YAMAHA PW80X PARTS CATALOGUE 08

PW80 (4BCJ) EUROPE,SOUTH AFRICA,JAPAN
PW80X (3RVN) OCEANIA

A2

1G4BC-300E1

2G4BC-300E1

()

PW80/PW80X

PARTS CATALOGUE

©2007 by Yamaha Motor Co., Ltd.

1st edition, May 2007

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan.

A3

FOREWORD

This Parts Catalogue is related to the parts for the model(s) on the cover page. When you are
ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers
and part names correctly.

1. Modifications or additions which have been made after the issue of the Parts Catalogue
will be announced in the Parts News.
It is advisable that you make the necessary corrections to the Parts Catalogue according
to the Parts News.

2. Abbreviations
The following abbreviations are used in this Parts Catalogue.

“UR” Use specified parts number.
“UN” Use as many as needed.
“AP” Alternate Parts
“LM” Locally Made (Parts need to be ordered locally)
“F#” Frame No. (Applicable machine No.)
“O/S” Over Size

3. The number of components for assembly

• Parts, which are to be supplied in an assembly, are listed with a dot (.) in front of the
part name as shown below.

• The numeral appearing to the right of each component part indicates the quantity of
parts for each assembly unit.

PART NO. DESCRIPTION Q’TY REMARKS

2F5–83310–60 FRONT FLASHER LIGHT ASSY 2

115–83311–60 .BULB (6V–18W) 1

6. The asterisk (*) before a reference number indicates modified items after the first edition.

4. Applicable colours of graphics are represented in the “REMARKS” as shown below.

PART NO. DESCRIPTION Q’TY REMARKS

2N4–24110–00–X5 FUEL TANK COMP. 2 MXR

3J1–24240–10 .GRAPHIC, FUEL TANK 1 FOR MXR

5. Note that the illustrations for reference in finding parts numbers are not to be used for
assembling. When assembling, please use the applicable service manual.

A4

7. Applicable Serial No.

Engine Serial No. Frame Serial No.

8. Applicable Colour Code (The (*) mark shows Model colour.)

Abbreviation Colour Name Colour Code

DPBSE(*) DEEP PURPLISH BLUE SOLID E 0583

LGB LOW GLOSS BLACK 0098

SL SILVER 0035

YB YAMAHA BLACK 0033

FOREWORD

A5

MODEL LABEL

(1) A label called “Model Label” is affixed in the location as indicated in (3) below.

When using this parts catalogue, please be sure to cross–reference the “model code –
production code No.” in the catalogue with the “model code – production code No.” indi­cated on the Model Label affixed onto the product concerned.

(2) “Model Label” Indication

(3) Model Label Affixing Location

(4) Colouring Information

Model Code

4BCJ

3RVN

Colouring

Type Code

A 0583

A 0583

Colour

Code

Colour Name

DEEP PURPLISH BLUE SOLID E DPBSE

DEEP PURPLISH BLUE SOLID E DPBSE

Abbrevia-

tion

(5) Model Code – Production Code Number of Model Listed in This Parts Catalogue

Model

Code

4BCJ

3RVN 010

Production

Code No.

010 EUROPE

020 JAPAN

030 SOUTH AFRICA

Country

(destination)

AUSTRALIA

NEW ZEALAND

Model

Code

Production

Code No.

Country

(destination)

A6

ENGINE

CYLINDER ............................................................................B2

CRANKSHAFT & PISTON ....................................................B3

OIL PUMP .............................................................................B4

INTAKE .................................................................................B5

CARBURETOR .....................................................................B6

EXHAUST .............................................................................B8

CRANKCASE ........................................................................B9

CRANKCASE COVER 1 .......................................................B10

STARTER ..............................................................................B11

CLUTCH ................................................................................B12

TRANSMISSION ...................................................................B14

SHIFT CAM & FORK .............................................................B15

SHIFT SHAFT .......................................................................C2

CHASSIS

FRAME ..................................................................................C3

FRONT FENDER ..................................................................C4

SIDE COVER ........................................................................C5

OIL TANK ..............................................................................C6

REAR ARM & SUSPENSION ...............................................C7

STEERING ............................................................................C8

FRONT FORK .......................................................................C9

FUEL TANK ...........................................................................C11

SEAT .....................................................................................C12

FRONT WHEEL .................................................................... C13

REAR WHEEL .......................................................................C14

STEERING HANDLE & CABLE ............................................D2

STAND & FOOTREST ..........................................................D3

GENERATOR ........................................................................D4

HANDLE SWITCH & LEVER ................................................D5

ELECTRICAL 1 .....................................................................D6

INDEX

NUMERICAL INDEX .............................................................M1

CONTENTS

FIG. 1 CYLINDER

REF.
NO.

