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Yamaha PW80(A) Owner's Manual
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Yamaha PW80(A) Owner's Manual

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

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Summary of Contents for Yamaha PW80(A)

  • 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(A) 3RV-28199-8L...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2010.04-0.4×1 CR AUF RECYCLINGPAPIER GEDRUCKT (E,F,G)
  • Page 3 Read this manual carefully before operating this vehicle. OWNER’S MANUAL PW80(A) 3RV-28199-8L-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 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product PW80 (JYA4BC00000110437–...
  • Page 5 INTRODUCTION EAU41583 Congratulations on your purchase of the Yamaha PW80(A). 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 leader in these fields.
  • Page 6 Your motorcycle is equipped 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(A) OWNER’S MANUAL ©2010 by Yamaha Motor Co., Ltd. 1st edition, March 2010 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 FOR YOUR SAFETY – Spoke wheels ....... 7-14 LABELS ..........1-1 PRE-OPERATION CHECKS ..... 5-1 Adjusting the brake lever free play ........... 7-14 SAFETY INFORMATION ....2-1 OPERATION AND IMPORTANT Adjusting the brake pedal free RIDING POINTS ........ 6-1 play ...........
  • Page 10 TABLE OF CONTENTS MOTORCYCLE CARE AND STORAGE ..........8-1 Matte color caution ......8-1 Care ..........8-1 Storage ...........8-3 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 PW80 3.7 kW 61 kg 4BC-2156A-10 2010 4AA-22259-40 YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN 8AC-2817L-00 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 the tire pressure when nitrogen gas. the tires are cold. Mishandling can cause an explosion.
  • Page 14 LOCATION OF IMPORTANT LABELS Model Name ****** Max. Power *** kW *** kg Mass In Running Order 1 Year of construction **** YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN...
  • Page 15 LOCATION OF IMPORTANT LABELS For Oceania and South Africa...
  • Page 16 LOCATION OF IMPORTANT LABELS For Oceania and South Africa WARNING • BEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER’S MANUAL AND ALL LABELS. • NEVER CARRY A PASSENGER. You increase your risk of losing control if you carry a passenger. •...

  • Page 17: Safety Information

    SAFETY INFORMATION EAU41218 Safe Riding yourself conspicuous appears to Perform the pre-operation checks each be very effective in reducing the time you use the vehicle to make sure it chance of this type of accident. Be a Responsible Owner is in safe operating condition. Failure to Therefore: As the vehicle’s owner, you are respon- inspect or maintain the vehicle properly...
  • Page 18 SAFETY INFORMATION Many accidents have been caused Protective Apparel Avoid Carbon Monoxide Poisoning by error of the motorcycle opera- The majority of fatalities from motorcy- All engine exhaust contains carbon tor. A typical error made by the op- cle accidents are the result of head in- monoxide, a deadly gas.
  • Page 19 Adding accessories to your motorcycle motorcycle before riding. mended by Yamaha, even if sold and can adversely affect stability and han- Check accessory mounts fre- installed by a Yamaha dealer. dling if the weight distribution of the mo- quently.

  • Page 20: Specifications

    SAFETY INFORMATION Never install accessories that tor and may limit control ability, Check that the fuel cock (if would impair the performance of therefore, such accessories are equipped) is in the “OFF” position your motorcycle. Carefully inspect not recommended. and that there are no fuel leaks. the accessory before using it to Use caution when adding electri- Point the front wheel straight...

  • Page 21: Description

    DESCRIPTION EAU10410 Left view 1. Air filter element (page 7-9) 2. Fuel cock (page 4-5) 3. Throttle stop screw (page 7-11) 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 22: Right View

    DESCRIPTION EAU10420 Right view 1. Spark arrester (page 7-10) 2. Seat (page 4-7) 3. Transmission oil filler cap (page 7-8) 4. Spark plug cap (page 7-6) 5. Brake pedal (page 4-2) 6. Transmission oil drain bolt (page 7-8) 7. Kickstarter (page 4-6)

  • Page 23: Controls And Instruments

    DESCRIPTION EAU10430 Controls and instruments 1. Engine stop switch (page 4-1) 2. Brake lever (page 4-2) 3. Throttle grip (page 7-12) 4. Fuel tank cap (page 4-2)

  • Page 24: Instrument And Control Functions

    Handlebar switch Power reduction plate Shift pedal Your motorcycle is equipped 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 25: 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 26: Fuel

    Never siphon gaso- can cause fuel to spill out of the Your Yamaha engine has been de- line by mouth. If you should swallow fuel tank. signed to use regular unleaded gaso-...

