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A WARNING The engine exhaust from this product contains chemicais known to the State of Caiifornia to cause cancer, birth defects 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.
NOTICE Some data in this manual may become outdated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please con sult your Yamaha dealer. INTRODUCTION Congratulations on your purchase of the Yamaha PW80. This model represents the product of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines.
A WARNING READ THIS MANUAL CAREFULLY FOR INSTRUCTIONS ON HOW TO PROPERLY OPERATE THIS MACHINE. ADULT INSTRUCTION AND SUPERVISION ARE REQUIRED. THIS MODEL IS PROVIDED WITH A POWER REDUCTION PLATE FOR THE BE GINNING RIDER. DO NOT REMOVE THESE ITEMS UNTILTHE ADULT SUPERVISIOR HAS JUDGED THE RIDER TO BE PROFICIENT. WEIGHT OF THE RIDER SHOULD NOT EXCEED 40 kg (88 lb). ALWAYS WEAR A HELMET AND SUITABLE PROTECTIVE CLOTHING WHEN RIDING. DO NOT TOUCH ANY MOVING PARTS OR HEATED AREAS.
FOR THE PARENTS Since this model is intended for beginning riders, it is equipped with an safety device that let you limit the operating speed of the machine; the power reduction plate. It limits 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.
YAMAHA MOTOR CORPORATION, U.S.A. OFF-ROAD MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that each new Yamaha off-road motorcycle purchas ed from an authorized Yamaha motorcycle dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations.
A SAFETY INFORMATION 1. Don't ride it on the street. 2. Don't run the engine inside a building.
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.
5. When riding the machine, be sure to wear a helmet as illustrated. Helmet Goggles Mouth guard Long sleeved trainer Gloves Motocross pants Boots 6. When going for riding, be sure to be with your family. Never go alone.
7. Before riding the machine, ask your parents to check the machine very carefully. 8. Don't touch the areas shown below, or you'll get burnt in the hand.
9. Don't touch rotating or moving parts. 10. Before starting the engine, be sure to shift the transmission into neutral.
CONTENTS GENERAL INFORMATION......................................................................................................................... 1 DESCRIPTION.................................................................................................................................... 1 MACHINE IDENTIFICATION .............................................................................................................1 CONTROL FUNCTIONS ..............................................................
GENERAL INFORMATION DESCRIPTION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the steering head pipe. 1. 2. 3. 4. Seat Fuel tank Front fender Front wheel 5. Brake pedal 6. Kick starter 7. Muffler 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.
MODEL LABEL The model label (T) is affixed to the frame under the rider's seat. This information will be needed to order spare parts. 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, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES: This indicates reserve. If you run out of fuel while riding, move the lever to this position.
SHIFT PEDAL FUEL TANK CAP The gear ratios of the constant mesh 3-speed transmission are ideally spaced. The gears can be shifted by using the shift pedal on the left side of the engine. Remove the fuel tank cap by turning counter clockwise. ▲ warning Do not overfill the fuel tank. Avoid spill ing fuel on the hot engine. STARTER LEVER (CHOKE) When cold, the engine requires a richer air/fuel mixture for starting.
Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R + M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gaso line or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost. ENGINE OIL (OIL TANK) 1. Dip stick 2. Maximum level 3. Minimum level Make sure there is sufficient engine oil in the oil tank. If necessary add oil.
PRE-OPERATION CHECKS Item Routine Page 5, 14 Brake Check operation/adjustment Transmission oil Change oil as required 4 Drive chain Spark plug Check alignment/ adjustment/ lubrication 15 10 Throttle Check for proper throttle cable operation Check color/condition 5, 12 Air filter Foam type — must be clean and damp w/oil always Wheels and tires Check pressure/runout/spoke tightness/bead stopper/axle nuts 5, 16,31 ~ 34 Fittings/fasteners Check all — tighten as necessary 5, 46, 47, 49 11^
WARMING UP STARTING AND OPERATION To get maximum engine life, always "warm up" the engine before starting off. Never ac celerate hard 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. CAUTION: Prior to operating the machine, perform steps listed in pre-operation check list. A WARNING A WARNING Before starting off, be sure to turn up or remove the side stand.
