Yamaha pw80 User Manual

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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

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. LIT-11626-18-30

LIT-CALIF-65-01

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Some data in this manual may become outdated due to improvements made to this model in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. You can now appreciate the high degrees
of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will
provide you with a good basic understanding of the features, operation, and basic maintenance
and inspection items of this vehicle. If you have any questions regarding the operation or main
tenance of your machine, please consult your Yamaha dealer.

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

^ SAFETY IS INVOLVED!

A WARNING

NOTE:

Failure to follow WARNING instructions could result in severe injury or

death to the machine operator, a bystander, or a person inspecting or repair
ing the machine.

A CAUTION indicates special precautions that must be taken to avoid
damage to the machine.

A NOTE provides key information to make procedures easier or clearer.

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.

ALWAYS PERFORM PRE-OPERATION CHECKS. REFER TO PAGE 5.
THIS MACHINE IS DESIGNED TO CARRY THE OPERATOR ONLY. NO

PASSENGERS.
THIS MACHINE IS DESIGNED FOR OFF-ROAD USE ONLY. IT IS NOT
SUITABLE FOR ON-ROAD USE.

IMPORTANT NOTICE

This machine is designed for off-road use only by young operators under adult instruction
and supervision. It is illegal for this machine to be operated on any public street, road, or
highway. Off-road use on public lands may be illegal. Please check local regulations before
riding.

A SAFETY INFORMATION

GASOLINE IS HIGHLY FLAMMABLE:
* Always turn off the engine when refueling.
* Take care not to spill on the engine or exhaust pipe/muffler, when refuel

ing.

* Never refuel while smoking or in the vicinity of an open flame.

If you should swallow some gasoline or inhale a lot of gasoline vapor, or
allow some gasoline to get in your eye(s), see your doctor immediately. If
any gasoline spills on your skin or clothing, immediately wash it with soap
and water, and change your clothes.
Always turn off the engine before leaving the machine unattended. When
parking the machine, note the following:
* The engine and exhaust pipe(s)/muffler(s) may be hot. Park the machine

in a place where pedestrians or children are not likely to touch the
machine.

* Do not park the machine on a slope or soft ground; the machine may over

turn.

When transporting the machine in another vehicle, be sure it is kept upright
and that the fuel cock is turned to the "OFF". If it should lean over, gasoline
may leak out of the carburetor or fuel tank.

5.

Never start your engine or let it run for any length of time in a closed area.

The exhaust fumes are poisonous and may cause loss of consciousness and
death within a short time. Always operate your machine in an area with ade

quate ventilation.
Always wear a helmet, gloves, boots, trousers, and jacket for motocross

6.

riding.

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.

• A power reduction plate is provided in the
cylinder exhaust port. Removal of this plate
adds to the vehicle output power.

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.

THE PERIOD OF WARRANTY for Yamaha off-road
motorcycles shall be ninety (90) days from the date
of purchase, with no mileage limitation.

MODELS EXCLUDED FROM WARRANTY include
those machines used for non-Yamaha-authorized ren
ting, leasing, or other commercial purposes.

DURING THE PERIOD OF WARRANTY any authorized
Yamaha motorcycle dealer will, free of charge, repair
or replace, at Yamaha's option, any part adjudged
defective by Yamaha due to faulty workmanship or
material from the factory. Parts used in warranty

repairs will be warranted for the balance of the pro
duct's warranty period. All parts replaced under war
ranty become property of Yamaha Motor Corporation
U.S.A.

GENERAL EXCLUSIONS from this warranty shall
include any failures caused by:
a. Competition or racing use (except TY models used

for sanctioned trials).

b. Installation of parts or accessories that are not

qualitatively equivalent to genuine Yamaha parts.
c. Abnormal strain, neglect, or abuse.
d. Lack of proper maintenance.
e. Accident or collision damage.
f. Modification to original parts.
g. Damage due to improper transportation.