  • Page 27: 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 28: Fuel Cock

    INSTRUMENT AND CONTROL FUNCTIONS EAU13561 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it al- The fuel cock has three positions: FUEL 1. 2-stroke engine oil tank 2. 2-stroke engine oil tank cap 1.

  • Page 29: 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 30: 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 31: 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 32: For Your Safety - Pre-Operation Checks

    Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 33 • Make sure that operation is smooth. • Check cable free play. Throttle grip 7-12, 7-19 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 7-19 •...

  • Page 34: 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 35: 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 36: Engine Break-In

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

  • Page 37: 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 38: Periodic Maintenance And Adjustment

    EWA15460 hicle or performing maintenance ac- WARNING a Yamaha dealer perform it for you. tivities incorrectly may increase Brake discs, calipers, drums, and your risk of injury or death during linings can become very hot during service or while using the vehicle.

  • Page 39: Periodic Maintenance Chart For The Emission Control System

    Periodic maintenance chart for the emission control system 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.

  • Page 40: General Maintenance And Lubrication Chart

    EAU41767 General 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 41 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. Chassis fasteners Replace if necessary.
  • Page 42 Correct if necessary. Check for oil leakage. Transmission oil Correct if necessary. Change (warm engine before draining). Apply Yamaha chain and cable lube or 15 * Control cables engine oil 10W-30 lightly. Check operation and free play. Throttle grip housing...

  • Page 43: 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, with the spark plug wrench includ- ed in the owner’s tool kit.

  • Page 44: Removing The Power Reduction Plate

    PERIODIC MAINTENANCE AND ADJUSTMENT To install the spark plug EAU41103 Removing the power reduc- 1. Clean the surface of the spark plug tion plate gasket and its mating surface, and To obtain full engine performance ca- then wipe off any grime from the pability, removing the power reduction spark plug threads.

  • Page 45: Transmission Oil

    PERIODIC MAINTENANCE AND ADJUSTMENT EAU49890 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 oil level 1.

  • Page 46: Cleaning The Air Filter Element

    PERIODIC MAINTENANCE AND ADJUSTMENT ECA10452 EAU41163 Cleaning the air filter element NOTICE The air filter element should be cleaned In order to prevent clutch slip- at the intervals specified in the periodic page (since the transmission oil maintenance and lubrication chart. also lubricates the clutch), do Clean or, if necessary, replace the air not mix any chemical additives.

  • Page 47: 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 1.

  • Page 48: Adjusting The Carburetor

    Yamaha dealer, who has the neces- periodic maintenance and lubrication sary professional knowledge and expe- chart.

  • Page 49: Adjusting The Throttle Cable Free Play

    3. Tighten the locknut. 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 50: Tires

    After extensive tests, only the tires list- The tire air pressure should be checked ed below have been approved for this and, if necessary, adjusted before each model by Yamaha Motor Co., Ltd. ride. 1. Tire sidewall EWA15370 2. Tire tread depth...

  • Page 51: Spoke Wheels

    4. Rubber cover age before each ride. If any dam- seating may cause tire failure, age is found, have a Yamaha The brake lever free play should mea- which may result in damage to dealer replace the wheel. Do not sure 10.0–20.0 mm (0.39–0.79 in) as...

  • Page 52: Adjusting The Brake Pedal Free Play

    PERIODIC MAINTENANCE AND ADJUSTMENT 3. To increase the brake lever free EAU39812 Adjusting the brake pedal free play, turn the adjusting bolt in di- play rection (a). To decrease the brake lever free play, turn the adjusting bolt in direction (b). 4.

  • Page 53: Checking The Shift Pedal

    If opera- The front and rear brake shoes must be tion is not smooth, have a Yamaha checked for wear at the intervals spec- dealer check the vehicle. ified in the periodic maintenance and lubrication chart.

  • Page 54: Drive Chain Slack

    4. If the drive chain slack is incorrect, less than 1.5 mm (0.06 in), have a chain slack, there should be no weight adjust it as follows. Yamaha dealer replace the brake on the motorcycle. shoes as a set. EAU40112 2.
  • Page 55 PERIODIC MAINTENANCE AND ADJUSTMENT 4. Adjust the brake pedal free play. (See page 7-15.) Using the alignment marks on each side of the swingarm, make sure that both drive chain pullers are in the same position for proper wheel alignment. 1.

  • Page 56: Cleaning And Lubricating The Drive Chain

    [EWA10711] drive chain with a brush or cloth. a moist cloth. Recommended lubricant: Yamaha Chain and Cable Lube or 4- For a thorough cleaning, have a stroke engine oil Yamaha dealer remove the drive chain and soak it in solvent.

