2010 YAMAHA PW80 fuel filter

TABLE OF CONTENTS
LOCATION OF IMPORTANT
LABELS
............................................. 1-1
SAFETY INFORMATION
.................. 2-1
DESCRIPTION
.................................. 3-1
Left view .......................................... 3-1
Right view ........................................ 3-2
Controls and instruments ................ 3-3
INSTRUMENT AND CONTROL
FUNCTIONS
....................................... 4-1
Handlebar switch ............................ 4-1
Power reduction plate ..................... 4-1
Shift pedal ...................................... 4-1
Brake lever ..................................... 4-2
Brake pedal .................................... 4-2
Fuel tank cap .................................. 4-2
Fuel ................................................ 4-3
Fuel tank breather hose ................. 4-4
2-stroke engine oil .......................... 4-4
Fuel cock ........................................ 4-5
Starter (choke) lever “ ” ................ 4-6
Kickstarter ...................................... 4-6
Seat ................................................ 4-7
Shock absorber assembly .............. 4-7
Sidestand ....................................... 4-8
FOR YOUR SAFETY –
PRE-OPERATION CHECKS
.............. 5-1
OPERATION AND IMPORTANT
RIDING POINTS
................................. 6-1
Starting and warming up a cold
engine ......................................... 6-1
Starting a warm engine .................. 6-2
Shifting ........................................... 6-2
Engine break-in .............................. 6-3
Parking ........................................... 6-4
PPERIODIC MAINTENANCE AND
ADJUSTMENT
................................... 7-1
Owner’s tool kit ............................... 7-1
Periodic maintenance and
lubrication chart .......................... 7-2
Checking the spark plug ................. 7-5
Removing the power reduction
plate ............................................ 7-6
Transmission oil ............................. 7-7
Cleaning the air filter element ........ 7-8
Cleaning the spark arrester ............ 7-9
Adjusting the carburetor ............... 7-10
Adjusting the engine idling
speed ........................................ 7-10
Adjusting the throttle cable free
play ........................................... 7-11
Tires ............................................. 7-12
Spoke wheels ............................... 7-13
Adjusting the brake lever free
play ........................................... 7-13
Adjusting the brake pedal free
play ........................................... 7-14Checking the front and rear
brake shoes ............................... 7-15
Drive chain slack ........................... 7-16
Cleaning and lubricating the
drive chain ................................. 7-17
Checking and lubricating the
cables ........................................ 7-18
Checking and lubricating the
throttle grip and cable ................ 7-18
Adjusting the Autolube pump ........ 7-18
Checking and lubricating the
brake lever ................................. 7-19
Checking and lubricating the
brake pedal ................................ 7-19
Checking and lubricating the
sidestand ................................... 7-19
Checking the front fork .................. 7-20
Checking the steering ................... 7-20
Checking the wheel bearings ........ 7-21
Supporting the motorcycle ............ 7-21
Front wheel ................................... 7-22
Rear wheel .................................... 7-24
Troubleshooting ............................ 7-26
Troubleshooting chart ................... 7-27
MOTORCYCLE CARE AND
STORAGE
.......................................... 8-1
Matte color caution ......................... 8-1
Care ................................................ 8-1
Storage ........................................... 8-3

INSTRUMENT AND CONTROL FUNCTIONS
4-5
2
3
45
6
7
8
9
tank cap and add the recommend-
ed oil.
3. Install the 2-stroke engine oil tank
cap.
NOTICE

ECA16670
Make sure that the 2-stroke engine
oil tank cap is properly installed.
4. Install the seat.
EAU13561
Fuel cock
The fuel cock supplies fuel from the
tank to the carburetor while filtering it al-
so.
The fuel cock has three positions:
OFF
With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.
ON
With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
RES

1. 2-stroke engine oil tank
2. 2-stroke engine oil tank cap
Recommended oil:
See page 9-1.
Oil quantity:
0.75 L (0.79 US qt, 0.66 Imp.qt)
1
2

1. Arrow mark positioned over “OFF”
RES
ONFUEL
OFF
1
1. Arrow mark positioned over “ON”
1. Arrow mark positioned over “RES”
ON
FUEL
RES
OFF
1
ON
OFF
ONFUEL RES
1
RES

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

SPECIFICATIONS
EAU2633X
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):
PW80 79.3 dB(A)
Vibration on seat (EN1032, ISO5008):
PW80 Will not exceed 0.5 m/s
2

Vibration on handlebar (EN1032, ISO5008):
PW80 Will not exceed 2.5 m/s
2

Engine:
Engine type:
Air cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
79 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:
PW80 Regular unleaded gasoline only
PW80Z Unleaded gasoline only
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:
Type
×
quantity:
VM15SC x 1
Spark plug (s):
Manufacturer/model:
PW80


NGK/BPR6HS
PW80Z NGK/BP6HS



DENSO/W20FP
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, multiple-disc automatic
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:

INDEX
A
Air filter element, cleaning ......................... 7-8
Autolube pump, adjusting ........................ 7-19
B
Brake lever ................................................ 4-2
Brake lever, checking and lubricating ...... 7-19
Brake lever free play, adjusting ............... 7-14
Brake pedal ............................................... 4-2
Brake pedal, checking and lubricating ..... 7-19
Brake pedal free play, adjusting .............. 7-15
Brake shoes, checking ............................ 7-15
C
Cables, checking and lubricating ............. 7-18
Carburetor, adjusting ............................... 7-10
Care ........................................................... 8-1
D
Drive chain, cleaning and lubricating ....... 7-18
Drive chain slack ..................................... 7-16
E
Engine break-in ......................................... 6-3
Engine idling speed ................................. 7-11
Engine oil ................................................... 4-4
Engine, starting a warm ............................. 6-2
Engine stop switch..................................... 4-1
F
Front fork, checking ................................. 7-20
Fuel............................................................ 4-3
Fuel cock ................................................... 4-5
Fuel tank breather hose............................. 4-4
Fuel tank cap ............................................. 4-2
H
Handlebar switch ....................................... 4-1
I
Identification numbers ............................. 10-1
K
Kickstarter ................................................. 4-6
L
Labels, location ......................................... 1-1
M
Matte color, caution ................................... 8-1
Model label .............................................. 10-1
P
Parking ...................................................... 6-4
Part locations............................................. 3-1
Periodic maintenance and lubrication
chart ........................................................ 7-2
Power reduction plate................................ 4-1
Power reduction plate, removing ............... 7-6
S
Safety information ..................................... 2-1
Seat ........................................................... 4-7
Shifting ...................................................... 6-2
Shift pedal ................................................. 4-1
Shock absorber assembly ......................... 4-7
Sidestand .................................................. 4-8
Sidestand, checking and lubricating ........ 7-20
Spark arrester, cleaning ............................ 7-9
Spark plug, checking ................................. 7-5
Specifications ............................................ 9-1
Starter (choke) lever .................................. 4-6
Starting and warming up a cold engine ..... 6-1
Steering, checking ................................... 7-21
Storage ...................................................... 8-3
Supporting the motorcycle....................... 7-22
T
Throttle cable free play, adjusting ........... 7-11Throttle grip and cable, checking and
lubricating ............................................. 7-18
Tires ........................................................ 7-12
Tool kit ...................................................... 7-1
Transmission oil ........................................ 7-7
Troubleshooting ...................................... 7-26
Troubleshooting chart ............................. 7-28
V
Vehicle identification number .................. 10-1
W
Wheel bearings, checking ....................... 7-21
Wheel (front) ........................................... 7-22
Wheel (rear) ............................................ 7-25
Wheels .................................................... 7-13