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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 |
LIT-CALIF-65-01 |
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
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Some data in this manual may become outdated due to improvements made to this model in the future.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 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.
NOTE: 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.
6. Always wear a helmet, gloves, boots, trousers, and jacket for motocross
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.
YAMAHA MOTOR CORPORATION, U.S.A. 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.
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. |
|
|
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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
P.O. Box 6555
Cypress, California 90630
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.
CHANGE OF ADDRESS
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.
WARRANTY DEPARTMENT
P.O. Box 6555
Cypress, California 90630
This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.
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.
Helmet
Goggles
Mouth guard
Long sleeved trainer
Gloves
Motocross pants
Boots
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 .. . ............................................................................... |
7 |
MAINTENANCE AND LUBRICATION SCHEDULE CHART............................................................ |
7 |
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 |
GENERAL INFORMATION
DESCRIPTION |
MACHINE |
|
IDENTIFICATION |
|
VEHICLE IDENTIFICATION NUMBER |
|
The vehicle identification number is stamped |
|
into the steering head pipe. |
1. |
Seat |
5. |
Brake pedal |
2. |
Fuel tank |
6. |
Kick starter |
3. |
Front fender |
7. |
Muffler |
4. |
Front wheel |
|
|
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.
ENGINE SERIAL NUMBER
The engine serial number is stamped on the left side of the engine on top of the crankcase.
1. |
Front fork |
5. |
Footrest |
2. |
Monocross suspension |
6. |
Shift pedal |
3. |
Rear wheel |
7. |
Air filter |
4. |
Sidestand |
|
|
1. Engine serial number
1.Front brake lever
2.Throttle grip
3."ENGINE STOP" switch
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.
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.
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.
"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
FRONT BRAKE LEVER
The front brake lever is located on the right handlebar, pull it toward the handlebar to ac tivate the front brake.
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.
The fuel cock supplies fuel from the tank to car |
1. Rear brake pedal |
buretor while filtering the fuel. The fuel cock |
|
has the three positions; |
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.
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.
1. Kickstarter
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.
▲ 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)
-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)
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.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.
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 |
Routine |
Page |
Brake |
Check operation/adjustment |
5, 14 |
Transmission oil |
Change oil as required |
4 |
Drive chain |
Check alignment/ adjustment/ lubrication |
15 |
Spark plug |
Check color/condition |
10 |
Throttle |
Check for proper throttle cable operation |
5, 12 |
Air filter |
Foam type — must be clean and damp w/oil always |
11^12 |
Wheels and tires |
Check pressure/runout/spoke tightness/bead stopper/axle nuts |
5, 16,31 ~ 34 |
Fittings/fasteners |
Check all — tighten as necessary |
5, 46, 47, 49 |
|
|
|
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.
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 |
100 kPa (1.0 kgf/cm^ 15 psi) |
Rear |
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
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Initial (hour) |
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Thereafter |
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Item |
Remarks |
Type |
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every (hour) |
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10 |
20 |
40 |
80 |
40 |
|
80 |
160 |
Transmission oil change |
Warm engine before draining |
Yamalube 4-cycle oil or SAE 10W30 |
|
O |
O |
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O |
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type SE motor oil |
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Drive chain |
Lube/Adjust as required |
Yamalube Chain and Cable Lube or |
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See service notes |
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Remove/ Clean / Lube/ Adjust |
SAE 10W30 motor oil |
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o |
|
O |
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Control cables |
All apply thoroughly |
Yamaha Cable Lube or WD-40 |
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|
o |
o |
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o |
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Throttle grip and housing |
Apply lightly |
Yamaha Cable Lube or WD-40 |
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|
o |
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|
o |
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Brake pedal shaft |
Apply lightly |
Yamaha Cable Lube or WD-40 |
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o |
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o |
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Stand shaft pivot |
Apply lightly |
Yamaha Cable Lube or WD-40 |
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o |
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o |
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Front forks |
Drain completely |
Yamaha fork oil 20 wt or equivalent |
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o |
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o |
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Steering ball race |
Inspect thoroughly/ Pack |
Medium-weight wheel bearing grease |
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o |
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o |
moderately |
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Wheel bearings |
Do not over-pack yearly or... |
Medium-weight wheel bearing grease |
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o |
O |
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o |
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Periodic maintenance intervals
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Initial (hour) |
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Thereafter |
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Remarks |
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every (hour) |
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Item |
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10 |
20 |
40 |
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80 |
40 |
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80 |
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160 |
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Brake system (complete) |
Check / Adjust as required — repair as required |
|
o |
o |
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O |
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Clutch |
Check / Adjust as required |
|
o |
o |
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o |
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Spark plug |
Inspect / Clean or replace as required |
O |
o |
o |
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o |
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Spark arrester |
Clean |
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o |
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Wheels and tires |
Pressure / Runout / Spoke — tension |
O |
o |
o |
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o |
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|
Fittings and fasteners |
Tighten before each trip and / or |
o |
o |
o |
|
|
o |
|
|
|
|
Drive chain |
Tension / Alignment (No.1) |
o |
o |
o |
|
|
o |
|
|
|
|
Air filter |
Wet type — clean / Replace as required (No.2) |
|
o |
o |
|
o |
o |
|
|
|
|
Fuel cock |
Clean / Flush tank as required |
o |
|
o |
|
|
o |
|
|
|
|
Ignition timing |
Adjust / Clean or replace as required |
|
o |
o |
|
o |
|
|
o |
|
|
Autolube pump |
Check / Adjust / Air bleeding |
o |
o |
o |
|
|
o |
|
|
|
|
Carburetor adjustment |
Check / operation / Timings |
|
o |
o |
|
o |
|
|
o |
|
|
Carburetor overhaul |
Clean / Repair as required / Refit / Adjust |
|
|
|
|
|
|
|
|
|
o |
Cylinder compression |
Preventive maintenance check |
|
o |
o |
|
o |
|
|
o |
|
|
Decarbonize engine |
Includes exhaust system |
|
|
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.
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.
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.Dynamic Spark Tester P/N. YM-34487
This instrument is necessary for checking the ignition system components.
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