Yamaha PW80 (2009) Manual
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3RV-28199-8K
PW80(Z)
OWNER’S MANUAL
MANUEL DU PROPRIÉTAIRE
BEDIENUNGSANLEITUNG
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.
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2009.04–0.2 1 ×!
(E, F, G)
PRINTED ON RECYCLED PAPER
AUF RECYCLINGPAPIER GEDRUCKT
IMPRIMÉ SUR PAPIER RECYCLÉ YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2009.04 0.2 1 –×!
(E, F, G)
PRINTED ON RECYCLED PAPER
AUF RECYCLINGPAPIER GEDRUCKT
IMPRIM SUR PAPIER RECYCLÉ É
3RV-28199-8K-E0
PW80(Z)
OWNER’S MANUAL
Read this manual carefully before operating this vehicle.
EAU48180
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 98/ 37/EC, 2006/42/EC
We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan,
declare in sole responsibility, that the product
PW80 JYA4BC00000109301 )(
(Make, model)
to whichthis declaration applies, conforms to the essential health
and safety requirements of Directive 98/ 37/EC, 2006/42/EC
If applicable
( )
and to the other relevant Directives of EEC
2004/ 108 /EC
Title
( )
and / or numberand date of issue of the other Directives of EEC
If applicable( )
To ef fec t correct application of the essential health and sa fety requirements
stat ed in the Directives of EEC, the following standards and /or technical
specifications were consulted:
Title
(and / or number and date of issue of )standards and/ or specifications
Authorized Representative
YAMAHA MOTOR EUROPE N.V.
Koolhovenlaan 101,1119 NC Schiphol Rijk,The Netherlands
Signature
Kunihiko Miwa
Division Manager
Motorcycle Headquarters
Product Development Operations
Date of Issue
27 February , 2009
INTRODUCTION
EAU41582
Congratulations on your purchase of the Yamaha PW80(Z). 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.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most cur-
rent product information available at the time of printing, there may be minor discrepancies between your motorcycle and this
manual. If there is any question concerning this manual, please consult a Yamaha dealer.
WARNING
EWA10031
Please read this manual carefully and completely before operating this motorcycle.
WARNING
EWA14351
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.
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 notice labels on the motorcycle.
●Never operate a motorcycle without proper training or instruction.
●Weight of the rider should not exceed 40 kg (88 lb).
INTRODUCTION
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.
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 this Owner’s Manual.
●Obtain qualified training in safe and proper riding techniques.
●Obtain professional technical service as indicated in this Owner’s Manual and/or when made necessary by mechanical
conditions.
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
IMPORTANT MANUAL INFORMATION
EAU10200
PW80(Z)
OWNER’S MANUAL
©2009 by Yamaha Motor Co., Ltd.
1st edition, March 2009
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
LOCATION OF IMPORTANT
LABELS ............................................. 1-1
SAFETY INFORMATION .................. 2-1
DESCRIPTION .................................. 3-1
Left view .......................................... 3-1
Right view........................................ 3-2
Controls and instruments ................ 3-3
INSTRUMENT AND CONTROL
FUNCTIONS ....................................... 4-1
Handlebar switch ............................ 4-1
Power reduction plate ..................... 4-1
Shift pedal ...................................... 4-1
Brake lever ..................................... 4-2
Brake pedal .................................... 4-2
Fuel tank cap .................................. 4-2
Fuel ................................................ 4-3
Fuel tank breather hose ................. 4-4
2-stroke engine oil .......................... 4-4
Fuel cock ........................................ 4-5
Starter (choke) lever “ ” ................4-6
Kickstarter ...................................... 4-6
Seat ................................................ 4-7
Shock absorber assembly .............. 4-7
Sidestand ....................................... 4-8
FOR YOUR SAFETY –
PRE-OPERATION CHECKS.............. 5-1
OPERATION AND IMPORTANT
RIDING POINTS................................. 6-1
Starting and warming up a cold
engine ......................................... 6-1
Starting a warm engine .................. 6-2
Shifting ........................................... 6-2
Engine break-in .............................. 6-3
Parking ........................................... 6-4
PPERIODIC MAINTENANCE AND
ADJUSTMENT................................... 7-1
Owner’s tool kit ............................... 7-1
Periodic maintenance and
lubrication chart .......................... 7-2
Checking the spark plug ................. 7-5