PERIODIC MAINTENANCE AND ADJUSTMENT MAINTENANCE AND LUBRICATION SCHEDULE CHART The maintenance and lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals. You must take into consideration that weather, terrain, geographical locations, and a variety of individual uses all tend to demand that each owner alter this time schedule to match his environment.
SPECIAL TOOLS The following special tools are required to per form maintenance, adjustments, and repairs on your machine. These tools can be obtained through your Yamaha dealer. FOR CHASSIS SERVICE 1. Ring Nut Wrench P/N. YU-1268 This tool is used to loosen or tighten the steer ing ring nut. FOR ENGINE SERVICE 1. Dial Gauge P/N. YU-3097 This tool is used for adjusting the oil pump stroke. FOR ELECTRICAL SERVICE 1. Yamaha Pocket Tester P/N.
LUBRICATION -9-
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. ADJUSTMENT A WARNING The engine, exhaust pipe(s), and muffler(s) will be very hot after the engine has been run. Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.
d. While running the engine at the specified speed, check to see that the stationary 3. Using uncontaminated cleaning solvent, thoroughly wash the filter element; wash it gently to avoid damage. 4. Squeeze the solvent from the filter ele ment. punch mark is aligned with the punch mark. If the marks are out of alignment, check to see that the woodruff key is broken or flywheel assembly is out of alignment. Ignition timing: 20.
CAUTiON: 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 possible engine overheating. Recommended oil: Foam-air-filter oil THROTTLE CABLE ADJUSTMENT If for any reason you should use another type, use air cooled 2-stroke engine oil. Check the play in turning direction of throttle grip.
4. 5. Turn the pilot air screw in or out until the idle speed is at the highest possible r/min. Turn the throttle stop screw in or out un til idle speed is at desired r/min. Idle speed: 1,650—1,750 r/min 1. Adjuster 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 the oil pump cover. b. Remove the bleeder bolt. c.
b. To adjust the plunger stroke, first loosen the lock nut. c. Turn the adjusting bolt in or out for pro per adjustment. Turning the adjusting bolt clockwise de creases the plunger stroke; while turning counterclockwise increases the plunger stroke. d. When the correct stroke is attained, tighten the lock nut. Minimum stroke 0.40 - 0.45 mm (0.016^0.0l8in) Maximum stroke 1.00 ~ 1.10 mm (0.039 «^0.043 in) Free play (a): 10-20 mm (0.39 - 0.
DRIVE CHAIN SLACK CHECK NOTE: ________________________ Before checking and/or adjusting, rotate rear wheel through several revolutions and check tension several times to find the tightest point. Adjust chain tension with rear wheel in this "tight chain" position. Elevate the rear wheel by placing the suit able stand under the engine. Then measure the play at the bottom of the chain at a point midway between the drive and driven sprockets. 3. Adjusting nut 4.
TIRE PRESSURE CHECK Improper tire pressure affects the smoothness of the tire, traction, handling and the life of the tires. Always maintain the correct tire pressure. Tire pressure: Front 100 kPa (1.0 kgf/cm^, 15 psi) Rear 100 kPad.O kgf/cmM5psi) CHECK THE SPOKES 1. Steering shaft bolt If the spokes are loose or bent, tighten or replace them. They should be checked before each use. 2. Ring Nut Wrench CAUTION: ___________________ Forks must swing from lock to lock without binding or catching. 3.
NOTE:______________________________ 3. Remove the number plate. Select the weight oil that suits local conditions and your preference (lighter 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. 4. 5. Remove the handlebar. Remove the front wheel. (Refer to page 6. 7. 32.) Remove the cap bolt from the inner tube.
1. Do not tamper with or attempt to open the cylinder assembly. Injury may result. 2. Do not subject shock absorber to an open flame or other high heat. This may cause the unit to explode due to excessive gas pressure. 3. Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance. 4. Handle it with great care, for a score or scratch in the piston rod sliding portion will cause oil leakage. 2. Remove the spring guide.
