto General Manager
2. INSTRUMENT AND CONTROL FUNCTIONS the throttle grip can only be opened ap proximately halfway If more power is required please consult a Yamaha dealer Improper adjustment of the speed limiter could cause improper throttle operation You could lose control have an accident or be injured Do not turn the adjusting screw out more than 7 mm 0 28 in before con sulting a Yamaha dealer Always make sure the throttle grip free play is adjusted to 1 5 3 5 mm 0 06 0 14 in See page 7 12 EWA14631 Power reduction 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 4 2 EAU12901 Front brake lever 1 Front brake lever The front brake lever is located on the right side of the handlebar To apply the front brake pull this lever toward the throttle grip USPG8BE0 book Page 3 Wednesday June 27 2012 2 53 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12951 Rear brake lever 1 Rear brake lever The rear brake lever is located on the left side of the handlebar To apply the rear brake pull this lever toward the handlebar grip Downloaded from www Manualslib com manuals search engine EAU13182 Fuel tank cap 1 Fuel tank cap To 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
3. TIP Throttle grip e Check operation e Check throttle grip free play and adjust if necessary Apply Yamaha chain and cable lube or engine oil 10W 30 lightly The air filter needs more frequent service if you are riding in unusually wet or dusty areas 7 5 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 6 Wednesday June 27 2012 2 53 PM EAU19604 Checking the spark plug The 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 mainte nance and lubrication chart In addition the condition of the spark plug can re veal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 1 Spark plug cap 2 Remove the spark plug as shown with the spark plug wrench includ ed in the owner s tool kit Downloaded from www Manualslib com manuals search engine PERIODIC MAINTENANCE AND ADJUSTMENT 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary Specified spark plug PW50 NGK BP4HS ZAF PW50 NGK BPR4HS AUT BEL CHE DEU DNk ESP FIN FRA GBR GRC IRL ITA NLD NOR POL PRT SVN SWE PW50D NGK BPR4HS To check the spark plug PW50D1 NGK BPR4HS 1 Check that the porcelain
4. MOTORCYCLE CARE AND STORAGE ne ha ceed 8 1 Matte color caution s s s 8 1 GARG 2eme eme 8 1 SIOTAQC 5er ces srleretrreserdnntasi ts 8 3 USPG8BE0 book Page 2 Wednesday June 27 2012 2 53 PM TABLE OF CONTENTS SPECIFICATIONS ee 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM LOCATION OF IMPORTANT LABELS EAU48115 Read and understand all of the labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label El is available from your Yamaha dealer For Canada 5 6 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 2 Wednesday June 27 2012 2 53 PM LOCATION OF IMPORTANT LABELS For Canada WARNING BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS NEVER CARRY A PASSENGER You increase your risk of losing control if you carry a passenger NEVER OPERATE THIS VEHICLE ON PUBLIC ROADS You can collide with another vehicle if you operate this vehicle on a public road ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing 3PT 2118K A1 AVERTISSEMENT THIS VEHICLE IS A RESTRICTED USE MOTORCYCLE AND
5. 7 1 EAU17302 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 replacement or repair of the emission control devic es and systems may be performed by any repair establishment or individual that is certified if applicable Yamaha dealers are trained and equipped to perform these particular services USPG8BE0 book Page 2 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17311 Owner s tool kit The service information included in this manual and the tools provided in the owners 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 7 2 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 3 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU41742 Periodic maintenance chart for the emission control system TIP Items marked with an asterisk should be performed by a Yamaha dealer
6. Displacement 49 cms Bore x stroke 40 0 x 39 2 mm 1 57 x 1 54 in Compression ratio 6 00 1 Starting system Kickstarter Lubrication system Separate lubrication Yamaha autolube Engine oil Type YAMALUBE 2S or 2 stroke engine oil JASO FC grade or ISO EG C or EG D grade Engine oil quantity Quantity 0 30 L 0 32 US at 0 26 Imp qt Transmission oil Type YAMALUBE 4 10W 40 or SAE 10W 40 Oil change quantity 0 30 L 0 32 US qt 0 26 Imp qt 9 1 Air filter Air filter element Wet element Fuel Recommended fuel PW50 Regular unleaded gasoline only PW50D Unleaded gasoline only PW50D1 Regular unleaded gasoline only Fuel tank capacity 2 0 L 0 53 US gal 0 44 Imp gal Carburetor Type x quantity VM12SC x 1 Spark plug s Manufacturer model PW50 NGK BP4HS ZAF PW50 NGK BPR4HS AUT BEL CHE DEU DNK ESP FIN FRA GBR GRC IRL ITA NLD NOR POL PRT SVN SWE PW50D NGK BPR4HS PW50D1 NGK BPR4HS Manufacturer model PW50 DENSO W14FP L ZAF Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet centrifugal automatic Transmission Primary reduction ratio 1 909 63 33 Final drive Shaft USPG8BE0 book Page 2 Wednesday June 27 2012 2 53 PM 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 PW50 EUR BRIDGESTONE KNOBBY PW5
7. face and hold it in an upright posi tion WARNING To avoid injury securely support the vehicle so there is no danger of it falling over Ewa10751 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly USPG8BE0 book Page 18 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU45511 EAU23291 Checking the steering Checking the wheel bearings Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe fs riodic maintenance and lubrication chart LA 1 Place the vehicle on the center stand WARNING To avoid inju ECA10590 ry securely support the vehicle NOTICE so there is no danger of it falling If any damage is found or the front OVET Ewa10751 Thetontand teat ee pealias moni fork does not operate smoothly 2 Hold the lower ends of the front Pe checked at the intervals specified in have a Vamaha dealer check or re fork legs and try to move them for the periodic maintenance and lubrica pair it ward and backward If any free 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 play can be felt have a Yamaha dealer check or repair the steering 7 18 Downloaded from www Manualslib com manuals search engine USPG8BE0
8. Autolube pump The Autolube pump is a vital and so phisticated component of the engine which must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart USPG8BE0 book Page 17 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT Lubricating the front and rear brake levers EAU23192 Checking and lubricating the centerstand The pivoting points of the front and rear brake levers must be lubricated at the intervals specified in the periodic main tenance and lubrication chart Recommended lubricant Lithium soap based grease Downloaded from www Manualslib com manuals search engine The operation of the centerstand should be checked before each ride and the pivots and metal to metal con tact surfaces should be lubricated if necessary If the centerstand does not move up and down smoothly have a Yamaha dealer check or repair it Otherwise the centerstand could contact the ground and distract the operator re sulting in a possible loss of control Recommended lubricant Lithium soap based grease 7 17 EWA11301 EAU42081 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition Check the inner tubes for scratches and damage To check the operation 1 Place the vehicle on a level sur
9. Place the motorcycle on the cen bas ENERGY CONSERVING II or terstand higher 2 Place an oil pan under the trans 4 Install the transmission oil drain 3 mission to collect the used oil Remove the transmission oil filler cap the transmission oil drain bolt and its gasket to drain the oil from the transmission 1 Transmission oil filler cap Downloaded from www Manualslib com manuals search engine bolt and its new gasket and then tighten the bolt to the specified torque Tightening torque Transmission oil drain bolt 14 Nm 1 4 mkgf 10 ft Ibf 5 Refill with the specified amount of the recommended transmission oil and then install and tighten the oil filler cap Recommended transmission oil See page 9 1 Oil change quantity 0 30 L 0 32 US at 0 26 Imp qt Make sure that no foreign mate rial enters the transmission 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 cause 7 USPG8BE0 book Page 9 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU41711 Middle and final gear 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
