2011 YAMAHA PW80 engine

OPERATION AND IMPORTANT RIDING POINTS
6-2
6
EAU16660
Starting a warm engine Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm. Instead, start
the engine with the throttle slightly
open.TIPIf the engine does not start after several
kicks, try again with the throttle 1/4 to
1/2 open.
EAU39901
Shifting This motorcycle has a 3-speed trans-
mission with a centrifugal, automatic
clutch. Shifting gears lets you control
the amount of engine power available
for starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the il-
lustration.TIPTo shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel.
NOTICE
ECA15441


Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.


Always release the throttle grip
before changing gears to avoid
damaging the engine, transmis-
sion, and drive train, which are
not designed to withstand the
shock of shifting when the throt-
tle grip is open.
EAU39911
To start out and accelerate
1. Close the throttle.
2. Shift into first gear and release the
shift pedal. NOTICE: Always
close the throttle before shifting
gears, otherwise damage to the
engine and drive train may re-
sult.
[ECA15461]
1. Shift pedal
2. Neutral position
1
12 3N2
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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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OPERATION AND IMPORTANT RIDING POINTS
6-4
6
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.
U3RV8LE0.book Page 4 Tuesday, April 13, 2010 8:48 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-1
7
EAU41952
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 electrical
parts 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.WARNING
EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
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.TIPIf you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-2
7
EAU49900
Periodic maintenance chart for the emission control system TIP

From 160 hours, repeat the maintenance intervals starting from 40 hours.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
Carburetor 4*
5*
6*Cylinder head and
exhaust system
Spark arrester NO. ITEM
1*
2
3Fuel line
Spark plug
Air filter elementCHECK OR MAINTENANCE JOBINITIAL THEREAFTER EVERY
10
hours20
hours40
hours80
hours40
hours80
hours160
hours
Check for leakage.Tighten if necessary.Decarbonize if necessary.Clean.Clean.Replace if necessary.Check engine idling speed and starter
operation.Check fuel hoses for cracks or damage.Replace if necessary.Clean with solvent.Replace if necessary.Check condition.Adjust gap and clean.Replace if necessary.
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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.
U3RV8LE0.book Page 5 Tuesday, April 13, 2010 8:48 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-6
7
EAU19604
Checking the spark plug The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
TIPIf the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
stead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
3. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
1. Spark plug cap
1
1. Spark plug wrench
1
Specified spark plug:
NGK/BPR6HS
1. Spark plug gap
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-7
7To install the spark plug
1. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
2. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
TIPIf 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.3. Install the spark plug cap.
EAU41103
Removing the power reduc-
tion 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.
TIPStore 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 and its
new gasket by installing the bolts,
and then tighten the bolts to the
specified torque.
Tightening torque:
Spark plug:
25 Nm (2.5 m·kgf, 18 ft·lbf)
1. Exhaust manifold bolt
1
1. Exhaust manifold
2. Gasket
3. Power reduction plateTightening torque:
Exhaust manifold bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
2 13
U3RV8LE0.book Page 7 Tuesday, April 13, 2010 8:48 AM