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

permission of Yamaha Motor Corporation

U.S.A. is expressly prohibited.

Printed in Japan.

P/N. LIT-11626-18-30

LIT-CALIF-65-01

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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Some data in this manual may become outdated due to improvements made to this model in the future.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.

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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.

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

riding.

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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.

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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

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A SAFETY INFORMATION

1. Don't ride it on the street.

2. Don't run the engine inside a building.

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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.

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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.

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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.

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9. Don't touch rotating or moving parts.

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

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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

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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.

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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.

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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

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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

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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.

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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

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.

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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.

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.

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.

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

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

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.

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Page 19

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

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 fork oil 20 wt or equivalent

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

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

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

The reafter

every (hour)

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.

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Page 20

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.

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LUBRICATION

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Page 22

ADJUSTMENT

A WARNING

The engine, exhaust pipe(s), and muffler(s) will be very hot after the engine has been run. Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.

SPARK PLU^

Standard spark plug:

BP6HS (NGK) or W20FP (DENSO)

1. Measure the electrode gap with a wire

thickness gauge.

This situation is quite common during the engine break-in period. However, use the standard plug. If the insulator tip shows a very light tan or white color or is actually pure white or if the electrodes show signs of melting, then a spark plug with a col der heat range is required.

NOTE:

If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1 /4 to 1 /2 turns past finger tight. Have the spark plug torqued to the cor rect value as soon as possible with a torque wrench.

______________________________

IGNITION TIMING CHECKING

1. Ignition timing is checked with Inductive Timing Light by observing the position of the stationary punch mark on the stator and the punch mark on the rotor.

Adjustment can be made by bending the side electrode.

Electrode gap:

0.6-0.7 mm (0.024-0.028 in)

When installing the plug, always, clean the gasket surface and use a new gasket. Wipe off any grime from the threads and torque the spark plug properly.

Spark plug torque:

25 Nm (2.5 m-kg, 18 ft lb)

2. The insulator must be a medium-to-light

tan color. If not, check carburetion, igni tion timing and gas-oil mixing ratio.

If the porcelain is a very dark brown or black color, then a plug with a hotter heat range may be required.

1. Punch mark

^ Using a Inductive Timing Light, check to

see that the stationary punch mark and punch mark on the flywheel magneto are aligned.

a. Remove the crankcase cover (L). b. Connect the timing light to the spark plug

lead.

c. Start the engine and keep it running at the

specified speed. Use a tachometer for checking.

2. Stationary punch mark

■10-

Page 23

d. While running the engine at the specified

speed, check to see that the stationary punch mark is aligned with the punch mark. If the marks are out of alignment, check to see that the woodruff key is broken or flywheel assembly is out of

alignment.

Ignition timing: 20.6°/4,000 r/min

AIR FILTER CLEANING

The most critical aspect of routine maintenance on a racing machine is proper air filter mainte

nance. The air filter on a motocross must be serviced after every practice session and moto to ensure maximum engine performance and

life. For convenience, many racers prepare two or three spare air filters ahead of time and simp

ly switch filters between practices and motos.

Follow these instructions to service foam air

filters correctly:

3. Using uncontaminated cleaning solvent, thoroughly wash the filter element; wash it gently to avoid damage.

4. Squeeze the solvent from the filter ele ment.

1. Remove the cleaner case cap.

2. Pull out the element and guide from the

cleaner case cap.

CAUTION:

Do not twist or wring the filter element,

as it can easily be torn or otherwise dam aged.

5. Using liquid dishwashing detergent and water, again wash the air filter element.

Rinse the element with water, squeeze it,

and allow the element to dry completely.

6 Pour a liberal amount of high-quality,

foam-air-filter oil into a plastic bag. Put the filter element in the bag and thorough

ly work the oil into the element.

-11

Page 24

Recommended oil: Foam-air-filter oil

If for any reason you should use another

type, use air cooled 2-stroke engine oil.

CAUTiON:

Never use motor oil on a foam air filter ele ment. Motor oil will not remain suspend ed in the filter element.

7. Remove the filter element from the plastic bag and squeeze out the excess oil. Again, avoid twisting or wringing the air filter element. The element should be damp, but not dripping, with oil.

CAUTiON:

Never operate the engine with the air filter

element removed. This will allow un filtered air to enter, causing rapid wear and

possible engine damage. Additionally, operation without the filter element will

affect carburetor jetting with subsequent

poor performance and possible engine

overheating.

THROTTLE CABLE ADJUSTMENT

Check the play in turning direction of throttle grip. The play should be 3~5 mm (0.12 — 0.20 in) at grip flange, loosen the lock nut and turn the cable adjuster to make the necessary ad

justment. Tighten the lock nut.

8. Reinstall the filter in the machine, and

make sure the sealing surface of the filter is seated properly. Complete reassembly of the machine, and check all the fittings for tightness.

NOTE:

Each time filter element maintenance is per

formed, check the air inlet to the filter case for obstructions. Check the air cleaner joint rub ber to the carburetor and manifold fittings for an air-tight seal. Tighten all fittings thoroughly to avoid the possibility of unfiltered air enter ing the engine.

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

IDLE SPEED ADJUSTMENT

1. Turn the pilot air screw in until lightly

seated.

2. Back out 1 and 1 /2 turns. Start the engine

and warm it up.

1. Pilot air screw

Pilot air screw:

1-1/2 turns out

3. Turn the throttle stop screw until idle is

at desired r/min.

-12-

Page 25

4. Turn the pilot air screw in or out until the

idle speed is at the highest possible r/min.

5. Turn the throttle stop screw in or out un til idle speed is at desired r/min.

Idle speed:

1,650—1,750 r/min

1. Throttle stop screw

If the engine, when warm, hesitates after adjusting as described, turn the idle air mixture screw in or out in 1/4 turn in crements until the problem is eliminate.

NOTE: --------------------------------------------------

Pilot air and throttle stop screws should be ad

justed so that engine response from idle posi

tion is rapid and without hesitation.

AUTOLUBE PUMP

1. Cable adjustment

a. Remove the grommet from the oil pump

cover.

b. Start the engine.

c. When the throttle cable becomes tight

and the engine begins to run faster, hold the throttle grip steady and check to see that the match mark on the adjust pulley

is aligned with the pump case mark. If not, loosen the pump cable locknut and make adjustment by turning the adjuster.

1. Adjuster

Lock nut

NOTE:-

After adjusting, be sure to tighten the lock nut completely.

2. Air bleeding

The oil pump just be bled after the oil pipe

or oil pump is reinstalled. a. Remove the oil pump cover. b. Remove the bleeder bolt. c. When the bleeder bolt is removed, oil con

taining air bubbles flows out. Let the oil flow out until air bubbles completely disappear, and reinstall the bleeder bolt.

NOTE:

______________________________

• Place a rag or oil can under the engine.

• Add the Autolube oil to the oil tank before

bleeding.

• Thoroughly clean the engine exterior of oil.

3. Minimum plunger stroke adjustment

a. Set the dial gauge as illustrated, and

check to see if the plunger stroke is cor rect while keeping the engine idling.

1. Set position

3. Pump case mark

2. Mark

-13-

Page 26

b. To adjust the plunger stroke, first loosen

the lock nut.

c. Turn the adjusting bolt in or out for pro

per adjustment.

Turning the adjusting bolt clockwise de

creases the plunger stroke; while turning counterclockwise increases the plunger stroke.

d. When the correct stroke is attained,

tighten the lock nut.

