2011 YAMAHA PW80 steering

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

SAFETY INFORMATION
2-4
2


Never install accessories that
would impair the performance of
your motorcycle. Carefully inspect
the accessory before using it to
make sure that it does not in any
way reduce ground clearance or
cornering clearance, limit suspen-
sion travel, steering travel or con-
trol operation.
Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution. If accesso-
ries are added to the handlebar
or front fork area, they must be
as lightweight as possible and
should be kept to a minimum.
Bulky or large accessories may
seriously affect the stability of
the motorcycle. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds.
Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-tor and may limit control ability,
therefore, such accessories are
not recommended.


Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match the
performance capabilities and to provide
the best combination of handling, brak-
ing, and comfort. Other tires, rims, siz-
es, and combinations may not be
appropriate. Refer to page 7-13 for tire
specifications and more information on
replacing your tires.
Transporting the motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.


Remove all loose items from the
motorcycle.


Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.


Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.


Shift the transmission in gear (for
models with a manual transmis-
sion).


Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or parts
that could break). Choose the lo-
cation for the straps carefully so
the straps will not rub against
painted surfaces during transport.


The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the mo-
torcycle will not bounce excessive-
ly during transport.
U3RV8LE0.book Page 4 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

PERIODIC MAINTENANCE AND ADJUSTMENT
7-22
7
EAU23283
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground. (See page 7-22 for more
information.) WARNING! To
avoid injury, securely support
the vehicle so there is no danger
of it falling over.
[EWA10751]
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
EAU23291
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAU24350
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
U3RV8LE0.book Page 22 Tuesday, April 13, 2010 8:48 AM

CONSUMER INFORMATION
10-1
10
EAU40791
Identification numbers Record the vehicle identification num-
ber and model label information in the
spaces provided below for assistance
when ordering spare parts from a
Yamaha dealer or for reference in case
the vehicle is stolen.
VEHICLE IDENTIFICATION
NUMBER:
MODEL LABEL INFORMATION:
EAU26400
Vehicle identification number
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro-
vided.TIPThe vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcy-
cle with the licensing authority in your
area.
EAU26460
Model label
The model label is affixed to the loca-
tion shown. Record the information on
this label in the space provided. This in-
formation will be needed when ordering
spare parts from a Yamaha dealer.
1. Vehicle identification number
1
1. Model label
1
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