YAMAHA PW80 2009 Workshop Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU43621
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.
EAU23202
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

EWA10731
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the sidestand could contact the
ground and distract the operator, re-
sulting in a possible loss of control.
EAU23272
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
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.
WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.

[EWA10751]

2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease

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NOTICE

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23282
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 6-1 for more in-
formation.)
WARNING! To avoid
injury, securely support the ve-
hicle 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.

PERIODIC MAINTENANCE AND ADJUSTMENT
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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.
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.

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU24360
Front wheel
EAU41532
To remove the front wheel
WARNING

EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.
1. Remove the brake cable holder by
removing the bolt.
2. Loosen the brake cable locknut at
the front wheel hub, and then turn
the brake cable free play adjusting
bolt fully in direction (a).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 brake cable free play
adjusting bolt and the brake cable
locknut at the front wheel hub.
7. Remove the axle nut and washer.
1. Brake cable holder
2. Bolt
2
1

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)

PERIODIC MAINTENANCE AND ADJUSTMENT
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8. Lift the front wheel off the ground
according to the procedure on
page 6-22.
9. 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.2. Lift the wheel up between the fork
legs.
TIP

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.
1. Washer
2. Axle nut
2
1

1. Brake shoe plate
1

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

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(See page 6-14.)
10. Push down hard on the handlebar
several times to check for proper
fork operation.

EAU25080
Rear wheel
EAU41561
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.
5. Lift the rear wheel off the ground
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
10
3

PERIODIC MAINTENANCE AND ADJUSTMENT
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according to the procedure on
page 6-22.
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.
TIP

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.
EAU41571
To install the rear wheel
1. Install the drive chain onto the rear
sprocket.2. Install the wheel by inserting the
chain pullers, spacer and then in-
sert the wheel axle from the
right-hand side.
3. Install the brake rod onto the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.
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 washer and axle nut,
and then lower the rear wheel so
that it is on the ground.
7. Adjust the drive chain slack. (See
page 6-16.)
8. Tighten the axle nut to the speci-
fied torque.9. Adjust the brake pedal free play.
(See page 6-15.)
Tightening torque:
Brake torque rod nut:
15.5 Nm (1.6 m·kgf, 11.2 ft·lbf)
Tightening torque:
Axle nut:
60 Nm (6.0 m·kgf, 43.4 ft·lbf)

PERIODIC MAINTENANCE AND ADJUSTMENT
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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
property damage.

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EAU25972
Troubleshooting chart
Check the fuel level in
the fuel tank.1. Fuel
There is
enough fuel.
There is
no fuel.
Supply fuel.
Operate the kickstarter.2. Compression
There is compression.
There is
no compression.Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.3. Ignition
Wet
DryWipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.The engine does not start.
Have a Yamaha dealer check the vehicle.
Open the throttle halfway and operate
the kickstarter.
Check the compression.
The engine does not start.
Check the compression.

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MOTORCYCLE CARE AND STORAGE
EAU37833
Matte color caution
NOTICE

ECA15192
Some models are equipped with
matte colored finished parts. Be
sure to consult a Yamaha dealer for
advice on what products to use be-
fore cleaning the vehicle. Using a
brush, harsh chemical products or
cleaning compounds when cleaning
these parts will scratch or damage
their surface. Wax also should not
be applied to any matte colored fin-
ished parts.
EAU40463
Care
While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your mo-
torcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
NOTICE

ECA10771

Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.

Improper cleaning can damage
plastic parts such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.

Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in