🏷️ Basic Information

Make:

Yamaha

Model:

PW80

Model Year:

2006

Vehicle Type:

Off-road Motorcycle / Mini Bike

Product Name:

Yamaha PW80 All 2006 Models Workshop Service Repair Manual

👋 Introduction

Market Segment:

Entry-level off-road motorcycle for junior riders and recreational use. Known for its reliability and ease of maintenance.

Competitors:

Honda XR50/CRF50F, Suzuki JR50, Kawasaki KX65 (though slightly higher displacement).

Ease Of Use:

Simple operation, automatic clutch (on some variations, though PW80 is typically manual clutch) and straightforward mechanics make it ideal for learning.

Durability:

Robust construction and proven Yamaha engineering contribute to its longevity.

Manual Value:

Essential for owners and technicians to maintain peak performance, diagnose issues, and perform repairs efficiently, maximizing the lifespan of the PW80.

📋 Manual Details

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital (likely PDF, as implied by common sales of service manuals)

Coverage Scope:

All 2006 Models

Page Count:

Estimated 200-300 pages (typical for comprehensive motorcycle workshop manuals)

📖 Manual Coverage

Engine:

Complete overhaul, assembly, disassembly, troubleshooting, tuning, specifications

Transmission:

Gearbox inspection, maintenance, repair, lubrication

Fuel System:

Carburetor tuning, cleaning, rebuilding, fuel tank and line maintenance

Cooling System:

Air cooling system analysis and maintenance

Ignition System:

Spark plug, CDI unit, stator coil testing and replacement

Exhaust System:

Muffler and pipe inspection, maintenance

Clutch System:

Clutch adjustment, plate inspection and replacement

Suspension Front:

Fork oil change, seal replacement, damper inspection

Suspension Rear:

Shock absorber inspection, linkage lubrication and maintenance

Brakes Front:

Drum brake inspection, adjustment, lining replacement

Brakes Rear:

Drum brake inspection, adjustment, lining replacement

Wheels And Tires:

Tire pressure, tread wear inspection, spoke tension, wheel bearing maintenance

Electrical System:

Wiring diagrams, lighting, horn, battery maintenance

Frame And Bodywork:

Chassis inspection, seat, fenders, handlebars, controls maintenance

Maintenance:

Routine checks, lubrication, filter replacement, spark plug replacement, chain adjustment

Troubleshooting:

Diagnostic flowcharts, common problem identification and solutions

Repair:

Component replacement, seal and gasket renewal, part adjustments

Overhaul:

Complete engine, transmission, and suspension component overhauls

Installation:

Instructions for fitting new parts and components

Special Tools:

Identification and usage of specialized tools required for repairs

Depth:

Comprehensive, covering detailed disassembly, assembly, torque specifications, and diagnostic procedures for all major systems.

📊 Manual Specifications

File Format:

Digital PDF (searchable text and high-resolution images are standard for quality manuals)

Print Quality:

High resolution, suitable for printing individual pages or the entire manual.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

Searchability:

Typically includes searchable text for quick access to specific information.

⚙️ Engine Specifications

Engine Type:

2-stroke, air-cooled

Displacement:

79 cc (cc)

Bore X Stroke:

Approx. 49.0 mm x 42.0 mm

Compression Ratio:

Approx. 6.5:1

Power Output:

Approximately 7.0 HP @ 7,000 RPM (varies slightly by market/tuning)

Torque:

Approximately 0.7 kgf-m @ 6,000 RPM (varies slightly)

Carburetor Model:

Mikuni VM20 (typical)

Fuel Type:

Unleaded gasoline (min. 87 octane recommended)

Fuel Oil Mix:

50:1 ratio (Yamalube 2-stroke oil or equivalent recommended by Yamaha)

Fuel Tank Capacity:

Approx. 3.0 Liters (0.79 US gal)

🔧 Transmission

Transmission Type:

