2009 YAMAHA PW80 maintenance

INTRODUCTION
EAU41582
Congratulations on your purchase of the Yamaha PW80(Y). This model is the result of Yamaha’s vast experience in the pro-
duction of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reli-
ability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you
have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable
at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of
the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the
recommended maintenance schedules and operating instructions contained within this manual.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most cur-
rent product information available at the time of printing, there may be minor discrepancies between your motorcycle and this
manual. If there is any question concerning this manual, please consult a Yamaha dealer.
WARNING

EWA10031
Please read this manual carefully and completely before operating this motorcycle.
WARNING

EWA14351
This motorcycle is designed and manufactured for off-road use only. It is illegal to operate this motorcycle on any
public street, road or highway. Such use is prohibited by law. This motorcycle complies with almost all state
off-highway noise level and spark arrester laws and regulations. Please check your local riding laws and regulations
before operating this motorcycle.
AN IMPORTANT SAFETY MESSAGE:

Read this manual carefully and completely before operating this motorcycle. Make sure you understand all instructions.

Pay close attention to the warning and notice labels on the motorcycle.

Never operate a motorcycle without proper training or instruction.

Weight of the rider should not exceed 40 kg (88 lb).

INTRODUCTION
AN IMPORTANT NOTE TO PARENTS:
This motorcycle is not a toy. Before you let your child ride this motorcycle, you should understand the instructions and warn-
ings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abil-
ities, and judgment. Some children may not be able to operate a motorcycle safely. Parents should supervise their child’s
use of the motorcycle at all times. Parents should permit continued use only if they determine that the child has the ability to
operate the motorcycle safely.
Your motorcycle was delivered with a removable power reduction plate. Yamaha recommends that all beginners start off with
the power reduction plate installed to limit the engine power available while they learn. Parents should decide when to re-
move the power reduction plate from the motorcycle for more power as their youngster’s riding skills improve. Once the rider
can operate with skill at the top speed permitted by power reduction plate installed, the power reduction plate can be re-
moved.
Motorcycles are single track vehicles. Their safe use and operation are dependent upon the use of proper riding
techniques as well as the expertise of the operator. Every operator should know the following requirements before
riding this motorcycle.
He or she should:


Obtain thorough instructions from a competent source on all aspects of motorcycle operation.

Observe the warnings and maintenance requirements in this Owner’s Manual.

Obtain qualified training in safe and proper riding techniques.

Obtain professional technical service as indicated in this Owner’s Manual and/or when made necessary by mechanical
conditions.

TABLE OF CONTENTS
SAFETY INFORMATION
................... 1-1
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 ................................................. 3-7
Shock absorber assembly ............... 3-7
FOR YOUR SAFETY –
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
ADJUSTMENT
.................................... 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
Adjusting the brake lever free
play ............................................ 6-14
Adjusting the brake pedal free
play ............................................ 6-15Checking the front and rear brake
shoes ..........................................6-15
Drive chain slack ............................6-16
Cleaning and lubricating the drive
chain ...........................................6-18
Checking and lubricating the
cables .........................................6-18
Checking and lubricating the throttle
grip and cable .............................6-18
Adjusting the Autolube pump .........6-19
Checking and lubricating the brake
and shift pedals ..........................6-19
Checking and lubricating the brake
lever ............................................6-20
Checking and lubricating the
sidestand ....................................6-20
Checking the front fork ...................6-20
Checking the steering ....................6-21
Checking the wheel bearings .........6-22
Supporting the motorcycle .............6-22
Front wheel ....................................6-23
Rear wheel .....................................6-25
Troubleshooting .............................6-27
Troubleshooting chart ....................6-28
MOTORCYCLE CARE AND
STORAGE
...........................................7-1
Matte color caution ..........................7-1
Care .................................................7-1
Storage ............................................7-3

INSTRUMENT AND CONTROL FUNCTIONS
3-4
2
34
5
6
7
8
9
curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.

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Fuel tank breather hose
Before operating the motorcycle:

Check the fuel tank breather hose
connection.

Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.

Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.
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2-stroke engine oil
Make sure that there is sufficient oil in
the 2-stroke engine oil tank. If the
2-stroke engine oil is at or below the
minimum level as shown in the illustra-
tion, add a sufficient amount of the rec-
ommended 2-stroke engine oil as
follows.
TIP

Make sure that the motorcycle is posi-
tioned straight up when checking the
2-stroke engine oil level. A slight tilt to
the side can result in a false reading.
1. Remove the seat. (See page 3-7.)
2. Remove the 2-stroke engine oil
1. Fuel tank breather hose
1

1. Minimum level
1

4-1
2
3
45
6
7
8
9

FOR YOUR SAFETY – PRE-OPERATION CHECKS
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Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING

EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:

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

PERIODIC MAINTENANCE AND ADJUSTMENT
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Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
WARNING

EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING

EWA15121
Turn off the engine when performing
maintenance unless otherwise
specified.

A running engine has moving
parts that can catch on body
parts or clothing and electricalparts that can cause shocks or
fires.

Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more in-
formation about carbon monox-
ide.
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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.
TIP

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

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

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Periodic maintenance and lubrication chart
TIP


From 160 hours, repeat the maintenance intervals starting from 40 hours.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM CHECK OR MAINTENANCE JOBINITIAL THEREAFTER EVERY
10
hours20
hours40
hours80
hours40
hours80
hours160
hours
1*Fuel line
Check fuel hoses for cracks or damage.Replace if necessary.
2Spark plugCheck condition.Adjust gap and clean.Replace if necessary.
3Air filter elementClean with solvent.Replace if necessary.
4*ClutchCheck operation.Adjust if necessary.
5*Front brakeCheck operation.Adjust brake lever free play.Replace brake shoes. Whenever worn to the limit
6*Rear brakeCheck operation.Adjust brake pedal free play.Replace brake shoes. Whenever worn to the limit
7*WheelsCheck runout, spoke tightness and for
damage.Tighten spokes if necessary.

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