1

2

3

PART NO. DESCRIPTION

21W–11111–00

1W7–11181–00

94701–00198

HEAD, CYLINDER 1 1 1 1 1

GASKET, CYLINDER HEAD 1 1 1 1 1

PLUG, SPARK (NGK BPR6HS) 1 1 1

EUR

ZAF

JPN

OCE

REMARKS

94703–00198

4

463–11161–01

5

21W–11162–00

6

3E5–11311–01

7

3E5–11162–00

8

4AW–11351–00

9

90116–07035

10

90179–07381

PLUG, SPARK (NGK BPR6HS) 1

ABSORBER 1 4 4 4 4

ABSORBER 2 1 1 1 1

CYLINDER 1 1 1 1 1

ABSORBER 2 2 2 2 2

GASKET, CYLINDER 1 1 1 1

BOLT, STUD 4 4 4 4

NUT 4444

B

2

FIG. 2 CRANKSHAFT & PISTON

REF.
NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

4BC–11400–00

4BC–11412–00

4BC–11681–00

93310–420F2

4BC–11651–00

4BC–11422–00

4BC–11557–00

93210–18023

90280–03017

90201–12535

95337–12600

90387–20603

93306–20517

93103–25098

93103–32099

CRANKSHAFT ASSY 1 1 1 1

.CRANK 1 1 1 1 1

.PIN, CRANK 1 1 1 1 1

.BEARING 1111

.ROD, CONNECTING 1 1 1 1

.CRANK 2 1 1 1 1

.WASHER 1 2 2 2 2

.O-RING 1 1 1 1

KEY, WOODRUFF 1111

WASHER, PLATE 1 1 1 1

NUT 1111

COLLAR 1111

BEARING 2 2 2 2

OIL SEAL 1 1 1 1

OIL SEAL 1 1 1 1

EUR

ZAF

JPN

OCE

REMARKS

B

3

16

3E5–11631–00–97

3E5–11635–00

3E5–11636–00

17

527–11633–00

18

14N–11603–00

14N–11604–00

14N–11605–00

19

93450–13022

20

93310–11268

PISTON (STD) 1 1 1 1

PISTON (0.25MM O/S) 1 1 1 1 AP

PISTON (0.50MM O/S) 1 1 1 1 AP

PIN, PISTON 1 1 1 1

PISTON RING SET (STD) 1 1 1 1

PISTON RING SET (0.25MM O/S) 1 1 1 1 AP

PISTON RING SET (0.50MM O/S) 1 1 1 1 AP

CIRCLIP 2 2 2 2

BEARING 1 1 1 1

FIG. 3 OIL PUMP

REF.
NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

2T8–13101–01

93210–26240

93101–10001

2T5–13124–00

93430–07012

93603–14026

90149–04135

90430–04004

296–13147–00

384–13138–00

90170–10105

90401–10029

90468–02033

98507–05020

98507–05035

OIL PUMP ASSY 1 1 1 1

.O-RING 1 1 1 1

.OIL SEAL 1 1 1 1

.GEAR, WORM WHEEL (71T) 1 1 1 1

.CIRCLIP 1 1 1 1

.PIN, DOWEL 1 1 1 1

.SCREW 1 1 1 1

.GASKET 1 1 1 1

.SHIM 1 1 1 1

.PLATE, ADJUSTING 1 1 1 1

.NUT 1111

.BOLT, UNION 1 1 1 1

CLIP 2222

SCREW, PAN HEAD 1 1 1 1

SCREW, PAN HEAD 1 1 1 1

EUR

ZAF

JPN

OCE

REMARKS

B

4

16

90480–10005

17

384–13174–00

18

53F–13178–00

19

93210–29282

20

384–13161–02

GROMMET 1 1 1 1

HOLDER, OIL PIPE 1 1 1 1

GEAR, PUMP DRIVE 1 1 1 1

O-RING 1 1 1 1

PIPE, DELIVERY 1 1 1 1 1

FIG. 4 INTAKE

REF.
NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

300–13610–04

300–13613–02

300–13616–00

98507–03008

92907–03100

21W–13555–00

300–13622–10

300–13621–10

98507–06030

4BC–14453–00

4BC–14455–00

90460–37130

4BC–14454–00

4BC–W1441–00

4BC–14451–00

REED VALVE ASSY 1 1 1 1

.REED, VALVE 1 1 1 1

.STOPPER, REED VALVE 1 1 1 1

.SCREW, PAN HEAD 3 3 3 3

.WASHER, SPRING 3 3 3 3

MANIFOLD, INTAKE 1111

GASKET, VALVE SEAT 1 1 1 1

