Yamaha PW80(Y) Owner'S Manual Download Page 7

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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.

A WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to the
vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

WARNING

NOTICE

TIP

Summary of Contents for PW80(Y)

Page 1: ...DIENUNGSANLEITUNG 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 ...

Page 2: ......

Page 3: ...3RV 28199 8J E0 PW80 Y OWNER S MANUAL Read this manual carefully before operating this vehicle ...

Page 4: ...EAU46151 ng this vehicle This manual should stay with this vehicle if it is sold s ...

Page 5: ...you and your Yamaha dealer pay close attention to the ating instructions contained within this manual uct design and quality Therefore while this manual contains the most cur nting there may be minor discrepancies between your motorcycle and this manual please consult a Yamaha dealer EWA10031 tely before operating this motorcycle EWA14351 ed for off road use only It is illegal to operate this moto...

Page 6: ...t all beginners start off with gine power available while they learn Parents should decide when to re le for more power as their youngster s riding skills improve Once the rider by power reduction plate installed the power reduction plate can be re afe use and operation are dependent upon the use of proper riding ator Every operator should know the following requirements before nt source on all as...

Page 7: ... to alert you to potential personal injury safety messages that follow this symbol to avoid possible injury cates a hazardous situation which if not avoided could result in injury tes special precautions that must be taken to avoid damage to the property y information to make procedures easier or clearer ...

Page 8: ...U10200 PW80 Y OWNER S MANUAL 8 by Yamaha Motor Co Ltd st edition March 2008 All rights reserved printing or unauthorized use ut the written permission of amaha Motor Co Ltd s expressly prohibited Printed in Japan ...

Page 9: ...he brake pedal free y 6 15 Checking the front and rear brake shoes 6 15 Drive chain slack 6 16 Cleaning and lubricating the drive chain 6 18 Checking and lubricating the cables 6 18 Checking and lubricating the throttle grip and cable 6 18 Adjusting the Autolube pump 6 19 Checking and lubricating the brake and shift pedals 6 19 Checking and lubricating the brake lever 6 20 Checking and lubricating...

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Page 11: ...ing urself conspicuous appears to very effective in reducing the ance of this type of accident erefore Wear a brightly colored jacket Use extra caution when you are approaching and passing through intersections since in tersections are the most likely places for motorcycle accidents to occur Ride where other motorists can see you Avoid riding in another motorist s blind spot Many accidents involve...

Page 12: ...gine exhaust Deadly levels of monoxide can collect rapidly and you can quickly be overcome and unable to save yourself Also deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas If you experience any symptoms of carbon monoxide poison ing leave the area immediately get fresh air and SEEK MEDICAL TREAT MENT Do not run engine indoors Even if you try to ...

Page 13: ...sories and Modifications While you may find aftermarket prod ucts similar in design and quality to genuine Yamaha accessories recog nize that some aftermarket accessories or modifications are not suitable be cause of potential safety hazards to you or others Installing aftermarket prod ucts or having other modifications per formed to your vehicle that change any of the vehicle s design or operatio...

Page 14: ... rims that came with your cle were designed to match the ance capabilities and to provide combination of handling brak comfort Other tires rims siz d combinations may not be iate Refer to page 6 12 for tire ations and more information on g your tires ...

Page 15: ...2 1 2 3 4 5 6 7 8 9 DESCRIPTION EAU10410 1 2 3 4 5 6 7 ...

Page 16: ...2 2 EAU10420 2 3 4 5 ...

Page 17: ...DESCRIPTION 2 3 2 3 4 5 6 7 8 9 EAU10430 1 2 4 3 ...

Page 18: ... should decide when to adjust orcycle for more power as their er s riding skills improve Once can operate with skill at the top with the power reduction plate d the power reduction plate can oved See page 6 6 EAU39850 Shift pedal This motorcycle is equipped with a con stant mesh 3 speed transmission The shift pedal is located on the left side of the engine Neutral is at the bottom po sition 1 Shif...

Page 19: ...the brake pedal EAU13182 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 EWA11091 Make sure that the fuel tank cap is properly closed after filling fuel Leaking fuel is a fire hazard e pedal 1 1 Fuel tank cap 1 ...

