Yamaha pw80- Manuals

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 plat...

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.

CONTENTS GENERAL INFORMATION......................................................................................................................... 1 DESCRIPTION.................................................................................................................................... 1 MA...

GENERAL INFORMATION DESCRIPTION 1. Seat 2. Fuel tank 3. Front fender 4. Front wheel 5. Brake pedal 6. Kick starter 7. Muffler 1. Front fork 2. Monocross suspension3. Rear wheel4. Sidestand 5. Footrest6. Shift pedal7. Air filter 1. Front brake lever 2. Throttle grip 3. "ENGINE STOP" switch MA...

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 i...

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 spar...

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 ex­haust fumes are poisonous and can cause loss of consciousness and death within a short tim...

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...

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 Li...

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 electro...

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 t...

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 ...

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 s...

NOTE: _________________________ Break each nut loose (1/4 turn) prior to remov­ ing. 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 ...

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) CLUTCH 7. If any of the above measurements exceed tol...

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. ^ New Minimum OFF spring free length 30.5 mm (1.20 In) 28.5 mm (1.12 ...

CHASSIS FRONT WHEEL REAR WHEEL 0 16Nm (1.6m-kg,11ft lb) 07Nm (0.7m-kg,5.1ft-lb) g) \ 7Nm (0.7m-kg,5.1ft-lb) 0 16Nm (1.6m kg,1in ibf 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

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. SWIN...

MISCELLANEOUS ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS 0 CDI unit0 "ENGINE STOP" switch 0 Ignition coil 0 Spark plug d) CDI magneto COLOR CODEB.......................Black 0 .......................Orange B/R................... Black/RedB/W.................. Black/White ...

TROUBLESHOOTIIMG 1. No spark is produced or weak. SPARK GAP TEST 1. Disconnect the spark plug cap from spark plug. "ENGINE STOP" SWITCH INSPECTION 1. Inspect: • "ENGINE STOP" switch conduct 2. The engine starts but will not pick up speed. . Clean or replace. • Check ignition timing. ...

IGNITION COIL INSPECTION 1. Inspect: •Primary coil resistance Out of specificationReplace. Tester ( + ) lead^Orange lead 0 Tester (-) lead^Black lead (5) Primary Coil Resistance Tester Selector Position 0.32-0.48 n at 20°C (68°F) fix 1 CDI MAGNETO INSPECTION 1. Inspect: • Charging coil resistance Ou...

General SPECIFICATIONS Item PW80 Model: Code Number 3RVJ Dimensions: Overall Length 1,540mm (60.6in) Overall Width 640 mm (25.2in) Overall Height 880 mm (34.6in) Seat Height 635mm (25.0in) Wheelbase 1,055mm (41.5in) Minimum Ground Clearance 185mm ( 7.3in) Dry Weight: Without oil and fuel 57.0 kg (12...

Engine Item Cylinder Head: Warp Limit PW80 0.03mm (0.0012in) * Lines indicate straightedge measurement. Cylinder: Bore Size Taper Limit Out of Round Limit 47.000-47.014 mm (1.8504-1.8509 in) 0.05 mm (0.0020 in)0.01 mm (0.0004 in) Piston: Piston Size/ Measuring Point* Piston Clearance Piston offset o...

Tightening Torque Part to be tightened Thread size Q'ty Nm m*kg ft-lb M14 xl.25 1 25 2.5 18 M 7 xl.O 4 10 1.0 7.2 M 7 xl.O 4 8 0.8 5.8 M 6 xl.O 1 7 0.7 5.1 M 6 xl.O 1 7 0.7 5.1 M 5 xO.8 2 4 0.4 2.9 M 6 xl.O 4 6 0.6 4.3 M 3 xO.5 3 1 0.1 0.7 M 8 xl.25 2 18 1.8 13 M 5 xO.8 2 4 0.4 2.9 M 6 xl.O 10 7 0.7...

Electrical Item PW80 Ignition System: Ignition Timing (B.T.D.C.) Advancer Type 20.6° at 4,000 r/min Electrical C.D.I.: Model/Manufacturer Charging Coil Resistance (Color) C.D.I. Unit-Model/Manufacturer 4BC-00 / SHY 200 - 300 Q at 20°C (68°F) (Black/Red - Black) 4BC-00 / SHY Ignition Coil: Model/ Man...

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 cy...

CABLE ROUTING Throttle cable 1 Cable cylinder Install the cable cylinder between the cleaner case and down-tube. -50-

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 int...