fuel YAMAHA PW80 2009 Owners Manual

TABLE OF CONTENTS
SAFETY INFORMATION
................... 1-1
DESCRIPTION
................................... 2-1
Left view ........................................... 2-1
Right view ......................................... 2-2
Controls and instruments ................. 2-3
INSTRUMENT AND CONTROL
FUNCTIONS
........................................ 3-1
Handlebar switch ............................. 3-1
Power reduction plate ...................... 3-1
Shift pedal ....................................... 3-1
Brake lever ...................................... 3-2
Brake pedal ..................................... 3-2
Fuel tank cap ................................... 3-2
Fuel ................................................. 3-3
Fuel tank breather hose .................. 3-4
2-stroke engine oil ........................... 3-4
Fuel cock ......................................... 3-5
Starter (choke) lever “
1
” ................ 3-6
Kickstarter ....................................... 3-6
Seat ................................................. 3-7
Shock absorber assembly ............... 3-7
FOR YOUR SAFETY –
PRE-OPERATION CHECKS
............... 4-1
Pre-operation check list ................... 4-2
OPERATION AND IMPORTANT
RIDING POINTS
.................................. 5-1
Starting and warming up a cold
engine .......................................... 5-1
Starting a warm engine ................... 5-2
Shifting ............................................ 5-2
Engine break-in ............................... 5-3
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT
.................................... 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance and lubrication
chart ............................................. 6-2
Checking the spark plug .................. 6-5
Removing the power reduction
plate ............................................. 6-6
Transmission oil .............................. 6-7
Cleaning the air filter element ......... 6-8
Cleaning the spark arrester ............. 6-9
Adjusting the carburetor ................ 6-10
Adjusting the engine idling
speed ......................................... 6-11
Adjusting the throttle cable free
play ............................................ 6-11
Tires .............................................. 6-12
Spoke wheels ................................ 6-13
Adjusting the brake lever free
play ............................................ 6-14
Adjusting the brake pedal free
play ............................................ 6-15Checking the front and rear brake
shoes ..........................................6-15
Drive chain slack ............................6-16
Cleaning and lubricating the drive
chain ...........................................6-18
Checking and lubricating the
cables .........................................6-18
Checking and lubricating the throttle
grip and cable .............................6-18
Adjusting the Autolube pump .........6-19
Checking and lubricating the brake
and shift pedals ..........................6-19
Checking and lubricating the brake
lever ............................................6-20
Checking and lubricating the
sidestand ....................................6-20
Checking the front fork ...................6-20
Checking the steering ....................6-21
Checking the wheel bearings .........6-22
Supporting the motorcycle .............6-22
Front wheel ....................................6-23
Rear wheel .....................................6-25
Troubleshooting .............................6-27
Troubleshooting chart ....................6-28
MOTORCYCLE CARE AND
STORAGE
...........................................7-1
Matte color caution ..........................7-1
Care .................................................7-1
Storage ............................................7-3

2-1
2
3
4
5
6
7
8
9

DESCRIPTION
EAU10410
Left view
1
23 4 5
6 7

1. Air filter element (page 6-8)
2. Fuel cock (page 3-5)
3. Throttle stop screw (page 6-11)
4. Starter (choke) lever (page 3-6)
5. 2-stroke engine oil tank (page 3-4)
6. Sidestand (page 6-20)
7. Shift pedal (page 3-1)

DESCRIPTION
2-3
2
3
4
5
6
7
8
9

EAU10430
Controls and instruments
12
43

1. Right handlebar switch (page 3-1)
2. Brake lever (page 3-2)
3. Throttle grip (page 6-11)
4. Fuel tank cap (page 3-2)

INSTRUMENT AND CONTROL FUNCTIONS
3-2
2
34
5
6
7
8
9

EAU12890
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
EAU12941
Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
EAU13182
Fuel tank cap
To remove the fuel tank cap, turn it
counterclockwise, and then pull it off.
To install the fuel tank cap, insert it into
the tank opening, and then turn it clock-
wise.
WARNING

EWA11091
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.
1. Brake lever
1

1. Brake pedal
1

1. Fuel tank cap
1

INSTRUMENT AND CONTROL FUNCTIONS
3-3
1
2
3
4
5
6
7
8
9

EAU13221
Fuel
Make sure there is sufficient gasoline in
the tank.
WARNING

EWA10881
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.
1. Before refueling, turn off the en-
gine and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the vi-
cinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters and
clothes dryers.
2. Do not overfill the fuel tank. When
refueling, be sure to insert the
pump nozzle into the fuel tank filler
hole. Stop filling when the fuel
reaches the bottom of the filler
tube. Because fuel expands when
it heats up, heat from the engine or
the sun can cause fuel to spill out
of the fuel tank.3. Wipe up any spilled fuel immedi-
ately.
NOTICE:
Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteri-
orate painted surfaces or plastic
parts.