10. actual level of exposure of work force include the characteristics of the work room the other sources of noise etc i e the number of machines and other adjacent processes and the length of time for which an operator is exposed to the noise Also the permis sible exposure level can vary from country This information however will enable the user of the machine to make a better evaluation of the hazard and risk Downloaded from www Manualslib com manuals search engine 9 3 USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM EAU40792 Identification numbers Record the vehicle identification num ber and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen VEHICLE IDENTIFICATION NUMBER ee MODEL LABEL INFORMATION Downloaded from www Manualslib com manuals search engine CONSUMER INFORMATION EAU26400 Vehicle identification number EAU26480 Model label 1 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided TIP The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area 10 1 1 Model label The model label is affixed to the frame under the seat See page 4 7 Record the info
11. bolt 3 Washer 7 21 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 22 Wednesday June 27 2012 2 53 PM 1 Rear arm 2 Washer 3 Rear arm nut 10 Pull the wheel to the right to sepa rate it from the final gear case and then remove the wheel EAU41523 To install the rear wheel 1 Apply a light coating of lithium soap based grease to the splines of the final gear case and wheel hub 2 Install the wheel by inserting it into the wheel hub 3 Install the rear arm by installing the washers and nuts 4 Install the axle nut Downloaded from www Manualslib com manuals search engine PERIODIC MAINTENANCE AND ADJUSTMENT 5 Install the right side rear shock ab sorber by installing the mounting bolt 6 While applying the rear brake tighten the axle nut to the specified torque 7 Tighten the rear arm nuts and rear shock absorber mounting bolt to the specified torques 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 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 7 22 Tightening torques Exhaust manifold bolt 9 Nm 0 9 m kgf 6 5 ft
12. engine USPG8BE0 book Page 4 Wednesday June 27 2012 2 53 PM LOCATION OF IMPORTANT LABELS For Europe Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 5 Wednesday June 27 2012 2 53 PM LOCATION OF IMPORTANT LABELS For Europe PW50 ER 2 1 kW 39 kg 5PG 2156A 10 5B6 2816R 00 C 5 5019 YAMAHA MOTOR a 2500 SHINGAL IWATA JAPAN in ED i 00 ge i one 5B6 2817L 00 15 psi 5 psi 5PG 2816R 00 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 6 Wednesday June 27 2012 2 53 PM LOCATION OF IMPORTANT LABELS Familiarize yourself with the following pictograms and read the explanatory text Read the Owner s manual Always use an approved helmet and protective gear Use from 6 years old Operation of this motorcycle by children under the age of 6 increase the risk of severe injury or death Adult supervision required for children Downloaded from www Manualslib com manuals search engine Never use on paved roads Never carry passengers This unit contains high pressure nitrogen gas Mishandling can cause an explosion Do not incinerate puncture or open Turn off the main switch after riding to avoid draining the battery USPG8BE0 book Page 7 Wednesday June 27 2012 2 53 PM LOCATION OF IMPORTANT LABELS Use unleaded gasoline only CE Year of construct
13. ex tensively tested at the Yamaha fac tory Changing these settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine Downloaded from www Manualslib com manuals search engine EAU21362 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart TIP A diagnostic tachometer is needed to make this adjustment 1 Attach the tachometer to the spark plug lead 2 Start the engine and warm it up for several minutes at 1000 2000 r min while occasionally revving it to 4000 5000 r min TIP The engine is warm when it quickly re sponds to the throttle 3 Check the engine idling speed and if necessary adjust it to spec ification by turning the throttle stop screw To increase the engine idling speed turn the screw in di 7 14 rection a To decrease the en gine idling speed turn the screw in direction b 1 Throttle stop screw Engine idling speed 1650 1750 r min TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment USPG8BE0 book Page 12 Wednesday June 27 2012 2 53 PM EAU21384 Checking the throttle grip free play 1 Throttle grip free play The throttle grip free play should mea sure 1 5 3 5 mm 0 06 0 14 in at the
14. lbf Exhaust chamber bolt 18 Nm 1 8 m kgf 13 ft lbf 11 Install the muffler by sliding the spring clamp up to its original posi tion and then installing the wash ers and muffler bolt TIP Make sure that the spring clamp is po sitioned with the projection side facing inward 1 Exhaust chamber 2 Spring clamp 3 Muffler 12 Tighten the muffler bolt to the specified torque USPG8BE0 book Page 23 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT Tightening torque Muffler bolt 18 Nm 1 8 m kgf 13 ft Ibf 13 Adjust the brake lever free play See page 7 14 14 Install the seat Downloaded from www Manualslib com manuals search engine EAU25851 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing 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 inferi or have a shorter service life and ca
15. motorcycle is designed for off road use only therefore it is illegal to operate it on public streets roads or highways even a dirt or gravel one Off road use on public lands may be illegal Please check local regulations before riding This motorcycle is designed to car ry the operator only No passen gers 2 1 e The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket e Use extra caution when you are approaching and _ passing through intersections since in tersections are the most likely places for motorcycle accidents to occur e Ride where other motorists can see you Avoid riding in another motorist s blind spot e Never maintain a motorcycle without proper knowledge Con tact an authorized motorcycle dealer to inform you on basic motorcycle maintenance Cer tain maintenance can only be carried out by certified staff USPG8BE0 book Page 2 Wednesday June 27 2012 2 53 PM e Many accidents involve inexperi enced operators Make sure that you are qualified and that you only lend your mo torcycle to other qualified opera tors e Know your skills and limits St
16. turn it clock wise Make sure that the fuel tank cap is properly closed after filling fuel Leaking fuel is a fire hazard EWA11091 4 3 EAU13212 Fuel Make sure there is sufficient gasoline in the tank Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling follow these instructions EWA10881 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 USPG8BE0 book Page 4 Wednesday June 27 2012 2 53 PM K 2 1 Fuel tank filler tube 2 Maximum fuel level 3 Wipe up any spilled fuel immedi ately NOTICE Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteri orate painted surfaces or plastic parts ECA10071 4 Be sure to securely close the fuel tank cap Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gaso line by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in
17. your eyes see your doctor immedi EWA15151 Downloaded from www Manualslib com manuals search engine INSTRUMENT AND CONTROL FUNCTIONS ately If gasoline spills on your skin wash with soap and water If gaso line spills on your clothing change your clothes EAU41983 For Canada Recommended fuel REGULAR UNLEADED GASO LINE ONLY Fuel tank capacity 2 0 L 0 53 US gal 0 44 Imp gal ECA15590 NOTICE Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi 4 4 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 contain ing 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 ve hicle performance problems For Europe Recommended fuel REGULAR UNLEADED GASO LINE ONLY Fuel tank capacity 2 0 L 0 53 US gal 0 44 Imp gal ECA15590 NOTICE Use only unleaded gas
18. 0 ZAF PW50D PW50D1 BRIDGESTONE KNOBBY IRC KNOBBY Speed rating 100 km h 62 mph Rear tire Type With tube Size 2 50 10 4PR Manufacturer model PW50 EUR BRIDGESTONE KNOBBY PW50 ZAF PW50D PW50D1 BRIDGESTONE KNOBBY IRC KNOBBY Downloaded from www Manualslib com manuals search engine Speed rating 100 km h 62 mph Loading Maximum rider weight 25 0 kg 55 Ib Tire air pressure measured on cold tires Front 100 kPa 1 00 kgf cm 15 psi Rear 100 kPa 1 00 kgf cm 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 Drum brake Operation Right hand operation Rear brake Type Drum brake Operation Left hand operation Front suspension Type Telescopic fork 9 2 SPECIFICATIONS Spring shock absorber type Coil spring oil damper Wheel travel 60 0 mm 2 36 in Rear suspension Type Unit swing Spring shock absorber type Coil spring oil damper Wheel travel 50 0 mm 1 97 in Electrical system Ignition system CDI USPG8BE0 book Page 3 Wednesday June 27 2012 2 53 PM SPECIFICATIONS EAU51131 For Europe only The figures quoted are emission levels and are not necessarily safe working levels Whilst there is a correlation be tween the emission and exposure lev els this cannot be used reliably to determine whether or not further pre cautions are required Factors that in fluence the
