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Yamaha PW80(X) Owner's Manual

Summary of PW80(X)

  • Page 1

    3rv-28199-8h pw80(x) owner’s manual manuel du propriÉtaire bedienungsanleitung.

  • Page 2

    Printed on recycled paper yamaha motor co., ltd. Printed in japan 2007.4–0.7 ×1 ! (e, f, g) auf recyclingpapier gedruckt imprimÉ sur papier recyclÉ printed on recycled paper yamaha motor co., ltd. Printed in japan 2007.4–0.7 ×1 ! (e, f, g) auf recyclingpapier gedruckt imprimÉ sur papier recyclÉ.

  • Page 3: 3Rv-28199-8H-E0

    3rv-28199-8h-e0 pw80(x) owner’s manual.

  • Page 5: Introduction

    Introduction eau41580 congratulations on your purchase of the yamaha pw80(x). 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 motorcycles are single track vehicles. Their safe use and operation are dependent upon the use of proper riding techniques as well as the expertise of the operator. Every opera- tor should know the following requirements before riding this motorcycle. He or she should: ● obtain thorough...

  • Page 7: Important Manual Information

    Important manual information eau41090 particularly important information is distinguished in this manual by the following notations: note: ● this manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. ● yamaha continuall...

  • Page 8: Important Manual Information

    Important manual information warning ewa10030 please read this manual carefully and completely before operating this motorcycle. Warning ewa14350 this motorcycle is designed and manufactured for off-road use only. It is illegal to oper- ate this motorcycle on any public street, road or highway. Such...

  • Page 9: Important Manual Information

    Important manual information eau10200 pw80(x) owner’s manual ©2007 by yamaha motor co., ltd. 1st edition, march 2007 all rights reserved. Any reprinting or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited. Printed in japan..

  • Page 10: Table of Contents

    Table of contents safety information ...................1-1 safe riding ........................................1-1 location of important labels .............1-4 description ...................................2-1 left view ...........................................2-1 right view ......................

  • Page 11: Table of Contents

    Table of contents storage ............................................7-3 specifications ..............................8-1 consumer information ..............9-1 identification numbers .....................9-1.

  • Page 12: Safety Information

    1-1 1 safety information eau41211 safe riding ● always make pre-operation checks. Careful checks may help prevent an accident. ● this motorcycle is designed for off-road use only, therefore, it is il- legal to operate it on public streets, roads, or highways, even a dirt or gravel one. Off-road use ...

  • Page 13: Safety Information

    Safety information 1-2 1 loading and accessories adding accessories to your motorcycle can adversely affect stability and han- dling if the weight distribution of the mo- torcycle is changed. To avoid the possibility of an accident, use extreme caution when adding accessories to your motorcycle. Use...

  • Page 14: Safety Information

    Safety information 1-3 1 electric failure could result, which could cause a dangerous loss of engine power. Gasoline and exhaust gas ● gasoline is highly flamma- ble: ● always turn the engine off when refueling. ● take care not to spill any gaso- line on the engine or exhaust pipe/muffler when refue...

  • Page 15: Safety Information

    Safety information 1-4 1 eau41370 location of important labels please read the following important labels carefully before operating this vehicle. 1 3 2.

  • Page 16: Safety Information

    Safety information 1-5 1 4 5.

  • Page 17: Safety Information

    Safety information 1-6 1 before you operate this vehicle, read the owner’s manual. 5pa-21568-00 prima di usare il veicolo, leggete il manuale di istruzioni. Lire le manuel du propriétaire avant d’utiliser ce véhicule. Lesen sie die bedienungsanleitung bevor sie dieses fahrzeug fahren. Antes de condu...

  • Page 18: Description

    2-1 1 2 3 4 5 6 7 8 9 description eau10410 left view 1 2 3 4 5 6 7 1. Air filter element (page 6-8) 2. Fuel cock (page 3-5) 3. Throttle stop screw (page 6-11) 4. Starter (choke) lever (page 3-6) 5. 2-stroke engine oil tank (page 3-4) 6. Sidestand (page 6-21) 7. Shift pedal (page 3-1).

  • Page 19: Description

    Description 2-2 2 3 4 5 6 7 8 9 eau10420 right view 6 1 2 3 4 5 1. Spark arrester (page 6-9) 2. Seat (page 3-6) 3. Transmission oil filler cap (page 6-7) 4. Spark plug cap (page 6-5) 5. Brake pedal (page 3-2) 6. Kickstarter (page 3-6).

  • Page 20: Description

    Description 2-3 1 2 3 4 5 6 7 8 9 eau10430 controls and instruments 1 2 4 3 1. Right handlebar switch (page 3-1) 2. Brake lever (page 3-2) 3. Throttle grip (page 6-11) 4. Fuel tank cap (page 3-2).

  • Page 21

    3-1 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 reducti...

  • Page 22

    Instrument and control functions 3-2 1 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 bra...