YAMAHA MOTOR CORPORATION, U.S.A.

SPECIFIC EXCLUSIONS from this warranty shall
include parts replaced due to normal wear or routine
maintenance.

THE CUSTOMER'S RESPONSIBILITY under this war
ranty shall be to:

1. Operate and maintain the motorcycle as specified
in the appropriate Owner's Manual, and

2. Give notice to an authorized Yamaha motorcycle
dealer of any and all apparent defects within ten
(10) days after discovery, and make the machine
available at that time for inspection and repairs at
such dealer's place of business.

WARRANTY TRANSFER: To transfer the warranty
from the original purchaser to any subsequent pur
chaser, it is imperative that the machine be inspected
and registered for warranty by an authorized Yamaha
motorcycle dealer. In order for this warranty to remain
in effect, this inspection and registration must take
place within ten (10) days after transfer. An inspec

tion and registration fee will be charged for this service.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO
OTHER WARRANTY OF ANY KIND, EXPRESSED OR
IMPLIED. ALL IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE WHICH EXCEED THE
OBLIGATIONS AND TIME LIMITS STATED IN THIS
WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA
MOTOR CORPORATION, U.S.A. AND EXCLUDED
FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON
HOW LONG AN IMPLIED WARRANTY LASTS, SO THE
ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO
EXCLUDED FROM THIS WARRANTY ARE ANY

INCIDENTAL OR CONSEQUENTIAL DAMAGES
INCLUDING LOSS OF USE. SOME STATES DO NOT
ALLOW THE EXCLUSION OR LIMITATION OF
INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO
THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL
RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS
WHICH VARY FROM STATE TO STATE.

YAMAHA MOTOR CORPORATION, U.S.A.

P. O. Box 6555

Cypress, California 90630

WARRANTY QUESTIONS AND ANSWERS CUSTOMER SERVICE

Q. What costs are my responsibility during the warranty period?
A. The customer's responsibility includes all costs of normal maintenance services, non

warranty repairs, accident and collision damage, and oil, oil filters, air filters, spark
plugs, and brake shoes or pads.

Q. What are some examples of "abnormal" strain, neglect, or abuse?
A. These terms are general and overlap each other in areas. Specific examples include:

Running the machine out of oil; sustained high-rpm, full-throttle use; operating the
machine with a broken or damaged part which causes another part to fail; damage
or failure due to improper or careless transporation and or tie down; and so on. If
you have any specific questions on operation or maintenance, please contact your
dealer for advice.

Q. Does the warranty cover incidental costs such as towing or transportation due to

a failure?

A. No. The warranty is limited to repair of the machine itself.
Q. May I perform any or all of the recommended maintenance shown in the Owner's

Manual instead of having the dealer do them?

A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owner's

and Service Manual. We do recommend, however, that items requiring special tools
or equipment be done by a Yamaha motorcycle dealer.

Q. Will the warranty be void or cancelled if I do not operate or maintain my new

motorcycle exactly as specified in the Owner's Manual?

A. No. The warranty on a new motorcycle cannot be "voided" or "cancelled." However,

if a particular failure is caused by operation or maintenance other than as shown
in the Owner's Manual, that failure may not be covered under warranty.

Q. What responsibility does my dealer have under this warranty?
A. Each Yamaha motorcycle dealer is expected to:

1. Completely set up every new machine before sale.

2. Explain the operation, maintenance, and warranty requirements to your satisfa­tion at the time of sale, and upon your request at any later date.

In addition, each Yamaha motorcycle dealer is held responsible for his setup, service
and warranty repair work.

Q. Is the warranty transferable to second owners?
A. Yes. The remainder of the existing warranty can be transferred upon request. The

unit has to be inspected and re-registered by an authorized Yamaha motorcycle dealer
for the warranty coverage to remain effective.

