Yamaha PW80(T) Manual Download

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Summary of Contents for PW80(T)

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Page 2: ...ects or other reproductive harm YAMAHA LIT CALIF 65 01 PW80T OWNER S SERVICE MANUAL 2004 by Yamaha Motor Corporation U S A 1st Edition April 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 18 30 ...

Page 3: ...ill provide you with a good basic understanding of the features operation and basic maintenance and inspection items of this vehicle If you have any questions regarding the operation or main tenance of your machine please consult your Yamaha dealer Particularly important information is distinguished in this manual by the following notations A WARNING NOTE The Safety Alert Symbol means ATTENTION BE...

Page 4: ...fueling Take care not to spill on the engine or exhaust pipe muffler when refuel ing Never refuel while smoking or in the vicinity of an open flame 2 If you should swallow some gasoline or inhale a lot of gasoline vapor or allow some gasoline to get in your eye s see your doctor immediately If any gasoline spills on your skin or clothing immediately wash it with soap and water and change your clot...

Page 5: ...ts the output of the engine As your child s riding skills improve you can remove the power reduction plate Since removal of this plate will result in a significant increase in power Please use this safety device to match the machine s output to your child s riding skills A power reduction plate is provided in the cylinder exhaust port Removal of this plate adds to the vehicle output power ...

Page 6: ...k plugs and brake shoes or pads Q What are some examples of abnormal strain neglect or abuse A These terms are general and overlap each other in areas Specific examples include If your machine requires warranty service you must take it to any authorized Yamaha motorcycle dealer within the continental United States Be sure to bring your warranty registration identification or other valid proof of t...

Page 7: ...A SAFETY INFORMATION 1 Don t ride it on the street 2 Don t run the engine inside a building ...

Page 8: ...3 This is a one seater motorbike Don t give any person a ride 4 Let s learn how to ride properly Ask your parents for any question ...

Page 9: ...5 When riding the machine be sure to wear a helmet as illustrated m IIM Gaggles 11 _______ Mouth guard Long sleeved trainer 6 When going for riding be sure to be with your family Never go alone ...

Page 10: ...7 Belore riding the nachine ask your parents to check the machine ver i carelullY 8 Don t touch the areas shown beloW or you ll get burnt in the hand ...

Page 11: ...9 Don t touch rotating or moving parts 10 Before starting the engine be sure to shift the transmission into neutral ...

Page 12: ...AINTENANCE AND ADJUSTMENT 7 MAINTENANCE AND LUBRICATION SCHEDULE CHART 7 SPECIAL TOOLS 8 ADJUSTMENT 10 MAINTENANCE AND MINOR REPAIRS 19 PREPARATION FOR SERVICE 19 ENGINE 19 CHASSIS 31 MISCELLANEOUS 37 ELECTRICAL COMPONENTS AND WIRING DIAGRAM 37 TROUBLESHOOTING 40 CLEANING AND STORAGE 41 SPECIFICATIONS 42 CABLE ROUTING 50 NOISE REGULATION 52 MAINTENANCE RECORD 52 ...

Page 13: ...stamped into the steering head pipe 1 Vehicle identification number NOTE The vehicle identification number is used to identify your machine and may be used to register your machine with the licensing authority in your state ENGINE SERIAL NUMBER The engine serial number is stamped on the left side of the engine on top of the crankcase 1 Engine serial number NOTE The first digits of these numbers ar...

Page 14: ...stem The engine will not start or run when the engine stop switch is turned to OFF 1 ENGINE STOP switch FUEL COCK The fuel cock supplies fuel from the tank to car buretor while filtering the fuel The fuel cock has the three positions 2 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 fu...

Page 15: ...er CD away from the en gine Push the starter down lightly with your foot until the gears engage then kick smoothly and forcefully to start the engine 1 Kick starter 3 FUEL TANK CAP Remove the fuel tank cap by turning counter clockwise A WARNING Do not overfill the fuel tank Avoid spill ing fuel on the hot engine 1 Fuel tank cap FUEL AND OIL FUEL Use regular gasoline Always use fresh name brand gas...

