2011 YAMAHA PW80 air 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 ....................................... 4-8FOR 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

DESCRIPTION
3-1
3
EAU10410
Left view
1
23 4 5
6 7
1. Air filter element (page 7-9)
2. Fuel cock (page 4-5)
3. Throttle stop screw (page 7-11)
4. Starter (choke) lever (page 4-6)
5. 2-stroke engine oil tank (page 4-4)
6. Sidestand (page 4-8)
7. Shift pedal (page 4-1)
U3RV8LE0.book Page 1 Tuesday, April 13, 2010 8:48 AM

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.
U3RV8LE0.book Page 2 Tuesday, April 13, 2010 8:48 AM

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
7-9
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
7-10
7 4. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the ex-
cess oil out.
TIPThe sponge material should be wet but
not dripping.5. Install the sponge material onto
the air filter case cover.
6. Insert the air filter element into the
air filter case. NOTICE: Make sure
that the air filter element is prop-
erly seated in the air filter case.
The engine should never be op-erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
[ECA10481]
7. Install the air filter case cover by in-
stalling the screws.
EAU41232
Cleaning the spark arrester The spark arrester should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
WARNING
EWA10980


Always let the exhaust system
cool prior to touching exhaust
components.


Do not start the engine when
cleaning the exhaust system.
1. Remove the tailpipe by removing
the bolt, and then pulling it out of
the muffler.
Recommended oil:
Yamaha foam air filter oil or other
quality foam air filter oil
1. Bolt
1
U3RV8LE0.book Page 10 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