If your machine requires warranty service, you must take it to any authorized
Yamaha motorcycle dealer within the continental United States. Be sure to
bring your warranty registration identification or other valid proof of the
original date of purchase. If a question or problem arises regarding warranty,
first contact the owner of the dealership. Since all warranty matters are
handled at the dealer level, this person is in the best position to help you.
If you are still not satisfied and require additional assistance, please write:

YAMAHA MOTOR CORPORATION U.S.A.

CUSTOMER RELATIONS DEPARTMENT

When contacting Yamaha Motor Corporation, U.S.A. don't forget to include
any important information such as names, addresses, model, V.I.N. (frame
number), dates, and receipts.

The federal government requires each manufacturer of a motor vehicle to
maintain a complete, up-to-date list of all first purchasers against the
possibility of a safety-related defect and recall. This list is compiled from
the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the
selling dealer at the time of your purchase.

If you should move after you have purchased your new motorcycle, please
advise us of your new address by sending a postcard listing your motorcycle
model name, V.I.N. (frame number), dealer number (or dealer's name) as it is
shown on your warranty identification, your name and new mailing address.
Mail to :

YAMAHA MOTOR CORPORATION, U.S.A.

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date
registration record in accordance with federal law.

P.O. Box 6555

Cypress, California 90630

CHANGE OF ADDRESS

WARRANTY DEPARTMENT

P.O. Box 6555

Cypress, California 90630

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.

Long sleeved trainer

Motocross pants

Boots

Helmet

Goggles

Mouth guard

Gloves

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 ....................................................................................................................2

FUEL AND OIL....................................................................................................................................3

PRE-OPERATION CHECKS...............................................................................................................5

STARTING AND OPERATION ..........................................................................................................6

PERIODIC MAINTENANCE AND ADJUSTMENT .. .

MAINTENANCE AND LUBRICATION SCHEDULE CHART

SPECIAL TOOLS .............................................................................................................................. 8

ADJUSTMENT...................................................................................................................................10

MAINTENANCE AND MINOR REPAIRS..................................................................................................19

PREPARATION FOR SERVICE.......................................................................................................19

ENGINE..............................................................................................................................................19

CHASSIS ......................................................................................................................................... 31

MISCELLANEOUS................................................................................................................................... 37

ELECTRICAL COMPONENTS AND WIRING DIAGRAM...............................................................37

TROUBLESHOOTING......................................................................................................................40

CLEANING AND STORAGE ...........................................................................................................41

SPECIFICATIONS.............................................................................................................................42

CABLE ROUTING.............................................................................................................................50

NOISE REGULATION............................................................................................................................... 52

MAINTENANCE RECORD ........................................................................................................................52

...................

............................................................

............................................................

7
7

GENERAL INFORMATION

1. Seat

2. Fuel tank

3. Front fender

4. Front wheel

DESCRIPTION

5. Brake pedal

6. Kick starter

7. Muffler

MACHINE

IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number is stamped
into the steering head pipe.

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.

--------------------------------------

1. Front fork

2. Monocross suspension

3. Rear wheel

4. Sidestand

1. Front brake lever

2. Throttle grip

3. "ENGINE STOP" switch

ENGINE SERIAL NUMBER

The engine serial number is stamped on the left
side of the engine on top of the crankcase.

5. Footrest

6. Shift pedal

7. Air filter

1. Engine serial number

NOTE:

The first digits of these numbers are for model
identifications; the remaining digits are the unit
production number.
Keep a record of these numbers for reference
when ordering parts from a Yamaha dealer.

-1-

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.

CONTROL FUNCTIONS

A WARNING

Before riding this machine, become tho

roughly familiar with all operating controls
and their function.

Consult a Yamaha dealer or other qualified
mechanic regarding any control or func

tion you do not thoroughly understand.

I— NOTICE:

This machine is designed strictly for

competition use only. It is not equipped

with highway approved lighting. Off

road use on public land may be illegal.