Page 16: ...ip stick com pletely out and then just rest the stick in the hole NOTE When checking transmission oil level with the dip stick let the unscrewed dip stick just rest on the case threads Also be sure the machine is positioned straight up 4 1 Dip stick 2 Maximum level 3 Minimum level Recommended oil Yamalube 4 10W30 or SAE 10W30 type SE motor oil Oil capacity Total amount 0 75 L 0 66 Imp qt 0 79 US q...

Page 17: ...PRE OPERATION CHECK is not working properly have it inspected and repaired before operating the machine BRAKE FRONT AND REAR Check for correct play in the brake lever and pedal and make sure they are working proper ly Check the brakes at tow speed shortly after starting out If the play is correct make an adjustment WHEEL Check the wheel runout and damage and check the tightness of spokes TIRES Che...

Page 18: ...rd with a cold engine To see whether or not the engine is warm see if it responds to throttle normally with the starter choke turned off A WARNING Before starting off be sure to turn up or remove the side stand Failure to retract the side stand completely can result in a serious accident when you try to turn a corner ENGINE BREAK IN 1 Prior to starting fill fuel tank with gasoline and oil tank wit...

Page 19: ...able Lube or WD 40 0 0 Front forks Drain completely Yamaha fork oil 20 wt or equivalent 0 0 Steering ball race Inspect thoroughly Pack Medium weight wheel bearing grease 0 0 moderately Wheel bearings Do not over pack yearly or Medium weight wheel bearing grease 0 0 0 Periodic maintenance intervals Initial hour Thereafter Item Remarks every hour 10 20 40 80 40 80 160 Brake system complete Check I A...

Page 20: ... checking the ignition timing YM 33277 A 3 Rotor Holding Tool P N YU 1235 This tool is used when loosening or tightening the flywheel magneto securing nut YU 1235 8 FOR CHASSIS SERVICE 1 Ring Nut Wrench P N YU 1268 This tool is used to loosen or tighten the steer ing ring nut YU 1268 FOR ELECTRICAL SERVICE 1 Yamaha Pocket Tester P N YU 3112 C Use this tool to inspect the coil resistance out put vo...

Page 21: ...LUBRICATION 9 ...

Page 22: ...d 10 This situation is quite common during the engine break in period However use the standard plug If the insulator tip shows a very light tan or white color or is actually pure white or if the electrodes show signs of melting then a spark plug with a col der heat range is required NOTE lf a torque wrench is not available when you are installing a spark plug a good estimate of the correct torque ...

Page 23: ... simp ly switch filters between practices and motos Follow these instructions to service foam air filters correctly 1 Remove the cleaner case cap 1 Cleaner case cap 2 Pull out the element and guide from the cleaner case cap 1 Guide 2 Air filter element 11 3 Using uncontaminated cleaning solvent thoroughly wash the filter element wash it gently to avoid damage 4 Squeeze the solvent from the filter ...

Page 24: ...fold fittings for an air tight seal Tighten all fittings thoroughly to avoid the possibility of unfiltered air enter ing the engine 12 Never operate the engine with the air filter element removed This will allow un filtered air to enter causing rapid wear and possible engine damage Additionally operation without the filter element will affect carburetor jetting with subsequent poor performance and...

Page 25: ...y and check to see that the match mark on the adjust pulley is aligned with the pump case mark If not loosen the pump cable locknut and make adjustment by turning the adjuster 1 Set position 2 Mark 3 Pump case mark 13 1 Adjuster 2 Lock nut NOTE After adjusting be sure to tighten the lock nut completely 2 Air bleeding The oil pump just be bled after the oil pipe or oil pump is reinstalled a Remove ...

Page 26: ... 20 mm 0 39 0 79 in should be maintained Free play can be ad justed at handlebar lever and brake shoe plate 1 Loosen the lock nut on the brake lever holder and then fully turn the adjuster in 2 Loosen the lock nut on the shoe plate and turn the adjuster in or out until proper ad justment is achieved 3 Unless the shoe plate adjuster helps bring a proper play turn the lever holder ad juster 4 Tighte...