19. CE AND ADJUSTMENT Owner s tool Kit eceeeeeeeeees Periodic maintenance chart for the emission control system General maintenance and lubrication Chart Checking the spark plug Removing the power reduction ALS 55m Transmission oil Middle and final gear cases Cleaning the air filter element Cleaning the spark arrester Adjusting the carburetor Adjusting the engine idling oeTM TE TABLE OF CONTENTS Checking the throttle grip free play sioro un 7 12 TIES orrai aa aE 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 ceeeeeeeeeeeeeeeees 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 eee 7 17 Checking the front fork 7 17 Checking the steering 7 18 Checking the wheel bearings 7 18 Front Wheel 3 52 r anesissss 7 19 Rear wheel scccceeeeeeseeees 7 20 Troubleshooting 7 23 Troubleshooting chart 5 7 24
20. Development Division 3rd Business Unit Motorcycle Business Operations YAMAHA MOTOR CO LTD Date of Issue 76 May 2012 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM INTRODUCTION EAU41074 Congratulations on your purchase of the Yamaha PW50 PW50D PW50D1 This model is the result of Yamaha s vast expe rience 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 operation 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 operation 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 Therefore while this manual contains the most cur rent product information available at the time of printing there may be minor discrepa
21. IS NOT INTENDED FOR LIRE LE MANUEL DU PROPRIETAIRE AINSI QUE TOUTES LES ETIQUETTES AVANT D UTILISER CE VEHICULE USE ON PUBLIC HIGHWAYS NE JAMAIS TRANSPORTER DE PASSAGER La conduite avec CE VEHICULE EST UNE MOTOCYCLETTE A passager augmente les risques de perte de contr le USAGE RESTREINT DONT LUSAGE N EST PAS NE JAMAIS ROULER SUR DES CHEMINS PUBLICS DESTINE AUX VOIES PUBLIQUES Vous pourriez entrer en collision avec un autre v hicule TOUJOURS PORTER UN CASQUE DE MOTOCYCLISTE SPreser 10 APPROUVE des lunettes et des v tements de protection 5PG 2118K 10 1 2 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 3 Wednesday June 27 2012 2 53 PM LOCATION OF IMPORTANT LABELS For Canada 5 6 TIRE INFORMATION INFORMATION SUR LES PNEUS a Cold tire normal pressure should be set as La pression des pneus a froid doit normalement follows tre r gl e comme suit FRONT 100 kPa 1 00 kgf cm 15 psi AVANT 100 kPa 1 00 kgf cm 15 psi REAR 100 kPa 1 00 kgf cm 15 psi ARRIERE 100 kPa 1 00 kgf cm 15 psi 3RV 21668 A0 3RV 21668 B0 This spark ignition system meets all requirements of the Canadian Interference Causing Equipment Regulations Ce syst me d allumage par tincelle de v hicule respecte toutes les exigences du R glement sur le mat riel brouilleur du Canada 3JK 82377 00 1 3 Downloaded from www Manualslib com manuals search
22. STORAGE 7 EAU37833 Matte color caution ECA15192 NOTICE Some models are equipped with matte colored finished parts Be sure to consult a Yamaha dealer for advice on what products to use be fore cleaning the vehicle Using a brush harsh chemical products or cleaning compounds when cleaning these parts will scratch or damage their surface Wax also should not be applied to any matte colored fin ished parts Downloaded from www Manualslib com manuals search engine EAU40635 Care While the open design of a motorcycle reveals the attractiveness of the tech nology it also makes it more vulnera ble Rust and corrosion can develop even if high quality components are used A rusty exhaust pipe may go un noticed on a car however it detracts from the overall appearance of a motor cycle Frequent and proper care does not only comply with the terms of the warranty but it will also keep your mo torcycle looking good extend its life and optimize its performance Before cleaning 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug cap are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod 8 1 ucts onto seals gaskets and wheel axles Always rinse the dirt and de gr
23. Wednesday June 27 2012 2 53 PM SAFETY INFORMATION EAU4093B Be a Responsible Owner As the vehicle s owner you are respon sible for the safe and proper operation of your motorcycle Motorcycles are single track vehicles Their safe use and operation are de pendent upon the use of proper riding techniques as well as the expertise of the operator Every operator should know the following requirements before riding this motorcycle He or she should e Obtain thorough instructions from a competent source on all aspects of motorcycle operation Observe the warnings and mainte nance requirements in this Own er s Manual e Obtain qualified training in safe and proper riding techniques e Obtain professional technical ser vice as indicated in this Owners Manual and or when made neces sary by mechanical conditions Downloaded from www Manualslib com manuals search engine e Never operate a motorcycle with out proper training or instruction Take a training course Beginners should receive training from a cer tified instructor Contact an autho rized motorcycle dealer to find out about the training courses nearest you Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage See page 5 1 for a list of pre operation checks This
24. ary Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary Wheel bearings Check bearings for smooth operation Replace if necessary Steering bearings Check bearing assemblies for looseness Moderately repack with lithium soap based grease every 2 years Middle and final gear cases e Check for grease leakage e Check gears for damage and wear e Lubricate gears with lithium soap based grease 7 4 Downloaded from www Manualslib com manuals search engine Every 2 years USPG8BE0 book Page 5 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT CHECK OR MAINTENANCE JOB INITIAL THEREAFTER EVERY 3 months 6 months 6 12 months months Chassis fasteners Check all chassis fitting and fasteners Correct if necessary Ni Autolube pump Check operation Correct if necessary Ni Transmission oil Check for oil leakage Correct if necessary Change Front and rear brake lever pivot Apply lithium soap based grease lightly y Centerstand pivot e Check operation e Apply lithium soap based grease lightly Shock absorber assemblies e Check operation and for oil leakage e Replace if necessary Control cables e Apply Yamaha chain and cable lube or engine oil 10W 30 lightly
25. as they require special tools data and technical skills THEREAFTER EVERY 3 6 12 months months months INITIAL CHECK OR MAINTENANCE JOB Check fuel hoses for cracks or damage N J Replace if necessary Check condition Adjust gap and clean Replace if necessary Clean with solvent Replace if necessary Check engine idling speed and starter operation Adjust if necessary Clean Check for leakage Tighten if necessary Decarbonize if necessary Clean Fuel line Spark plug Air filter element Carburetor Cylinder head and exhaust system Spark arrester 7 3 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 4 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT General maintenance and lubrication chart TIP EAU41757 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills CHECK OR MAINTENANCE JOB INITIAL THEREAFTER EVERY 3 months 6 months 6 12 months months Front brake Check operation Adjust brake lever free play Replace brake shoes Whenever worn to the limit Rear brake Check operation Adjust brake lever free play Replace brake shoes Whenever worn to the limit Wheels Check runout and for damage Replace if necess
26. aying within your limits may help you to avoid an accident We recommend that you prac tice riding your motorcycle until you have become thoroughly fa miliar with the motorcycle and all of its controls Many accidents have been caused by error of the motorcycle opera tor A typical error made by the op erator is veering wide on a turn due to excessive speed or under cornering insufficient lean angle for the speed Never travel faster than warranted by conditions 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 Downloaded from www Manualslib com manuals search engine SAFETY INFORMATION the handlebar and both feet on the operator footrests during operation to maintain control of the motorcy cle e 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 preven tion or reduction of head injuries e Always wear an approved helmet e Wear a face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard e The use of a jacket heavy boots trousers gloves etc is effective in preventing or redu
