brake YAMAHA PW80 2009 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
2
3
4
5
67
8
9

EAU22120
Adjusting the brake lever free
play
The brake lever free play should mea-
sure 10.0–20.0 mm (0.39–0.79 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the brake le-
ver.
2. To increase the brake lever free
play, turn the adjusting bolt in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
bolt in direction (b).3. If the specified brake lever free
play could be obtained as de-
scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.
4. Fully turn the adjusting bolt at the
brake lever in direction (a) to loos-
en the brake cable.
5. Loosen the locknut at the brake
shoe plate.
6. To increase the brake lever free
play, turn the adjusting nut in direc-
tion (a). To decrease the brake le-
ver free play, turn the adjusting nut
in direction (b).
7. Tighten the locknut at the brakeshoe plate and at the brake lever.
1. Brake lever free play
2. Locknut
3. Adjusting bolt
1
2
3
(a)
(b)

1. Locknut
2. Adjusting nut
12
(a)
(b)

PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
1
2
3
4
5
6
7
8
9

EAU39812
Adjusting the brake pedal free
play
The brake pedal free play should mea-
sure 10.0–20.0 mm (0.39–0.79 in) at
the brake pedal end as shown. Period-
ically check the brake pedal free play
and, if necessary, adjust it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).
WARNING

EWA10680

After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.

If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this ad-
justment.

After adjusting the brake pedal
free play, check the operation of
the brake light.
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 6-23.

To remove the rear wheel: See
page 6-25.
Front
1. Brake pedal free play
1

1. Brake pedal free play adjusting nut
1
(a)
(b)

PERIODIC MAINTENANCE AND ADJUSTMENT
6-16
2
3
4
5
67
8
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.
EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.
TIP

When checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.4. If the drive chain slack is incorrect,
adjust it as follows.
EAU40111
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut, axle nut, and locknut
at each end of the swingarm.
Drive chain slack:
40.0–53.0 mm (1.57–2.09 in)
1. Drive chain slack
1

PERIODIC MAINTENANCE AND ADJUSTMENT
6-17
1
2
3
4
5
6
7
8
9
2. To tighten the drive chain, turn the
drive chain slack adjusting nut at
each end of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting nut at each end
of the swingarm in direction (b),
and then push the rear wheel for-
ward.
NOTICE:
Improper drive
chain slack will overload the en-
gine as well as other vital parts
of the motorcycle and can lead
to chain slippage or breakage.
To prevent this from occurring,
keep the drive chain slack with-in the specified limits.

[ECA10571]

TIP

Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po-
sition for proper wheel alignment.
3. Tighten both locknuts and the axle
nut to the specified torques.4. Adjust the brake pedal free play.
(See page 6-15.)
1. Brake pedal free play adjusting nut
2. Locknut
3. Drive chain slack adjusting nut
4. Wheel axle
2
14 3

1. Alignment marks
2. Drive chain slack adjusting nut
3. Locknut
4. Washer
5. Axle nut
5
42
1
(a)
(b)3

Tightening torques:
Locknut:
6.5 Nm (0.7 m·kgf, 4.7 ft·lbf)
Axle nut:
60 Nm (6.0 m·kgf, 43.4 ft·lbf)

PERIODIC MAINTENANCE AND ADJUSTMENT
6-19
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.
EAU44271
Checking and lubricating the
brake and shift pedals
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
Recommended lubricant:
Lithium-soap-based grease

PERIODIC MAINTENANCE AND ADJUSTMENT
6-20
2
3
4
5
67
8
9

EAU43621
Checking and lubricating the
brake lever
The operation of the brake lever should
be checked before each ride, and the
lever pivots should be lubricated if nec-
essary.
EAU23202
Checking and lubricating the
sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
WARNING

EWA10731
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the sidestand could contact the
ground and distract the operator, re-
sulting in a possible loss of control.
EAU23272
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,
damage and excessive oil leakage.
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.
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease

PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
1
2
3
4
5
6
7
8
9

EAU24360
Front wheel
EAU41532
To remove the front wheel
WARNING

EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.
1. Remove the brake cable holder by
removing the bolt.
2. Loosen the brake cable locknut at
the front wheel hub, and then turn
the brake cable free play adjusting
bolt fully in direction (a).3. Loosen the locknut at the brake le-
ver, and then turn the adjusting
bolt fully in direction (a).4. Disconnect the brake cable from
the front brake lever.
5. Disconnect the brake cable from
the brake camshaft lever.
6. Remove the brake cable free play
adjusting bolt and the brake cable
locknut at the front wheel hub.
7. Remove the axle nut and washer.
1. Brake cable holder
2. Bolt
2
1

1. Adjusting nut
2. Locknut
3. Washer
4. Axle nut
5. Brake camshaft lever
4
5
3
1
2

1. Adjusting bolt
2. Locknut
2 1
(a)

PERIODIC MAINTENANCE AND ADJUSTMENT
6-24
2
3
4
5
67
8
9
8. Lift the front wheel off the ground
according to the procedure on
page 6-22.
9. Pull the wheel axle out, and then
remove the wheel.

EAU41550
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, and then in-
stall the washer and axle nut.
4. Lower the front wheel so that it is
on the ground.
5. Connect the brake cable at the
wheel hub.
6. Connect the brake cable at the
front brake lever.
7. Install the brake cable holder by in-
stalling the bolt.
8. Tighten the axle nut to the speci-
fied torque.
9. Adjust the brake lever free play.
1. Washer
2. Axle nut
2
1

1. Brake shoe plate
1

1. Retainer
Tightening torque:
Axle nut:
35 Nm (3.5 m·kgf, 25.3 ft·lbf)
1

PERIODIC MAINTENANCE AND ADJUSTMENT
6-25
1
2
3
4
5
6
7
8
9
(See page 6-14.)
10. Push down hard on the handlebar
several times to check for proper
fork operation.

EAU25080
Rear wheel
EAU41561
To remove the rear wheel
WARNING

EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.
1. Loosen the axle nut.
2. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod from the brake cam-shaft lever.
3. Disconnect the brake torque rod
from the brake shoe plate by re-
moving the cotter pin, the nut, and
the bolt.
4. Loosen the locknut and drive chain
adjusting nut on each end of the
swingarm.
5. Lift the rear wheel off the ground
1. Drive chain slack adjusting nut
2. Locknut
3. Chain puller
4. Washer
5. Axle nut
5
41
2
3

1. Brake pedal free play adjusting nut
2. Spacer
3. Chain puller
4. Wheel axle
5. Drive chain slack adjusting nut
6. Locknut
7. Brake torque rod
8. Brake torque rod bolt
9. Cotter pin
10. Brake torque rod nut
165
24
7
98
10
3

PERIODIC MAINTENANCE AND ADJUSTMENT
6-26
2
3
4
5
67
8
9
according to the procedure on
page 6-22.
6. Remove the axle nut and washer,
and then pull the wheel axle out.
7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
TIP

The drive chain does not need to be
disassembled in order to remove and
install the wheel.
8. Remove the spacer, chain pullers
and wheel by pulling it back.
EAU41571
To install the rear wheel
1. Install the drive chain onto the rear
sprocket.2. Install the wheel by inserting the
chain pullers, spacer and then in-
sert the wheel axle from the
right-hand side.
3. Install the brake rod onto the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.
4. Connect the brake torque rod onto
the brake shoe plate by installing
the bolt and nut, and then tighten
the nut to the specified torque.
5. Insert a new cotter pin into the
brake torque rod bolt.
WARNING!
Always use a new cotter
pin.
[EWA10831]

6. Install the washer and axle nut,
and then lower the rear wheel so
that it is on the ground.
7. Adjust the drive chain slack. (See
page 6-16.)
8. Tighten the axle nut to the speci-
fied torque.9. Adjust the brake pedal free play.
(See page 6-15.)
Tightening torque:
Brake torque rod nut:
15.5 Nm (1.6 m·kgf, 11.2 ft·lbf)
Tightening torque:
Axle nut:
60 Nm (6.0 m·kgf, 43.4 ft·lbf)