2011 YAMAHA PW80 transmission

OPERATION AND IMPORTANT RIDING POINTS
6-3
63. Open the throttle gradually.
4. Once the motorcycle has reached
a speed high enough to change
gears, close the throttle.
5. Shift into second gear and release
the shift pedal.
6. Open the throttle gradually.
7. Follow the same procedure when
shifting to the next higher gear.
EAU16710
To decelerate
1. Close the throttle and apply both
the front and the rear brakes to
slow the motorcycle.
2. Downshift through the gears and
shift the transmission into the neu-
tral position when the motorcycle
is almost completely stopped.
EAU39920
Engine break-in There is never a more important period
in the life of your engine than the first 5
hours of riding. It is also important to ac-
custom the rider to the motorcycle dur-
ing this time. Please read the following
information carefully.
Since the engine is brand new, do not
put an excessive load on it for the first 5
hours of operation. The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided. However, momentary full-
throttle operation under load (i.e., two
to three seconds maximum) does not
harm the engine. Each full-throttle ac-
celeration should be followed with a
substantial rest period for the engine.
To allow the engine to cool down from
the temporary buildup of heat, cruise at
a lower engine speed.
After the first 5 hours of operation, thor-
oughly check the motorcycle for loose
parts, oil leakage and any other prob-
lems. Be sure to inspect and make ad-justments thoroughly, especially cable
and drive chain slack and loose
spokes. In addition, check all fittings
and fasteners for looseness, and tight-
en if necessary.
NOTICE
ECA10270
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-5
7
TIPThe air filter needs more frequent service if you are riding in unusually wet or dusty areas.13 *
14
15 *
16 *
17
18Autolube pump
Transmission oil
Control cables
Throttle grip housing
and cable
Brake lever pivot shaft
Brake pedal pivot
shaft NO. ITEM CHECK OR MAINTENANCE JOBINITIAL THEREAFTER EVERY
10
hours20
hours40
hours80
hours40
hours80
hours160
hours
Check for oil leakage.Correct if necessary.Change (warm engine before draining).Check operation.Correct if necessary.Check operation and free play.Apply Yamaha chain and cable lube or
engine oil 10W-30 lightly.Apply lithium-soap-based grease lightly.Apply Yamaha chain and cable lube or
engine oil 10W-30 lightly.Apply lithium-soap-based grease lightly.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-8
7
EAU49890
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.TIPMake sure that the vehicle is positioned
straight 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.TIPThe transmission oil should be be-
tween the tip of the dipstick and maxi-
mum level mark.
3. If the oil does not reach the tip of
the dipstick, 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, the trans-
mission oil drain bolt and its gasket
to drain the oil from the transmis-
sion.3. Install the transmission oil drain
bolt and its new gasket, and then
tighten the bolt to the specified
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. Tip of the dipstick
2
3
41
1
1. Transmission oil drain bolt
2. Gasket
Tightening torque:
Transmission oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
Recommended transmission oil:
See page 9-1.
Oil change quantity:
0.65 L (0.69 US qt, 0.57 Imp.qt)
12
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-9
7
NOTICE
ECA10452


In order to prevent clutch slip-
page (since the transmission oil
also lubricates the clutch), do
not mix any chemical additives.
Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-
rial enters the transmission.
5. Start the engine, and then let it idle
for several minutes while checking
the transmission for oil leakage. If
oil is leaking, immediately turn the
engine off and check for the cause.
EAU41163
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean or, if necessary, replace the air
filter element more frequently if you are
riding in unusually wet or dusty areas.
1. Remove the air filter case cover by
removing the screws.
2. Pull the air filter element out.3. Remove the sponge material from
the air filter case cover, clean it
with solvent, and then squeeze the
remaining solvent out.1. Air filter case cover
2. Screw
2
2
1
1. Sponge material
2. Air filter case cover
1
2
U3RV8LE0.book Page 9 Tuesday, April 13, 2010 8:48 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-17
7Rear
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.
TIPBe sure to measure the brake lining at
the thinnest portion.
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.TIPWhen checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.4. If the drive chain slack is incorrect,
adjust it as follows.
EAU40112
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut, axle nut, and locknut
at each end of the swingarm.
Drive chain slack:
40.0–53.0 mm (1.57–2.09 in)
1. Drive chain slack
1
U3RV8LE0.book Page 17 Tuesday, April 13, 2010 8:48 AM

