5PG-28199-87 PW50(X) BEDIENUNGSANLEITUNG ... - Yamaha …

5PG-28199-87

PW50(X)

OWNER’S MANUALMANUEL DU PROPRIÉTAIRE

BEDIENUNGSANLEITUNG

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN2007.4–1.1×1 !

(E, F, G)

PRINTED ON RECYCLED PAPER

AUF RECYCLINGPAPIER GEDRUCKTIMPRIMÉ SUR PAPIER RECYCLÉ

YAMAHA MOTOR CO., LTD.


(E, F, G)

PRINTED ON RECYCLED PAPER

AUF RECYCLINGPAPIER GEDRUCKTIMPRIMÉ SUR PAPIER RECYCLÉ

5PG-28199-87-E0

PW50(X)

OWNER’S MANUAL

INTRODUCTION

EAU41070

Congratulations on your purchase of the Yamaha PW50(X). This model is the result of Yamaha’s vast experience in the pro-duction of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reli-ability 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 youhave 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 applicableat the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation ofthe motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to therecommended maintenance schedules and operating instructions contained within this manual.

AN IMPORTANT SAFETY MESSAGE:

�

READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. MAKE SUREYOU UNDERSTAND ALL INSTRUCTIONS.

�

PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MOTORCYCLE.

�

NEVER OPERATE A MOTORCYCLE WITHOUT PROPER TRAINING OR INSTRUCTION.

�

WEIGHT OF THE RIDER SHOULD NOT EXCEED 25 kg (55 lb).

AN IMPORTANT NOTE TO PARENTS:

This motorcycle is not a toy. Before you let your child ride this motorcycle, you should understand the instructions and 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 should supervise their child’suse of the motorcycle at all times. Parents should permit continued use only if they determine that the child has the ability tooperate the motorcycle safely.

INTRODUCTION

Your motorcycle was delivered with an adjustable speed limiter and power reduction plate. Yamaha recommends that allbeginners 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 speedas the beginner becomes more familiar with operating the motorcycle. Parents should decide when to adjust the motorcyclefor more power as their youngster’s riding skills improve. Once the rider can operate with skill at the top speed permitted byadjusting 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 UPONTHE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERA-TOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE.

HE OR SHE SHOULD:

�

OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLEOPERATION.

�

OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.

�

OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.

�

OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHENMADE NECESSARY BY MECHANICAL CONDITIONS.

IMPORTANT MANUAL INFORMATION

EAU41090

Particularly important information is distinguished in this manual by the following notations:

NOTE:

�

This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycleis subsequently sold.

�

Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the mostcurrent product information available at the time of printing, there may be minor discrepancies between your motorcycle

and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to themotorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:


WARNING

EWA10030

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.

WARNING

EWA14350

THIS MOTORCYCLE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS ILLEGAL TO OPER-ATE 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 ARRESTERLAWS AND REGULATIONS. PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERAT-

ING THIS MOTORCYCLE.

*Product and specifications are subject to change without notice.


EAU10200

PW50(X)OWNER’S MANUAL

©2007 by Yamaha Motor Co., Ltd.1st edition, April 2007

All rights reserved.Any reprinting or unauthorized use without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

Printed in Japan.

TABLE OF CONTENTS

SAFETY INFORMATION

...................1-1Safe riding ........................................1-1Location of important labels .............1-4

DESCRIPTION

...................................2-1Left view ...........................................2-1Right view .........................................2-2Controls and instruments..................2-3

INSTRUMENT AND CONTROL FUNCTIONS

........................................3-1Handlebar switch .............................3-1Speed limiter and power reduction

plate .............................................3-1Front brake lever .............................3-2Rear brake lever ..............................3-3Fuel tank cap ...................................3-3Fuel ..................................................3-3Fuel tank breather hose ...................3-52-stroke engine oil ...........................3-5Fuel cock .........................................3-5Starter (choke) lever “

1

” .................3-6Kickstarter ........................................3-6Seat .................................................3-7

PRE-OPERATION CHECKS

...............4-1Pre-operation check list ...................4-2

OPERATION AND IMPORTANT RIDING POINTS

.................................. 5-1Starting and warming up a cold

engine .......................................... 5-1Starting a warm engine ................... 5-1Starting off ....................................... 5-2Acceleration and deceleration ......... 5-2Braking ............................................ 5-2Engine break-in ............................... 5-3Parking ............................................ 5-4

PERIODIC MAINTENANCE AND MINOR REPAIR

.................................. 6-1Owner’s tool kit ................................ 6-1Periodic maintenance chart for the

emission control system .............. 6-2General maintenance and lubrication

chart ............................................. 6-3Checking the spark plug .................. 6-5Removing the power reduction

plate ............................................. 6-6Transmission oil .............................. 6-7Middle and final gear cases ............ 6-8Cleaning the air filter element ......... 6-8Cleaning the spark arrester ............. 6-9Adjusting the carburetor ................ 6-10Adjusting the engine idling

speed ......................................... 6-10Checking the throttle cable free

play ............................................ 6-11Tires .............................................. 6-11

Panel wheels ................................. 6-13Accessories and replacement

parts ........................................... 6-13Adjusting the front and rear brake

lever free play ............................ 6-14Checking the front and rear brake

shoes ......................................... 6-15Checking and lubricating the

cables ........................................ 6-15Checking and lubricating the throttle

grip and cable ............................ 6-16Adjusting the Autolube pump ........ 6-16Lubricating the front and rear brake

levers ......................................... 6-16Checking and lubricating the

centerstand ................................ 6-17Checking the front fork .................. 6-17Checking the steering ................... 6-18Checking the wheel bearings ........ 6-18Front wheel ................................... 6-19Rear wheel .................................... 6-20Troubleshooting ............................ 6-23Troubleshooting chart ................... 6-24

MOTORCYCLE CARE AND STORAGE

........................................... 7-1Matte color caution .......................... 7-1Care ................................................ 7-1Storage ........................................... 7-3

SPECIFICATIONS

............................. 8-1

TABLE OF CONTENTS

CONSUMER INFORMATION

..............9-1Identification numbers .....................9-1

1-1

1

SAFETY INFORMATION

EAU40931

Safe riding

�

Always make pre-operationchecks. Careful checks may helpprevent an accident.

�

This motorcycle is designed foroff-road use only, therefore, it is il-legal to operate it on public streets,roads, or highways, even a dirt orgravel one. Off-road use on publiclands may be illegal. Please checklocal regulations before riding.

�

This motorcycle is designed to car-ry the operator only. No passen-gers.

�

Many accidents involve inexperi-enced operators.

�

Make sure that the operator isqualified and that you only lendyour motorcycle to other quali-fied operators.

�

Know your skills and limits.Staying within your limits mayhelp you to avoid an accident.

�

Many accidents have been causedby error of the motorcycle opera-tor. A typical error made by the op-erator is veering wide on a turndue to EXCESSIVE SPEED or un-

dercornering (insufficient lean an-gle for the speed). Never travelfaster than warranted by condi-tions.

�

Ride cautiously in unfamiliar ar-eas. You may encounter hiddenobstacles that could cause an ac-cident.

�

The posture of the operator is im-portant for proper control. The op-erator should keep both hands onthe handlebar and both feet on theoperator footrests during operationto maintain control of the motorcy-cle.

�

Never ride under the influence ofalcohol 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 thesingle most critical factor in the preven-tion or reduction of head injuries.

�

Always wear an approved helmet.

�

Wear a face shield or goggles.Wind in your unprotected eyescould contribute to an impairment

of vision that could delay seeing ahazard.

�

The use of a jacket, heavy boots,trousers, gloves, etc., is effective inpreventing or reducing abrasionsor lacerations.

�

Never wear loose-fitting clothes,otherwise they could catch on thecontrol levers, footrests, or wheelsand cause injury or an accident.

�

Never touch the engine or exhaustsystem during or after operation.They become very hot and cancause burns. Always wear protec-tive clothing that covers your legs,ankles, and feet.

Modifications

Modifications made to this motorcyclenot approved by Yamaha, or the re-moval of original equipment, may ren-der the motorcycle unsafe for use andmay cause severe personal injury.Modifications may also make your mo-torcycle illegal to use.

