2011 YAMAHA PW80 oil

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

DESCRIPTION
3-2
3
EAU10420
Right view
7 12
3
4 5
6
1. Spark arrester (page 7-10)
2. Seat (page 4-7)
3. Transmission oil filler cap (page 7-8)
4. Spark plug cap (page 7-6)
5. Brake pedal (page 4-2)
6. Transmission oil drain bolt (page 7-8)
7. Kickstarter (page 4-6)U3RV8LE0.book Page 2 Tuesday, April 13, 2010 8:48 AM

INSTRUMENT AND CONTROL FUNCTIONS
4-4
4 curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
EAU13412
Fuel tank breather hose Before operating the motorcycle:

Check the fuel tank breather hose
connection.


Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.


Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.
EAU41202
2-stroke engine oil Make sure that there is sufficient oil in
the 2-stroke engine oil tank. If the 2-
stroke engine oil is at or below the min-
imum level as shown in the illustration,
add a sufficient amount of the recom-
mended 2-stroke engine oil as follows.TIPMake sure that the motorcycle is posi-
tioned straight up when checking the 2-
stroke engine oil level. A slight tilt to the
side can result in a false reading.1. Remove the seat. (See page 4-7.)
2. Remove the 2-stroke engine oil
tank cap and add the recommend-
ed oil.
1. Fuel tank breather hose
1
1. Minimum level
1
U3RV8LE0.book Page 4 Tuesday, April 13, 2010 8:48 AM

INSTRUMENT AND CONTROL FUNCTIONS
4-5
4
3. Install the 2-stroke engine oil tank
cap.
NOTICE
ECA16670
Make sure that the 2-stroke engine
oil tank cap is properly installed.4. Install the seat.
EAU13561
Fuel cock The fuel cock supplies fuel from the
tank to the carburetor while filtering it al-
so.
The fuel cock has three positions:
OFF
With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.ON
With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
RES
1. 2-stroke engine oil tank
2. 2-stroke engine oil tank capRecommended oil:
See page 9-1.
Oil quantity:
0.75 L (0.79 US qt, 0.66 Imp.qt)
1
2
1. Arrow mark positioned over “OFF”
RES
ONFUEL
1
OFF
1. Arrow mark positioned over “ON”
1. Arrow mark positioned over “RES”
ON
FUEL
RES
OFF
1
ON
OFF
ONFUEL RES
RES
1
U3RV8LE0.book Page 5 Tuesday, April 13, 2010 8:48 AM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-1
5
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check the fuel tank breather/overflow hose for obstructions, cracks or damage,
and check the hose connection.4-3, 4-4
2-stroke engine oilCheck oil level in oil tank.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.4-4
Transmission oilCheck oil level in transmission case.
If necessary, add recommended oil to specified level.7-8
Front brakeCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.7-14, 7-16
Rear brakeCheck operation.
Check pedal free play.
Adjust if necessary.7-15, 7-16
U3RV8LE0.book Page 1 Tuesday, April 13, 2010 8:48 AM

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.
U3RV8LE0.book Page 3 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