Free play (a):

10-20 mm (0.39 - 0.79 in)

Minimum stroke

Maximum stroke

0.40 - 0.45 mm

(0.016^0.0l8in)

1.00 ~ 1.10 mm

(0.039 «^0.043 in)

FRONT BRAKE ADJUSTMENT

Front brake cable free play can be adjusted to suit rider preference, but a minimum free play of 10 ~ 20 mm (0.39 ~ 0.79 in) should be maintained. Free play can be ad

justed at handlebar lever and brake shoe

plate.

1. Loosen the lock nut on the brake lever

holder and then, fully turn the adjuster in.

2. Loosen the lock nut on the shoe plate and

turn the adjuster in or out until proper ad justment is achieved.

3. Unless the shoe plate adjuster helps bring

a proper play, turn the lever holder ad juster.

4. Tighten the lock nuts.

REAR BRAKE ADJUSTMENT

The rear brake should be adjusted so the end of the brake pedal moves 20 ~ 30 mm (0.8 ~ 1.2 in). To adjust, turn the adjuster on the brake

rod clockwise to reduce play; turn the adjuster counterclockwise to increase play.

Free play (a):

10-20 mm (0.39 - 0.79 in)

-14-

Page 27

DRIVE CHAIN SLACK CHECK

NOTE:

Before checking and/or adjusting, rotate rear wheel through several revolutions and check tension several times to find the tightest point. Adjust chain tension with rear wheel in this "tight chain" position.

Elevate the rear wheel by placing the suit able stand under the engine.

Then measure the play at the bottom of the

chain at a point midway between the drive and driven sprockets.

________________________

3. Adjusting nut

4. After adjusting, be sure to tighten the

rear wheel axle nut.

Tightening torque:

60 Nm (6.0 m • kg, 43 ft • lb)

5. Also tighten the lock nuts against the

rear arm.

The normal vertical deflection is approximate ly 40~53 mm (1.6~2.1 in). If the chain deflection is not as specified, adjust the chain tension.

Drive chain slack (a):

40 ~ 53 mm (1.6 ~ 2.1 in)

DRIVE CHAIN SLACK ADJUSTMENT

CAUTION:

Too small chain slack will overload the en gine and other vital parts; keep the slack within the specified limits.

1. Loosen the rear brake rod adjuster.

2. Loosen the rear wheel axle nut and

lock nuts.

3. To tighten chain, turn chain puller adjust

ing nut clockwise. Too loosen chain, turn adjusting nuts counterclockwise and push wheel forward. Turn each adjusting nut exactly the same amount to maintain correct axle alignment. (There are marks on each side of rear arm and on each chain puller; use them to check for proper alignment.)

Tightening torque:

7 Nm (0.7 m-kg, 5.1 ft-lb)

6. In the final step, adjust the play in the

brake pedal.

DRIVE CHAIN LUBRICATION

The chain consists of many parts which work against each other. If the chain is not maintain ed properly, it will wear out rapidly. Form the

habit of periodically servicing the chain. This

service is especially necessary when driving in

dusty conditions.

1. Use any of the many brands of spray type chain lubricant. First, remove dirt and mud from the chain with a brush or cloth and then spray the lubricant between both rows of side plates and on all center rollers.

2. To clean the entire chain, first remove the chain from the machine, dip it in solvent and clean out as much dirt as possible. Then take the chain out of the solvent and dry it. After drying, lubricate the chain to prevent the formation of rust.

-15-

Page 28

TIRE PRESSURE CHECK

Improper tire pressure affects the smoothness of the tire, traction, handling and the life of the tires. Always maintain the correct tire pressure.

Tire pressure:

Front 100 kPa (1.0 kgf/cm^, 15 psi) Rear 100 kPad.O kgf/cmM5psi)

CHECK THE SPOKES

If the spokes are loose or bent, tighten or replace them. They should be checked before

each use.

STEERING HEAD INSPECTION

Periodically inspect the condition of the steer ing. Worn out or loose steering bearings may

be dangerous. Place a suitable stand under the engine to hold

the front wheel of the machine off the ground; then hold the lower end of the front fork and try to move forward and backward.

1. Steering shaft bolt

2. Ring Nut Wrench

CAUTION: ___________________

Forks must swing from lock to lock without binding or catching.

3. Tighten the steering shaft bolt.

Tightening torque:

42 Nm (4.2 m *kg, 30ft‘lb)

NOTE:---------------------------------------------------

Steering head disassembly must be perform ed by a Yamaha dealer or other qualified mechanic.

FRONT FORK OIL CHANGE

A WARNING

1. Fork oil leakage can cause loss of stability and safe handling. Have any

problem corrected before operating

the machine.

2. Support the machine securely so there is no danger of it falling over.

STEERING HEAD ADJUSTMENT

1. To adjust, loosen the steering shaft bolt.

2. Use the Ring Nut Wrench to tighten the

ring nut.

1. Elevate the front wheel by placing a suitable stand under the engine.

2. Remove the brake cable clamp.

1. Brake cable clamp

-16-

Page 29

3. Remove the number plate.

NOTE:

Select the weight oil that suits local conditions and your preference (lighter for less damping; heavier for more damping).

11. After filling, slowly pump the outer tube

______________________________

up and down to distribute the oil.

4. Remove the handlebar.

5. Remove the front wheel. (Refer to page

32.)

6. Remove the cap bolt from the inner tube.

7. Loosen the pinch bolt.

8. Remove the front fork.

9. Drain the fork oil.

10. Installing the front fork on the machine.

Bring up the front fork to the correct po sition and partially tighten the underbrack et pinch bolt.

Pour specified amount of oil into the in ner tube through the upper end opening.

NOTE:

Adjust the oil levels in both right and left front forks so they are even.

12. Inspect 0-ring on fork cap bolt and

1. Cap bolt

13. Install the front wheel. (Refer to page 32.)

14. Install the handlebar.

___________^__________________

replace if damaged. Install the fork cap bolt and torque to

specification.

Fork cap bolt torque:

40 Nm (4.0 m • kg, 29 ft • lb)

2. 0-ring

Handle holder upper torque:

13 Nm (1.3 m.kg, 9.4 ft-lb)

Recommended oil:

Yamaha fork oil 15 wt or equivalent

Capacity per leg:

60 cm^ (2.1 Imp oz, 20 US oz)

Pinch bolt torque:

33 Nm (3.3 m-kg, 24 ft-lb)

15. Install the number plate and the brake ca ble clamp.

REAR SHOCK ABSORBER (MONOCROSS

SUSPENSION "DE CARBON" SYSTEM)

A WARNING

This shock absorber contains highly com pressed nitrogen gas.

Read and understand the following infor mation before handling the shock ab

sorber. The manufacturer cannot be held responsible for property damage or per sonal injury that may result from improper handling.

-17-

Page 30

1. Do not tamper with or attempt to open the cylinder assembly. Injury may result.

2. Do not subject shock absorber to an open flame or other high heat. This may cause the unit to explode due to excessive gas pressure.

3. Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance.

4. Handle it with great care, for a score or scratch in the piston rod sliding portion will cause oil leakage.

NOTES ON DISPOSAL (YAMAHA DEALERS ONLY)

Gas pressure must be released before disposal of shock absorber. To do so, drill a 2 ~ 3 mm (0.08 ~ 0.12 in) hole ® through the cylinder

wall at a point 10 ~ 15 mm (0.4 ~ 0.6 in) (a)

above the bottom of the cylinder.

2. Remove the spring guide.

NOTE: ______________________________ While compressing the spring, remove the

spring guide.