Loading and accessories

Adding accessories to your motorcycle

SAFETY INFORMATION

1-2

1

can adversely affect stability and han-dling if the weight distribution of the mo-torcycle is changed. To avoid thepossibility of an accident, use extremecaution when adding accessories toyour motorcycle. Use extra care whenriding a motorcycle that has added ac-cessories. Here are some generalguidelines to follow if adding accesso-ries to your motorcycle:

Loading

�

The weight of the operator mustnot exceed 25 kg (55 lb).

�

Accessory weight should be keptas low and close to the motorcycleas possible. Make sure to distrib-ute the weight as evenly as possi-ble on both sides of the motorcycleto minimize imbalance or instabili-ty.

�

Shifting weights can create a sud-den imbalance. Make sure that ac-cessories are securely attached tothe motorcycle before riding.Check accessory mounts fre-quently.

�

Never attach any large or heavy

items to the handlebar, front fork,or front fender.

AccessoriesGenuine Yamaha accessories havebeen specifically designed for use onthis motorcycle. Since Yamaha cannottest all other accessories that may beavailable, you must personally be re-sponsible for the proper selection, in-stallation and use of non-Yamahaaccessories. Use extreme cautionwhen selecting and installing any ac-cessories.Keep these guidelines in mind formounting accessories in addition tothose provided under “Loading”.

�

Never install accessories or thatwould impair the performance ofyour motorcycle. Carefully inspectthe accessory before using it tomake sure that it does not in anyway reduce ground clearance orcornering clearance, limit suspen-sion travel, steering travel or con-trol operation.

�

Accessories fitted to the handle-bar or the front fork area can

create instability due to improperweight distribution or aerody-namic changes. If accessoriesare added to the handlebar orfront fork area, they must be aslightweight as possible andshould be kept to a minimum.

�

Bulky or large accessories mayseriously affect the stability ofthe motorcycle due to aerody-namic effects. Wind may at-tempt to lift the motorcycle, orthe motorcycle may become un-stable in cross winds.

�

Certain accessories can dis-place the operator from his orher normal riding position. Thisimproper position limits the free-dom of movement of the opera-tor and may limit control ability,therefore, such accessories arenot recommended.

�

Use caution when adding electri-cal accessories. If electrical acces-sories exceed the capacity of themotorcycle’s electrical system anelectric failure could result, whichcould cause a dangerous loss of

SAFETY INFORMATION

1-3

1

engine power.

Gasoline and exhaust gas

�

GASOLINE IS HIGHLY FLAMMA-BLE:

�

Always turn the engine off whenrefueling.

�

Take care not to spill any gaso-line on the engine or exhaustpipe/muffler when refueling.

�

Never refuel while smoking or inthe vicinity of an open flame.

�

Never start the engine or let it runfor any length of time in a closedarea. The exhaust fumes are poi-sonous and may cause loss ofconsciousness and death within ashort time. Always operate yourmotorcycle in an area that has ad-equate ventilation.

�

Always turn the engine off beforeleaving the motorcycle unattend-ed. When parking the motorcycle,note the following:

�

The engine and exhaust pipe/muffler may be hot, therefore,park the motorcycle in a placewhere pedestrians or children

are not likely to touch these hotareas.

�

Do not park the motorcycle on aslope or soft ground, otherwise itmay fall over.

�

Do not park the motorcycle neara flammable source (e.g., a ker-osene heater, or near an openflame), otherwise it could catchfire.

�

When transporting the motorcyclein another vehicle, make sure thatit is kept upright and that the fuelcock is turned to “S” (stop). If themotorcycle should lean over, gas-oline may leak out of the carbure-tor or fuel tank.

�

If you should swallow any gaso-line, inhale a lot of gasoline vapor,or allow gasoline to get into youreyes, see your doctor immediate-ly. If any gasoline spills on yourskin or clothing, immediately washthe affected area with soap andwater and change your clothes.

SAFETY INFORMATION

1-4

1

EAU41970

Location of important labels

Please read the following important labels carefully before operating this vehicle.

For Canada

32

4

1

5

SAFETY INFORMATION

1-5

1

For Canada

1

WARNINGBEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER’SMANUAL AND ALL LABELS.NEVER CARRY A PASSENGER. You increase your risk of losingcontrol if you carry a passenger.NEVER OPERATE THIS VEHICLE ON PUBLIC ROADS. You cancollide 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-A0

2

3

4

AVERTISSEMENTLIRE LE MANUELETIQUETTESNE LapassagerNEVousTOUJOURS

des5PG-2118K-10

DU PROPRIETAIRE AINSI QUE TOUTES LESAVANT D’UTILISER CE VEHICULE.

JAMAIS TRANSPORTER DE PASSAGER. conduite avecaugmente les risques de perte de contrôle.

JAMAIS ROULER SUR DES CHEMINS PUBLICS.pourriez entrer en collision avec un autre véhicule.

PORTER UN CASQUE DE MOTOCYCLISTEAPPROUVE, lunettes et des vêtements de protection.

follows.FRONT :

:REAR3RV-21668-A0

Cold tire normal pressure should be set as

100 kPa,{1.00 kgf/cm2}, 15 psi100 kPa,{1.00 kgf/cm2}, 15 psi

être réglée comme suit.AVANT :

:ARRIERE3RV-21668-B0


La pression des pneus à froid doit normallement

5

SAFETY INFORMATION

1-6

1

Except for Canada

43

5

1 2

SAFETY INFORMATION

1-7

1

Except for Canada

1

WARNINGBEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER’SMANUAL AND ALL LABELS.NEVER CARRY A PASSENGER. You increase your risk of losingcontrol if you carry a passenger.NEVER OPERATE THIS VEHICLE ON PUBLIC ROADS. You cancollide 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-A0

2

Before you operate this vehicle, read the owner’s manual.

5PA-21568-00

Prima di usare il veicolo, leggete il manuale di istruzioni.Lire le manuel du propriétaire avant d’utiliser ce véhicule.Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.Antes de conducir este vehículo, lea el Manual del Propietario.

3

4

follows.FRONT :

:REAR3RV-21668-A0

Cold tire normal pressure should be set as


5

SAFETY INFORMATION

1-8

1

2-1

1

2

3

4

5

6

7

8

9

DESCRIPTION

EAU10410

Left view

1 2 3

45

1. Fuel cock (page 3-5)2. Throttle stop screw (page 6-10)3. Air filter element (page 6-8)4. Kickstarter (page 3-6)5. Centerstand (page 6-17)

DESCRIPTION

2-2

2

3

4

5

6

7

8

9

EAU10420

Right view

31 2 4

1. Spark arrester (page 6-9)2. Seat (page 3-7)3. Transmission oil filler cap (page 6-7)4. 2-stroke engine oil tank (page 3-5)

DESCRIPTION

2-3

1

2

3

4

5

6

7

8

9

EAU10430

Controls and instruments

1 2

7

3 4 5

6

1. Rear brake lever (page 3-3)2. Starter (choke) lever (page 3-6)3. 2-stroke engine oil tank cap (page 3-5)4. Right handlebar switch (page 3-1)5. Front brake lever (page 3-2)6. Throttle grip (page 6-11)7. Fuel tank cap (page 3-3)

3-1

2

3

4

5

6

7

8

9


EAU40660

Handlebar switch

EAU40673

Engine stop 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 beforestarting off. Set this switch to “OFF” tostop the engine.

NOTE:

�

The engine cannot be started withthis switch set to the “RUN” posi-tion.

�

The engine speed is limited whilethis switch is set to the “START”position, therefore the motorcycle

cannot be ridden in that switch po-

sition.

EAU41041

Speed limiter and power reduction plate

Your motorcycle was delivered with anadjustable speed limiter and a powerreduction plate. The speed limiterkeeps the throttle from fully opening,even when the throttle grip is turned tothe maximum. The power reductionplate is installed in the exhaust mani-fold to limit the amount of power avail-able while they learn.

Speed limiter

1. Loosen the locknut.2. To increase the maximum engine

power available and the maximumspeed of the motorcycle, turn theadjusting screw in direction (a). Todecrease the maximum enginepower available and the maximumspeed of the motorcycle, turn theadjusting screw in direction (b).

1. Engine stop switch “OFF/RUN/START”

1


3-2

1

2

3

4

5

6

7

8

9

3. Tighten the locknut.

NOTE:

The adjusting range of the speed limiterscrew is from the fully turned-in positionto 7 mm (0.28 in) turned out. When the

screw is turned out to 7 mm (0.28 in),the throttle grip can only be opened ap-proximately halfway. If more power isrequired, please consult a Yamaha

dealer.

