warning YAMAHA PW80 2011 Owner's Manual

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
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-23
7a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU24360
Front wheel
EAU49911
To remove the front wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Loosen the brake cable locknut at
the front wheel hub, and then turn
the brake lever free play adjusting
bolt fully in direction (a).
2. Slide the rubber cover back at the
brake lever.3. Loosen the locknut at the brake le-
ver, and then turn the adjusting
bolt fully in direction (a).
4. Disconnect the brake cable from
the front brake lever.
5. Slide the rubber cover down at the
front wheel hub, and then turn the
front brake lever free play adjust-
ing bolt fully in direction (b) to dis-
connect the brake cable from the
front wheel hub.
6. Remove the axle nut and washer.1. Brake lever free play adjusting bolt
2. Locknut
3. Rubber cover3
1
2 (a)
(b)
1. Rubber cover
2. Brake lever free play adjusting bolt
3. Locknut
3 2
1
(a)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-25
79. Adjust the brake lever free play.
(See page 7-14.)
10. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU41563
To remove the rear wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Loosen the axle nut.
2. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod from the brake cam-
shaft lever.3. Disconnect the brake torque rod
from the brake shoe plate by re-
moving the cotter pin, the nut, and
the bolt.
4. Loosen the locknut and drive chain
adjusting nut on each end of the
swingarm.
Tightening torque:
Axle nut:
35 Nm (3.5 m·kgf, 25 ft·lbf)
1. Drive chain slack adjusting nut
2. Locknut
3. Drive chain puller
4. Washer
5. Axle nut
5
41
2
3
1. Brake rod
2. Brake pedal free play adjusting nut
3. Brake camshaft lever
4. Spacer
5. Drive chain puller
6. Wheel axle
7. Drive chain slack adjusting nut
8. Locknut
9. Brake torque rod
10.Brake torque rod bolt
11.Cotter pin
12.Brake torque rod nut
287
46
9
1110
12
1
3
5
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-26
7 5. Lift the rear wheel off the ground
according to the procedure on
page 7-22.
6. Remove the axle nut and washer,
and then pull the wheel axle out.
7. Remove the spacer and chain pull-
ers.
8. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
TIPThe drive chain does not need to be
disassembled in order to remove and
install the wheel.9. Remove the wheel by pulling it
back.
EAU41573
To install the rear wheel
1. Insert the brake shoe plate into the
wheel hub, and then insert the
wheel into the swingarm.
2. Install the drive chain onto the rear
sprocket.
3. Install the wheel by inserting the
chain pullers, spacer and then in-
sert the wheel axle from the right-
hand side.
4. Connect the brake torque rod onto
the brake shoe plate by installing
the bolt and nut, and then tighten
the nut to the specified torque.
5. Insert a new cotter pin into the
brake torque rod bolt. WARNING!
Always use a new cotter pin.
[EWA10831]
6. Install the brake rod into the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.
7. Install the washer and axle nut.8. Lower the rear wheel so that it is
on the ground, and then put the
sidestand down.
9. Adjust the drive chain slack. (See
page 7-17.)
10. Tighten the axle nut to the speci-
fied torque.
11. Adjust the brake pedal free play.
(See page 7-15.)Tightening torque:
Brake torque rod nut:
16 Nm (1.6 m·kgf, 12 ft·lbf)
Tightening torque:
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-27
7
EAU25851
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
WARNING
EWA15141
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from waterheaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or
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MOTORCYCLE CARE AND STORAGE
8-3
88. Let the motorcycle dry completely
before storing or covering it.
WARNING
EWA14501
Contaminants on the brakes or tires
can cause loss of control.

Make sure that there is no oil or
wax on the tires.


If necessary, wash the tires with
warm water and a mild deter-
gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor-
nering behavior.
NOTICE
ECA10800


Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.


Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.


Avoid using abrasive polishing
compounds as they will wear
away the paint.
TIPConsult a Yamaha dealer for advice on
what products to use.
EAU40653
Storage Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover. Be
sure the engine and the exhaust sys-
tem are cool before covering the motor-
cycle.NOTICE
ECA10810


Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.


To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your motorcycle for sev-
eral months:
1. Follow all the instructions in the
“Care” section of this chapter.
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MOTORCYCLE CARE AND STORAGE
8-4
8 2. For motorcycles equipped with a
fuel cock that has an “OFF” posi-
tion: Turn the fuel cock lever to
“OFF”.
3. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to pro-
tect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap. WARNING! To
prevent damage or injury
from sparking, make sure to
ground the spark plug elec-
trodes while turning the en-
gine over.
[EWA10951]
6. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sidestand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.TIPMake any necessary repairs before
storing the motorcycle.
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