3. To stiffen the spring preload, install the circlip into the groove (a). To soften the spring preload, install the circlip into

the groove ®.

NOTE: ______________________________ Do not spread the circlip too much.

CAUTiOM;

Wear eye protection to prevent eye damage from escaping gas and/or metal chips.

A WARNING

To dispose of a damage or wornout shock

absorber, take the unit to your Yamaha dealer for this disposal procedure.

REAR SHOCK ABSORBER SPRING PRE LOAD ADJUSTMENT

1. Remove the rear shock absorber. (Refer to page 34.)

Standard installation position.

Groove (g)

4. Install the spring guide.

NOTE:

_________________

While compressing the spring, install the spring guide.

5. Install the rear shock absorber. (Refer to page 35.)

■18-

Page 31

MAINTENANCE AND MINOR

REPAIRS

PREPARATION FOR

SERVICE

1. Before servicing the machine, be sure to

clean machine exteriors.

2. Place the removed parts, always on a tray

in the order of removal.

3. When replacing parts, always use genuine

Yamaha parts to maintain better perfor

mance, durability and safety.

4. All gaskets and seals should be replaced when an engine is overhauled. All gasket surfaces must be cleaned.

5. Properly oil all mating engine and trans

mission parts during assembly.

6. All circlips should be inspected before

assembly. Replace distorted circlips.

7. Always replace cotter pins and piston pin

clips after one use.

8. When installing parts, apply grease or oil to them, as required, and following the torque chart. (Refer to "Maintenance and

Lubrication Schedule Chart.")

9. For assembly, reverse the procedure for

removal.

ENGINE

CARBURETOR

-19-

1. Turn fuel cock lever to the "OFF".

2. Disconnect the fuel hose and oil delivery

pipe.

3. Loosen the carburetor joint screw and air

cleaner joint screw.

Page 32

4. Rotate the carburetor, remove the mix ing chamber top, and carburetor assem bly.

1. Carburetor

5. Remove the float chamber body and main

jet.

Standard main jet: #125

2. Mixing chamber top

Inspection

1. Examine carburetor body and fuel

passages. If contaminated, wash car buretor in petroleum based solvent. Do not use caustic carburetor cleaning solu

tions. Blow out all passages and jets with compressed air.

2. Examine condition of floats. If floats are leaking or damaged, they should be replaced.

3. Inspect inlet needle valve and seat for

wear or contamination. Replace these components as a set.

r- IMPORTANT;

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

The Carburetor has been set for

normal sea level conditions. The standard setting is the result of exten sive testing and does not usuaiiy re quire changing. However, under condi tions of high atmospheric pressure or heavy ioad (deep sand or mud) the standard main jet should be replaced with another main jet. if the carburetor requires any other setting changes to suit iocai conditions of aititude, weath er, etc., the change must be made with great care. Improper carburetor setting changes wiil cause poor engine perfor

mance and possibie engine damage. Please consult a Yamaha dealer or other

qualified mechanic about any carbure tor setting changes before actuaiiy go

ing about them.

Adjustment

1. Float height a. Checking

Hold the carburetor in an upside down position. Incline the carburetor at 60°~70° (so that the end of the float valve does not hang down of float weight), and measure the distance from the mating surface of the float chamber (gasket removed) and carburetor to the

top of the float using a gauge.

Float height:

20.8 - 22.8 mm (0.82 - 0.90 in) Level with carburetor base

-20-

Page 33

b. Adjustment

CAUTION:

L The valve stopper controls the movement

of the valve. Check the valve stopper height.

Check the needle valve and valve seat for

wear before adjustment.

Make the adjustment by bending the tang

on the float arm.

2. Jet needle

The mid-range air/fuel supply is affected by the position of the needle in the nee dle jet. If it is necessary to alter the mid

range air/fuel mixture characteristics of the machine, the jet needle position may be changed. Move the jet needle up for a leaner condition or toward the bottom position for a richer condition.

Jet needle type: 3E3 Clip position: No. 3 Groove

Valve stopper height (a):

7.4~7.8 mm (0.291 -0.307 in)

If the valve stopper height is not within

specification, replace the valve stopper.

tolerance, replace reed valve.

Reed valve bending limit:

0.2 mm (0.008 in)

Inspection

1. Inspect rubber intake manifold for signs

of weathering, checking or other deterio

ration.

2. Inspect reed petals for signs of fatigue and cracks. Reed petals should fit flush or nearly flush against neoprene seats. If in doubt as to sealing ability, apply suction

to carburetor side of assembly. Leakage

should be slight to moderate.

5. Manifold:

Check the distortion of manifold surface. If the distortion is out of limit, resurface it on the #600 wet sandpaper.

Distortion limit: 0.1 mm (0.004 in)

-21-

Page 34

MUFFLER

With the carburetor removed, proceed as follows:

^WARNING

Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester.

Removal

1. Remove the two nuts and remove seat.

2. Remove the three bolts from the side

cover assembly and two bands.

1. Muffler

a. Using a rounded scraper, remove ex

cess carbon deposits from manifold area of exhaust pipe.

b. Check muffler gasket condition. The

gasket seat is located around the

cylinder exhaust port.

2. Spark arrester cleaning a. Remove the bolt ®. b. Remove the tailpipe (2) by pulling out

of the muffler.

c. Use a wire brush to remove any car

bon deposits from the spark arrester portion of the tailpipe (2).

d. Tap the tailpipe (2) lightly and remove

the carbon deposits from the outside

portion of the tailpipe.

e. Insert the tailpipe into the muffler

and align the bolt hole.

f. Install the bolt ® and tighten it.

3. Remove the muffler mounting bolts from the cylinder and remove the silencer

mounting bolts.

Maintenance

^WARNING

•Always let the exhaust system cool prior

to touching exhaust components.

•Do not start the engine when cleaning

the exhaust system.

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

------------------------------------------------------------------------------------------------------------------------------------------------^22-

Tightening torque:

8 Nm (0.8 m-kg, 5.8 ft-lb)

1. Bolt

a. Tailpipe

TOP END Removal

1. Remove spark plug cap and spark plug.

2. Remove the cylinder head securing nuts

(4 nuts).

Remove cylinder head and gasket.

Page 35

NOTE:

Break each nut loose (1/4 turn) prior to remov

ing.

_________________________

Maintenance

Cylinder head

1. Using a rounded scraper, remove car

bon deposits from combustion chamber.

Take care to avoid damaging the spark

plug threads. Do not use a sharp instru ment. Avoid scratching the metal sur

face.

3. With the piston at top dead center, raise

the cylinder until the cylinder skirts clear crankcase. Stuff a clean shop rag into crankcase cavity, around rod, to prevent dirt and other foreign particles from enter

ing. Remove cylinder.

4. Remove the piston pin clip from the

piston. Push the piston pin out from op posite side. Remove the piston.

NOTE:

If the pin hangs up, use a piston pin puller. Do

not hammer on pin as damage to rod, piston and bearing will result.

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

2. Place the head on a surface plate. There

should be no warpage. Correct by resur facing. Place 400 ~ 600 grit wet emery sandpaper on surface plate and re-sur face head using a figure-eight sanding pattern. Rotate head several times to avoid removing too much material from one side.

3. Clean the spark plug gasket mating sur face throughly.

Cylinder

1. Using a rounded scraper, remove carbon

deposits from exhaust port.

■=!-23-

Page 36

2. Check cylinder bore. Using a cylinder hone, remove any scoring. Hone lightly, using smooth stones. Hone no more than required to avoid excess piston clearance.

center and bottom just above exhaust

port. Compare minimum and maximum measurements. If over tolerance and not correctable by honing, rebore to next oversize.

