2011 YAMAHA PW80 wheel

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
U3RV8LE0.book Page 18 Tuesday, April 13, 2010 8:48 AM

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)
U3RV8LE0.book Page 23 Tuesday, April 13, 2010 8:48 AM

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)
U3RV8LE0.book Page 24 Tuesday, April 13, 2010 8:48 AM

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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PERIODIC MAINTENANCE AND ADJUSTMENT
7-26
7 5. Lift the rear wheel off the ground
according to the procedure on
page 7-22.
6. Remove the axle nut and washer,
and then pull the wheel axle out.
7. Remove the spacer and chain pull-
ers.
8. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
TIPThe drive chain does not need to be
disassembled in order to remove and
install the wheel.9. Remove the wheel by pulling it
back.
EAU41573
To install the rear wheel
1. Insert the brake shoe plate into the
wheel hub, and then insert the
wheel into the swingarm.
2. Install the drive chain onto the rear
sprocket.
3. Install the wheel by inserting the
chain pullers, spacer and then in-
sert the wheel axle from the right-
hand side.
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 brake rod into the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.
7. Install the washer and axle nut.8. Lower the rear wheel so that it is
on the ground, and then put the
sidestand down.
9. Adjust the drive chain slack. (See
page 7-17.)
10. Tighten the axle nut to the speci-
fied torque.
11. Adjust the brake pedal free play.
(See page 7-15.)Tightening torque:
Brake torque rod nut:
16 Nm (1.6 m·kgf, 12 ft·lbf)
Tightening torque:
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
U3RV8LE0.book Page 26 Tuesday, April 13, 2010 8:48 AM

MOTORCYCLE CARE AND STORAGE
8-1
8
EAU37833
Matte color caution NOTICE
ECA15192
Some models are equipped with
matte colored finished parts. Be
sure to consult a Yamaha dealer for
advice on what products to use be-
fore cleaning the vehicle. Using a
brush, harsh chemical products or
cleaning compounds when cleaning
these parts will scratch or damage
their surface. Wax also should not
be applied to any matte colored fin-
ished parts.
EAU40465
Care While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your mo-
torcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
NOTICE
ECA10772


Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.


Improper cleaning can damage
plastic parts (such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc.) and
the mufflers. Use only a soft,
clean cloth or sponge with wa-
ter to clean plastic. However, if
the plastic parts cannot be thor-
oughly cleaned with water, di-
luted mild detergent with water
may be used. Be sure to rinse
U3RV8LE0.book Page 1 Tuesday, April 13, 2010 8:48 AM