YAMAHA PW80 2008 Workshop Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
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4. If the drive chain slack is incorrect,
adjust it as follows.

EAU40110
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut, axle nut, and locknut
at each end of the swingarm.2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction (a). To loos-
en the drive chain, turn the adjust-
ing nut at each end of the
swingarm in direction (b), and then
push the rear wheel forward.
NOTE:

Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po-
sition for proper wheel alignment.
CAUTION:

ECA10570
Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.
3. Tighten both locknuts and the axle
nut to the specified torques.
1. Drive chain slack
1

1. Brake pedal free play adjusting nut
2. Locknut
3. Drive chain slack adjusting nut
4. Wheel axle
2
14 3

1. Alignment marks
2. Drive chain slack adjusting nut
3. Locknut
4. Washer
5. Axle nut
5
42
1
(a)
(b)3

PERIODIC MAINTENANCE AND MINOR REPAIR
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4. Adjust the brake pedal free play.
(See page 6-15.)

EAU23013
Cleaning and lubricating the
drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
CAUTION:

ECA10581
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.
NOTE:

For a thorough cleaning, have a
Yamaha dealer remove the drive chain
and soak it in solvent.
2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on both sides
and on the middle of the chain,
making sure that all side plates
and rollers have been sufficientlyoiled.
Tightening torques:
Locknut:
6.5 Nm (0.7 m·kgf, 4.7 ft·lbf)
Axle nut:
60 Nm (6.0 m·kgf, 43.4 ft·lbf)

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU41840
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING

EWA10710
Damage to the outer housing of ca-
bles may result in internal rusting
and cause interference with cable
movement. Replace damaged ca-
bles as soon as possible to prevent
unsafe conditions.
EAU23111
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
EAU23120
Adjusting the Autolube pump
The Autolube pump is a vital and so-
phisticated component of the engine,
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil SAE 10W-30 (API SE)

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU44270
Checking and lubricating the
brake and shift pedals
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
EAU43620
Checking and lubricating the
brake lever
The operation of the brake lever should
be checked before each ride, and the
lever pivots should be lubricated if nec-
essary.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
1. Grease nipple
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU23200
Checking and lubricating the
sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
WARNING

EWA10730
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
EAU23271
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU23280
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.
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
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.
EAU23290
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.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
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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
a jack either under each side of theframe in front of the rear wheel or under
each side of the swingarm.

EAU24360
Front wheel
EAU41530
To remove the front wheel
WARNING

EWA10820

It is advisable to have a Yamaha
dealer service the wheel.

Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Remove the brake cable holder by
removing the bolt.
2. Loosen the brake cable locknut
and the brake cable free play ad-
1. Brake cable holder
2. Bolt
2
1

PERIODIC MAINTENANCE AND MINOR REPAIR
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justing nut at the front wheel hub.
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. Disconnect the brake cable from
the brake camshaft lever.
6. Remove the axle nut and washer.7. Lift the front wheel off the ground
according to the procedure on
page 6-23.
8. Pull the wheel axle out, and then
remove the wheel.

EAU41550
To install the front wheel
1. Install the brake shoe plate into the
wheel hub as shown.
1. Adjusting nut
2. Locknut
3. Washer
4. Axle nut
5. Brake camshaft lever
4
5
3
1
2

1. Adjusting bolt
2. Locknut
2 1
(a)

1. Washer
2. Axle nut
2
1

PERIODIC MAINTENANCE AND MINOR REPAIR
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2. Lift the wheel up between the fork
legs.
NOTE:

Make sure that the slot in the brake
shoe plate fits over the retainer on the
fork leg.3. Insert the wheel axle, and then in-
stall the washer and axle nut.
4. Lower the front wheel so that it is
on the ground.
5. Connect the brake cable at the
wheel hub.
6. Connect the brake cable at the
front brake lever.
7. Install the brake cable holder by in-
stalling the bolt.
8. Tighten the axle nut to the speci-
fied torque.
9. Adjust the brake lever free play.(See page 6-14.)
10. Push down hard on the handlebar
several times to check for proper
fork operation.
1. Brake shoe plate
1

1. Retainer
Tightening torque:
Axle nut:
35 Nm (3.5 m·kgf, 25.3 ft·lbf)
1

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU25080
Rear wheel
EAU41560
To remove the rear wheel
WARNING

EWA10820

It is advisable to have a Yamaha
dealer service the wheel.

Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Loosen the axle nut.
2. Remove the brake pedal free playadjusting 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 theswingarm.
5. Lift the rear wheel off the ground
according to the procedure on
page 6-23.
6. Remove the axle nut and washer,
and then pull the wheel axle out.
7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:

The drive chain does not need to be
disassembled in order to remove and
install the wheel.
8. Remove the spacer, chain pullers
and wheel by pulling it back.
1. Drive chain slack adjusting nut
2. Locknut
3. Chain puller
4. Washer
5. Axle nut
5
41
2
3

1. Brake pedal free play adjusting nut
2. Spacer
3. Chain puller
4. Wheel axle
5. Drive chain slack adjusting nut
6. Locknut
7. Brake torque rod
8. Brake torque rod bolt
9. Cotter pin
10. Brake torque rod nut
165
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98
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