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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.
OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
BEDIENUNGSANLEITUNG
PW80(Z)
3RV-28199-8K

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Table of Contents

   Summary of Contents for YAMAHA PW80(Z)

  • Page 1 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. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE BEDIENUNGSANLEITUNG PW80(Z) 3RV-28199-8K...
  • 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 2009.04–0.2×1 ! 2009.04–0.2×1 !
  • Page 3 Read this manual carefully before operating this vehicle. OWNER’S MANUAL PW80(Z) 3RV-28199-8K-E0...
  • Page 4 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, 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product PW80...
  • 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 Your motorcycle was delivered with a removable power reduction plate. Yamaha recommends that all beginners start off with the power reduction plate installed to limit the engine power available while they learn. Parents should decide when to re- move the power reduction plate from the motorcycle for more power as their youngster’s riding skills improve.
  • 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 injury or death.
  • Page 8 IMPORTANT MANUAL INFORMATION EAU10200 PW80(Z) OWNER’S MANUAL ©2009 by Yamaha Motor Co., Ltd. 1st edition, March 2009 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 LOCATION OF IMPORTANT OPERATION AND IMPORTANT Checking the front and rear LABELS ..........1-1 RIDING POINTS......... 6-1 brake shoes ....... 7-15 Starting and warming up a cold Drive chain slack ......7-16 SAFETY INFORMATION ....2-1 engine ......... 6-1 Cleaning and lubricating the Starting a warm engine ....
  • Page 10 TABLE OF CONTENTS SPECIFICATIONS ......9-1 CONSUMER INFORMATION... 10-1 Identification numbers ....10-1...
  • Page 11: Location Of Important Labels

    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 available from your Yamaha dealer. For Europe...
  • Page 12: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS For Europe 5PG-2817L-10 1.00 1.00 5PG-2816R-00...
  • Page 13: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS Familiarize yourself with the following pictograms and read the explanatory text. Read the Owner’s manual. Use unleaded gasoline only. This unit contains high-pressure Measure tire pressure when nitrogen gas. tires are cold. Mishandling can cause explosion. Do not incinerate, puncture or open.
  • Page 14 LOCATION OF IMPORTANT LABELS For Oceania and South Africa...
  • Page 15 LOCATION OF IMPORTANT LABELS For Oceania and South Africa 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.
  • Page 16: Safety Information

    SAFETY INFORMATION EAU41214 Safe Riding Therefore: Perform the pre-operation checks each Wear a brightly colored jacket. time you use the vehicle to make sure it Use extra caution when you are Be a Responsible Owner is in safe operating condition. Failure to approaching passing As the vehicle’s owner, you are respon-...
  • Page 17 SAFETY INFORMATION erator is veering wide on a turn Wear a face shield or goggles. any engine exhaust. Deadly levels of due to excessive speed or under- Wind in your unprotected eyes carbon monoxide can collect rapidly cornering (insufficient lean angle could contribute to an impairment and you can quickly be overcome and for the speed).
  • Page 18 Yamaha accessories, which are avail- formed to your vehicle that change any could cause an accident. able only from a Yamaha dealer, have of the vehicle’s design or operation The weight of the operator must been designed, tested, and approved characteristics can put you and others not exceed 40.0 kg (88 lb).
  • Page 19 SAFETY INFORMATION bar or the front fork area can Aftermarket Tires and Rims create instability due to improper The tires and rims that came with your weight distribution. If accesso- motorcycle were designed to match the ries are added to the handlebar performance capabilities and to provide or front fork area, they must be the best combination of handling, brak-...
  • Page 20: Description

    DESCRIPTION EAU10410 Left view 1. Air filter element (page 7-8) 2. Fuel cock (page 4-5) 3. Throttle stop screw (page 7-10) 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)
  • Page 21: Right View

    DESCRIPTION EAU10420 Right view 1. Spark arrester (page 7-9) 2. Seat (page 4-7) 3. Transmission oil filler cap (page 7-7) 4. Spark plug cap (page 7-5) 5. Brake pedal (page 4-2) 6. Kickstarter (page 4-6)
  • Page 22: Controls And Instruments