WARNING

EWA14630

Improper adjustment of the speedlimiter could cause improper throttleoperation. You could lose control,have an accident or be injured. Donot turn the adjusting screw outmore than 7 mm (0.28 in) before con-sulting a Yamaha dealer. Alwaysmake sure the throttle cable freeplay is adjusted to 1.5–3.5 mm

(0.06–0.14 in). (See page 6-11.)

Power reduction plate

Once the rider can operate with skill atthe top speed permitted by adjustingthe speed limiter alone, the power re-duction plate can be removed. (Seepage 6-6.)

EAU12900

Front brake lever

The front brake lever is located on theright handlebar grip. To apply the frontbrake, pull this lever toward the handle-bar grip.

1. Locknut2. Adjusting screw

1. No more than 7 mm (0.28 in)

1

(a)

(b)

2

1

1. Front brake lever

1


3-3

2

3

4

5

6

7

8

9

EAU12950

Rear brake lever

The rear brake lever is located on theleft handlebar grip. To apply the rearbrake, pull this lever toward the handle-bar grip.

EAU13181

Fuel tank cap

To remove the fuel tank cap, turn itcounterclockwise, and then pull it off.To install the fuel tank cap, insert it intothe tank opening, and then turn it clock-wise.

WARNING

EWA11090

Make sure that the fuel tank cap is

properly closed before riding.

EAU13220

Fuel

Make sure that there is sufficient fuel inthe tank. When refueling, be sure to in-sert the pump nozzle into the fuel tankfiller hole and to fill the tank to the bot-tom of the filler tube as shown.

WARNING

EWA10880

�

Do not overfill the fuel tank, oth-erwise it may overflow when thefuel warms up and expands.

�

Avoid spilling fuel on the hot en-

gine.

1. Rear brake lever

1

1. Fuel tank cap

1

1. Fuel tank filler tube2. Fuel level

21


3-4

1

2

3

4

5

6

7

8

9

CAUTION:

ECA10070

Immediately wipe off spilled fuelwith a clean, dry, soft cloth, sincefuel may deteriorate painted surfac-

es or plastic parts.

EAU41980

For Canada

CAUTION:

ECA15590

Use only unleaded gasoline. The useof leaded gasoline will cause severedamage 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 researchoctane number of 91 or higher. If

knocking (or pinging) occurs, use agasoline of a different brand or premi-um unleaded fuel. Use of unleaded fuelwill extend spark plug life and reducemaintenance cost.

Gasohol

There are two types of gasohol: gaso-hol containing ethanol and that contain-ing methanol. Gasohol containingethanol can be used if ethanol contentdoes not exceed 10%. Gasohol con-taining methanol is not recommendedby Yamaha because it can cause dam-age to the fuel system or vehicle perfor-mance problems.

Except for Canada

CAUTION:

ECA15590

Use only unleaded gasoline. The use

of leaded gasoline will cause severedamage 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 of91 or higher. If knocking (or pinging) oc-curs, use a gasoline of a different brandor premium unleaded fuel. Use of un-leaded fuel will extend spark plug lifeand reduce maintenance costs.

Recommended fuel:

REGULAR UNLEADED GASOLINE ONLY

Fuel tank capacity:

2.0 L (0.53 US gal) (0.44 Imp.gal)

Recommended fuel:

For Europe: REGULAR UNLEADED GASOLINE ONLYExcept for Canada and Europe: UN-LEADED GASOLINE ONLY

Fuel tank capacity:

2.0 L (0.53 US gal) (0.44 Imp.gal)


3-5

2

3

4

5

6

7

8

9

EAU13412

Fuel tank breather hose

Before operating the motorcycle:

�

Check the fuel tank breather hoseconnection.

�

Check the fuel tank breather hosefor cracks or damage, and replaceit if damaged.

�

Make sure that the fuel tankbreather hose is not blocked, andclean it if necessary.

EAU13452

2-stroke engine oil

Make sure that there is sufficient2-stroke engine oil in the oil tank. Addthe recommended 2-stroke engine oilas necessary.

NOTE:

Make sure that the 2-stroke engine oil

tank cap is properly installed.

EAU40701

Fuel cock

The fuel cock supplies fuel from thetank to the carburetor while filtering it al-so.The fuel cock has two positions:

S (stop)

With the lever in this position, fuel willnot flow. Always return the lever to thisposition when the engine is not running.

1. Fuel tank breather hose

1

1. 2-stroke engine oil tank cap2. Minimum level mark

Recommended oil:

See page 8-1.

Oil quantity:

0.30 L (0.32 US qt) (0.26 Imp.qt)

2

1

1. Arrow mark pointing to “S” (stop)

1


3-6

1

2

3

4

5

6

7

8

9

O (on)

With the lever in this position, fuel flowsto the carburetor. Normal riding is donewith the lever in this position.

EAU13590

Starter (choke) lever “ ”

Starting a cold engine requires a richerair-fuel mixture, which is supplied bythe starter (choke).Move the lever in direction (a) to turn onthe starter (choke).Move the lever in direction (b) to turn offthe starter (choke).

EAU13680

Kickstarter

To start the engine, fold out the kick-starter lever, move it down lightly withyour foot until the gears engage, andthen push it down smoothly but force-fully.

1. Arrow mark pointing to “O” (on)

1

1. Starter (choke) lever “ ”

1

(a)

(b)

1. Kickstarter

1


3-7

2

3

4

5

6

7

8

9

EAU40920

Seat

To remove the seat

1. Remove the mudguard by remov-ing the bolts and washers.

2. Pull the seat off.

To install the seat

1. Insert the projection on the front ofthe seat into the seat holder asshown.

2. Place the seat in the original posi-tion.

3. Install the mudguard by installingthe washers and bolts.

NOTE:

Make sure that the seat is properly se-

cured before riding.

1. Bolt2. Mudguard

12

1. Seat holder2. Projection

1 2

4-1

1

2

3

4

5

6

7

8

9


EAU15593

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or lossof tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-tion, to check the following points before each ride.

NOTE:

Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short

time; and the added safety it assures is more than worth the time involved.

WARNING

EWA11150

If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating

the vehicle.


4-2

2

3

4

5

6

7

8

9

EAU15605

Pre-operation check list

ITEM CHECKS PAGE

Fuel

�

Check fuel level in fuel tank.

�

Refuel if necessary.

�

Check fuel line for leakage.3-3

2-stroke engine oil

�

Check oil level in oil tank.

�

If necessary, add recommended oil to specified level.

�

Check vehicle for oil leakage.3-5

Middle and final gear cases

�

Check vehicle for grease leakage. 6-8

Front brake

�

Check operation.

�

Lubricate cable if necessary.

�

Check lever free play.

�

Adjust if necessary.

6-14, 6-15

Rear brake

�

Check operation.

�

Lubricate cable if necessary.

�

Check lever free play.

�

Adjust if necessary.

6-14, 6-15

Throttle grip

�

Make sure that operation is smooth.

�

Check cable free play.

�

If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.

6-11, 6-16

Control cables

�


�

Lubricate if necessary.6-15

Wheels and tires

�

Check for damage.

�

Check tire condition and tread depth.

�

Check air pressure.

�

Correct if necessary.

6-11, 6-13

Brake levers

�


�

Lubricate lever pivoting points if necessary.6-16

Centerstand

�


�

Lubricate pivot if necessary.6-17


4-3

1

2

3

4

5

6

7

8

9

Chassis fasteners

�

Make sure that all nuts, bolts and screws are properly tightened.

�

Tighten if necessary.—

Engine stop switch

�

Check operation. 3-1

ITEM CHECKS PAGE

5-1

2

3

4

5

6

7

8

9


EAU40771

WARNING

EWA14531

�

This model is designed foroff-road use only. Become thor-oughly familiar with all operat-ing controls and their functionsbefore riding. Consult a Yamahadealer regarding any control orfunction that you do not thor-oughly understand.

�

Never start the engine or oper-ate it in a closed area for anylength of time. Exhaust fumesare poisonous, and inhalingthem can cause loss of con-sciousness and death within ashort time. Always make surethat there is adequate ventila-

tion.

EAU40883

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) on and

completely close the throttle. (Seepage 3-6.)

4. While applying the front or rearbrake, start the engine by pushingthe kickstarter lever down.

5. After starting the engine, move thestarter (choke) back halfway.

CAUTION:

ECA11130

For maximum engine life, alwayswarm the engine up before startingoff. Never accelerate hard when the

engine is cold!