SPECIFICATIONS
9-1
9
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 kg (134 lb)Noise and vibration level:Noise level (77/311/EEC):
PW80 79.3 dB(A)@2750 r/min
Vibration on seat (EN1032, ISO5008):
PW80 Will not exceed 0.5 m/s²
Vibration on handlebar (EN1032, ISO5008):
PW80 Will not exceed 2.5 m/s²Engine:Engine type:
Air cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
79 cm³
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 2S 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 elementFuel:Recommended fuel:
PW80 Regular unleaded gasoline only
PW80A 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:
NGK/BPR6HS
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:
Wet, multiple-disc automaticTransmission: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:
26.00 °
U3RV8LE0.book Page 1 Tuesday, April 13, 2010 8:48 AM

INDEX
AAir filter element, cleaning ...................... 7-9
Autolube pump, adjusting ..................... 7-20BBrake lever ............................................. 4-2
Brake lever, checking and lubricating ... 7-20
Brake lever free play, adjusting ............ 7-14
Brake pedal ............................................ 4-2
Brake pedal, checking and
lubricating ........................................... 7-20
Brake pedal free play, adjusting ........... 7-15
Brake shoes, checking ......................... 7-16CCables, checking and lubricating .......... 7-19
Carburetor, adjusting ............................ 7-11
Care ........................................................ 8-1DDrive chain, cleaning and lubricating .... 7-19
Drive chain slack .................................. 7-17EEngine break-in ...................................... 6-3
Engine idling speed .............................. 7-11
Engine oil ................................................ 4-4
Engine, starting a warm .......................... 6-2
Engine stop switch.................................. 4-1FFront fork, checking .............................. 7-21
Fuel......................................................... 4-3
Fuel cock ................................................ 4-5
Fuel tank breather hose.......................... 4-4
Fuel tank cap .......................................... 4-2GGeneral maintenance and lubrication
chart ..................................................... 7-3
HHandlebar switch..................................... 4-1IIdentification numbers ........................... 10-1KKickstarter ............................................... 4-6LLabels, location .......................................1-1MMaintenance, emission control system ... 7-2
Matte color, caution .................................8-1
Model label ............................................ 10-1PParking ....................................................6-4
Part locations .......................................... 3-1
Power reduction plate ............................. 4-1
Power reduction plate, removing............. 7-7SSafety information ...................................2-1
Seat ......................................................... 4-7
Shifting ....................................................6-2
Shift pedal ............................................... 4-1
Shift pedal, checking ............................. 7-16
Shock absorber assembly ....................... 4-7
Sidestand ................................................ 4-8
Sidestand, checking and lubricating...... 7-21
Spark arrester, cleaning ........................ 7-10
Spark plug, checking ...............................7-6
Specifications .......................................... 9-1
Starter (choke) lever................................ 4-6
Starting and warming up a cold engine ... 6-1
Steering, checking.................................7-22
Storage....................................................8-3
Supporting the motorcycle .................... 7-22
TThrottle cable free play, adjusting ......... 7-12
Throttle grip and cable, checking and
lubricating ........................................... 7-19
Tires ...................................................... 7-13
Tool kit .................................................... 7-1
Transmission oil ...................................... 7-8
Troubleshooting .................................... 7-27
Troubleshooting chart ........................... 7-28VVehicle identification number ................ 10-1WWheel bearings, checking..................... 7-22
Wheel (front) ......................................... 7-23
Wheel (rear) .......................................... 7-25
Wheels .................................................. 7-14
U3RV8LE0.book Page 1 Tuesday, April 13, 2010 8:48 AM