Page 20: ... on your skin wash with soap and water If gaso line spills on your clothing change your clothes EAU41960 NOTICE 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...

Page 21: ... engine 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 follows TIP 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...

Page 22: ...on fuel will Always return the lever to this when 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 mark positioned over OFF RES ON FUEL 1 1 Arrow mark positioned over ON 1 Arrow mark positioned over RES ON FUEL RES OFF 1 ON OFF ON FUEL RES 1 RES ...

Page 23: ...upplied by rter choke he lever in direction a to turn on rter choke he lever in direction b to turn off rter 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 er choke lever 1 a b 1 Kickstarter 1 ...

Page 24: ...ng the shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Do not subject the shock ab sorber assembly to an open flame or other high heat source This may cause the unit to ex plode due to excessive gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out shock absorb...

Page 25: ...re the vehicle is in safe operating condition Always follow the inspection cribed in the Owner s Manual EWA11151 perly increases the possibility of an accident or equipment damage blem If a problem cannot be corrected by the procedures provided in Yamaha dealer nts ...

Page 26: ...ommended oil to specified level leakage 3 4 nsmission case commended oil to specified level 6 7 cessary y 6 14 6 15 ay 6 15 ation is smooth ay amaha dealer adjust cable free play and lubricate cable 6 11 6 18 ation is smooth ry 6 18 on ry 6 16 and tread depth 6 12 6 13 ...

Page 27: ...RATION CHECKS 4 3 2 3 4 5 6 7 8 9 ration is smooth oting points if necessary 6 19 ration is smooth ting point if necessary 6 20 ration is smooth cessary 6 20 uts bolts and screws are properly tightened y 3 1 CHECKS PAGE ...

Page 28: ...the sidestand wn n the starter choke on and mpletely close the throttle See ge 3 6 rt the engine by pushing the kstarter lever down er starting the engine move the rter choke back halfway TICE For maximum engine always warm the engine up ore starting off Never accel te hard when the engine is d ECA11131 en the engine is warm turn the starter choke off TIP The engine is warm when it responds normal...

Page 29: ...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 lubrication may damage the transmission Always release the throttle grip before changing gears to avoid damaging the engine transmis sion and drive train which are not designed to withstand the shock of shifting when the throt tle...

Page 30: ...However momentary tle operation under load i e hree seconds maximum does m the engine Each full throttle ation should be followed with a tial rest period for the engine w the engine to cool down from porary buildup of heat cruise at engine speed e first 5 hours of operation thor check the motorcycle for loose il leakage and any other prob e sure to inspect and make ad justments thoroughly especial...

Page 31: ...RATION AND IMPORTANT RIDING POINTS 5 4 2 3 4 5 6 7 8 9 ...

Page 32: ... 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 maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have a Yamah...

Page 33: ...0 hours ormed by a Yamaha dealer as they require special tools data and technical TENANCE JOB INITIAL THEREAFTER EVERY 10 hours 20 hours 40 hours 80 hours 40 hours 80 hours 160 hours cracks or damage e play Whenever worn to the limit ee play Whenever worn to the limit tightness and for essary ...

Page 34: ...ss h lithium soap based gnment and condi hain with Yamaha thoroughly Every ride ng and fasteners ased grease lightly for oil leakage for oil leakage peed and starter TENANCE JOB INITIAL THEREAFTER EVERY 10 hours 20 hours 40 hours 80 hours 40 hours 80 hours 160 hours ...

Page 35: ...8 9 re riding in unusually wet or dusty areas e and cable lube or ghtly free play and cable lube or ghtly ased grease lightly ased grease lightly ssary TENANCE JOB INITIAL THEREAFTER EVERY 10 hours 20 hours 40 hours 80 hours 40 hours 80 hours 160 hours ...

Page 36: ...t to e such problems yourself In have a Yamaha dealer check cle eck the spark plug for electrode sion and excessive carbon or other deposits and replace it if necessary To install the spark plug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion plug wrench 1 Specified spark plug NGK BP6HS AUS NZL NGK BPR6HS AUT BEL CHE DEU DNK ESP FIN FRA G...