    DESCRIPTION EAU10430 Controls and instruments 1. Handlebar switch (page 4-1) 2. Brake lever (page 4-2) 3. Throttle grip (page 7-11) 4. Fuel tank cap (page 4-2)
  • Page 23: 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 24: Brake Lever

    INSTRUMENT AND CONTROL FUNCTIONS EAU12890 EAU12941 EAU13182 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 25: Fuel

    Handle gaso- tube. Because fuel expands when line with care. Never siphon gaso- Your Yamaha engine has been de- it heats up, heat from the engine or line by mouth. If you should swallow signed to use regular unleaded gaso-...
  • Page 26: Fuel Tank Breather Hose

    INSTRUMENT AND CONTROL FUNCTIONS curs, use a gasoline of a different brand EAU13412 EAU41202 Fuel tank breather hose 2-stroke engine oil or premium unleaded fuel. Use of un- Make sure that there is sufficient oil in leaded fuel will extend spark plug life the 2-stroke engine oil tank.
  • Page 27: Fuel Cock

    INSTRUMENT AND CONTROL FUNCTIONS tank cap and add the recommend- EAU13561 Fuel cock ed oil. The fuel cock supplies fuel from the tank to the carburetor while filtering it al- The fuel cock has three positions: FUEL 1. Arrow mark positioned over “ON” 1.
  • Page 28: Starter (choke) Lever

    INSTRUMENT AND CONTROL FUNCTIONS This indicates reserve. If you run out of EAU13590 EAU13680 Starter (choke) lever “ ” Kickstarter 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”...
  • Page 29: Seat

    Do not dispose of a damaged or worn-out shock absorber as- sembly yourself. Take the shock absorber assembly to a Yamaha dealer for any service.
  • Page 30: Sidestand

    INSTRUMENT AND CONTROL FUNCTIONS EAU37490 Sidestand 1. 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. EWA14190 WARNING The vehicle must not be ridden with the sidestand down, or if the side- stand cannot be properly moved up (or does not stay up), otherwise the...
  • Page 31: For Your Safety - Pre-operation Checks

    Adjust if necessary. Make sure that operation is smooth. Check cable free play. Throttle grip 7-11, 7-18 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. Make sure that operation is smooth. Control cables 7-18...
  • Page 32 FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM CHECKS PAGE Check chain slack. Adjust if necessary. Drive chain 7-16, 7-17 Check chain condition. Lubricate if necessary. Check for damage. Check tire condition and tread depth. Wheels and tires 7-12, 7-13 Check air pressure. Correct if necessary.
  • Page 33: Operation And Important Riding Points

    1. Turn the fuel cock lever to “ON”. (choke) turned off. there is a control or function you do not 2. Set the engine stop switch to understand, ask your Yamaha dealer. “RUN”. EWA10271 3. Shift the transmission into the neu- WARNING tral position.
  • Page 34: Starting A Warm Engine

    OPERATION AND IMPORTANT RIDING POINTS EAU16660 EAU39901 ECA15441 Starting a warm engine Shifting NOTICE 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 35: Engine Break-in

    Since the engine is brand new, do not during the engine break-in period, shifting to the next higher gear. put an excessive load on it for the first 5 immediately have a Yamaha dealer hours of operation. The various parts in check the vehicle. EAU16710...
  • Page 36: Parking

    OPERATION AND IMPORTANT RIDING POINTS EAU17191 Parking When parking, stop the engine, and then turn the fuel cock lever to “OFF”. EWA10311 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 and be burned.
  • Page 37: Pperiodic Maintenance And Adjustment

    Failure to properly maintain the ve- ence required for a particular job, have hicle or performing maintenance ac- a Yamaha dealer perform it for you. tivities incorrectly may increase your risk of injury or death during service or while using the vehicle. If...
  • Page 38: Periodic Maintenance And Lubrication Chart