MAINTENANCE AND MINOR REPAIRS PREPARATION FOR SERVICE 1. 2. 3. 4. 5. 6. 7. 8. 9. ENGINE CARBURETOR Before servicing the machine, be sure to clean machine exteriors. Place the removed parts, always on a tray in the order of removal. When replacing parts, always use genuine Yamaha parts to maintain better perfor mance, durability and safety. All gaskets and seals should be replaced when an engine is overhauled. All gasket surfaces must be cleaned.
4. Rotate the carburetor, remove the mix ing chamber top, and carburetor assem bly. 1. Carburetor 5. 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. Inspect inlet needle valve and seat for wear or contamination.
b. Adjustment L The valve stopper controls the movement of the valve. Check the valve stopper height. CAUTION: Check the needle valve and valve seat for wear before adjustment. Valve stopper height (a): 7.4~7.8 mm (0.291 -0.307 in) Make the adjustment by bending the tang on the float arm. 2. Jet needle The mid-range air/fuel supply is affected by the position of the needle in the nee dle jet.
MUFFLER With the carburetor removed, proceed as follows: 1. a. Muffler Using a rounded scraper, remove 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. Spark arrester cleaning ^WARNING Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. Removal 1. Remove the two nuts and remove seat. 2. a. b. 2. Remove the three bolts from the side cover assembly and two bands.
NOTE: _________________________ Break each nut loose (1/4 turn) prior to remov ing. Maintenance Cylinder head 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. 3. 4. With the piston at top dead center, raise the cylinder until the cylinder skirts clear crankcase.
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. Check cylinder bore. Using a cylinder hone, remove any scoring. Hone lightly, using smooth stones. Hone no more than required to avoid excess piston clearance. Piston 1. 2. 3. 2. Using a scraper, remove carbon deposits from piston crown. Break a used piston ring in two. File end square.
If beyond tolerance replace piston or rebore cylinder as required. Piston rings 1. Remove ring from piston. 2. Insert ring into cylinder. Push down ap proximately 20 mm (0.79 in) using piston crown to maintain right-angle to bore. Measure installed end gap. If beyond tolerance, replace. NOTE: -----------------------------------------Ring end gap installed (top and 2nd): 0.15-0.35 mm (0.006-0.014 in) 3. New rings require break-in. Follow first portion of new machine break-in procedure.
6. CLUTCH Remove the dial gauge and slide the con necting rod to one side. Insert a feeler gauge between the side of the connec ting rod big end and the crank wheel. Measure clearance. Connecting rod/crank side clearance: 0.30-0.80 mm (0.012-0.031 in) 7. 8. If any of the above measurements exceed tolerance, crankshaft repair is required. Take the machine to your authorized dealer. During reassembly apply a liberal coating of two-stroke oil to the piston pin and bearing.
1. Rotor Holder 4. NOTE: ------------------------------------------ Remove the circlip, pressure plate, clutch plates, friction plates, one-way clutch, and clutch boss from the clutch housing. 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) Inspection 1.
KICK STARTER Removal 1. 7. Unhook the kick spring from 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. Measure the gap between the friction plate and pressure plate with a thickness gauge. If the gap is found incorrect, it should be properly adjusted by changing the thickness of the clutch plate. Thickness: 1.2, 1.4 or 1.6 mm (0.047, 0.055, 0.
Inspection Reassembly 1. While keeping the kick stopper upwards, engage the kick axle return spring with the slot on the end of the kick axle. And hook the spring to the spring hook. Check whether the kick starter acts cor rectly and whether it returns to its home position. 2. 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.
CRANKCASE ®=3»y KICK STARTER -30-
CHASSIS FRONT WHEEL REAR WHEEL 07Nm (0.7m-kg,5.1ft-lb) g) \ 7Nm (0.7m-kg,5.1ft-lb) 0 16Nm (1.6m-kg,11ft lb) 0 16Nm (1.6m kg,1in ibf 25Nm (2.5m-kg,18ft lb) 0: Tightening torque 0: Apply grease 0 7Nm (0.7m kg,5.1ft-lb) 60Nm (6.
FRONT WHEEL Removal 1. 2. 3. REAR WHEEL Removal 1. Elevate the front wheel by placing a suitable stand under the engine. Remove the brake cable: Loosen all ca ble adjuster screws and remove cable from handle lever holder. Then remove cable from cam lever at front brake shoe plate. 2. Remove the axle nut ® and the wash er®. 3. 4. 5. 4. Turn and pull out the front wheel axle; the wheel assembly can now be removed.
