Yamaha PW80 W 2007 Owner's manual
OWNER’S MANUAL
MANUEL DU PROPRIÉTAIRE
BEDIENUNGSANLEITUNG
PW80(W)
3RV-28199-8G
PRINTED ON RECYCLED PAPER
PRINTED ON RECYCLED PAPER
IMPRESO EN PAPEL RECICLADO
IMPRESO EN PAPEL RECICLADO
AUF RECYCLINGPAPIER GEDRUCKT
AUF RECYCLINGPAPIER GEDRUCKT
YAMAHA MOTOR CO., LTD.
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
PRINTED IN JAPAN
2006.4–0.6×1 !
2006.4–0.6×1 !
(E, F, G)
(E, F, G)
OWNER’S MANUAL
PW80(W)
3RV-28199-8G-E0
INTRODUCTION
EAU41580
Congratulations on your purchase of the Yamaha PW80 . This model is the result of Yamaha’s vast experience in the
production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and
reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you
have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable
at the date of manufacture. 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.
AN IMPORTANT SAFETY MESSAGE:
●
READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. 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 warnings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abilities, and judgment. Some children may not be able to operate a motorcycle safely. Parents should supervise their child’s
use of the motorcycle at all times. Parents should permit continued use only if they determine that the child has the ability to
operate the motorcycle safely.
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 remove the power reduction plate from the motorcycle for more power as their youngster’s riding skills improve. Once the rider
can operate with skill at the top speed permitted by power reduction plate installed, the power reduction plate can be removed.
INTRODUCTION
MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON
THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE.
HE OR SHE SHOULD:
●
OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE
OPERATION.
●
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 MECHANICAL CONDITIONS.
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
EAU41090
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
NOTE:
●
This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle
is subsequently sold.
●
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your motorcycle
and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
IMPORTANT MANUAL INFORMATION
EWA10030
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
EWA14350
WARNING
THIS MOTORCYCLE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS ILLEGAL TO OPERATE 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 OPERATING THIS MOTORCYCLE.
*Product and specifications are subject to change without notice.
IMPORTANT MANUAL INFORMATION
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.
TABLE OF CONTENTS
SAFETY INFORMATION
Safe riding ........................................1-1
Location of important labels .............1-4
DESCRIPTION
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS
Handlebar switch .............................3-1
Power reduction plate ......................3-1
Shift pedal ........................................3-1
Brake lever ......................................3-2
Brake pedal .....................................3-2
Fuel tank cap ...................................3-2
Fuel ..................................................3-3
Fuel tank breather hose ...................3-4
2-stroke engine oil ...........................3-4
Fuel cock .........................................3-5
Starter (choke) lever “1” .................3-6
Kickstarter ........................................3-6
Seat .................................................3-6
Shock absorber ...............................3-7
PRE-OPERATION CHECKS
Pre-operation check list ...................4-2
...................................2-1
........................................3-1
...................1-1
...............4-1
OPERATION AND IMPORTANT
RIDING POINTS
Starting and warming up a cold
engine .......................................... 5-1
Starting a warm engine ...................5-2
Shifting ............................................ 5-2
Engine break-in ...............................5-3
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR
Owner’s tool kit ................................ 6-1
Periodic maintenance and lubrication
chart ............................................. 6-2
Checking the spark plug .................. 6-5
Removing the power 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
.................................. 5-1
.................................. 6-1
Adjusting the brake pedal free
play ............................................ 6-15
Checking the front and rear brake
shoes ......................................... 6-16
Drive chain slack ........................... 6-16
Cleaning and lubricating the drive
chain .......................................... 6-18
Checking and lubricating the
cables ........................................ 6-19
Checking and lubricating the throttle
grip and cable ............................ 6-19
Adjusting the Autolube pump ........ 6-19
Checking and lubricating the brake
and shift pedals ......................... 6-20
Checking and lubricating the brake
lever ........................................... 6-20
Checking and lubricating the
sidestand ................................... 6-21
Checking the front fork .................. 6-21
Checking the steering ................... 6-22
Checking the wheel bearings ........ 6-22
Supporting the motorcycle ............ 6-23
Front wheel ................................... 6-23
Rear wheel .................................... 6-26
Troubleshooting ............................ 6-27
Troubleshooting chart ................... 6-28
MOTORCYCLE CARE AND
STORAGE
Care ................................................ 7-1
Storage ........................................... 7-3
........................................... 7-1
TABLE OF CONTENTS
SPECIFICATIONS
CONSUMER INFORMATION
Identification numbers .....................9-1
..............................8-1
..............9-1
SAFETY INFORMATION
Safe riding
●
1
●
●
●
●
EAU41211
Always make pre-operation
checks. Careful checks may help
prevent an accident.
This motorcycle is designed for
off-road use only, therefore, it is illegal to operate it on public streets,
roads, or highways, even a dirt or
gravel one. Off-road use on public
lands may be illegal. Please check
local regulations before riding.
This motorcycle is designed to carry the operator only. No passengers.
Many accidents involve inexperienced operators.
●
Make sure that the operator is
qualified and that you only lend
your motorcycle to other qualified operators.
●
Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
Many accidents have been caused
by error of the motorcycle operator. A typical error made by the operator is veering wide on a turn
due to EXCESSIVE SPEED or un-
dercornering (insufficient lean angle for the speed). Never travel
faster than warranted by conditions.