    EAU41765 Periodic maintenance and lubrication chart 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 39 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 Replace if necessary.
  • Page 40 Correct if necessary. Check for oil leakage. Transmission oil Correct if necessary. Change (warm engine before draining). Apply Yamaha chain and cable lube or 19 * Control cables engine oil 10W-30 lightly. Check operation and free play. Throttle grip housing...
  • Page 41: Checking The Spark Plug

    Do not attempt to 1. Spark plug gap diagnose such problems yourself. In- Spark plug gap: stead, have a Yamaha dealer check 1. Spark plug cap 0.6–0.7 mm (0.024–0.028 in) the vehicle. 2. Remove the spark plug as shown, 2.
  • Page 42: Removing The Power Reduction Plate

    PERIODIC MAINTENANCE AND ADJUSTMENT spark plug threads. EAU41102 Removing the power 3. Install the spark plug with the reduction plate spark plug wrench, and then tight- en it to the specified torque. To obtain full engine performance ca- pability, removing the power reduction Tightening torque: plate is required.
  • Page 43: Transmission Oil

    PERIODIC MAINTENANCE AND ADJUSTMENT EAU19943 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 44: Cleaning The Air Filter Element

    PERIODIC MAINTENANCE AND ADJUSTMENT EAU41162 Recommended transmission oil: Cleaning the air filter element See page 9-1. 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 45: Cleaning The Spark Arrester

    The sponge material should be wet but not dripping. Recommended oil: Yamaha foam air filter oil or other quality foam air filter oil 5. Install the sponge material onto the air filter case cover. 6. Insert the air filter element into the air filter case.
  • Page 46: Adjusting The Carburetor

    Therefore, most car- checked and, if necessary, adjusted as buretor adjustments should be left to a follows at the intervals specified in the Yamaha dealer, who has the neces- periodic maintenance and lubrication sary professional knowledge and expe- chart.
  • Page 47: Adjusting The Throttle Cable Free Play

    Periodically check the obtained as described above, have a throttle cable free play and, if neces- Yamaha dealer make the adjustment. sary, adjust it as follows. The engine idling speed must be cor- rectly adjusted before checking and ad- justing the throttle cable free play.
  • Page 48: Tire Air Pressure/inspection

    After extensive tests, only the tires list- EWA14381 ed below have been approved for this WARNING model by Yamaha Motor Co., Ltd. Operation of this vehicle with im- proper tire pressure may cause se- Front tire: vere injury or death from loss of Size: control.
  • Page 49: Spoke Wheels

    The wheel rims should be checked left to a Yamaha dealer, who has for cracks, bends or warpage, and necessary professional the spokes for looseness or dam- knowledge and experience.
  • Page 50: Adjusting The Brake Pedal Free Play

    PERIODIC MAINTENANCE AND ADJUSTMENT 3. If the specified brake lever free shoe plate and at the brake lever. EAU39812 Adjusting the brake pedal free play could be obtained as de- play scribed above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows.
  • Page 51: Checking The Front And Rear Brake Shoes

    EWA10680 page 7-22. less than 1.5 mm (0.06 in), have a WARNING To remove the rear wheel: See Yamaha dealer replace the brake After adjusting the drive chain page 7-24. shoes as a set. slack or removing and installing the rear wheel, always check the...
  • Page 52: Drive Chain Slack

    PERIODIC MAINTENANCE AND ADJUSTMENT EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. EAU22773 To check the drive chain slack 1. Place the motorcycle on the side- stand. 1. Drive chain slack 1.
  • Page 53: Cleaning And Lubricating The Drive Chain

    1. Alignment marks 2. Drive chain slack adjusting nut For a thorough cleaning, have a 3. Locknut Yamaha dealer remove the drive chain 4. Washer and soak it in solvent. 5. Axle nut 3. Tighten both locknuts and the axle 2.
  • Page 54: 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 55: Checking And Lubricating The Brake Lever

    Lithium-soap-based grease Lithium-soap-based grease WARNING If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Otherwise, the sidestand could contact the ground and distract the operator, re- sulting in a possible loss of control.
  • Page 56: Checking The Front Fork