Removing the power reduction
plate ............................................ 7-6
Transmission oil ............................. 7-7
Cleaning the air filter element ........ 7-8
Cleaning the spark arrester ............ 7-9
Adjusting the carburetor ............... 7-10
Adjusting the engine idling
speed ........................................ 7-10
Adjusting the throttle cable free
play ........................................... 7-11
Tires ............................................. 7-12
Spoke wheels ............................... 7-13
Adjusting the brake lever free
play ........................................... 7-13
Adjusting the brake pedal free
play ........................................... 7-14
Checking the front and rear
brake shoes ............................... 7-15
Drive chain slack ........................... 7-16
Cleaning and lubricating the
drive chain ................................. 7-17
Checking and lubricating the
cables ........................................ 7-18
Checking and lubricating the
throttle grip and cable ................ 7-18
Adjusting the Autolube pump ........ 7-18
Checking and lubricating the
brake lever ................................. 7-19
Checking and lubricating the
brake pedal ................................ 7-19
Checking and lubricating the
sidestand ................................... 7-19
Checking the front fork .................. 7-20
Checking the steering ................... 7-20
Checking the wheel bearings ........ 7-21
Supporting the motorcycle ............ 7-21
Front wheel ................................... 7-22
Rear wheel .................................... 7-24
Troubleshooting ............................ 7-26
Troubleshooting chart ................... 7-27
MOTORCYCLE CARE AND
STORAGE .......................................... 8-1
Matte color caution ......................... 8-1
Care ................................................ 8-1
Storage ........................................... 8-3
TABLE OF CONTENTS
SPECIFICATIONS ............................. 9-1
CONSUMER INFORMATION ........... 10-1
Identification numbers .................. 10-1
1-1
1
2
3
4
5
6
7
8
9
LOCATION OF IMPORTANT LABELS
EAU48130
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
3
4
12
LOCATION OF IMPORTANT LABELS
1-2
1
2
3
4
5
6
7
8
9
For Europe
4
5PG-2817L-10
100
1.00
15
100
1.00
15
5PG-2816R-00
1
2
3
LOCATION OF IMPORTANT LABELS
1-3
1
2
3
4
5
6
7
8
9
Familiarize yourself with the following pictograms and read the explanatory text.
**.* kPa
*.** kgf/cm²
*.* psi
**.* kPa
*.** kgf/cm²
*.* psi
Read the Owner’s manual.
This unit contains high-pressure
nitrogen gas.
Mishandling can cause
explosion. Do not incinerate,
puncture or open.
Turn off the main switch after
riding to avoid draining the
battery.
Use unleaded gasoline only.
Measure tire pressure when
tires are cold.
Adjust tire pressure.
Improper tire pressure can
cause loss of control.
Loss of control can result in
severe injury or death.
LOCATION OF IMPORTANT LABELS
1-4
1
2
3
4
5
6
7
8
9
For Oceania and South Africa
1
32
LOCATION OF IMPORTANT LABELS
1-5
1
2
3
4
5
6
7
8
9
For Oceania and South Africa
Before you operate this vehicle, read the owner’s manual.
5PA-21568-01
Prima di usare il veicolo, leggete il manuale di istruzioni.
Lire le manuel du propri
étaire avant d
’utiliser ce v
éhicule.
Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.
Antes de conducir este veh culo, lea el Manual del Propietario.í
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
31
2
2-1
1
2
3
4
5
6
7
8
9
SAFETY INFORMATION
EAU41214
Be a Responsible Owner
As the vehicle’s owner, you are respon-
sible for the safe and proper operation
of your motorcycle.
Motorcycles are single-track vehicles.
Their safe use and operation are de-
pendent 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 mainte-
nance requirements in this Own-
er’s Manual.
●Obtain qualified training in safe
and proper riding techniques.
●Obtain professional technical ser-
vice as indicated in this Owner’s
Manual and/or when made neces-
sary by mechanical conditions.
Safe Riding
Perform the pre-operation checks each
time you use the vehicle to make sure it
is in safe operating condition. Failure to
inspect or maintain the vehicle properly
increases the possibility of an accident
or equipment damage. See page 5-1
for a list of pre-operation checks.
●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.
●The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
Therefore:
●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 inexperi-
enced operators.
●Make sure that you are qualified
and that you only lend your mo-
torcycle to other qualified opera-
tors.
●Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
●We recommend that you prac-
tice riding your motorcycle until
you have become thoroughly fa-
miliar with the motorcycle and all
of its controls.
●Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
2-2
2
3
4
5
6
7
8
9
SAFETY INFORMATION
erator is veering wide on a turn
due to excessive speed or under-
cornering (insufficient lean angle
for the speed). Never travel faster
than warranted by conditions.
●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.
●Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause burns.
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing car-
bon monoxide can cause headaches,
dizziness, drowsiness, nausea, confu-
sion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be
present even if you do not see or smell
any engine exhaust. Deadly levels of
carbon 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 ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
●Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
●Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loading
Adding accessories to your motorcycle
can adversely affect stability and han-
2-3
1
2
3
4
5
6
7
8
9
SAFETY INFORMATION
dling if the weight distribution of the mo-
torcycle 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 ac-
cessories. Here are some general
guidelines to follow if adding accesso-
ries to your motorcycle:
Operation of an overloaded vehicle
could cause an accident.
●The weight of the operator must
not exceed 40.0 kg (88 lb).
●Accessory weight should be kept
as low and close to the motorcycle
as possible. Securely pack your
heaviest items as close to the cen-
ter of the vehicle as possible and
make sure to distribute the weight
as evenly as possible on both
sides of the motorcycle to mini-
mize imbalance or instability.
●Shifting weights can create a sud-
den imbalance. Make sure that
accessories are securely at-
tached to the motorcycle before
riding. Check accessory mounts
frequently.
●Properly adjust the suspension
for your load, and check the con-
dition and pressure of your tires.
●Never attach any large or heavy
items to the handlebar, front
fork, or front fender.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail-
able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection to
Yamaha manufacture parts and acces-
sories or offer other modifications for
Yamaha vehicles. Yamaha is not in a
position to test the products that these
aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories,
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 operation
characteristics can put you and others
at greater risk of serious injury or death.
You are responsible for injuries related
to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
●Never install accessories 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 suspen-
sion travel, steering travel or con-
trol operation.
●Accessories fitted to the handle-
2-4
2
3
4
5
6
7
8
9
SAFETY INFORMATION
bar or the front fork area can
create instability due to improper
weight distribution. If accesso-
ries 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. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds.
●Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.
●Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match the
performance capabilities and to provide
the best combination of handling, brak-
ing, and comfort. Other tires, rims, siz-
es, and combinations may not be
appropriate. Refer to page 7-12 for tire
specifications and more information on
replacing your tires.
3-1
1
2
3
4
5
6
7
8
9
DESCRIPTION
EAU10410
Left view
1 2 3 4 5
67
1. Air filter element (page 7-8)
2. Fuel cock (page 4-5)
3. Throttle stop screw (page 7-10)
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)
DESCRIPTION
3-2
2
3
4
5
6
7
8
9
EAU10420
Right view
6
1 2 3
45
1. Spark arrester (page 7-9)
2. Seat (page 4-7)
3. Transmission oil filler cap (page 7-7)
4. Spark plug cap (page 7-5)
5. Brake pedal (page 4-2)
6. Kickstarter (page 4-6)
DESCRIPTION
3-3
1
2
3
4
5
6
7
8
9
EAU10430
Controls and instruments
1 2
4 3
1. Handlebar switch (page 4-1)
2. Brake lever (page 4-2)
3. Throttle grip (page 7-11)
4. Fuel tank cap (page 4-2)
4-1
2
3
4
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 7-6.)
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
4-2
1
2
3
4
5
6
7
8
9
EAU12890
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
EAU12941
Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on 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.
1. Brake lever
1
1. Brake pedal
1
1. Fuel tank cap
1
INSTRUMENT AND CONTROL FUNCTIONS
4-3
2
3
4
5
6
7
8
9
EAU13221
Fuel
Make sure there is sufficient gasoline in
the tank.
WARNING
EWA10881
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.
1. Before refueling, turn off the en-
gine and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the vi-
cinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters and
clothes dryers.
2. Do not overfill the fuel tank. When
refueling, be sure to insert the
pump nozzle into the fuel tank filler
hole. Stop filling when the fuel
reaches the bottom of the filler
tube. Because fuel expands when
it heats up, heat from the engine or
the sun can cause fuel to spill out
of the fuel tank.
3. Wipe up any spilled fuel immedi-
ately. NOTICE: Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteri-
orate painted surfaces or plastic
parts.[ECA10071]
4. Be sure to securely close the fuel
tank cap.
