brake YAMAHA PW80 2010 Owners Manual

TABLE OF CONTENTS
LOCATION OF IMPORTANT
LABELS
............................................. 1-1
SAFETY INFORMATION
.................. 2-1
DESCRIPTION
.................................. 3-1
Left view .......................................... 3-1
Right view ........................................ 3-2
Controls and instruments ................ 3-3
INSTRUMENT AND CONTROL
FUNCTIONS
....................................... 4-1
Handlebar switch ............................ 4-1
Power reduction plate ..................... 4-1
Shift pedal ...................................... 4-1
Brake lever ..................................... 4-2
Brake pedal .................................... 4-2
Fuel tank cap .................................. 4-2
Fuel ................................................ 4-3
Fuel tank breather hose ................. 4-4
2-stroke engine oil .......................... 4-4
Fuel cock ........................................ 4-5
Starter (choke) lever “ ” ................ 4-6
Kickstarter ...................................... 4-6
Seat ................................................ 4-7
Shock absorber assembly .............. 4-7
Sidestand ....................................... 4-8
FOR YOUR SAFETY –
PRE-OPERATION CHECKS
.............. 5-1
OPERATION AND IMPORTANT
RIDING POINTS
................................. 6-1
Starting and warming up a cold
engine ......................................... 6-1
Starting a warm engine .................. 6-2
Shifting ........................................... 6-2
Engine break-in .............................. 6-3
Parking ........................................... 6-4
PPERIODIC MAINTENANCE AND
ADJUSTMENT
................................... 7-1
Owner’s tool kit ............................... 7-1
Periodic maintenance and
lubrication chart .......................... 7-2
Checking the spark plug ................. 7-5
Removing the power reduction
plate ............................................ 7-6
Transmission oil ............................. 7-7
Cleaning the air filter element ........ 7-8
Cleaning the spark arrester ............ 7-9
Adjusting the carburetor ............... 7-10
Adjusting the engine idling
speed ........................................ 7-10
Adjusting the throttle cable free
play ........................................... 7-11
Tires ............................................. 7-12
Spoke wheels ............................... 7-13
Adjusting the brake lever free
play ........................................... 7-13
Adjusting the brake pedal free
play ........................................... 7-14Checking the front and rear
brake shoes ............................... 7-15
Drive chain slack ........................... 7-16
Cleaning and lubricating the
drive chain ................................. 7-17
Checking and lubricating the
cables ........................................ 7-18
Checking and lubricating the
throttle grip and cable ................ 7-18
Adjusting the Autolube pump ........ 7-18
Checking and lubricating the
brake lever ................................. 7-19
Checking and lubricating the
brake pedal ................................ 7-19
Checking and lubricating the
sidestand ................................... 7-19
Checking the front fork .................. 7-20
Checking the steering ................... 7-20
Checking the wheel bearings ........ 7-21
Supporting the motorcycle ............ 7-21
Front wheel ................................... 7-22
Rear wheel .................................... 7-24
Troubleshooting ............................ 7-26
Troubleshooting chart ................... 7-27
MOTORCYCLE CARE AND
STORAGE
.......................................... 8-1
Matte color caution ......................... 8-1
Care ................................................ 8-1
Storage ........................................... 8-3

DESCRIPTION
3-2
2
34
5
6
7
8
9

EAU10420
Right view
6 12
3
4 5

1. Spark arrester (page 7-9)
2. Seat (page 4-7)
3. Transmission oil filler cap (page 7-7)
4. Spark plug cap (page 7-5)
5. Brake pedal (page 4-2)
6. Kickstarter (page 4-6)

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

EAU10430
Controls and instruments
12
43

1. Handlebar switch (page 4-1)
2. Brake lever (page 4-2)
3. Throttle grip (page 7-11)
4. Fuel tank cap (page 4-2)

INSTRUMENT AND CONTROL FUNCTIONS
4-2
1
2
3
4
5
6
7
8
9

EAU12890
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
EAU12941
Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
EAU13182
Fuel tank cap
To remove the fuel tank cap, turn it
counterclockwise, and then pull it off.
To install the fuel tank cap, insert it into
the tank opening, and then turn it clock-
wise.
WARNING

EWA11091
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.
1. Brake lever
1

1. Brake pedal
1

1. Fuel tank cap
1

5-1
2
3
4
56
7
8
9

FOR YOUR SAFETY – PRE-OPERATION CHECKS
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING

EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.4-3
2-stroke engine oil

Check oil level in oil tank.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.4-4
Transmission oil

Check oil level in transmission case.

If necessary, add recommended oil to specified level.7-7
Front brake

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.7-13, 7-15
Rear brake

Check operation.

Check pedal free play.

Adjust if necessary.7-14
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.7-11, 7-18
Control cables

Make sure that operation is smooth.

Lubricate if necessary.7-18

FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-2
1
2
3
4
5
6
7
8
9

Drive chain

Check chain slack.

Adjust if necessary.

Check chain condition.

Lubricate if necessary.7-16, 7-17
Wheels and tires

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.7-12, 7-13
Shift pedal

Make sure that operation is smooth.

Correct if necessary.—
Brake pedal

Make sure that operation is smooth.

Lubricate pedal pivoting point if necessary.7-19
Brake lever

Make sure that operation is smooth.

Lubricate lever pivoting point if necessary.7-19
Sidestand

Make sure that operation is smooth.

Lubricate pivot if necessary.7-19
Chassis fasteners

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

Tighten if necessary.—
Engine stop switch

Check operation.4-1
ITEM CHECKS PAGE

OPERATION AND IMPORTANT RIDING POINTS
6-3
2
3
4
5
67
8
9
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.
NOTICE

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

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

EAU41765
Periodic maintenance and lubrication chart
TIP


From 160 hours, repeat the maintenance intervals starting from 40 hours.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM CHECK OR MAINTENANCE JOBINITIAL THEREAFTER EVERY
10
hours20
hours40
hours80
hours40
hours80
hours160
hours
1*Fuel line
Check fuel hoses for cracks or damage.Replace if necessary.
2Spark plugCheck condition.Adjust gap and clean.Replace if necessary.
3Air filter elementClean with solvent.Replace if necessary.
4*ClutchCheck operation.Adjust if necessary.
5*Front brakeCheck operation.Adjust brake lever free play.Replace brake shoes. Whenever worn to the limit
6*Rear brakeCheck operation.Adjust brake pedal free play.Replace brake shoes. Whenever worn to the limit
7*WheelsCheck runout, spoke tightness and for
damage.Tighten spokes if necessary.

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

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.
18Transmission oilCheck for oil leakage .Correct if necessary.Change (warm engine before draining).
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.
21
Brake lever pivot shaftApply lithium-soap-based g
rease lightly.
22Brake pedal pivot
shaft
Apply lithium-soap-based g
rease lightly.
23 *Cylinder head and
exhaust system
Check 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 ADJUSTMENT
7-13
2
3
4
5
6
78
9 sively worn tires decreases
riding stability and can lead to
loss of control.


The replacement of all
wheel-and brake-related parts,
including the tires, should be
left to a Yamaha dealer, who has
the necessary professional
knowledge and experience.

It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a
high-quality product.
EAU21940
Spoke wheels
To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU22120
Adjusting the brake lever free
play
The brake lever free play should mea-
sure 10.0–20.0 mm (0.39–0.79 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the brake le-
ver.
2. To increase the brake lever free
play, turn the adjusting bolt in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
bolt in direction (b).
1. Brake lever free play
2. Locknut
3. Adjusting bolt
1
2
3
(a)
(b)