Page 37: ...ystem ol prior to touching exhaust mponents EWA14581 move the gasket move the power reduction ate TIP Store the power reduction plate with the Owner s Manual so that it is readily available whenever you want to reduce the engine power 4 Install the exhaust manifold by in stalling the bolts ust manifold bolt 1 1 Exhaust manifold 2 Gasket 3 Power reduction plate Tightening torque Exhaust manifold bo...

Page 38: ... type to raise it to correct level ert the dipstick into the oil filler e and then tighten the oil filler p To change the transmission oil 1 Place an oil pan under the trans mission to collect the used oil 2 Remove the oil filler cap and drain bolt to drain the oil from the trans mission 3 Install the transmission oil drain bolt and then tighten it to the spec ified torque 4 Refill with the specif...

Page 39: ...d lubrication chart the air filter element more fre if you are riding in unusually dusty areas move the air filter case cover by moving the screws ll the air filter element out 3 Remove the sponge material from the air filter case cover clean it with solvent and then squeeze the remaining solvent out ter case cover w 2 2 1 Sponge material 2 Air filter case cover 1 2 ...

Page 40: ...rrester 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 the engine when cleaning the exhaust system TIP Make sure to select a well ventilated area free of combustible materials to clean the spark arrester 1 Remove the tailpipe by removing the bolt and...

Page 41: ...e 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 NOTICE ECA10550 The carburetor has been set and ex tensively tested at the Yamaha fac tory Changing these settings without sufficient technical knowl edge...

Page 42: ... the throttle grip Periodically check the throttle cable free play and if neces sary adjust it as follows TIP The engine idling speed must be cor rectly adjusted before checking and ad justing the throttle cable free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting nut in direc tion a To decrease the throttle le stop screw ne idling speed 50 1750 r min 1 a b ...

Page 43: ... and adjusted on cold es i e when the temperature the tires equals the ambient mperature e tire air pressure must be ad sted in accordance with the eight of the rider the riding eed and the riding condi ns 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 hav...

Page 44: ...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 wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel sho...

Page 45: ... herwise proceed as follows lly turn the adjusting bolt at the ake lever in direction a to loos the brake cable osen the locknut at the brake oe plate increase the brake lever free ay turn the adjusting nut in direc n a To decrease the brake le r free play turn the adjusting nut direction b ghten the locknut at the brake shoe plate and at the brake lever nut sting nut 1 2 a b ...

Page 46: ...usting the brake pedal e play check the operation of brake light EAU41052 Checking the front and rear brake shoes The front and rear brake shoes must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart TIP The wheels must be removed to check brake shoe lining thickness To remove the front wheel See page 6 23 To remove the rear wheel See page 6 25 Front...

Page 47: ...be no weight motorcycle ift the transmission into the neu l position ove the rear wheel by pushing e motorcycle to locate the tight t portion of the drive chain and en measure the drive chain slack shown 4 If the drive chain slack is incorrect adjust it as follows EAU40111 To adjust the drive chain slack 1 Loosen the brake pedal free play adjusting nut axle nut and locknut at each end of the swing...

Page 48: ...ting nuts are in the same po r proper wheel alignment hten both locknuts and the axle to the specified torques 4 Adjust the brake pedal free play See page 6 15 ment marks chain slack adjusting nut ut er ut 4 2 a b 3 Tightening torques Locknut 6 5 Nm 0 7 m kgf 4 7 ft lbf Axle nut 60 Nm 6 0 m kgf 43 4 ft lbf ...

Page 49: ...check or replace it ING Damage to the outer g of cables may result in in rusting and cause interfer with cable movement Replace ed cables as soon as possi o prevent unsafe condi WA10711 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 peri...

Page 50: ...NT 6 19 EAU44271 king and lubricating the and shift pedals eration of the brake and shift should be checked before each d the pedal pivots should be lu if necessary Recommended lubricant Lithium soap based grease ...

Page 51: ...t fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition 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 WARNING To avoid injury securely support the vehicl...

