Yamaha PW80 (2008) manual

3RV-28199-8J PW80(Y) OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE BEDIENUNGSANLEITUNG 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.[...]

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3RV-28199-8J-E0 PW80(Y) OWNER’S MANUAL Read this manual carefully before operating this vehicle.[...]

EAU46151 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. EC Declaration of Conformity conforming to Directive 98/ 37/ EC We, Y AMAHA MO TOR CO., L TD. 2500 Shingai, Iwata, Japan, declare in sole responsibility , that the product PW80 J Y A4BC00000107910 ) ( (Make, model) to which th[...]

INTRODUCTION EAU41582 Congratulations on your purchase of the Yamaha PW80(Y). This model is the result of Yamaha’s vast experience in the pro- duction of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reli- ability that have made Yamaha a leader in these fields. This manual will give yo[...]

INTRODUCTION AN IMPORTANT NOTE TO PARENTS: This motorcycle is not a toy. Before you let your child ride this motorcycle, you should understand the instructions and warn- ings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abil - ities, and judgment. Some children may not be ab[...]

IMPORTANT MANUAL INFORMATION EAU10132 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messa ges that follo w this symbol to av oid possible injury or death. A W ARNING indicates a hazar dous s[...]

IMPORTANT MANUAL INFORMATION EAU10200 PW80(Y) O WNER’S MANU AL ©2008 by Y amaha Motor Co., Ltd. 1st edition, March 2008 All rights reserved. Any reprinting or unauthorized use without the written permission of Y amaha Motor Co., Ltd. is expressl y prohibited. Printed in Japan.[...]

TABLE OF CONTENTS SAFETY INFORMATION ................... 1-1 DESCRIPTION ................................... 2-1 Left view ........................................... 2-1 Right view ......................................... 2-2 Controls and instruments ................. 2-3 INSTRUMENT AND CONTROL FUNCTIONS ........................................ 3[...]

TABLE OF CONTENTS SPECIFICATIONS .............................. 8-1 CONSUMER INFORMATION .............. 9-1 Identification numbers .....................9-1[...]

1-1 1 2 3 4 5 6 7 8 9 SAFETY INFORMATION EAU41214 Be a Responsible Owner As the vehicle’s owner, you are respon- sible for the safe and proper operation of your motorcycle. Motorcycles are single-track vehicles. Their safe use and operation are de- pendent upon the use of proper riding techniques as well as the expertise of the operator. Every op[...]

SAFETY INFORMATION 1-2 1 cornering (insufficient lean angle for the speed). Never travel faster than warranted by conditions. ● Ride cautiously in unfamiliar ar- eas. You may encounter hidden obstacles that could cause an ac- cident. ● The posture of the operator is im- portant for proper control. The op- erator should keep both hands on the ha[...]

SAFETY INFORMATION 1-3 1 possibility of an accident, use extreme caution when adding accessories to your motorcycle. Use extra care when riding a motorcycle that has added ac- cessories. Here are some general guidelines to follow if adding accesso- ries to your motorcycle: Operation of an overloaded vehicle could cause an accident. ● The weight o[...]

SAFETY INFORMATION 1-4 1 ● Accessories fitted to the handle- bar or the front fork area can create instability due to improper weight distribution. If accesso- ries are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. ● Bulky or large accessories may seriously affect the stabili[...]

2-1 2 3 4 5 6 7 8 9 DESCRIPTION EAU10410 Left view 1 23 4 5 6 7 1. Air filter element (page 6-8) 2. Fuel coc k (page 3-5) 3. Throttle stop scre w (page 6-11) 4. Starter (choke) lev er (page 3-6) 5. 2-strok e engine oil tank (page 3-4) 6. Sidestand (page 6-20) 7. Shift pedal (page 3-1)[...]

