2008 YAMAHA PW80 torque

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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU41950
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of mo-
torcycle inspection, adjustment, and
lubrication are explained on the follow-
ing pages.
Maintenance, replacement, or repair
of the emission control devices and
systems may be performed by any
repair establishment or individual
that is certified (if applicable).
WARNING

EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
EAU17320
Owner’s tool kit
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
WARNING

EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es.

PERIODIC MAINTENANCE AND MINOR REPAIR
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2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
4. Install the spark plug cap.
EAU41100
Removing the power
reduction plate
To obtain full engine performance ca-
pability, removing the power reduction
plate is required.
WARNING

EWA14580
Always let the exhaust system cool
prior to touching exhaust compo-
nents.
1. Remove the exhaust manifold by
removing the bolts.
2. Remove the gasket.
3. Remove the power reduction
plate.
NOTE:

Store the power reduction plate with the
owner’s manual so that it is readily
available whenever you want to reduce
the engine power.
4. Install the exhaust manifold by in-
stalling the bolts.
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Tightening torque:
Spark plug:
25 Nm (2.5 m·kgf, 18.1 ft·lbf)
1. Exhaust manifold bolt
1
1. Exhaust manifold
2. Gasket
3. Power reduction plate
Tightening torque:
Exhaust manifold bolt:
18 Nm (1.8 m·kgf, 13.0 ft·lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU19942
Transmission oil
The transmission oil level should be
checked before each ride. In addition,
the transmission oil must be changed
at the intervals specified in the periodic
maintenance and lubrication chart.
To check the transmission oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:

Make sure that the vehicle is positionedstraight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
2. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
NOTE:

The transmission oil should be be-
tween the minimum and maximum lev-
el marks.
3. If the oil is below the minimum lev-
el mark, add sufficient oil of the
recommended type to raise it to
the correct level.
4. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
To change the transmission oil
1. Place an oil pan under the trans-
mission to collect the used oil.
2. Remove the oil filler cap and drain
bolt to drain the oil from the trans-
mission.
3. Install the transmission oil drain
bolt, and then tighten it to the spec-
ified torque.
4. Add the specified amount of the
recommended transmission oil,
and then install and tighten the oil
filler cap.
1. Transmission oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
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1. Transmission oil drain bolt
Tightening torque:
Transmission oil drain bolt:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
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4. If the drive chain slack is incorrect,
adjust it as follows.

EAU40110
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.2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction (a). To loos-
en the drive chain, turn the adjust-
ing nut at each end of the
swingarm in direction (b), and then
push the rear wheel forward.
NOTE:

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.
CAUTION:

ECA10570
Improper drive chain slack will over-
load the engine 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 within the
specified limits.
3. Tighten both locknuts and the axle
nut to the specified torques.
1. Drive chain slack
1

1. Brake pedal free play adjusting nut
2. Locknut
3. Drive chain slack adjusting nut
4. Wheel axle
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1. Alignment marks
2. Drive chain slack adjusting nut
3. Locknut
4. Washer
5. Axle nut
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(a)
(b)3

PERIODIC MAINTENANCE AND MINOR REPAIR
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4. Adjust the brake pedal free play.
(See page 6-15.)

EAU23013
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.
CAUTION:

ECA10581
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.
NOTE:

For 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 both sides
and on the middle of the chain,
making sure that all side plates
and rollers have been sufficientlyoiled.
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 MINOR REPAIR
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2. Lift the wheel up between the fork
legs.
NOTE:

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.(See page 6-14.)
10. Push down hard on the handlebar
several times to check for proper
fork operation.
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 MINOR REPAIR
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EAU25080
Rear wheel
EAU41560
To remove the rear wheel
WARNING

EWA10820

It is advisable to have a Yamaha
dealer service the wheel.

Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Loosen the axle nut.
2. Remove the brake pedal free playadjusting 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 theswingarm.
5. Lift the rear wheel off the ground
according to the procedure on
page 6-23.
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.
NOTE:

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.
1. Drive chain slack adjusting nut
2. Locknut
3. Chain puller
4. Washer
5. Axle nut
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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
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EAU41570
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

EWA10830
Always use a new cotter pin.
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.)
EAU25850
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
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)