Yamaha PW80(Z) Owner'S Manual Download Page 51

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-15

WARNING

EWA10680

●

After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.

●

If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this ad-
justment.

●

After adjusting the brake pedal
free play, check the operation of

the brake light.

EAU41052

Checking the front and rear
brake shoes

The front and rear brake shoes must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.

TIP

The wheels must be removed to check
brake shoe lining thickness.

●

To remove the front wheel: See
page 7-22.

●

To remove the rear wheel: See

page 7-24.

Front

Rear

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.

TIP

Be sure to measure the brake lining at

the thinnest portion.

1. Brake pedal free play adjusting nut

(a)

(b)

Summary of Contents for PW80(Z)

Page 1: ...DIENUNGSANLEITUNG Read this manual carefully before operating this vehicle Il convient de lire attentivement ce manuel avant la pre mière utilisation du véhicule Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen ...

Page 2: ...YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2009 04 0 2 1 E F G D PAPER R GEDRUCKT RECYCLÉ YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2009 04 0 2 1 E F G D PAPER R GEDRUCKT RECYCLÉ ...

Page 3: ...3RV 28199 8K E0 PW80 Z OWNER S MANUAL Read this manual carefully before operating this vehicle ...

Page 4: ...forms to the essential health of Directive 98 37 EC 2006 42 EC Directives of EEC 2004 108 EC e of issue of the other Directives of EEC tion of the essential health and safety requirements of EEC the following standards and or technical ulted and date of issue of standards and or specifications e N V Schiphol Rijk The Netherlands Signature Kunihiko Miwa Division Manager Motorcycle Headquarters Prod...

Page 5: ... schedules and operating instructions contained within this manual ks advancements in product design and quality Therefore while this manual contains the most cur available at the time of printing there may be minor discrepancies between your motorcycle and this uestion concerning this manual please consult a Yamaha dealer EWA10031 al carefully and completely before operating this motorcycle EWA14...

Page 6: ...led to limit the engine power available while they learn Parents should decide when to re on plate from the motorcycle for more power as their youngster s riding skills improve Once the rider the top speed permitted by power reduction plate installed the power reduction plate can be re e track vehicles Their safe use and operation are dependent upon the use of proper riding the expertise of the op...

Page 7: ...sonal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer ...

Page 8: ...200 PW80 Z OWNER S MANUAL 2009 by Yamaha Motor Co Ltd 1st edition March 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 9: ...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 14 Checking 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...

Page 10: ...ONTENTS 9 1 ION 10 1 10 1 ...

Page 11: ...T LABELS EAU48130 all of the labels on your vehicle They contain important information for safe and proper operation of move any labels from your vehicle If a label becomes difficult to read or comes off a replacement label amaha dealer 3 4 1 2 ...

Page 12: ...F IMPORTANT LABELS 1 2 4 2817L 10 100 1 00 15 100 1 00 15 5PG 2816R 00 ...

Page 13: ... unit contains high pressure nitrogen gas Mishandling can cause explosion Do not incinerate puncture or open Turn off the main switch after riding to avoid draining the battery Use unleaded gasoline only Measure tire pressure when tires are cold Adjust tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death ...

Page 14: ...F IMPORTANT LABELS 1 4 h Africa 1 3 2 ...

Page 15: ...the owner s manual 5PA 21568 01 colo leggete il manuale di istruzioni ropriétaire avant d utiliser ce véhicule nungsanleitung bevor Sie dieses Fahrzeug fahren ste vehículo lea el Manual del Propietario 3RV 21668 A0 ssure should be set as 1 00 kgf cm2 15 psi 1 00 kgf cm2 15 psi 3 ...

Page 16: ...n gers The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when yo...

Page 17: ...burns Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide a deadly gas Breathing car bon monoxide can cause headaches dizziness drowsiness nausea confu sion and eventually death Carbon Monoxide is a colorless odor less tasteless gas which may be present even if you do not see or smell any engine exhaust Deadly levels of carbon monoxide can collect rapidly and you can quickl...

Page 18: ...produce Therefore Yamaha can neither en dorse nor recommend the use of ac cessories not sold by Yamaha or modifications not specifically recom mended by Yamaha even if sold and installed by a Yamaha dealer Aftermarket Parts Accessories and Modifications While you may find aftermarket prod ucts similar in design and quality to genuine Yamaha accessories recog nize that some aftermarket accessories ...

Page 19: ... opera t control ability accessories are ed adding electri electrical acces capacity of the rical system an ld result which ngerous loss of wer Aftermarket Tires and Rims The tires and rims that came with your motorcycle were designed to match the performance capabilities and to provide the best combination of handling brak ing and comfort Other tires rims siz es and combinations may not be approp...

Page 20: ...3 1 N EAU10410 1 2 3 4 5 6 7 8 e 7 10 ge 4 6 page 4 4 ...

Page 21: ...DESCRIPTION 3 2 2 3 4 5 6 7 8 9 EAU10420 6 1 2 3 4 5 9 p page 7 7 5 ...

