maintenance YAMAHA PW50 2011 Owner's Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
7-15
7
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.TIPThe 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.
FrontRear
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.
TIPBe 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 conditions.[EWA10711]Recommended lubricant:
Yamaha Chain and Cable Lube or 4-
stroke engine oil
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-16
7
EAU23113
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 by a
Yamaha dealer at the intervals speci-
fied in the periodic maintenance chart.
The throttle cable is equipped with a
rubber boot. Make sure that the boot is
securely installed. Even though the
boot is installed correctly, it does not
completely protect the cable from water
entry. Therefore, use care not to pour
water directly onto the boot or cable
when washing the vehicle. If the cable
or boot becomes dirty, wipe clean with
a moist cloth.
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.
Recommended lubricant:
Lithium-soap-based grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-17
7
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.
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.
Recommended lubricant:
Lithium-soap-based grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-18
7
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.
EAU23291
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
EAU41023
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 hub by removing the brake
lever free play adjusting nut, then
removing the cable from the brake
camshaft lever and brake shoe
plate.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-19
73. 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 the
wheel hub as shown.
2. Lift the wheel up between the fork
legs.TIPMake 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 7-14.)
7. Take the motorcycle off the center-
stand so that the front wheel is on
the ground.
1. Brake camshaft lever
2. Brake shoe plate
3. Washer
4. Axle nut
5. Brake cable
6. Brake lever free play adjusting nut
1. Wheel axle
5
6 13
4
2
1
1. RetainerTightening torque:
Axle nut:
40 Nm (4.0 m·kgf, 29 ft·lbf)
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-20
7 8. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU41084
To remove the rear 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. Remove the seat. (See page 4-7.)
3. Remove the muffler bolt and wash-
ers. WARNING! Always let the
exhaust system cool prior to
touching exhaust components.
[EWA14581]
4. Slide the spring clamp down, and
then remove the muffler.5. Remove the exhaust chamber bolt
and washers.
1. Muffler
2. Washer
3. Muffler bolt
4. Spring clamp
1. Exhaust chamber
2. Exhaust chamber bolt
3. Washer
3
1
24
2 1
3
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-21
76. Remove the exhaust manifold
bolts, and then remove the ex-
haust chamber, the power reduc-
tion plate and the gasket.
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, and
then remove the wheel.
EAU41522
To install the rear wheel
1. Apply a light coating of lithium-
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.
1. Exhaust manifold bolt
1
1. Rear shock absorber mounting bolt
1. Axle nut
1
1
1. Rear arm
2. Washer
3. Rear arm nut
1
2
3
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-22
7 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.
8. Install the exhaust chamber by in-
stalling the bolt and washers.
9. Install the power reduction plate, a
new gasket, and then install the
exhaust manifold bolts.
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.
TIPMake 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 7-14.)
14. Install the seat.
Tightening torques:
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
Rear arm nut:
29 Nm (2.9 m·kgf, 21 ft·lbf)
Rear shock absorber mounting bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
Tightening torques:
Exhaust manifold bolt:
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Exhaust chamber bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
1. Exhaust chamber
2. Spring clamp
3. Muffler
1
2
3
Tightening torque:
Muffler bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-23
7
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 waterheaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or
property damage.U5PG8AE0.book Page 23 Thursday, April 8, 2010 8:37 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-24
7
EAU25972
Troubleshooting chart
Check the fuel level in
the fuel tank.1. Fuel
There is
enough fuel.
There is
no fuel.
Supply fuel.
Operate the kickstarter.2. Compression
There is compression.
There is
no compression.Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.3. Ignition
Wet
DryWipe off with a dry cloth and correct the
spark 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 operate
the kickstarter.
Check the compression.
The engine does not start.
Check the compression.
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