6. When the engine is warm, turn thestarter (choke) off and set the en-gine stop switch to “RUN”.

NOTE:

The engine is warm when it respondsnormally to the throttle with the starter

(choke) turned off.

EAU16660

Starting a warm engine

Follow the same procedure as for start-ing a cold engine with the exceptionthat the starter (choke) is not requiredwhen the engine is warm. Instead, startthe engine with the throttle slightlyopen.

NOTE:

If the engine does not start after sever-al kicks, try again with the throttle 1/4

to 1/2 open.


5-2

1

2

3

4

5

6

7

8

9

EAU41000

Starting off NOTE:

Before starting off, allow the engine to

warm up.

1. While applying the rear brake le-ver, push the motorcycle off thecenterstand.

2. Completely close the throttle.3. Set the engine stop switch to

“RUN”.4. Check for oncoming off-road vehi-

cles, and then slowly turn the throt-tle grip in order to take off.

EAU16780

Acceleration and deceleration

The speed can be adjusted by openingand closing the throttle. To increase thespeed, turn the throttle grip in direction(a). To reduce the speed, turn the throt-tle grip in direction (b).

EAU41011

Braking

1. Close the throttle completely.2. Apply both front and rear brakes

simultaneously while gradually in-creasing the pressure.

Front

(a)

(b)


5-3

2

3

4

5

6

7

8

9

Rear

WARNING

EWA14571

�

Avoid braking hard or suddenly(especially when leaning over toone side), otherwise the motor-cycle may skid or overturn.

�

Keep in mind that braking onwet surfaces is much more diffi-cult.

�

Ride slowly down a hill, as brak-ing downhill can be very diffi-

cult.

EAU42030

Engine break-in

There is never a more important periodin the life of your engine than the first 5hours of riding. It is also important to ac-custom the rider to the motorcycle dur-ing this time. Please read the followinginformation carefully.Since the engine is brand new, do notput an excessive load on it for the first 5hours of operation. The various parts inthe engine wear and polish themselvesto the correct operating clearances.During this period, prolonged full-throt-tle operation or any condition that mightresult in engine overheating must beavoided. However, momentaryfull-throttle operation under load (i.e.,two to three seconds maximum) doesnot harm the engine. Each full-throttleacceleration should be followed with asubstantial rest period for the engine.To allow the engine to cool down fromthe temporary buildup of heat, cruise ata lower engine speed.After the first 5 hours of operation, thor-oughly check the motorcycle for looseparts, oil leakage and any other prob-lems. Be sure to inspect and make ad-

justments thoroughly, especiallycables. In addition, check all fittings andfasteners for looseness, and tighten ifnecessary.

CAUTION:

ECA10270

If any engine trouble should occurduring the engine break-in period,immediately have a Yamaha dealer

check the vehicle.


5-4

1

2

3

4

5

6

7

8

9

EAU40721

Parking

When parking, stop the engine, andthen turn the fuel cock lever to “S”(stop).

WARNING

EWA10310

�

Since the engine and exhaustsystem can become very hot,park in a place where pedestri-ans or children are not likely totouch them.

�

Do not park on a slope or on softground, otherwise the vehicle

may overturn.

6-1

2

3

4

5

6

7

8

9


EAU41950

Safety is an obligation of the owner. Pe-riodic inspection, adjustment and lubri-cation will keep your vehicle in thesafest and most efficient condition pos-sible. The most important points of mo-torcycle inspection, adjustment, andlubrication are explained on the follow-ing pages.

Maintenance, replacement, or repairof the emission control devices andsystems may be performed by anyrepair establishment or individualthat is certified (if applicable).

WARNING

EWA10320

If you are not familiar with mainte-nance work, have a Yamaha dealer

do it for you.

EAU17320

Owner’s tool kit

The service information included in thismanual and the tools provided in theowner’s tool kit are intended to assistyou in the performance of preventivemaintenance and minor repairs. How-ever, additional tools such as a torquewrench may be necessary to performcertain maintenance work correctly.

NOTE:

If you do not have the tools or experi-ence required for a particular job, have

a Yamaha dealer perform it for you.

WARNING

EWA10350

Modifications not approved byYamaha may cause loss of perfor-mance and render the vehicle un-safe for use. Consult a Yamahadealer before attempting any chang-

es.


6-2

1

2

3

4

5

6

7

8

9

EAU41741

Periodic maintenance chart for the emission control system NOTE:

�

From 18 months, repeat the maintenance intervals starting from 6 months.

�

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical

skills.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIALTHEREAFTER

EVERY

1month

3 months

6 months

6 months

12 months

1 * Fuel lineCheck fuel hoses for cracks or damage.Replace if necessary.

2 Spark plugCheck condition.Adjust gap and clean.Replace if necessary.

3 Air filter elementClean with solvent.Replace if necessary.

4 * CarburetorCheck engine idling speed and starter operation.Adjust if necessary.Clean.

5 *Cylinder head and exhaust system

Check for leakage.Tighten if necessary.Decarbonize if necessary.

6 * Spark arrester Clean.


6-3

2

3

4

5

6

7

8

9

EAU41752

General maintenance and lubrication chart


INITIALTHEREAFTER

EVERY

1month

3months

6months

6months

12 months

1 * Front brakeCheck operation.Adjust brake lever free play.Replace brake shoes. Whenever worn to the limit

2 * Rear brakeCheck operation.Adjust brake lever free play.Replace brake shoes. Whenever worn to the limit

3 * WheelsCheck runout and for damage.Replace if necessary.

4 * Tires

Check tread depth and for damage.Replace if necessary.Check air pressure.Correct if necessary.

5 * Wheel bearingsCheck bearings for smooth operation.Replace if necessary.

6 * Steering bearingsCheck bearing assemblies for looseness.Moderately repack with lithium-soap-based grease every 2 years.

7 *Middle and final gear cases

Check for grease leakage.Check gears for damage and wear.Lubricate gears with lithium-soap-based grease.

Every 2 years

8 * Chassis fastenersCheck all chassis fitting and fasteners.Correct if necessary.

9 * Autolube pumpCheck operation.Correct if necessary.Bleed.


6-4

1

2

3

4

5

6

7

8

9

NOTE:

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

10 * Transmission oilCheck for oil leakage.Correct if necessary.Change.

11 *Front and rear brake lever pivot

Apply lithium-soap-based grease (all-purpose grease) lightly.

12 * Centerstand pivotCheck operation.Apply lithium-soap-based grease (all-purpose grease) lightly.

13 *Shock absorber assemblies

Check operation and for oil leakage.Replace if necessary.

14 * Control cableApply Yamaha chain and cable lube or engine oil 10W-30 lightly.

15 *Throttle grip housing and cable

Check operation and free play.Apply Yamaha chain and cable lube or engine oil 10W-30 lightly.


INITIALTHEREAFTER

EVERY

1month

3months

6months

6months

12 months


6-5

2

3

4

5

6

7

8

9

EAU19603

Checking the spark plug

The spark plug is an important enginecomponent, which is easy to check.Since heat and deposits will cause anyspark plug to slowly erode, the sparkplug should be removed and checkedin 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.

2. Remove the spark plug as shown,with the spark plug wrench includ-ed in the owner’s tool kit.

To check the spark plug

1. Check that the porcelain insulatoraround the center electrode of thespark plug is a medium-to-light tan(the ideal color when the vehicle isridden normally).

NOTE:

If the spark plug shows a distinctly dif-ferent color, the engine could be oper-ating improperly. Do not attempt todiagnose such problems yourself. In-stead, have a Yamaha dealer check

the vehicle.

2. Check the spark plug for electrodeerosion and excessive carbon orother deposits, and replace it if

necessary.

To install the spark plug

1. Measure the spark plug gap with awire thickness gauge and, if nec-essary, adjust the gap to specifica-tion.

2. Clean the surface of the spark plug

1. Spark plug cap

1

1. Spark plug wrench

1

Specified spark plug:

NGK/BP4HS (AUS)(NZL)NGK/BPR4HS (AUT)(BEL)(CAN)(CHE)(DEU)(DNK)(ESP)(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)(SWE)(ZAF)DENSO/W14FPL (AUS)(NZL)

1. Spark plug gap

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

1


6-6

1

2

3

4

5

6

7

8

9

gasket and its mating surface, andthen wipe off any grime from thespark plug threads.

