brake YAMAHA PW50 2016 User Guide

Periodic maintenance an d a djustment
7-5
7TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty
areas.
11 *Front and rear brake
lever pivot Apply lithium-soap-based grease
lightly.
12 *Centerstand pivot Check operation.
13
*Shock absorber
assemblies Check operation and for oil leakage.
14
*Control cables Apply Yamaha cable lubricant or other
suitable cable lubricant.
15 *Throttle grip Check operation.
Check throttle grip free play, and
adjust if necessary.
Apply Yamaha cable lubricant or other suitable cable lubricant.
Replace if necessary. Apply lithium-soap-based grease
lightly.
NO. ITEM CHECK OR MAINTENANCE JOB
1 month3 months
6 months
6 months12 months
√√√ √
√√√ √√√
√
√√
√
√
√√
THEREAFTER
EVERYINITIAL
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Periodic maintenance an d a djustment
7-16
7
EAU40782
Panel wheels
WARNING
EWA10611
The wheels on this mod el are not
d esi gne d for use with tu beless tires.
Do not attempt to use tu beless tires
on this mod el.
To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.
 The wheel rims should be
checked for cracks, bends, warp-
age 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.
EAU22153
Adjustin g the front an d rear
b rake lever free play
The front and rear brake lever free play
should be measured at the positions as
shown.
Front
Rear
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).
1. Front brake lever free play
1. Rear brake lever free play
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
1
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Periodic maintenance an d a djustment
7-17
7 Front
Rear
WARNING
EWA10651
If proper a
djustment cannot be o b-
taine d as d escri bed , have a Yamaha
d ealer make this ad justment.
EAU41054
Checking the front an d rear
b rake 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 7-22.
 To remove the rear wheel: See
page 7-24.
Front
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.
1. Front brake lever free play adjusting nut
1. Rear brake lever free play adjusting nut
1
(a)
(b)
1
(a)(b)
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Periodic maintenance an d a djustment
7-18
7
TIP
Be sure to measure the brake lining at
the thinnest portion.
EAU23098
Checkin g an d lu bricatin g the
ca bles
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 lubri-
cated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or re-
place it. WARNING! Dama ge to the
outer housin g of cab les may result
in internal rustin g an d cause inter-
ference with cab le movement. Re-
place damag ed cab les as soon as
possi ble to prevent unsafe con di-
tions.
[EWA10712]
Recommen ded lu bricant:
Yamaha cable lubricant or other
suitable cable lubricant
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Periodic maintenance an d a djustment
7-20
7
EAU43634
Lub ricatin g the front an d rear
b rake 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.
EAU23193
Checkin g an d lu bricatin g the
centerstan d
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
EWA11302
If the centerstan d d oes not move up
an d d own smoothly, have a Yamaha
d ealer check or repair it. Otherwise,
the centerstan d coul d contact the
g roun d an d d istract the operator, re-
sultin g in a possib le loss of control.
Recommen ded lu bricant:
Lithium-soap-based grease
Recommen ded lu bricant:
Lithium-soap-based grease
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Periodic maintenance an d a djustment
7-21
7
EAU42082
Checkin g the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
To check the con dition
Check the inner tubes for scratches
and damage.
To check the operation 1. Place the vehicle on a level surfa- ce and hold it in an upright posi-
tion. WARNING! To avoi d injury,
securely support the vehicle so
there is no dan ger of it fallin g
over.
[EWA10752]
2. While applying the front brake, push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
NOTICE
ECA10591
If any d amage is foun d or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU45512
Checkin g the steerin g
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
periodic maintenance and lubrication
chart.
1. Place the vehicle on the center- stand. WARNING! To avoi d inju-
ry, securely support the vehicle
so there is no dan ger of it fallin g
over.
[EWA10752]
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 steer-
ing.
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Periodic maintenance an d a djustment
7-22
7
EAU23292
Checkin g the wheel b earings
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.
EAU24361
Front wheel
EAU56510
To remove the front wheel
WARNING
EWA10822
To avoi d injury, securely support the
vehicle so there is no dan ger of it
fallin g over.
1. Place the motorcycle on the cen-
terstand.
2. Disconnect the brake cable at the wheel hub by removing the front
brake lever free play adjusting nut,
then removing 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 camshaft lever
2. Brake shoe plate
3. Washer
4. Axle nut
5. Brake cable
6. Front brake lever free play adjusting nut
5
6
1 3
4
2
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Periodic maintenance an d a djustment
7-23
7 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 rightside.
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 lever free play adjusting nut.
6. Adjust the brake lever free play. (See page 7-16.)
7. Take the motorcycle off the cen- terstand 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. Retainer
1
1
Tightening torque:
Axle nut: 40 Nm (4.0 m·kgf, 29 ft·lbf)
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Periodic maintenance an d a djustment
7-25
7 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 re- move it from the rear axle.
To install the rear wheel 1. Apply a light coating of lithium- soap-based grease to the splines
of the rear axle and wheel hub.
2. Install the wheel to the rear axle.
3. Install the rear arm by installing the washers and nuts.
4. Install the axle nut.
5. Install the right-side rear shock absorber by installing the mount-
ing bolt. 6. While applying the rear brake,
tighten the axle nut to the speci-
fied 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 po-
sition, and then installing the
washers and muffler bolt.
TIP
Make sure that the spring clamp is po-
sitioned with the projection side facing
inward.
1. Axle nut
1. Rear arm
2. Washer
3. Rear arm nut
1
12
3
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)
Ti ghtening 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)
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Periodic maintenance an d a djustment
7-26
7
12. Tighten the muffler bolt to the
specified torque.
13. Adjust the brake lever free play. (See page 7-16.)
14. Install the seat.
EAU25852
Trou bleshootin g
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur
during 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
inferior, have a shorter service life and
can lead to expensive repair bills.
WARNING
EWA15142
When checkin g the fuel system, do
not smoke, an d make sure there are
no open flames or sparks in the ar-
ea, inclu din g pilot li ghts from water
heaters or furnaces. Gasoline or
g asoline vapors can i gnite or ex-
plo de, causin g severe injury or prop-
erty damag e.
1. Exhaust chamber
2. Spring clamp
3. Muffler
Tightening torque:
Muffler bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
1
2
3
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