Transmission YAMAHA PW80 2008 User Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
1
2
3
4
5
6
7
8
9
CAUTION:

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.
EAU41161
Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently 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.
Recommended transmission oil:
See page 8-1.
Oil change quantity:
0.65 L (0.69 US qt) (0.57 Imp.qt)
1. Air filter case cover
2. Screw
2
2
1

1. Sponge material
2. Air filter case cover
1
2

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
1
2
3
4
5
6
7
8
9

EAU41052
Checking the front and rear
brake shoes
The front and rear brake shoes must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
NOTE:

The wheels must be removed to check
brake shoe lining thickness.

To remove the front wheel: See
page 6-23.

To remove the rear wheel: See
page 6-26.
FrontRear
If the lining thickness of a brake shoe is
less than 1.5 mm (0.06 in), have a
Yamaha dealer replace the brake
shoes as a set.
NOTE:

Be sure to measure the brake lining at
the thinnest portion.
EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.
NOTE:

When checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.
Drive chain slack:
40.0–53.0 mm (1.57–2.09 in)

8-1
2
3
4
5
6
7
89

SPECIFICATIONS
EAU2633K
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:
61.0 kg (134 lb)
Engine:
Engine type:
Air cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
79.0 cm
3

Bore
×
stroke:
47.0
×
45.6 mm (1.85
×
1.80 in)
Compression ratio:
6.60 :1
Starting system:
KickstarterLubrication system:
Separate lubrication (Yamaha autolube)

Engine oil:
Type:
YAMALUBE 2 or 2-stroke engine oil (JASO
FC grade) or (ISO EG-C or EG-D grade)
Engine oil quantity:
Quantity:
0.95 L (1.00 US qt) (0.84 Imp.qt)
Transmission oil:
Type:
YAMALUBE 4 (10W30) or SAE 10W30
Oil change quantity:
0.65 L (0.69 US qt) (0.57 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Regular unleaded gasoline only
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)
Unleaded gasoline only (AUS)(NZL)
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:
Manufacturer:
MIKUNI
Type
×
quantity:
VM15SC x 1
Spark plug (s):
Manufacturer/model:
NGK/BP6HS (AUS)(NZL)
NGK/BPR6HS
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)
Manufacturer/model:
DENSO/W20FP (AUS)(NZL)
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, multiple-disc automatic
Transmission:
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)

INDEX
A
Accessories and replacement parts ........ 6-14
Air filter element, cleaning......................... 6-8
Autolube pump, adjusting ....................... 6-19
B
Brake and shift pedals, checking and
lubricating ............................................. 6-20
Brake lever ................................................ 3-2
Brake lever, checking and lubricating ..... 6-20
Brake lever free play, adjusting............... 6-14
Brake pedal ............................................... 3-2
Brake pedal free play, adjusting.............. 6-15
Brake shoes, checking ............................ 6-16
C
Cables, checking and lubricating ............ 6-19
Carburetor, adjusting .............................. 6-10
Care .......................................................... 7-1
D
Drive chain, cleaning and lubricating ...... 6-18
Drive chain slack ..................................... 6-16
E
Engine break-in ......................................... 5-3
Engine idling speed................................. 6-11
Engine oil .................................................. 3-4
Engine, starting a warm ............................ 5-2
Engine stop switch .................................... 3-1
F
Front fork, checking ................................ 6-21
Fuel ........................................................... 3-3
Fuel cock................................................... 3-5
Fuel tank breather hose ............................ 3-4
Fuel tank cap ............................................ 3-2
H
Handlebar switch ...................................... 3-1
I
Identification numbers................................9-1
K
Kickstarter ..................................................3-6
L
Labels, location of ......................................1-4
M
Matte color, caution ...................................7-1
Model label ................................................9-1
P
Parking.......................................................5-4
Part locations .............................................2-1
Periodic maintenance and lubrication
chart ........................................................6-2
Power reduction plate ................................3-1
Power reduction plate, removing ...............6-6
Pre-operation check list .............................4-2
S
Safety information ......................................1-1
Seat ...........................................................3-6
Shifting .......................................................5-2
Shift pedal ..................................................3-1
Shock absorber..........................................3-7
Sidestand, checking and lubricating ........6-21
Spark arrester, cleaning.............................6-9
Spark plug, checking .................................6-5
Specifications.............................................8-1
Starter (choke) lever ..................................3-6
Starting and warming up a cold engine .....5-1
Steering, checking ...................................6-22
Storage ......................................................7-3
Supporting the motorcycle .......................6-23
T
Throttle cable free play, adjusting ............6-11Throttle grip and cable, checking and
lubricating .............................................. 6-19
Tires ........................................................ 6-12
Tool kit ....................................................... 6-1
Transmission oil ........................................ 6-7
Troubleshooting....................................... 6-27
Troubleshooting chart.............................. 6-28
V
Vehicle identification number .................... 9-1
W
Wheel bearings, checking ....................... 6-22
Wheel (front)............................................ 6-23
Wheel (rear) ............................................ 6-26
Wheels .................................................... 6-13