lock YAMAHA PW80 2011 Owners Manual

INSTRUMENT AND CONTROL FUNCTIONS
4-2
4
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
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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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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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PERIODIC MAINTENANCE AND ADJUSTMENT
7-14
7


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge 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.


Ride conservatively after
changing a tire since the tire
must seat itself on the rim prop-
erly. Failure to allow proper
seating may cause tire failure,
which may result in damage to
the motorcycle and injury to the
rider.
EAU21942
Spoke wheels
WARNING
EWA10610
The wheels on this model are not de-
signed for use with tubeless tires.
Do not attempt to use tubeless tires
on this model.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.
EAU44882
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. Slide the rubber cover back.
2. Loosen the locknut at the brake le-
ver.1. Brake lever free play
2. Locknut
3. Brake lever free play adjusting bolt
4. Rubber cover1
2
3
4(a)
(b)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-15
73. 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).
4. If the specified brake lever free
play could be obtained as de-
scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.
5. Fully turn the adjusting bolt at the
brake lever in direction (a) to loos-
en the brake cable.
6. Loosen the locknut at the brake
shoe plate.
7. To increase the brake lever free
play, turn the adjusting bolt at the
brake shoe plate in direction (a).
To decrease the brake lever free
play, turn the adjusting bolt in di-
rection (b).8. Tighten the locknut at the brake
shoe plate and at the brake lever.
9. Slide the rubber cover to its origi-
nal position.
EAU39812
Adjusting the brake pedal free
play The brake pedal free play should mea-
sure 10.0–20.0 mm (0.39–0.79 in) at
the brake pedal end as shown. Period-
ically check the brake pedal free play
and, if necessary, adjust it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).
1. Locknut
2. Brake lever free play adjusting bolt
12
(a)
(b)
1. Brake pedal free play
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-17
7Rear
If the lining thickness of a brake shoe is
less than 1.5 mm (0.06 in), have a
Yamaha dealer replace the brake
shoes as a set.
TIPBe sure to measure the brake lining at
the thinnest portion.
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.TIPWhen 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.
EAU40112
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.
Drive chain slack:
40.0–53.0 mm (1.57–2.09 in)
1. Drive chain slack
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-18
7 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-
in the specified limits.
[ECA10571]
TIPUsing the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the same
position for proper wheel alignment.3. Tighten both locknuts and the axle
nut to the specified torques.4. Adjust the brake pedal free play.
(See page 7-15.)
1. Brake pedal free play adjusting nut
2. Locknut
3. Drive chain slack adjusting nut
4. Wheel axle
2
14 3
1. Alignment marks
2. Drive chain slack adjusting nut
3. Locknut
4. Drive chain puller
5. Washer
6. Axle nut
Tightening torques:
Locknut:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
62
1
(a)(b)
5
4
3
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-23
7a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU24360
Front wheel
EAU49911
To remove the front wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Loosen the brake cable locknut at
the front wheel hub, and then turn
the brake lever free play adjusting
bolt fully in direction (a).
2. Slide the rubber cover back at the
brake lever.3. Loosen the locknut at the brake le-
ver, and then turn the adjusting
bolt fully in direction (a).
4. Disconnect the brake cable from
the front brake lever.
5. Slide the rubber cover down at the
front wheel hub, and then turn the
front brake lever free play adjust-
ing bolt fully in direction (b) to dis-
connect the brake cable from the
front wheel hub.
6. Remove the axle nut and washer.1. Brake lever free play adjusting bolt
2. Locknut
3. Rubber cover3
1
2 (a)
(b)
1. Rubber cover
2. Brake lever free play adjusting bolt
3. Locknut
3 2
1
(a)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-25
79. Adjust the brake lever free play.
(See page 7-14.)
10. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU41563
To remove the rear wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Loosen the axle nut.
2. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod from the brake cam-
shaft lever.3. Disconnect the brake torque rod
from the brake shoe plate by re-
moving the cotter pin, the nut, and
the bolt.
4. Loosen the locknut and drive chain
adjusting nut on each end of the
swingarm.
Tightening torque:
Axle nut:
35 Nm (3.5 m·kgf, 25 ft·lbf)
1. Drive chain slack adjusting nut
2. Locknut
3. Drive chain puller
4. Washer
5. Axle nut
5
41
2
3
1. Brake rod
2. Brake pedal free play adjusting nut
3. Brake camshaft lever
4. Spacer
5. Drive chain puller
6. Wheel axle
7. Drive chain slack adjusting nut
8. Locknut
9. Brake torque rod
10.Brake torque rod bolt
11.Cotter pin
12.Brake torque rod nut
287
46
9
1110
12
1
3
5
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