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Yamaha PW80(T) User Manual

Yamaha PW80(T)
190 pages
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OWNER’S SERVICE MANUAL
MANUEL D’ATELIER DU
PROPRIETAIRE
FAHRER-UND
WARTUNGS-HANDBUCH
PW80(T)
3RV-28199-8EPRINTED IN JAPAN
2004.4—1.8 X 1 !
(E,F,G)
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
PRINTED ON RECYCLED PAPER
PW80(T)
3RV-8ECover 04.4.12 16:12 Page 1

Table of Contents

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Yamaha PW80(T) Specifications

General IconGeneral
Engine Type2-stroke, air-cooled, single cylinder
Displacement79cc
IgnitionCDI
Final DriveChain
Front SuspensionTelescopic fork
Front BrakeDrum
Rear BrakeDrum
Front Tire2.50-14
Rear Tire3.00-12
Starting SystemKick
Transmission3-speed
Rear SuspensionSwingarm

Summary

INTRODUCTION

SAFETY INFORMATION

GASOLINE IS HIGHLY FLAMMABLE

Key safety advice regarding gasoline's flammability and handling precautions.

FOR THE PARENTS

GENERAL INFORMATION

DESCRIPTION

Identifies and labels the main parts of the Yamaha PW80 motorcycle.

MACHINE IDENTIFICATION

FRAME SERIAL NUMBER

Location and method for identifying the vehicle's frame serial number.

ENGINE SERIAL NUMBER

Location and method for identifying the engine serial number.

CONTROL FUNCTIONS

ENGINE STOP SWITCH

Explanation and operation of the emergency engine stop switch.

FUEL COCK

Description of the fuel cock positions and their functions.

PRE-OPERATION CHECKS

BRAKE (FRONT AND REAR)

Checks for correct play and operation of front and rear brakes.

TIRES

Instructions for checking tire pressure and condition.

THROTTLE GRIP

Procedure for checking throttle grip free play.

STARTING AND OPERATION

STARTING A COLD ENGINE

Step-by-step guide to starting the motorcycle engine when cold.

ENGINE BREAK-IN

Procedures for the initial break-in period of the new engine.

PERIODIC MAINTENANCE AND ADJUSTMENT

MAINTENANCE AND LUBRICATION SCHEDULE CHART

Schedule outlining recommended periodic maintenance and lubrication intervals.

SPECIAL TOOLS

FOR ENGINE SERVICE

Lists special tools required for engine maintenance and adjustments.

FOR ELECTRICAL SERVICE

Lists special tools required for electrical system checks.

ADJUSTMENT

SPARK PLUG

Procedure for checking and adjusting the spark plug gap.

IGNITION TIMING CHECKING

Steps to check and verify the engine's ignition timing.

AIR FILTER CLEANING

Cleaning

Detailed instructions for cleaning the air filter element.

THROTTLE CABLE ADJUSTMENT

Free play

Guide to adjusting the throttle cable free play for optimal operation.

IDLE SPEED ADJUSTMENTS

Adjustments

Steps for adjusting the engine's idle speed and mixture.

AUTOLUBE ADJUSTMENT

Cable adjustment

Procedure for adjusting the engine's autolube system cable.

FRONT BRAKE ADJUSTMENT

Free play

Steps to adjust the front brake lever free play.

REAR BRAKE ADJUSTMENT

DRIVE CHAIN SLACK CHECK

Procedure for checking and adjusting the drive chain slack.

STEERING INSPECTION

STEERING ADJUSTMENT

How to inspect and adjust the steering system.

FRONT FORK OIL CHANGE

Removal

Steps to remove the front fork assembly for oil service.

Installation

Steps to install the front fork assembly after servicing.

REAR SHOCK ABSORBER (MONOCROSS SUSPENSION)

REAR SHOCK ABSORBER SPRING PRE-LOAD ADJUSTMENT

Procedure to adjust the rear shock absorber spring preload.

MAINTENANCE AND MINOR REPAIRS

PREPARATION FOR SERVICE

General guidelines and precautions before performing service or repairs.

ENGINE

CARBURETOR

Instructions for carburetor inspection and main jet replacement.

TROUBLESHOOTING

TROUBLESHOOTING CHART

A flowchart to diagnose common engine starting and running issues.

CLEANING AND STORAGE

Cleaning

Detailed procedures for cleaning the motorcycle.

Storage

Guidelines for long-term storage of the motorcycle.

SPECIFICATIONS

GENERALITES

General technical specifications for the PW80 model.

TORQUE SPECIFICATIONS

CHASSIS

Torque values for chassis components.

DEFINITION OF UNITS

Units

Definitions of measurement units used in the manual.

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