27. be measured at the positions as shown Front 1 Front brake lever free play Rear 1 Rear brake lever free play 7 14 Front brake lever free play 10 0 20 0 mm 0 39 0 79 in Rear brake lever free play 10 0 20 0 mm 0 39 0 79 in Periodically check the front and rear brake lever free play and if necessary adjust them as follows To increase the brake lever free play turn the adjusting nut at the brake shoe plate in direction a To decrease the brake lever free play turn the adjusting nut in direction b Front 1 Brake lever free play adjusting nut USPG8BE0 book Page 15 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT 1 Brake lever free play adjusting nut If proper adjustment cannot be ob tained as described have a Yamaha dealer make this adjustment Downloaded from www Manualslib com manuals search engine EAU41052 Checking the front and rear brake shoes The front and rear brake shoes must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart TIP The wheels must be removed to check brake shoe lining thickness e To remove the front wheel See page 7 19 e To remove the rear wheel See page 7 20 Front 7 15 If the lining thickness of a brake shoe is less than 1 5 mm 0 06 in have a Yamaha dealer replace the brake shoes as a set TIP Be sure to measure the brake lining at the t
28. book Page 19 Wednesday June 27 2012 2 53 PM Downloaded from www Manualslib com manuals search engine PERIODIC MAINTENANCE AND ADJUSTMENT EAU24360 Front wheel EAU41024 To remove the front wheel To avoid injury securely support the vehicle so there is no danger of it falling over EWA10821 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 Brake camshaft lever Brake shoe plate Washer Axle nut Brake cable Brake lever free play adjusting nut O O1 BR D 3 Remove the axle nut and washer 4 Pull the wheel axle out and then remove the wheel 1 Wheel axle 7 19 EAU41032 To install the front wheel 1 Install the brake shoe plate into the wheel hub as shown ITS 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 USPG8BE0 book Page 20 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT 8 Push down hard on the handlebar R heal RA J2000 several times to check for proper ear wnee fork operation EAU41084 To remove the rear wheel To avoid injury securely support the vehicle so there is no danger of it EWA10821 falling over 1 FAR 1 Place the motorcycle o
29. cation will keep your vehicle in the safest and most efficient condition pos sible Safety is an obligation of the vehi cle owner operator The most important points of vehicle inspection adjust ment and lubrication are explained 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 Failure to properly maintain the ve hicle or performing maintenance ac tivities incorrectly may increase your risk of injury or death during service or while using the vehicle If you are not familiar with vehicle ser vice have a Yamaha dealer perform service EWA10321 Downloaded from www Manualslib com manuals search engine EWA15122 Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires e Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 2 for more in formation about carbon monox ide Brake discs calipers drums and linings can become very hot during use To avoid possible burns let brake components cool before touching them EWA15460
30. checking c eeeeee 7 17 FUG RP ITR 4 3 Fuel COCK siiis 4 6 Fuel tank breather hose 4 5 Fuel tank Cap 2 dsssssss sun 4 3 H Handlebar switch 4 1 Downloaded from www Manualslib com manuals search engine l Identification numbers 10 1 K KiCKStart r i 2sisrannenseetepirstieiiniteents 4 7 L Labels location ccccccccceseessssseeeeeee 1 1 M Maintenance and lubrication periodic 7 4 Maintenance emission control system 7 3 Matte color caution Middle and final gear cases Modellab l 2 retirent P Parking iduna nan 6 4 Part locations ionici 3 1 Power reduction plate removing 7 7 S Safety information 2 1 SOO T T T 4 7 Spark arrester cleaning 7 10 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 Steering checking SIOTADE ram er Gee T Throttle grip and cable checking and lubricating Throttle grip free play checking Tool kit 7 2 Transmission oil 7 8 Troubleshooting 7 23 Troubleshooting chart 7 24 V Vehicle Emission Control Information label For Canada Vehicle identification nu
31. cing abrasions or lacerations e Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident 2 2 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 Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide a deadly gas Breathing car bon monoxide can cause headaches dizziness drowsiness nausea confu sion and eventually death Carbon Monoxide is a colorless odor less tasteless gas which may be present even if you do not see or smell any engine exhaust Deadly levels of carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself Also deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas If you experience any symptoms of carbon monoxide poison ing leave the area immediately get fresh air and SEEK MEDICAL TREAT MENT USPG8BE0 book Page 3 Wednesday June 27 2012 2 53 PM SAFETY INFORMATION e 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 e Do not run engine outdoors where engine exhau
32. e 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT Tire information This motorcycle is equipped with panel wheels and tube tires Tires age even if they have not been used or have only been used occasion ally Cracking of the tread and sidewall rubber sometimes accompanied by carcass deformation is an evidence of ageing Old and aged tires shall be checked by tire specialists to ascertain their suitability for further use The front and rear tires should be of the same make and design other wise the handling characteristics of the vehicle may be different which could lead to an accident EWA10461 After extensive tests only the tires list ed below have been approved for this model by Yamaha Motor Co Ltd Downloaded from www Manualslib com manuals search engine Front tire Size 2 50 10 4PR Manufacturer model PW50 EUR BRIDGESTONE KNOBBY PW50 ZAF PW50D PW50D1 BRIDGESTONE KNOBBY IRC KNOBBY Rear tire Size 2 50 10 4PR Manufacturer model PW50 EUR BRIDGESTONE KNOBBY PW50 ZAF PW50D PW50D1 BRIDGESTONE KNOBBY IRC KNOBBY EWA15541 e Have a Yamaha dealer replace excessively worn tires Operat ing the motorcycle with exces sively worn tires decreases riding stability and can lead to loss of control e The replacement of all wheel and brake related parts includ ing the tires should be left to a 7 13 Yamaha dealer who has the necessary professional knowl edge and exp
33. easer off with water Cleaning ECA17110 NOTICE e Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray e Improper cleaning can damage plastic parts such as cowlings panels etc and the mufflers Use only a soft clean cloth or sponge with water to clean plas tic However if the plastic parts cannot be thoroughly cleaned with water diluted mild deter gent with water may be used Be sure to rinse off any detergent residue using plenty of water as it is harmful to plastic parts USPG8BE0 book Page 2 Wednesday June 27 2012 2 53 PM e Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products solvent or thinner fuel gasoline rust re movers or inhibitors brake flu id antifreeze or electrolyte e Do not use high pressure wash ers or steam jet cleaners since they cause water seepage and deterioration in the following ar eas seals of wheel and swing arm bearings fork and brakes electric components couplers connectors and switches breather hoses and vents After normal use Remove dirt with warm water a mild detergent and a s
34. erience It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and replace it as soon as possible with a high quality product Ride conservatively after changing a tire since the tire must seat itself on the rim prop erly Failure to allow proper seating may cause tire failure which may result in damage to the motorcycle and injury to the rider USPG8BE0 book Page 14 Wednesday June 27 2012 2 53 PM EAU40781 Panel wheels The wheels on this model are not de signed for use with tubeless tires Do not attempt to use tubeless tires on this model EWA10610 To maximize the performance durabil ity and safe operation of your motorcy cle note the following points regarding the specified wheels e The wheel rims should be checked for cracks bends warpage or damage before each ride If any damage is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced e The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Downloaded from www Manualslib com manuals search engine PERIODIC MAINTENANCE AND ADJUSTMENT EAU22152 Adjusting the front and rear brake lever free play The front and rear brake lever free play should
35. gears at the intervals specified in the periodic maintenance and lubrication chart Downloaded from www Manualslib com manuals search engine EAU40903 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean or if necessary replace the air filter element more frequently if you are riding in unusually wet or dusty areas 1 Remove the seat See page 4 7 2 Remove the air filter case cover by removing the screw 1 Air filter case cover 2 Screw 3 Pull the sponge material out clean it with solvent and then squeeze the remaining solvent out 7 9 1 Sponge material 4 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the ex cess oil out TIP The sponge material should be wet but not dripping USPG8BE0 book Page 10 Wednesday June 27 2012 2 53 PM Recommended oil Yamaha foam air filter oil or other quality foam air filter oil 7 Insert the sponge material into the air filter case NOTICE Make sure that the sponge material is prop erly seated in the air filter case The engine should never be op erated without the sponge mate rial installed otherwise the piston s and or cylinder s may become excessively worn ECA15621 Install the air filter case cover by in stalling the screw Install the seat Downloaded f
