2010 YAMAHA PW80 warning

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FOR YOUR SAFETY – PRE-OPERATION CHECKS
EAU15596
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:
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.4-3
2-stroke engine oil

Check oil level in oil tank.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.4-4
Transmission oil

Check oil level in transmission case.

If necessary, add recommended oil to specified level.7-7
Front brake

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.7-13, 7-15
Rear brake

Check operation.

Check pedal free play.

Adjust if necessary.7-14
Throttle grip

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.7-11, 7-18
Control cables

Make sure that operation is smooth.

Lubricate if necessary.7-18

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OPERATION AND IMPORTANT RIDING POINTS
EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING

EWA10271
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU41155
Starting and warming up a
cold engine
1. Turn the fuel cock lever to “ON”.
2. Set the engine stop switch to
“RUN”.
3. Shift the transmission into the neu-
tral position.
WARNING

EWA14410

Be sure to shift the transmis-
sion into neutral before starting
the engine.

Never ride with the sidestand
down.
4. Turn the starter (choke) on and
completely close the throttle. (See
page 4-6.)
5. Start the engine by pushing the
kickstarter lever down.
6. After starting the engine, move the
starter (choke) back halfway.
NOTICE:
For maximum engine
life, never accelerate hard when
the engine is cold!

[ECA11041]

7. When the engine is warm, turn the
starter (choke) off.
TIP

The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.

OPERATION AND IMPORTANT RIDING POINTS
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EAU17191
Parking
When parking, stop the engine, and
then turn the fuel cock lever to “OFF”.
WARNING

EWA10311

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them and be burned.

Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn, increasing the
risk of a fuel leak and fire.

Do not park near grass or other
flammable materials which
might catch fire.

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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 2-1 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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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.
Tightening torque:
Spark plug:
25 Nm (2.5 m·kgf, 18.1 ft·lbf)
1. Exhaust manifold bolt
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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 ADJUSTMENT
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4. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the ex-
cess oil out.
TIP

The sponge material should be wet but
not dripping.
5. Install the sponge material onto
the air filter case cover.
6. Insert the air filter element into the
air filter case.
NOTICE:
Make sure
that the air filter element is prop-
erly seated in the air filter case.
The engine should never be op-erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
[ECA10481]

7. Install the air filter case cover by in-
stalling the screws.
EAU41232
Cleaning the spark arrester
The spark arrester should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
WARNING

EWA10980

Always let the exhaust system
cool prior to touching exhaust
components.

Do not start the engine when
cleaning the exhaust system.
1. Remove the tailpipe by removing
the bolt, and then pulling it out of
the muffler.
2. Tap the tailpipe lightly, and then
use a wire brush to remove any
Recommended oil:
Yamaha foam air filter oil or other
quality foam air filter oil
1. Bolt
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU39821
Tires
To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING

EWA14381
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.

The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).

The tire air pressure must be ad-
justed in accordance with the
weight of the rider, the riding
speed, and the riding condi-
tions.Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
Tire information
This motorcycle is equipped with spoke
wheels and tube tires.
WARNING

EWA10461
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, which
could lead to an accident.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
WARNING

EWA14390

Have a Yamaha dealer replace
excessively worn tires. Operat-
ing the motorcycle with exces-
Standard tire air pressure:
Front:
100 kPa (1.00 kgf/cm 2
, 15 psi)
Rear:
100 kPa (1.00 kgf/cm
2

, 15 psi)
1. Tire sidewall
2. Tire tread depth
Minimum tire tread depth (front and
rear):
4.0 mm (0.16 in)
12

Front tire:
Size:
2.50-14 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY
Rear tire:
Size:
3.00-12 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY

PERIODIC MAINTENANCE AND ADJUSTMENT
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WARNING

EWA10680

After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.

If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this ad-
justment.

After adjusting the brake pedal
free play, check the operation of
the brake light.
EAU41052
Checking the front and rear
brake shoes
The front and rear brake shoes must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
TIP

The wheels must be removed to check
brake shoe lining thickness.

To remove the front wheel: See
page 7-22.

To remove the rear wheel: See
page 7-24.
FrontRear
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.
1. Brake pedal free play adjusting nut
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