1. DL manuals
  2. Yamaha
  3. Motorcycle
  4. PW80(A)
  5. Owner's Manual

Yamaha PW80(A) Owner's Manual

Summary of PW80(A)

  • Page 1

    Dic183 3rv-28199-8l pw80(a) owner’s manual manuel du propriÉtaire bedienungsanleitung 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. Read this manual carefu...

  • Page 2

    Printed on recycled paper imprimÉ sur papier recyclÉ auf recyclingpapier gedruckt yamaha motor co., ltd. Printed in japan 2010.04-0.4 ×1 cr (e,f,g) dic183.

  • Page 3: Owner’S Manual

    Read this manual carefully before operating this vehicle. Owner’s manual pw80(a) 3rv-28199-8l-e0 u3rv8le0.Book page 1 tuesday, april 13, 2010 8:48 am.

  • Page 4

    Eau48181 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 2006/42/ec we, yamaha motor co., ltd. 2500 shingai, iwata, japan, declare in sole responsibility, that the product pw80 (jy...

  • Page 5: Introduction

    Introduction eau41583 congratulations on your purchase of the yamaha pw80(a). 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 ...

  • Page 6: Introduction

    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- i...

  • Page 7: Important Manual Information

    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 messages that follow this symbol to avoid possible injur...

  • Page 8: Important Manual Information

    Important manual information eau10200 pw80(a) owner’s manual ©2010 by yamaha motor co., ltd. 1st edition, march 2010 all rights reserved. Any reprinting or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited. Printed in japan. U3rv8le0.Book page 2 tuesda...

  • Page 9: Table of Contents

    Table of contents location of important labels ............................................1-1 safety information ..................2-1 description ..................................3-1 left view ..........................................3-1 right view ........................................3-2 con...

  • Page 10: Table Of Contents

    Table of contents motorcycle care and storage ..........................................8-1 matte color caution .........................8-1 care ................................................8-1 storage ...........................................8-3 specifications .............................9-1...

  • Page 11: Location of Important Labels

    Location of important labels 1-1 1 eau48133 read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is av...

  • Page 12: Location of Important Labels

    Location of important labels 1-2 1 for europe 100 1.00 15 100 1.00 15 5pg-2816r-00 4aa-22259-40 8ac-2817l-00 yamaha motor co., ltd. 2500 shingai, iwata, japan 2010 4bc-2156a-10 pw80 3.7 kw 61 kg 1 2 3 4 u3rv8le0.Book page 2 tuesday, april 13, 2010 8:48 am.

  • Page 13: Location of Important Labels

    Location of important labels 1-3 1 familiarize yourself with the following pictograms and read the explanatory text. **.* kpa *.** kgf/cm² *.* psi **.* kpa *.** kgf/cm² *.* psi read the owner’s manual. This unit contains high-pressure nitrogen gas. Mishandling can cause an explosion. Do not incinera...

  • Page 14: Location of Important Labels

    Location of important labels 1-4 1 ****** *** kw *** kg 1 2 3 yamaha motor co., ltd. 2500 shingai, iwata, japan **** 1 1 2 3 model name max. Power mass in running order 1 year of construction u3rv8le0.Book page 4 tuesday, april 13, 2010 8:48 am.

  • Page 15: Location of Important Labels

    Location of important labels 1-5 1 for oceania and south africa 1 3 2 u3rv8le0.Book page 5 tuesday, april 13, 2010 8:48 am.

  • Page 16: Location of Important Labels

    Location of important labels 1-6 1 for oceania and south africa follows. Front : : rear 3rv-21668-a0 cold tire normal pressure should be set as 100 kpa,{1.00 kgf/cm 2 }, 15 psi 100 kpa,{1.00 kgf/cm 2 }, 15 psi 4aa-22259-40 warning 3pt-2118k-a1 • before you operate this vehicle, read the owner’s manu...

  • Page 17: Safety Information

    2-1 2 safety information eau41218 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 exp...