3. Install the spark plug with thespark plug wrench, and then tight-en it to the specified torque.

NOTE:

If a torque wrench is not available wheninstalling a spark plug, a good estimateof the correct torque is 1/4–1/2 turnpast finger tight. However, the sparkplug should be tightened to the speci-

fied torque as soon as possible.

4. Install the spark plug cap.

EAU41100

Removing the power reduction plate

To obtain full engine performance ca-pability, removing the power reductionplate is required.

WARNING

EWA14580

Always let the exhaust system coolprior to touching exhaust compo-

nents.

1. Remove the exhaust manifold byremoving the bolts.

2. Remove the gasket.3. Remove the power reduction

plate.

NOTE:

Store the power reduction plate with theowner’s manual so that it is readilyavailable whenever you want to reduce

the engine power.

4. Install the exhaust manifold by in-stalling the bolts.

Tightening torque:

Spark plug:20 Nm (2.0 m·kgf, 14.5 ft·lbf)

1. Exhaust manifold bolt

1

1. Exhaust manifold2. Gasket3. Power reduction plate

Tightening torque:

Exhaust manifold bolt:8.5 Nm (0.9 m·kgf, 6.1 ft·lbf)

1

2

3


6-7

2

3

4

5

6

7

8

9

EAU40891

Transmission oil

The transmission oil must be checkedfor oil leakage before each ride. If anyleakage is found, have a Yamaha deal-er check and repair the motorcycle. Inaddition, the transmission oil must bechanged at the intervals specified in theperiodic maintenance and lubricationchart.

1. Place the motorcycle on the cen-terstand.

2. Place an oil pan under the trans-mission to collect the used oil.

3. Remove the oil filler cap and drainbolt to drain the oil from the trans-mission.

4. Install the transmission oil drainbolt, and then tighten it to the spec-ified torque.

5. Add the specified amount of therecommended transmission oil,and then install and tighten the oilfiller cap.

CAUTION:

ECA10452

�

In order to prevent clutch slip-page (since the transmission oilalso lubricates the clutch), donot mix any chemical additives.Do not use oils with a dieselspecification of “CD” or oils of ahigher quality than specified. Inaddition, do not use oils labeled“ENERGY CONSERVING II” orhigher.

�

Make sure that no foreign mate-

rial enters the transmission.

6. Start the engine, and then let it idlefor several minutes while checkingthe transmission for oil leakage. Ifoil is leaking, immediately turn theengine off and check for the cause.

1. Transmission oil filler cap

1

1. Transmission oil drain bolt

Tightening torque:

Transmission oil drain bolt:14 Nm (1.4 m·kgf, 10.1 ft·lbf)

Recommended transmission oil:

See page 8-1.

Oil change quantity:

0.30 L (0.32 US qt) (0.26 Imp.qt)

1


6-8

1

2

3

4

5

6

7

8

9

EAU41711

Middle and final gear cases

The middle and final gear cases mustbe checked for grease leakage beforeeach ride. If any leakage is found, havea Yamaha dealer check and repair themotorcycle. In addition, have aYamaha dealer check and lubricate themiddle and final gears at the intervalsspecified in the periodic maintenanceand lubrication chart.

EAU40901

Cleaning the air filter element

The air filter element should be cleanedat the intervals specified in the periodicmaintenance and lubrication chart.Clean the air filter element more fre-quently if you are riding in unusuallywet or dusty areas.

1. Remove the seat. (See page 3-7.)2. Remove the air filter case cover by

removing the screw.

3. Pull the sponge material out, cleanit with solvent, and then squeezethe remaining solvent out.

4. Apply oil of the recommended typeto the entire surface of the spongematerial, and then squeeze the ex-cess oil out.

NOTE:

The sponge material should be wet but

1. Air filter case cover2. Screw

2

1

1. Sponge material

1


6-9

2

3

4

5

6

7

8

9

not dripping.

5. Insert the sponge material into theair filter case.

CAUTION:

ECA15620

�

Make sure that the sponge ma-terial is properly seated in theair filter case.

�

The engine should never be op-erated without the sponge mate-rial installed, otherwise thepiston(s) and/or cylinder(s) may

become excessively worn.

6. Install the air filter case cover by in-stalling the screw.

7. Install the seat.

EAU41220

Cleaning the spark arrester

The spark arrester should be cleanedat the intervals specified in the periodicmaintenance and lubrication chart.

WARNING

EWA10980

�

Always let the exhaust systemcool prior to touching exhaustcomponents.

�

Do not start the engine when

cleaning the exhaust system.

NOTE:

Make sure to select a well-ventilatedarea free of combustible materials to

clean the spark arrester.

1. Remove the tailpipe by removingthe screw, and then pulling it out ofthe muffler.

2. Tap the tailpipe lightly, and thenuse a wire brush to remove anycarbon deposits from the spark ar-rester portion of the tailpipe and in-side of the tailpipe housing.

Recommended oil:

Yamaha foam air filter oil or other quality foam air filter oil

1. Tailpipe2. Screw3. Muffler

12

3


6-10

1

2

3

4

5

6

7

8

9

3. Insert the tailpipe into the muffler,and then install and tighten thescrew.

NOTE:

Make sure to align the screw hole when

inserting the tailpipe.

EAU39930

Adjusting the carburetor

The carburetor is an important part ofthe engine and requires very sophisti-cated adjustment. Therefore, most car-buretor adjustments should be left to aYamaha dealer, who has the neces-sary professional knowledge and expe-rience. The adjustment described in thefollowing section, however, may be ser-viced by the owner as part of routinemaintenance.

CAUTION:

ECA10550

The carburetor has been set and ex-tensively tested at the Yamaha fac-tory. Changing these settingswithout sufficient technical knowl-edge may result in poor perfor-

mance of or damage to the engine.

EAU21360

Adjusting the engine idling speed

The engine idling speed must bechecked and, if necessary, adjusted asfollows at the intervals specified in theperiodic maintenance and lubricationchart.

NOTE:

A diagnostic tachometer is needed to

make this adjustment.

1. Attach the tachometer to the sparkplug lead.

2. Start the engine and warm it upfor several minutes at 1000–2000r/min while occasionally revving itto 4000–5000 r/min.

NOTE:

The engine is warm when it quickly re-

sponds to the throttle.

3. Check the engine idling speedand, if necessary, adjust it to spec-ification by turning the throttle stopscrew. To increase the engineidling speed, turn the screw in di-rection (a). To decrease the en-gine idling speed, turn the screw in

1. Spark arrester

1


6-11

2

3

4

5

6

7

8

9

direction (b).

NOTE:

If the specified idling speed cannot beobtained as described above, have a

Yamaha dealer make the adjustment.

EAU21382

Checking the throttle cable free play

The throttle cable free play should mea-sure 1.5–3.5 mm (0.06–0.14 in) at thethrottle grip. Periodically check thethrottle cable free play and, if neces-sary, have a Yamaha dealer adjust it.

EAU40910

Tires

To maximize the performance, durabil-ity, and safe operation of your motorcy-cle, note the following points regardingthe specified tires.

Tire air pressure

The tire air pressure should be checkedand, if necessary, adjusted before eachride.

WARNING

EWA14380

�

The tire air pressure must bechecked and adjusted on coldtires (i.e., when the temperatureof the tires equals the ambienttemperature).

�

The tire air pressure must be ad-justed in accordance with theweight of the rider, the ridingspeed, and the riding condi-

tions.

1. Throttle stop screw

Engine idling speed:

1650–1750 r/min

1

(a)(b)

1. Throttle cable free play

1

Standard tire air pressure:

Front:100 kPa (15 psi) (1.00 kgf/cm

2

)Rear:

100 kPa (15 psi) (1.00 kgf/cm

2

)


6-12

1

2

3

4

5

6

7

8

9

Tire inspection

The tires must be checked before eachride. If the center tread depth reachesthe specified limit, if the tire has a nail orglass fragments in it, or if the sidewall iscracked, have a Yamaha dealer re-place the tire immediately.

Tire information

This motorcycle is equipped with panelwheels and tube tires.

WARNING

EWA10460

�

The front and rear tires shouldbe of the same make and de-sign, otherwise the handlingcharacteristics of the vehiclecannot be guaranteed.

�

After extensive tests, only thetires listed below have been ap-proved for this model by

Yamaha Motor Co., Ltd.

WARNING

EWA14390

�

Have a Yamaha dealer replaceexcessively worn tires. Operat-ing the motorcycle with exces-

sively worn tires decreasesriding stability and can lead toloss of control.

