2021 YAMAHA PW50 brake

Periodic maintenance an d a djustment
7-1
7
EAU17246
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10322
Failure to properly maintain the vehi-
cle or performin g maintenance ac-
tivities incorrectly may increase
your risk of injury or d eath durin g
service or while usin g the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha d ealer perform
service.
WARNING
EWA15123
Turn off the en gine when performin g
maintenance unless otherwise
specified .
 A runnin g en gine has movin g
parts that can catch on body
parts or clothin g an d electrical
parts that can cause shocks or
fires.
 Runnin g the en gine while ser-
vicing can lead to eye injury,
b urns, fire, or car bon monoxi de
poisonin g – possi bly lea din g to d
eath. See pag e 2-2 for more in-
formation a bout car bon monox-
i d e.
WARNING
EWA15461
Brake discs, calipers, drums, an d
linin gs can b ecome very hot during
use. To avoi d possi ble burns, let
b rake components cool before
touchin g them.
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Periodic maintenance an d a djustment
7-4
7
EAU69202
General maintenance an d lu brication chart
TIP
Items marked with an asterisk should be performed by a Yamaha dealer as they
require special tools, data and technical skills.
4 *Tires Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
5
*Wheel bearings Check bearings for smooth operation.
Replace if necessary.
6
*Steering bearings Check bearing assemblies for
looseness.
7 *Middle and final gear
cases Check for grease leakage.
8
*Chassis fasteners Check all chassis fitting and fasteners.
9
*Autolube pump Check operation.
10
*Transmission oil Check for oil leakage.
Correct if necessary.
Change. Correct if necessary. Correct if necessary. Check gears for damage and wear.
Lubricate gears with
lithium-soap-based grease.
Moderately repack with
lithium-soap-based grease.
NO. ITEM CHECK OR MAINTENANCE JOB
1 month3 months
6 months
6 months12 months
1 *
*
*Front brake Check operation.
Adjust brake lever free play.√√√
√
√√√ √
√√√ √
√√√ √
√√√ √
√√√ √
√√√ √
√√√ √ √
√
√√√ √
Replace brake shoes.
Whenever worn to the limit.
2Rear brake Check operation.
Adjust brake lever free play.
Replace brake shoes. Whenever worn to the limit.
Every 2 years
Every 2 years
3Wheels Check runout and for damage.
Replace if necessary.
THEREAFTER
EVERYINITIAL
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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
7-17
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 ad justment.
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)
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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.
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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
Lu bricatin 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
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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 sur- face and hold it in an upright posi-
tion. WARNING! To avoi d injury,
securely support the vehicle so
there is no d anger 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 dealer check or re-
pair it.
Recommen ded lu bricant:
Lithium-soap-based grease
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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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