Page 27: ...the same amount to maintain correct axle alignment There are marks on each side of rear arm and on each chain puller use them to check for proper alignment 1 Rear wheel axle nut a Marks for alignment 2 Lock nut 3 Adjusting nut 4 After adjusting be sure to tighten the rear wheel axle nut Tightening torque 60 Nm 6 0 m kg 43 ft lb 5 Also tighten the lock nuts against the rear arm lightening torque 7 ...

Page 28: ...nd of the front fork and try to move forward and backward STEERING HEAD ADJUSTMENT 1 To adjust loosen the steering shaft bolt 2 Use the Ring Nut Wrench to tighten the ring nut 16 1 Steering shaft bolt 2 Ring Nut Wrench Forks must swing from lock to lock without binding or catching 3 Tighten the steering shaft bolt Tightening torque 42 Nm 4 2 m kg 30 ft lb NOTE Steering head disassembly must be per...

Page 29: ...er for less damping heavier for more damping 11 After filling slowly pump the outer tube up and down to distribute the oil NOTE Adjust the oil levels in both right and left front forks so they are even 12 Inspect 0 ring on fork cap bolt and replace if damaged Install the fork cap bolt and torque to specification Fork cap bolt torque 40 Nm 4 0 m kg 29 ft lb 1 Cap bolt 2 0 ring 13 Install the front ...

Page 30: ...10 15 mm 0 4 0 6 in above the bottom of the cylinder Wear eye protection to prevent eye damage from escaping gas and or metal chips A WARNING To dispose of a damage or wornout shock absorber take the unit to your Yamaha dealer for this disposal procedure REAR SHOCK ABSORBER SPRING PRE LOAD ADJUSTMENT 1 Remove the rear shock absorber Refer to page 34 18 2 Remove the spring guide 1 Spring guide NOTE...

Page 31: ...d 5 Properly oil all mating engine and trans mission parts during assembly 6 All circlips should be inspected before assembly Replace distorted circlips 7 Always replace cotter pins and piston pin clips after one use 8 When installing parts apply grease or oil to them as required and following the torque chart Refer to Maintenance and Lubrication Schedule Chart 9 For assembly reverse the procedure...

Page 32: ...ther qualified mechanic about any carbure tor setting changes before actually go ing about them Inspection 1 Examine carburetor body and fuel passages If contaminated wash car buretor in petroleum based solvent Do not use caustic carburetor cleaning solu tions Blow out all passages and jets with compressed air 2 Examine condition of floats If floats are leaking or damaged they should be replaced 3...

Page 33: ...weathering checking or other deterio ration 2 Inspect reed petals for signs of fatigue and cracks Reed petals should fit flush or nearly flush against neoprene seats If in doubt as to sealing ability apply suction to carburetor side of assembly Leakage should be slight to moderate 21 3 The valve stopper controls the movement of the valve Check the valve stopper height Valve stopper height 7 4 7 8 ...

Page 34: ...emove ex cess carbon deposits from manifold area of exhaust pipe b Check muffler gasket condition The gasket seat is located around the cylinder exhaust port 2 Spark arrester cleaning a Remove the bolt G b Remove the tailpipe by pulling out of the muffler c Use a wire brush to remove any car bon deposits from the spark arrester portion of the tailpipe d Tap the tailpipe lightly and remove the carb...

Page 35: ...n and bearing will result 0 15 0 35 mm 0 006 0 014 in End gap Installed Maintenance Cylinder head UP Piston clearance 0 033 0 038 mm 0 0013 0 0015 in 1 Using a rounded scraper remove car bon deposits from combustion chamber Take care to avoid damaging the spark plug threads Do not use a sharp instru ment Avoid scratching the metal sur face 2 Place the head on a surface plate There should be no war...

Page 36: ... a cylinder gauge set to standard bore size measure the cylinder Measure front to rear and side to side at top 24 center and bottom just above exhaust port Compare minimum and maximum measurements If over tolerance and not correctable by honing rebore to next oversize 2 Piston outside diameter measurement Using an outside micrometer measure piston diameter The measuring point is at right angles to...

