2009 YAMAHA PW80 transmission

PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
2
3
4
5
67
8
9
TIP

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
17 *Autolube pump
Check operation.Correct if necessary.Bleed.
18Transmission oilCheck for oil leakage .Correct if necessary.Change.
19 *Control cablesApply Yamaha chain and cable lube or
engine oil 10W-30 lightly.
20 *Throttle grip housing
and cableCheck operation and free play.Apply Yamaha chain and cable lube or
engine oil 10W-30 lightly.
21Brake lever pivot shaftApply lithium-soap-based grease lightly.
22Brake pedal pivot
shaftApply lithium-soap-based grease lightly.
23 *Cylinder head and
exhaust systemCheck for leakage.Tighten if necessary.Decarbonize if necessary.
24 *Spark arresterClean. NO. ITEM CHECK OR MAINTENANCE JOBINITIAL THEREAFTER EVERY
10
hours20
hours40
hours80
hours40
hours80
hours160
hours

PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
1
2
3
4
5
6
7
8
9

EAU19943
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.
TIP

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.
TIP

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. Refill with 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
2
3
41
1

1. Transmission oil drain bolt
Tightening torque:
Transmission oil drain bolt:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
1

PERIODIC MAINTENANCE AND ADJUSTMENT
6-8
2
3
4
5
67
8
9
NOTICE

ECA10452

In order to prevent clutch slip-
page (since the transmission oil
also lubricates the clutch), do
not mix any chemical additives.
Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

Make sure that no foreign mate-
rial enters the transmission.
5. Start the engine, and then let it idle
for several minutes while checking
the transmission for oil leakage. If
oil is leaking, immediately turn the
engine off and check for the cause.
EAU41162
Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case cover by
removing the screws.
2. Pull the air filter element out.3. Remove the sponge material from
the air filter case cover, clean it
with solvent, and then squeeze the
remaining solvent out.
Recommended transmission oil:
See page 8-1.
Oil change quantity:
0.65 L (0.69 US qt, 0.57 Imp.qt)
1. Air filter case cover
2. Screw
2
2
1

1. Sponge material
2. Air filter case cover
1
2

PERIODIC MAINTENANCE AND ADJUSTMENT
6-16
2
3
4
5
67
8
9 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.
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.
TIP

When 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.
EAU40111
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

8-1
1
2
3
4
5
6
7
8
9

SPECIFICATIONS
EAU2633P
Dimensions:
Overall length:
1540 mm (60.6 in)
Overall width:
640 mm (25.2 in)
Overall height:
880 mm (34.6 in)
Seat height:
635 mm (25.0 in)
Wheelbase:
1055 mm (41.5 in)
Ground clearance:
185 mm (7.28 in)
Minimum turning radius:
1700 mm (66.9 in)
Weight:
With oil and fuel:
61.0 kg (134 lb)
Noise and vibration level:
Noise level (77/311/EEC):
79.3 dB(A)
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)
Vibration on seat (EN1032, ISO5008):
Will not exceed 0.5 m/s
2


(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)Vibration on handlebar (EN1032, ISO5008):
Will not exceed 2.5 m/s
2


(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)
Engine:
Engine type:
Air cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
79.0 cm
3

Bore
×
stroke:
47.0
×
45.6 mm (1.85
×
1.80 in)
Compression ratio:
6.60 :1
Starting system:
Kickstarter
Lubrication system:
Separate lubrication (Yamaha autolube)

Engine oil:
Type:
YAMALUBE 2 or 2-stroke engine oil (JASO
FC grade) or (ISO EG-C or EG-D grade)
Engine oil quantity:
Quantity:
0.75 L (0.79 US qt, 0.66 Imp.qt)
Transmission oil:
Type:
YAMALUBE 4 (10W-40) or SAE 10W-40
Oil change quantity:
0.65 L (0.69 US qt, 0.57 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Regular unleaded gasoline only
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)
Unleaded gasoline only (AUS)(NZL)
Fuel tank capacity:
4.9 L (1.29 US gal, 1.08 Imp.gal)
Fuel reserve amount:
1.0 L (0.26 US gal, 0.22 Imp.gal)
Carburetor:
Manufacturer:
MIKUNI
Type
×
quantity:
VM15SC x 1
Spark plug (s):
Manufacturer/model:
NGK/BP6HS (AUS)(NZL)
NGK/BPR6HS
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)
Manufacturer/model:
DENSO/W20FP (AUS)(NZL)
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, multiple-disc automatic

SPECIFICATIONS
8-2
2
3
4
5
6
7
89 Transmission:

Primary reduction system:
Helical gear
Primary reduction ratio:
66/21 (3.143)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
32/15 (2.133)
Transmission type:
Constant mesh 3-speed
Operation:
Left foot operation
Gear ratio:
1st:
39/12 (3.250)
2nd:
29/16 (1.812)
3rd:
22/17 (1.294)
Chassis:
Frame type:
Steel tube backbone
Caster angle:
26.00 °
Trail:
62.0 mm (2.44 in)
Front tire:
Type:
With tube
Size:
2.50-14 4PRManufacturer/model:
CHENG SHIN/KNOBBY
Rear tire:
Type:
With tube
Size:
3.00-12 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY
Loading:
Maximum rider weight:
40.0 kg (88 lb)
Maximum load:
40 kg (88 lb)
* (Total weight of rider, cargo and
accessories)
Tire air pressure (measured on cold
tires):
Front:
100 kPa (1.00 kgf/cm
2

, 15 psi)
Rear:
100 kPa (1.00 kgf/cm
2
, 15 psi)
Front wheel:
Wheel type:
Spoke wheel
Rim size:
14x1.40
Rear wheel:
Wheel type:
Spoke wheel
Rim size:
12x1.60
Front brake:
Type:
Drum brake
Operation:
Right hand operation
Rear brake:
Type:
Drum brake
Operation:
Right foot operation
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
110.0 mm (4.33 in)
Rear suspension:
Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
95.0 mm (3.74 in)
Electrical system:
Ignition system:
CDI

INDEX
A
Air filter element, cleaning .........................6-8
Autolube pump, adjusting ........................6-19
B
Brake and shift pedals, checking and
lubricating ..............................................6-19
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 ............................6-15
C
Cables, checking and lubricating .............6-18
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 .................................6-20
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
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 ........................................................... 3-7
Shifting ...................................................... 5-2
Shift pedal ................................................. 3-1
Shock absorber assembly ......................... 3-7
Sidestand, checking and lubricating ........ 6-20
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 ................................... 6-21
Storage ...................................................... 7-3
Supporting the motorcycle....................... 6-22
T
Throttle cable free play, adjusting ........... 6-11
Throttle grip and cable, checking and
lubricating .............................................. 6-18Tires ........................................................ 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) ............................................ 6-25
Wheels .................................................... 6-13