Yamaha PW80(W), Owner'S Manual

Page 1: ...3RV 28199 8G PW80 W OWNER S MANUAL MANUEL DU PROPRIÉTAIRE BEDIENUNGSANLEITUNG ...

Page 2: ...R CO LTD PRINTED IN JAPAN 2006 4 0 6 1 E F G AUF RECYCLINGPAPIER GEDRUCKT IMPRESO EN PAPEL RECICLADO PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 4 0 6 1 E F G AUF RECYCLINGPAPIER GEDRUCKT IMPRESO EN PAPEL RECICLADO ...

Page 3: ...3RV 28199 8G E0 PW80 W OWNER S MANUAL ...

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Page 5: ...TORCYCLE MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MOTORCYCLE NEVER OPERATE A MOTORCYCLE WITHOUT PROPER TRAINING OR INSTRUCTION WEIGHT OF THE RIDER SHOULD NOT EXCEED 40 kg 88 lb 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 ...

Page 6: ...ING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE HE OR SHE SHOULD OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER S MANUAL OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND OR WHEN MADE NECESSARY BY MECHAN...

Page 7: ... available at the time of printing there may be minor discrepancies between your motorcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator a bystander or a person ins...

Page 8: ...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 PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERAT ING THIS MOTORCYCLE Product and specifications are subject to change without notice ...

Page 9: ...EAU10200 PW80 W OWNER S MANUAL 2006 by Yamaha Motor Co Ltd 1st edition March 2006 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: ...ower reduction plate 6 6 Transmission oil 6 7 Cleaning the air filter element 6 8 Cleaning the spark arrester 6 9 Adjusting the carburetor 6 10 Adjusting the engine idling speed 6 11 Adjusting the throttle cable free play 6 11 Tires 6 12 Spoke wheels 6 13 Accessories and replacement parts 6 14 Adjusting the brake lever free play 6 14 Adjusting the brake pedal free play 6 15 Checking the front and ...

Page 11: ...TABLE OF CONTENTS SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 ...

Page 12: ...hould keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcy cle Never ride under the influence of alcohol or other drugs Be sure the transmission is in neu tral before starting the engine Protective apparel The majority of fatalities from motorcy cle accidents are the result of head in juries The use of a safety helmet is the s...

Page 13: ...or the proper selection in stallation and use of non Yamaha accessories Use extreme caution when selecting and installing any ac cessories Keep these guidelines in mind for mounting accessories in addition to those provided under Loading Never install accessories or that would impair the performance of your motorcycle Carefully inspect the accessory before using it to make sure that it does not in...

Page 14: ...arking the motorcycle note the following The engine and exhaust pipe muffler may be hot therefore park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a ker osene heater or near an open flame otherwise it could catch ...

Page 15: ...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 1 5 1 4 5 ...

Page 17: ...i istruzioni Lire le manuel du propriétaire avant d utiliser ce véhicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario follows FRONT REAR 3RV 21668 A0 Cold tire normal pressure should be set as 100 kPa 1 00 kgf cm2 15 psi 100 kPa 1 00 kgf cm2 15 psi 4 5 1 2 3 ...

Page 18: ...ION 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: ...TION 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 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: ...duction plate installed to limit the amount of power available while they learn Parents should decide when to adjust the motorcycle for more power as their youngster s riding skills improve Once the rider can operate with skill at the top speed with the power reduction plate installed the power reduction plate can be removed See page 6 6 EAU39850 Shift pedal This motorcycle is equipped with a con ...

Page 22: ... brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal EAU13180 Fuel tank cap To remove the fuel tank cap turn it counterclockwise and then pull it off To install the fuel tank cap insert it into the tank opening and then turn it clock wise WARNING EWA11090 Make sure that the fuel tank cap is properly closed before riding 1 Brake lever 1 1 Brake p...

Page 23: ... or plastic parts EAU41960 CAUTION ECA15590 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand or premiu...

Page 24: ...imum level as shown in the illustra tion add a sufficient amount of the rec ommended 2 stroke engine oil as follows NOTE Make sure that the motorcycle is posi tioned straight up when checking the 2 stroke engine oil level A slight tilt to the side can result in a false reading 1 Remove the seat See page 3 6 2 Remove the 2 stroke engine oil tank cap and add the recommend ed oil 3 Install the 2 stro...

Page 25: ...n the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES 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 1 Arrow mark positioned over OFF RES ON FUEL OFF 1 1 Arrow mark pos...

Page 26: ...er in direction b to turn off the starter choke EAU13680 Kickstarter To start the engine fold out the kick starter lever move it down lightly with your foot until the gears engage and then push it down smoothly but force fully 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 show...

Page 27: ...information before handling the shock absorber The manufacturer cannot be held re sponsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder ...