GASKET, VALVE SEAT 1 1 1 1

SCREW, PAN HEAD 4 4 4 4

JOINT, AIR CLEANER 1 1 1 1 1

BAND 1111

CLAMP, HOSE 1 1 1 1

JOINT 1 1 1 1

AIR CLEANER CASE COMP. 1 1 1 1

ELEMENT, AIR CLEANER 1 1 1 1

EUR

ZAF

JPN

OCE

REMARKS

B

5

16

4BC–14412–00

17

4BC–14458–00

18

4BC–14457–00

19

9760M–05225

20

9760M–05250

21

97007–08016

22

92907–08600

CAP, CLEANER CASE 1 1 1 1 1

GUIDE 1 1 1 1

SEAL 1 1 1 1

SCREW, PAN HEAD WITH WASHER 2 2 2 2

SCREW, PAN HEAD WITH WASHER 2 2 2 2

BOLT 2222

WASHER, PLATE 2 2 2 2

FIG. 5 CARBURETOR

REF.
NO.

1

2

3

4

PART NO. DESCRIPTION

21W–14101–01

296–14184–01

127–14141–14

127–14143–25

CARBURETOR ASSY 1 1 1 1 1

.GASKET, FLOAT CHAMBER 1 1 1 1

.NOZZLE, MAIN 1 1 1 1

.JET, MAIN (#125) 1 1 1 1 STD

EUR

ZAF

JPN

OCE

REMARKS

127–14143–24

127–14143–26

5

21W–1490J–00

6

21W–14107–12

7

127–14186–00

8

12R–14191–00

9

98502–04018

10

92902–04100

11

2E9–14185–00

12

296–14112–25

13

296–14131–00

14

296–14198–01

15

307–14169–10

16

12G–14104–00

17

98802–05100

18

98502–05030

19

98502–04010

.JET, MAIN (#120) 1 1 1 1 UR

.JET, MAIN (#130) 1 1 1 1 UR

.NEEDLE SET 1 1 1 1

.NEEDLE VALVE SET 1 1 1 1

.PIN, FLOAT 1 1 1 1

.PLUG, DRAIN 1 1 1 1

.SCREW, PAN HEAD 4 4 4 4

.WASHER, SPRING 4 4 4 4

.FLOAT 1111

.VALVE, THROTTLE 1 1 1 1 1

.SPRING, THROTTLE VALVE 1 1 1 1

.GASKET 1 1 1 1

.CAP 1111

.AIR SCREW SET 1 1 1 1

.NUT 1111

.SCREW, PAN HEAD 1 1 1 1

.SCREW, PAN HEAD 2 2 2 2

B

6

20

12G–14103–00

21

21W–14503–00

22

127–14135–00

23

127–14171–00

24

193–14142–15

25

1R0–14169–00

.THROTTLE SCREW SET 1 1 1 1

.ADJUST SCREW SET 1 1 1 1

.SPRING, PLUNGER 1 1 1 1

.PLUNGER, STARTER 1 1 1 1

.JET, PILOT (# 15) 1 1 1 1

.CAP 1111

FIG. 5 CARBURETOR

REF.
NO.

26

27

28

29

PART NO. DESCRIPTION

1M3–14997–00

1V3–14271–00

90445–05390

90445–07036

.SEAL 1 1 1 1

.INSULATOR 1 1 1 1

HOSE (L120) 1 1 1 1

HOSE (L130) 1 1 1 1

EUR

ZAF

JPN

OCE

REMARKS

B

7

FIG. 6 EXHAUST

REF.
NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

21W–14610–02

3RV–14623–00

97007–08020

92907–08100

21W–14708–00

90157–05003

3RV–14766–00

4X4–14714–00

90467–22048

97007–08016

92907–08100

92907–08600

4BC–14753–00

97007–08016

92907–08100

EXHAUST PIPE ASSY 1 1 1 1 1

GASKET, EXHAUST PIPE 1 1 1 1

BOLT 2222

WASHER, SPRING 2 2 2 2

PROTECTOR ASSY 1 1 1 1

SCREW, PAN HEAD 3 3 3 3

WASHER, PROTECTOR 6 6 6 6

GASKET, MUFFLER 1 1 1 1

CLIP 1111

BOLT 1111

WASHER, SPRING 1 1 1 1

WASHER, PLATE 1 1 1 1

SILENCER, EXHAUST 1 1 1 1

BOLT 1111

WASHER, SPRING 1 1 1 1

EUR

ZAF

JPN

OCE

REMARKS

B

8

16

92907–08600

17

4BC–14758–00

18

9850M–05006

19

4BC–14766–00

WASHER, PLATE 1 1 1 1

PROTECTOR, SILENCER 1 1 1 1

SCREW, PAN HEAD 2 2 2 2

WASHER, PROTECTOR 4 4 4 4