WARNING
EWA15151
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gaso-
line by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline vapor, or get some gasoline in
your eyes, see your doctor immedi-
ately. If gasoline spills 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. If knocking (or pinging) oc-
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
4-4
1
2
3
4
5
6
7
8
9
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.
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.
EAU41202
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.
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 reading.
1. Remove the seat. (See page 4-7.)
2. Remove the 2-stroke engine oil
1. Fuel tank breather hose
1
1. Minimum level
1
INSTRUMENT AND CONTROL FUNCTIONS
4-5
2
3
4
5
6
7
8
9
tank cap and add the recommend-
ed oil.
3. Install the 2-stroke engine oil tank
cap.
NOTICE
ECA16670
Make sure that the 2-stroke engine
oil tank cap is properly installed.
4. Install the seat.
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
1. 2-stroke engine oil tank
2. 2-stroke engine oil tank cap
Recommended oil:
See page 9-1.
Oil quantity:
0.75 L (0.79 US qt, 0.66 Imp.qt)
12
1. Arrow mark positioned over “OFF”
RES
ON
FUEL
OFF
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
INSTRUMENT AND CONTROL FUNCTIONS
4-6
1
2
3
4
5
6
7
8
9
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!
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.
1. Starter (choke) lever “ ”
1
(a)
(b)
1. Kickstarter
1
INSTRUMENT AND CONTROL FUNCTIONS
4-7
2
3
4
5
6
7
8
9
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.
2. Place the seat in the original posi-
tion, and then tighten the nuts.
TIP
Make sure that the seat is properly se-
cured before riding.
EAU46021
Shock absorber assembly
WARNING
EWA10221
This shock absorber assembly con-
tains highly pressurized nitrogen
gas. Read and understand the fol-
lowing information before handling
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 absorber as-
sembly yourself. Take the shock
absorber assembly to a Yamaha
dealer for any service.
1. Nut
1
1. Seat holder
2. Projection
2
1
INSTRUMENT AND CONTROL FUNCTIONS
4-8
1
2
3
4
5
6
7
8
9
EAU37490
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.
WARNING
EWA14190
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
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
1. Sidestand
1
5-1
2
3
4
5
6
7
8
9
FOR YOUR SAFETY PRE-OPERATION CHECKS–
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner s Manual.’
WARNING
EWA11151
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:
ITEM CHECKS PAGE
Fuel
●Check fuel level in fuel tank.
●Refuel if necessary.
●Check fuel line for leakage.
4-3
2-stroke engine oil
●Check oil level in oil tank.
●If necessary, add recommended oil to speci ed level.fi
●Check vehicle for oil leakage.
4-4
Transmission oil ●Check oil level in transmission case.
●If necessary, add recommended oil to speci ed level.fi7-7
Front brake
●Check operation.
●Lubricate cable if necessary.
●Check lever free play.
●Adjust if necessary.
7-13, 7-15
Rear brake
●Check operation.
●Check pedal free play.
●Adjust if necessary.
7-14
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.
7-11, 7-18
Control cables ●Make sure that operation is smooth.
●Lubricate if necessary. 7-18
FOR YOUR SAFETY PRE-OPERATION CHECKS–
5-2
1
2
3
4
5
6
7
8
9
Drive chain
●Check chain slack.
●Adjust if necessary.
●Check chain condition.
●Lubricate if necessary.
7-16, 7-17
Wheels and tires
●Check for damage.
●Check tire condition and tread depth.
●Check air pressure.
●Correct if necessary.
7-12, 7-13
Shift pedal ●Make sure that operation is smooth.
●Correct if necessary. —
Brake pedal ●Make sure that operation is smooth.
●Lubricate pedal pivoting point if necessary. 7-19
Brake lever ●Make sure that operation is smooth.
●Lubricate lever pivoting point if necessary. 7-19
Sidestand ●Make sure that operation is smooth.
●Lubricate pivot if necessary. 7-19
Chassis fasteners ●Make sure that all nuts, bolts and screws are properly tightened.
●Tighten if necessary. —
Engine stop switch ●Check operation. 4-1
ITEM CHECKS PAGE
6-1
2
3
4
5
6
7
8
9
OPERATION AND IMPORTANT RIDING POINTS
EAU15951
Read the Owner s Manual carefully to’
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWA10271
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU41155
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 starter (choke) on and
completely close the throttle. (See
page 4-6.)
5. Start the engine by pushing the
kickstarter lever down.