Page 28: ... pressure could have serious consequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the...

Page 29: ...eration Lubricate cable if necessary Check lever free play Adjust if necessary 6 14 6 16 Rear brake Check operation Check pedal free play Adjust if necessary 6 15 6 16 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 6 11 6 19 Control cables Make sure that operation is smooth Lubricate...

Page 30: ...sary 6 20 Brake lever Make sure that operation is smooth Lubricate lever pivoting point if necessary 6 20 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 21 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Engine stop switch Check operation 3 1 ITEM CHECKS PAGE ...

Page 31: ...d contact the ground and distract the opera tor resulting in a possible loss of control EAU41150 Starting and warming up a cold engine 1 Turn the fuel cock lever to ON 2 Set the engine stop switch to RUN 3 Shift the transmission into the neu tral position WARNING EWA14410 Be sure to shift the transmis sion into neutral before starting the engine Never ride with the sidestand down 4 Turn the starte...

Page 32: ...tion NOTE To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel CAUTION ECA15441 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate ...

Page 33: ...arefully Since the engine is brand new do not put an excessive load on it for the first 5 hours of operation The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided However momentary full throttle operation under load i e two to three...

Page 34: ...king 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 them Do not park on a slope or on soft ground otherwise the vehicle may overturn ...

Page 35: ...RNING EWA10320 If you are not familiar with mainte nance work have a Yamaha dealer do it for you EAU17320 Owner s tool kit The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain mainte...

Page 36: ...rs 40 hours 80 hours 40 hours 80 hours 160 hours 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check condition Adjust gap and clean Replace if necessary 3 Air filter element Clean with solvent Replace if necessary 4 Clutch Check operation Adjust if necessary 5 Front brake Check operation Adjust brake lever free play Replace brake shoes Whenever worn to the lim...

Page 37: ...e chain with Yamaha chain and cable lube thoroughly Every ride Remove and clean 12 Chassis fasteners Check all chassis fitting and fasteners Correct if necessary 13 Sidestand pivot Check operation Apply lithium soap based grease all pur pose grease lightly 14 Front fork Check operation and for oil leakage Replace if necessary 15 Shock absorber assembly Check operation and for oil leakage Replace i...

Page 38: ... 30 lightly 20 Throttle grip housing and cable Check operation and free play Apply Yamaha chain and cable lube or engine oil 10W 30 lightly 21 Brake lever pivot shaft Apply lithium soap based grease all pur pose grease lightly 22 Brake pedal pivot shaft Apply lithium soap based grease all pur pose grease lightly 23 Cylinder head and exhaust system Check for leakage Tighten if necessary Decarbonize...

Page 39: ... Check that the porcelain insulator around the center electrode of the spark plug is a medium to light tan the ideal color when the vehicle is ridden normally NOTE 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 the vehicle 2 Check the spark plug for electrode erosi...

Page 40: ...the power reduction plate To obtain full engine performance ca pability removing the power reduction plate is required WARNING EWA14580 Always let the exhaust system cool prior to touching exhaust compo nents 1 Remove the exhaust manifold by removing the bolts 2 Remove the gasket 3 Remove the power reduction plate NOTE Store the power reduction plate with the owner s manual so that it is readily a...

Page 41: ...e it again to check the oil level NOTE The transmission oil should be be tween the minimum and maximum lev el marks 3 If the oil is below the minimum lev el mark add sufficient oil of the recommended type to raise it to the correct level 4 Insert the dipstick into the oil filler hole and then tighten the oil filler cap To change the transmission oil 1 Place an oil pan under the trans mission to co...

Page 42: ...kage If oil is leaking immediately turn the engine off and check for the cause EAU41161 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove the air filter case cover by removing the screws 2 Pull t...

Page 43: ...e ment installed otherwise the piston s and or cylinder s may become excessively worn 7 Install the air filter case cover by in stalling the screws EAU41230 Cleaning the spark arrester The spark arrester should be cleaned at the intervals specified in the periodic maintenance and lubrication chart WARNING EWA10980 Always let the exhaust system cool prior to touching exhaust components Do not start...

Page 44: ...e carburetor is an important part of the engine and requires very sophisti cated adjustment 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 maintenance CAUTION ECA10550 The carburetor has been set and ex te...

Page 45: ...ease the engine idling speed turn the screw in di rection a To decrease the en gine idling speed turn the screw in direction b NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EAU21370 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 Periodically check th...

Page 46: ...ires equals the ambient temperature The tire air pressure must be ad justed in accordance with the weight of the rider the riding speed and the riding condi tions Tire inspection The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer re place the tire immedia...

Page 47: ...y and replace it as soon as possible with a high quality product EAU21940 Spoke wheels To maximize the performance durabil ity and safe operation of your motorcy cle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wh...