--------------------------------------------

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. FILL THE TANK AT THE

FIRST OPPORTUNITY. BE SURE TO

SET THE LEVER TO "ON" AFTER

REFUELING.

FRONT BRAKE LEVER

The front brake lever is located on the right

handlebar, pull it toward the handlebar to ac
tivate the front brake.

"ENGINE STOP" SWITCH

Make sure that the engine stop switch is posi

tioned to "RUN". The engine switch has been

equipped to ensure safety in an emergency
such when the machine is upset or trouble
takes place in the throttle system. The engine
will not start or run when the engine stop
switch is turned to "OFF".

FUEL COCK

The fuel cock supplies fuel from the tank to car
buretor while filtering the fuel. The fuel cock
has the three positions;

REAR BRAKE PEDAL

The rear brake pedal is on the right side of the
machine. Press down on the brake pedal to ac
tivate the rear brake.

1. Rear brake pedal

2-

SHIFT PEDAL

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.

STARTER LEVER (CHOKE)

When cold, the engine requires a richer air/fuel
mixture for starting. A separate starter circuit,
which is controlled by the starter lever, sup
plies this mixture.

Pull the lever out to open the circuit (for star

ting) and push the lever in to close the circuit.

FUEL TANK CAP

Remove the fuel tank cap by turning counter
clockwise.

▲ warning

Do not overfill the fuel tank. Avoid spill
ing fuel on the hot engine.

FUEL AND OIL

FUEL

Use regular gasoline. Always use fresh, name
brand gasoline.

1. Starter lever

KICK STARTER

▲WARNING

Before starting the engine, be sure to
shift the transmission into neutral.

Rotate the kick starter 0 away from the en
gine. Push the starter down lightly with your
foot until the gears engage, then kick
smoothly and forcefully to start the engine.

▲ warning

Do not overfill the fuel tank. Avoid spill

ing fuel on the hot engine. Do not fill the
fuel tank above the bottom of the filler
tube as shown in the illustration or it may

overflow when the fuel heats up later and

expands.

Recommended fuel:

UNLEADED GASOLINE ONLY

Fuel tank capacity:

Total:

4.9 L (1.08 Imp gal, 1.29 US gal)

Reserve:

1.0 L (0.22 Imp gal, 0.26 US gal)

1. Kickstarter

-3-

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)

Make sure there is sufficient engine oil in the

oil tank. If necessary add oil.

Recommended oil:

Yamalube 2-S or air-cooled
2-stroke engine oil

Oil tank capacity:

0.95 L (0.84 Imp qt, 1.00 US qt)

1. Dip stick

2. Maximum level

3. Minimum level

Recommended oil

Yamalube 4 (10W30)
or SAE 10W30 type SE motor oil

Oil capacity:

Total amount:

0.75 L (0.66 Imp qt, 0.79 US qt)

Periodic oil change:

0.65 L (0.57 Imp qt, 0.69 US qt)

The dip stick has a Minimum and Maximum
mark, and the oil level should be between the
two. If the level is lower, then and sufficient
oil to raise it to the proper level.
On the bottom of the engine there is a drain
plug. Remove it and drain all the transmission
oil out. Reinstall the drain plug (make sure it

is tight). Add oil through the dip stick hole.

TRANSMISSION OIL

The only servicing for you to do is to check and
fill the transmission lubricating oil. The trans

mission dip stick is located right above the kick

starter. To check the level, warm the engine

up for several minutes, screw the dip stick com
pletely out and then just rest the stick in the
hole.

NOTE:

When checking transmission oil level with the
dip stick, let the unscrewed dip stick just rest
on the case threads. Also, be sure the machine
is positioned straight up.

------------------------------------------

1. Drain plug

Drain plug torque:

20 Nm (2.0m*kg, 14fHb)

NOTE: ______________________________

Do not add any chemical additives. Transmis

sion oil also lubricates the clatch and additives
could cause the clutch to slip.