6. After starting the engine, move the
starter (choke) back halfway.
NOTICE: For maximum engine
life, never accelerate hard when
the engine is cold![ECA11041]
7. When the engine is warm, turn the
starter (choke) off.
TIP
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
OPERATION AND IMPORTANT RIDING POINTS
6-2
1
2
3
4
5
6
7
8
9
EAU16660
Starting a warm engine
Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm. Instead, start
the engine with the throttle slightly
open.
TIP
If the engine does not start after sever-
al kicks, try again with the throttle 1/4
to 1/2 open.
EAU39901
Shifting
This motorcycle has a 3-speed trans-
mission with a centrifugal, automatic
clutch. Shifting gears lets you control
the amount of engine power available
for starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the il-
lustration.
TIP
To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel.
NOTICE
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 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 grip is open.
EAU39911
To start out and accelerate
1. Close the throttle.
2. Shift into first gear and release the
shift pedal. NOTICE: Always
close the throttle before shifting
gears, otherwise damage to the
engine and drive train may re-
sult.[ECA15461]
1. Shift pedal
2. Neutral position
1
1
2
3
N
2
OPERATION AND IMPORTANT RIDING POINTS
6-3
2
3
4
5
6
7
8
9
3. Open the throttle gradually.
4. Once the motorcycle has reached
a speed high enough to change
gears, close the throttle.
5. Shift into second gear and release
the shift pedal.
6. Open the throttle gradually.
7. Follow the same procedure when
shifting to the next higher gear.
EAU16710
To decelerate
1. Close the throttle and apply both
the front and the rear brakes to
slow the motorcycle.
2. Downshift through the gears and
shift the transmission into the neu-
tral position when the motorcycle
is almost completely stopped.
EAU39920
Engine break-in
There is never a more important period
in the life of your engine than the first 5
hours of riding. It is also important to ac-
custom the rider to the motorcycle dur-
ing this time. Please read the following
information carefully.
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 seconds maximum) does
not harm the engine. Each full-throttle
acceleration should be followed with a
substantial rest period for the engine.
To allow the engine to cool down from
the temporary buildup of heat, cruise at
a lower engine speed.
After the first 5 hours of operation, thor-
oughly check the motorcycle for loose
parts, oil leakage and any other prob-
lems. Be sure to inspect and make ad-
justments thoroughly, especially cable
and drive chain slack and loose
spokes. In addition, check all fittings
and fasteners for looseness, and tight-
en if necessary.
NOTICE
ECA10270
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
OPERATION AND IMPORTANT RIDING POINTS
6-4
1
2
3
4
5
6
7
8
9
EAU17191
Parking
When parking, stop the engine, and
then turn the fuel cock lever to OFF“ ”.
WARNING
EWA10311
●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.
●Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn, increasing the
risk of a fuel leak and fire.
●Do not park near grass or other
flammable materials which
might catch fire.
7-1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU41951
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
WARNING
EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING
EWA15121
Turn off the engine when performing
maintenance unless otherwise
specified.
●A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
●Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 2-1 for more in-
formation about carbon monox-
ide.
EAU17311
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 maintenance work correctly.
TIP
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
PERIODIC MAINTENANCE AND ADJUSTMENT
7-2
1
2
3
4
5
6
7
8
9
EAU41765
Periodic maintenance and lubrication chart
TIP
●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.
NO. ITEM CHECK OR MAINTENANCE JOB
INITIAL THEREAFTER EVERY
10
hours
20
hours
40
hours
80
hours
40
hours
80
hours
160
hours
1 * Fuel line Check fuel hoses for cracks or damage.
Replace if necessary.
2Spark plug
Check condition.
Adjust gap and clean.
Replace if necessary.
3Air lter elementfiClean 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 limit
6 * Rear brake
Check operation.
Adjust brake pedal free play.
Replace brake shoes. Whenever worn to the limit
7 * Wheels
Check runout, spoke tightness and for
damage.
Tighten spokes if necessary.
PERIODIC MAINTENANCE AND ADJUSTMENT
7-3
2
3
4
5
6
7
8
9
8 * Tires
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
9 * Wheel bearings Check bearings for smooth operation.
Replace if necessary.
10 * Steering bearings
Check bearing assemblies for looseness.
Moderately repack with lithium-soap-based
grease.
11 Drive chain
Check chain slack/alignment and condi-
tion.
Adjust and lubricate chain with Yamaha
chain and cable lube thoroughly.
