brake YAMAHA PW50 2018 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 cab
le lubricant or other
suitab le cable lubricant.
15*Throttle grip Check operation.
Check throttle grip free play, and
adjust if necessary.
Apply Yamaha cab le lubricant or other
suitab le 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
U2SA84E0.book Page 5 Wednesday, May 10, 2017 9:37 AM

Periodic maintenance an d a djustment
7-17
7
EAU22153
A djustin 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). Front
Rear
WARNING
EWA10651
If proper a
djustment cannot b e ob-
taine d as d escri bed , have a Yamaha
d ealer make this a djustment.
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
1. Front brake lever free play adjusting nut
1. Rear brake lever free play adjusting nut
1
(a)
(b)
1
(a)(b)
U2SA84E0.book Page 17 Wednesday, May 10, 2017 9:37 AM

Periodic maintenance an d a djustment
7-18
7
EAU41054
Checkin g 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 7-23.
 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.
TIP
Be sure to measure the brake lining at
the thinnest portion.
U2SA84E0.book Page 18 Wednesday, May 10, 2017 9:37 AM

Periodic maintenance an d a djustment
7-20
7
EAU23121
A djustin g the Autolu be 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.
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.
Recommen ded lu bricant:
Lithium-soap-based grease
U2SA84E0.book Page 20 Wednesday, May 10, 2017 9:37 AM

Periodic maintenance an d a djustment
7-21
7
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 possi ble loss of control.
EAU23273
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,
damage and excessive oil leakage.
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 damag e is foun d or the front
fork does not operate smoothly,
have a Yamaha d ealer check or re-
pair it.
Recommen ded lu bricant:
Lithium-soap-based grease
U2SA84E0.book Page 21 Wednesday, May 10, 2017 9:37 AM

Periodic maintenance an d a djustment
7-23
7
EAU24361
Front wheel
EAU56510
To remove the front wheel
WARNING
EWA10822
To avoi d injury, securely support the
vehicle so there is no d anger 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. 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.
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
1. Wheel axle
1. Retainer
1
1
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Periodic maintenance an d a djustment
7-24
7 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 lever free play adjusting nut.
6. Adjust the brake lever free play. (See page 7-17.)
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.
EAU25081
Rear wheel
EAU56822
To remove the rear 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. Remove the seat. (See page 4-8.)
3. Remove the muffler bolt and washers. WARNING! Always let
the exhaust system cool prior to
touching exhaust components.
[EWA14582]
4. Slide the spring clamp down, and
then remove the muffler.
5. Remove the exhaust chamber bolt and washers.
Tightenin g torque:
Axle nut: 36 N·m (3.6 kgf·m, 27 lb·ft)
1. Muffler
2. Washer
3. Muffler bolt
4. Spring clamp
312 4
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Periodic maintenance an d a djustment
7-25
7
6. 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 up-
ward 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 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.
1. Exhaust chamber
2. Exhaust chamber bolt
3. Washer
1. Exhaust manifold bolt
1. Rear shock absorber mounting bolt
2
1
3
1
1
1. Axle nut
1. Rear arm
2. Washer
3. Rear arm nut
1
1
2
3
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Periodic maintenance an d a djustment
7-26
7 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.
12. Tighten the muffler bolt to thespecified torque.
13. Adjust the brake lever free play. (See page 7-17.)
14. Install the seat.
Ti ghtenin g torques:
Axle nut: 60 N·m (6.0 kgf·m, 44 lb·ft)
Rear arm nut:
29 N·m (2.9 kgf·m, 21 lb·ft)
Rear shock absorber mounting bolt: 23 N·m (2.3 kgf·m, 17 lb·ft)
1. Exhaust manifold
2. Gasket
3. Power reduction plate
4. Exhaust manifold bolt
Tightenin g torques:
Exhaust manifold bolt: 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Exhaust chamber bolt:
18 N·m (1.8 kgf·m, 13 lb·ft)
2
3
4
1
1. Exhaust chamber
2. Spring clamp
3. Muffler
Tightening torque:
Muffler bolt: 18 N·m (1.8 kgf·m, 13 lb·ft)
1
2
3
U2SA84E0.book Page 26 Wednesday, May 10, 2017 9:37 AM

Motorcycle care and stora ge
8-2
8 structe
d. Also, thorou ghly rinse
the area off with water, imme di-
ately dry it, an d then apply a cor-
rosion protection spray.
 Improper cleanin g can d amage
plastic parts (such as cowlin gs,
panels, etc.) an d the mufflers.
Use only a soft, clean cloth or
spon ge with water to clean
plastic. However, if the plastic
parts cannot be thorou ghly
cleaned with water, dilute d mil d
d eter gent with water may b e
use d. Be sure to rinse off any
d eter gent resi due using plenty
of water, as it is harmful to plas-
tic parts.
 Do not use any harsh chemical
prod ucts on plastic parts. Be
sure to avoi d using cloths or
spon ges which have been in
contact with stron g or a brasive
cleanin g prod ucts, solvent or
thinner, fuel (g asoline), rust re-
movers or inhi bitors, brake flui d,
antifreeze or electrolyte.
 Do not use hi
gh-pr
essure wash-
ers or steam-jet cleaners since
they cause water seepa ge an d
d eterioration in the followin g ar-
eas: seals (of wheel an d swin g-
arm bearin gs, fork an d b rakes),
electric components (couplers,
connectors, an d switches),
b reather hoses an d vents.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain or near the sea
Since sea salt is extremely corrosive,
carry out the following steps after each
ride in the rain or near the sea.
1. Clean the motorcycle with cold water and a mild detergent, after
the engine has cooled down.
NOTICE: Do not use warm wa-
ter since it increases the corro-
sive action of the salt.
[ECA10792]
2. Apply a corrosion protection spray on all metal, including chrome-
and nickel-plated, surfaces to pre-
vent corrosion.
After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth.
2. Use a chrome polish to shine chrome, aluminum and stainless-
steel parts.
3. To prevent corrosion, it is recom- mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean- er to remove any remaining dirt.
5. Touch up minor paint damage caused by stones, etc.
6. Wax all painted surfaces.
7. Let the motorcycle dry completely before storing or covering it.
WARNING
EWA14502
Contaminants on the brakes or tires
can cause loss of control.
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