Piston

1. Using a scraper, remove carbon deposits

from piston crown.

2. Break a used piston ring in two. File end square. De-burr edges to avoid scratching ring groove and clean carbon deposits from ring grooves.

Using 400 ~ 600 grit wet sandpaper, lightly

sand score marks and lacquer deposits

from sides of piston. Sand in a crisscross

pattern. Do not sand excessively.

Piston outside diameter measurement

Using an outside micrometer, measure piston diameter. The measuring point is at right-angles to the piston pin holes, about 5 mm (0.2 in) from the bottom of the piston skirts. Make a correct calculation of the piston clearance using the following formula.

• PISTON CLEARANCE

= Minimum Cylinder Diameter

- Maximum Piston Diameter

Piston clearance

1. Cylinder bore measurement

Using a cylinder gauge set to standard

bore size, measure the cylinder. Measure front-to-rear and side-to-side at top.

EXAMPLE:

PISTON CLEARANCE

= 47.000 mm-46.965 mm = 0.035 mm

(1.8504 in-1.8490 in = 0.0014 in)

Norminal piston clearance

0.033-0.038 mm (0.0013-0.0015 in)

-24-

Page 37

If beyond tolerance replace piston or rebore cylinder as required.

Piston rings

1. Remove ring from piston.

2. Insert ring into cylinder. Push down ap

proximately 20 mm (0.79 in) using piston crown to maintain right-angle to bore.

Measure installed end gap. If beyond

tolerance, replace.

Ring end gap installed (top and 2nd):

0.15-0.35 mm (0.006-0.014 in)

3. With rings installed in grooves, insert feeler gauge between ring and groove. If beyond tolerance, replace ring and/or piston as required.

Ring groove clearance:

0.020-0.060 mm (0.0008-0.0024 in)

NOTE:

New rings require break-in. Follow first portion

of new machine break-in procedure.

Piston pin bearing and connecting rod

1. Check the pin for signs of wear. If any

2. Check the pin and bearing for signs of

3. Check the bearing cage for excessive

4. Apply a light film of oil to pin and bear

5. Mount the dial gauge at right angles to

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

wear is evident, replace pin and bearing.

heat discoloration. If excessive (heavily blued), replace both.

wear. Check the rollers for signs of flat spots. If found, replace pin and bearing.

ing surfaces. Install in connecting rod small end. Check for play. There should

be no noticeable vertical play. If play ex ists, check connecting rod small end

diameter for wear. Replace pin and bear ing or all as required.

connecting rod small end holding the bot tom of rod toward the dial indicator, rock top of rod and measure axial play.

Holding cylinder towards light, check for

full seating of ring around bore. If not fully seated, check cylinder. If cylinder is not out-of-round, replace piston ring.

During installation, make sure ring ends

are properly fitted around ring locating pin

in piston groove. Apply liberal coating of

two-stroke oil to ring.

Connecting rod axial play:

1.0 mm (0.04 in)

-25-

Page 38

6. Remove the dial gauge and slide the con

necting rod to one side. Insert a feeler

gauge between the side of the connec ting rod big end and the crank wheel.

Measure clearance.

Connecting rod/crank side clearance:

0.30-0.80 mm (0.012-0.031 in)

7. If any of the above measurements exceed tolerance, crankshaft repair is required. Take the machine to your authorized dealer.

8. During reassembly apply a liberal coating of two-stroke oil to the piston pin and

bearing. Apply several drops of oil to the connecting rod big end. Apply several drops of oil into each crankshaft bearings oil delivery hole.

CLUTCH

Removal

1. Remove the kick starter.

2. Remove the pan head screws holding the case cover in place and remove the cover. Note the position of the dowel pins.

NOTE:

Drain transmission oil before removing cover.

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

3. Using the Rotor Holder, remove the

clutch securing nut and lock washer. Re move the clutch boss and driven gear

(clutch housing).

-26-

Page 39

1. Rotor Holder

4. Remove the circlip, pressure plate, clutch plates, friction plates, one-way clutch, and clutch boss from the clutch housing.

Inspection

1. Measure each clutch spring and off

spring. If beyond tolerance, replace.

NOTE:

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

For optimum performance, if any plate requires replacement, it is advisable to replace the en

tire set.

4. Check each clutch plate for signs of heat damage and warpage. Place on surface plate (plate glass is acceptable) and use feeler gauge.

Clutch plate warp allowance:

0.1 mm (0.004 in)

OFF spring free length

Clutch spring free length

New

30.5 mm (1.20 In)

12.9 mm (0.51 in)

Minimum

28.5 mm (1.12 in)

11.9 mm (0.47 in)

2. Check the plates for signs of warpage and

heat damage, replace as required.

3. Measure the friction plates at three or four

points. If their minimum thickness ex ceeds tolerance, replace.

Friction plate

thickness

New

3.0 mm

(0.118 In)

Wear limit

2.7 mm

(0.106 in)

Checking the ball

Check balls for excessive wear or damage. If such wear is found, replace balls. Checking the ratchet mechanism Check for damage or wear on each pawl and dog. If damaged or worn to excess, replace it. Check the pawl-spring for damage and tension. If damaged or fatigued to excess, replace it.

-27-

Page 40

7. Measure the gap between the friction plate and pressure plate with a thickness gauge.

If the gap is found incorrect, it should be properly adjusted by changing the

thickness of the clutch plate.

Thickness:

1.2, 1.4 or 1.6 mm (0.047, 0.055, 0.063 in)

Clutch adjustment gap (a):

1.40-1.75 mm (0.055-0.069 in)

KICK STARTER

Removal

1. Unhook the kick spring from its post in the crankcase. Allow it to relax. Then

remove the kick axle assembly by rotating

the shaft counterclockwise and then pull ing out the entire assembly. Check the gear teeth for wear and breakage.

Inspection

1. The kick clip friction force is 0.9 — 1.5 kg

(2.0-3.3 lb). If above pressure is too strong, spring

wear and kick starter slipping will result.

If it is too weak, the same slippage will occur particularly at low temperatures. Do not try to bend the clip.

2. Check the clip for damage and wear, and determine whether or not, it should be

replaced.

-28-

Page 41

Reassembly

1. While keeping the kick stopper upwards, engage the kick axle return spring with the slot on the end of the kick axle. And hook the spring to the spring hook. Check whether the kick starter acts cor rectly and whether it returns to its home position.

2. After installing the kick assembly be sure

to check whether it operates smoothly or not.

Inspection

1. Check the shift shaft for bends. If bent excessively replace it.

2. Check the shift lever and the return spring

for fatigue. If fatigued excessively, replace it.

3. Check the stopper lever for wear. If worn to excess, replace it.

SHIFTER

NOTE:

Shifter maintenance should be performed with

clutch assembly removed.

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

Removal

1. Remove the shift lever assembly and stop per lever.

4. After installation of the shift shaft, check the clearances A and A' (between the prongs of shift lever 1 and shift drum pins) are equal.

1. Stopper lever

Installation

1. Before installation, grease the shift shaft

oil seal.

