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Yamaha PW80(N) User Manual

Yamaha PW80(N)
190 pages
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OWNER’S SERVICE MANUAL
MANUEL D’ATELIER DU
PROPRIETAIRE
FAHRER-UND
WARTUNGS-HANDBUCH
PPW80(N)
3RV-28199-8A
PPW80(N)
PW80_80Cover 00.10.12 10:37 PM Page 1 (2,1) (Magenta plate)

Table of Contents

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Yamaha PW80(N) Specifications

General IconGeneral
Displacement79cc
Compression Ratio6.6:1
IgnitionCDI
Final DriveChain
Front SuspensionTelescopic fork
Front BrakeDrum
Rear BrakeDrum
Engine TypeAir-cooled, 2-stroke, single cylinder
StarterKick
Transmission3-speed
Rear SuspensionSwingarm
Front Tire2.50-14
Rear Tire3.00-12
Ground Clearance190mm

Summary

Introduction and Safety Alerts

Safety Alert Symbol and Basic Warnings

Explains safety symbols (Warning, Caution, Note) and provides initial safety messages.

General Safety Precautions

Rider Safety and Operational Guidelines

Lists critical safety advice for operation, including supervision, rider weight limits, protective gear, and intended use.

Rider Safety Information

Safe Gasoline Handling and Refueling

Details safety precautions for handling gasoline, including turning off the engine, avoiding spills, and handling accidental ingestion.

Parental Guidance

Machine Design for Young Riders

Explains the model's suitability for beginners and its speed-limiting safety feature for controlled engine output.

Visual Safety Instructions

Illustrative Safety Practices

Depicts essential safety practices through images, covering street riding, indoor operation, passenger limits, and learning to ride.

Starting and Operation

Starting a Cold Engine

Provides step-by-step instructions for starting the engine when cold, including fuel cock, choke, and engine stop switch.

General Information

Vehicle Component Identification

Identifies and labels various parts of the motorcycle using numbered diagrams for clarity.

Machine Identification

Vehicle Identification Numbers and Labels

Details the location and purpose of frame serial numbers, VIN, engine serial numbers, and model labels for identification.

Control Functions

Engine Stop Switch and Fuel Cock Operation

Explains the operation of the engine stop switch and the three positions of the fuel cock (OFF, ON, RES).

Machine Controls Overview

Brake and Shift Controls

Describes the front brake lever, rear brake pedal, and shift pedal for vehicle operation.

Starting and Engine Stop Controls

Details the operation of the starter lever (choke) and the engine stop switch for starting and stopping the engine.

Starting and Fuel System Controls

Kick Starter and Fuel Tank Cap

Explains the operation of the kick starter for engine ignition and the fuel tank cap for refueling.

Fuel and Oil Specifications

Fuel Recommendations and Capacity

Specifies recommended fuel types, octane ratings, and the total fuel tank capacity.

Engine Oil and Transmission Oil

Details recommended engine and transmission oil types, grades, and capacities for maintenance.

Transmission Oil Maintenance

Checking and Servicing Transmission Oil

Provides instructions on checking and maintaining the correct level of transmission oil for smooth gear operation.

Pre-Operation Checks

Essential Pre-Ride Inspection Checklist

Lists critical checks for brakes, wheels, tires, throttle, and engine stop switch before operating the vehicle.

Starting and Operation Procedures

Warming Up the Engine

Guides on warming up the engine to ensure maximum life and proper operation.

Engine Break-In Procedure

Outlines the recommended steps for breaking in a new engine to ensure longevity and performance.

Engine Warm-Up and Break-In

Engine Break-In Procedures

Details the process for breaking in a new engine, including operating procedures and checks.

Periodic Maintenance and Lubrication

Maintenance Schedule Chart

Presents a comprehensive chart detailing periodic maintenance tasks and lubrication intervals.

Maintenance and Lubrication Details

Lubrication Intervals

Specifies the recommended intervals for lubricating various parts of the motorcycle.

Periodic Maintenance Intervals

Outlines the schedule for routine maintenance tasks based on operating hours or time.

Special Tools

Tools for Engine Service

Lists and illustrates specialized tools required for engine maintenance and adjustments.

Service Tools

Tools for Chassis Service

Identifies essential tools for servicing the motorcycle's chassis components.

Tools for Electrical Service

Lists specialized tools necessary for diagnosing and repairing electrical system issues.

