engine YAMAHA PW80 2008 User Guide

PRE-OPERATION CHECKS
4-2
2
3
45
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, 6-16
Rear brake

Check operation.

Check pedal free play.

Adjust if necessary.6-15, 6-16
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, 6-19
Control cables

Make sure that operation is smooth.

Lubricate if necessary.6-19
Drive chain

Check chain slack.

Adjust if necessary.

Check chain condition.

Lubricate if necessary.6-16, 6-18
Wheels and tires

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.6-12, 6-13

PRE-OPERATION CHECKS
4-3
1
2
3
4
5
6
7
8
9

Brake and shift pedals

Make sure that operation is smooth.

Lubricate pedal pivoting points if necessary.6-20
Brake lever

Make sure that operation is smooth.

Lubricate lever pivoting point if necessary.6-20
Sidestand

Make sure that operation is smooth.

Lubricate pivot if necessary.6-21
Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened.

Tighten if necessary.—
Engine stop switch

Check operation.3-1
ITEM CHECKS PAGE

5-1
2
3
4
56
7
8
9

OPERATION AND IMPORTANT RIDING POINTS
EAU41680
WARNING

EWA14620

This model is designed for
off-road use only. Become thor-
oughly familiar with all operat-
ing controls and their functions
before riding. Consult a Yamaha
dealer regarding any control or
function that you do not thor-
oughly understand.

Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.

Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU41151
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.
CAUTION:

ECA11130
For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold!
7. When the engine is warm, turn the
starter (choke) off.
NOTE:

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

OPERATION AND IMPORTANT RIDING POINTS
5-2
1
2
3
4
5
6
7
8
9

EAU16660
Starting a warm engine
Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm. Instead, start
the engine with the throttle slightly
open.
NOTE:

If the engine does not start after sever-
al kicks, try again with the throttle 1/4 to
1/2 open.
EAU39901
Shifting
This motorcycle has a 3-speed trans-
mission with a centrifugal, automatic
clutch. Shifting gears lets you control
the amount of engine power available
for starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the il-
lustration.
NOTE:

To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel.
CAUTION:

ECA15441

Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.

Always release the throttle grip
before changing gears to avoid
damaging the engine, transmis-
sion, and drive train, which are
not designed to withstand the
shock of shifting when the throt-
tle grip is open.
EAU39910
To start out and accelerate
1. Close the throttle.
2. Shift into first gear and release the
shift pedal.
CAUTION:

ECA15460
Always close the throttle before
1. Shift pedal
2. Neutral position
1
12 3N2

OPERATION AND IMPORTANT RIDING POINTS
5-3
2
3
4
56
7
8
9 shifting gears, otherwise damage to
the engine and drive train may re-

sult.
3. 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
acceleration 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.
CAUTION:

ECA10270
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.

OPERATION AND IMPORTANT RIDING POINTS
5-4
1
2
3
4
5
6
7
8
9

EAU17190
Parking
When parking, stop the engine, and
then turn the fuel cock lever to “OFF”.
WARNING

EWA10310

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.

Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
2
3
4
5
67
8
9
8*Tires
Check tread depth and for damage.Replace if necessary.Check air pressure.Correct if necessary.
9*Wheel bearingsCheck bearings for smooth operation.Replace if necessary.
10 *Steering bearingsCheck bearing assemblies for looseness.Moderately repack with lithium-soap-based
grease.
11Drive chainCheck chain slack/alignment and condi-
tion.Adjust and lubricate chain with Yamaha
chain and cable lube thoroughly.Every rideRemove and clean.
12 *Chassis fastenersCheck all chassis fitting and fasteners.Correct if necessary.
13Sidestand pivotCheck operation.Apply lithium-soap-based grease (all-pur-
pose grease) lightly.
14 *Front forkCheck operation and for oil leakage.Replace if necessary.
15 *Shock absorber
assemblyCheck operation and for oil leakage.Replace if necessary.
16 *CarburetorCheck engine idling speed and starter
operation.Clean.Replace if necessary. NO. ITEM CHECK OR MAINTENANCE JOBINITIAL THEREAFTER EVERY
10
hours20
hours40
hours80
hours40
hours80
hours160
hours

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

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
17 *Autolube pump
Check operation.Correct if necessary.Bleed.
18Transmission oilCheck for oil leakage .Correct if necessary.Change.
19 *Control cablesApply Yamaha chain and cable lube or
engine oil 10W-30 lightly.
20 *Throttle grip housing
and cableCheck operation and free play.Apply Yamaha chain and cable lube or
engine oil 10W-30 lightly.
21Brake lever pivot shaftApply lithium-soap-based grease (all-pur-
pose grease) lightly.
22Brake pedal pivot
shaftApply lithium-soap-based grease (all-pur-
pose grease) lightly.
23 *Cylinder head and
exhaust systemCheck for leakage.Tighten if necessary.Decarbonize if necessary.
24 *Spark arresterClean. NO. ITEM CHECK OR MAINTENANCE JOBINITIAL THEREAFTER EVERY
10
hours20
hours40
hours80
hours40
hours80
hours160
hours

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
2
3
4
5
67
8
9

EAU19603
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
NOTE:

If the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
stead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for electrode
erosion and excessive carbon orother deposits, and replace it if
necessary.
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
1. Spark plug cap
1

1. Spark plug wrench
1

Specified spark plug:
NGK/BP6HS (AUS)(NZL)
NGK/BPR6HS
(AUT)(BEL)(CHE)(DEU)(DNK)
(ESP)(FIN)(FRA)(GBR)(GRC)(IRL)
(NLD)(NOR)(PRT)(SWE)(ZAF)
DENSO/W20FP (AUS)(NZL)
1. Spark plug gap
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
1
2
3
4
5
6
7
8
9
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
4. Install the spark plug cap.
EAU41100
Removing the power
reduction plate
To obtain full engine performance ca-
pability, removing the power reduction
plate is required.
WARNING

EWA14580
Always let the exhaust system cool
prior to touching exhaust compo-
nents.
1. Remove the exhaust manifold by
removing the bolts.
2. Remove the gasket.
3. Remove the power reduction
plate.
NOTE:

Store the power reduction plate with the
owner’s manual so that it is readily
available whenever you want to reduce
the engine power.
4. Install the exhaust manifold by in-
stalling the bolts.
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Tightening torque:
Spark plug:
25 Nm (2.5 m·kgf, 18.1 ft·lbf)
1. Exhaust manifold bolt
1
1. Exhaust manifold
2. Gasket
3. Power reduction plate
Tightening torque:
Exhaust manifold bolt:
18 Nm (1.8 m·kgf, 13.0 ft·lbf)
2 13