36. hat there is no oil or wax on the tires If necessary wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s braking performance and cor nering behavior ECA10800 NOTICE Apply spray oil and wax spar ingly and make sure to wipe off any excess e Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product USPG8BE0 book Page 3 Wednesday June 27 2012 2 53 PM MOTORCYCLE CARE AND STORAGE e Avoid using abrasive polishing St EAUB CM compounds as they will wear orage away the paint d P Short term TIP Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover Be sure the engine and the exhaust sys tem are cool before covering the motor cycle Consult a Yamaha dealer for advice on what products to use ECA10810 NOTICE e Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust e To prevent corrosion avoid damp cellars stables because of the presence of ammonia 8 and areas where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 8 3 Downloaded from www Manualslib com manuals search engine For motorcyc
37. hinnest portion USPG8BE0 book Page 16 Wednesday June 27 2012 2 53 PM EAU50800 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING Damage to the outer housing of cables may result in in ternal rusting and cause interfer ence with cable movement Replace damaged cables as soon as possi ble to prevent unsafe conditions EWA10711 Recommended lubricant Yamaha Chain and Cable Lube or 4 stroke engine oil Downloaded from www Manualslib com manuals search engine PERIODIC MAINTENANCE AND ADJUSTMENT EAU23114 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated by a Yamaha dealer at the intervals speci fied in the periodic maintenance chart The throttle cable is equipped with a rubber cover Make sure that the cover is securely installed Even though the cover is installed correctly it does not completely protect the cable from water entry Therefore use care not to pour water directly onto the cover or cable when washing the vehicle If the cable or cover becomes dirty wipe clean with a moist cloth 7 16 EAU23120 Adjusting the
38. ine parts such as the piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use unleaded gasoline with a research octane number of 91 or high er If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs 4 5 EAU13412 Fuel tank breather hose 1 Fuel tank breather hose Before operating the motorcycle e Check the fuel tank breather hose connection e Check the fuel tank breather hose for cracks or damage and replace it if damaged e Make sure that the fuel tank breather hose is not blocked and clean it if necessary USPG8BE0 book Page 6 Wednesday June 27 2012 2 53 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13453 EAU40701 O on 2 stroke engine oil Fuel cock on Make sure that there is sufficient 2 The fuel cock supplies fuel from the stroke engine oil in the oil tank Add the tank to the carburetor while filtering it al recommended 2 stroke engine oil as so necessary The fuel cock has two positions S stop 1 Arrow mark pointing to O on With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position 1 2 stroke engine oil tank cap 2 Minimum level mark 1 Arrow mark pointing to S stop Recommended oil f ps See page 9 1 With the lever in this posi
39. inner edge of the throttle grip Periodi cally check the throttle grip free play and if necessary have a Yamaha deal er adjust it Downloaded from www Manualslib com manuals search engine PERIODIC MAINTENANCE AND ADJUSTMENT EAU40914 Tires Tires are the only contact between the vehicle and the road Safety in all con ditions of riding depends on a relatively small area of road contact Therefore it is essential to maintain the tires in good condition at all times and replace them at the appropriate time with the speci fied tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient tempera ture EWA15370 7 12 Standard tire air pressure Front 100 kPa 1 00 kgf cm 15 psi Rear 100 kPa 1 00 kgf cm 15 psi Tire inspection 1 Tire sidewall 2 Tire tread depth The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer re place the tire immediately Minimum tire tread depth front and rear 4 0 mm 0 16 in USPG8BE0 book Page 13 Wednesday Jun
40. insulator PW50 DENSO W14FP L ZAF around the center electrode of the 1 Spark plug wrench spark plug is a medium to light tan 3 Measure the spark plug gap with a the ideal color when the vehicle is wire thickness gauge and if nec ridden normally essary adjust the gap to specifica tion TIP If 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 1 Spark plug gap 7 6 USPG8BE0 book Page 7 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU41103 Spark plug gap Removing the power reduc 0 6 0 7 mm 0 024 0 028 in z tion plate To obtain full engine performance ca To install the spark plug pability removing the power reduction 1 Clean the surface of the spark plug plate is required gasket and its mating surface and Remove the exhaust manifold by then wipe off any grime from the removing the bolts WARNING spark plug threads Always let the exhaust system 2 Install the spark plug with the cool prior to touching exhaust Exhaust manifold spark plug wrench and then tight components jewaisss1 Gaskel en it to the specified torque 3 Power reduction plate Tightening torque Spark plug TIP Store the power reduction plate with the Owners Manual so that it is readily available whenever you want to red
41. ion YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN Measure the tire pressure when the tires are cold Adjust the tire pressure Improper tire pressure can cause loss of control Loss of control can result in kPa kPa kgtlom 2 kgf em severe injury or death psi psi Model Name Max Power kkkkkk kkk kW kkk kg Mass In Running Order 1 7 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 8 Wednesday June 27 2012 2 53 PM LOCATION OF IMPORTANT LABELS For Oceania and South Africa Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 9 Wednesday June 27 2012 2 53 PM LOCATION OF IMPORTANT LABELS For Oceania and South Africa 2 TIRE INFORMATION a BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS Cold tire normal pressure should be set as follows NEVER CARRY A PASSENGER You increase your risk of losing control if you carry a passenger FRONT 100 kPa 1 00 kgf cm 15 psi NEVER OPERATE THIS VEHICLE ON PUBLIC ROADS You can REAR 100 kPa 1 00 kgf cm 15 psi collide with another vehicle if you operate this vehicle on a public road ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET SRV 21668 A0 eye protection and protective clothing 3PT 2118K A1 1 9 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 1
42. les equipped with a fuel cock that has an S stop po sition Turn the fuel cock lever to eG Drain the carburetor float chamber by loosening the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating Perform the following steps to pro tect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder wall with oil USPG8BE0 book Page 4 Wednesday June 27 2012 2 53 PM MOTORCYCLE CARE AND STORAGE e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap WARNING To prevent damage or injury from sparking make sure to ground the spark plug elec trodes while turning the en gine Over Ewaio951 6 Lubricate all control cables and the pivoting points of all levers as well as of the centerstand 7 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of it
43. mber W Wheel bearings checking Wheel front ceee Wheell r ar ss sinus Wheels USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM EAU53771 AWARNING Improper motorcycle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY AN APPROVED ON PAVED PASSENGERS HELMET AND ROADS PROTECTIVE GEAR NEVER operate ALWAYS without proper training or instruction use proper riding techniques to avoid e at speeds too fast for your skills or the vehicle overturns on hills and rough conditions terrain and in turns e on public roads a collision can occur with avoid paved surfaces pavement may another vehicle seriously affect handling and control e with a passenger passengers affect balance and steering and increase risk of losing control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS YAMAHA PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2012 07 0 6x1 CR E Downloaded from www Manualslib com manuals search engine
