Yamaha PW80(X) User manual

3RV-28199-8H
PW80(X)
OWNER’S MANUAL
MANUEL DU PROPRIÉTAIRE
BEDIENUNGSANLEITUNG

PRINTED ON RECYCLED PAPER
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2007.4–0.7×1 !
(E, F, G)
AUF RECYCLINGPAPIER GEDRUCKT
IMPRIMÉ SUR PAPIER RECYCLÉ
PRINTED ON RECYCLED PAPER
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2007.4–0.7×1 !
(E, F, G)
AUF RECYCLINGPAPIER GEDRUCKT
IMPRIMÉSUR PAPIER RECYCLÉ

3RV-28199-8H-E0
PW80(X)
OWNER’S 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.

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 OPERA-
TOR 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
EAU41090
Particularly important information is distinguished in this manual by the following notations:
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.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
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.
WARNING
CAUTION:
NOTE:

IMPORTANT MANUAL INFORMATION
WARNING
EWA10030
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
WARNING
EWA14350
THIS MOTORCYCLE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS ILLEGAL TO OPER-
ATE 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 OPERAT-
ING THIS MOTORCYCLE.
*Product and specifications are subject to change without notice.

IMPORTANT MANUAL INFORMATION
EAU10200
PW80(X)
OWNER’S MANUAL
©2007 by Yamaha Motor Co., Ltd.
1st edition, March 2007
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 ...................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 ............................................6-14
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 ........................................... 7-1
Matte color caution .......................... 7-1
Care ................................................ 7-1

TABLE OF CONTENTS
Storage ............................................7-3
SPECIFICATIONS ..............................8-1
CONSUMER INFORMATION ..............9-1
Identification numbers .....................9-1

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
1-2
1
Loading and accessories
Adding accessories to your motorcycle
can adversely affect stability and han-
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:
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 distrib-
ute the weight as evenly as possi-
ble on both sides of the motorcycle
to minimize imbalance or instabili-
ty.
● Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories 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 re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac-
cessories.
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 suspen-
sion travel, steering travel or con-
trol operation.
● Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic 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 aerody-
namic effects. 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

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.

SAFETY INFORMATION
1-4
1
EAU41370
Location of important labels
Please read the following important labels carefully before operating this vehicle.
1
3
2

SAFETY INFORMATION
1-5
1
4
5

SAFETY INFORMATION
1-6
1
Before you operate this vehicle, read the owner’s manual.
5PA-21568-00
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 vehículo, lea el Manual del Propietario.
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
4
5
1
2
3

2-1
1
2
3
4
5
6
7
8
9
DESCRIPTION
EAU10410
Left view
123 4 5
67
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)

DESCRIPTION
2-2
2
3
4
5
6
7
8
9
EAU10420
Right view
6
12
3
45
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)

DESCRIPTION
2-3
1
2
3
4
5
6
7
8
9
EAU10430
Controls and instruments
12
43
1. Right handlebar switch (page 3-1)
2. Brake lever (page 3-2)
3. Throttle grip (page 6-11)
4. Fuel tank cap (page 3-2)