Constant mesh, 5-speed

Clutch Type:

Wet, multi-plate

Gear Ratios:

Typically: 1st: 2.833, 2nd: 1.867, 3rd: 1.333, 4th: 1.045, 5th: 0.913 (Exact ratios can vary slightly)

Final Drive:

Chain drive

Transmission Oil Capacity:

Approx. 0.9 Liter (0.95 US qt) of SAE 80 API GL-4 hypoid gear oil

📐 Dimensions

Overall Length:

Approx. 1640 mm (64.6 in)

Overall Width:

Approx. 700 mm (27.6 in)

Overall Height:

Approx. 970 mm (38.2 in)

Seat Height:

Approx. 720 mm (28.3 in)

Wheelbase:

Approx. 1140 mm (44.9 in)

Dry Weight:

Approx. 62 kg (137 lbs)

Wet Weight:

Approx. 66 kg (146 lbs) (with all fluids)

Gross Vehicle Weight Rating:

Not typically specified for this class of vehicle, but operator + gear should be considered.

🛡️ Safety Features

Safety Standards:

Designed to meet applicable safety standards for off-road motorcycles.

Braking System:

Drum brakes front and rear for reliable stopping power suitable for its performance level.

Tire Type:

Knobby tires for off-road traction and stability.

Frame Construction:

Durable steel frame designed for off-road use and rider control.

Lighting:

Headlight and taillight for visibility, though typically not street-legal without modification.

💡 Technology Features

Infotainment System:

N/A (Basic off-road motorcycle, no advanced electronic infotainment)

Ignition Control:

CDI (Capacitor Discharge Ignition) for reliable spark generation.

🔧 Maintenance

Oil Change Transmission:

Every 6,000 km (3,700 miles) or 12 months (refer to manual for precise intervals).

Spark Plug Check:

Every 1,000 km (620 miles) or 6 months.

Air Filter Cleaning:

Every 500 km (310 miles) or more frequently in dusty conditions.

Chain Lubrication Adjustment:

Every 500 km (310 miles) or as needed.

Brake Adjustment:

As needed, check for free play.

Transmission Oil Spec:

SAE 80 API GL-4 hypoid gear oil.

2 Stroke Oil Spec:

Yamalube 2-stroke oil (or equivalent API TC, JASO FD certified) mixed at 50:1.

Fork Oil Spec:

Yamaha Genuine Fork Oil 10W (or equivalent SAE 10W fork oil)

Carburetor Fouling:

Common issue with 2-stroke engines, especially if not run regularly or with incorrect fuel mix. Manual covers cleaning and tuning.

Clutch Slippage:

Can occur due to worn clutch plates or improper adjustment. Manual details inspection and replacement.

Air Filter Clogging:

Essential to keep clean for proper engine performance and longevity, especially in dusty environments.

Exhaust Port Fouling:

Carbon buildup can occur, requiring periodic cleaning as per the manual's recommendations.

📚 Vehicle History

Brand Focus:

Yamaha is a renowned Japanese manufacturer known for its high-performance motorcycles, musical instruments, and marine products. In motorcycles, they have a strong legacy in racing and recreational vehicles.

Pw Series Origin:

The PW series (Pee-Wee) has a long history of being Yamaha's entry-level off-road offering, designed to introduce young riders to motorcycling. The PW80 has been a consistent performer in this segment for decades.

Production Period:

The PW80 has been in continuous production with minor updates for many years, making it a staple in the mini-bike category.

Manufacturing Origin:

Primarily manufactured in Japan by Yamaha Motor Corporation.

🏆 Awards & Recognition

Industry Reputation:

Consistently recognized as a reliable, durable, and excellent platform for introducing young riders to off-road motorcycling.

Owner Satisfaction:

Generally high owner satisfaction due to its simple mechanics, durability, and fun factor.

Emissions Compliance:

Meets emissions standards for off-road recreational vehicles in its production year.