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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
BEDIENUNGSANLEITUNG
PW80(X)
3RV-28199-8H

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Table of Contents

   Summary of Contents for YAMAHA PW80(X)

  • Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE BEDIENUNGSANLEITUNG PW80(X) 3RV-28199-8H...
  • Page 2 PRINTED ON RECYCLED PAPER PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ IMPRIMÉ SUR PAPIER RECYCLÉ YAMAHA MOTOR CO., LTD. YAMAHA MOTOR CO., LTD. AUF RECYCLINGPAPIER GEDRUCKT AUF RECYCLINGPAPIER GEDRUCKT PRINTED IN JAPAN PRINTED IN JAPAN 2007.4–0.7×1 ! 2007.4–0.7×1 !
  • Page 3 OWNER’S MANUAL PW80(X) 3RV-28199-8H-E0...
  • Page 5 Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.
  • Page 6 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 INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
  • Page 7: Important Manual Information

    This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle...
  • Page 8 IMPORTANT MANUAL INFORMATION EWA10030 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. EWA14350 WARNING 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 USE IS PROHIBITED BY LAW. THIS MOTORCYCLE COMPLIES WITH ALMOST ALL STATE OFF-HIGHWAY NOISE LEVEL AND SPARK ARRESTER LAWS AND REGULATIONS.
  • Page 9 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 OPERATION AND IMPORTANT Adjusting the brake pedal free Safe riding ........1-1 RIDING POINTS........5-1 play ..........6-15 Location of important labels .....1-4 Starting and warming up a cold Checking the front and rear brake engine ..........
  • Page 11 TABLE OF CONTENTS Storage ..........7-3 SPECIFICATIONS ......8-1 CONSUMER INFORMATION....9-1 Identification numbers .....9-1...
  • Page 12: Safety Information

    Modifications made to this motorcycle Know your skills and limits. The majority of fatalities from motorcy- not approved by Yamaha, or the re- Staying within your limits may cle accidents are the result of head in- moval of original equipment, may ren- help you to avoid an accident.
  • Page 13 Since Yamaha cannot should be kept to a minimum. cessories. Here are some general test all other accessories that may be...
  • Page 14 SAFETY INFORMATION electric failure could result, which park the motorcycle in a place could cause a dangerous loss of where pedestrians or children engine power. are not likely to touch these hot areas. Gasoline and exhaust gas Do not park the motorcycle on a GASOLINE IS HIGHLY FLAMMA- slope or soft ground, otherwise it BLE:...
  • Page 15: Location Of Important Labels

    SAFETY INFORMATION EAU41370 Location of important labels Please read the following important labels carefully before operating this vehicle.
  • Page 16 SAFETY INFORMATION...
  • Page 17 SAFETY INFORMATION Before you operate this vehicle, read the owner’s manual. Prima di usare il veicolo, leggete il manuale di istruzioni. Lire le manuel du propri étaire avant d ’utiliser ce v éhicule. Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren. Antes de conducir este vehículo, lea el Manual del Propietario.
  • Page 18: Description

    DESCRIPTION EAU10410 Left view 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: Right View

    DESCRIPTION EAU10420 Right view 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: Controls And Instruments

    DESCRIPTION EAU10430 Controls and instruments 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: Instrument And Control Functions

    Handlebar switch Power reduction plate Shift pedal Your motorcycle was delivered with a power reduction plate. Yamaha recom- mends that all beginning riders start off with the power reduction plate installed to limit the amount of power available while they learn.
  • Page 22: Brake Lever

    INSTRUMENT AND CONTROL FUNCTIONS EAU12890 EAU12941 EAU13181 Brake lever Brake pedal Fuel tank cap 1. Brake lever 1. Brake pedal 1. Fuel tank cap The brake lever is located at the right The brake pedal is on the right side of To remove the fuel tank cap, turn it handlebar grip.
  • Page 23: Fuel

    Avoid spilling fuel on the hot en- the exhaust system. gine. Your Yamaha engine has been de- signed to use regular unleaded gaso- line with a research octane number of...
  • Page 24: Fuel Tank Breather Hose

