2009 YAMAHA PW80 torque

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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU41951
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.
EAU17311
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
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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.
TIP

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.
EAU41102
Removing the power
reduction plate
To obtain full engine performance ca-
pability, removing the power reduction
plate is required.
1. Remove the exhaust manifold by
removing the bolts.
WARNING!
Always let the exhaust system
cool prior to touching exhaust
components.
[EWA14581]

2. Remove the gasket.
3. Remove the power reduction
plate.
TIP

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)
2 13

PERIODIC MAINTENANCE AND ADJUSTMENT
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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
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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)
1

PERIODIC MAINTENANCE AND ADJUSTMENT
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2. Tap the tailpipe lightly, and then
use a wire brush to remove any
carbon deposits from the spark ar-
rester portion of the tailpipe and in-
side of the tailpipe housing.3. Insert the tailpipe into the muffler,
and then install and tighten the bolt
to the specified torque.
TIP

Make sure to align the bolt hole when
inserting the tailpipe.
EAU39930
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in the
following section, however, may be ser-
viced by the owner as part of routine
maintenance.
NOTICE

ECA10550
The carburetor has been set and ex-
tensively tested at the Yamaha fac-
tory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine.
1. Bolt
1

1. Tailpipe
2. Spark arrester
3. Bolt
Tightening torque:
Tailpipe bolt:
7.5 Nm (0.8 m·kgf, 5.5 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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2. To tighten the drive chain, turn the
drive chain slack adjusting nut at
each end of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting nut at each end
of the swingarm in direction (b),
and then push the rear wheel for-
ward.
NOTICE:
Improper drive
chain slack will overload the en-
gine 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 with-in the specified limits.

[ECA10571]

TIP

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.
3. Tighten both locknuts and the axle
nut to the specified torques.4. Adjust the brake pedal free play.
(See page 6-15.)
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

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 ADJUSTMENT
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8. Lift the front wheel off the ground
according to the procedure on
page 6-22.
9. Pull the wheel axle out, and then
remove the wheel.

EAU41550
To install the front wheel
1. Install the brake shoe plate into the
wheel hub as shown.2. Lift the wheel up between the fork
legs.
TIP

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.
1. Washer
2. Axle nut
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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 ADJUSTMENT
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(See page 6-14.)
10. Push down hard on the handlebar
several times to check for proper
fork operation.

EAU25080
Rear wheel
EAU41561
To remove the rear wheel
WARNING

EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.
1. Loosen the axle nut.
2. Remove the brake pedal free play
adjusting 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 the
swingarm.
5. Lift the rear wheel off the ground
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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PERIODIC MAINTENANCE AND ADJUSTMENT
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according to the procedure on
page 6-22.
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.
TIP

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.
EAU41571
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!
Always use a new cotter
pin.
[EWA10831]

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.)
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)