DESCRIPTION 2-2 1 2 3 4 5 6 7 8 9 EAU10420 Right view 6 12 3 4 5 1. Spark arrester (page 6-9) 2. Seat (page 3-7) 3. T ransmission oil filler cap (page 6-7) 4. Spark plug cap (page 6-5) 5. Brak e pedal (page 3-2) 6. Kic kstar ter (page 3-6)[...]

DESCRIPTION 2-3 2 3 4 5 6 7 8 9 EAU10430 Controls and instruments 12 43 1. Right handlebar s witch (page 3-1) 2. Brak e lev er (page 3-2) 3. Throttle grip (page 6-11) 4. Fuel tank cap (page 3-2)[...]

3-1 1 2 3 4 5 6 7 8 9 INSTRUMENT AND CONTROL FUNCTIONS EAU40660 Handlebar switch EAU41130 Engine stop switch “ ENGINE STOP ” Set this switch to “RUN” before starting the engine. Set this switch to “OFF” to stop the engine. EAU41590 Power reduction plate Your motorcycle was delivered with a power reduction plate. Yamaha recom- mends that[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-2 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 tan[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-3 1 2 3 4 5 6 7 8 9 EAU13221 Fuel Make sure there is sufficient gasoline in the tank. W ARNING EWA10881 Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions. 1. Before refueling, turn off the en- gine and be s[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-4 2 3 4 5 6 7 8 9 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[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-5 1 2 3 4 5 6 7 8 9 tank cap and add the recommend- ed oil. 3. Install the 2-stroke engine oil tank cap. TIP Make sure that the 2-stroke engine oil tank cap is properly closed. 4. Install the seat. EAU13561 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it al- so. The fuel co[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-6 2 3 4 5 6 7 8 9 This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first oppor- tunity. Be sure to set the lever back to “ ON ” after refueling! EAU13590 Starter (choke) lever “” Starting a cold engine requires a richer air-fuel mixture, whi[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-7 1 2 3 4 5 6 7 8 9 EAU41140 Seat To remove the seat Remove the nuts, and then pull the seat off. To install the seat 1. Insert the projection on the front of the seat into the seat holder as shown. 2. Place the seat in the original posi- tion, and then tighten the nuts. TIP Make sure that the seat is properly se-[...]

4-1 2 3 4 5 6 7 8 9 FOR YOUR SAFETY – PRE-OPERATION CHECKS EAU15595 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. W ARNING EWA11151 Failure to inspect or maintain the vehicle properly incr[...]

FOR YOUR SAFETY – PRE-OPERATION CHECKS 4-2 1 2 3 4 5 6 7 8 9 EAU15605 Pre-operation check list ITEM CHECKS P A GE Fuel ● Check fuel le vel in fuel tank. ● Refuel if necessary . ● Check fuel line f or leakage. 3-3 2-stroke engine oil ● Check oil le vel in oil tank. ● If necessary , add recommended oil to speci fi ed lev el. ● Check v [...]

FOR YOUR SAFETY – PRE-OPERATION CHECKS 4-3 2 3 4 5 6 7 8 9 Brake and shift pedals ● Make sure that operation is smooth. ● Lubricate pedal pivoting points if necessary . 6-19 Brake lever ● Make sure that operation is smooth. ● Lubricate lev er pivoting point if necessary . 6-20 Sidestand ● Make sure that operation is smooth. ● Lubricat[...]

5-1 1 2 3 4 5 6 7 8 9 OPERATION AND IMPORTANT RIDING POINTS 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. W ARNING EWA10271 Failure to familiarize yourself with the controls can lead to loss of con- trol, which could cause an acci[...]

OPERATION AND IMPORTANT RIDING POINTS 5-2 2 3 4 5 6 7 8 9 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. TIP If the engine does not start after sever- al kicks, tr[...]

OPERATION AND IMPORTANT RIDING POINTS 5-3 1 2 3 4 5 6 7 8 9 sult. [ECA15461] 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 [...]