    INSTRUMENT AND CONTROL FUNCTIONS EAU13412 EAU41201 tank cap and add the recommend- Fuel tank breather hose 2-stroke engine oil ed 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...
  • Page 25: Fuel Cock

    INSTRUMENT AND CONTROL FUNCTIONS EAU13561 This indicates reserve. If you run out of Fuel cock fuel while riding, move the lever to this The fuel cock supplies fuel from the position. Fill the tank at the first oppor- tank to the carburetor while filtering it al- tunity.
  • Page 26: Starter (choke) Lever "1

    INSTRUMENT AND CONTROL FUNCTIONS EAU13590 EAU13680 EAU41140 Starter (choke) lever “ ” Kickstarter Seat To remove the seat Remove the nuts, and then pull the seat off. 1. Kickstarter 1. Starter (choke) lever “ ” To start the engine, fold out the kick- Starting a cold engine requires a richer starter lever, move it down lightly with air-fuel mixture, which is supplied by...
  • Page 27: Shock Absorber

    Do not deform or damage the gas cylinder in any way, as this will result in poor damping per- formance. Always have a Yamaha dealer service the shock absorber.
  • Page 28: Pre-operation Checks

    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 loss of tire air pressure could have serious consequences.
  • Page 29: Pre-operation Check List

    Adjust if necessary. Make sure that operation is smooth. Check cable free play. Throttle grip 6-11, 6-19 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. Make sure that operation is smooth. Control cables 6-19 Lubricate if necessary.
  • Page 30 PRE-OPERATION CHECKS ITEM CHECKS PAGE Make sure that operation is smooth. Brake and shift pedals 6-20 Lubricate pedal pivoting points if necessary. Make sure that operation is smooth. Brake lever 6-20 Lubricate lever pivoting point if necessary. Make sure that operation is smooth. Sidestand 6-21 Lubricate pivot if necessary.
  • Page 31: Operation And Important Riding Points

    (choke) turned off. oughly familiar with all operat- 3. Shift the transmission into the neu- ing controls and their functions tral position. before riding. Consult a Yamaha EWA14410 dealer regarding any control or WARNING function that you do not thor- Be sure to shift the transmis- oughly understand.
  • Page 32: Starting A Warm Engine

    OPERATION AND IMPORTANT RIDING POINTS EAU16660 EAU39901 ECA15441 Starting a warm engine Shifting CAUTION: Follow the same procedure as for start- Even with the transmission in ing a cold engine with the exception the neutral position, do not that the starter (choke) is not required coast for long periods of time when the engine is warm.
  • Page 33: Engine Break-in

    Since the engine is brand new, do not during the engine break-in period, the shift pedal. put an excessive load on it for the first 5 immediately have a Yamaha dealer 6. Open the throttle gradually. hours of operation. The various parts in check the vehicle.
  • Page 34: Parking

    OPERATION AND IMPORTANT RIDING POINTS EAU17190 Parking When parking, stop the engine, and then turn the fuel cock lever to “OFF”. EWA10310 WARNING 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.
  • Page 35: Periodic Maintenance And Minor Repair

    If you do not have the tools or experi- systems may be performed by any ence required for a particular job, have repair establishment or individual a Yamaha dealer perform it for you. that is certified (if applicable). EWA10350 EWA10320...
  • Page 36: Periodic Maintenance And Lubrication Chart

    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 and technical skills. INITIAL THEREAFTER EVERY...
  • Page 37 Steering bearings Moderately repack with lithium-soap-based grease. Check chain slack/alignment and condi- tion. Every ride Adjust and lubricate chain with Yamaha Drive chain chain and cable lube thoroughly. Remove and clean. Check all chassis fitting and fasteners. 12 * Chassis fasteners Correct if necessary.
  • Page 38 Autolube pump Correct if necessary. Bleed. Check for oil leakage. Transmission oil Correct if necessary. Change. Apply Yamaha chain and cable lube or 19 * Control cables engine oil 10W-30 lightly. Check operation and free play. Throttle grip housing 20 *...
  • Page 39: Removing/installing Spark Plug

    If the spark plug shows 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 1. Spark plug cap the vehicle. 2. Remove the spark plug as shown, 1.
  • Page 40: Removing The Power Reduction Plate

