2010 YAMAHA PW80 steering wheel

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

PERIODIC MAINTENANCE AND ADJUSTMENT
7-3
2
3
4
5
6
78
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.Replace if necessary.
13
Sidestand pivotCheck operation.Apply lithium-soap-based g
rease lightly.
14 *Front fork
Check 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
7-20
1
2
3
4
5
6
7
8
9

EAU23272
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.

[EWA10751]

2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
NOTICE

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23283
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 7-21 for more
information.)
WARNING! To
avoid injury, securely support
the vehicle 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 ......................... 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