  • Page 23

    Instrument and control functions 3-3 2 3 4 5 6 7 8 9 eau13220 fuel make sure that there is sufficient fuel in the tank. When refueling, be sure to in- sert the pump nozzle into the fuel tank filler hole and to fill the tank to the bot- tom of the filler tube as shown. Warning ewa10880 ● do not overf...

  • Page 24

    Instrument and control functions 3-4 1 2 3 4 5 6 7 8 9 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 i...

  • Page 25

    Instrument and control functions 3-5 2 3 4 5 6 7 8 9 eau13561 fuel cock the fuel cock supplies fuel from the tank to the carburetor while filtering it al- so. The fuel cock has three positions: off with the lever in this position, fuel will not flow. Always return the lever to this position when the...

  • Page 26

    Instrument and control functions 3-6 1 2 3 4 5 6 7 8 9 eau13590 starter (choke) lever “ ” starting a cold engine requires a richer air-fuel mixture, 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 t...

  • Page 27

    Instrument and control functions 3-7 2 3 4 5 6 7 8 9 2. Place the seat in the original posi- tion, and then tighten the nuts. Note: make sure that the seat is properly se- cured before riding. Eau15090 shock absorber warning ewa10220 this shock absorber contains highly pressurized nitrogen gas. For ...

  • Page 28: Pre-Operation Checks

    4-1 1 2 3 4 5 6 7 8 9 pre-operation checks eau15593 the condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or lo...

  • Page 29: Pre-Operation Checks

    Pre-operation checks 4-2 2 3 4 5 6 7 8 9 eau15605 pre-operation check list item checks page fuel ● check fuel level in fuel tank. ● refuel if necessary. ● check fuel line for leakage. 3-3 2-stroke engine oil ● check oil level in oil tank. ● if necessary, add recommended oil to specified level. ● che...

  • Page 30: Pre-Operation Checks

    Pre-operation checks 4-3 1 2 3 4 5 6 7 8 9 brake and shift pedals ● make sure that operation is smooth. ● lubricate pedal pivoting points if necessary. 6-20 brake lever ● make sure that operation is smooth. ● lubricate lever pivoting point if necessary. 6-20 sidestand ● make sure that operation is s...

  • Page 31

    5-1 2 3 4 5 6 7 8 9 operation and important riding points eau41680 warning ewa14620 ● this model is designed for off-road use only. Become thor- oughly familiar with all operat- ing controls and their functions before riding. Consult a yamaha dealer regarding any control or function that you do not ...

  • Page 32

    Operation and important riding points 5-2 1 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. Note: ...

  • Page 33

    Operation and important riding points 5-3 2 3 4 5 6 7 8 9 shifting gears, otherwise damage to the engine and drive train may re- sult. 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...

  • Page 34

    Operation and important riding points 5-4 1 2 3 4 5 6 7 8 9 eau17190 parking when parking, stop the engine, and then turn the fuel cock lever to “off”. Warning ewa10310 ● since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch ...

  • Page 35

    6-1 2 3 4 5 6 7 8 9 periodic maintenance and minor repair eau41950 safety is an obligation of the owner. Pe- riodic inspection, adjustment and lubri- cation will keep your vehicle in the safest and most efficient condition pos- sible. The most important points of mo- torcycle inspection, adjustment,...

  • Page 36

    Periodic maintenance and minor repair 6-2 1 2 3 4 5 6 7 8 9 eau41763 periodic maintenance and lubrication chart note: ● 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 ...

  • Page 37

    Periodic maintenance and minor repair 6-3 2 3 4 5 6 7 8 9 8 * tires check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. 9 * wheel bearings check bearings for smooth operation. Replace if necessary. 10 * steering bearings check bearing assemblies for loos...

  • Page 38

    Periodic maintenance and minor repair 6-4 1 2 3 4 5 6 7 8 9 note: 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 transmission oil check for oil leakage. Correct if necessary. Change. 19...

  • Page 39

    Periodic maintenance and minor repair 6-5 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 p...

  • Page 40

    Periodic maintenance and minor repair 6-6 1 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. Note: if a t...

  • Page 41

    Periodic maintenance and minor repair 6-7 2 3 4 5 6 7 8 9 eau19942 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...

  • Page 42

    Periodic maintenance and minor repair 6-8 1 2 3 4 5 6 7 8 9 caution: 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 speci...

  • Page 43

    Periodic maintenance and minor repair 6-9 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. Note: the sponge material should be wet but not dripping. 5. Install the sponge material onto the air filter case cover....

  • Page 44

    Periodic maintenance and minor repair 6-10 1 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 tigh...

  • Page 45

    Periodic maintenance and minor repair 6-11 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 t...

  • Page 46

    Periodic maintenance and minor repair 6-12 1 2 3 4 5 6 7 8 9 cable free play, turn the adjusting nut in direction (b). 3. Tighten the locknut. Eau39820 tires to maximize the performance, durabil- ity, and safe operation of your motorcy- cle, note the following points regarding the specified tires. T...

