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Yamaha PW50 Owner's Manual
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Yamaha PW50 Owner's Manual

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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
BEDIENUNGSANLEITUNG
Read this manual carefully before oper-
ating this vehicle.
Il convient de lire attentivement ce manuel
avant la première utilisation du véhicule.
Bitte lesen Sie diese Bedienungsanlei-
tung sorgfältig durch, bevor Sie das Fahr-
zeug in Betrieb nehmen.
PW50
MOTORCYCLE
MOTO
MOTORRAD
PW50
PW50G
PW50G2
2SA-28199-82

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  • Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE BEDIENUNGSANLEITUNG PW50 MOTORCYCLE MOTO MOTORRAD Read this manual carefully before oper- ating this vehicle. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Bitte lesen Sie diese Bedienungsanlei- tung sorgfältig durch, bevor Sie das Fahr- zeug in Betrieb nehmen.
  • Page 2 Original instructions Notice originale Originalbetriebsanleitung PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2015.06-1.2×1 CR AUF RECYCLINGPAPIER GEDRUCKT (E,F,G)
  • Page 3 OWNER’S MANUAL PW50 MOTORCYCLE Read this manual carefully before oper- ating this vehicle. PW50 PW50G PW50G2 2SA-28199-82-E0...
  • Page 4 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 98/37/EC, 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product PW50 (JYA3PT00000460165– )
  • Page 5 Introduction EAU41075 Congratulations on your purchase of the Yamaha PW50 / PW50G / PW50G2. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of crafts- manship and reliability that have made Yamaha a leader in these fields.
  • Page 6 Your motorcycle is equipped with an adjustable speed limiter and a power reduc- tion plate. Yamaha recommends that all beginners start off with the speed limiter adjusting screw turned in and the power reduction plate installed in the exhaust manifold to limit the power available while they learn.

  • Page 7: Important Manual Information

    A TIP provides key information to make proce- dures easier or clearer. *Product and specifications are subject to change without notice. EAU10201 PW50 / PW50G / PW50G2 OWNER’S MANUAL ©2015 by Yamaha Motor Co., Ltd. 1st edition, May 2015 All rights reserved.

  • Page 8: Table Of Contents

    Table of contents Location of important labels... 1-1 Checking the spark plug ....7-6 Removing the power reduction Safety information......2-1 plate ..........7-7 Transmission oil ......7-8 Description ........3-1 Middle and final gear cases ....7-9 Left view ......... 3-1 Cleaning the air filter element ..7-10 Right view........

  • Page 9: Location Of Important Labels

    Read and understand all of the labels on your vehicle. They contain important in- formation 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 is available from your Yamaha dealer. For Canada...
  • Page 10 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.
  • Page 11 Location of important labels For Canada TIRE INFORMATION Cold tire nor mal pressure should be set as follows. F RO NT : 1 0 0 k Pa , {1 .0 0 k gf/c m ²}, 15 psi R E AR : 1 0 0 k Pa , {1 .0 0 k gf/c m ²}, 15 psi 3RV-21668-A0 INFORMATION SUR LES PNEUS...
  • Page 12 Location of important labels For Europe...
  • Page 13 Location of important labels For Europe 5B6-2816R-00 PW50 2.1 kW 39 kg 5PG-2156A-10 EN16029 2015 YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN 5B6-2817L-00 100 kPa 100 kPa 1.00 kgf/cm² 1.00 kgf/cm² 15 psi 15 psi 5PG-2816R-00...
  • Page 14 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.
  • Page 15 Loss of control can result in severe injury or **.* kPa **.* kPa death. *.** kgf/cm² *.** kgf/cm² *.* psi *.* psi Model Name ****** Max. Power *** kW *** kg Mass In Running Order 1 Year of construction **** YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN...
  • Page 16 Location of important labels For Oceania and South Africa...
  • Page 17 Location of important labels For Oceania and South Africa 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. •...

  • Page 18: Safety Information

    Safety information EAU4093C an accident or equipment damage. See page 5-1 for a list of pre-operation checks. Be a Responsible Owner  This motorcycle is designed for As the vehicle’s owner, you are re- off-road use only, therefore, it is il- sponsible for the safe and proper oper- legal to operate it on public ation of your motorcycle.
  • Page 19 Safety information sic motorcycle maintenance. Protective Apparel Certain maintenance can only The majority of fatalities from motorcy- be carried out by certified staff. cle accidents are the result of head in-  Many accidents involve inexperi- juries. The use of a safety helmet is the enced operators.
  • Page 20 Yamaha accessories, which are avail- dling if the weight distribution of the able only from a Yamaha dealer, have motorcycle is changed. To avoid the been designed, tested, and approved possibility of an accident, use extreme by Yamaha for use on your vehicle.

