engine YAMAHA PW80 2008 Owners Manual

INTRODUCTION
EAU41580
Congratulations on your purchase of the Yamaha PW80(X). 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.
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 warn-
ings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abil-
ities, 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 re-
move 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 re-
moved.

TABLE OF CONTENTS
SAFETY INFORMATION
...................1-1
Safe riding ........................................1-1
Location of important labels .............1-4
DESCRIPTION
...................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS
........................................3-1
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
...............4-1
Pre-operation check list ...................4-2
OPERATION AND IMPORTANT
RIDING POINTS
.................................. 5-1
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
.................................. 6-1
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 ............................................ 6-14Adjusting 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
........................................... 7-1
Matte color caution .......................... 7-1
Care ................................................ 7-1

1-1
1
SAFETY INFORMATION
EAU41211
Safe riding

Always make pre-operation
checks. Careful checks may help
prevent an accident.

This motorcycle is designed for
off-road use only, therefore, it is il-
legal 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 car-
ry the operator only. No passen-
gers.

Many accidents involve inexperi-
enced operators.

Make sure that the operator is
qualified and that you only lend
your motorcycle to other quali-
fied 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 opera-
tor. A typical error made by the op-
erator is veering wide on a turn
due to EXCESSIVE SPEED or un-dercornering (insufficient lean an-
gle for the speed). Never travel
faster than warranted by condi-
tions.

Ride cautiously in unfamiliar ar-
eas. You may encounter hidden
obstacles that could cause an ac-
cident.

The posture of the operator is im-
portant for proper control. The op-
erator should 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
single most critical factor in the preven-
tion or reduction of head injuries.

Always wear an approved helmet.

Wear a face shield or goggles.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 protec-
tive clothing that covers your legs,
ankles, and feet.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the re-
moval of original equipment, may ren-
der the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your mo-
torcycle illegal to use.

SAFETY INFORMATION
1-3
1
electric failure could result, which
could cause a dangerous loss of
engine power.
Gasoline and exhaust gas

GASOLINE IS HIGHLY FLAMMA-
BLE:

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 poi-
sonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has ad-
equate ventilation.

Always turn the engine off before
leaving the motorcycle unattend-
ed. 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 ker-
osene 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 mo-
torcycle should lean over, gasoline
may leak out of the carburetor or
fuel tank.

If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediate-
ly. If any gasoline spills on your
skin or clothing, immediately wash
the affected area with soap and
water and change your clothes.

2-1
1
2
3
4
5
6
7
8
9

DESCRIPTION
EAU10410
Left view1
23 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)

3-1
2
34
5
6
7
8
9

INSTRUMENT AND CONTROL FUNCTIONS
EAU40660
Handlebar switch
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 recom-
mends 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
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. Engine stop switch “ENGINE STOP”
1

1. Shift pedal
1

INSTRUMENT AND CONTROL FUNCTIONS
3-3
2
34
5
6
7
8
9

EAU13220
Fuel
Make sure that there is sufficient fuel in
the tank. When refueling, be sure to in-
sert the pump nozzle into the fuel tank
filler hole and to fill the tank to the bot-
tom of the filler tube as shown.
WARNING

EWA10880

Do not overfill the fuel tank, oth-
erwise it may overflow when the
fuel warms up and expands.

Avoid spilling fuel on the hot en-
gine.
CAUTION:

ECA10070
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfac-
es 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 of91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
1. Fuel tank filler tube
2. Fuel level
2 1

Recommended fuel:
For Europe: REGULAR UNLEADED
GASOLINE ONLY
Except for Europe: UNLEADED
GASOLINE ONLY
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)

INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
2
3
4
5
6
7
8
9

EAU13412
Fuel tank breather hose
Before operating the motorcycle:

Check the fuel tank breather hose
connection.

Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.

Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.
EAU41201
2-stroke 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.
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 oiltank cap and add the recommend-
ed oil.
3. Install the 2-stroke engine oil tank
cap.
NOTE:

Make sure that the 2-stroke engine oil
tank cap is properly closed.
4. Install the seat.
1. Fuel tank breather hose
1

1. Minimum level
1

1. 2-stroke engine oil tank
2. 2-stroke engine oil tank cap
Recommended oil:
See page 8-1.
Oil quantity:
0.95 L (1.00 US qt) (0.84 Imp.qt)
1
2

INSTRUMENT AND CONTROL FUNCTIONS
3-5
2
34
5
6
7
8
9

EAU13561
Fuel cock
The fuel cock supplies fuel from the
tank to the carburetor while filtering it al-
so.
The fuel cock has three positions:
OFF
With the lever in this position, fuel will
not flow. Always return the lever to this
position 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
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
ONFUEL
OFF
1

1. Arrow mark positioned over “ON”
1. Arrow mark positioned over “RES”
ON
FUEL
RES
OFF
1
ON
OFF
ONFUEL RES
1
RES

INSTRUMENT AND CONTROL FUNCTIONS
3-6
1
2
3
4
5
6
7
8
9

EAU13590
Starter (choke) lever “”
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the lever in direction (a) to turn on
the starter (choke).
Move the lever 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
shown.

1. Starter (choke) lever “”
1
(a)(b)

1. Kickstarter
1

1. Nut
1