44. mportant 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 acces sories 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 and Modifications While you may find aftermarket prod ucts similar in design and quality to genuine Yamaha accessories recog nize that some aftermarket accessories or modifications are not suitable be cause of potential safety hazards to you or others Installing aftermarket prod USPG8BE0 book Page 4 Wednesday June 27 2012 2 53 PM ucts or having other modifications per formed 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 e Never install accessories that would impair the performance of your motorcycle Carefully inspec
45. n lead to expensive repair bills When checking the fuel system do not smoke and make sure there are no open flames or sparks in the ar ea including pilot lights from water EWA15141 7 23 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage USPG8BE0 book Page 24 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU25972 Troubleshooting chart 1 Fuel m Lu aad m Check the compression Check the fuel level in Eee the fuel tank 7 gt There is f The engine does not start no fuel supply Wel Check the compression m There is compression Check the ignition There is Have a Yamaha dealer no compression check the vehicle 2 Compression Operate the kickstarter 3 Ignition Wet Wipe off with a dry cloth and correct the Open the throttle halfway and operate the kickstarter spark plug gap or replace the spark plug Remove the spark plug and check the electrodes The engine does not start Dry Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle a 7 24 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM MOTORCYCLE CARE AND
46. n the cen 3 Insert the wheel axle from the right terstand side 2 Remove the seat See page 4 7 4 Install the washer and axle nut 3 Remove the muffler bolt and wash and then tighten the axle nut to the ers WARNING Always let the specified torque exhaust system cool prior to touching exhaust components Tightening torque EWA14581 Axle nut 4 Slide the spring clamp down and 40 Nm 4 0 mikat eo f0 then remove the muffler 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 14 7 Take the motorcycle off the center stand so that the front wheel is on the ground 7 20 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 21 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT 6 Remove the exhaust manifold bolts and then remove the ex haust chamber the power reduc tion plate and the gasket 1 Muffler 1 Rear shock absorber mounting bolt 2 Washer 3 Muffler bolt 4 Spring clamp 5 Remove the exhaust chamber bolt and washers 7 Remove the right side rear shock absorber mounting bolt and then tilt the rear shock absorber upward as shown 8 Remove the axle nut while apply ing the rear brake 1 Exhaust manifold bolt 1 Axle nut 9 Remove the rear arm by removing the nuts and washers 1 Exhaust chamber 2 Exhaust chamber
47. ncies between your motorcycle and this manual If there is any question concerning this manual please consult a Yamaha dealer Please read this manual carefully and completely before operating this motorcycle This motorcycle is designed and manufactured for off road use only It is illegal to operate this motorcycle on any public street road or highway Such use is prohibited by law This motorcycle complies with almost all state off highway noise level and spark arrester laws and regulations Please check your local riding laws and regulations before operating this motorcycle AN IMPORTANT SAFETY MESSAGE e Read this manual carefully and completely before operating this motorcycle Make sure you understand all instructions e Pay close attention to the warning and notice labels on the motorcycle e Never operate a motorcycle without proper training or instruction e Weight of the rider should not exceed 25 kg 55 lb EWA10031 EWA14351 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 2 Wednesday June 27 2012 2 53 PM INTRODUCTION 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 warn ings in this Owner s Manual Then be sure your child understands and will follow them Children differ in skills physical abil ities and judgment Some children may not be able to operate a motorcycle safely Parents
48. ng the throttle To increase the speed turn the throttle grip in direction a To reduce the speed turn the throt tle grip in direction b 6 2 EAU41012 Braking e Avoid braking hard or suddenly especially when leaning over to one side otherwise the motor cycle may skid or overturn e Keep in mind that braking on wet surfaces is much more diffi cult Ride slowly down a hill as brak ing downhill can be very diffi cult 1 Close the throttle completely 2 Apply both front and rear brakes 6 simultaneously while gradually in creasing the pressure EWA14571 USPG8BE0 book Page 3 Wednesday June 27 2012 2 53 PM OPERATION AND IMPORTANT RIDING POINTS Rear Downloaded from www Manualslib com manuals search engine EAU42030 Engine break in There is never a more important period in the life of your engine than the first 5 hours of riding It is also important to ac custom the rider to the motorcycle dur ing this time Please read the following 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 themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided However momentary full throttle operation under load i e two to three seconds maximum does not harm
49. not be 2 4 appropriate Refer to page 7 12 for tire specifications and more information on replacing your tires Transporting the Motorcycle Be sure to observe following instruc tions before transporting the motorcy cle in another vehicle e 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 e Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to pre vent movement e Shift the transmission in gear for models with a manual transmis sion e 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 lo USPG8BE0 book Page 5 Wednesday June 27 2012 2 53 PM SAFETY INFORMATION cation 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 2 downs if possible so that the mo torcycle will not bounce excessive ly during transport Downloaded from www Manualslib com manuals search engine 2 5 USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM DESCRIPTION EAU10410 Left view Spark plug page 7 6 Fuel cock page 4 6 Thr
50. nspection and maintenance procedures and schedules described in the Owner s Manual Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage Do not operate the vehicle if you find any problem If a problem cannot be corrected by the procedures provided in this manual have the vehicle inspected by a Yamaha dealer EWA11151 Before using this vehicle check the following points CHECKS Check fuel level in fuel tank e Refuel if necessary e Check fuel line for leakage e Check fuel tank breather hose for obstructions cracks or damage and check hose connection e Check oil level in oil tank 2 stroke engine oil If necessary add recommended oil to specified level 4 6 e Check vehicle for oil leakage e Check oil level in transmission case 7 8 Transmission oil ses aes If necessary add recommended oil to specified level Middle and final gear cases e Check vehicle for grease leakage 7 9 e Check operation e Lubricate cable if necessary Check lever free play 7 14 7 15 e Adjust if necessary Front brake e Check operation e Lubricate cable if necessary Check lever free play e Adjust if necessary Rear brake 5 1 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 2 Wednesday June 27 2012 2 53 PM FOR YOUR SAFETY PRE OPERATION CHECKS CHECKS Make sure that operation i
51. oft 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 Downloaded from www Manualslib com manuals search engine MOTORCYCLE CARE AND STORAGE 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 wa ter and a mild detergent after the engine has cooled down NOTICE Do not use warm water since it increases the corrosive action of the salt ca10791 2 Apply a corrosion protection spray on all metal including chrome and nickel plated surfaces to prevent 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 8 2 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 EWA14501 A WARNING Contaminants on the brakes or tires can cause loss of control e Make sure t
52. oline The use of leaded gasoline will cause severe damage to internal engine parts such as the piston rings as well as to the exhaust system USPG8BE0 book Page 5 Wednesday June 27 2012 2 53 PM INSTRUMENT AND CONTROL FUNCTIONS 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 oc curs use a gasoline of a different brand or premium unleaded fuel Use of un leaded fuel will extend spark plug life and reduce maintenance costs For South Africa Recommended fuel REGULAR UNLEADED GASO LINE ONLY Fuel tank capacity 2 0 L 0 53 US gal 0 44 Imp gal ECA15590 NOTICE Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the piston rings 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 oc curs use a gasoline of a different brand Downloaded from www Manualslib com manuals search engine or premium unleaded fuel Use of un leaded fuel will extend spark plug life and reduce maintenance costs For Oceania Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 2 0 L 0 53 US gal 0 44 Imp gal ECA15590 NOTICE Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal eng
