2011 YAMAHA PW80 ABS

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 ....................................... 4-8FOR 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
PERIODIC MAINTENANCE AND
ADJUSTMENT................................... 7-1
Owner’s tool kit .............................. 7-1
Periodic maintenance chart for the
emission control system ............. 7-2
General maintenance and
lubrication chart .......................... 7-3
Checking the spark plug ................ 7-6
Removing the power reduction
plate ............................................ 7-7
Transmission oil ............................. 7-8
Cleaning the air filter element ........ 7-9
Cleaning the spark arrester ......... 7-10
Adjusting the carburetor ............... 7-11
Adjusting the engine idling
speed ........................................ 7-11
Adjusting the throttle cable free
play ........................................... 7-12
Tires ............................................. 7-13Spoke wheels ............................... 7-14
Adjusting the brake lever free
play ........................................... 7-14
Adjusting the brake pedal free
play ........................................... 7-15
Checking the shift pedal ............... 7-16
Checking the front and rear brake
shoes ........................................ 7-16
Drive chain slack .......................... 7-17
Cleaning and lubricating the drive
chain ......................................... 7-19
Checking and lubricating the
cables ....................................... 7-19
Checking and lubricating the
throttle grip and cable ............... 7-19
Adjusting the Autolube pump ....... 7-20
Checking and lubricating the
brake lever ................................ 7-20
Checking and lubricating the
brake pedal ............................... 7-20
Checking and lubricating the
sidestand .................................. 7-21
Checking the front fork ................. 7-21
Checking the steering .................. 7-22
Checking the wheel bearings ....... 7-22
Supporting the motorcycle ........... 7-22
Front wheel .................................. 7-23
Rear wheel ................................... 7-25
Troubleshooting ........................... 7-27
Troubleshooting chart .................. 7-28
U3RV8LE0.book Page 1 Tuesday, April 13, 2010 8:48 AM

INSTRUMENT AND CONTROL FUNCTIONS
4-7
4
EAU41140
Seat To remove the seat
Remove the nuts, and then pull the seat
off.
To install the seat
1. Insert the projection on the front of
the seat into the seat holder as
shown.2. Place the seat in the original posi-
tion, and then tighten the nuts.
TIPMake sure that the seat is properly se-
cured before riding.
EAU46021
Shock absorber assembly
WARNING
EWA10221
This shock absorber assembly con-
tains highly pressurized nitrogen
gas. Read and understand the fol-
lowing information before handling
the shock absorber assembly.

Do not tamper with or attempt to
open the cylinder assembly.


Do not subject the shock ab-
sorber assembly to an open
flame or other high heat source.
This may cause the unit to ex-
plode due to excessive gas
pressure.


Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.


Do not dispose of a damaged or
worn-out shock absorber as-
sembly yourself. Take the shock
absorber assembly to a Yamaha
dealer for any service.
1. Nut
1
1. Seat holder
2. Projection
2
1
U3RV8LE0.book Page 7 Tuesday, April 13, 2010 8:48 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
7
Steering bearings
Drive chain
Chassis fasteners
Sidestand pivot
Front fork
Shock absorber
assembly 7*
8
9*
10
11 *
12 *NO. ITEM CHECK OR MAINTENANCE JOBINITIAL THEREAFTER EVERY
10
hours20
hours40
hours80
hours40
hours80
hours160
hours
Every ride
Check bearing assemblies for looseness.Moderately repack with lithium-soap-based
grease.Check all chassis fitting and fasteners.Replace if necessary.Check operation.Apply lithium-soap-based grease lightly.Check operation and for oil leakage.Replace if necessary.Check operation and for oil leakage.Replace if necessary.Remove and clean.Check chain slack/alignment and condi-
tion.Adjust and lubricate chain with Yamaha
chain and cable lube thoroughly.
U3RV8LE0.book Page 4 Tuesday, April 13, 2010 8:48 AM

MOTORCYCLE CARE AND STORAGE
8-2
8 off any detergent residue using
plenty of water, as it is harmful
to plastic parts.


Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.


Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.


For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.
After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain or near the seaSince sea salt is extremely corrosive,
carry out the following steps after each
ride in the rain or near the sea.
1. Clean the motorcycle with cold wa-
ter and a mild detergent, after the
engine has cooled down.
NOTICE: Do not use warm water
since it increases the corrosive
action of the salt.
[ECA10791]
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
U3RV8LE0.book Page 2 Tuesday, April 13, 2010 8:48 AM

SPECIFICATIONS
9-2
9
Trail:
62.0 mm (2.44 in)Front tire:Type:
With tube
Size:
2.50-14 4PR
Manufacturer/model:
CHENG SHIN/KNOBBYRear tire:Type:
With tube
Size:
3.00-12 4PR
Manufacturer/model:
CHENG SHIN/KNOBBYLoading:Maximum rider weight:
40.0 kg (88 lb)Tire air pressure (measured on cold
tires):
Front:
100 kPa (1.00 kgf/cm², 15 psi)
Rear:
100 kPa (1.00 kgf/cm², 15 psi)
Front wheel:Wheel type:
Spoke wheel
Rim size:
14x1.40Rear wheel:Wheel type:
Spoke wheelRim size:
12x1.60
Front brake:Type:
Drum brake
Operation:
Right hand operationRear brake:Type:
Drum brake
Operation:
Right foot operationFront suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
110.0 mm (4.33 in)Rear suspension:Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
95.0 mm (3.74 in)Electrical system:Ignition system:
CDI
U3RV8LE0.book Page 2 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