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU41100 Spark plug gap: Removing the power 0.6–0.7 mm (0.024–0.028 in) reduction plate 2. Clean the surface of the spark plug To obtain full engine performance ca- gasket and its mating surface, and pability, removing the power reduction then wipe off any grime from the plate is required.
  • Page 41: Transmission Oil

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU19942 straight up when checking the oil level. To change the transmission oil Transmission oil A slight tilt to the side can result in a The transmission oil level should be false reading. checked before each ride. In addition, 2.
  • Page 42: Cleaning The Air Filter Element

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU41161 Recommended transmission oil: Cleaning the air filter element See page 8-1. The air filter element should be cleaned Oil change quantity: at the intervals specified in the periodic 0.65 L (0.69 US qt) (0.57 Imp.qt) maintenance and lubrication chart.
  • Page 43: Cleaning The Spark Arrester

    1. Remove the tailpipe by removing the bolt, and then pulling it out of Recommended oil: the muffler. Yamaha foam air filter oil or other quality foam air filter oil 5. Install the sponge material onto the air filter case cover.
  • Page 44: Adjusting The Carburetor

    Therefore, most car- buretor adjustments should be left to a Yamaha dealer, who has the neces- sary professional knowledge and expe- rience. The adjustment described in the following section, however, may be ser- viced by the owner as part of routine 1.
  • Page 45: Adjusting The Engine Idling Speed

    Periodically check the obtained as described above, have a plug lead. throttle cable free play and, if neces- Yamaha dealer make the adjustment. 2. Check the engine idling speed sary, adjust it as follows. and, if necessary, adjust it to spec-...
  • Page 46: Tires

    Yamaha dealer re- The tire air pressure must be ad- place the tire immediately. justed in accordance with the...
  • Page 47: Spoke Wheels

    Yamaha dealer, who has sign, otherwise the handling the specified wheels. necessary...
  • Page 48: Accessories And Replacement Parts

    1. Brake lever free play ed to be compatible with your vehi- ver free play, turn the adjusting nut 2. Locknut cle. Yamaha recommends the use of in direction (b). 3. Adjusting bolt Genuine Yamaha Parts and Acces- sories before making a purchase.
  • Page 49: Adjusting The Brake Pedal Free Play

    PERIODIC MAINTENANCE AND MINOR REPAIR shoe plate and at the brake lever. EAU39811 Adjusting the brake pedal free play 1. Brake pedal free play adjusting nut 1. 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.
  • Page 50: Checking The Front And Rear Brake Shoes

    6-23. less than 1.5 mm (0.06 in), have a chain slack, there should be no weight To remove the rear wheel: See Yamaha dealer replace the brake on the motorcycle. page 6-26. shoes as a set. 2. Shift the transmission into the neu-...
  • Page 51 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Drive chain slack 1. Brake pedal free play adjusting nut 1. Alignment marks 2. Locknut 2. Drive chain slack adjusting nut 4. If the drive chain slack is incorrect, 3. Drive chain slack adjusting nut 3.
  • Page 52: Cleaning And Lubricating The Drive Chain

    1. Remove all dirt and mud from the drive chain with a brush or cloth. NOTE: 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...
  • Page 53: Checking And Lubricating The Cables

    The operation of all control cables and The operation of the throttle grip should which must be adjusted by a Yamaha the condition of the cables should be be checked before each ride. In addi-...
  • Page 54: Checking And Lubricating The Brake And Shift Pedals

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU44270 EAU43620 Recommended lubricant: Checking and lubricating the Checking and lubricating the Lithium-soap-based grease (all-pur- brake and shift pedals brake lever pose grease) 1. Grease nipple The operation of the brake lever should be checked before each ride, and the lever pivots should be lubricated if nec- essary.
  • Page 55: Checking And Lubricating The Sidestand

    Check the inner tubes for scratches, fork does not operate smoothly, The operation of the sidestand should damage and excessive oil leakage. have a Yamaha dealer check or re- be checked before each ride, and the pair it. sidestand pivot and metal-to-metal...
  • Page 56: Checking The Steering

    2. Hold the lower ends of the front fork legs and try to move them for- ward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering. 6-22...
  • Page 57: Supporting The Motorcycle

