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Yamaha PW50W 2007 User Manual

Yamaha PW50W 2007
168 pages
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SERVICE MANUAL
5PG-28197-10
LIT-11616-20-15
PW50W
S5PG10_cover 2006.4.22 1:17 PM Page 1

Table of Contents

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Yamaha PW50W 2007 Specifications

General IconGeneral
Year2007
ManufacturerYamaha
ModelPW50W
CategoryMotorcycle
Displacement49 cc
Fuel SystemCarburetor
IgnitionCDI
Starting SystemKick start
TransmissionAutomatic
Final DriveChain
Front SuspensionTelescopic fork
Front BrakesDrum
Rear BrakesDrum
Front Tire2.50-10
Engine TypeSingle cylinder, 2-stroke
Bore x Stroke40.0 mm x 39.2 mm
Rear SuspensionSwingarm
Rear Tire2.50-10

Summary

How to Use This Manual

Understanding Manual Structure

Guidance on navigating the manual, understanding its layout, and interpreting its content effectively.

Interpreting Symbols

Explanation and identification of various symbols used throughout the manual to convey specific information.

CHAPTER 1 GENERAL INFORMATION

Vehicle Identification

Information on locating and identifying the vehicle's identification numbers, including frame and engine serial numbers.

Important Information for Service

Key guidelines for preparing for disassembly, selecting replacement parts, and handling seals and gaskets.

Checking Connections

Procedure for inspecting and ensuring the integrity of electrical connections, checking for stains, rust, and moisture.

Special Tools Required

List of specialized tools necessary for accurate tune-up and assembly, with part numbers and descriptions.

CHAPTER 2 SPECIFICATIONS

General Vehicle Specifications

Basic physical and dimensional specifications for the vehicle model, including weight and dimensions.

Engine Maintenance Specifications

Technical data and specifications for engine components, including dimensions, clearances, and fluid capacities.

Chassis Specifications

Specifications related to the vehicle's chassis, including frame type, wheel dimensions, and tire information.

Brake and Suspension Specifications

Detailed specifications for the front and rear brake systems, steering, and front/rear suspension components.

Tightening Torque and Unit Definitions

Standard tightening torques for fasteners and definitions of measurement units used in the manual.

Lubrication Points and Types

Identification of lubrication points and recommended lubricant types for engine and chassis components.

Cable Routing Guide

Diagrams and instructions illustrating the correct routing and securing of various cables and wires on the vehicle.

CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS

Introduction and Maintenance Schedules

Overview of checks, maintenance intervals, and schedules for vehicle upkeep.

Side Covers, Seat and Fuel Tank Maintenance

Procedures for accessing and maintaining body panels, seat, and fuel tank components.

Engine Checks and Adjustments

Detailed steps for maintaining and adjusting engine components like oil, idling, and autolube pump.

Chassis Checks and Adjustments

Procedures for checking and adjusting chassis parts including brakes, steering, forks, tires, and wheels.

Electrical System Checks

Inspection and testing of electrical components, focusing on the spark plug and ignition system.

CHAPTER 4 CHASSIS

Front Wheel, Rear Wheel, and Brake Systems

Detailed procedures for removing, checking, disassembling, assembling, and installing wheels and brakes.

Handlebar Service

Instructions for removing, inspecting, and reinstalling the vehicle's handlebar assembly.

Front Fork Service

Comprehensive guide to servicing the front fork legs, including disassembly, inspection, and reassembly.

Steering Head Maintenance

Procedures for servicing the steering head, including bearing checks and adjustments for proper steering.

Rear Suspension and Swingarm Service

Steps for removing, checking, and installing the rear shock absorber assembly and swingarm.

Shaft Drive System Service

Maintenance procedures for the shaft drive system, including disassembly, inspection, and reassembly of components.

CHAPTER 5 ENGINE

Engine Removal and Installation

Detailed steps for safely removing and reinstalling the entire engine assembly from the vehicle frame.

Cylinder Head, Cylinder, and Piston Service

Procedures for servicing the cylinder head, cylinder, and piston, including removal, checking, and installation.

Reed Valve System Maintenance

Instructions for removing, checking, and installing the reed valve assembly for optimal engine performance.

Clutch System Service

Procedures for servicing the clutch, including removal, checking, assembly, and installation of clutch components.

Autolube Pump System Service

Detailed steps for removing, disassembling, checking, assembling, and installing the autolube pump.

Kick Starter System Service

Maintenance and troubleshooting guide for the kick starter mechanism, including removal, checking, and installation.

CDI Magneto System Service

Procedures for servicing the CDI magneto, including removal, checking, and installation of ignition system components.

Crankcase and Crankshaft Service

Steps for separating and servicing the crankcase and crankshaft, including checks and assembly procedures.

Middle Gear System Service

Maintenance procedures for the middle gear system, including removal, checking, and installation of its components.

CHAPTER 6 CARBURETOR

Carburetor Removal and Disassembly

Instructions for removing and taking apart the carburetor for inspection and servicing.

Carburetor Checking and Assembly

Procedures for inspecting carburetor components and reassembling the unit correctly.

Carburetor Installation and Adjustment

Steps for installing the serviced carburetor and performing final adjustments for optimal engine operation.

CHAPTER 7 ELECTRICAL SYSTEM

Electrical Components Overview

Identification and overview of the main electrical components used in the vehicle's system.

Switch and Continuity Checks

Testing procedures for switches to verify continuity and proper electrical connections.

Ignition System Diagnosis

Troubleshooting guide for ignition system failures, including circuit diagrams and step-by-step diagnostic procedures.

CHAPTER 8 TROUBLESHOOTING

General Troubleshooting Guidelines

Basic troubleshooting advice and common causes for starting failures, covering engine, fuel, and electrical systems.

Performance and Operational Issues

Diagnosing and resolving issues related to engine idling, performance, clutch operation, and overheating.

Braking and Handling Problems

Troubleshooting guides for poor braking, front fork malfunctions, and unstable vehicle handling.

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