  • Page 21: Specifications

    While you may find aftermarket prod- unstable in cross winds. ucts similar in design and quality to • Certain accessories can dis- genuine Yamaha accessories, recog- place the operator from his or nize that some aftermarket accesso- her normal riding position. This...
  • Page 22 Safety information  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). ...

  • Page 23: Description

    Description EAU63371 Left view 1. Spark plug (page 7-6) 2. Fuel cock (page 4-7) 3. Throttle stop screw (page 7-12) 4. Air filter element (page 7-10) 5. Kickstarter (page 4-8) 6. Centerstand (page 7-20)

  • Page 24: Right View

    Description EAU63391 Right view 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)

  • Page 25: Controls And Instruments

    Description EAU63401 Controls and instruments 1. Rear brake lever (page 4-3) 2. Starter (choke) lever (page 4-7) 3. Engine stop switch (page 4-1) 4. Front brake lever (page 4-2) 5. Throttle grip (page 7-13)

  • Page 26: Instrument And Control Functions

    Instrument and control functions EAU40661 EAU41045 Handlebar switch 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.

  • Page 27: Front Brake Lever

    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 7-13.)

  • Page 28: Rear Brake Lever

    Instrument and control functions EAU12952 EAU13183 Rear brake lever Fuel tank cap 1. Rear brake lever 1. Fuel tank cap The rear brake lever is located on the To remove the fuel tank cap, turn it left side of the handlebar. To apply the counterclockwise, and then pull it off.

  • Page 29: Fuel

    1. Fuel tank filler tube Your Yamaha engine has been de- 2. Maximum fuel level signed to use regular unleaded gaso- 3. Wipe up any spilled fuel immedi-...
  • Page 30 Use only unleaded gasoline. The use containing methanol is not recom- of leaded gasoline will cause severe mended by Yamaha because it can damage to internal engine parts, cause damage to the fuel system or such as the piston rings as well as to vehicle performance problems.

  • Page 31: Fuel Tank Breather Hose

    Instrument and control functions EAU13414 EAU13454 Fuel tank breather hose 2-stroke engine oil Make sure that there is sufficient 2- stroke engine oil in the oil tank. Add the recommended 2-stroke engine oil as necessary. 1. Fuel tank breather hose Before operating the motorcycle: ...

  • Page 32: Fuel Cock

    Instrument and control functions EAU40702 EAU13591 Fuel cock Starter (choke) lever “ ” The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has two positions: S (stop) 1. Starter (choke) lever “ ”...

  • Page 33: Kickstarter

    Instrument and control functions EAU13681 EAU40921 Kickstarter Seat To remove the seat 1. Remove the mudguard by remov- ing the bolts and washers. 1. Kickstarter To start the engine, fold out the kick- starter lever, move it down lightly with your foot until the gears engage, and 1.

  • Page 34: Cable Lock (For Europe)

    Instrument and control functions EAU53762 Cable lock (for Europe) Make sure that the seat is properly se- Your motorcycle came with an external cured before riding. anti-theft device to help prevent unau- thorized use. Please locate the cable and lock assembly that came with your motorcycle.
  • Page 35 Instrument and control functions 1. Correct cable and lock assembly use 5. Perform the above steps in re- verse order before riding your mo- torcycle. 4-10...

  • Page 36: For Your Safety - Pre-Operation Checks

    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. Before using this vehicle, check the following points:...
  • Page 37 For your safety – pre-operation checks ITEM CHECKS PAGE • Make sure that operation is smooth. Centerstand 7-20 • Lubricate pivot if necessary. • Make sure that all nuts, bolts and screws are properly Chassis fasteners tightened. — • Tighten if necessary. Engine stop switch •...

  • Page 38: Operation And Important Riding Points

    If 1. Turn the fuel cock lever to “O” there is a control or function you do not (on). understand, ask your Yamaha dealer. 2. Set the engine stop switch to EWA10272 “START”. WARNING 3.

  • Page 39: Starting A Warm Engine

    Operation and important riding points EAU16661 EAU41004 Starting a warm engine Starting off Follow the same procedure as for 1. While applying the rear brake le- starting a cold engine with the excep- ver, push the motorcycle off the tion that the starter (choke) is not re- centerstand.

  • Page 40: Acceleration And Deceleration

    Operation and important riding points EAU16782 EAU41013 Acceleration and deceleration Braking EWA14572 WARNING  Avoid braking hard or suddenly (especially when leaning over to one side), otherwise the motor- cycle may skid or overturn.  Keep in mind that braking on wet surfaces is much more diffi- cult.

