Yamaha PW50W 2007 User manual

SERVICE MANUAL
5PG-28197-10
LIT-11616-20-15
PW50W
S5PG10_cover 2006.4.22 1:17 PM Page 1

PW50W
SERVICE MANUAL
©2006 by Yamaha Motor Corporation
U.S.A.
First edition May 2006
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-20-15
EAS00000
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NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their ualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehi-
cles should have a basic understanding of mechanics and the techni ues to repair these types of
vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to ren-
der the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any uestion about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental uality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
8This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
8Designs and specifications are subject to change without notice.
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
QThe Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
wFailure to follow WARNING instructions could result in severe injury or death to the
vehicle operator, a bystander or a person checking or repairing the vehicle.
cCA CAUTION indicates special precautions that must be taken to avoid damage to
the vehicle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
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HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic.
Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check
procedures are laid out with the individual steps in sequential order.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
efer to "SYMBOLS".
2Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 ("PE IODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s)
appears.
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates
a disassembly step.
6Symbols indicate parts to be lubricated or replaced.
efer to "SYMBOLS".
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described
sequentially.
1
2
6
3
5
4
7
8
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SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1to 8indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Carburetor
7Electrical system
8Troubleshooting
Symbols 9to yindicate the following.
9Serviceable with engine mounted
0Filling fluid
qLubricant
wSpecial tool
eTightening torque
rWear limit, clearance
tEngine speed
yElectrical data
Symbols uto sin the exploded diagrams
indicate the types of lubricants and lubrication
points.
uEngine oil
iGear oil
oMolybdenum-disulfide oil
pWheel-bearing grease
aLithium-soap-based grease
sMolybdenum-disulfide grease
Symbols dto fin the exploded diagrams
indicate the following.
dApply locking agent (LOCTITE®)
feplace the part
12
34
56
78
90
qw
er
ty
ui o
pas
df
GEN
INFO SPEC
CHK
ADJ
ENG CARB
CHAS
ELEC TRBL
SHTG
LT
New
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SPECIFICATIONS
TROUBLESHOOTING
ELECTRICAL SYSTEM
CARBURETOR
CHASSIS
PERIODIC CHECKS AND
ADJUSTMENTS
GENERAL INFORMATION GEN
INFO
TRBL
SHTG
ELEC
CARB
CHAS
CHK
ADJ
SPEC
TABLE OF CONTENTS
4
6
7
8
3
2
1
ENGINE ENG
5
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GEN
INFO
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION .............................................................................1-1
VEHICLE IDENTIFICATION NUMBE .......................................................1-1
ENGINE SE IAL NUMBE .........................................................................1-1
IMPORTANT INFORMATION............................................................................1-2
P EPA ATION FO EMOVAL AND DISASSEMBLY ..............................1-2
EPLACEMENT PA TS .............................................................................1-2
GASKETS, OIL SEALS AND O- INGS ......................................................1-2
LOCK WASHE S/PLATES AND COTTE PINS .......................................1-3
BEA INGS AND OIL SEALS ......................................................................1-3
CI CLIPS ....................................................................................................1-3
CHECKING THE CONNECTIONS ...................................................................1-4
SPECIAL TOOLS .............................................................................................1-5
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1-1
GEN
INFO
VEHICLE IDENTIFICATION
GENERAL INFORMATION
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The number 1is stamped into the frame
head pipe.
ENGINE SERIAL NUMBER
The engine serial number 1is stamped into
the crankcase.
NOTE:
Designs and specifications are subject to
change without notice.
1
1
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