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Yamaha PW80(R) User Manual
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PW80(R)
OWNER’S SERVICE MANUAL
©2002 by Y
amaha Motor Co., Ltd.
1st Edition, April 2002
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Y
amaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
1
3
Table of Contents
Introduction
4
Important Notice
8
Safety Information
8
Contents
20
General Information
22
Description
22
Machine Identification
24
Frame Serial Number
24
Vehicle Identification Number
24
Engine Serial Number
24
Control Functions
26
Engine Stop Switch
26
Fuel Cock
26
Front Brake Lever
28
Rear Brake Pedal
28
Shift Pedal
28
Starter Lever
28
Kick Starter
30
Fuel Tank Cap
30
Fuel
32
Engine Oil
32
Recommended Fuel
32
Fuel Tank Capacity
32
Transmission Oil
34
Pre-Operation Checks
36
Brake
38
Wheel
38
Tires
38
Throttle Grip
38
Staring and Operation
40
Starting a Cold Engine
40
Starting a Warm Engine
40
Warming up
42
Engine Break-In
42
Periodic Maintenance and Adjustment
46
Maintenance and Lubrication Schedule Chart
46
Lubrication Intervals
46
Special Tools
50
For Engine Service
50
Lubrication
54
Engine
56
Spark Plug
56
Ignition Timing Checking
58
Air Filter Cleaning
60
Throttle Cable Adjustment
62
Idle Speed Adjustments
64
Autolube Pump
66
Front Brake Adjustment
68
Rear Brake Adjustment
70
Drive Chain Slack Check
70
Drive Chain Slack Adjustment
72
Drive Chain Lubrication
74
Tire Air Pressure
74
Tire Pressure
74
Steering Inspection
76
Steering Adjustment
76
Front Fork Oil Change
76
Recommended Oil
80
Pinch Bolt Torque
80
Fork Cap Bolt Torque
80
Handle Holder Upper Torque
80
Rear Shock Absorber
82
Notes on Disposal
82
Rear Shock Absorber Spring Preload Adjustment
84
Maintenance and Minor Repairs
86
Preparation for Service
86
Engine Carburetor
88
Replacement of Main Jet
88
Reed Valve
94
Valve Stopper Height
94
Reed Valve Bending Limit
94
Cylinder
104
Piston
104
Piston Clearance
104
Cylinder Bore Measurement
104
Piston Outside Diameter Measurement
106
Piston Rings
106
Ring Groove Clearance
108
Piston Pin Bearing and Connecting Rod
108
Connecting Rod/Crank Side Clearance
110
Clutch Plate Warm Allowance
114
Kick Starter Removal
116
Kick Starter Inspection
116
Clutch Adjustment Gap
116
Shifter
118
Chassis
124
Front Wheel
124
Rear Wheel
124
Brake Shoe Inspection
128
Axle Nut Torque
128
Tension Bar Nut
128
Brake Drum Inspection
130
Tire
130
Replacing Wheel Bearings
134
Checking Rim
134
Swingarm Inspection
138
Lubrication of Lever, Pedals, Etc.
138
Cable Inspection and Lubrication
140
Throttle Cable and Grip
140
Miscellaneous
144
Electrical Components
144
Color Code
144
Wiring Diagram
144
Troubleshooting
146
Spark Gap Test
148
Engine Stop Switch Inspection
148
Ignition Coil Inspection
150
CDI Magneto Inspection
152
Cleaning
158
Storage
160
Specifications
164
Tightening Torque
168
Electrical
170
Torque Specifications
184
Definition of Units
186
Cable Routing
187
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Yamaha PW80(R) Specifications
General
Brand
Yamaha
Model
PW80(R)
Category
Motorcycle
Language
English
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