Page 37: ...g locating pin in piston groove Apply liberal coating of two stroke oil to ring 25 NOTE New rings require break in Follow first portion of new machine break in procedure Piston pin bearing and connecting rod 1 Check the pin for signs of wear If any wear is evident replace pin and bearing 2 Check the pin and bearing for signs of heat discoloration If excessive heavily blued replace both 3 Check the...

Page 38: ...al coating of two stroke oil to the piston pin and bearing Apply several drops of oil to the connecting rod big end Apply several drops of oil into each crankshaft bearings oil delivery hole 26 r 50 Nm 5 0 m kg 36 ft lb I Tightening torque Apply grease Apply transmission oil Removal 1 Remove the kick starter 2 Remove the pan head screws holding the case cover in place and remove the cover Note the...

Page 39: ...kness ex ceeds tolerance replace New Wear limit Friction plate 3 0 mm 2 7 mm thickness 0 118 in 0 106 in 27 NOTE For optimum performance if any plate requires replacement it is advisable to replace the en tire set 4 Check each clutch plate for signs of heat damage and warpage Place on surface plate plate glass is acceptable and use feeler gauge Clutch plate warp allowance 0 1 mm 0 004 in 5 Checkin...

Page 40: ... its post in the crankcase Allow it to relax Then remove the kick axle assembly by rotating the shaft counterclockwise and then pull ing out the entire assembly Check the gear teeth for wear and breakage Inspection 1 The kick clip friction force is 0 9 1 5 kg 2 0 3 3 lb If above pressure is too strong spring wear and kick starter slipping will result If it is too weak the same slippage will occur ...

Page 41: ...ed Removal 1 Remove the shift lever assembly and stop per lever 1 Shift lever assembly 1 Stopper lever 29 Inspection 1 Check the shift shaft for bends If bent excessively replace it 2 Check the shift lever and the return spring for fatigue If fatigued excessively replace it 3 Check the stopper lever for wear If worn to excess replace it 4 After installation of the shift shaft check the clearances ...

Page 42: ...C D I MAGNETO CRANKCASE TRANSMISSION KICK STARTER 30 ...

Page 43: ...AR WHEEL Nm 0 m kg 5 1 ft lb Jt7Nm 0 7m kg 5 1fl lb ii fl f 16Nm 16mkg 11ftl7 G f 16Nm 1 6m kg 11fl lb _y I Tightening torque Apply grease _e T 25Nm 2 5m kg 18ft lb I Tightening torque Apply grease T 60Nm 6 0m kg 43ft lb 31 ...

Page 44: ... rear wheel by placing a suitable stand under the engine 2 Remove the tension bar and the brake rod from the brake shoe plate The tension bar can be removed by removing the cotter pin and nut from the tension bar bolt The brake rod can be removed by removing the adjuster 3 Disconnect the drive chain 4 Loosen the lock nuts and chain slack adjusting nuts on both sides 5 Remove the axle nut and washe...

Page 45: ... bead off the rim NOTE Use a tire removal lubricant and be careful not to pinch the tube with the tire irons 5 Remove the valve stem from its hole and remove the tube 6 If the tire is to be changed remove the second bead from the rim using the tire irons and tire lubricant Inspection 1 Use a cloth to check for nails or other sharp objects in the tire 111 Always use a cloth to avoid cutting your ha...

Page 46: ...deflection exceeds tolerance check wheel bearing or replace wheel as required Rim run out limits Vertical 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in REAR SHOCK ABSORBER MONOCROSS SUSPENSION Removal 1 Remove the seat and side cover assembly 34 2 Turn the fuel cock to OFF and discon nect the fuel pipe 3 Remove the fuel tank mounting bolt and holding band from fuel tank Lift rear of the fuel tank up and p...

Page 47: ...rease on the pins 0 Apply molybdenum disulfide grease SWINGARM INSPECTION 35 1 With shock absorber removed grasp the ends of the swingarm and move them from right to left to check for free play Swingarm free play 1 0 mm 0 04 in 0 Apply molybdenum disulfide grease LUBRICATION OF LEVER PEDALS ETC 1 Lubricate the pivoting parts of the brake lever with Yamaha Chain and Cable Lube or SAE 1OW30 motor oi...