�

The replacement of allwheel-and brake-related parts,including the tires, should beleft to a Yamaha dealer, who hasthe necessary professionalknowledge and experience.

�

It is not recommended to patcha punctured tube. If unavoid-able, however, patch the tubevery carefully and replace it assoon as possible with a

high-quality product.

1. Tire sidewall2. Tire tread depth

Minimum tire tread depth (front and rear):

4.0 mm (0.16 in)

1

2

Front tire:

Size:2.50-10 4PR

Manufacturer/model:BRIDGESTONE/KNOBBYIRC/KNOBBY

Rear tire:

Size:2.50-10 4PR

Manufacturer/model:BRIDGESTONE/KNOBBYIRC/KNOBBY


6-13

2

3

4

5

6

7

8

9

EAU40780

Panel wheels

WARNING

EWA10610

The wheels on this model are not de-signed for use with tubeless tires.Do not attempt to use tubeless tires

on this model.

To maximize the performance, durabil-ity, and safe operation of your motorcy-cle, note the following points regardingthe specified wheels.

�

The wheel rims should be checkedfor cracks, bends, warpage ordamage before each ride. If anydamage is found, have a Yamahadealer replace the wheel. Do notattempt even the smallest repair tothe wheel. A deformed or crackedwheel must be replaced.

�

The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced. Anunbalanced wheel can result inpoor performance, adverse han-dling characteristics, and a short-ened tire life.

�

Ride conservatively after changing

a tire since the tire must seat itselfon the rim properly. Failure to al-low proper seating may cause tirefailure, which may result in dam-age to the motorcycle and injury tothe rider.

EAU40431

Accessories and replacement parts

WARNING

EWA14481

The accessories or replacementparts you choose for your vehicleshould be designed specifically forthis model, and they must be se-curely mounted to maintain the in-herent stability of the originaldesign. Genuine Yamaha Parts andAccessories are designed and test-ed to be compatible with your vehi-cle. Yamaha recommends the use ofGenuine Yamaha Parts and Acces-sories before making a purchase.Use of non-Yamaha-approved ac-cessories or replacement parts maycause loss of handling stability andriding safety. Since Yamaha cannotcontrol the quality of accessories orparts manufactured by other compa-nies, Yamaha cannot be held liablefor any consequences caused bythe use of items which have not

been approved by Yamaha.


6-14

1

2

3

4

5

6

7

8

9

EAU22151

Adjusting the front and rear brake lever free play

Front

Rear

The front and rear brake lever free playshould be measured at the positions asshown.

Periodically check the front and rearbrake lever free play and, if necessary,adjust them as follows.To increase the brake lever free play,turn the adjusting nut at the brake shoeplate in direction (a). To decrease thebrake lever free play, turn the adjustingnut in direction (b).

Front

Rear

WARNING

EWA10650

If proper adjustment cannot be ob-tained as described, have a Yamaha

dealer make this adjustment.

1. Front brake lever free play

1. Rear brake lever free play

1

1

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)

1. Brake lever free play adjusting nut

1

(a)

(b)

1. Brake lever free play adjusting nut

1

(a)

(b)


6-15

2

3

4

5

6

7

8

9

EAU41052

Checking the front and rear brake shoes

The front and rear brake shoes must bechecked for wear at the intervals spec-ified in the periodic maintenance andlubrication chart.

NOTE:

The wheels must be removed to checkbrake shoe lining thickness.

�

To remove the front wheel: Seepage 6-19.

�

To remove the rear wheel: See

page 6-20.

Front

Rear

If the lining thickness of a brake shoe isless than 1.5 mm (0.06 in), have aYamaha dealer replace the brakeshoes as a set.

NOTE:

Be sure to measure the brake lining at

the thinnest portion.

EAU41840

Checking and lubricating the cables

The operation of all control cables andthe condition of the cables should bechecked before each ride, and the ca-bles and cable ends should be lubricat-ed if necessary. If a cable is damagedor does not move smoothly, have aYamaha dealer check or replace it.

WARNING

EWA10710

Damage to the outer housing of ca-bles may result in internal rustingand cause interference with cablemovement. Replace damaged ca-bles as soon as possible to prevent

unsafe conditions.

Recommended lubricant:

Yamaha Chain and Cable Lube or engine oil SAE 10W-30 (API SE)


6-16

1

2

3

4

5

6

7

8

9

EAU23111

Checking and lubricating the throttle grip and cable

The operation of the throttle grip shouldbe checked before each ride. In addi-tion, the cable should be lubricated atthe intervals specified in the periodicmaintenance chart.

EAU23120

Adjusting the Autolube pump

The Autolube pump is a vital and so-phisticated component of the engine,which must be adjusted by a Yamahadealer at the intervals specified in theperiodic maintenance and lubricationchart.

EAU43630

Lubricating the front and rear brake levers

The pivoting points of the front and rearbrake levers must be lubricated at theintervals specified in the periodic main-tenance and lubrication chart.


Lithium-soap-based grease (all-pur-pose grease)


6-17

2

3

4

5

6

7

8

9

EAU23191

Checking and lubricating the centerstand

The operation of the centerstandshould be checked before each ride,and the pivots and metal-to-metal con-tact surfaces should be lubricated ifnecessary.

WARNING

EWA11300

If the centerstand does not move upand down smoothly, have a Yamaha

dealer check or repair it.

EAU23271

Checking the front fork

The condition and operation of the frontfork must be checked as follows at theintervals specified in the periodic main-tenance and lubrication chart.

To check the condition

WARNING

EWA10750

Securely support the vehicle so that

there is no danger of it falling over.

Check the inner tubes for scratches,damage and excessive oil leakage.

To check the operation

1. Place the vehicle on a level sur-face and hold it in an upright posi-tion.

2. While applying the front brake,push down hard on the handlebarsseveral times to check if the frontfork compresses and reboundssmoothly.

CAUTION:

ECA10590

If any damage is found or the frontfork does not operate smoothly,have a Yamaha dealer check or re-

pair it.

1. Centerstand


Lithium-soap-based grease (all-pur-pose grease)


6-18

1

2

3

4

5

6

7

8

9

EAU23280

Checking the steering

Worn or loose steering bearings maycause danger. Therefore, the operationof the steering must be checked as fol-lows at the intervals specified in the pe-riodic maintenance and lubricationchart.

1. Place a stand under the engine toraise the front wheel off theground.

WARNING

EWA10750

Securely support the vehicle so that

there is no danger of it falling over.

2. Hold the lower ends of the frontfork legs and try to move them for-ward and backward. If any freeplay can be felt, have a Yamahadealer check or repair the steering.

EAU23290

Checking the wheel bearings

The front and rear wheel bearings mustbe checked at the intervals specified inthe periodic maintenance and lubrica-tion chart. If there is play in the wheelhub or if the wheel does not turnsmoothly, have a Yamaha dealer checkthe wheel bearings.


6-19

2

3

4

5

6

7

8

9

EAU24360

Front wheel

EAU41021

To remove the front wheel

WARNING

EWA10820

�

It is advisable to have a Yamahadealer service the wheel.

�

Securely support the motorcy-cle so that there is no danger of

it falling over.


2. Disconnect the brake cable at thewheel by removing the brake leverfree play adjusting nut, then re-moving the cable from the brakecamshaft lever and brake shoeplate.

3. Remove the axle nut and washer.4. Pull the wheel axle out, and then

remove the wheel.

EAU41031

To install the front wheel

1. Install the brake shoe plate into thewheel hub as shown.

2. Lift the wheel up between the forklegs.

NOTE:

Make sure that the slot in the brakeshoe plate fits over the retainer on the

fork leg.

1. Brake lever free play adjusting nut2. Brake camshaft lever3. Washer4. Axle nut5. Brake cable

1. Wheel axle

5

1

2

3 4

1


6-20

1

2

3

4

5

6

7

8

9

3. Insert the wheel axle from the rightside.

4. Install the washer and axle nut,and then tighten the axle nut to thespecified torque.

5. Connect the brake cable at thewheel hub, and then install thebrake cable free play adjusting nut.

6. Adjust the brake lever free play.(See page 6-14.)

7. Take the motorcycle off the center-stand so that the front wheel is onthe ground.

8. Push down hard on the handlebarseveral times to check for properfork operation.

EAU25080

Rear wheel

EAU41081

To remove the rear wheel

WARNING

EWA10820

�

It is advisable to have a Yamahadealer service the wheel.