Page 22: ...N 3 3 EAU10430 uments 1 2 4 3 4 1 ...

Page 23: ...mount of power available while they learn Parents should decide when to adjust the motorcycle for more power as their youngster s riding skills improve Once the rider can operate with skill at the top speed with the power reduction plate installed the power reduction plate can be removed See page 7 6 EAU39850 Shift pedal This motorcycle is equipped with a con stant mesh 3 speed transmission The sh...

Page 24: ... 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 1 Brake pedal 1 1 Fuel tank cap 1 ...

Page 25: ...ath Handle gaso line with care Never siphon gaso line by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If gasoline spills on your skin wash with soap and water If gaso line spills on your clothing change your clothes EAU41960 NOTICE ECA15590 Use only unleaded gasoline The use of leaded gasoline will cause...

Page 26: ... 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 minimum level as shown in the illustra tion add a sufficient amount of the rec ommended 2 stroke engine oil as follows TIP Make sure that the motorcycle is posi tioned straight up when checking the 2 stroke engine oil level A slight tilt to th...

Page 27: ...three positions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES cap 66 Imp qt 1 2 1 Arrow mark positioned over OFF RES ON FUEL OFF 1 1 Arrow mark positioned over ON 1 Arrow mark positioned over RES O...

Page 28: ...which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke EAU13680 Kickstarter To start the engine fold out the kick starter lever move it down lightly with your foot until the gears engage and then push it down smoothly but force fully 1 Starter choke lever 1 a b 1 Kickstarter 1 ...

Page 29: ...nd understand the fol lowing information before handling the shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Do not subject the shock ab sorber assembly to an open flame or other high heat source This may cause the unit to ex plode due to excessive gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performanc...

Page 30: ...AND CONTROL FUNCTIONS 4 8 EAU37490 on the left side e sidestand or hile holding the EWA14190 be ridden with or if the side erly moved up otherwise the act the ground ator resulting ontrol ...

Page 31: ... CHECKS PAGE Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 3 Check oil level in oil tank If necessary add recommended oil to specified level Check vehicle for oil leakage 4 4 Check oil level in transmission case If necessary add recommended oil to specified level 7 7 Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 7 13 7 15 C...

Page 32: ...7 12 7 13 Make sure that operation is smooth Correct if necessary Make sure that operation is smooth Lubricate pedal pivoting point if necessary 7 19 Make sure that operation is smooth Lubricate lever pivoting point if necessary 7 19 Make sure that operation is smooth Lubricate pivot if necessary 7 19 Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Check operat...

Page 33: ...NING 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 ECA...

Page 34: ...A15441 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 tr...

Page 35: ...earances 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 buil...

Page 36: ...TANT RIDING POINTS 6 4 EAU17191 e engine and ever to OFF EWA10311 and exhaust ome very hot here pedestri e not likely to e burned lope or on soft e the vehicle ncreasing the and fire grass or other erials which ...

Page 37: ... the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 1 for more in formation about carbon monox ide EAU17311 Owner s tool kit The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever addi...

Page 38: ...hours 80 hours 40 hours 80 hours 160 hours Check fuel hoses for cracks or damage Replace if necessary Check condition Adjust gap and clean Replace if necessary Clean with solvent Replace if necessary Check operation Adjust if necessary Check operation Adjust brake lever free play Replace brake shoes Whenever worn to the limit Check operation Adjust brake pedal free play Replace brake shoes Wheneve...

Page 39: ...condi tion Adjust and lubricate chain with Yamaha chain and cable lube thoroughly Every ride Remove and clean s 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 Check engine idling speed and starter operation Clean Rep...

Page 40: ...maha chain and cable lube or engine oil 10W 30 lightly sing Check operation and free play Apply Yamaha chain and cable lube or engine oil 10W 30 lightly shaft Apply lithium soap based grease lightly Apply lithium soap based grease lightly d Check for leakage Tighten if necessary Decarbonize if necessary Clean CHECK OR MAINTENANCE JOB INITIAL THEREAFTER EVERY 10 hours 20 hours 40 hours 80 hours 40 ...

Page 41: ... a distinctly dif ferent color the engine could be oper ating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the vehicle 2 Check the spark plug for elec trode erosion and excessive car bon or other deposits and replace it if necessary To install the spark plug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap...

Page 42: ... by removing the bolts WARNING Always let the exhaust system cool prior to touching exhaust components EWA14581 2 Remove the gasket 3 Remove the power reduction plate TIP Store the power reduction plate with the Owner s Manual so that it is readily available whenever you want to reduce the engine power 4 Install the exhaust manifold by in stalling the bolts 18 1 ft lbf 1 Exhaust manifold bolt 1 1 ...

Page 43: ... tween the minimum and maximum lev el marks 3 If the oil is below the minimum lev el mark 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 and drain bolt to drain t...

Page 44: ...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...

Page 45: ...81 7 Install the air filter case cover by in stalling the screws EAU41232 Cleaning the spark arrester The spark arrester should be cleaned at the intervals specified in the periodic maintenance and lubrication chart WARNING EWA10980 Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system 1 Remove the tailpipe by removing the ...