Page 48: ... Lube or SAE 10W30 motor oil FRONT FORK 36 THROTTLE CABLE AND GRIP LUBRICATION The throttle twist grip assembly should be greased at the time that the cable is lubricated since the grip must be removed to get at the end of the throttle cable Two screws clamp the throttle housing to the handlebar Once these two are removed the end of the cable can be held high to pour in several drops of lubricant ...

Page 49: ...ECTRICAL COMPONENTS CD CDI unit ENGINE STOP switch Ignition coil Spark plug CDI magneto WIRING IGNITION COIL SPARK PLUG l DIAGRAM GROUND 0 B B W B B CDI UNIT COLOR CODE B Black 0 Orange B R Black Red B W Black White ENGINE STOP SWITCH B R B R B CDI MAGNETO 37 ...

Page 50: ...tarts but will not pick up speed Spark plug Clean or replace OK Ignition timing Check ignition timing OK I IC D I unit I In case of ignition failure with all the above check ups providing in good order replace the C D I unit 38 SPARK GAP TEST 1 Disconnect the spark plug cap from spark plug 2 Connect the Dynamic Spark Tester G as shown 2 Spark plug cap Spark plug 3 Kick the kick starter 4 Check the...

Page 51: ...nspect Secondary coil resistance Out of specification Replace Tester lead Spark plug lead G Tester lead Orange lead Secondary Coil Tester Selector Resistance Position 5 68 8 52 kQ at kUx 1 20 C 68 F 39 CDI MAGNETO INSPECTION 1 Inspect Charging coil resistance Out of specification Replace Tester lead Black Red lead CD Tester lead Black lead Z Charging Coil Tester Selector Resistance Position 200 30...

Page 52: ...and more expensive repairs may be necessitated Any fault in the fuel compression or ignition system can cause poor starting or loss of power while riding The troubleshooting chart describes quick and easy procedures for checking these systems Water or dirt r Clean filter element mixed in fuel and fuel tank Check fuel flow INo fuel I Fuel cock clogged There is fuel Turn the fuel cock to 1 Fuel Chec...

Page 53: ...motive chrome cleaner 8 Clean the seat with a vinyl uphostery cleaner to keep the cover pliable and glossy 9 Automotive type wax may be applied to all painted and chrome plate surfaces Avoid combination cleaner waxes Many contain abrasive which may mar paint or protective finish on fuel and oil tanks 10 After finishing start the engine im mediately and allow to idle for several minutes NOTE Water ...

Page 54: ... 2 67 US oz Bore x Stroke 47 0 x45 6 mm 1 850 x 1 795 in Compression a Ratio 6 6 1 Starting System Kick starter Lubrication System Separate system Yamaha Autolube Engine Oil Oil Tank Capacity 0 95 L 0 84 Imp qt 1 00 US qt Oil Grade Yamalube 2 S or air cooled 2 stroke engine oil Transmission Oil Periodic Oil Change 0 65 L 0 57 Imp qt 0 69 US qt Total Amount 0 75 L 0 66 Imp qt 0 79 US qt Oil Grade Y...

Page 55: ...kbone Caster Angle 26 Trail 62mm 2 44in Tire Type With tube Size F 2 50 14 4PR Size R 3 00 12 4PR Tire Pressure Front 100 kPa 1 0 kgf cm 15 psi Rear 100 kPa 1 0 kgf cm 15 psi Brake Front Brake Type Drum brake Operation Right hand operation Rear Brake Type Drum brake Operation Right foot operation Suspension Front Suspension Telescopic fork Rear Suspension Swingarm Monocross suspension Shock Absorb...