�

Securely support the motorcy-cle so that there is no danger of

it falling over.


2. Remove the seat. (See page 3-7.)

WARNING

EWA14580

Always let the exhaust system coolprior to touching exhaust compo-

nents.

3. Remove the muffler bolt andwashers.

1. Retainer

Tightening torque:

Axle nut:40 Nm (4.0 m·kgf, 28.9 ft·lbf)

1


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2

3

4

5

6

7

8

9

4. Slide the spring clamp down, andthen remove the muffler.

5. Remove the exhaust chamber boltand washers.

6. Remove the exhaust manifoldbolts, and then remove the ex-haust chamber.

7. Remove the right-side rear shockabsorber mounting bolt and thentilt the rear shock absorber upwardas shown.

8. Remove the axle nut while apply-ing the rear brake.

9. Remove the rear arm by removingthe nuts and washers.

1. Muffler2. Washer3. Muffler bolt4. Spring clamp

1. Exhaust chamber2. Exhaust chamber bolt3. Washer

31 2

4

2

1

3

1. Exhaust manifold bolt

1

1. Rear shock absorber mounting bolt

1. Axle nut

1

1


6-22

1

2

3

4

5

6

7

8

9

10. Pull the wheel to the right to sepa-rate it from the final gear case, andthen remove the wheel.

EAU41521

To install the rear wheel

1. Apply a light coating of lithi-um-soap-based grease to thesplines of the final gear case andwheel hub.

2. Install the wheel by inserting it intothe wheel hub.

3. Install the rear arm by installing thewashers and nuts.

4. Install the axle nut.5. Install the right-side rear shock ab-

sorber by installing the mountingbolt.

6. While applying the rear brake,tighten the axle nut to the specifiedtorque.

7. Tighten the rear arm nuts and rearshock absorber mounting bolt tothe specified torques.

8. Install the exhaust chamber andthen install the exhaust manifoldbolts.

9. Install the washers and exhaustchamber bolt.

10. Tighten the exhaust manifold boltsand exhaust chamber bolt to thespecified torques.

11. Install the muffler by sliding thespring clamp up to its original posi-tion, and then installing the wash-ers and muffler bolt.

NOTE:

Make sure that the spring clamp is po-sitioned with the projection side facing

inward.

12. Tighten the muffler bolt to thespecified torque.

1. Rear arm2. Washer3. Rear arm nut

1 23

Tightening torques:

Axle nut:60 Nm (6.0 m·kgf, 43.4 ft·lbf)

Rear arm nut:28.5 Nm (2.9 m·kgf, 20.6 ft·lbf)

Rear shock absorber mounting bolt:22.5 Nm (2.3 m·kgf, 16.3 ft·lbf)

Tightening torques:

Exhaust manifold bolt:8.5 Nm (0.9 m·kgf, 6.1 ft·lbf)

Exhaust chamber bolt:17.5 Nm (1.8 m·kgf, 12.7 ft·lbf)

1. Exhaust chamber2. Spring clamp3. Muffler

Tightening torque:

Muffler bolt:17.5 Nm (1.8 m·kgf, 12.7 ft·lbf)

1

2

3


6-23

2

3

4

5

6

7

8

9

13. Adjust the brake lever free play.(See page 6-14.)

14. Install the seat.

EAU25850

Troubleshooting

Although Yamaha motorcycles receivea thorough inspection before shipmentfrom the factory, trouble may occur dur-ing operation. Any problem in the fuel,compression, or ignition systems, forexample, can cause poor starting andloss of power.The following troubleshooting chartrepresents a quick and easy procedurefor checking these vital systems your-self. However, should your motorcyclerequire any repair, take it to a Yamahadealer, whose skilled technicians havethe necessary tools, experience, andknow-how to service the motorcycleproperly.Use only genuine Yamaha replace-ment parts. Imitation parts may look likeYamaha parts, but they are often inferi-or, have a shorter service life and canlead to expensive repair bills.


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EAU25971

Troubleshooting chart

WARNING

EWA10840

Keep away open flames and do not smoke while checking or working on the fuel system.

Check the fuel level inthe fuel tank.

1. FuelThere is enough fuel.

There is no fuel.

Supply fuel.

Operate the kickstarter.

2. CompressionThere is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealercheck the vehicle.

Remove the spark plugand check the electrodes.

3. IgnitionWet

Dry

Wipe off with a dry cloth and correct thespark plug gap, or replace the spark plug.

Have a Yamaha dealer check the vehicle.The engine does not start.Have a Yamaha dealer check the vehicle.

Open the throttle halfway and operatethe kickstarter.

Check the compression.

The engine does not start. Check the compression.

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EAU37833

Matte color caution

CAUTION:

ECA15192

Some models are equipped withmatte colored finished parts. Besure to consult a Yamaha dealer foradvice on what products to use be-fore cleaning the vehicle. Using abrush, harsh chemical products orcleaning compounds when cleaningthese parts will scratch or damagetheir surface. Wax also should notbe applied to any matte colored fin-

ished parts.

EAU40632

Care

While the open design of a motorcyclereveals the attractiveness of the tech-nology, it also makes it more vulnera-ble. Rust and corrosion can developeven if high-quality components areused. A rusty exhaust pipe may go un-noticed on a car, however, it detractsfrom the overall appearance of a motor-cycle. Frequent and proper care doesnot only comply with the terms of thewarranty, but it will also keep your mo-torcycle looking good, extend its lifeand optimize its performance.

Before cleaning

1. Cover the muffler outlet with aplastic bag after the engine hascooled down.

2. Make sure that all caps and coversas well as all electrical couplersand connectors, including thespark plug cap, are tightly in-stalled.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply such prod-

ucts onto seals, gaskets and wheelaxles. Always rinse the dirt and de-greaser off with water.

Cleaning

CAUTION:

ECA10771

�

Avoid using strong acidic wheelcleaners, especially on spokedwheels. If such products areused on hard-to-remove dirt, donot leave the cleaner on the af-fected area any longer than in-structed. Also, thoroughly rinsethe area off with water, immedi-ately dry it, and then apply a cor-rosion protection spray.

�

Improper cleaning can damageplastic parts such as cowlings,panels, windshields, headlightlenses, meter lenses, etc. Useonly a soft, clean cloth orsponge with mild detergent andwater to clean plastic.

�

Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abrasive


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cleaning products, solvent orthinner, fuel (gasoline), rust re-movers or inhibitors, brake flu-id, antifreeze or electrolyte.

�

Do not use high-pressure wash-ers or steam-jet cleaners sincethey cause water seepage anddeterioration in the following ar-eas: seals (of wheel and swing-arm bearings, fork and brakes),electric components (couplers,connectors, instruments,switches and lights), breatherhoses and vents.

�

For motorcycles equipped witha windshield: Do not use strongcleaners or hard sponges asthey will cause dulling orscratching. Some cleaning com-pounds for plastic may leavescratches on the windshield.Test the product on a small hid-den part of the windshield tomake sure that it does not leaveany marks. If the windshield isscratched, use a quality plasticpolishing compound after

washing.

After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottlebrushfor hard-to-reach areas. Stubborn dirtand insects will come off more easily ifthe area is covered with a wet cloth fora few minutes before cleaning.

After riding in the rain or near the seaSince sea salt is extremely corrosive,carry out the following steps after eachride in the rain or near the sea.

1. Clean the motorcycle with cold wa-ter and a mild detergent, after theengine has cooled down.

CAUTION:

ECA10790

Do not use warm water since it in-creases the corrosive action of the

salt.

2. Apply a corrosion protection sprayon all metal, including chrome- andnickel-plated, surfaces to preventcorrosion.

After cleaning

1. Dry the motorcycle with a chamoisor an absorbing cloth.

2. Use a chrome polish to shinechrome, aluminum and stain-less-steel parts, including the ex-haust system. (Even the thermallyinduced discoloring of stain-less-steel exhaust systems can beremoved through polishing.)

3. To prevent corrosion, it is recom-mended to apply a corrosion pro-tection spray on all metal,including chrome- and nickel-plat-ed, surfaces.

4. Use spray oil as a universal clean-er to remove any remaining dirt.

5. Touch up minor paint damagecaused by stones, etc.

6. Wax all painted surfaces.7. Let the motorcycle dry completely

before storing or covering it.

WARNING

EWA14500

�

Make sure that there is no oil orwax on the tires.

