check oil 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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INSTRUMENT AND CONTROL FUNCTIONS
4-4
4 curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
EAU13412
Fuel tank breather hose Before operating the motorcycle:

Check the fuel tank breather hose
connection.


Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.


Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.
EAU41202
2-stroke engine oil Make sure that there is sufficient oil in
the 2-stroke engine oil tank. If the 2-
stroke engine oil is at or below the min-
imum level as shown in the illustration,
add a sufficient amount of the recom-
mended 2-stroke engine oil as follows.TIPMake sure that the motorcycle is posi-
tioned straight up when checking the 2-
stroke engine oil level. A slight tilt to the
side can result in a false reading.1. Remove the seat. (See page 4-7.)
2. Remove the 2-stroke engine oil
tank cap and add the recommend-
ed oil.
1. Fuel tank breather hose
1
1. Minimum level
1
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-1
5
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
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check the fuel tank breather/overflow hose for obstructions, cracks or damage,
and check the hose connection.4-3, 4-4
2-stroke engine oilCheck oil level in oil tank.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.4-4
Transmission oilCheck oil level in transmission case.
If necessary, add recommended oil to specified level.7-8
Front brakeCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.7-14, 7-16
Rear brakeCheck operation.
Check pedal free play.
Adjust if necessary.7-15, 7-16
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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
7-4
7
Steering bearings
Drive chain
Chassis fasteners
Sidestand pivot
Front fork
Shock absorber
assembly 7*
8
9*
10
11 *
12 *NO. ITEM CHECK OR MAINTENANCE JOBINITIAL THEREAFTER EVERY
10
hours20
hours40
hours80
hours40
hours80
hours160
hours
Every ride
Check bearing assemblies for looseness.Moderately repack with lithium-soap-based
grease.Check all chassis fitting and fasteners.Replace if necessary.Check operation.Apply lithium-soap-based grease lightly.Check operation and for oil leakage.Replace if necessary.Check operation and for oil leakage.Replace if necessary.Remove and clean.Check chain slack/alignment and condi-
tion.Adjust and lubricate chain with Yamaha
chain and cable lube thoroughly.
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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
7-8
7
EAU49890
Transmission oil The transmission oil level should be
checked before each ride. In addition,
the transmission oil must be changed at
the intervals specified in the periodic
maintenance and lubrication chart.
To check the transmission oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.TIPMake sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.2. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.TIPThe transmission oil should be be-
tween the tip of the dipstick and maxi-
mum level mark.
3. If the oil does not reach the tip of
the dipstick, add sufficient oil of the
recommended type to raise it to
the correct level.
4. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
To change the transmission oil
1. Place an oil pan under the trans-
mission to collect the used oil.
2. Remove the oil filler cap, the trans-
mission oil drain bolt and its gasket
to drain the oil from the transmis-
sion.3. Install the transmission oil drain
bolt and its new gasket, and then
tighten the bolt to the specified
torque.
4. Refill with the specified amount of
the recommended transmission
oil, and then install and tighten the
oil filler cap.1. Transmission oil filler cap
2. Dipstick
3. Maximum level mark
4. Tip of the dipstick
2
3
41
1
1. Transmission oil drain bolt
2. Gasket
Tightening torque:
Transmission oil drain bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
Recommended transmission oil:
See page 9-1.
Oil change quantity:
0.65 L (0.69 US qt, 0.57 Imp.qt)
12
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-9
7
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.
EAU41163
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean or, if necessary, replace the air
filter element more frequently 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.1. Air filter case cover
2. Screw
2
2
1
1. Sponge material
2. Air filter case cover
1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-19
7
EAU23016
Cleaning and lubricating the
drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.NOTICE
ECA10583
The drive chain must be lubricated
after washing the motorcycle, riding
in the rain or riding in wet areas.1. Remove all dirt and mud from the
drive chain with a brush or cloth.TIPFor a thorough cleaning, have a
Yamaha dealer remove the drive chain
and soak it in solvent.2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on the entire
chain, making sure that all side
plates and rollers have been suffi-
ciently oiled.
EAU41842
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
housing of cables may result in in-
ternal rusting and cause interfer-
ence with cable movement. Replace
damaged cables as soon as possi-
ble to prevent unsafe conditions.[EWA10711]EAU23113
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated by a
Yamaha dealer at the intervals speci-
fied in the periodic maintenance chart.
The throttle cable is equipped with a
rubber boot. Make sure that the boot is
securely installed. Even though the
boot is installed correctly, it does not
completely protect the cable from water
entry. Therefore, use care not to pour
water directly onto the boot or cable
when washing the vehicle. If the cable
or boot becomes dirty, wipe clean with
a moist cloth.
Recommended lubricant:
Yamaha Chain and Cable Lube or 4-
stroke engine oil
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-21
7
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.
NOTICE
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
Recommended lubricant:
Lithium-soap-based grease
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