Page 48: ... not been approved by Yamaha 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 brake le ver 2 To increase the brake lever free play turn the adjusting bolt in di rection a To decrease the brake lever free play turn t...

Page 49: ... 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 increase the brake pedal free play turn the adjusting nut at the brake rod in direction a To decrease the brake pedal free play turn the adjusting nut in direction b 1 Brake pedal free play 1 1 Brake pedal free play adjusting nut 1 a b ...

Page 50: ...mm 0 06 in have a Yamaha dealer replace the brake shoes as a set NOTE Be sure to measure the brake lining at the thinnest portion EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22771 To check the drive chain slack 1 Place the motorcycle on the side stand NOTE When checking and adjusting the drive chain slack there should be no weigh...

Page 51: ...rd NOTE Using the alignment marks on each side of the swingarm make sure that both adjusting nuts are in the same po sition for proper wheel alignment CAUTION ECA10570 Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 3 T...

Page 52: ... chain as follows CAUTION ECA10581 The drive chain must be lubricated after washing the motorcycle and riding in the rain 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 drive chain lubricant on both sides and on the m...

Page 53: ...use interference with cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU23120 Adjusting the Autolube pump The Autolube pum...

Page 54: ...d before each ride and the pedal pivots should be lu bricated if necessary EAU23152 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 Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease ...

Page 55: ...e intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down h...

Page 56: ...he ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 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 EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic m...

Page 57: ...rcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the s...

Page 58: ...Disconnect the brake cable from the brake camshaft lever 6 Remove the axle nut and washer 7 Lift the front wheel off the ground according to the procedure on page 6 23 8 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 1 Adjusting nut 2 Locknut 3 Washer 4 Axle nut 5 Brake camshaft lever 4 5 3 1 2 1 Adju...

Page 59: ...r the front wheel so that it is on the ground 5 Connect the brake cable at the wheel hub 6 Connect the brake cable at the front brake lever 7 Install the brake cable holder by in stalling the bolt 8 Tighten the axle nut to the speci fied torque 9 Adjust the brake lever free play See page 6 14 10 Push down hard on the handlebar several times to check for proper fork operation 1 Brake shoe plate 1 1...

Page 60: ...rive chain adjusting nut on each end of the swingarm 5 Lift the rear wheel off the ground according to the procedure on page 6 23 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 NOTE The drive chain does not need to be disassembled in order to remove and install the wheel 8 Remove the spacer chain pul...

Page 61: ... Tighten the axle nut to the speci fied torque 9 Adjust the brake pedal free play See page 6 15 EAU25850 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 loss of power The following troubleshooting chart repres...

Page 62: ...ckstarter 2 Compression There is compression There is no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wet Dry Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle Open the throttle ha...

Page 63: ...ducts are used on hard to remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use...

Page 64: ...prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stain less steel parts including the ex haust system Even the thermally induced discoloring of stain less steel exhaust systems can be removed through polishing 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 5 Use spray oil as a univ...

Page 65: ...5 Perform the following steps to pro tect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over seve...

Page 66: ... SAE10W30 type SE motor oil Oil change quantity 0 65 L 0 69 US qt 0 57 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Regular unleaded gasoline only AUT BEL CHE DEU DNK ESP FIN FRA GBR GRC IRL NLD NOR PRT SWE ZAF Unleaded gasoline only AUS NZL Fuel tank capacity 4 9 L 1 29 US gal 1 08 Imp gal Fuel reserve amount 1 0 L 0 26 US gal 0 22 Imp gal Carburetor Manufacturer MIKUNI ...

Page 67: ...red on cold tires Front 100 kPa 15 psi 1 00 kgf cm2 Rear 100 kPa 15 psi 1 00 kgf cm2 Front wheel Wheel type Spoke wheel Rim size 14x1 40 Rear wheel Wheel type Spoke wheel Rim size 12x1 60 Front brake Type Drum brake Operation Right hand operation Rear brake Type Drum brake Operation Right foot operation Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel t...

Page 68: ...tion number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area EAU26480 Model label The model label is affixed to the frame under the seat See page 3 6 Record the information...

Page 69: ...r switch 3 1 I Identification numbers 9 1 K Kickstarter 3 6 L Labels location of 1 4 M Model label 9 1 P Parking 5 4 Part locations 2 1 Periodic maintenance and lubrication chart 6 2 Power reduction plate 3 1 Power reduction plate removing 6 6 Pre operation check list 4 2 S Safety information 1 1 Seat 3 6 Shifting 5 2 Shift pedal 3 1 Shock absorber 3 7 Sidestand checking and lubricating 6 21 Spark...

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Page 72: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 4 0 6 1 E ...