Every ride
Remove and clean.
12 * Chassis fasteners Check all chassis fitting and fasteners.
Replace if necessary.
13 Sidestand pivot Check operation.
Apply lithium-soap-based 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 if necessary.
16 * Carburetor
Check engine idling speed and starter
operation.
Clean.
Replace if necessary.
NO. ITEM CHECK OR MAINTENANCE JOB
INITIAL THEREAFTER EVERY
10
hours
20
hours
40
hours
80
hours
40
hours
80
hours
160
hours
PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
1
2
3
4
5
6
7
8
9
TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
17 * Autolube pump Check operation.
Correct if necessary.
18 Transmission oil
Check for oil leakage.
Correct if necessary.
Change (warm engine before draining).
19 * Control cables Apply Yamaha chain and cable lube or
engine oil 10W-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 lightly.
22 Brake pedal pivot
shaft Apply lithium-soap-based grease lightly.
23 * Cylinder head and
exhaust system
Check for leakage.
Tighten if necessary.
Decarbonize if necessary.
24 * Spark arrester Clean.
NO. ITEM CHECK OR MAINTENANCE JOB
INITIAL THEREAFTER EVERY
10
hours
20
hours
40
hours
80
hours
40
hours
80
hours
160
hours
PERIODIC MAINTENANCE AND ADJUSTMENT
7-5
2
3
4
5
6
7
8
9
EAU19603
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner s tool kit.’
To check the spark plug
1. 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).
TIP
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 elec-
trode erosion and excessive car-
bon 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.
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
1. Spark plug cap
1
1. Spark plug wrench
1
Specified spark plug:
PW80
NGK/BPR6HS
PW80Z NGK/BP6HS
DENSO/W20FP
1. Spark plug gap
Spark plug gap:
0.6 0.7 mm (0.024 0.028 in)– –
1
PERIODIC MAINTENANCE AND ADJUSTMENT
7-8
1
2
3
4
5
6
7
8
9
NOTICE
ECA10452
●In order to prevent clutch slip-
page (since the transmission oil
also lubricates the clutch), do
not mix any chemical additives.
Do not use oils with a diesel
specification of or oils of a“CD”
higher quality than specified. In
addition, do not use oils labeled
“ ”ENERGY CONSERVING II or
higher.
●Make sure that no foreign mate-
rial enters the transmission.
5. Start the engine, and then let it idle
for several minutes while checking
the transmission for oil leakage. If
oil is leaking, immediately turn the
engine off and check for the cause.
EAU41162
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 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.
Recommended transmission oil:
See page 9-1.
Oil change quantity:
0.65 L (0.69 US qt, 0.57 Imp.qt)
1. Air lter case coverfi
2. Screw
2
2
1
1. Sponge material
2. Air lter case coverfi
1
2
PERIODIC MAINTENANCE AND ADJUSTMENT
7-10
1
2
3
4
5
6
7
8
9
carbon deposits from the spark ar-
rester portion of the tailpipe and in-
side of the tailpipe housing.
3. Insert the tailpipe into the muffler,
and then install and tighten the bolt
to the specified torque.
TIP
Make sure to align the bolt hole when
inserting the tailpipe.
EAU39930
Adjusting the carburetor
The 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.
NOTICE
ECA10550
The carburetor has been set and ex-
tensively tested at the Yamaha fac-
tory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine.
EAU21340
Adjusting the engine idling
speed
The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before
making this adjustment.
TIP
●The engine is warm when it quickly
responds to the throttle.
●A diagnostic tachometer is needed
to make this adjustment.
1. Attach the tachometer to the spark
plug lead.
2. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
rection (a). To decrease the en-
gine idling speed, turn the screw in
direction (b).
1. Tailpipe
2. Spark arrester
3. Bolt
Tightening torque:
Tailpipe bolt:
7.5 Nm (0.8 m kgf, 5.5 ft lbf)· ·
23
1
PERIODIC MAINTENANCE AND ADJUSTMENT
7-11
2
3
4
5
6
7
8
9
TIP
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 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
cable free play, turn the adjusting
nut in direction (b).
3. Tighten the locknut.
1. Throttle stop screw
Engine idling speed:
1650 1750 r/min–
1
(a)
(b)
1. Throttle cable free play
1
1. Locknut
2. Adjusting nut
12
(a)
(b)
PERIODIC MAINTENANCE AND ADJUSTMENT
7-12
1
2
3
4
5
6
7
8
9
EAU39821
Tires
To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING
EWA14381
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.
