2011 YAMAHA PW80 engine

EAU48181
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 2006/42/EC
We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan,
declare in sole responsibility, that the product
PW80 (JYA4BC00000110437– )
(Make, model)
to which this declaration applies, conforms to the essential health
and safety requirements of Directive 2006/42/EC(If applicable)and to the other relevant Directives of EEC
2004/108/EC
(Title and/or number and date of issue of the other Directives of EEC)
(If applicable)
To effect correct application of the essential health and safety requirements
stated 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
Executive Officer
Commuter Vehicle Section
Engineering Section
Motorcycle Business Operation
YAMAHA MOTOR CO., LTD.
Date of Issue
4 March , 2010
– –
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INTRODUCTIONAN 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 is equipped 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.
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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 ....................................... 4-8FOR 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
PERIODIC MAINTENANCE AND
ADJUSTMENT................................... 7-1
Owner’s tool kit .............................. 7-1
Periodic maintenance chart for the
emission control system ............. 7-2
General maintenance and
lubrication chart .......................... 7-3
Checking the spark plug ................ 7-6
Removing the power reduction
plate ............................................ 7-7
Transmission oil ............................. 7-8
Cleaning the air filter element ........ 7-9
Cleaning the spark arrester ......... 7-10
Adjusting the carburetor ............... 7-11
Adjusting the engine idling
speed ........................................ 7-11
Adjusting the throttle cable free
play ........................................... 7-12
Tires ............................................. 7-13Spoke wheels ............................... 7-14
Adjusting the brake lever free
play ........................................... 7-14
Adjusting the brake pedal free
play ........................................... 7-15
Checking the shift pedal ............... 7-16
Checking the front and rear brake
shoes ........................................ 7-16
Drive chain slack .......................... 7-17
Cleaning and lubricating the drive
chain ......................................... 7-19
Checking and lubricating the
cables ....................................... 7-19
Checking and lubricating the
throttle grip and cable ............... 7-19
Adjusting the Autolube pump ....... 7-20
Checking and lubricating the
brake lever ................................ 7-20
Checking and lubricating the
brake pedal ............................... 7-20
Checking and lubricating the
sidestand .................................. 7-21
Checking the front fork ................. 7-21
Checking the steering .................. 7-22
Checking the wheel bearings ....... 7-22
Supporting the motorcycle ........... 7-22
Front wheel .................................. 7-23
Rear wheel ................................... 7-25
Troubleshooting ........................... 7-27
Troubleshooting chart .................. 7-28
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SAFETY INFORMATION
2-2
2


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 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.
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SAFETY INFORMATION
2-3
2


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-
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 weightas 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 ac-
cessories are securely attached to
the motorcycle before riding.
Check accessory mounts fre-
quently.
Properly adjust the suspension
for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure 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 aposition 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.
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SAFETY INFORMATION
2-4
2


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-
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 7-13 for tire
specifications and more information on
replacing your tires.
Transporting the motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.


Remove all loose items from the
motorcycle.


Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.


Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.


Shift the transmission in gear (for
models with a manual transmis-
sion).


Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or parts
that could break). Choose the lo-
cation for the straps carefully so
the straps will not rub against
painted surfaces during transport.


The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the mo-
torcycle will not bounce excessive-
ly during transport.
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DESCRIPTION
3-1
3
EAU10410
Left view
1
23 4 5
6 7
1. Air filter element (page 7-9)
2. Fuel cock (page 4-5)
3. Throttle stop screw (page 7-11)
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)
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DESCRIPTION
3-3
3
EAU10430
Controls and instruments
12
43
1. Engine stop switch (page 4-1)
2. Brake lever (page 4-2)
3. Throttle grip (page 7-12)
4. Fuel tank cap (page 4-2)
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