  • Page 41: Engine Break-In

    Be sure to inspect and make adjustments thoroughly, especially ca- bles. In addition, check all fittings and fasteners for looseness, and tighten if necessary. ECA10271 NOTICE If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle.

  • Page 42: Periodic Maintenance And Adjustment

    If you are not familiar with vehicle ser- vice, have a Yamaha dealer perform service. EWA15123 WARNING Turn off the engine when performing...

  • Page 43: Owner's Tool Kit

    Yamaha dealer perform it for you. individual that is certified (if applicable). Yamaha dealers are trained and equipped to perform these particular...

  • Page 44: Periodic Maintenance Chart For The Emission Control System

    Periodic maintenance and adjustment EAU69180 Periodic maintenance chart for the emission control system Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. THEREAFTER INITIAL EVERY ITEM CHECK OR MAINTENANCE JOB •...

  • Page 45: General Maintenance And Lubrication Chart

    Periodic maintenance and adjustment EAU69202 General maintenance and lubrication chart Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. THEREAFTER INITIAL EVERY ITEM CHECK OR MAINTENANCE JOB • Check operation.
  • Page 46 • Check operation and for oil leakage. √ √ √ √ 13 * assemblies • Replace if necessary. • Apply Yamaha cable lubricant or other √ √ √ 14 * Control cables suitable cable lubricant. • Check operation. • Check throttle grip free play, and √...

  • Page 47: Checking The Spark Plug

    Do not attempt to can reveal the condition of the engine. diagnose such problems yourself. In- stead, have a Yamaha dealer check To remove the spark plug the vehicle. 1. Remove the spark plug cap.

  • Page 48: Removing The Power Reduction Plate

    Periodic maintenance and adjustment EAU41104 Spark plug gap: Removing the power reduc- 0.6–0.7 mm (0.024–0.028 in) 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 plate is required.

  • Page 49: Transmission Oil

    Owner’s Manual so that it is readily for oil leakage before each ride. If any available whenever you want to reduce leakage is found, have a Yamaha deal- the engine power. er check and repair the motorcycle. In addition, the transmission oil must be 4.

  • Page 50: Middle And Final Gear Cases

    The middle and final gear cases must tighten the bolt to the specified be checked for grease leakage before torque. each ride. If any leakage is found, have a Yamaha dealer check and repair the Tightening torque: motorcycle. addition, have Transmission oil drain bolt: 14 Nm (1.4 m·kgf, 10 ft·lbf)

  • Page 51: Cleaning The Air Filter Element

    The sponge material should be wet but not dripping. Recommended oil: Yamaha foam air filter oil or other quality foam air filter oil 1. Air filter case cover 2. Screw 5. Insert the sponge material into the 3.

  • Page 52: Cleaning The Spark Arrester

    Periodic maintenance and adjustment EAU41222 Cleaning the spark arrester The spark arrester should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. EWA10981 WARNING  Always let the exhaust system cool prior to touching exhaust components. 1.

  • Page 53: Adjusting The Carburetor

    Therefore, most checked and, if necessary, adjusted as carburetor adjustments should be left follows at the intervals specified in the to a Yamaha dealer, who has the nec- periodic maintenance and lubrication essary professional knowledge and ex- chart.

  • Page 54: 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 inner edge of the throttle grip. Periodi- cally check the throttle grip free play and, if necessary, have a Yamaha deal- er adjust it. 7-13...

  • Page 55: Tires

    WARNING or glass fragments in it, or if the side- Operation of this vehicle with im- wall is cracked, have a Yamaha dealer proper tire pressure may cause se- replace the tire immediately. vere injury or death from loss of control.
  • Page 56 Manufacturer/model: BRIDGESTONE/M29 IRC/Z MARK II (PW50_ZAF, PW50G, PW50G2) EWA15542 WARNING  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.  The replacement of all wheel-...

  • Page 57: Panel Wheels

    If any damage is found, have a Yamaha dealer replace the wheel. 1. Front brake lever free play Do not attempt even the smallest Rear repair to the wheel. A deformed or cracked wheel must be replaced.

  • Page 58: Checking The Front And Rear Brake Shoes

    EWA10651 WARNING If proper adjustment cannot be ob- Rear tained as described, have a Yamaha dealer make this adjustment. 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.

  • Page 59: Checking And Lubricating The Cables

    If a cable is damaged or does not move smoothly, have a Yamaha dealer check or re- place it. WARNING! Damage to the outer housing of cables may result in internal rusting and cause inter- ference with cable movement.

  • Page 60: Checking And Lubricating The Throttle Grip And Cable

    In dealer at the intervals specified in the addition, the cable should be lubricat- periodic maintenance and lubrication ed by a Yamaha dealer at the intervals chart. specified in the periodic maintenance chart. The throttle cable is equipped with a rubber cover.