[ECA10071]

4. Be sure to securely close the fuel
tank cap.
WARNING

EWA15151
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gaso-
line by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline vapor, or get some gasoline inyour eyes, see your doctor immedi-
ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change
your clothes.
EAU41960
NOTICE

ECA15590
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the piston rings as well as to
the exhaust system.
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging) oc-
1. Fuel tank filler tube
2. Fuel level
2 1

Recommended fuel:
For Europe: REGULAR UNLEADED
GASOLINE ONLY
Except for Europe: 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)

INSTRUMENT AND CONTROL FUNCTIONS
3-4
2
34
5
6
7
8
9
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.
EAU41201
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
minimum level as shown in the illustra-
tion, add a sufficient amount of the rec-
ommended 2-stroke engine oil as
follows.
TIP

Make 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 3-7.)
2. Remove the 2-stroke engine oil
1. Fuel tank breather hose
1

1. Minimum level
1

INSTRUMENT AND CONTROL FUNCTIONS
3-5
1
2
3
4
5
6
7
8
9
tank cap and add the recommend-
ed oil.
3. Install the 2-stroke engine oil tank
cap.
TIP

Make sure that the 2-stroke engine oil
tank cap is properly closed.
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 cap
Recommended oil:
See page 8-1.
Oil quantity:
0.75 L (0.79 US qt, 0.66 Imp.qt)
1
2

1. Arrow mark positioned over “OFF”
RES
ONFUEL
OFF
1
1. Arrow mark positioned over “ON”
1. Arrow mark positioned over “RES”
ON
FUEL
RES
OFF
1
ON
OFF
ONFUEL RES
1
RES

INSTRUMENT AND CONTROL FUNCTIONS
3-6
2
34
5
6
7
8
9
This indicates reserve. If you run out of
fuel while riding, move the lever to this
position. Fill the tank at the first oppor-
tunity. Be sure to set the lever back to
“ON” after refueling!

EAU13590
Starter (choke) lever “”
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the lever in direction (a) to turn on
the starter (choke).
Move the lever in direction (b) to turn off
the starter (choke).
EAU13680
Kickstarter
To start the engine, fold out the kick-
starter lever, move it down lightly with
your foot until the gears engage, and
then push it down smoothly but force-
fully.
1. Starter (choke) lever “”
1
(a)(b)

1. Kickstarter
1

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
1
2
3
4
5
6
7
8
9

EAU15605
Pre-operation check list
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.3-3
2-stroke engine oil

Check oil level in oil tank.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.3-4
Transmission oil

Check oil level in transmission case.

If necessary, add recommended oil to specified level.6-7
Front brake

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.6-14, 6-15
Rear brake

Check operation.

Check pedal free play.

Adjust if necessary.6-15
Throttle grip

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-11, 6-18
Control cables

Make sure that operation is smooth.

Lubricate if necessary.6-18
Drive chain

Check chain slack.

Adjust if necessary.

Check chain condition.

Lubricate if necessary.6-16
Wheels and tires

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.6-12, 6-13

5-1
1
2
3
4
5
6
7
8
9

OPERATION AND IMPORTANT RIDING POINTS
EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING

EWA10271
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU41154
Starting and warming up a
cold engine
1. Turn the fuel cock lever to “ON”.
2. Set the engine stop switch to
“RUN”.
3. Shift the transmission into the neu-
tral position.
WARNING

EWA14410

Be sure to shift the transmis-
sion into neutral before starting
the engine.

Never ride with the sidestand
down.
4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-6.)
5. Start the engine by pushing the
kickstarter lever down.
6. After starting the engine, move the
starter (choke) back halfway.
NOTICE:
For maximum engine
life, always warm the engine up
before starting off. Never accel-
erate hard when the engine is
cold!

[ECA11131]

7. When the engine is warm, turn thestarter (choke) off.
TIP

The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.