3. Tighten the axle nut and tension bar nut. 4. Axle nut torque: 60 Nm (6.0 m*kg, 43 ft»lb) Tension bar nut: 16 Nm (1.6 m*kg, 11 ft*lb) 4. Starting opposite the valve stem on one side, use two round-ended tire irons to work the bead off the rim. NOTE: _________________________ Use a tire removal lubricant and be careful not to pinch the tube vyith the tire irons. 5. Remove the valve stem from its hole and remove the tube. 6.
CAUTION: _____________________ Check the valve stem; it must be pointing directly at center of wheel hub. If angled in any direction, release air and adjust tube position. REPLACING WHEEL BEARINGS If the bearings allow excessive play in the wheel or if they do not turn smoothly have your dealer replace the wheel bearings. 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.
7. SWINGARM INSPECTION Remove the rear shock absorber from the machine. (To remove, pull the rear shock 1. With shock absorber removed, grasp the ends of the swingarm and move them from right to left to check for free play. backward while lifting up the frame.) Swingarm free play: 1.0 mm (0.04 in) 8. When reassembling, reverse the removal procedure taking care of the following points: a. Always use new cotter pins. b. Apply the molybdenum disulfide grease on the pins.
THROTTLE CABLE AND GRIP LUBRICATION CABLE INSPECTION AND LUBRICATION 1. 2. Damage to the outer housing of the vari ous cables, may cause corrosion and often free movement will be obstructed. An unsafe condition may result so replace as soon as possible. If the inner cables do not operate smooth ly, lubricate or ask a Yamaha dealer or other qualified mechanic to replace them.
MISCELLANEOUS ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS COLOR CODE B.......................Black 0 .......................Orange B/R...................Black/Red B/W..................
SPARK GAP TEST TROUBLESHOOTIIMG 1. Disconnect the spark plug cap from spark plug. 1. No spark is produced or weak. "ENGINE STOP" SWITCH INSPECTION 1. Inspect: • "ENGINE STOP" switch conduct 2. The engine starts but will not pick up speed. . Clean or replace. • Check ignition timing. • In case of ignition failure with all the above check ups providing in good order, replace the C.D.I. unit.
CDI MAGNETO INSPECTION IGNITION COIL INSPECTION 1. Inspect: • Charging coil resistance Out of specification-^Replace. 1. Inspect: •Primary coil resistance Out of specificationReplace. Tester ( + ) leadBlack/Red lead 0 Tester (-) lead-»Black lead (2) Tester ( + ) lead^Orange lead 0 Tester (-) lead^Black lead (5) Primary Coil Resistance Tester Selector Position Charging Coil Resistance Tester Selector Position 0.32-0.48 n at 20°C (68°F) fix 1 200 - 300 Q at 20°C (68°F) fix 100 2.
TROUBLESHOOTING tion parts are similar in shape but often in ferior in quality of materials and workman ship; consequently, service life is shorter 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.
9. CLEANING AND STORAGE Cleaning Frequent thorough cleaning of your machine will not only enhance its appearance but will improve general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off end of exhaust pipe to prevent water entry; a plastic bag and strong rub ber band may be used. b. Remove air cleaner or protect it from water with plastic covering. c. Make sure spark plug(s), fuel tank cap, transmission oil filler cap are properly installed. 2.
SPECIFICATIONS General Item PW80 Model: Code Number 3RVJ Dimensions: Overall Length Overall Width Overall Height Seat Height Wheelbase Minimum Ground Clearance 1,540mm (60.6in) 640 mm (25.2in) 880 mm (34.6in) 635mm (25.0in) 1,055mm (41.5in) 185mm ( 7.3in) Dry Weight: 57.0 kg (125.
PW80 Item Spark Plug: Ty pe / Ma n uf a ct u rer Gap BP6HS/NGK, W20FP/DENSO 0.6~ 0.7 mm (0.024 ~ 0.028in) Clutch Type: Wet, centrifugal automatic Transmission: Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Transmission Type Operation Gear Ratio: 1st 2nd 3rd Gear 66/21 (3.143) Chain drive 32/15(2.133) Constant mesh, 3-speed Left foot operation 39/12(3.250) 29/16(1.812) 22/17(1.
