Yamaha PW80(T)

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PW80(T)

OWNER’S SERVICE MANUAL

1st Edition, April 2004

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan

3RV-8ECover 04.4.12 16:12 Page 2

Main Page

Introduction4
Safety Precautions6
Important Notice8
Safety Information8
For the Parents12
Contents20
General Information22
Description22
Machine Identification24
Frame Serial Number24
Engine Serial Number24
Model Label24
Control Functions26
"Engine Stop" Switch26
Fuel Cock26
Front Brake Lever28
Rear Brake Pedal28
Shift Pedal28
Starter Lever (Choke)28
Kick Starter30
Fuel Tank Cap30
Fuel and Oil32
Engine Oil (Oil Tank)32
Transmission Oil34
Pre-Operation Checks36
Brake (Front and Rear)38
Wheel38
Tires38
Throttle Grip38
Starting and Operation40
Starting a Cold Engine40
Starting a Warm Engine40
Warming up42
Engine Break-In42
Periodic Maintenance and Adjustment46
Maintenance and Lubrication Schedule Chart46
Service Notes46
Lubrication and Periodic Maintenance Intervals46
Special Tools50
For Engine Service50
For Chassis Service52
For Electrical Service52
Lubrication54
Adjustment56
Engine56
Spark Plug56
Ignition Timing Checking58
Air Filter Cleaning60
Air Filter Removal60
Throttle Cable Adjustment62
Idle Speed Adjustments64
Autolube Pump66
Front Brake Adjustment68
Rear Brake Adjustment70
Drive Chain Slack Check70
Drive Chain Slack Adjustment72
Drive Chain Lubrication74
Tire Air Pressure74
Tire Pressure74
Steering Inspection76
Steering Adjustment76
Front Fork Oil Change76
Notes on Disposal (Yamaha Dealers Only)82
Rear Shock Absorber82
Rear Shock Absorber Spring Pre-Load Adjustment84
Maintenance and Minor Repairs86
Preparation for Service86
Carburetor88
Replacement of Main Jet88
Carburetor Inspection90
Carburetor Adjustment92
Reed Valve Inspection94
Muffler Removal96
Top End Removal98
Muffler Maintenance98
Cylinder Head Maintenance102
Cylinder Maintenance104
Piston Maintenance104
Piston Clearance Maintenance104
Piston Rings Maintenance106
Clutch110
Clutch Removal112
Clutch Inspection112
Kick Starter Removal116
Kick Starter Inspection116
Shifter Removal118
Shifter Inspection118
Kick Starter Reassembly118
Shifter Installation120
C.D.I. Magneto122
Crankcase122
Transmission122
Chassis124
Front Wheel124
Rear Wheel124
Front Wheel Removal126
Front Wheel Installation126
Rear Wheel Removal126
Brake Shoe Inspection128
Rear Wheel Installation128
Brake Drum Inspection130
Tire Removal and Repair130
Tire Inspection130
Tire Reassembly132
Replacing Wheel Bearings134
Checking Rim134
Rear Shock Absorber (Monocross Suspension) Removal134
Swingarm Inspection138
Lubrication of Lever, Pedals, Etc.138
Cable Inspection and Lubrication140
Throttle Cable and Grip Lubrication140
Apply Molybdenum Disulfide Grease142
Apply Grease142
Miscellaneous144
Electrical Components and Wiring Diagram144
Color Code144
Troubleshooting146
Spark Gap Test148
"Engine Stop" Switch Inspection148
Ignition Coil Inspection150
CDI Magneto Inspection152
Troubleshooting Chart156
Cleaning and Storage158
Specifications164
Tightening Torque168
Chassis168
Torque Specifications184
Definition of Units186
Cable Routing187

Yamaha PW80(T) - Page 2

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