2. Be sure to install the stopper lever first, and then shift shaft assembly.

-29-

Page 42

CRANKCASE

®=3»y

KICK STARTER

-30-

Page 43

CHASSIS

FRONT WHEEL

REAR WHEEL

0 16Nm (1.6m-kg,11ft lb)

0 16Nm (1.6m kg,1in ibf

07Nm (0.7m-kg,5.1ft-lb)

g) \ 7Nm (0.7m-kg,5.1ft-lb)

25Nm (2.5m-kg,18ft lb)

0: Tightening torque 0: Apply grease

0 7Nm (0.7m kg,5.1ft-lb)

60Nm (6.0m-kg,43ft-lb)

-31

Page 44

FRONT WHEEL Removal

1. Elevate the front wheel by placing a

suitable stand under the engine.

2. Remove the brake cable: Loosen all ca

ble adjuster screws and remove cable from handle lever holder. Then remove cable from cam lever at front brake shoe plate.

3. Remove the axle nut ® and the wash er®.

REAR WHEEL Removal

1. Elevate the rear wheel by placing a

suitable stand under the engine.

2. Remove the tension bar and the brake rod from the brake shoe plate. The tension bar can be removed by removing the cotter pin and nut from the tension bar bolt. The brake rod can be removed by removing the adjuster.

Disconnect the drive chain. Loosen the lock nuts and chain slack

4. adjusting nuts on both sides.

Remove the axle nut and washer.

4. Turn and pull out the front wheel axle; the wheel assembly can now be removed.

Installation

When installing front wheel, reverse the

removal procedure taking the following steps:

1. Check for proper engagement of the boss

on the outer fork tube with the locating slot on the brake shoe plate.

2. Tighten the axle nut. Axle nut torque:

35 Nm (3.5 m -kg, 25 ft lb)

1. Adjuster

2. Brake rod

3. Tension bar

4. Lock nut

5. Adjusting nut

6. Axle nut

Washer

6. The rear wheel assembly can be removed from the machine by pulling the wheel axle.

Installation

The rear wheel can be installed by reversing the removal procedure. Take the following steps.

1. When connecting the chain, make certain closed end of master link clip is facing direction of rotation.

-32-

2. Be sure to adjust the chain slack. (Refer

to "Drive chain slack adjustment".)

Page 45

3. Tighten the axle nut and tension bar

nut.

Axle nut torque:

60 Nm (6.0 m*kg, 43 ft»lb)

Tension bar nut:

16 Nm (1.6 m*kg, 11 ft*lb)

4. Insert the new cotter pin into the ten sion bar bolt.

A WARNING

Always use a new cotter pin.

4. Starting opposite the valve stem on one side, use two round-ended tire irons to work the bead off the rim.

NOTE:

Use a tire removal lubricant and be careful not

to pinch the tube vyith the tire irons.

5. Remove the valve stem from its hole and

6. If the tire is to be changed, remove the

____

_____________________

remove the tube.

second bead from the rim using the tire

irons and tire lubricant.

5. Bend the end of the cotter pin.

BRAKE SHOE INSPECTION

Measure the outside diameter of the brake shoe

set with slide calipers.

If they measure less than replacement limit, replace them. Smooth out any rough spots on shoe surface with sandpaper.

Brake shoe diameter

Replacement limit

Front

95 mm

(3.74 in)

92 mm

(3.62 in)

Rear

110 mm (4.33 in)

107 mm

(4.21 in)

BRAKE DRUM INSPECTION

Check the inner surface of the brake drum and remove any scratches with emery cloth. Remove any oil with a cloth dipped in solvent. If damage is more extensive, have a Yamaha dealer or other qualified mechanic replace the

wheel hub.

TIRE

Removal and repair

1. Remove the wheel from the machine.

2. Remove the lock nut from valve stem and release as much air as possible from the

tire.

3. Push both tire beads away from the edges of the rim.

Inspection

1. Use a cloth to check for nails or other

sharp objects in the tire.

CAUTION:

_____________________

Always use a cloth to avoid cutting your

hand.

2. Check for faults in the side wall. If there is any fault, the tire should be replaced as a damaged tire may burst at high speeds, which is extremely dangerous.

3. Inflate the tube with air and check the

valve stem and the tube for damage and

leakage, replace as required. Some leaks can be patched in an emergency, but it is best to replace tube.

Reassembly

1. Install one tire bead on the rim using tire irons and lubricant and then install the tube.

2. Inflate tube with air to about one-third the

specified pressure. Hit the outer cir

cumference of the tire with a soft ham mer to make certain the tube is hot caught between tire and rim. Release air from

tube.

Inspect rim band and replace if damaged.

Install second tire bead starting opposite the valve stem using the irons and tire mounting lubricant.

Inflate tire to approximately 294 kPa (3

kgf/cm^, 42 psi) and then reduce pres sure to specified setting.

-33-

Page 46

CAUTION:

_____________________

Check the valve stem; it must be pointing directly at center of wheel hub. If angled in any direction, release air and adjust tube position.

REPLACING WHEEL BEARINGS

If the bearings allow excessive play in the wheel

or if they do not turn smoothly have your dealer

replace the wheel bearings.

CHECKING RIM

1. Check for cracks, bends or warpage of rim. If a rim is deformed or cracked, it must be replaced.

2. Check the wheel run-out.

If deflection exceeds tolerance, check

wheel bearing or replace wheel as required.

2. Turn the fuel cock to “OFF" and discon nect the fuel pipe.

3. Remove the fuel tank mounting bolt and holding band from fuel tank. Lift rear of

the fuel tank up and pull back to clear frame mounts. Remove tank.

Rim run-out limits;

Vertical — 2.0 mm (0.08 in)

Lateral — 2.0 mm (0.08 in)

REAR SHOCK ABSORBER (MONOCROSS SUSPENSION) Removal

1. Remove the seat and side cover assembly.

4. Elevate rear wheel by placing a suitable

stand under the engine.

5. Remove the cotter pin and remove the pin

from the frame.

6. Remove the cotter pin and remove the pin

from the swingarm.

-34-

Page 47

7. Remove the rear shock absorber from the machine. (To remove, pull the rear shock

backward while lifting up the frame.)

8. When reassembling, reverse the removal procedure taking care of the following points:

a. Always use new cotter pins.

b. Apply the molybdenum disulfide

grease on the pins.

SWINGARM INSPECTION

1. With shock absorber removed, grasp the ends of the swingarm and move them

from right to left to check for free play.

Swingarm free play: 1.0 mm (0.04 in)

LUBRICATION OF LEVER, PEDALS, ETC.

1. Lubricate the pivoting parts of the brake lever with Yamaha Chain and Cable Lube or SAE 10W30 motor oil.

2. Lubricate the shaft of the brake pedal with

lithium base grease.

-35-

Page 48

CABLE INSPECTION AND LUBRICATION

1. Damage to the outer housing of the vari

ous cables, may cause corrosion and often free movement will be obstructed. An unsafe condition may result so replace as soon as possible.

2. If the inner cables do not operate smooth

ly, lubricate or ask a Yamaha dealer or other qualified mechanic to replace them.

Recommended lubricant:

Yamaha Chain and Cable Lube or SAE 10W30 motor oil

THROTTLE CABLE AND GRIP

LUBRICATION

The throttle twist grip assembly should be greased at the time that the cable is lubricated, since the grip must be removed to get at the end of the throttle cable. Two screws clamp the throttle housing to the handlebar. Once these two are removed, the end of the cable can be held high to pour in several drops of lubricant. With the throttle grip disassembled, coat the metal surface of the grip assembly with a suitable all-purpose grease to cut down fric tion. (See lubrication chart.)

