2009 YAMAHA PW80 steering wheel

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

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

PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
1
2
3
4
5
6
7
8
9
NOTICE

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23282
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. (See page 6-1 for more in-
formation.)
WARNING! To avoid
injury, securely support the ve-
hicle so there is no danger of it
falling over.
[EWA10751]

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.

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