    Yamaha dealer check or re- tion. WARNING! To avoid injury, of it falling over. [EWA10751] pair it.
  • Page 57: Checking The Wheel Bearings

    Yamaha dealer check right. Check that the motorcycle is in a the wheel bearings. stable and level position before starting any maintenance.
  • Page 58: Front Wheel

    PERIODIC MAINTENANCE AND ADJUSTMENT frame in front of the rear wheel or under EAU24360 Front wheel each side of the swingarm. EAU41532 To remove the front wheel EWA10821 WARNING To avoid injury, securely support the vehicle so there is no danger of it falling over.
  • Page 59 PERIODIC MAINTENANCE AND ADJUSTMENT 1. Adjusting bolt 1. Washer 1. Brake shoe plate 2. Locknut 2. Axle nut 2. Lift the wheel up between the fork 4. Disconnect the brake cable from 8. Lift the front wheel off the ground legs.
  • Page 60: Rear Wheel

    PERIODIC MAINTENANCE AND ADJUSTMENT (See page 7-13.) EAU25080 Rear wheel 10. Push down hard on the handlebar several times to check for proper EAU41562 fork operation. To remove the rear wheel EWA10821 WARNING To avoid injury, securely support the vehicle so there is no danger of it falling over.
  • Page 61 PERIODIC MAINTENANCE AND ADJUSTMENT the brake rod from the brake cam- 5. Lift the rear wheel off the ground EAU41571 To install the rear wheel shaft lever. according to the procedure on 1. Install the drive chain onto the rear 3.
  • Page 62: Troubleshooting

    However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly.
  • Page 63: Troubleshooting Chart

    Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug. the kickstarter. 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. 7-27...
  • Page 64: 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 ECA10772 advice on what products to use be- NOTICE used.
  • Page 65 MOTORCYCLE CARE AND STORAGE off any detergent residue using scratches on the windshield. action of the salt. [ECA10791] plenty of water, as it is harmful Test the product on a small hid- 2. Apply a corrosion protection spray to plastic parts. den part of the windshield to on all metal, including chrome- and Do not use any harsh chemical...
  • Page 66: Storage

    MOTORCYCLE CARE AND STORAGE 7. Wax all painted surfaces. EAU40652 Storage 8. Let the motorcycle dry completely Consult a Yamaha dealer for ad- before storing or covering it. vice on what products to use. Short-term EWA14501 Washing, rainy weather or humid...
  • Page 67 MOTORCYCLE CARE AND STORAGE “OFF”. install the spark plug and the 3. Drain the carburetor float chamber spark plug cap. WARNING! To by loosening the drain bolt; this will prevent damage or injury prevent fuel deposits from building from sparking, make sure to up.
  • Page 68: Specifications

    1540 mm (60.6 in) PW80 NGK/BPR6HS Kickstarter Overall width: PW80Z NGK/BP6HS Lubrication system: 640 mm (25.2 in) DENSO/W20FP Separate lubrication (Yamaha autolube) Overall height: Spark plug gap: Engine oil: 880 mm (34.6 in) 0.6–0.7 mm (0.024–0.028 in) Seat height: Type: Clutch: 635 mm (25.0 in)
  • Page 69 SPECIFICATIONS 26.00 ° Rear wheel: Trail: Wheel type: 62.0 mm (2.44 in) Spoke wheel Front tire: Rim size: Type: 12x1.60 With tube Front brake: Size: Type: 2.50-14 4PR Drum brake Manufacturer/model: Operation: CHENG SHIN/KNOBBY Right hand operation Rear tire: Rear brake: Type: Type: With tube...
  • Page 70: Consumer Information

    Model label 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 NUM- BER: 1.
  • Page 71 INDEX Throttle grip and cable, checking and lubricating ..........7-18 Air filter element, cleaning ......7-8 Identification numbers ......10-1 Tires ............7-12 Autolube pump, adjusting ......7-19 Tool kit ............7-1 Kickstarter ..........4-6 Transmission oil ........7-7 Brake lever ..........4-2 Troubleshooting ........
  • Page 72 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2009.04–0.2×1 !

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