53. 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 TIP The engine is warm when it responds quickly to the throttle with the starter choke turned off ECA11042 NOTICE For maximum engine life never ac celerate hard when the engine is cold 6 1 EAU16660 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm Instead start the engine with the throttle slightly open TIP If the engine does not start after several kicks try again with the throttle 1 4 to 1 2 open USPG8BE0 book Page 2 Wednesday June 27 2012 2 53 PM EAU41002 Starting off 1 N While applying the rear brake le ver push the motorcycle off the centerstand Completely close the throttle Set the engine stop switch to RUN Check for oncoming off road vehi cles and then slowly turn the throt tle grip in order to take off Downloaded from www Manualslib com manuals search engine OPERATION AND IMPORTANT RIDING POINTS EAU16780 Acceleration and deceleration a The speed can be adjusted by opening and closi
54. ottle stop screw page 7 11 Air filter element page 7 9 Kickstarter page 4 7 Centerstand page 7 17 OO O1 BB D 3 1 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 2 Wednesday June 27 2012 2 53 PM DESCRIPTION EAU10420 Right view 3 SSS SS EWS Ba A gt CN RR TO OJO N IZ Ke 1 Spark arrester page 7 10 2 Seat page 4 7 8 Transmission oil filler cap page 7 8 4 2 stroke engine oil tank page 4 6 5 Transmission oil drain bolt page 7 8 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 3 Wednesday June 27 2012 2 53 PM DESCRIPTION EAU10430 Controls and instruments A LESS z hal eal 16 Li W Rear brake lever page 4 3 Starter choke lever page 4 7 2 Stroke engine oil tank cap page 4 6 Engine stop switch page 4 1 Front brake lever page 4 2 Throttle grip page 7 12 Fuel tank cap page 4 3 N OO O1 OD 3 3 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM INSTRUMENT AND CONTROL FUNCTIONS ERA e The engine speed is limited while this switch is set to the START position therefore the motorcycle cannot be ridden in that switch po sition Handlebar switch j 1 Engine stop switch OFF RUN START EAU40674 Engine sto
55. p switch OFF RUN START Set this switch to START before start ing the engine Set this switch to RUN after warming up the engine or before starting off Set this switch to OFF to stop the engine TIP e The engine cannot be started with this switch set to the RUN posi tion 4 1 Downloaded from www Manualslib com manuals search engine EAU41044 Speed limiter and power re duction plate Your motorcycle is equipped with an adjustable speed limiter and a power reduction plate The speed limiter keeps the throttle from fully opening even when the throttle grip is turned to the maximum The power reduction plate is installed in the exhaust mani fold to limit the amount of power avail able while learning Speed limiter 1 Loosen the locknut 2 To increase the maximum engine power available and the maximum speed of the motorcycle turn the adjusting screw in direction a To decrease the maximum engine power available and the maximum speed of the motorcycle turn the adjusting screw in direction b USPG8BE0 book Page 2 Wednesday June 27 2012 2 53 PM 1 Locknut 2 Adjusting screw 3 Tighten the locknut 1 No more than 7 mm 0 28 in TIP The adjusting range of the speed limiter screw is from the fully turned in position to 7 mm 0 28 in turned out When the screw is turned out to 7 mm 0 28 in Downloaded from www Manualslib com manuals search engine
56. rmation on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer USPG8BE0 book Page 2 Wednesday June 27 2012 2 53 PM CONSUMER INFORMATION Vehi EF EAu4s120 tions related to exhaust emissions as ehicle Emission Control Informa required by federal law state law and tion label For Canada Em ronment Canada 1 Vehicle Emission Control Information label 10 The Vehicle Emission Control Informa tion label is affixed at the location in the illustration This label shows specifica 10 2 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM A Acceleration and deceleration 6 2 Air filter element cleaning 005 7 9 Autolube pump adjusting 2 7 16 B Brake lever front cccccsseceeeeeeeeeseee 4 2 Brake lever rear cccccccccccsssseceeeeeeeeeees 4 3 Brake levers lubricating 0 05 Brake shoes checking Braking easier C Cable lock for Europe 4 8 Cables checking and lubricating 7 16 Carburetor adjusting Centerstand checking and lubricating 7 17 E Engine break in 6 3 Engine idling speed l 7 11 Engine oil s Engine starting a warm 6 1 Engine stop switch 4 1 F Front and rear brake lever free play AJUS NG gaie iaat ena 7 14 Front fork
57. rom www Manualslib com manuals search engine EAU41221 Cleaning the spark arrester The spark arrester should be cleaned at the intervals specified in the periodic maintenance and lubrication chart EWA10980 WARNING e Always let the exhaust system cool prior to touching exhaust components e Do not start the engine when cleaning the exhaust system 1 Remove the tailpipe by removing the screw and then pulling it out of the muffler 1 Tailpipe 2 Screw 3 Muffler 7 10 2 10 EMPINTERENCE AND ADJUSTMENT Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark ar rester portion of the tailpipe and in side of the tailpipe housing 1 Spark arrester 3 TIP Insert the tailpipe into the muffler and then install and tighten the screw Make sure to align the screw hole when inserting the tailpipe 7 USPG8BE0 book Page 11 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU39930 Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisti cated adjustment Therefore most car buretor adjustments should be left to a Yamaha dealer who has the neces sary professional knowledge and expe rience The adjustment described in the following section however may be ser viced by the owner as part of routine maintenance ECA10550 NOTICE The carburetor has been set and
58. s wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it TIP Make any necessary repairs before storing the motorcycle 8 4 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM SPECIFICATIONS 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 1300 mm 51 2 in Weight Curb weight 39 kg 86 Ib Technical permissible mass Maximum load curb weight 64 kg 141 lb Noise and vibration level Noise level 77 311 EEC PW50 75 1 dB A 2750 r min AUT BEL CHE DEU DNK ESP FIN FRA GBR GRC IRL ITA NLD NOR POL PRT SVN SWE Vibration on seat EN1032 ISO5008 PW50 Will not exceed 0 5 m s AUT BEL CHE DEU DNK ESP FIN FRA GBR GRC IRL ITA NLD NOR POL PRT SVN SWE Downloaded from www Manualslib com manuals search engine Vibration on handlebar EN1032 ISO5008 PW50 Will not exceed 2 5 m s AUT BEL CHE DEU DNK ESP FIN FRA GBR GRC IRL ITA NLD NOR POL PRT SVN SWE Engine Engine type Air cooled 2 stroke Cylinder arrangement Single cylinder
59. s Manual e Obtain qualified training in safe and proper riding techniques e Obtain professional technical service as indicated in this Owner s Manual and or when made necessary by mechanical conditions Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM IMPORTANT MANUAL INFORMATION EAU10133 Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in A WARNING death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the NOTICE vehicle or other property TIP A TIP provides key information to make procedures easier or clearer Product and specifications are subject to change without notice Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 2 Wednesday June 27 2012 2 53 PM IMPORTANT MANUAL INFORMATION EAU10200 PW50 PW50D PW50D1 OWNER S MANUAL 2012 by Yamaha Motor Co Ltd 1st edition June 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan Downloaded from ww
60. s smooth Check throttle grip free play If necessary have Yamaha dealer adjust throttle grip free play and lubricate cable and grip housing Throitle grip e Make sure that operation is smooth Control cables e Lubricate if necessary Check for damage e Check tire condition and tread depth e Check air pressure Correct if necessary Wheels and tires 7 12 7 14 e Make sure that operation is smooth Brake levers e Lubricate lever pivoting points if necessary Make sure that operation is smooth Centerstand e Lubricate pivot if necessary Make sure that all nuts bolts and screws are properly tightened Chassis rasteners e Tighten if necessary Engine stop switch Check operation 5 2 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM OPERATION AND IMPORTANT RIDING POINTS EAU15951 Read the Owners Manual carefully to become familiar with all controls If there is a control or function you do not understand ask your Yamaha dealer EWA10271 A WARNING Failure to familiarize yourself with the controls can lead to loss of con trol which could cause an accident or injury Downloaded from www Manualslib com manuals search engine EAU40889 Starting and warming up a cold engine 1 Turn the fuel cock lever to O on 2 Set the engine stop switch to START 3 Turn the starter choke