●The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires 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 immediately.
Tire information
This motorcycle is equipped with spoke
wheels and tube tires.
WARNING
EWA10461
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, which
could lead to an accident.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
WARNING
EWA14390
●Have a Yamaha dealer replace
excessively worn tires. Operat-
ing the motorcycle with exces-
Standard tire air pressure:
Front:
100 kPa (1.00 kgf/cm
2, 15 psi)
Rear:
100 kPa (1.00 kgf/cm
2, 15 psi)
1. Tire sidewall
2. Tire tread depth
Minimum tire tread depth (front and
rear):
4.0 mm (0.16 in)
1
2
Front tire:
Size:
2.50-14 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY
Rear tire:
Size:
3.00-12 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY
PERIODIC MAINTENANCE AND ADJUSTMENT
7-15
2
3
4
5
6
7
8
9
WARNING
EWA10680
●After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.
●If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this ad-
justment.
●After adjusting the brake pedal
free play, check the operation of
the 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 7-22.
●To remove the rear wheel: See
page 7-24.
Front
Rear
If the lining thickness of a brake shoe is
less than 1.5 mm (0.06 in), have a
Yamaha dealer replace the brake
shoes as a set.
TIP
Be sure to measure the brake lining at
the thinnest portion.
1. Brake pedal free play adjusting nut
1
(a)
(b)
PERIODIC MAINTENANCE AND ADJUSTMENT
7-16
1
2
3
4
5
6
7
8
9
EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.
TIP
When checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as 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 swingarm.
2. To tighten the drive chain, turn the
drive chain slack adjusting nut at
each end of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting nut at each end
of the swingarm in direction (b),
and then push the rear wheel for-
ward. NOTICE: Improper drive
chain slack will overload the en-
gine 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 with-
Drive chain slack:
40.0 53.0 mm (1.57 2.09 in) – –
1. Drive chain slack
1
1. Brake pedal free play adjusting nut
2. Locknut
3. Drive chain slack adjusting nut
4. Wheel axle
2
1
4
3
PERIODIC MAINTENANCE AND ADJUSTMENT
7-18
1
2
3
4
5
6
7
8
9
EAU41842
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
housing of cables may result in in-
ternal rusting and cause interfer-
ence with cable movement. Replace
damaged cables as soon as possi-
ble to prevent unsafe condi-
tions.[EWA10711]
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 pump is a vital and so-
phisticated component of the engine,
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
Recommended lubricant:
Yamaha Chain and Cable Lube or
4-stroke engine oil
PERIODIC MAINTENANCE AND ADJUSTMENT
7-20
1
2
3
4
5
6
7
8
9
EAU23272
Checking the front 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 vehicle so
there is no danger of it falling
over.[EWA10751]
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
NOTICE
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23283
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground. (See page 7-21 for more
information.) WARNING! To
avoid injury, securely support
the vehicle so there is no danger
of it falling over.[EWA10751]
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.
PERIODIC MAINTENANCE AND ADJUSTMENT
7-21
2
3
4
5
6
7
8
9
EAU23290
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAU24350
Supporting the motorcycle
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle 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
MOTORCYCLE CARE AND STORAGE
8-4
2
3
4
5
6
7
8
9
“ ”OFF .
3. Drain the carburetor 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. 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 several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap. WARNING! To
prevent damage or injury
from sparking, make sure to
ground the spark plug elec-
trodes while turning the en-
gine over. [EWA10951]
6. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sidestand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
TIP
Make any necessary repairs before
storing the motorcycle.