●
Ride cautiously in unfamiliar areas. You may encounter hidden
obstacles that could cause an accident.
●
The posture of the operator is important for proper control. The operator should keep both hands on
the handlebar and both feet on the
operator footrests during operation
to maintain control of the motorcycle.
●
Never ride under the influence of
alcohol or other drugs.
●
Be sure the transmission is in neutral before starting the engine.
Protective apparel
The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the
single most critical factor in the prevention or reduction of head injuries.
●
Always wear an approved helmet.
●
Wear a face shield or goggles.
1-1
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
●
The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
●
Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
●
Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protective clothing that covers your legs,
ankles, and feet.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your motorcycle illegal to use.
SAFETY INFORMATION
Loading and accessories
Adding accessories to your motorcycle
can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the
possibility of an accident, use extreme
caution when adding accessories to
your motorcycle. Use extra care when
riding a motorcycle that has added accessories. Here are some general
guidelines to follow if adding accessories to your motorcycle:
Loading
●
The weight of the operator must
not exceed 40 kg (88 lb).
●
Accessory weight should be kept
as low and close to the motorcycle
as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle
to minimize imbalance or instability.
●
Shifting weights can create a sudden imbalance. Make sure that accessories are securely attached to
the motorcycle before riding.
Check accessory mounts fre-
quently.
●
Never attach any large or heavy
items to the handlebar, front fork,
or front fender.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be responsible for the proper selection, installation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any accessories.
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 any
way reduce ground clearance or
cornering clearance, limit suspension travel, steering travel or control operation.
●
Accessories fitted to the handlebar or the front fork area can
create instability due to improper
weight distribution or aerodynamic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
●
Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or
the motorcycle may become unstable in cross winds.
●
Certain accessories can displace the operator from his or
her normal riding position. This
improper position limits the freedom of movement of the operator and may limit control ability,
therefore, such accessories are
not recommended.
●
Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the
motorcycle’s electrical system an
1
1-2
SAFETY INFORMATION
electric failure could result, which
could cause a dangerous loss of
engine power.
1
Gasoline and exhaust gas
●
GASOLINE IS HIGHLY FLAMMABLE:
●
Always turn the engine off when
refueling.
●
Take care not to spill any gaso-
line on the engine or exhaust
pipe/muffler when refueling.
●
Never refuel while smoking or in
the vicinity of an open flame.
●
Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poisonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has adequate ventilation.
●
Always turn the engine off before
leaving the motorcycle unattended. When parking 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 kerosene heater, or near an open
flame), otherwise it could catch
fire.
●
When transporting the motorcycle
in another vehicle, make sure that
it is kept upright and that the fuel
cock is turned to “OFF”. If the motorcycle should lean over, gasoline
may leak out of the carburetor or
fuel tank.
●
If you should swallow any gasoline, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediately. If any gasoline spills on your
skin or clothing, immediately wash
the affected area with soap and
water and change your clothes.
1-3
Location of important labels
Please read the following important labels carefully before operating this vehicle.
SAFETY INFORMATION
EAU41370
2
1
1
3
1-4
SAFETY INFORMATION
5
1
4
1-5
SAFETY INFORMATION
1
2
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
Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.
Antes de conducir este vehículo, lea el Manual del Propietario.
étaire avant d
’utiliser ce v
éhicule.
5PA-21568-00
3
Cold tire normal pressure should be set as
follows.
FRONT :
100 kPa,{1.00 kgf/cm
100 kPa,{1.00 kgf/cm2}, 15 psi
:REAR
2
}, 15 psi
3RV-21668-A0
4
1
5
1-6
DESCRIPTION
Left view
EAU10410
1
2
3
4
5
6
7
8
1. Air filter element (page 6-8)
2. Fuel cock (page 3-5)
9
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)
1 23 4 5
67
2-1
Right view
DESCRIPTION
EAU10420
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)
12
3
6
2
3
4
5
6
7
45
8
9
2-2
DESCRIPTION
Controls and instruments
EAU10430
1
2
3
4
5
6
7
8
1. Right handlebar switch (page 3-1)
2. Brake lever (page 3-2)
9
3. Throttle grip (page 6-11)
4. Fuel tank cap (page 3-2)
12
43
2-3
INSTRUMENT AND CONTROL FUNCTIONS
1
EAU40660
Handlebar switch
1
1. Engine stop switch “ENGINE STOP”
EAU41130
Engine stop switch “ENGINE STOP”
Set this switch to “RUN” before starting
the engine. Set this switch to “OFF” to
stop the engine.
EAU41590
Power reduction plate
Your motorcycle was delivered with a
power reduction plate. Yamaha recommends that all beginning riders start off
with the power reduction 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
1. Shift pedal
This motorcycle is equipped with a constant-mesh 3-speed transmission. The
shift pedal is located on the left side of
the engine. Neutral is at the bottom position.
2
3
4
5
6
7
8
9
3-1
INSTRUMENT AND CONTROL FUNCTIONS
1
Brake lever
1
1
2
3
4
1. Brake lever
The brake lever is located at the right
5
handlebar grip. To apply the front
brake, pull the lever toward the handle-
6
bar grip.
7
8
9
EAU12890
EAU12941
Brake pedal
1
1. Brake pedal
The 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
1. 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 clockwise.
EWA11090
WARNING
Make sure that the fuel tank cap is
properly closed before riding.
3-2
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