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Yamaha PW80(Y) Owner's Manual

Summary of PW80(Y)

  • Page 1

    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 ...

  • Page 3: 3Rv-28199-8J-E0

    3rv-28199-8j-e0 pw80(y) owner’s manual read this manual carefully before operating this vehicle..

  • Page 4

    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, yamaha motor co., ltd. 2500 shingai, iwata, japan, declare in sole responsibility, that the product pw80 jya...

  • Page 5: Introduction

    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 ...

  • 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(y) owner’s manual ©2008 by yamaha motor co., ltd. 1st edition, march 2008 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: Table of Contents

    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 functio...

  • Page 10: Table of Contents

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

  • Page 11: Safety Information

    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...

  • Page 12: Safety Information

    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. T...

  • Page 13: Safety Information

    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...

  • Page 14: Safety Information

    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 larg...

  • Page 15: Description

    2-1 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 6-20) 7. Shift pedal (page 3-1).

  • Page 16: Description

    Description 2-2 1 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 3-7) 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 17: Description

    Description 2-3 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 18

    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 reduc...

  • Page 19

    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...

  • Page 20

    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. 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....

  • Page 21

    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 h...

  • Page 22

    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...

  • Page 23

    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 engin...

  • Page 24

    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...

  • Page 25

    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. Warning ewa11151 failure to in...

  • Page 26

    For your safety – pre-operation checks 4-2 1 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 sp...

  • Page 27

    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 lever pivoting point if necessary. 6-20 sidestand ● make sure tha...

  • Page 28

    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. Warning ewa10271 failure to familiarize yourself with the controls can lead to...

  • Page 29

    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 t...

  • Page 30

    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 th...

  • Page 31

    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”. 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 th...

  • Page 32

    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...

  • Page 33

    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 te...

  • Page 34

    Periodic maintenance and adjustment 6-3 1 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 35

    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 transmission oil check for oil leakage. Correct if necessary. Change. 19 * con...

  • Page 36

    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 p...

  • Page 37

    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 ...

  • Page 38

    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...

  • Page 39

    Periodic maintenance and adjustment 6-8 2 3 4 5 6 7 8 9 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. ...

  • Page 40

    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...

  • Page 41

    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 ...

  • Page 42

    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 t...

  • Page 43

    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 ...

  • Page 44

    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. 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 c...

  • Page 45

    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 ...

  • Page 46

    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 i...

  • Page 47

    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 slac...

  • Page 48

    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 wh...

  • Page 49

    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 dust...

  • Page 50

    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 c...

  • Page 51

    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 t...

  • Page 52

    Periodic maintenance and adjustment 6-21 1 2 3 4 5 6 7 8 9 notice 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 s...

  • Page 53

    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, ha...

  • Page 54

    Periodic maintenance and adjustment 6-23 1 2 3 4 5 6 7 8 9 eau24360 front wheel eau41532 to remove the front wheel warning 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...

  • Page 55

    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...

  • Page 56

    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 warning ewa10821 to avoid injury, securely support the vehicle so there is no danger...

  • Page 57

    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 disassembl...

  • Page 58

    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...

  • Page 59

    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 ...

  • Page 60: Motorcycle Care and Storage

    7-1 1 2 3 4 5 6 7 8 9 motorcycle care and storage 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 cl...

  • Page 61: Motorcycle Care and Storage

    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 a...

  • Page 62: Motorcycle Care and Storage

    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...

  • Page 63: Motorcycle Care and Storage

    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 al...

  • Page 64: Specifications

    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:...

  • Page 65: Specifications

    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/...

  • Page 66: Consumer Information

    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 identif...

  • Page 67: Index

    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, c...

  • Page 70

    Yamaha motor co., ltd. Printed on recycled paper printed in japan 2008.4–1.1 × 2 ! (e).