�

If necessary, wash the tires withwarm water and a mild deter-gent. Before riding at higher


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speeds, test the motorcycle’sbraking performance and cor-

nering behavior.

CAUTION:

ECA10800

�

Apply spray oil and wax spar-ingly and make sure to wipe offany excess.

�

Never apply oil or wax to anyrubber and plastic parts, buttreat them with a suitable careproduct.

�

Avoid using abrasive polishingcompounds as they will wear

away the paint.

NOTE:

Consult a Yamaha dealer for advice on

what products to use.

EAU40642

Storage

Short-term

Always store your motorcycle in a cool,dry place and, if necessary, protect itagainst dust with a porous cover.

CAUTION:

ECA10810

�

Storing the motorcycle in apoorly ventilated room or cover-ing it with a tarp, while it is stillwet, will allow water and humid-ity to seep in and cause rust.

�

To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)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.

2. For motorcycles equipped with afuel cock that has an “S” (stop) po-sition: Turn the fuel cock lever to

“S”.3. Drain the carburetor float chamber

by loosening the drain bolt; this willprevent fuel deposits from buildingup. Pour the drained fuel into thefuel tank.

4. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting and thefuel from deteriorating.

5. 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 placethe spark plug on the cylinderhead so that the electrodes aregrounded. (This will limit spark-ing during the next step.)

d. Turn the engine over severaltimes with the starter. (This willcoat the cylinder wall with oil.)

e. Remove the spark plug capfrom the spark plug, and then


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install the spark plug and thespark plug cap.

WARNING

EWA10950

To prevent damage or injury fromsparking, make sure to ground thespark plug electrodes while turning

the engine over.

6. Lubricate all control cables and thepivoting points of all levers andpedals as well as of the center-stand.

7. Check and, if necessary, correctthe tire air pressure, and then liftthe motorcycle so that both of itswheels are off the ground. Alterna-tively, turn the wheels a little everymonth in order to prevent the tiresfrom becoming degraded in onespot.

8. Cover the muffler outlet with aplastic bag to prevent moisturefrom entering it.

NOTE:

Make any necessary repairs before

storing the motorcycle.

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SPECIFICATIONS

EAU2633K

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:

With oil and fuel: 39.0 kg (86 lb)

Engine:

Engine type: Air cooled 2-stroke

Cylinder arrangement: Forward-inclined single cylinder

Displacement: 49.0 cm

3

Bore

×

stroke: 40.0

×

39.2 mm (1.57

×

1.54 in)Compression ratio:

6.00 :1Starting system:

Kickstarter

Lubrication system: Separate lubrication (Yamaha autolube)

Engine oil:

Type: YAMALUBE 2 or 2-stroke engine oil (JASOFC grade) or (ISO EG-C or EG-D grade)

Engine oil quantity:

Quantity: 0.30 L (0.32 US qt) (0.26 Imp.qt)

Transmission oil:

Type: YAMALUBE 4 (10W30) or SAE 10W30

Oil change quantity: 0.30 L (0.32 US qt) (0.26 Imp.qt)

Air filter:

Air filter element: Wet element

Fuel:

Recommended fuel: Regular unleaded gasoline only(AUT)(BEL)(CAN)(CHE)(DEU)(DNK)(ESP)(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)(SWE)(ZAF)Unleaded gasoline only (AUS)(NZL)

Fuel tank capacity: 2.0 L (0.53 US gal) (0.44 Imp.gal)

Carburetor:

Manufacturer: MIKUNI

Type

×

quantity: VM12SC x 1

Spark plug (s):

Manufacturer/model: NGK/BP4HS (AUS)(NZL)NGK/BPR4HS(AUT)(BEL)(CAN)(CHE)(DEU)(DNK)(ESP)(FIN)(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)(SWE)(ZAF)

Manufacturer/model: DENSO/W14FPL (AUS)(NZL)

Spark plug gap: 0.6–0.7 mm (0.024–0.028 in)

Clutch:

Clutch type: Wet, centrifugal automatic

Transmission:

Primary reduction system: Spur gear

Primary reduction ratio: 63/33 (1.909)

Secondary reduction system: Shaft drive

Secondary reduction ratio: 19/15

×

54/11 (6.218)

Chassis:

Frame type: Steel tube backbone

Caster angle: 25.50 °

Trail: 50.0 mm (1.97 in)

Front tire:

Type: With tube

SPECIFICATIONS

8-2

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Size: 2.50-10 4PR

Manufacturer/model: BRIDGESTONE/KNOBBY

Manufacturer/model: IRC/KNOBBY

Rear tire:

Type: With tube

Size: 2.50-10 4PR

Manufacturer/model: BRIDGESTONE/KNOBBY

Manufacturer/model: IRC/KNOBBY

Loading:

Maximum rider weight: 25.0 kg (55 lb)

* (Total weight of rider, cargo and accessories)

Tire air pressure (measured on coldtires):

Front: 100 kPa (15 psi) (1.00 kgf/cm

2

)Rear:

100 kPa (15 psi) (1.00 kgf/cm

2

)

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

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

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CONSUMER INFORMATION

EAU40790

Identification numbers

Record the vehicle identification num-ber and model label information in thespaces provided below for assistancewhen ordering spare parts from aYamaha dealer or for reference in casethe vehicle is stolen.VEHICLE IDENTIFICATION NUMBER:

MODEL LABEL INFORMATION:

EAU26400

Vehicle identification number

The vehicle identification number isstamped into the steering head pipe.Record this number in the space pro-vided.

NOTE:

The vehicle identification number isused to identify your motorcycle andmay be used to register your motorcy-cle with the licensing authority in your

area.

EAU26480

Model label

The model label is affixed to the frameunder the seat. (See page 3-7.) Recordthe information on this label in thespace provided. This information will beneeded when ordering spare parts froma Yamaha dealer.

1. Vehicle identification number

1

1. Model label

1

INDEX

A

Acceleration and deceleration................... 5-2Accessories and replacement parts........ 6-13Air filter element, cleaning......................... 6-8Autolube pump, adjusting ....................... 6-16

B

Brake lever, front....................................... 3-2Brake lever, rear ....................................... 3-3Brake levers, lubricating.......................... 6-16Brake shoes, checking............................ 6-15Braking...................................................... 5-2

C

Cables, checking and lubricating ............ 6-15Carburetor, adjusting .............................. 6-10Care .......................................................... 7-1Centerstand, checking and lubricating.... 6-17

E

Engine break-in......................................... 5-3Engine idling speed................................. 6-10Engine oil .................................................. 3-5Engine, starting a warm ............................ 5-1Engine stop switch .................................... 3-1

F

Front and rear brake lever free play, adjusting ............................................... 6-14

Front fork, checking ................................ 6-17Fuel ........................................................... 3-3Fuel cock................................................... 3-5Fuel tank breather hose ............................ 3-5Fuel tank cap ............................................ 3-3

H

Handlebar switch ...................................... 3-1

I

Identification numbers............................... 9-1

K

Kickstarter..................................................3-6

L

Labels, location of......................................1-4

M

Maintenance and lubrication, periodic .......6-3Maintenance, emission control system......6-2Matte color, caution ...................................7-1Middle and final gear cases.......................6-8Model label ................................................9-1

P

Parking.......................................................5-4Part locations.............................................2-1Power reduction plate, removing ...............6-6Pre-operation check list .............................4-2

S

Safety information......................................1-1Seat ...........................................................3-7Spark arrester, cleaning.............................6-9Spark plug, checking .................................6-5Specifications.............................................8-1Speed limiter and power reduction plate ...3-1Starter (choke) lever ..................................3-6Starting and warming up a cold engine .....5-1Starting off .................................................5-2Steering, checking ...................................6-18Storage ......................................................7-3

T

Throttle cable free play, checking............6-11Throttle grip and cable, checking and

lubricating ..............................................6-16Tires.........................................................6-11Tool kit .......................................................6-1Transmission oil.........................................6-7

Troubleshooting.......................................6-23Troubleshooting chart..............................6-24

V

Vehicle identification number ....................9-1

W

Wheel bearings, checking .......................6-18Wheel (front)............................................6-19Wheel (rear) ............................................6-20Wheels ....................................................6-13

PRINTED ON RECYCLED PAPERYAMAHA MOTOR CO., LTD.


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5PG-28199-87 PW50(X) BEDIENUNGSANLEITUNG ... - Yamaha …

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