Page 46: ...nging 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...

Page 47: ...eck the throttle cable free play and if neces sary adjust it as follows TIP The 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 Thrott...

Page 48: ...quipped with spoke wheels and tube tires WARNING EWA10461 The front and rear tires should be of the same make and design other wise the handling characteristics of the vehicle may be different which could lead to an accident After extensive tests only the tires list ed below have been approved for this model by Yamaha Motor Co Ltd WARNING EWA14390 Have a Yamaha dealer replace excessively worn tire...

Page 49: ...r 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...

Page 50: ...at the brake lever 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 nu...

Page 51: ... shoes must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart TIP The wheels must be removed to check brake shoe lining thickness To remove the front wheel See page 7 22 To remove the rear wheel See page 7 24 Front Rear 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 TIP Be sur...

Page 52: ...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 br...

Page 53: ... in dusty or wet areas Service the drive chain as follows NOTICE ECA10581 The drive chain must be lubricated after washing the motorcycle and riding in the rain 1 Remove all dirt and mud from the drive chain with a brush or cloth TIP For 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 chai...

Page 54: ... 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 at the intervals specified in the periodic maintenance chart EAU23120 Adjusting the Autolube pump The Autolube pump is a vital and so phisticated component of the engine which must be adjusted by a Yamaha dealer at the intervals specified in the...

Page 55: ...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 l...

Page 56: ...283 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground See page 7 21 for more information WARNING To avoid injury securely support the vehicle so there is no dan...

Page 57: ...r performing other maintenance requiring the motorcycle to stand up right Check that the motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a ja...

Page 58: ...ling over 1 Remove the brake cable holder by removing the bolt 2 Loosen the brake cable locknut at the front wheel hub and then turn the brake cable free play adjusting bolt fully in direction a 3 Loosen the locknut at the brake le ver and then turn the adjusting bolt fully in direction a 1 Brake cable holder 2 Bolt 2 1 1 Adjusting nut 2 Locknut 3 Washer 4 Axle nut 5 Brake camshaft lever 4 5 3 1 2...

Page 59: ...off the ground according to the procedure on page 7 21 9 Pull the wheel axle out and then remove the wheel EAU41550 To install the front wheel 1 Install the brake shoe plate into the wheel hub as shown 2 Lift the wheel up between the fork legs TIP Make sure that the slot in the brake shoe plate fits over the retainer on the fork leg 1 Washer 2 Axle nut 2 1 1 Brake shoe plate 1 ...

Page 60: ...r several times to check for proper fork operation EAU25080 Rear wheel EAU41562 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 25 3 ft lbf 1 1 Drive chain slack adjusting nut 2 Locknut 3 Chain puller 4 Washer 5 Axle nut 5 4 1 2 ...

Page 61: ...Install the drive chain onto the rear sprocket 2 Install the wheel by inserting the chain pullers spacer and then in sert the wheel axle from the right hand side 3 Install the brake rod onto the brake camshaft lever and then install the brake pedal free play adjusting nut onto the brake rod 4 Connect the brake torque rod onto the brake shoe plate by installing the bolt and nut and then tighten the...

Page 62: ...ever should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills WARNING EWA15141 When checking the...

Page 63: ...k the ignition Have a Yamaha dealer check the vehicle Wet Dry Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle Open the throttle halfway and operate the kickstarter Check the compression The engine does not start Check the compression ...

Page 64: ...s well as all electrical couplers and connectors including the spark plug cap are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and de greaser off with water Cleaning NOTICE ECA10772 Avoid using strong acidic ...

Page 65: ... for a few minutes before cleaning After riding in the rain or near the sea Since sea salt is extremely corrosive carry out the following steps after each ride in the rain or near the sea 1 Clean the motorcycle with cold wa ter and a mild detergent after the engine has cooled down NOTICE Do not use warm water since it increases the corrosive action of the salt ECA10791 2 Apply a corrosion protecti...

Page 66: ...e moisture from the lens EAU40652 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover NOTICE ECA10810 Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the ...

Page 67: ...spark plug cap WARNING To prevent damage or injury from sparking make sure to ground the spark plug elec trodes while turning the en gine over EWA10951 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand 7 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna ti...

Page 68: ...gular 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 Hel...

Page 69: ... Right hand operation Rear brake Type Drum brake Operation Right foot operation Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 110 0 mm 4 33 in Rear suspension Type Swingarm monocross Spring shock absorber type Coil spring gas oil damper Wheel travel 95 0 mm 3 74 in Electrical system Ignition system CDI ...

Page 70: ...umber in the space pro vided TIP The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area EAU26460 Model label The model label is affixed to the loca tion shown Record the information on this label in the space provided This in formation will be needed when ordering spare parts from a Yamaha dealer ...

Page 71: ...formation 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 11 Throttle grip and cab...

Page 72: ...ED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2009 04 0 2 1 E ...

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