OPERATION AND IMPORTANT RIDING POINTS 5-4 2 3 4 5 6 7 8 9 EAU17191 Parking When parking, stop the engine, and then turn the fuel cock lever to “ OFF ” . W ARNING EWA10311 ● Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them and be burned. ● Do not park on a s[...]

6-1 1 2 3 4 5 6 7 8 9 PERIODIC MAINTENANCE AND ADJUSTMENT EAU41951 Periodic inspection, adjustment, and lu- brication will keep your vehicle in the safest and most efficient condition pos- sible. Safety is an obligation of the vehi- cle owner/operator. The most important points of vehicle inspection, adjust- ment, and lubrication are explained on t[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-2 2 3 4 5 6 7 8 9 EAU41764 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[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-3 1 2 3 4 5 6 7 8 9 8* Tires Check tread depth and f or damage. Replace if necessary . Check air pressure . Correct if necessary . 9* Wheel bearings Check bearings f or smooth operation. Replace if necessary . 10 * Steering bearings Check bearing assemblies f or looseness. Moderately repack with lithium-soap-ba[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-4 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 . Bleed. 18 T ransmission oil Check for oil leakage . Correct if necessary . Change. 19 * Control cables Apply Y amaha chain and cable lube[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-5 1 2 3 4 5 6 7 8 9 EAU19603 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic mainte- nance and lubrication chart. In ad[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-6 2 3 4 5 6 7 8 9 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug with the spark plug wrench, and then tight- en it to the specified torque. TIP If a torque wrench is not available when installing a spark pl[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-7 1 2 3 4 5 6 7 8 9 EAU19943 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- fa[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-8 2 3 4 5 6 7 8 9 NO TICE 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 “ [...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-9 1 2 3 4 5 6 7 8 9 4. Apply oil of the recommended type to the entire surface of the sponge material, and then squeeze the ex- cess oil out. TIP The sponge material should be wet but not dripping. 5. Install the sponge material onto the air filter case cover. 6. Insert the air filter element into the air filte[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-10 2 3 4 5 6 7 8 9 2. 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. TIP Make sure to[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-11 1 2 3 4 5 6 7 8 9 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[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-12 2 3 4 5 6 7 8 9 cable free play, turn the adjusting nut in direction (b). 3. Tighten the locknut. EAU39821 Tires To maximize the performance, durabil- ity, and safe operation of your motorcy- cle, note the following points regarding the specified tires. Tire air pressure The tire air pressure should be check[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-13 1 2 3 4 5 6 7 8 9 Tire information This motorcycle is equipped with spoke wheels and tube tires. W ARNING 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, [...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-14 2 3 4 5 6 7 8 9 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 le[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-15 1 2 3 4 5 6 7 8 9 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 th[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-16 2 3 4 5 6 7 8 9 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. EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted [...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-17 1 2 3 4 5 6 7 8 9 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 [...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-18 2 3 4 5 6 7 8 9 EAU23013 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[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-19 1 2 3 4 5 6 7 8 9 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 periodic maintenance and lubrication chart. EAU44271 Checking and lubricating the brake and shift pedals[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-20 2 3 4 5 6 7 8 9 EAU43621 Checking and lubricating the brake lever The operation of the brake lever should be checked before each ride, and the lever pivots should be lubricated if nec- essary. EAU23202 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride, a[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-21 1 2 3 4 5 6 7 8 9 NO TICE ECA10590 If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or re- pair it. EAU23282 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 inter[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-22 2 3 4 5 6 7 8 9 EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica- tion chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. EAU24[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-23 1 2 3 4 5 6 7 8 9 EAU24360 Front wheel EAU41532 To remove the front wheel W ARNING EWA10821 To avoid injury, securely support the vehicle so there is no danger of it falling 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 th[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-24 2 3 4 5 6 7 8 9 8. Lift the front wheel off the ground according to the procedure on page 6-22. 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 tha[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-25 1 2 3 4 5 6 7 8 9 (See page 6-14.) 10. Push down hard on the handlebar several times to check for proper fork operation. EAU25080 Rear wheel EAU41561 To remove the rear wheel W ARNING EWA10821 To avoid injury, securely support the vehicle so there is no danger of it falling over. 1. Loosen the axle nut. 2. R[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-26 2 3 4 5 6 7 8 9 according to the procedure on page 6-22. 6. Remove the axle nut and washer, and then pull the wheel axle out. 7. Push the wheel forward, and then remove the drive chain from the rear sprocket. TIP The drive chain does not need to be disassembled in order to remove and install the wheel. 8. Re[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-27 1 2 3 4 5 6 7 8 9 EAU25851 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur dur- ing operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following trouble[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 6-28 2 3 4 5 6 7 8 9 EAU25972 Troubleshooting chart Check the fuel level in the fuel tank. 1. Fuel There is enough fuel. There is no fuel. Supply fuel. Operate the kickstarter. 2. Compression There is compression. There is no compression. Check the ignition. Have a Yamaha dealer check the vehicle. Remove the spar[...]