-36-

Page 49

MISCELLANEOUS

ELECTRICAL COMPONENTS AND WIRING DIAGRAM

ELECTRICAL COMPONENTS

0 CDI unit 0 "ENGINE STOP" switch 0 Ignition coil 0 Spark plug d) CDI magneto

COLOR CODE

B.......................Black

0 .......................Orange

B/R

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

B/W

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

Black/Red Black/White

WIRING DIAGRAM

-37-

Page 50

TROUBLESHOOTIIMG

1. No spark is produced or weak.

SPARK GAP TEST

1. Disconnect the spark plug cap from spark

plug.

2. The engine starts but will not pick up

speed.

. Clean or replace.

• Check ignition timing.

• In case of ignition failure

with all the above check

ups providing in good order, replace the C.D.I. unit.

"ENGINE STOP" SWITCH INSPECTION

1. Inspect:

• "ENGINE STOP" switch conduct

Tester (-I-) lead^Black/White lead (T) Tester ( —) lead^Black lead (2)

B/W© B(D

---

OFF

RUN

No continuity in the "OFF" position^ Replace. Continuity in the "RUN" position-»Replace.

---

Tester selector position

fixl

-38-

Page 51

IGNITION COIL INSPECTION

1. Inspect:

•Primary coil resistance

Out of specificationReplace.

CDI MAGNETO INSPECTION

1. Inspect:

• Charging coil resistance

Out of specification-^Replace.

Tester ( + ) lead^Orange lead 0 Tester (-) lead^Black lead (5)

Primary Coil

Resistance

0.32-0.48 n at 20°C (68°F)

Tester Selector

Position

fix 1

2. Inspect:

•Secondary coil resistance

Out of specification-»Replace.

Tester ( + ) leadBlack/Red lead 0 Tester (-) lead-»Black lead (2)

Charging Coil

Resistance

200 - 300 Q at

20°C (68°F)

Tester Selector

Position

fix 100

Tester (+) lead -»Spark plug lead ® Tester (-) lead Orange lead (2)

Secondary Coil

Resistance

5.68-8.52 kQ at 20°C (68°F)

Tester Selector

Position

kfixl

-39-

Page 52

TROUBLESHOOTING

Although Yamaha machines are given a rigid inspection before shipment from the factory, trouble may occur in operation. If this hap pens, check the machine in accordance with the procedures given in the troubleshooting chart below. If repair is necessary, ask a

Yamaha dealer.

The skilled technicians at a Yamaha dealer

provide excellent service. For replacement parts, use only genuine Yamaha parts. Imita

Troubleshooting chart

tion parts are similar in shape but often in ferior in quality of materials and workman ship; consequently, service life is shorter and

more expensive repairs may be necessitated. Any fault in the fuel, compression or ignition

system can cause poor starting or loss of

power while riding. The troubleshooting chart describes quick and easy procedures for

checking these systems.

-40-

Page 53

CLEANING AND

STORAGE

Cleaning

Frequent thorough cleaning of your machine will not only enhance its appearance but will improve general performance and extend the

useful life of many components.

1. Before cleaning the machine:

a. Block off end of exhaust pipe to prevent

water entry; a plastic bag and strong rub ber band may be used.

b. Remove air cleaner or protect it from

water with plastic covering.

c. Make sure spark plug(s), fuel tank cap,

transmission oil filler cap are properly

installed.

2. If engine case is excessively greasy, app

ly degreaser with a paint brush. Do not

apply degreaser to chain, sprockets, or wheel axles.

3. Rinse dirt and degreaser off with garden hose, using only enough hose pressure to do the job.

CAUTION:

Excessive hose pressure may cause water seepage and contamination of wheel bear ings, front forks, brakes, and transmission seals. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers.

4. Once the majority of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old tooth brush or bottle brush is handy to reach hard-to-get-to places.

5. Rinse machine off immediately with clean water and dry all surfaces with a chamois, clean towel, or soft absorbent cloth.

6. Immediately after washing, remove ex cess moisture from chain and lubricate to

prevent rust.

7. Chrome-plated parts such as handlebars,

rims, spokes, forks, etc., may be further cleaned with automotive chrome cleaner.

8. Clean the seat with a vinyl uphostery

cleaner to keep the cover pliable and glossy.

9. Automotive-type wax may be applied to all painted and chrome-plate surfaces.

Avoid combination cleaner-waxes. Many

contain abrasive which may mar paint or protective finish on fuel and oil tanks.

10. After finishing, start the engine im

mediately and allow to idle for several minutes.

NOTE:

Water may enter the air cleaner case during washing the machine. Be sure to remove the grommet attached to the lower left part of the case and drain the water, as required.

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

Storage

Long term storage (60 days or more) of your motorcycle will require some preventive pro

cedures to insure against deterioration. After cleaning machine thoroughly, prepare for storage as follows:

1. Drain fuel tank, fuel lines, and carburetor

float bowl(s).

2. Remove the empty fuel tank, pour a cup of SAE 10W30 oil in tank, shake the tank to coat inner surfaces thoroughly and drain off excess oil. Reinstall the tank.

3. Remove spark plug(s), pour about one tablespoon of SAE 10W30 oil in spark plug hole(s) and reinstall spark plugs. Kick engine over seceral times (with ignition off) to coat cylinder walls with oil.

4. Remove drive chain. Clean thoroughly with solvent and lubricate. Re-install chain or store in a plastic bag (tie to frame for safe-keeping).

5. Lubricate all the control cables.

6. Block up frame to raise both wheels off ground.

7. Tie a plastic bag over exhaust pipe outlet(s) to prevent moisture from entering.

8. If storing in humid or salt-air atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to rub ber parts or seat cover.

NOTE:

Make any necessary repairs before storing the machine.

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

-41

Page 54

General

SPECIFICATIONS

Model:

Code Number

Dimensions:

Overall Length Overall Width Overall Height Seat Height Wheelbase Minimum Ground Clearance

Dry Weight:

Without oil and fuel

Engine:

Engine Type

Cylinder Arrangement

Displacement: Bore X Stroke

Compression a Ratio

Starting System

Lubrication System:

Engine Oil:

Oil Tank Capacity Oil Grade

Item

PW80

3RVJ

1,540mm (60.6in)

640 mm (25.2in) 880 mm (34.6in)

635mm (25.0in)

1,055mm (41.5in)

185mm ( 7.3in)

57.0 kg (125.7 lb)

Air cooled 2-stroke, gasoline, torque induction

Single cylinder, forward inclined

79 cm^ (2.78 Imp oz, 2.67 US oz)

47.0x45.6 mm (1.850x1.795 in)

6.6; 1 Kick Starter

Separate system (Yamaha Autolube)

0.95 L (0.84 Imp qt, 1.00 US qt)

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

Transmission Oil:

Periodic Oil Change 0.65 L (0.57 Imp qt, 0.69 US qt)

Total Amount

Oil Grade

Air Filter:

Fuel:

Type Tank Capacity

Reserve Amount

Carburetor:

Type Manufacturer

0.75 L (0.66 Imp qt, 0.79 US qt) Yamalube 4 (10W30) or SAE 10W30 type SE motor oil

Wet type element

UNLEADED GASOLINE ONLY

4.9 L (1.08 Imp gal, 1.29 US gal)

1.0 L (0.22 Imp gal, 0.26 US gal)

VM15SC MIKUNI

-42-

Page 55

Spark Plug:

Ty pe / Ma n uf a ct u rer

Gap

Item

PW80

BP6HS/NGK, W20FP/DENSO

0.6~ 0.7 mm (0.024 ~ 0.028in)

Clutch Type: Transmission:

Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Transmission Type Operation

Gear Ratio: 1st

2nd 3rd

Chassis:

