transmission YAMAHA PW80 2010 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
7-8
1
2
3
4
5
6
7
8
9
NOTICE

ECA10452

In order to prevent clutch slip-
page (since the transmission oil
also lubricates the clutch), do
not mix any chemical additives.
Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

Make sure that no foreign mate-
rial enters the transmission.
5. Start the engine, and then let it idle
for several minutes while checking
the transmission for oil leakage. If
oil is leaking, immediately turn the
engine off and check for the cause.
EAU41162
Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case cover by
removing the screws.
2. Pull the air filter element out.3. Remove the sponge material from
the air filter case cover, clean it
with solvent, and then squeeze the
remaining solvent out.
Recommended transmission oil:
See page 9-1.
Oil change quantity:
0.65 L (0.69 US qt, 0.57 Imp.qt)
1. Air filter case cover
2. Screw
2
2
1

1. Sponge material
2. Air filter case cover
1
2

PERIODIC MAINTENANCE AND ADJUSTMENT
7-16
1
2
3
4
5
6
7
8
9

EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.
TIP

When checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.4. If the drive chain slack is incorrect,
adjust it as follows.
EAU40111
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
drive chain slack adjusting nut at
each end of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting nut at each end
of the swingarm in direction (b),
and then push the rear wheel for-
ward.
NOTICE:
Improper drive
chain slack will overload the en-
gine 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 with-

Drive chain slack:
40.0–53.0 mm (1.57–2.09 in)
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

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

SPECIFICATIONS
EAU2633X
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):
PW80 79.3 dB(A)
Vibration on seat (EN1032, ISO5008):
PW80 Will not exceed 0.5 m/s
2

Vibration on handlebar (EN1032, ISO5008):
PW80 Will not exceed 2.5 m/s
2

Engine:
Engine type:
Air cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
79 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:
PW80 Regular unleaded gasoline only
PW80Z Unleaded gasoline only
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:
Type
×
quantity:
VM15SC x 1
Spark plug (s):
Manufacturer/model:
PW80


NGK/BPR6HS
PW80Z NGK/BP6HS



DENSO/W20FP
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, multiple-disc automatic
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:

INDEX
A
Air filter element, cleaning ......................... 7-8
Autolube pump, adjusting ........................ 7-19
B
Brake lever ................................................ 4-2
Brake lever, checking and lubricating ...... 7-19
Brake lever free play, adjusting ............... 7-14
Brake pedal ............................................... 4-2
Brake pedal, checking and lubricating ..... 7-19
Brake pedal free play, adjusting .............. 7-15
Brake shoes, checking ............................ 7-15
C
Cables, checking and lubricating ............. 7-18
Carburetor, adjusting ............................... 7-10
Care ........................................................... 8-1
D
Drive chain, cleaning and lubricating ....... 7-18
Drive chain slack ..................................... 7-16
E
Engine break-in ......................................... 6-3
Engine idling speed ................................. 7-11
Engine oil ................................................... 4-4
Engine, starting a warm ............................. 6-2
Engine stop switch..................................... 4-1
F
Front fork, checking ................................. 7-20
Fuel............................................................ 4-3
Fuel cock ................................................... 4-5
Fuel tank breather hose............................. 4-4
Fuel tank cap ............................................. 4-2
H
Handlebar switch ....................................... 4-1
I
Identification numbers ............................. 10-1
K
Kickstarter ................................................. 4-6
L
Labels, location ......................................... 1-1
M
Matte color, caution ................................... 8-1
Model label .............................................. 10-1
P
Parking ...................................................... 6-4
Part locations............................................. 3-1
Periodic maintenance and lubrication
chart ........................................................ 7-2
Power reduction plate................................ 4-1
Power reduction plate, removing ............... 7-6
S
Safety information ..................................... 2-1
Seat ........................................................... 4-7
Shifting ...................................................... 6-2
Shift pedal ................................................. 4-1
Shock absorber assembly ......................... 4-7
Sidestand .................................................. 4-8
Sidestand, checking and lubricating ........ 7-20
Spark arrester, cleaning ............................ 7-9
Spark plug, checking ................................. 7-5
Specifications ............................................ 9-1
Starter (choke) lever .................................. 4-6
Starting and warming up a cold engine ..... 6-1
Steering, checking ................................... 7-21
Storage ...................................................... 8-3
Supporting the motorcycle....................... 7-22
T
Throttle cable free play, adjusting ........... 7-11Throttle grip and cable, checking and
lubricating ............................................. 7-18
Tires ........................................................ 7-12
Tool kit ...................................................... 7-1
Transmission oil ........................................ 7-7
Troubleshooting ...................................... 7-26
Troubleshooting chart ............................. 7-28
V
Vehicle identification number .................. 10-1
W
Wheel bearings, checking ....................... 7-21
Wheel (front) ........................................... 7-22
Wheel (rear) ............................................ 7-25
Wheels .................................................... 7-13