Lubrication Guide

Key Lubrication Points

Illustrates and describes the lubrication points on the motorcycle for proper maintenance.

Adjustment Procedures

Spark Plug Adjustment and Specifications

Details how to check and adjust the spark plug gap and provides the correct specifications.

Ignition System Checks

Ignition Timing Checking

Explains the procedure for checking and verifying the engine's ignition timing.

Air Filter Maintenance

Air Filter Cleaning and Replacement

Provides instructions for removing, cleaning, and reinstalling the air filter element.

Cable Adjustments

Throttle Cable Adjustment

Details the procedure for adjusting the throttle cable free play for optimal response.

Idle Speed Adjustments

Adjusting Carburetor Idle Speed

Explains how to adjust the pilot air and throttle stop screws for the correct idle speed.

Autolube System

Autolube Pump Adjustment and Bleeding

Describes how to adjust the autolube pump and bleed air from the oil delivery system.

Brake Adjustments

Front Brake Cable Free Play Adjustment

Details how to adjust the free play in the front brake cable for proper braking response.

Rear Brake and Chain Adjustment

Rear Brake Adjustment

Explains how to adjust the rear brake pedal and rod for correct braking force.

Drive Chain Slack Check and Adjustment

Guides on checking and adjusting the drive chain slack for optimal performance and longevity.

Tire Maintenance

Tire Air Pressure Specifications

Lists the correct tire pressure for front and rear tires for safe riding.

Steering System Maintenance

Steering Inspection and Adjustment

Outlines procedures for inspecting steering head bearings and adjusting steering head tightness.

Front Fork Maintenance

Front Fork Oil Change Procedure

Provides detailed steps for draining, refilling, and checking the oil level in the front forks.

Shock Absorber Information

Rear Shock Absorber Disposal and Handling

Provides crucial safety notes and disposal information for the rear shock absorber, emphasizing proper handling.

Rear Shock Absorber Adjustment

Spring Pre-Load Adjustment

Details how to adjust the spring preload on the rear shock absorber to suit rider preference.

Maintenance and Minor Repairs

Preparation for Service

Lists essential steps and precautions to take before performing any maintenance or repair work.

Engine Components

Carburetor Service

Covers the replacement of the main jet and inspection of carburetor components.

Carburetor Adjustments

Carburetor Float Height Adjustment

Explains how to measure and adjust the float height for correct fuel delivery.

Jet Needle and Jet Adjustments

Details how to adjust the jet needle position and other jet settings for optimal fuel mixture.

Carburetor and Reed Valve

Reed Valve Inspection and Bending Limit

Guides on inspecting the reed valve and its bending limit for proper engine breathing.

Manifold and Muffler Service

Manifold Distortion Check

Describes how to check the manifold for distortion and resurface if necessary.

Muffler Removal and Maintenance

Provides steps for removing the muffler and cleaning carbon deposits.

Top End Servicing

Cylinder Head Maintenance

Details cleaning carbon deposits from the cylinder head and spark plug threads.

Cylinder and Piston Service

Cylinder Cleaning and Piston Inspection

Guides on cleaning the cylinder and inspecting the piston for wear or damage.

Piston and Ring Service

Piston Ring Groove Clearance

Explains how to measure piston ring groove clearance and replace rings if necessary.

Crankshaft and Connecting Rod

Piston Pin and Connecting Rod Checks

Details checks for piston pin wear, connecting rod bearing condition, and radial play.

Crankshaft and Piston Measurements

Piston Clearance Measurement

Provides procedures and formulas for measuring piston diameter and clearance.

Clutch Assembly Service

Clutch Spring and Friction Plate Inspection

Guides on inspecting clutch springs for length and friction plates for wear or damage.

Clutch Component Service

Clutch Assembly and Disassembly

Illustrates the clutch assembly and provides notes on disassembly and reassembly.

Clutch Inspection and Wear Limits

Clutch Plate Thickness and Warp Allowance

Details how to measure clutch plate thickness and warp allowance.

Clutch Ball and Ratchet Mechanism Check

Explains how to check the clutch ball and ratchet mechanism for wear or damage.

Kick Starter Service

Kick Starter Removal and Inspection

Provides steps for removing the kick starter mechanism and inspecting its components for wear.

Shifter Mechanism Service

Shifter Removal and Inspection

Details the procedure for removing the shifter lever and checking its components for wear.

Electrical Components and Systems

CDI Magneto and Transmission Systems

Shows exploded views of the CDI magneto and transmission components.

