2008 YAMAHA PW80 ABS

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

INSTRUMENT AND CONTROL FUNCTIONS
3-7
2
34
5
6
7
8
9
2. Place the seat in the original posi-
tion, and then tighten the nuts.
NOTE:

Make sure that the seat is properly se-
cured before riding.
EAU15090
Shock absorber
WARNING

EWA10220
This shock absorber contains highly
pressurized nitrogen gas. For prop-
er handling, read and understand
the following information before
handling the shock absorber. The
manufacturer cannot be held re-
sponsible for property damage or
personal injury that may result from
improper handling.

Do not tamper with or attempt to
open the gas cylinder.

Do not subject the shock ab-
sorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.

Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping per-
formance.

Always have a Yamaha dealer
service the shock absorber.
1. Seat holder
2. Projection
2
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
2
3
4
5
67
8
9
8*Tires
Check tread depth and for damage.Replace if necessary.Check air pressure.Correct if necessary.
9*Wheel bearingsCheck bearings for smooth operation.Replace if necessary.
10 *Steering bearingsCheck bearing assemblies for looseness.Moderately repack with lithium-soap-based
grease.
11Drive chainCheck chain slack/alignment and condi-
tion.Adjust and lubricate chain with Yamaha
chain and cable lube thoroughly.Every rideRemove and clean.
12 *Chassis fastenersCheck all chassis fitting and fasteners.Correct if necessary.
13Sidestand pivotCheck operation.Apply lithium-soap-based grease (all-pur-
pose grease) lightly.
14 *Front forkCheck operation and for oil leakage.Replace if necessary.
15 *Shock absorber
assemblyCheck operation and for oil leakage.Replace if necessary.
16 *CarburetorCheck engine idling speed and starter
operation.Clean.Replace if necessary. NO. ITEM CHECK OR MAINTENANCE JOBINITIAL THEREAFTER EVERY
10
hours20
hours40
hours80
hours40
hours80
hours160
hours

MOTORCYCLE CARE AND STORAGE
7-2
1
2
3
4
5
6
7
8
9contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.


Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.

For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain or near the seaSince sea salt is extremely corrosive,
carry out the following steps after each
ride in the rain or near the sea.
1. Clean the motorcycle with cold wa-
ter and a mild detergent, after the
engine has cooled down.CAUTION:

ECA10790
Do not use warm water since it in-
creases the corrosive action of the
salt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stain-
less-steel parts, including the ex-
haust system. (Even the thermally
induced discoloring of stain-
less-steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
WARNING

EWA14500

Make sure that there is no oil or

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

3rd:
22/17 (1.294)
Chassis:
Frame type:
Steel tube backbone
Caster angle:
26.00 °
Trail:
62.0 mm (2.44 in)
Front tire:
Type:
With tube
Size:
2.50-14 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY
Rear tire:
Type:
With tube
Size:
3.00-12 4PR
Manufacturer/model:
CHENG SHIN/KNOBBY
Loading:
Maximum rider weight:
40.0 kg (88 lb)
Maximum load:
40 kg (88 lb)
* (Total weight of rider, cargo and
accessories)
Tire air pressure (measured on cold
tires):
Front:
100 kPa (15 psi) (1.00 kgf/cm
2

)
Rear:
100 kPa (15 psi) (1.00 kgf/cm
2

)
Front wheel:
Wheel type:
Spoke wheel
Rim size:
14x1.40
Rear wheel:
Wheel type:
Spoke wheel
Rim size:
12x1.60
Front brake:
Type:
Drum brake
Operation:
Right hand operation
Rear brake:
Type:
Drum brake
Operation:
Right foot operation
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
110.0 mm (4.33 in)
Rear suspension:
Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
95.0 mm (3.74 in)
Electrical system:
Ignition system:
CDI

INDEX
A
Accessories and replacement parts ........ 6-14
Air filter element, cleaning......................... 6-8
Autolube pump, adjusting ....................... 6-19
B
Brake and shift pedals, checking and
lubricating ............................................. 6-20
Brake lever ................................................ 3-2
Brake lever, checking and lubricating ..... 6-20
Brake lever free play, adjusting............... 6-14
Brake pedal ............................................... 3-2
Brake pedal free play, adjusting.............. 6-15
Brake shoes, checking ............................ 6-16
C
Cables, checking and lubricating ............ 6-19
Carburetor, adjusting .............................. 6-10
Care .......................................................... 7-1
D
Drive chain, cleaning and lubricating ...... 6-18
Drive chain slack ..................................... 6-16
E
Engine break-in ......................................... 5-3
Engine idling speed................................. 6-11
Engine oil .................................................. 3-4
Engine, starting a warm ............................ 5-2
Engine stop switch .................................... 3-1
F
Front fork, checking ................................ 6-21
Fuel ........................................................... 3-3
Fuel cock................................................... 3-5
Fuel tank breather hose ............................ 3-4
Fuel tank cap ............................................ 3-2
H
Handlebar switch ...................................... 3-1
I
Identification numbers................................9-1
K
Kickstarter ..................................................3-6
L
Labels, location of ......................................1-4
M
Matte color, caution ...................................7-1
Model label ................................................9-1
P
Parking.......................................................5-4
Part locations .............................................2-1
Periodic maintenance and lubrication
chart ........................................................6-2
Power reduction plate ................................3-1
Power reduction plate, removing ...............6-6
Pre-operation check list .............................4-2
S
Safety information ......................................1-1
Seat ...........................................................3-6
Shifting .......................................................5-2
Shift pedal ..................................................3-1
Shock absorber..........................................3-7
Sidestand, checking and lubricating ........6-21
Spark arrester, cleaning.............................6-9
Spark plug, checking .................................6-5
Specifications.............................................8-1
Starter (choke) lever ..................................3-6
Starting and warming up a cold engine .....5-1
Steering, checking ...................................6-22
Storage ......................................................7-3
Supporting the motorcycle .......................6-23
T
Throttle cable free play, adjusting ............6-11Throttle grip and cable, checking and
lubricating .............................................. 6-19
Tires ........................................................ 6-12
Tool kit ....................................................... 6-1
Transmission oil ........................................ 6-7
Troubleshooting....................................... 6-27
Troubleshooting chart.............................. 6-28
V
Vehicle identification number .................... 9-1
W
Wheel bearings, checking ....................... 6-22
Wheel (front)............................................ 6-23
Wheel (rear) ............................................ 6-26
Wheels .................................................... 6-13