2008 YAMAHA PW80 steering wheel

TABLE OF CONTENTS
SAFETY INFORMATION
...................1-1
Safe riding ........................................1-1
Location of important labels .............1-4
DESCRIPTION
...................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS
........................................3-1
Handlebar switch .............................3-1
Power reduction plate ......................3-1
Shift pedal ........................................3-1
Brake lever ......................................3-2
Brake pedal .....................................3-2
Fuel tank cap ...................................3-2
Fuel ..................................................3-3
Fuel tank breather hose ...................3-4
2-stroke engine oil ...........................3-4
Fuel cock .........................................3-5
Starter (choke) lever “
1
” .................3-6
Kickstarter ........................................3-6
Seat .................................................3-6
Shock absorber ...............................3-7
PRE-OPERATION CHECKS
...............4-1
Pre-operation check list ...................4-2
OPERATION AND IMPORTANT
RIDING POINTS
.................................. 5-1
Starting and warming up a cold
engine .......................................... 5-1
Starting a warm engine ................... 5-2
Shifting ............................................ 5-2
Engine break-in ............................... 5-3
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR
.................................. 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance and lubrication
chart ............................................. 6-2
Checking the spark plug .................. 6-5
Removing the power reduction
plate ............................................. 6-6
Transmission oil .............................. 6-7
Cleaning the air filter element ......... 6-8
Cleaning the spark arrester ............. 6-9
Adjusting the carburetor ................ 6-10
Adjusting the engine idling
speed ......................................... 6-11
Adjusting the throttle cable free
play ............................................ 6-11
Tires .............................................. 6-12
Spoke wheels ................................ 6-13
Accessories and replacement
parts ........................................... 6-14
Adjusting the brake lever free
play ............................................ 6-14Adjusting the brake pedal free
play ............................................ 6-15
Checking the front and rear brake
shoes ......................................... 6-16
Drive chain slack ........................... 6-16
Cleaning and lubricating the drive
chain .......................................... 6-18
Checking and lubricating the
cables ........................................ 6-19
Checking and lubricating the throttle
grip and cable ............................ 6-19
Adjusting the Autolube pump ........ 6-19
Checking and lubricating the brake
and shift pedals ......................... 6-20
Checking and lubricating the brake
lever ........................................... 6-20
Checking and lubricating the
sidestand ................................... 6-21
Checking the front fork .................. 6-21
Checking the steering ................... 6-22
Checking the wheel bearings ........ 6-22
Supporting the motorcycle ............ 6-23
Front wheel ................................... 6-23
Rear wheel .................................... 6-26
Troubleshooting ............................ 6-27
Troubleshooting chart ................... 6-28
MOTORCYCLE CARE AND
STORAGE
........................................... 7-1
Matte color caution .......................... 7-1
Care ................................................ 7-1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
2
3
4
5
67
8
9
8*Tires
Check tread depth and for damage.Replace if necessary.Check air pressure.Correct if necessary.
9*Wheel bearingsCheck bearings for smooth operation.Replace if necessary.
10 *Steering bearingsCheck bearing assemblies for looseness.Moderately repack with lithium-soap-based
grease.
11Drive chainCheck chain slack/alignment and condi-
tion.Adjust and lubricate chain with Yamaha
chain and cable lube thoroughly.Every rideRemove and clean.
12 *Chassis fastenersCheck all chassis fitting and fasteners.Correct if necessary.
13Sidestand pivotCheck operation.Apply lithium-soap-based grease (all-pur-
pose grease) lightly.
14 *Front forkCheck operation and for oil leakage.Replace if necessary.
15 *Shock absorber
assemblyCheck operation and for oil leakage.Replace if necessary.
16 *CarburetorCheck engine idling speed and starter
operation.Clean.Replace if necessary. NO. ITEM CHECK OR MAINTENANCE JOBINITIAL THEREAFTER EVERY
10
hours20
hours40
hours80
hours40
hours80
hours160
hours

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
1
2
3
4
5
6
7
8
9

EAU23280
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.
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
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.
EAU23290
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.

INDEX
A
Accessories and replacement parts ........ 6-14
Air filter element, cleaning......................... 6-8
Autolube pump, adjusting ....................... 6-19
B
Brake and shift pedals, checking and
lubricating ............................................. 6-20
Brake lever ................................................ 3-2
Brake lever, checking and lubricating ..... 6-20
Brake lever free play, adjusting............... 6-14
Brake pedal ............................................... 3-2
Brake pedal free play, adjusting.............. 6-15
Brake shoes, checking ............................ 6-16
C
Cables, checking and lubricating ............ 6-19
Carburetor, adjusting .............................. 6-10
Care .......................................................... 7-1
D
Drive chain, cleaning and lubricating ...... 6-18
Drive chain slack ..................................... 6-16
E
Engine break-in ......................................... 5-3
Engine idling speed................................. 6-11
Engine oil .................................................. 3-4
Engine, starting a warm ............................ 5-2
Engine stop switch .................................... 3-1
F
Front fork, checking ................................ 6-21
Fuel ........................................................... 3-3
Fuel cock................................................... 3-5
Fuel tank breather hose ............................ 3-4
Fuel tank cap ............................................ 3-2
H
Handlebar switch ...................................... 3-1
I
Identification numbers................................9-1
K
Kickstarter ..................................................3-6
L
Labels, location of ......................................1-4
M
Matte color, caution ...................................7-1
Model label ................................................9-1
P
Parking.......................................................5-4
Part locations .............................................2-1
Periodic maintenance and lubrication
chart ........................................................6-2
Power reduction plate ................................3-1
Power reduction plate, removing ...............6-6
Pre-operation check list .............................4-2
S
Safety information ......................................1-1
Seat ...........................................................3-6
Shifting .......................................................5-2
Shift pedal ..................................................3-1
Shock absorber..........................................3-7
Sidestand, checking and lubricating ........6-21
Spark arrester, cleaning.............................6-9
Spark plug, checking .................................6-5
Specifications.............................................8-1
Starter (choke) lever ..................................3-6
Starting and warming up a cold engine .....5-1
Steering, checking ...................................6-22
Storage ......................................................7-3
Supporting the motorcycle .......................6-23
T
Throttle cable free play, adjusting ............6-11Throttle grip and cable, checking and
lubricating .............................................. 6-19
Tires ........................................................ 6-12
Tool kit ....................................................... 6-1
Transmission oil ........................................ 6-7
Troubleshooting....................................... 6-27
Troubleshooting chart.............................. 6-28
V
Vehicle identification number .................... 9-1
W
Wheel bearings, checking ....................... 6-22
Wheel (front)............................................ 6-23
Wheel (rear) ............................................ 6-26
Wheels .................................................... 6-13