  • Page 18: Safety Information

    Safety information 2-2 2 ● many accidents have been caused by error of the motorcycle opera- tor. A typical error made by the op- erator is veering wide on a turn due to excessive speed or under- cornering (insufficient lean angle for the speed). Never travel faster than warranted by conditions. ● r...

  • Page 19: Safety Information

    Safety information 2-3 2 ● do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors. Loading adding accessories to your motorcycle can adversely affect stability and han- dling if the weight distribution of the mo- torcycle is changed. T...

  • Page 20: Safety Information

    Safety information 2-4 2 ● never install accessories that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit suspen- sion travel, steering travel or con- trol ...

  • Page 21: Description

    Description 3-1 3 eau10410 left view 1 2 3 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) u3rv8le0.Book page 1 tuesday, ap...

  • Page 22: Description

    Description 3-2 3 eau10420 right view 7 1 2 3 4 5 6 1. Spark arrester (page 7-10) 2. Seat (page 4-7) 3. Transmission oil filler cap (page 7-8) 4. Spark plug cap (page 7-6) 5. Brake pedal (page 4-2) 6. Transmission oil drain bolt (page 7-8) 7. Kickstarter (page 4-6) u3rv8le0.Book page 2 tuesday, apri...

  • Page 23: Description

    Description 3-3 3 eau10430 controls and instruments 1 2 4 3 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) u3rv8le0.Book page 3 tuesday, april 13, 2010 8:48 am.

  • Page 24

    Instrument and control functions 4-1 4 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. Eau41591 power reduction plate your motorcycle is equipped with a power reduction plate. Yamaha...

  • Page 25

    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 o...

  • Page 26

    Instrument and control functions 4-3 4 eau13212 fuel make sure there is sufficient gasoline in the tank. Warning 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 refuelin...

  • Page 27

    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...

  • Page 28

    Instrument and control functions 4-5 4 3. Install the 2-stroke engine oil tank cap. Notice eca16670 make sure that the 2-stroke engine oil tank cap is properly installed. 4. Install the seat. Eau13561 fuel cock the fuel cock supplies fuel from the tank to the carburetor while filtering it al- so. Th...

  • Page 29

    Instrument and control functions 4-6 4 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 r...

  • Page 30

    Instrument and control functions 4-7 4 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 ...

  • Page 31

    Instrument and control functions 4-8 4 eau37490 sidestand the sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright. Warning ewa14190 the vehicle must not be ridden with the sidestand down, or if the side- stand cannot be...

  • Page 32

    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 maint...

  • Page 33

    For your safety – pre-operation checks 5-2 5 throttle grip • make 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 cables • make sure that operation is smooth. • lubricate if nec...

  • Page 34

    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- tr...

  • Page 35

    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. Tip if the engine does...

  • Page 36

    Operation and important riding points 6-3 6 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...

  • Page 37

    Operation and important riding points 6-4 6 eau17191 parking when parking, stop the engine, and then turn the fuel cock lever to “off”. Warning 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 burn...

  • Page 38

    Periodic maintenance and adjustment 7-1 7 eau41952 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, ...

  • Page 39

    Periodic maintenance and adjustment 7-2 7 eau49900 periodic maintenance chart for the emission control system 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 ...

  • Page 40

    Periodic maintenance and adjustment 7-3 7 eau41767 general 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....

  • Page 41

    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 job initial thereafter every 10 hours 20 hours 40 hours 80 hours 40 hours 80 hours 160 hours every ride ch...

  • Page 42

    Periodic maintenance and adjustment 7-5 7 tip the air filter needs more frequent service if you are riding in unusually wet or dusty areas. 13 * 14 15 * 16 * 17 18 autolube pump transmission oil control cables throttle grip housing and cable brake lever pivot shaft brake pedal pivot shaft no. Item c...

  • Page 43

    Periodic maintenance and adjustment 7-6 7 eau19604 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- ...

  • Page 44

    Periodic maintenance and adjustment 7-7 7 to install the spark plug 1. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 2. Install the spark plug with the spark plug wrench, and then tight- en it to the specified torque. Tip ...

