brake YAMAHA PW50 2010 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
7-12
1
2
3
4
5
6
7
8
9Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
Tire information
This motorcycle is equipped with panel
wheels and tube tires.
WARNING

EWA10461
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, which
could lead to an accident.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
WARNING

EWA14390

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-and brake-related parts,
including the tires, should be
left to a Yamaha dealer, who has
the necessary professional
knowledge and experience.

It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a
high-quality product.
Standard tire air pressure:
Front:
100 kPa (1.00 kgf/cm
2

, 15 psi)
Rear:
100 kPa (1.00 kgf/cm
2

, 15 psi)
1. Tire sidewall
2. Tire tread depth
Minimum tire tread depth (front and
rear):
4.0 mm (0.16 in)
12

Front tire:
Size:
2.50-10 4PR
Manufacturer/model:
BRIDGESTONE/KNOBBY
IRC/KNOBBY
Rear tire:
Size:
2.50-10 4PR
Manufacturer/model:
BRIDGESTONE/KNOBBY
IRC/KNOBBY

PERIODIC MAINTENANCE AND ADJUSTMENT
7-13
2
3
4
5
6
78
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 regarding
the specified wheels.

The wheel rims should be checked
for cracks, bends, warpage or
damage before each ride. If any
damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

Ride conservatively after changinga tire since the tire must seat itself
on the rim properly. Failure to al-
low proper seating may cause tire
failure, which may result in dam-
age to the motorcycle and injury to
the rider.
EAU22151
Adjusting the front and rear
brake lever free play
Front
Rear
The front and rear brake lever free play
1. Front brake lever free play
1. Rear brake lever free play
1
1

PERIODIC MAINTENANCE AND ADJUSTMENT
7-14
1
2
3
4
5
6
7
8
9
should be measured at the positions as
shown.
Periodically check the front and rear
brake lever free play and, if necessary,
adjust them as follows.
To increase the brake lever free play,
turn the adjusting nut at the brake shoe
plate in direction (a). To decrease the
brake lever free play, turn the adjusting
nut in direction (b).
FrontRear
WARNING

EWA10650
If proper adjustment cannot be ob-
tained as described, have a Yamaha
dealer make this adjustment.
EAU41052
Checking the front and rear
brake shoes
The front and rear brake shoes must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
TIP

The wheels must be removed to check
brake shoe lining thickness.

To remove the front wheel: See
page 7-18.

To remove the rear wheel: See
page 7-20.
Front
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 nut1
(a)(b)

PERIODIC MAINTENANCE AND ADJUSTMENT
7-15
2
3
4
5
6
78
9 Rear
If the lining thickness of a brake shoe is
less than 1.5 mm (0.06 in), have a
Yamaha dealer replace the brake
shoes as a set.
TIP

Be sure to measure the brake lining at
the thinnest portion.
EAU41842
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
housing of cables may result in in-
ternal rusting and cause interfer-
ence with cable movement. Replace
damaged cables as soon as possi-
ble to prevent unsafe condi-
tions.
[EWA10711]

EAU23111
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
Recommended lubricant:
Yamaha Chain and Cable Lube or
4-stroke engine oil

PERIODIC MAINTENANCE AND ADJUSTMENT
7-16
1
2
3
4
5
6
7
8
9

EAU23120
Adjusting the Autolube pump
The Autolube pump is a vital and so-
phisticated component of the engine,
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
EAU43631
Lubricating the front and rear
brake levers
The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic main-
tenance and lubrication chart.
EAU23192
Checking and lubricating the
centerstand
The operation of the centerstand
should be checked before each ride,
and the pivots and metal-to-metal con-
tact surfaces should be lubricated if
necessary.
WARNING

EWA11301
If the centerstand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the centerstand could contact the
ground and distract the operator, re-
sulting in a possible loss of control.
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease

PERIODIC MAINTENANCE AND ADJUSTMENT
7-17
2
3
4
5
6
78
9

EAU42081
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
Check the inner tubes for scratches
and damage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.

[EWA10751]

2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
NOTICE

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU45511
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place the vehicle on the center-
stand.
WARNING! To avoid inju-
ry, securely support the vehicle
so there is no danger of it falling
over.
[EWA10751]

2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

PERIODIC MAINTENANCE AND ADJUSTMENT
7-18
1
2
3
4
5
6
7
8
9

EAU23290
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAU24360
Front wheel
EAU41022
To remove the front wheel
WARNING

EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.
1. Place the motorcycle on the cen-
terstand.
2. Disconnect the brake cable at the
wheel by removing the brake lever
free play adjusting nut, then re-
moving the cable from the brake
camshaft lever and brake shoe
plate.3. Remove the axle nut and washer.
4. Pull the wheel axle out, and then
remove the wheel.
1. Brake lever free play adjusting nut
2. Brake camshaft lever
3. Washer
4. Axle nut
5. Brake cable
5
1 23
4

PERIODIC MAINTENANCE AND ADJUSTMENT
7-19
2
3
4
5
6
78
9

EAU41031
To install the front wheel
1. Install the brake shoe plate into the
wheel hub as shown.
2. Lift the wheel up between the fork
legs.
TIP

Make sure that the slot in the brake
shoe plate fits over the retainer on the
fork leg.
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.
5. Connect the brake cable at the
wheel hub, and then install the
brake cable free play adjusting nut.6. Adjust the brake lever free play.
(See page 7-13.)
7. Take the motorcycle off the center-
stand so that the front wheel is on
the ground.
8. Push down hard on the handlebar
several times to check for proper
fork operation.
1. Wheel axle
1

1. Retainer
Tightening torque:
Axle nut:
40 Nm (4.0 m·kgf, 28.9 ft·lbf)
1

PERIODIC MAINTENANCE AND ADJUSTMENT
7-21
2
3
4
5
6
78
9
7. Remove the right-side rear shock
absorber mounting bolt and then
tilt the rear shock absorber upward
as shown.
8. Remove the axle nut while apply-
ing the rear brake.9. Remove the rear arm by removing
the nuts and washers.
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 the
splines of the final gear case and
wheel hub.
2. Install the wheel by inserting it into
the wheel hub.
3. Install the rear arm by installing the
washers and nuts.
4. Install the axle nut.
5. Install the right-side rear shock ab-
sorber by installing the mounting
bolt.
6. While applying the rear brake,
tighten the axle nut to the specified
torque.
7. Tighten the rear arm nuts and rear
shock absorber mounting bolt to
the specified torques.
1. Exhaust manifold bolt
1. Rear shock absorber mounting bolt
1
1

1. Axle nut
1. Rear arm
2. Washer
3. Rear arm nut1
1
2
3

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)

PERIODIC MAINTENANCE AND ADJUSTMENT
7-22
1
2
3
4
5
6
7
8
9
8. Install the exhaust chamber and
then install the exhaust manifold
bolts.
9. Install the washers and exhaust
chamber bolt.
10. Tighten the exhaust manifold bolts
and exhaust chamber bolt to the
specified torques.
11. Install the muffler by sliding the
spring clamp up to its original posi-
tion, and then installing the wash-
ers and muffler bolt.
TIP

Make sure that the spring clamp is po-
sitioned with the projection side facing
inward.12. Tighten the muffler bolt to the
specified torque.
13. Adjust the brake lever free play.
(See page 7-13.)
14. Install the seat.
EAU25851
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
WARNING

EWA15141
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from water
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 chamber
2. Spring clamp
3. Muffler
Tightening torque:
Muffler bolt:
17.5 Nm (1.8 m·kgf, 12.7 ft·lbf)
1
2
3