Engine Item PW80 Cylinder Head: Warp Limit 0.03mm (0.0012in) * Lines indicate straightedge measurement. Cylinder: Bore Size Taper Limit Out of Round Limit Piston: Piston Size/ Measuring Point* Piston Clearance 47.000-47.014 mm (1.8504-1.8509 in) 0.05 mm (0.0020 in) 0.01 mm (0.0004 in) o 46.964-46.979 mm (1.8490-1.8496 in)/5 mm (0.2 in) 0.033^0.038 mm (0.0013^0.0015 in) Piston offset Piston Ring: Sectional Sketch 0.2 mm (0.008 in), IN-side Keystone B = 2.0 mm (0.079 in) T = 2.0mm (0.
PW80 Item Clutch: Friction Plate Thickness/Quantity Wear Limit Clutch Plate Thickness/Quantity Warp Limit Clutch Spring Free Length/Quantity 2 . 9 ' - S A mm (0.114-0.122 in) 2.7 mm (0.106 in) 1.2--1.6 mm (0.047 — 0.063 in)x5 0.1 mm (0.004 in) 12.9 mm (0.51 in) x6 Shifter: Shifting Type Cam drum and guide bar Kick Starter Type: Kick Clip Friction Force Ratchet type P = 0.9-1.5 kg (2.0-3.3 lb) Carburetor: Type/Manufacturer/Quantity I.D. Mark Main Jet (M.J.) (M.A.J.
Tightening Torque Part to be tightened Spark plug Cylinder head (nut) (stud) Oil pump cover (upper) (lower) Oil pump Carburetor joint Read valve Exhaust pipe (front) Silencer protector Crankcase Oil drain bolt Blind plug Crankcase cover (left) Crankcase cover (right) Kick starter Primary drive gear Clutch boss Bearing plate cover Shift guide Torsion spring (shift shaft) stopper bolt Stopper lever Shift pedal Rotor Stator Thread size M14 xl.25 M 7 xl.O M 7 xl.O M 6 xl.O M 6 xl.O M 5 xO.8 M 6 xl.O M 3 xO.
Item PW80 Swingarm: Swingarm Free Play Limit End 1.0 mm (0.04 in) Wheel: Front Wheel Type Rear Wheel Type Front Rim Size/Material Rear Rim Size/Material Rim Runout Limit Vertical Lateral Spoke Wheel Spoke Wheel 1.40x14/Steel 1.60x12/Steel 2.0mm (0.08in) 2.0mm (0.08in) Drive Chain: Type/ Manufacturer Number of Links Chain Free Play DID420M/DAIDO 83 links + joint 40 - 53 mm (1.6 ~ 2.1 in) Drum Brake: Leading trailing Leading trailing 95mm (3.74in) Limit: 96 mm (3.78 in) 110 mm (4.
Electrical Item PW80 Ignition System: Ignition Timing (B.T.D.C.) Advancer Type 20.6° at 4,000 r/min Electrical C.D.I.: Model/Manufacturer Charging Coil Resistance (Color) C.D.I. Unit-Model/Manufacturer 4BC-00 / SHY 200 - 300 Q at 20°C (68°F) (Black/Red - Black) 4BC-00 / SHY Ignition Coil: Model/ Manufacturer Minimum Spark Gap Primary Winding Resistance Secondary Winding Resistance 4BC-00 / SHY 6 mm (0.24 in) 0.32 ~ 0.48 n at 20“C (68°F) 5.68 ~ 8.
TORQUE SPECIFICATIONS The list below covers those stud/bolt sizes with standard I.S.O. pitch threads. Torque specifi cations for components with thread pitches other than standard are given within the ap plicable chapter. Torque specifications call for dry, clean threads. Components such as the cylinder or cylinder head should be at room temperature prior to torquing.
CABLE ROUTING Throttle cable 1 Cable cylinder Install the cable cylinder between the cleaner case and down-tube.
Position the clamp 70 mm (2.76 in) before the center of the carburetor.
NOISE REGULATION.