Frame Type Caster Angle Trail

Tire:

Type Size(F) Size(R)

Tire Pressure:

Front Rear

Brake:

Front Brake Type

Operation

Rear Brake Type

Operation

Wet, centrifugal automatic

Gear 66/21 (3.143) Chain drive

32/15(2.133)

Constant mesh, 3-speed

Left foot operation 39/12(3.250) 29/16(1.812) 22/17(1.294)

Steel tube backbone 26° 62 mm (2.44in)

With tube

2.50-14-4PR

3.00-12-4PR

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

100 kPa (1.0 kgf/cm^ 15 psi)

Drum brake Right hand operation Drum brake Right foot operation

Suspension:

Front Suspension

Rear Suspension

Shock Absorber:

Front Shock Absorber Rear Shock Absorber

Wheel Travel:

Front Wheel Travel Rear Wheel Travel

Electrical:

Ignition System Generator System

Telescopic fork

Swingarm (Monocrosssuspension)

Coil spring. Oil damper Gas, Coil spring. Oil damper

110 mm (4.3 In)

95 mm (3.7 in)

C.D.I. Magneto Flywheel magneto

-43-

Page 56

Engine

Cylinder Head:

Warp Limit

Cylinder:

Bore Size Taper Limit Out of Round Limit

Piston:

Piston Size/

Measuring Point*

Piston Clearance

Piston offset

Piston Ring:

Sectional Sketch

Item

Top Ring/2nd Ring

PW80

0.03mm (0.0012in) * Lines indicate straightedge measurement.

47.000-47.014 mm (1.8504-1.8509 in)

0.05 mm (0.0020 in)

0.01 mm (0.0004 in)

46.964-46.979 mm (1.8490-1.8496 in)/5 mm (0.2 in)

0.033^0.038 mm (0.0013^0.0015 in)

0.2 mm (0.008 in), IN-side

Keystone

B = 2.0 mm (0.079 in) T = 2.0mm (0.079 in)

End Gap (Installed) Side Clearance (Installed) Top Ring/2nd Ring

Crankshaft:

Crank Width “k" Run Out Limit ''C" Connecting Rod Big End Side Clearance '"D" Small End Free Play “F’

Top Ring/2nd Ring

0.15 - 0.35 mm (0.006 - 0.014 in)

0.020^ 0.060 mm (0.0008-0.0024 in)

47.90-47.95 mm (1.886-1.888 in)

0.05 mm (0.0020 in)

0.30-0.80 mm (0.012-0.031 in)

1.0 mm (0.039 in)

-44-

Page 57

Item

Clutch:

Friction Plate Thickness/Quantity Wear Limit Clutch Plate Thickness/Quantity Warp Limit

Clutch Spring Free Length/Quantity

Shifter:

Shifting Type

PW80

2.9'-SA mm (0.114-0.122 in)

2.7 mm (0.106 in)

1.2--1.6 mm (0.047 — 0.063 in)x5

0.1 mm (0.004 in)

12.9 mm (0.51 in) x6

Cam drum and guide bar

Kick Starter Type:

Kick Clip Friction Force

Carburetor:

Type/Manufacturer/Quantity

I.D. Mark

Main Jet (M.J.)

Main Air Jet Jet Needle-clip Position (J.N.) 3E3-3

Needle Jet

Cutaway

Pilot Jet

Pilot Qutlet Size Air Screw (turns out) Valve Seat Size

Starter Jet (G.S.)

Float Height (F.H.)

Reed Valve:

Material

Thickness*

Valve Stopper Height Valve Bending Limit

(M.A.J.) 02.5

(N.J.) (C.A.) (P.J.) (P.Q.) (P.A.S.) (V.S.)

Ratchet type P = 0.9-1.5 kg (2.0-3.3 lb)

VM15SC/MIKUNI/1 pc. 21W01 #125

E-4

2.5 #15

00.9

01.2

20.8 - 22.8 mm (0.82 - 0.90 in)

Gl N6

0.2 mm (0.008 in)

7.4-7.8 mm (0.291-0.307 In)

0.2 mm (0.008 in)

1-1/2

#30

-45-

Page 58

Tightening Torque

Part to be tightened Thread size Spark plug Cylinder head (nut)

(stud)

Oil pump cover (upper)

(lower) Oil pump Carburetor joint

Read valve

Exhaust pipe (front) Silencer protector Crankcase Oil drain bolt

Blind plug Crankcase cover (left) Crankcase cover (right)

Kick starter

Primary drive gear Clutch boss

Bearing plate cover Shift guide Torsion spring (shift shaft) stopper bolt Stopper lever Shift pedal

Rotor Stator

Q'ty M14 xl.25 M 7 xl.O M 7 xl.O M 6 xl.O M 6 xl.O 1 M 5 xO.8 M 6 xl.O

1 4 4 1 7 0.7

2 4 0.4 4

Nm m*kg

25 2.5 18 10 1.0

8 0.8 5.8

7 0.7

6 0.6 4.3 M 3 xO.5 3 1 0.1 M 8 xl.25 M 5 xO.8 M 6 xl.O 10

18 1.8 13

2 4 0.4

7 0.7 M12 x1.5 1 20 2.0 M10 xl.25 M 6 xl.O M 6 xl.O

23 2.3 4 7 0.7 7 7 0.7

M 6 xl.O 1 15 1.5 M12 xl.O

50 5.0 36

ft-lb

7.2

5.1

2.9

0.7

2.9

5.1 14 17

5.1

M16 xl.O 1 50 5.0 36 M 6 xl.O M 6 xl.O M 8 xl.25 M 6 xl.O 1 10 1.0 M 6 xl.O M12 xl.25 M 5 xO.8

2 2 1

8 0.8 5.8 8 0.8 5.8

20 2.0

1 7 0.7 1 2

60 6.0 43

5 0.5 3.6

7.2

5.1

Chassis

Steering System:

Steering Bearing Type

Front Suspension:

Front Fork Travel Fork Spring Free Length Spring Rate Optional Spring Oil Capacity or Oil Level

Oil Grade

Rear Suspension:

Shock Absorber Travel Spring Free Length Spring Rate Optional Spring

Enclosed Gas Pressure

Item

PW80

Ball bearing

110 mm (4.3 in)

425.1 mm (16.74 in) K = 3.5 N/mm (0.35 kg/mm, 19.6 Ib/in) No

60 cm^ (2.1 Imp oz, 2.0 US oz)/188.5 mm (7.42 in)

(From top of inner tube fully compressed without spring)

Yamaha fork oil 15wt or equivalent

48mm (1.89in)

169 mm (6.65in)

K = 42.3 N/mm (4.23 kg/mm, 237 Ib/in)

2,000 kPa (20 kg/cm^ 284 psi)

-46-

Page 59

Item

Swingarm:

Swingarm Free Play Limit End

Wheel:

Front Wheel Type Rear Wheel Type Front Rim Size/Material 1.40x14/Steel Rear Rim Size/Material

Rim Runout Limit Vertical 2.0mm (0.08in)

Lateral

Drive Chain:

Type/ Manufacturer Number of Links 83 links + joint Chain Free Play

Drum Brake:

Type Front

Rear Leading trailing

Drum Inside Dia. Front 95mm (3.74in)

Rear 110 mm (4.33 in)

Brake Lever & Brake Pedal:

Brake Lever Free Play Brake Pedal Position 3mm (0.12in) Brake Pedal Free Play

1.0 mm (0.04 in)

Spoke Wheel Spoke Wheel

1.60x12/Steel

2.0mm (0.08in)

DID420M/DAIDO

40 - 53 mm (1.6 ~ 2.1 in)

Leading trailing

Limit: 96 mm (3.78 in)

Limit: 111 mm (4.37 in)

10-20 mm (0.39 ~ 0.79 in)

10-20 mm (0.39 - 0.79 in) (Vertical height below footrest top.)