Page 52: ...e maintenance and lubrication ce a stand under the engine to se the front wheel off the und See page 6 1 for more in mation WARNING To avoid ury securely support the ve le so there is no danger of it ing over EWA10751 d the lower ends of the front k legs and try to move them for rd and backward If any free y can be felt have a Yamaha aler check or repair the steering ...

Page 53: ...A strong wooden n be placed under the engine for stability vice the front wheel abilize the rear of the motorcycle using a motorcycle stand or if additional motorcycle stand is t available by placing a jack un r the frame in front of the rear eel ise the front wheel off the ound by using a motorcycle and vice the rear wheel he rear wheel off the ground by motorcycle stand or if a motor tand is not...

Page 54: ...ect the brake cable from the front brake lever 5 Disconnect the brake cable from the brake camshaft lever 6 Remove the brake cable free play adjusting bolt and the brake cable locknut at the front wheel hub 7 Remove the axle nut and washer ing nut ut er ut camshaft lever 4 5 3 1 2 1 Adjusting bolt 2 Locknut 2 1 a ...

Page 55: ...tall the washer and axle nut 4 Lower 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 e shoe plate 1 Retainer Tightening torque Axle nut 35 Nm 3 5 m kgf 25 3 ft lbf 1 ...

Page 56: ...e brake torque rod from the brake shoe plate by re moving the cotter pin the nut and the bolt 4 Loosen the locknut and drive chain adjusting nut on each end of the swingarm 5 Lift the rear wheel off the ground chain slack adjusting nut ut puller er ut 4 1 2 3 1 Brake pedal free play adjusting nut 2 Spacer 3 Chain puller 4 Wheel axle 5 Drive chain slack adjusting nut 6 Locknut 7 Brake torque rod 8 ...

Page 57: ...brake shoe plate by installing e bolt and nut and then tighten e nut to the specified torque sert a new cotter pin into the ake torque rod bolt WARNING ways use a new cotter n EWA10831 stall the washer and axle nut d then lower the rear wheel so at it is on the ground just the drive chain slack See ge 6 16 ghten the axle nut to the speci d torque 9 Adjust the brake pedal free play See page 6 15 te...

Page 58: ...ND ADJUSTMENT 6 27 or furnaces Gasoline or e vapors can ignite or ex causing severe injury or y damage ...

Page 59: ...check the vehicle e off with a dry cloth and correct the k plug gap or replace the spark plug e a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle Open the throttle halfway and operate the kickstarter Check the compression The engine does not start Check the compression ...

Page 60: ...nt onto the crankcase h a degreasing agent and a sh but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and de greaser off with water Cleaning NOTICE ECA10771 Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner on the af fected area any longer th...

Page 61: ...ll metal including chrome and kel plated surfaces to prevent rrosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to 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 c...

Page 62: ...retor float chamber by loosening the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 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...

Page 63: ...MOTORCYCLE CARE AND STORAGE 7 4 2 3 4 5 6 7 8 9 ...

Page 64: ...E 10W 40 nge quantity 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 Type quantity VM15SC x 1 Spark ...

Page 65: ...kgf cm2 15 psi wheel type oke wheel ze 1 40 heel type oke wheel ze 1 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 travel 110 0 mm 4 33 in Rear suspension Type Swingarm monocross Spring shock absorber type Coil spring gas oil damper...

Page 66: ...mber is identify your motorcycle and used to register your motorcy the licensing authority in your EAU26460 Model label The model label is affixed to the loca tion shown Record the information on this label in the space provided This in formation will be needed when ordering spare parts from a Yamaha dealer e identification number 1 1 Model label 1 ...

Page 67: ... and lubricating 6 20 arrester cleaning 6 9 plug checking 6 5 cations 8 1 choke lever 3 6 g and warming up a cold engine 5 1 g checking 6 21 e 7 3 ting the motorcycle 6 22 e cable free play adjusting 6 11 e grip and cable checking and ating 6 18 Tires 6 12 Tool kit 6 1 Transmission oil 6 7 Troubleshooting 6 27 Troubleshooting chart 6 28 V Vehicle identification number 9 1 W Wheel bearings checking...

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