YAMAHA PW80 2009 Repair Manual

MOTORCYCLE CARE AND STORAGE
7-2
2
3
4
5
6
78
9 contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.


Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.

For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain or near the seaSince sea salt is extremely corrosive,
carry out the following steps after each
ride in the rain or near the sea.
1. Clean the motorcycle with cold wa-
ter and a mild detergent, after the
engine has cooled down.
NOTICE:
Do not use warm water
since it increases the corrosive
action of the salt.

[ECA10791]

2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stain-
less-steel parts, including the ex-
haust system. (Even the thermally
induced discoloring of stain-
less-steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
WARNING

EWA14501
Contaminants on the brakes or tires

MOTORCYCLE CARE AND STORAGE
7-3
1
2
3
4
5
6
7
8
9can 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.
TIP

Consult a Yamaha dealer for advice on
what products to use.
EAU40652
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
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.
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

MOTORCYCLE CARE AND STORAGE
7-4
2
3
4
5
6
78
9
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.
TIP

Make any necessary repairs before
storing the motorcycle.

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

SPECIFICATIONS
EAU2633P
Dimensions:
Overall length:
1540 mm (60.6 in)
Overall width:
640 mm (25.2 in)
Overall height:
880 mm (34.6 in)
Seat height:
635 mm (25.0 in)
Wheelbase:
1055 mm (41.5 in)
Ground clearance:
185 mm (7.28 in)
Minimum turning radius:
1700 mm (66.9 in)
Weight:
With oil and fuel:
61.0 kg (134 lb)
Noise and vibration level:
Noise level (77/311/EEC):
79.3 dB(A)
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)
Vibration on seat (EN1032, ISO5008):
Will not exceed 0.5 m/s
2


(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)Vibration on handlebar (EN1032, ISO5008):
Will not exceed 2.5 m/s
2


(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)
Engine:
Engine type:
Air cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
79.0 cm
3

Bore
×
stroke:
47.0
×
45.6 mm (1.85
×
1.80 in)
Compression ratio:
6.60 :1
Starting system:
Kickstarter
Lubrication system:
Separate lubrication (Yamaha autolube)

Engine oil:
Type:
YAMALUBE 2 or 2-stroke engine oil (JASO
FC grade) or (ISO EG-C or EG-D grade)
Engine oil quantity:
Quantity:
0.75 L (0.79 US qt, 0.66 Imp.qt)
Transmission oil:
Type:
YAMALUBE 4 (10W-40) or SAE 10W-40
Oil change quantity:
0.65 L (0.69 US qt, 0.57 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Regular unleaded gasoline only
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)
Unleaded gasoline only (AUS)(NZL)
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)
Carburetor:
Manufacturer:
MIKUNI
Type
×
quantity:
VM15SC x 1
Spark plug (s):
Manufacturer/model:
NGK/BP6HS (AUS)(NZL)
NGK/BPR6HS
(AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN)
(FRA)(GBR)(GRC)(IRL)(NLD)(NOR)(PRT)
(SWE)(ZAF)
Manufacturer/model:
DENSO/W20FP (AUS)(NZL)
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, multiple-disc automatic

SPECIFICATIONS
8-2
2
3
4
5
6
7
89 Transmission:

Primary reduction system:
Helical gear
Primary reduction ratio:
66/21 (3.143)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
32/15 (2.133)
Transmission type:
Constant mesh 3-speed
Operation:
Left foot operation
Gear ratio:
1st:
39/12 (3.250)
2nd:
29/16 (1.812)
3rd:
22/17 (1.294)
Chassis:
Frame type:
Steel tube backbone
Caster angle:
26.00 °
Trail:
62.0 mm (2.44 in)
Front tire:
Type:
With tube
Size:
2.50-14 4PRManufacturer/model:
CHENG SHIN/KNOBBY
Rear tire:
Type:
With tube
Size:
3.00-12 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY
Loading:
Maximum rider weight:
40.0 kg (88 lb)
Maximum load:
40 kg (88 lb)
* (Total weight of rider, cargo and
accessories)
Tire air pressure (measured on cold
tires):
Front:
100 kPa (1.00 kgf/cm
2