  • Page 61: Lubricating The Front And Rear Brake Levers

    EWA11302 Lithium-soap-based grease WARNING 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.

  • Page 62: Checking The Front Fork

    If any free there is no danger of it falling play can be felt, have a Yamaha over. dealer check or repair the steer- [EWA10752] 2.

  • Page 63: Checking The Wheel Bearings

    Yamaha dealer then removing the cable from the check the wheel bearings. brake camshaft lever and brake shoe plate.
  • Page 64 Periodic maintenance and adjustment 3. Insert the wheel axle from the right side. 4. Install the washer and axle nut, and then tighten the axle nut to the specified torque. Tightening torque: Axle nut: 40 Nm (4.0 m·kgf, 29 ft·lbf) 5.

  • Page 65: Rear Wheel

    Periodic maintenance and adjustment EAU25081 Rear wheel EAU56822 To remove the rear wheel EWA10822 WARNING To avoid injury, securely support the vehicle so there is no danger of it 1. Exhaust chamber falling over. 2. Exhaust chamber bolt 3. Washer 1.
  • Page 66 Periodic maintenance and adjustment 8. Remove the axle nut while apply- 6. While applying the rear brake, ing the rear brake. tighten the axle nut to the speci- fied torque. 7. Tighten the rear arm nuts and rear shock absorber mounting bolt to the specified torques.

  • Page 67: Troubleshooting

    3. Muffler self. However, should your motorcycle 12. Tighten the muffler bolt to the require any repair, take it to a Yamaha specified torque. dealer, whose skilled technicians have the necessary tools, experience, and...

  • Page 68: Troubleshooting Chart

    Check the vehicle. compression. 3. Compression The engine does not start. There is compression. Have a Yamaha dealer check the vehicle. Operate the kickstarter. There is no Have a Yamaha dealer check the vehicle. compression. 7-27...

  • Page 69: Motorcycle Care And Storage

    Rust and corrosion can develop matte colored finished parts. Be even if high-quality components are sure to consult a Yamaha dealer for used. A rusty exhaust pipe may go un- advice on what products to use be- noticed on a car, however, it detracts fore cleaning the vehicle.
  • Page 70 Motorcycle care and storage and insects will come off more easily if structed. Also, thoroughly rinse the area off with water, immedi- the area is covered with a wet cloth for ately dry it, and then apply a cor- a few minutes before cleaning. rosion protection spray.

  • Page 71: Storage

    Consult a Yamaha dealer for advice on Long-term what products to use. Before storing your motorcycle for sev- eral months: 1.
  • Page 72 Motorcycle care and storage 5. Perform the following steps to protect the cylinder, piston rings, Make any necessary repairs before etc. from corrosion. storing the motorcycle. a. Remove the spark plug cap and spark plug. b. Pour a teaspoonful of engine oil into the spark plug bore.

  • Page 73: Specifications

    Specifications Dimensions: Displacement: 49 cm³ Overall length: Bore × stroke: 1245 mm (49.0 in) 40.0 × 39.2 mm (1.57 × 1.54 in) Overall width: Compression ratio: 575 mm (22.6 in) 6.0 : 1 Overall height: Starting system: 715 mm (28.1 in) Kickstarter Seat height: Lubrication system:...
  • Page 74 Specifications Clutch: Front wheel: Clutch type: Wheel type: Wet, centrifugal, shoe Panel wheel Drivetrain: Rim size: 10x1.50 Primary reduction ratio: Rear wheel: 1.909 (63/33) Final drive: Wheel type: Shaft Panel wheel Secondary reduction ratio: Rim size: 6.218 (19/15 x 54/11) 10x1.50 Chassis: Front brake:...
  • Page 75 Specifications EAU51132 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.

  • Page 76: Consumer Information

    Yamaha dealer. area. VEHICLE IDENTIFICATION NUMBER: EAU26442 Engine serial number...
  • Page 77 Consumer information space provided. This information will be needed when ordering spare parts from a Yamaha dealer. EAU48121 Vehicle Emission Control Informa- tion label (For Canada) 1. Vehicle Emission Control Information label 1. Vehicle Emission Control Information label The Vehicle Emission Control Informa- tion label is affixed at the location in the illustration.

  • Page 78: Index

    Index Power reduction plate, removing ... 7-7 Acceleration and deceleration ....6-3 Air filter element, cleaning ....7-10 Safety information ........2-1 Autolube pump, adjusting.....7-19 Seat ............4-8 Spark arrester, cleaning ....... 7-11 Spark plug, checking ......7-6 Brake lever, front ........4-2 Specifications .........
  • Page 80 WARNING 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: • without proper training or instruction. • at speeds too fast for your skills or the conditions. •...

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