Kick Starter Assembly

Illustrates the kick starter assembly components.

Chassis Components

Front and Rear Wheel Assembly

Provides diagrams and torque specifications for front and rear wheel installation.

Wheel Service

Front Wheel Removal and Installation

Details the steps for removing and installing the front wheel assembly.

Rear Wheel Removal and Installation

Provides instructions for removing and installing the rear wheel assembly and drive chain.

Drive Chain and Brake Service

Drive Chain Lubrication and Adjustment

Guides on lubricating the drive chain and adjusting its tension.

Brake Shoe Inspection

Explains how to inspect brake shoes for wear and measure their thickness.

Tire and Brake Drum Service

Tire Removal and Installation

Details the process for removing and installing tires, including checking for damage.

Brake Drum Inspection

Guides on inspecting the brake drum surface for wear or damage.

Tire Servicing Procedures

Tire Inflation and Reassembly

Provides steps for inflating tires and reassembling the wheel after service.

Wheel Bearing and Rim Service

Replacing Wheel Bearings

Outlines the procedure for replacing wheel bearings and checking rim run-out.

Rear Shock Absorber Service

Rear Shock Absorber Removal

Details the steps for removing the rear shock absorber from the motorcycle.

Swingarm and Lever Service

Swingarm Inspection and Lubrication

Guides on inspecting the swingarm for play and lubricating pivot points.

Lever and Pedal Lubrication

Explains how to lubricate control levers and pedals for smooth operation.

Cable Lubrication and Inspection

Throttle Cable and Grip Lubrication

Details how to lubricate the throttle cable and grip assembly for smooth rotation.

Miscellaneous Information

Electrical Components and Wiring Diagram

Identifies key electrical components and presents the motorcycle's wiring diagram.

Troubleshooting Guide

Engine Performance Troubleshooting

Provides a step-by-step guide to diagnose and resolve common engine starting and running issues.

Troubleshooting and Repair

General Troubleshooting Approach

Offers advice on diagnosing and repairing issues, emphasizing the use of skilled technicians and genuine parts.

Troubleshooting Chart

Fuel and Ignition System Troubleshooting Flowchart

Presents a visual flowchart for diagnosing fuel and ignition system problems.

Cleaning and Storage

Machine Cleaning Procedures

Details comprehensive steps for cleaning the motorcycle after use and before storage.

Storage Procedures

Long-Term Storage Preparation

Outlines essential steps for preparing the motorcycle for long-term storage to prevent deterioration.

Specifications - General

General Vehicle Specifications

Lists key specifications for the model, including dimensions, weight, and engine details.

Specifications - Chassis and Drivetrain

Chassis and Transmission Specifications

Provides detailed specifications for the chassis, wheels, brakes, suspension, and transmission.

Specifications - Engine Details

Cylinder, Piston, and Crankshaft Specifications

Lists detailed specifications for engine internal components like cylinder, piston, rings, and crankshaft.

Specifications - Clutch and Carburetor

Clutch, Carburetor, Starter, and Valves Specifications

Provides specific details for clutch components, carburetor settings, and the kick starter.

Torque Specifications

General Torque Values

Lists torque specifications for various fasteners and components, categorized by size.

Electrical System Specifications

Ignition System and CDI Specifications

Details specifications for the ignition system, timing, CDI unit, and coils.

Technical Data - General

General Vehicle Technical Data

Compiles general technical data including dimensions, weight, engine, fuel, air filter, and carburetor details.

Technical Data - Drivetrain and Chassis

Drivetrain, Chassis, Wheels, and Brakes Data

Lists technical data for transmission, chassis, wheels, tires, and brakes.

Technical Data - Engine Internals

Engine Cylinder, Piston, and Crankshaft Data

Provides technical data for cylinder bore, piston dimensions, ring specifications, and crankshaft measurements.

Technical Data - Clutch and Carburetor

Clutch, Carburetor, Starter, and Valves Data

Lists technical data for clutch components, carburetor settings, starter, and reed valve.

Torque Specifications

General Torque Values

Lists torque specifications for various fasteners and components, categorized by size.

Unit Definitions

Metric and Imperial Unit Definitions

Defines common units used in the manual, such as mm, cm, kg, N, Pa, L, and r/min.

Cable Routing Diagrams

Throttle, Brake, and Engine Stop Switch Cable Routing

Illustrates the routing of throttle, brake, and engine stop switch cables for proper management.

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