-4-

PRE-OPERATION CHECKS

Item

Brake

Transmission oil

Drive chain

Spark plug
Throttle Check for proper throttle cable operation
Air filter
Wheels and tires

Fittings/fasteners

Check operation/adjustment
Change oil as required
Check alignment/ adjustment/ lubrication
Check color/condition

Foam type — must be clean and damp w/oil always 11^12
Check pressure/runout/spoke tightness/bead stopper/axle nuts
Check all — tighten as necessary

NOTE:______________________________________________________________________

Pre-operation checks should be made each time the machine is used. Such an inspection can
be thoroughly accomplished in a very short time; and the added safety it assures is more than

worth the time involved.

Routine Page

5, 14

4

15
10

5, 12

5, 16,31 ~ 34
5, 46, 47, 49

A WARNING

If any item in the PRE-OPERATION CHECK is not working properly, have it inspected

and repaired before operating the machine.

BRAKE (FRONT AND REAR)

Check for correct play in the brake lever and
pedal and make sure they are working proper
ly. Check the brakes at tow speed shortly after

starting out. If the play is correct, make an

adjustment.

WHEEL

Check the wheel runout and damage, and
check the tightness of spokes.

TIRES

Check the tire pressure and check the tires for

wear.

Front
Rear

100 kPa (1.0 kgf/cm^ 15 psi)
100 kPa (1.0 kgf/cm', 15 psi)

THROTTLE GRIP

Turn the throttle grip to see that it operates pro
perly and that the play is normal. Make certain
the throttle springs are closed when released.

"ENGINE STOP" SWITCH

Start the engine and make sure the "ENGINE

STOP" switch functions properly.

FITTINGS/FASTENERS

Always check the tightness of chassis fittings
and fasteners before a ride. Use the chart on

page 46, 47 and 49 to find the correct torque.

-5-

STARTING AND

OPERATION

CAUTION:

Prior to operating the machine, perform

steps listed in pre-operation check list.

A WARNING

Never start your engine or let it run for any

length of time in a closed area. The ex
haust fumes are poisonous and can cause
loss of consciousness and death within a
short time. Always operate your machine
in an area with adequate ventilation.

STARTING A COLD ENGINE

AWARNING

Before starting the engine, be sure to

shift the transmission into neutral.

1. Turn the fuel cock to "ON".

2. Operate the starter (choke) and complete
ly close the throttle grip.

3. Slide the "ENGINE STOP" switch to the
"RUN".

4. Kick the kick starter with full strength to
start the engine.

5. After the engine starts, warm up for one
or two minutes. Make sure the starter
(choke) is returned to the original position
before riding.

STARTING A WARM ENGINE

To start a warm engine, refer to the "Starting
a cold engine" section. The starter (choke)
should not be used. The throttle should be
opened slightly.

CAUTION:

See "Break-in Section" prior to operating
engine for the first time.

WARMING UP

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.

A WARNING

Before starting off, be sure to turn up or
remove the side stand.
Failure to retract the side stand completely
can result in a serious accident when you
try to turn a corner.

ENGINE BREAK-IN

1. Prior to starting, fill fuel tank with gasoline

and oil tank with specified oil.

2. Allow engine to warm up. Check engine
idling speed. Check operating controls

and engine stop switch operation.

3. Operate machine is lower gears at

moderate throttle setting for 3 — 5 min
utes. Check spark plug condition.

4.

Allow engine to cool. Repeat procedure,
running for 5 minutes. Very briefly, shift
to higher gears and check full throttle
response. Check spark plug condition.

5.

Allow engine to cool. Repeat procedure,

running for 5 minutes. Full throttle and
higher gears may be used, but avoid sus
tained full throttle operation. Check spark
plug condition.

6.

Allow engine to cool. Remove top end
and inspect. Remove "high" spots on
piston with No. 600 grit, wet sandpaper.
Clean, and carefully reassemble.

7.