Page 56: ...imit C F c _ D foo A Connecting Rod Big End Side Clearance D Small End Free Play F PW80 0 03 mm 0 0012 in Lines indicate straightedge measurement 47 000 47 014 mm 1 8504 1 8509 in 0 05 mm 0 0020 in 0 01 mm 0 0004 in 46 964 46 979 mm 1 8490 1 8496 in I 5 mm 0 2 in 0 033 0 038 mm 0 0013 0 0015 in 0 2mm 0 008in IN side Keystone B 2 0 mm 0 079 in T 2 0mm 0 079in 0 15 0 35 mm 0 006 0 014 in 0 020 0 060...

Page 57: ... Clip Friction Force P 0 9 1 5 kg 2 0 3 3 lb Carburetor Type Manufacturer Quantity VM15SC MIKUNI 1 pc I D Mark 21W01 Main Jet M J 125 Main Air Jet M A J 02 5 Jet Needle clip Position J N 3E3 3 Needle Jet N J E 4 Cutaway C A 2 5 Pilot Jet P J 15 Pilot Outlet Size P O 00 9 Air Screw turns out P A S 1 1 2 Valve Seat Size V S 01 2 Starter Jet G S 30 Float Height F H 20 8 22 8 mm 0 82 0 90 in Reed Valv...

Page 58: ...h boss M16 x 1 0 1 50 5 0 36 Bearing plate cover M 6 x1 0 2 8 0 8 5 8 Shift guide M 6 x1 0 2 8 0 8 5 8 Torsion spring shift shaft stopper bolt M 8 x1 25 1 20 2 0 14 Stopper lever M 6 x1 0 1 10 1 0 7 2 Shift pedal M 6 x1 0 1 7 0 7 5 1 Rotor M12 x1 25 1 60 6 0 43 Stator M 5 x0 8 2 5 0 5 3 6 Chassis Item PW80 Steering System Steering Bearing Type Ball bearing Front Suspension Front Fork Travel 110 mm...

Page 59: ...wn Inner tube M20 x 1 0 2 40 4 0 29 Under bracket Inner tube M10 x 1 25 2 33 3 3 24 Handle crown Steering shaft M10x1 25 1 42 4 2 30 Handle crown Handle holder under M10x1 25 2 40 4 0 29 Handle holder under Handle holder upper M 6 x 1 0 4 13 1 3 9 4 Steering ring nut M25 x 1 0 1 1 0 1 0 7 Engine mount Front M 8 x 1 25 1 23 2 3 17 Engine mount Under M 8 x 1 25 1 26 2 6 19 Engine mount Center M 8 x ...

Page 60: ... OO SHY Charging Coil Resistance Color 200 300 n at 20 C 68 F Black Red Black C D I Unit Model Manufacturer 4BC OO SHY Ignition Coil Model Manufacturer 4BC OO SHY Minimum Spark Gap 6 mm 0 24 in Primary Winding Resistance 0 32 0 48 n at 20 C 68 F Secondary Winding Resistance 5 68 8 52 kn at 20 C 68 F Charging System Flywheel magneto 48 ...

Page 61: ...is reached The method is similar to installing as automobile wheel and will avoid warping the component DEFINITION OF UNITS Unit Read Definition mm millimeter 10 1 meter cm centimeter 10 2 meter kg kilogram 101 gram N Newton 1 kg x m sec 2 Nm Newton meter Nxm m kg Meter kilogram m Xkg Pa Pascal N m 2 N mm Newton per millimeter N mm L Liter cm Cubic centimeter r min Revolution per minute 49 General...

Page 62: ...d ENGINES Band Cable cylind e cylinder between the Install the ca nd down tube cleaner case a Band C D I unit Throttle cable 1 Clamp Front brake cable 50 Throttle cable 1 Clamp Oil pipe Oil pump cable Band TOP switch lead ENGINES ...

Page 63: ... Throttle cable 1 Front brake cable Throttle cable 2 51 Throttle cable 1 Front brake cable Band Position the clamp 70 mm 2 76 in before the center of the carburetor Ignition coil Locate the choke lever tip 45 to the rear of the perpendicular ...

Page 64: ...ED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Intake system Air cleaner element Intake duct MAINTENANCE RECORD Copies of work orders and or receipts for parts you purchase and install will be required to docu ment maintenance done in accordance w...

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