61. 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 reduction plate Yamaha recommends that all be ginners start off with the speed limiter adjusting screw turned in and the power reduction plate installed in the exhaust man ifold 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 rider 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 sig nificant increase in power turn the speed limiter back in again adjust it out in stages as you did before Motorcycles are single track vehicles Their safe use and operation are dependent upon the use of proper riding techniques as well as the expertise of the operator Every operator should know the following requirements before riding this motorcycle He or she should Obtain thorough instructions from a competent source on all aspects of motorcycle operation e Observe the warnings and maintenance requirements in this Owner
62. st can be drawn into a building through openings such as windows and doors Loading Adding accessories to your motorcycle can adversely affect stability and han dling if the weight distribution of the mo torcycle 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 overloaded vehicle could cause an accident Downloaded from www Manualslib com manuals search engine The weight of the operator must not exceed 25 kg 55 Ib Accessory weight should be kept as low and close to the motorcycle as possible Securely pack your heaviest items as close to the cen ter of the vehicle as possible and make sure to distribute the weight as evenly as possible on both sides of the motorcycle to mini mize imbalance or instability Shifting weights can create a sud den imbalance Make sure that ac cessories are securely attached to the motorcycle before riding Check accessory mounts fre quently e 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 2 3 Genuine Yamaha Accessories Choosing accessories for your vehicle is an i
63. t 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 e Accessories fitted to the handle bar or the front fork area can create instability due to improper weight distribution If accesso ries are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Downloaded from www Manualslib com manuals search engine SAFETY INFORMATION 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 un stable in cross winds e Certain accessories can dis place the operator from his or her normal riding position This improper position limits the free dom of movement of the opera tor and may limit control ability therefore such accessories are not recommended e Use caution when adding electri cal accessories If electrical acces sories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Aftermarket Tires and Rims The tires and rims that came with your motorcycle were designed to match the performance capabilities and to provide the best combination of handling brak ing and comfort Other tires rims siz es and combinations may
64. the engine Each full throttle ac celeration should be followed 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 thor oughly check the motorcycle for loose parts oil leakage and any other prob lems Be sure to inspect and make ad 6 3 justments thoroughly especially cables In addition check all fittings and fasteners for looseness and tighten if necessary ECA10270 NOTICE If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle USPG8BE0 book Page 4 Wednesday June 27 2012 2 53 PM EAU40722 Parking When parking stop the engine and then turn the fuel cock lever to S stop Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned e Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire e Do not park near grass or other flammable materials which might catch fire EWA10311 Downloaded from www Manualslib com manuals search engine OPERATION AND IMPORTANT RIDING POINTS 6 4 USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17244 Periodic inspection adjustment and lu bri
65. the washers and bolts TIP Make sure that the seat is properly se cured before riding Downloaded from www Manualslib com manuals search engine INSTRUMENT AND CONTROL FUNCTIONS Eausszeo 4 Route one end of the cable Cable lock for Europe through the rear wheel and then Your motorcycle came with an external insert both ends of the cable into anti theft device to help prevent unau the lock assembly and lock it thorized use Please locate the cable and lock assembly that came with your motorcycle Properly stow the cable and lock as sembly inside a bag or other secure location before operating your mo torcycle Do not hang your cable lock from anywhere on the motorcy cle or your person It may become entangled with the wheels handle 5 Perform the above steps in re bars or other parts of the motorcy verse order before riding your mo cle causing loss of control and torcycle possibly an accident EWA16300 1 Correct cable and lock assembly use To lock your motorcycle 1 Park your motorcycle in the de sired location 2 Make sure that the motorcycle is securely parked Use the side stand or other support 3 Disconnect the cable from the lock assembly 4 8 USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM FOR YOUR SAFETY PRE OPERATION CHECKS EAU15596 Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition Always follow the i
66. tion fuel will Oil quantity not flow Always return the lever to this 0 30 L 0 32 US at 0 26 Imp qt position when the engine is not running ECA16670 NOTICE Make sure that the 2 stroke engine oil tank cap is properly installed 4 6 Downloaded from www Manualslib com manuals search engine USPG8BE0 book Page 7 Wednesday June 27 2012 2 53 PM INSTRUMENT AND CONTROL FUNCTIONS AU13590 Starter choke lever al 1 Starter choke lever ja Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke Downloaded from www Manualslib com manuals search engine EAU13680 Kickstarter 1 Kickstarter To start the engine fold out the kick starter lever move it down lightly with your foot until the gears engage and then push it down smoothly but force fully 4 7 EAU40920 Seat To remove the seat 1 Remove the mudguard by remov ing the bolts and washers 1 Bolt and washer 2 Mudguard 2 Pull the seat off To install the seat 1 Insert the projection on the front of the seat into the seat holder as shown USPG8BE0 book Page 8 Wednesday June 27 2012 2 53 PM eat holder rojection S P 2 Place the seat in the original posi tion 3 Install the mudguard by installing
67. uce the engine power 20 Nm 2 0 m kgf 14 ft lbf TIP If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn 4 Install the exhaust manifold and its new gasket by installing the bolts past finger tight However the spark 1 Exhaust manifold bolt and then tighten the bolts to the plug should be tightened to the speci 2 Remove the gasket specified torque fied torque as soon as possible 3 Remove the power reduction plate Tightening torque 3 Install the spark plug cap Exhaust manifold bolt 9 Nm 0 9 m kgf 6 5 ft lbf 7 7 Downloaded from www Manualslib com manuals search engine PERIODIC MAINTENANCE AND ADJUSTMENT ECA10452 USPG8BE0 book Page 8 Wednesday June 27 2012 2 53 PM EAU40893 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 lubrication NOTICE a MG In order to prevent clutch slip page since the transmission oil 1 also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In chart sas t Tansmissionoiidrainbolt addition do not use oils labeled 1
68. w Manualslib com manuals search engine USPG8BE0 book Page 1 Wednesday June 27 2012 2 53 PM LOCATION OF IMPORTANT LABELS uuu cece essere 1 1 SAFETY INFORMATION 2 1 DESCRIPTION o 3 1 Left view 3 1 Right view 3 2 Controls and instruments 00000 3 3 INSTRUMENT AND CONTROL FUNCTIONS 4 1 Handlebar switch 4 1 Speed limiter and power reduction DIALS 38h nes 4 1 Front brake lever 4 2 Rear brake lever 4 3 Fuel tank cap ou eee eee 4 3 FU l E tune 4 3 Fuel tank breather hose nnnn 00 4 5 2 stroke engine oil 4 6 Fuel COCK oseas etsaiaren 4 6 Starter choke lever 0 4 7 Kickstarter 4 7 SAT tete Ne sean 4 7 Cable lock for Europe 0 4 8 Downloaded from www Manualslib com manuals search engine FOR YOUR SAFETY PRE OPERATION CHECKS OPERATION AND IMPORTANT RIDING POINTS Starting and warming up a cold engine Starting a warm engine n s Starting Off oo eeeeeesssteeeesseees Acceleration and deceleration Braking nsss tiene send Engine break in Parking cecsacenteyenettesncesdersgeccntattocense PERIODIC MAINTENAN

User Manual PDF

Contents

Download Pdf Manuals

Related Search

Related Contents