PW80

Tightening Torque

Part to be tightened

Front wheel axle Handle crown - Inner tube Under bracket - Inner tube MlOx 1.25 Handle crown - Steering shaft Handle crown - Handle holder under Handle holder under - Handle holder upper

Steering ring nut

Engine mount - Front Engine mount - Under Engine mount - Center Rear wheel axle Lock nut (drive chain puller)

Nipple (spoke) Sprocket wheel Footrest - Frame (R) Footrest - Frame (L) Footrest - Sidestand

Front brake cam lever

Rear brake cam lever Tension bar - Swingarm Tension bar - Brake shoe plate Starter lever

Swingarm - Frame

Fuel tank - Frame

Fuel tank - Fuel cock

Thread Size

MlOx 1.25

M20x 1.0 2

MlOx 1.25 1 MlOx 1.25

M 6x 1.0

M25x 1.0

M 8x 1.25

M 8 X 1.25

M 8x1.25

M12x 1.25 1

M 6x1.0

—

M 8 X 1.25 4 25 M 8x1.25 M 8x1.25

M 8 X 1.25

M 6x 1.0 M 6x 1.0

M 8x1.25

M 8x 1.25

Mil X 1.25

MlOx 1.25

M 6x 1.0 M 6x 1.0

Q'ty

1 35 3.5 25

2 40 4.0 4

1 26 2.6 1 26 1 1 1 1

1 1 1 31 3.1 2 10 2

Nm m*kg ft*lb

40 33 42

1 0.1 23 2.3 26 2.6 23 2.3 60 6.0 43

21 2.1 15

7 0.7

7 0.7 5.1 16 16

4.0 29

3.3

4.2

1.3

0.7

0.2

2.5

2.6 19

1.6

0.1

1.0

0.7 5.1

24 30

9.4

0.7 17 19 17

5.1

1.4 18

5.1

11 11

0.7 22

7.2

-47-

Page 60

Electrical

Item

Ignition System:

Ignition Timing (B.T.D.C.) Advancer Type

C.D.I.:

Model/Manufacturer Charging Coil Resistance (Color) C.D.I. Unit-Model/Manufacturer

Ignition Coil:

Model/ Manufacturer Minimum Spark Gap

Primary Winding Resistance

Secondary Winding Resistance

Charging System:

PW80

20.6° at 4,000 r/min Electrical

4BC-00 / SHY

200 - 300 Q at 20°C (68°F) (Black/Red - Black)

4BC-00 / SHY

6 mm (0.24 in)

0.32 ~ 0.48 n at 20“C (68°F)

5.68 ~ 8.52 k£2 at 20°C (68°F) Flywheel magneto

-48-

Page 61

TORQUE SPECIFICATIONS

The list below covers those stud/bolt sizes with standard I.S.O. pitch threads. Torque specifi cations for components with thread pitches other than standard are given within the ap plicable chapter. Torque specifications call for dry, clean threads. Components such as the cylinder or cylinder head should be at room temperature prior to torquing. A cylinder head or any other item with several fasteners should be torqued down in a cross-wise pattern in suc cessive stages until torque specification is reached. The method is similar to installing as automobile wheel and will avoid warping the component.

(Nut)

(Bolt)

10 mm 12 mm 8 mm 14 mm 10 mm 17 mm 12 mm 19 mm 14 mm 22 mm

6 mm 6

16 mm

General torque

specifications

15 30 55 85

130

mkg

ftib

0.6

1.5

3.0 22

5.5

8.5 13

4.3 11

A. Distance across flats B. Outside thread diameter

DEFINITION OF UNITS

Unit Read

mm millimeter cm centimeter

kg N Nm

m kg Meter kilogram

N/mm Newton per millimeter N/mm Spring rate L

cm^

r/min

kilogram Newton 1 kg X m/sec^ Newton meter

Pascal N/m'

Liter Cubic centimeter or Capacity

Revolution per minute

Definition

10“^ meter 10'^ meter

lO^gram Weight

N X m

m X kg

Length Length

Force Torque

Torque

Pressure

Volume

Engine Speed

Measure

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Page 62

CABLE ROUTING

Throttle cable 1

Cable cylinder Install the cable cylinder between the cleaner case and down-tube.

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Page 63

'ENGINE STOP” switch lead

Position the clamp 70 mm (2.76 in) before the center of the carburetor.

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Page 64

NOISE REGULATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1)

The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW."

These acts include tampering with the following systems; i.e., modification, removal, etc.

Muffler

Exhaust system

Intake system

Exhaust pipe Silencer

Air cleaner case Air cleaner element

Intake duct

MAINTENANCE RECORD

Copies of work orders and/or receipts for parts you purchase and install will be required to docu ment maintenance done in accordance with the emission warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

MAINTENANCE

INTERVAL

1 Month 4 Months 7 Months

13 Months 19 Months 25 Months 31 Months 37 Months 43 Months 49 Months 55 Months 61 Months

DATE

SERVICE

MILEAGE

SERVICING DEALER

NAME AND ADDRESS

REMARKS

-52-

Yamaha pw80 User Manual

A WARNING

INTRODUCTION

A WARNING

IMPORTANT NOTICE

A SAFETY INFORMATION

FOR THE PARENTS

A SAFETY INFORMATION

CONTENTS

GENERAL INFORMATION

MACHINE

IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

NOTE:

ENGINE SERIAL NUMBER

NOTE:

CONTROL FUNCTIONS

A WARNING

FRONT BRAKE LEVER

"ENGINE STOP" SWITCH

REAR BRAKE PEDAL

STARTER LEVER (CHOKE)

FUEL TANK CAP

FUEL AND OIL

FUEL

▲WARNING

ENGINE OIL (OIL TANK)

TRANSMISSION OIL

NOTE:

PRE-OPERATION CHECKS

Fittings/fasteners

A WARNING

BRAKE (FRONT AND REAR)

WHEEL

TIRES

THROTTLE GRIP

"ENGINE STOP" SWITCH

CAUTION:

A WARNING

STARTING A COLD ENGINE

AWARNING

STARTING A WARM ENGINE

CAUTION:

WARMING UP

A WARNING

ENGINE BREAK-IN

MAINTENANCE AND LUBRICATION SCHEDULE CHART

Lubrication intervals

Periodic maintenance intervals

SPECIAL TOOLS

FOR ENGINE SERVICE

FOR CHASSIS SERVICE

FOR ELECTRICAL SERVICE

ADJUSTMENT

A WARNING

SPARK PLU^

NOTE:

IGNITION TIMING CHECKING

AIR FILTER CLEANING

CAUTION:

CAUTiON:

CAUTiON:

THROTTLE CABLE ADJUSTMENT

NOTE:

AUTOLUBE PUMP

NOTE:

FRONT BRAKE ADJUSTMENT

REAR BRAKE ADJUSTMENT

TIRE PRESSURE CHECK

CHECK THE SPOKES

STEERING HEAD INSPECTION

FRONT FORK OIL CHANGE

A WARNING

2. Support the machine securely so there is no danger of it falling over.

STEERING HEAD ADJUSTMENT

NOTE:

A WARNING

CAUTiOM;

A WARNING

Inspection