Check entire unit for loose or misadjusted
fittings/controls/fasteners.

8.

Re-start engine and check through entire
operating range thoroughly. Stop. Check
spark plug condition. Re-start. After 10 ~

15 minutes operation, machine is ready
to ride.

-6-

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. For example, if the machine is continually operated
in an area of high humidity then all parts must be lubricated much more frequently that shown
on the chart to avoid rust and damage. If you are in doubt as to how closely you can follow these
time recommendations, check with the Yamaha dealer in your area.

Lubrication intervals

Item

Transmission oil change

Drive chain

Con trol cables All apply thoroughly

Throttle grip and housing App ly lig htly

Brake pe dal shaft

Stand sh aft pivot

Front forks

Steering ball race

Wheel bearings Do not over-p ack yearly or...

Warm en gine before draining

Lub e/Adjust as req uired

Rem ove/ Clea n / Lube/ Adjust

App ly lig htly

App ly lig htly

Drain completely

Inspect thoroughly / Pack
moderately

Rem arks

Yam alub e 4-cycle oil or SAE 10W30
type SE motor oil

Yam alub e Chain and Cable L ube or
SAE 10W 30 m otor oil

Yam aha Cable Lub e or WD-40

Yam aha Cable Lub e or WD-40

Yam aha Cable Lub e or WD-40

Yam aha Cable Lub e or WD-40

Yam aha fork oil 20 wt or equivalent

Medium-weight wh eel bearin g grease

Medium-weight wh eel bearin g grease

Periodic maintenance intervals

Item

Brake sy stem (com plete)

Clutch

Spa rk plug

Spa rk arrester

Wheels and tires

Fittings and fasten ers

Drive chain

Air filter Wet type — clean / Replace as required (No .2)

Fue l cock

Ignition timing

Autolube pum p

Carburetor ad justm ent Chec k / operation / Timings

Carburetor overhaul

Cylinder compression Preventive maintenance check

Dec arbonize e ngin e

Che ck / Adjust as required — repair as required

Che ck / Adjust as required

Inspect / Clean or replace as requ ired

Clean

Pressure / Runout / Spoke — tension

Tighten before eac h trip and / or

Ten sion / Alig nment (No.1)

Clean / F lush tank as require d

Adjust / Clean or replac e as required

Che ck / Adjust / Air bleeding

Clean / R epair as required / Refit / Adjust

Includes exhaust s ystem

Rem arks

Typ e

Initial (hour)

10 20 40

O

O O

See service notes

o
o

The reafter

every (hour)

80 4 0 80 160

O
o o
o o

o
o

o
o

o o
o

o O o

Initial (hour)

10 20 40 80 40 80 160

o o O
o o o

O o o o

O o o o
o o o o
o o o o

o o o o

o o o

o o o o

o o o o

o o

o

o o o o

o o

The reafter

every (hour)

o

o

o

o

SERVICE NOTES:_____________________________________________________________

No. 1. DRIVE CHAIN: In addition to tension and alignment, chain must be lubricated every 0.5-1.0

hour. If unit is subjected to extremely hard usage and wet weather riding, chain must

be checked constantly. See "Lubrication Intervals" for additional details.

No. 2. AIR FILTER: Remove and clean filter every 20 - 40 hours.

-7-

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 ENGINE SERVICE

1. Dial Gauge

P/N. YU-3097

This tool is used for adjusting the oil pump

stroke.

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 ELECTRICAL SERVICE

1. Yamaha Pocket Tester

P/N. YU-3112-C

Use this tool to inspect the coil resistance, out
put voltage and amperage.

2. Inductive Timing Light

P/N. YM-33277-A

This tool is necessary for checking the ignition
timing.

3. Rotor Holding Tool

P/N. YU-1235

This tool is used when loosening or tightening
the flywheel magneto securing nut.

2. Dynamic Spark Tester

P/N. YM-34487

This instrument is necessary for checking the
ignition system components.