  • Page 47

    Periodic maintenance and minor repair 6-13 2 3 4 5 6 7 8 9 warning ewa10460 ● the front and rear tires should be of the same make and de- sign, otherwise the handling characteristics of the vehicle cannot be guaranteed. ● after extensive tests, only the tires listed below have been ap- proved for th...

  • Page 48

    Periodic maintenance and minor repair 6-14 1 2 3 4 5 6 7 8 9 eau40431 accessories and replacement parts warning ewa14481 the accessories or replacement parts you choose for your vehicle should be designed specifically for this model, and they must be se- curely mounted to maintain the in- herent sta...

  • Page 49

    Periodic maintenance and minor repair 6-15 2 3 4 5 6 7 8 9 shoe plate and at the brake lever. Eau39811 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 ne...

  • Page 50

    Periodic maintenance and minor repair 6-16 1 2 3 4 5 6 7 8 9 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. Note: the wheels must be removed to check brake shoe l...

  • Page 51

    Periodic maintenance and minor repair 6-17 2 3 4 5 6 7 8 9 4. If the drive chain slack is incorrect, adjust it as follows. Eau40110 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. 2. To tighten the drive chain, tur...

  • Page 52

    Periodic maintenance and minor repair 6-18 1 2 3 4 5 6 7 8 9 4. Adjust the brake pedal free play. (see page 6-15.) 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, otherwis...

  • Page 53

    Periodic maintenance and minor repair 6-19 2 3 4 5 6 7 8 9 eau41840 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 o...

  • Page 54

    Periodic maintenance and minor repair 6-20 1 2 3 4 5 6 7 8 9 eau44270 checking and lubricating the brake and shift pedals the operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lu- bricated if necessary. Eau43620 checking and lubricating the br...

  • Page 55

    Periodic maintenance and minor repair 6-21 2 3 4 5 6 7 8 9 eau23200 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 ewa10730 if the sidesta...

  • Page 56

    Periodic maintenance and minor repair 6-22 1 2 3 4 5 6 7 8 9 eau23280 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...

  • Page 57

    Periodic maintenance and minor repair 6-23 2 3 4 5 6 7 8 9 eau24350 supporting the motorcycle since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up- right. Check that t...

  • Page 58

    Periodic maintenance and minor repair 6-24 1 2 3 4 5 6 7 8 9 justing nut at the front wheel hub. 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. Disconnect the brake cable from the brake...

  • Page 59

    Periodic maintenance and minor repair 6-25 2 3 4 5 6 7 8 9 2. Lift the wheel up between the fork legs. Note: make sure that the slot in the brake shoe plate fits over the retainer on the fork leg. 3. Insert the wheel axle, and then in- stall the washer and axle nut. 4. Lower the front wheel so that ...

  • Page 60

    Periodic maintenance and minor repair 6-26 1 2 3 4 5 6 7 8 9 eau25080 rear wheel eau41560 to remove the rear wheel warning ewa10820 ● it is advisable to have a yamaha dealer service the wheel. ● securely support the motorcy- cle so that there is no danger of it falling over. 1. Loosen the axle nut. ...

  • Page 61

    Periodic maintenance and minor repair 6-27 2 3 4 5 6 7 8 9 eau41570 to install the rear wheel 1. 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 br...

  • Page 62

    Periodic maintenance and minor repair 6-28 1 2 3 4 5 6 7 8 9 eau25971 troubleshooting chart warning ewa10840 keep away open flames and do not smoke while checking or working on the fuel system. Check the fuel level in the fuel tank. 1. Fuel there is enough fuel. There is no fuel. Supply fuel. Operat...

  • Page 63: Motorcycle Care and Storage

    7-1 2 3 4 5 6 7 8 9 motorcycle care and storage eau37833 matte color caution caution: 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 cl...

  • Page 64: Motorcycle Care and Storage

    Motorcycle care and storage 7-2 1 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...

  • Page 65: Motorcycle Care and Storage

    Motorcycle care and storage 7-3 2 3 4 5 6 7 8 9 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. Caution: eca10800 ● apply spray oil and wax spar- ingly and mak...

  • Page 66: Motorcycle Care and Storage

    Motorcycle care and storage 7-4 1 2 3 4 5 6 7 8 9 install the spark plug and the spark plug cap. Warning ewa10950 to prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. 6. Lubricate all control cables and the pivoting points of all lev...

  • Page 67: Specifications

    8-1 2 3 4 5 6 7 8 9 specifications eau2633k 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: w...

  • Page 68: Specifications

    Specifications 8-2 1 2 3 4 5 6 7 8 9 3rd: 22/17 (1.294) chassis: frame type: steel tube backbone caster angle: 26.00 ° 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 s...

  • Page 69: Consumer Information

    9-1 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 identific...

  • Page 70: Index

    Index a accessories and replacement parts........ 6-14 air filter element, cleaning......................... 6-8 autolube pump, adjusting ....................... 6-19 b brake and shift pedals, checking and lubricating ............................................. 6-20 brake lever.......................

  • Page 72

    Printed on recycled paper yamaha motor co., ltd. Printed in japan 2007.4–0.7 ×1 ! (e).