9-1
1
2
3
4
5
6
7
8
9
SPECIFICATIONS
EAU2633X
Dimensions:
Overall length:
1540 mm (60.6 in)
Overall width:
640 mm (25.2 in)
Overall height:
880 mm (34.6 in)
Seat height:
635 mm (25.0 in)
Wheelbase:
1055 mm (41.5 in)
Ground clearance:
185 mm (7.28 in)
Minimum turning radius:
1700 mm (66.9 in)
Weight:
With oil and fuel:
61.0 kg (134 lb)
Noise and vibration level:
Noise level (77/311/EEC):
PW80 79.3 dB(A)
Vibration on seat (EN1032, ISO5008):
PW80 Will not exceed 0.5 m/s 2
Vibration on handlebar (EN1032, ISO5008):
PW80 Will not exceed 2.5 m/s 2
Engine:
Engine type:
Air cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
79 cm 3
Bore × stroke:
47.0 × 45.6 mm (1.85 × 1.80 in)
Compression ratio:
6.60 :1
Starting system:
Kickstarter
Lubrication system:
Separate lubrication (Yamaha autolube)
Engine oil:
Type:
YAMALUBE 2 or 2-stroke engine oil (JASO
FC grade) or (ISO EG-C or EG-D grade)
Engine oil quantity:
Quantity:
0.75 L (0.79 US qt, 0.66 Imp.qt)
Transmission oil:
Type:
YAMALUBE 4 (10W-40) or SAE 10W-40
Oil change quantity:
0.65 L (0.69 US qt, 0.57 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
PW80 Regular unleaded gasoline only
PW80Z 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)
Carburetor:
Type × quantity:
VM15SC x 1
Spark plug (s):
Manufacturer/model:
PW80
NGK/BPR6HS
PW80Z NGK/BP6HS
DENSO/W20FP
Spark plug gap:
0.6 0.7 mm (0.024 0.028 in)– –
Clutch:
Clutch type:
Wet, multiple-disc automatic
Transmission:
Primary reduction system:
Helical gear
Primary reduction ratio:
66/21 (3.143)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
32/15 (2.133)
Transmission type:
Constant mesh 3-speed
Operation:
Left foot operation
Gear ratio:
1st:
39/12 (3.250)
2nd:
29/16 (1.812)
3rd:
22/17 (1.294)
Chassis:
Frame type:
Steel tube backbone
Caster angle:
INDEX
A
Air filter element, cleaning .........................7-8
Autolube pump, adjusting ........................7-19
B
Brake lever ................................................4-2
Brake lever, checking and lubricating......7-19
Brake lever free play, adjusting ...............7-14
Brake pedal ...............................................4-2
Brake pedal, checking and lubricating.....7-19
Brake pedal free play, adjusting ..............7-15
Brake shoes, checking ............................7-15
C
Cables, checking and lubricating.............7-18
Carburetor, adjusting ...............................7-10
Care...........................................................8-1
D
Drive chain, cleaning and lubricating.......7-18
Drive chain slack .....................................7-16
E
Engine break-in .........................................6-3
Engine idling speed .................................7-11
Engine oil...................................................4-4
Engine, starting a warm.............................6-2
Engine stop switch.....................................4-1
F
Front fork, checking .................................7-20
Fuel............................................................4-3
Fuel cock ...................................................4-5
Fuel tank breather hose.............................4-4
Fuel tank cap .............................................4-2
H
Handlebar switch .......................................4-1
I
Identification numbers ............................. 10-1
K
Kickstarter ................................................. 4-6
L
Labels, location ......................................... 1-1
M
Matte color, caution ................................... 8-1
Model label.............................................. 10-1
P
Parking ...................................................... 6-4
Part locations............................................. 3-1
Periodic maintenance and lubrication
chart ........................................................ 7-2
Power reduction plate................................ 4-1
Power reduction plate, removing............... 7-6
S
Safety information ..................................... 2-1
Seat ........................................................... 4-7
Shifting ...................................................... 6-2
Shift pedal ................................................. 4-1
Shock absorber assembly......................... 4-7
Sidestand .................................................. 4-8
Sidestand, checking and lubricating........ 7-20
Spark arrester, cleaning ............................ 7-9
Spark plug, checking ................................. 7-5
Specifications ............................................ 9-1
Starter (choke) lever.................................. 4-6
Starting and warming up a cold engine..... 6-1
Steering, checking................................... 7-21
Storage...................................................... 8-3
Supporting the motorcycle....................... 7-22
T
Throttle cable free play, adjusting ........... 7-11
Throttle grip and cable, checking and
lubricating ............................................. 7-18
Tires........................................................ 7-12
Tool kit ...................................................... 7-1
Transmission oil ........................................ 7-7
Troubleshooting ...................................... 7-26
Troubleshooting chart ............................. 7-28
V
Vehicle identification number .................. 10-1
W
Wheel bearings, checking....................... 7-21
Wheel (front) ........................................... 7-22
Wheel (rear)............................................ 7-25
Wheels.................................................... 7-13
Produkt Specifikationer
| Mærke: | Yamaha |
| Kategori: | Motor |
| Model: | PW80 (2009) |
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