, 15 psi)
Rear:
100 kPa (1.00 kgf/cm
2
, 15 psi)
Front wheel:
Wheel type:
Spoke wheel
Rim size:
14x1.40
Rear wheel:
Wheel type:
Spoke wheel
Rim size:
12x1.60
Front brake:
Type:
Drum brake
Operation:
Right hand operation
Rear brake:
Type:
Drum brake
Operation:
Right foot operation
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
110.0 mm (4.33 in)
Rear suspension:
Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
95.0 mm (3.74 in)
Electrical system:
Ignition system:
CDI

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

CONSUMER INFORMATION
EAU40790
Identification numbers
Record the vehicle identification num-
ber and model label information in the
spaces provided below for assistance
when ordering spare parts from a
Yamaha dealer or for reference in case
the vehicle is stolen.
VEHICLE IDENTIFICATION
NUMBER:
MODEL LABEL INFORMATION:
EAU26400
Vehicle identification number
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro-
vided.
TIP

The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcy-
cle with the licensing authority in your
area.
EAU26460
Model label
The model label is affixed to the loca-
tion shown. Record the information on
this label in the space provided. This in-
formation will be needed when ordering
spare parts from a Yamaha dealer.
1. Vehicle identification number
1

1. Model label
1

INDEX
A
Air filter element, cleaning .........................6-8
Autolube pump, adjusting ........................6-19
B
Brake and shift pedals, checking and
lubricating ..............................................6-19
Brake lever ................................................3-2
Brake lever, checking and lubricating ......6-20
Brake lever free play, adjusting ...............6-14
Brake pedal ...............................................3-2
Brake pedal free play, adjusting ..............6-15
Brake shoes, checking ............................6-15
C
Cables, checking and lubricating .............6-18
Carburetor, adjusting ...............................6-10
Care ...........................................................7-1
D
Drive chain, cleaning and lubricating .......6-18
Drive chain slack .....................................6-16
E
Engine break-in .........................................5-3
Engine idling speed .................................6-11
Engine oil ...................................................3-4
Engine, starting a warm .............................5-2
Engine stop switch.....................................3-1
F
Front fork, checking .................................6-20
Fuel ............................................................3-3
Fuel cock ...................................................3-5
Fuel tank breather hose.............................3-4
Fuel tank cap .............................................3-2
H
Handlebar switch .......................................3-1
I
Identification numbers ............................... 9-1
K
Kickstarter ................................................. 3-6
M
Matte color, caution ................................... 7-1
Model label ................................................ 9-1
P
Parking ...................................................... 5-4
Part locations............................................. 2-1
Periodic maintenance and lubrication
chart ........................................................ 6-2
Power reduction plate................................ 3-1
Power reduction plate, removing ............... 6-6
Pre-operation check list ............................. 4-2
S
Safety information ..................................... 1-1
Seat ........................................................... 3-7
Shifting ...................................................... 5-2
Shift pedal ................................................. 3-1
Shock absorber assembly ......................... 3-7
Sidestand, checking and lubricating ........ 6-20
Spark arrester, cleaning ............................ 6-9
Spark plug, checking ................................. 6-5
Specifications ............................................ 8-1
Starter (choke) lever .................................. 3-6
Starting and warming up a cold engine ..... 5-1
Steering, checking ................................... 6-21
Storage ...................................................... 7-3
Supporting the motorcycle....................... 6-22
T
Throttle cable free play, adjusting ........... 6-11
Throttle grip and cable, checking and
lubricating .............................................. 6-18Tires ........................................................ 6-12
Tool kit....................................................... 6-1
Transmission oil ........................................ 6-7
Troubleshooting ...................................... 6-27
Troubleshooting chart ............................. 6-28
V
Vehicle identification number .................... 9-1
W
Wheel bearings, checking ....................... 6-22
Wheel (front) ........................................... 6-23
Wheel (rear) ............................................ 6-25
Wheels .................................................... 6-13

YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPERPRINTED IN JAPAN
2008.4–1.1
×
2
!
(E)