  • Page 57: Adjusting The Autolube Pump

    The Autolube pump is a vital and so- brake lever brake pedal phisticated component of the engine, which must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. The operation of the brake lever should...

  • Page 58: Checking And Lubricating The Sidestand

    WARNING! To avoid injury, have a Yamaha dealer check or re- sidestand pivot and metal-to-metal securely support the vehicle so pair it.

  • Page 59: Checking The Steering

    Yamaha dealer check ward and backward. If any free not available, by placing a jack un- the wheel bearings. play can be felt, have a Yamaha der the frame in front of the rear wheel. dealer check or repair the steering.

  • Page 60: Front Wheel

    PERIODIC MAINTENANCE AND ADJUSTMENT a jack either under each side of the EAU24360 3. Loosen the locknut at the brake le- Front wheel frame in front of the rear wheel or under ver, and then turn the adjusting each side of the swingarm. bolt fully in direction (a).
  • Page 61 PERIODIC MAINTENANCE AND ADJUSTMENT 3. Insert the wheel axle from the right side, and then install the washer and axle nut. 4. Lower the front wheel so that it is on the ground, and then put the sidestand down. 5. Connect the brake cable to the brake camshaft lever.

  • Page 62: Rear Wheel

    PERIODIC MAINTENANCE AND ADJUSTMENT EAU25080 Tightening torque: Rear wheel Axle nut: 35 Nm (3.5 m·kgf, 25 ft·lbf) EAU41563 To remove the rear wheel 9. Adjust the brake lever free play. EWA10821 (See page 7-14.) WARNING 10. Push down hard on the handlebar To avoid injury, securely support the several times to check for proper vehicle so there is no danger of it...
  • Page 63 PERIODIC MAINTENANCE AND ADJUSTMENT 5. Lift the rear wheel off the ground EAU41573 8. Lower the rear wheel so that it is To install the rear wheel according to the procedure on on the ground, and then put the 1. Insert the brake shoe plate into the page 7-22.

  • Page 64: 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 65: 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. 7-28...

  • Page 66: Motorcycle Care And Storage

    Rust and corrosion can develop matte colored finished parts. Be Cleaning even if high-quality components are sure to consult a Yamaha dealer for ECA10772 advice on what products to use be- used. A rusty exhaust pipe may go un- NOTICE fore cleaning the vehicle.
  • Page 67 MOTORCYCLE CARE AND STORAGE off any detergent residue using Test the product on a small hid- 2. Apply a corrosion protection spray plenty of water, as it is harmful den part of the windshield to on all metal, including chrome- and to plastic parts.

  • Page 68: Storage

    MOTORCYCLE CARE AND STORAGE 8. Let the motorcycle dry completely EAU40653 Storage before storing or covering it. Consult a Yamaha dealer for advice on EWA14501 what products to use. Short-term WARNING Always store your motorcycle in a cool, Contaminants on the brakes or tires dry place and, if necessary, protect it can cause loss of control.
  • Page 69 MOTORCYCLE CARE AND STORAGE 2. For motorcycles equipped with a e. Remove the spark plug cap fuel cock that has an “OFF” posi- from the spark plug, and then tion: Turn the fuel cock lever to install the spark plug and the “OFF”.

  • Page 70: Specifications

    1540 mm (60.6 in) NGK/BPR6HS Kickstarter Overall width: Spark plug gap: Lubrication system: 640 mm (25.2 in) 0.6–0.7 mm (0.024–0.028 in) Separate lubrication (Yamaha autolube) Overall height: Clutch: Engine oil: 880 mm (34.6 in) Clutch type: Seat height: Type: Wet, multiple-disc automatic 635 mm (25.0 in)
  • Page 71 SPECIFICATIONS Trail: Rim size: 62.0 mm (2.44 in) 12x1.60 Front tire: Front brake: Type: Type: With tube Drum brake Size: Operation: 2.50-14 4PR Right hand operation Manufacturer/model: Rear brake: CHENG SHIN/KNOBBY Type: Rear tire: Drum brake Type: Operation: With tube Right foot operation Size: Front suspension:...

  • Page 72: 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 73 INDEX Air filter element, cleaning ...... 7-9 Handlebar switch........4-1 Throttle cable free play, adjusting..7-12 Autolube pump, adjusting ..... 7-20 Throttle grip and cable, checking and lubricating ........... 7-19 Identification numbers ......10-1 Tires............7-13 Brake lever ..........4-2 Tool kit ............ 7-1 Brake lever, checking and lubricating...
  • Page 74 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2010.04-0.4×1 CR...

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