    EWA10820 wheel or performing other maintenance WARNING requiring the motorcycle to stand up- It is advisable to have a Yamaha right. Check that the motorcycle is in a dealer service the wheel. stable and level position before starting Securely support the motorcy- any maintenance.
  • Page 58 PERIODIC MAINTENANCE AND MINOR REPAIR justing nut at the front wheel hub. 1. Adjusting bolt 1. Washer 2. Locknut 2. Axle nut 1. Adjusting nut 2. Locknut 4. Disconnect the brake cable from 7. Lift the front wheel off the ground 3.
  • Page 59 PERIODIC MAINTENANCE AND MINOR REPAIR (See page 6-14.) 10. Push down hard on the handlebar several times to check for proper fork operation. 1. Brake shoe plate 1. Retainer 2. Lift the wheel up between the fork 3. Insert the wheel axle, and then in- legs.
  • Page 60: Rear Wheel

    6. Remove the axle nut and washer, EWA10820 and then pull the wheel axle out. WARNING 7. Push the wheel forward, and then It is advisable to have a Yamaha remove the drive chain from the dealer service the wheel. rear sprocket. Securely support the motorcy- cle so that there is no danger of it falling over.
  • Page 61: Troubleshooting

    4. Connect the brake torque rod onto self. However, should your motorcycle the brake shoe plate by installing require any repair, take it to a Yamaha the bolt and nut, and then tighten dealer, whose skilled technicians have the nut to the specified torque.
  • Page 62: Troubleshooting Chart

    Open the throttle halfway and operate the kickstarter. spark plug gap, or replace the spark plug. Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Have a Yamaha dealer check the vehicle. 6-28...
  • Page 63: Motorcycle Care And Storage

    Be ble. Rust and corrosion can develop Cleaning sure to consult a Yamaha dealer for even if high-quality components are ECA10771 CAUTION: advice on what products to use be- used.
  • Page 64 MOTORCYCLE CARE AND STORAGE contact with strong or abrasive washing. After cleaning cleaning products, solvent or 1. Dry the motorcycle with a chamois thinner, fuel (gasoline), rust re- or an absorbing cloth. After normal use movers or inhibitors, brake flu- 2.
  • Page 65: Storage

    NOTE: Long-term grounded. (This will limit spark- Consult a Yamaha dealer for advice on Before storing your motorcycle for sev- ing during the next step.) what products to use. eral months: d.
  • Page 66 MOTORCYCLE CARE AND STORAGE install the spark plug and the spark plug cap. EWA10950 WARNING 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 levers and pedals as well as of the sidestand.
  • Page 67: Specifications

    SPECIFICATIONS EAU2633K Lubrication system: Spark plug (s): Separate lubrication (Yamaha autolube) Manufacturer/model: Engine oil: Dimensions: NGK/BP6HS (AUS)(NZL) Type: NGK/BPR6HS Overall length: YAMALUBE 2 or 2-stroke engine oil (JASO (AUT)(BEL)(CHE)(DEU)(DNK)(ESP)(FIN) 1540 mm (60.6 in) FC grade) or (ISO EG-C or EG-D grade)
  • Page 68 SPECIFICATIONS 3rd: Tire air pressure (measured on cold Rear suspension: 22/17 (1.294) tires): Type: Chassis: Swingarm (monocross) Front: Frame type: Spring/shock absorber type: 100 kPa (15 psi) (1.00 kgf/cm Steel tube backbone Coil spring/gas-oil damper Rear: Caster angle: Wheel travel: 100 kPa (15 psi) (1.00 kgf/cm 26.00 °...
  • Page 69: Consumer Information

    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: 1. Vehicle identification number 1.
  • Page 70 INDEX Throttle grip and cable, checking and lubricating..........6-19 Accessories and replacement parts..6-14 Identification numbers........9-1 Tires ............6-12 Air filter element, cleaning......6-8 Tool kit............6-1 Autolube pump, adjusting ....... 6-19 Kickstarter..........3-6 Transmission oil ........6-7 Troubleshooting........6-27 Brake and shift pedals, checking and Labels, location of........1-4 Troubleshooting chart......
  • Page 72 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2007.4–0.7×1 !

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