  • Page 45

    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. Pl...

  • Page 46

    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, d...

  • Page 47

    Periodic maintenance and adjustment 7-10 7 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 ai...

  • Page 48

    Periodic maintenance and adjustment 7-11 7 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 th...

  • Page 49

    Periodic maintenance and adjustment 7-12 7 tip if 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. ...

  • Page 50

    Periodic maintenance and adjustment 7-13 7 eau39824 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 checked and, if necessary, adjusted before each rid...

  • Page 51

    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, p...

  • Page 52

    Periodic maintenance and adjustment 7-15 7 3. 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 ...

  • Page 53

    Periodic maintenance and adjustment 7-16 7 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 adjustin...

  • Page 54

    Periodic maintenance and adjustment 7-17 7 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 ch...

  • Page 55

    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. N...

  • Page 56

    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...

  • Page 57

    Periodic maintenance and adjustment 7-20 7 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. Eau43622 checking and lubr...

  • Page 58

    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...

  • Page 59

    Periodic maintenance and adjustment 7-22 7 eau23283 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...

  • Page 60

    Periodic maintenance and adjustment 7-23 7 a 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 fall...

  • Page 61

    Periodic maintenance and adjustment 7-24 7 7. Lift the front wheel off the ground according to the procedure on page 7-22. 8. Pull the wheel axle out, and then remove the wheel. Eau41553 to install the front wheel 1. Install the brake shoe plate into the wheel hub as shown. 2. Lift the wheel up betw...

  • Page 62

    Periodic maintenance and adjustment 7-25 7 9. 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 ...

  • Page 63

    Periodic maintenance and adjustment 7-26 7 5. Lift the rear wheel off the ground according to the procedure on page 7-22. 6. Remove the axle nut and washer, and then pull the wheel axle out. 7. Remove the spacer and chain pull- ers. 8. Push the wheel forward, and then remove the drive chain from the...

  • Page 64

    Periodic maintenance and adjustment 7-27 7 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 lo...

  • Page 65

    Periodic maintenance and adjustment 7-28 7 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 deale...

  • Page 66: Motorcycle Care and Storage

    Motorcycle care and storage 8-1 8 eau37833 matte color caution notice 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...

  • Page 67: Motorcycle Care and Storage

    Motorcycle care and storage 8-2 8 off any detergent residue using plenty of water, as it is harmful to plastic parts. ● do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or t...

  • Page 68: Motorcycle Care and Storage

    Motorcycle care and storage 8-3 8 8. Let the motorcycle dry completely before storing or covering it. Warning ewa14501 contaminants on the brakes or tires 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-...

  • Page 69: Motorcycle Care and Storage

    Motorcycle care and storage 8-4 8 2. For motorcycles equipped with a fuel cock that has an “off” posi- tion: turn the fuel cock lever to “off”. 3. Drain the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tan...

  • Page 70: Specifications

    Specifications 9-1 9 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 kg...

  • Page 71: Specifications

    Specifications 9-2 9 trail: 62.0 mm (2.44 in) front tire: type: with tube size: 2.50-14 4pr manufacturer/model: cheng shin/knobby rear tire: type: with tube size: 3.00-12 4pr manufacturer/model: cheng shin/knobby loading: maximum rider weight: 40.0 kg (88 lb) tire air pressure (measured on cold tire...

  • Page 72: Consumer Information

    Consumer information 10-1 10 eau40791 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...

  • Page 73: Index

    Index a air filter element, cleaning ...................... 7-9 autolube pump, adjusting ..................... 7-20 b brake lever ............................................. 4-2 brake lever, checking and lubricating ... 7-20 brake lever free play, adjusting ............ 7-14 brake pedal .............

  • Page 74

    Yamaha motor co., ltd. Printed on recycled paper printed in japan 2010.04-0.4 ×1 cr (e) u3rv8le0.Book page 1 tuesday, april 13, 2010 8:48 am.