Throttle YAMAHA PW80 2011 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 ....................................... 4-8FOR 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
PERIODIC MAINTENANCE AND
ADJUSTMENT................................... 7-1
Owner’s tool kit .............................. 7-1
Periodic maintenance chart for the
emission control system ............. 7-2
General maintenance and
lubrication chart .......................... 7-3
Checking the spark plug ................ 7-6
Removing the power reduction
plate ............................................ 7-7
Transmission oil ............................. 7-8
Cleaning the air filter element ........ 7-9
Cleaning the spark arrester ......... 7-10
Adjusting the carburetor ............... 7-11
Adjusting the engine idling
speed ........................................ 7-11
Adjusting the throttle cable free
play ........................................... 7-12
Tires ............................................. 7-13Spoke wheels ............................... 7-14
Adjusting the brake lever free
play ........................................... 7-14
Adjusting the brake pedal free
play ........................................... 7-15
Checking the shift pedal ............... 7-16
Checking the front and rear brake
shoes ........................................ 7-16
Drive chain slack .......................... 7-17
Cleaning and lubricating the drive
chain ......................................... 7-19
Checking and lubricating the
cables ....................................... 7-19
Checking and lubricating the
throttle grip and cable ............... 7-19
Adjusting the Autolube pump ....... 7-20
Checking and lubricating the
brake lever ................................ 7-20
Checking and lubricating the
brake pedal ............................... 7-20
Checking and lubricating the
sidestand .................................. 7-21
Checking the front fork ................. 7-21
Checking the steering .................. 7-22
Checking the wheel bearings ....... 7-22
Supporting the motorcycle ........... 7-22
Front wheel .................................. 7-23
Rear wheel ................................... 7-25
Troubleshooting ........................... 7-27
Troubleshooting chart .................. 7-28
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DESCRIPTION
3-1
3
EAU10410
Left view
1
23 4 5
6 7
1. Air filter element (page 7-9)
2. Fuel cock (page 4-5)
3. Throttle stop screw (page 7-11)
4. Starter (choke) lever (page 4-6)
5. 2-stroke engine oil tank (page 4-4)
6. Sidestand (page 4-8)
7. Shift pedal (page 4-1)
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DESCRIPTION
3-3
3
EAU10430
Controls and instruments
12
43
1. Engine stop switch (page 4-1)
2. Brake lever (page 4-2)
3. Throttle grip (page 7-12)
4. Fuel tank cap (page 4-2)
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-2
5
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.7-12, 7-19
Control cablesMake sure that operation is smooth.
Lubricate if necessary.7-19
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.7-17, 7-19
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.7-13, 7-14
Shift pedalMake sure that operation is smooth.
Correct if necessary.7-16
Brake pedalMake sure that operation is smooth.
Lubricate pedal pivoting point if necessary.7-20
Brake leverMake sure that operation is smooth.
Lubricate lever pivoting point if necessary.7-20
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.7-21
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Engine stop switchCheck operation.4-1 ITEM CHECKS PAGE
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OPERATION AND IMPORTANT RIDING POINTS
6-1
6
EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWA10271
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU41156
Starting and warming up a
cold engine 1. Turn the fuel cock lever to “ON”.
2. Set the engine stop switch to
“RUN”.
3. Shift the transmission into the neu-
tral position.
WARNING
EWA14410


Be sure to shift the transmis-
sion into neutral before starting
the engine.


Never ride with the sidestand
down.
4. Turn the starter (choke) on and
completely close the throttle. (See
page 4-6.)
5. Start the engine by pushing the
kickstarter lever down.
6. After starting the engine, move the
starter (choke) back halfway.
NOTICE: For maximum engine
life, never accelerate hard when
the engine is cold!
[ECA11041]
7. When the engine is warm, turn the
starter (choke) off.
TIPThe engine is warm when it responds
quickly to the throttle with the starter
(choke) turned off.
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OPERATION AND IMPORTANT RIDING POINTS
6-2
6
EAU16660
Starting a warm engine Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm. Instead, start
the engine with the throttle slightly
open.TIPIf the engine does not start after several
kicks, try again with the throttle 1/4 to
1/2 open.
EAU39901
Shifting This motorcycle has a 3-speed trans-
mission with a centrifugal, automatic
clutch. Shifting gears lets you control
the amount of engine power available
for starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the il-
lustration.TIPTo shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel.
NOTICE
ECA15441


Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.


Always release the throttle grip
before changing gears to avoid
damaging the engine, transmis-
sion, and drive train, which are
not designed to withstand the
shock of shifting when the throt-
tle grip is open.
EAU39911
To start out and accelerate
1. Close the throttle.
2. Shift into first gear and release the
shift pedal. NOTICE: Always
close the throttle before shifting
gears, otherwise damage to the
engine and drive train may re-
sult.
[ECA15461]
1. Shift pedal
2. Neutral position
1
12 3N2
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OPERATION AND IMPORTANT RIDING POINTS
6-3
63. 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 ac-
celeration 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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-5
7
TIPThe air filter needs more frequent service if you are riding in unusually wet or dusty areas.13 *
14
15 *
16 *
17
18Autolube pump
Transmission oil
Control cables
Throttle grip housing
and cable
Brake lever pivot shaft
Brake pedal pivot
shaft NO. ITEM CHECK OR MAINTENANCE JOBINITIAL THEREAFTER EVERY
10
hours20
hours40
hours80
hours40
hours80
hours160
hours
Check for oil leakage.Correct if necessary.Change (warm engine before draining).Check operation.Correct if necessary.Check operation and free play.Apply Yamaha chain and cable lube or
engine oil 10W-30 lightly.Apply lithium-soap-based grease lightly.Apply Yamaha chain and cable lube or
engine oil 10W-30 lightly.Apply lithium-soap-based grease lightly.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-11
72. Tap the tailpipe lightly, and then
use a wire brush to remove any
carbon deposits from the spark ar-
rester portion of the tailpipe and in-
side of the tailpipe housing.
3. Insert the tailpipe into the muffler,
and then install and tighten the bolt
to the specified torque.
TIPMake sure to align the bolt hole when
inserting the tailpipe.
EAU39930
Adjusting the carburetor The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in the
following section, however, may be ser-
viced by the owner as part of routine
maintenance.NOTICE
ECA10550
The carburetor has been set and ex-
tensively tested at the Yamaha fac-
tory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine.
EAU21340
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before
making this adjustment.TIP

The engine is warm when it quickly
responds to the throttle.


A diagnostic tachometer is needed
to make this adjustment.
1. Attach the tachometer to the spark
plug lead.
2. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
rection (a). To decrease the en-
gine idling speed, turn the screw in
direction (b).
1. Tailpipe
2. Spark arrester
3. BoltTightening torque:
Tailpipe bolt:
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
23
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-12
7
TIPIf the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
EAU21372
Adjusting the throttle cable
free play The throttle cable free play should mea-
sure 3.0–5.0 mm (0.12–0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, adjust it as follows.TIPThe engine idling speed must be cor-
rectly adjusted before checking and ad-
justing the throttle cable free play.1. Loosen the locknut.2. To increase the throttle cable free
play, turn the adjusting nut in direc-
tion (a). To decrease the throttle
cable free play, turn the adjusting
nut in direction (b).
3. Tighten the locknut.
1. Throttle stop screwEngine idling speed:
1650–1750 r/min
1
(a) (b)
1. Throttle cable free play
1
1. Locknut
2. Throttle cable free play adjusting nut
1
2
(a)
(b)
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