7-1 1 2 3 4 5 6 7 8 9 MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution NO TICE ECA15192 Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use be- fore cleaning the vehicle. Using a brush, harsh chemical products or cleaning compounds when cleaning these parts will s[...]

MOTORCYCLE CARE AND STORAGE 7-2 2 3 4 5 6 7 8 9 contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust re- movers or inhibitors, brake flu- id, antifreeze or electrolyte. ● Do not use high-pressure wash- ers or steam-jet cleaners since they cause water seepage and deterioration in the following ar- eas: seals[...]

MOTORCYCLE CARE AND STORAGE 7-3 1 2 3 4 5 6 7 8 9 can cause loss of control. ● Make sure that there is no oil or wax on the tires. ● If necessary, wash the tires with warm water and a mild deter- gent. Before riding at higher speeds, test the motorcycle ’ s braking performance and cor- nering behavior. NO TICE ECA10800 ● Apply spray oil and[...]

MOTORCYCLE CARE AND STORAGE 7-4 2 3 4 5 6 7 8 9 install the spark plug and the 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[...]

8-1 1 2 3 4 5 6 7 8 9 SPECIFICATIONS EAU2633P Dimensions: Overall length: 1540 mm (60.6 in) Overall width: 640 mm (25.2 in) Overall height: 880 mm (34.6 in) Seat height: 635 mm (25.0 in) Wheelbase: 1055 mm (41.5 in) Ground clearance: 185 mm (7.28 in) Minimum turning radius: 1700 mm (66.9 in) Weight: With oil and fuel: 61.0 kg (134 lb) Noise and vib[...]

SPECIFICATIONS 8-2 2 3 4 5 6 7 8 9 Transmission: Primary reduction system: Helical gear Primary reduction ratio: 66/21 (3.143) Secondary reduction system: Chain drive Secondary reduction ratio: 32/15 (2.133) Transmission type: Constant mesh 3-speed Operation: Left foot operation Gear ratio: 1st: 39/12 (3.250) 2nd: 29/16 (1.812) 3rd: 22/17 (1.294) C[...]

9-1 1 2 3 4 5 6 7 8 9 CONSUMER INFORMATION EAU40790 Identification numbers Record the vehicle identification num- ber and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. VEHICLE IDENTIFICATION NUMBER: MODEL LABEL INFORMATION: EAU26400 [...]

INDEX A Air filter element, cleaning ......................... 6-8 Autolube pump, adjusting ........................ 6-19 B Brake and shift pedals, checking and lubricating .............................................. 6-19 Brake lever ................................................ 3-2 Brake lever, checking and lubricating ...... 6-20 Brake leve[...]

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Y AMAHA MOTOR CO. , L TD. PRINTED ON RECYCLED PAPER PRINTED IN JAP AN 2008.4 – 1.1 × 2 ! (E)[...]