maintenance YAMAHA PW80 2011 Owner's Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
7-16
7
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.
EAU44820
Checking the shift pedal The operation of the shift pedal should
be checked before each ride. If opera-
tion is not smooth, have a Yamaha
dealer check the vehicle.
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 7-23.


To remove the rear wheel: See
page 7-25.
Front
1. Brake pedal free play adjusting nut
1
(a)
(b)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-17
7Rear
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.
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.TIPWhen 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.
EAU40112
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
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-18
7 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]
TIPUsing the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the same
position 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 7-15.)
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. Drive chain puller
5. Washer
6. Axle nut
Tightening torques:
Locknut:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
62
1
(a)(b)
5
4
3
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-19
7
EAU23016
Cleaning and lubricating the
drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.NOTICE
ECA10583
The drive chain must be lubricated
after washing the motorcycle, riding
in the rain or riding in wet areas.1. Remove all dirt and mud from the
drive chain with a brush or cloth.TIPFor a thorough cleaning, have a
Yamaha dealer remove the drive chain
and soak it in solvent.2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on the entire
chain, making sure that all side
plates and rollers have been suffi-
ciently oiled.
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]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.
Recommended lubricant:
Yamaha Chain and Cable Lube or 4-
stroke engine oil
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-20
7
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.
EAU43622
Checking and lubricating the
brake lever The operation of the brake lever should
be checked before each ride, and the
lever pivot should be lubricated if nec-
essary.
EAU23182
Checking and lubricating the
brake pedal The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-21
7
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.
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
7-22
7
EAU23283
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 a stand under the engine to
raise the front wheel off the
ground. (See page 7-22 for more
information.) WARNING! To
avoid injury, 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.
EAU24350
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-23
7a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU24360
Front wheel
EAU49911
To remove the front wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Loosen the brake cable locknut at
the front wheel hub, and then turn
the brake lever free play adjusting
bolt fully in direction (a).
2. Slide the rubber cover back at the
brake lever.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. Slide the rubber cover down at the
front wheel hub, and then turn the
front brake lever free play adjust-
ing bolt fully in direction (b) to dis-
connect the brake cable from the
front wheel hub.
6. Remove the axle nut and washer.1. Brake lever free play adjusting bolt
2. Locknut
3. Rubber cover3
1
2 (a)
(b)
1. Rubber cover
2. Brake lever free play adjusting bolt
3. Locknut
3 2
1
(a)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-24
7 7. Lift the front wheel off the ground
according to the procedure on
page 7-22.
8. Pull the wheel axle out, and then
remove the wheel.
EAU41553
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, and then install the washer
and axle nut.
4. Lower the front wheel so that it is
on the ground, and then put the
sidestand down.
5. Connect the brake cable to the
brake camshaft lever.
6. Turn the front brake lever free play
adjusting bolt at the wheel hub in
direction (a), and then slide the
rubber cover to its original position.
7. Connect the brake cable at the
front brake lever.
8. Tighten the axle nut to the speci-
fied torque.
1. Washer
2. Axle nut
2
1
1. Brake shoe plate
1. Retainer
1
1
1. Brake lever free play adjusting bolt
2. Rubber cover
3. Brake camshaft lever23
1
(a)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-25
79. Adjust the brake lever free play.
(See page 7-14.)
10. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU41563
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.
Tightening torque:
Axle nut:
35 Nm (3.5 m·kgf, 25 ft·lbf)
1. Drive chain slack adjusting nut
2. Locknut
3. Drive chain puller
4. Washer
5. Axle nut
5
41
2
3
1. Brake rod
2. Brake pedal free play adjusting nut
3. Brake camshaft lever
4. Spacer
5. Drive chain puller
6. Wheel axle
7. Drive chain slack adjusting nut
8. Locknut
9. Brake torque rod
10.Brake torque rod bolt
11.Cotter pin
12.Brake torque rod nut
287
46
9
1110
12
1
3
5
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