Table Of Contents - Yamaha PW80(R) Owner's Service Manual

Table of Contents

Introduction4
Important Notice8
Safety Information8
Contents20
General Information22
Description22
Machine Identification24
Frame Serial Number24
Vehicle Identification Number24
Engine Serial Number24
Control Functions26
Engine Stop Switch26
Fuel Cock26
Front Brake Lever28
Rear Brake Pedal28
Shift Pedal28
Starter Lever28
Kick Starter30
Fuel Tank Cap30
Fuel32
Engine Oil32
Recommended Fuel32
Fuel Tank Capacity32
Transmission Oil34
Pre-Operation Checks36
Brake38
Wheel38
Tires38
Throttle Grip38
Staring And Operation40
Starting A Cold Engine40
Starting A Warm Engine40
Warming Up42
Engine Break-In42
Periodic Maintenance And Adjustment46
Maintenance And Lubrication Schedule Chart46
Lubrication Intervals46
Special Tools50
For Engine Service50
Lubrication54
Engine56
Spark Plug56
Ignition Timing Checking58
Air Filter Cleaning60
Throttle Cable Adjustment62
Idle Speed Adjustments64
Autolube Pump66
Front Brake Adjustment68
Rear Brake Adjustment70
Drive Chain Slack Check70
Drive Chain Slack Adjustment72
Drive Chain Lubrication74
Tire Air Pressure74
Tire Pressure74
Steering Inspection76
Steering Adjustment76
Front Fork Oil Change76
Recommended Oil80
Pinch Bolt Torque80
Fork Cap Bolt Torque80
Handle Holder Upper Torque80
Rear Shock Absorber82
Notes On Disposal82
Rear Shock Absorber Spring Preload Adjustment84
Maintenance And Minor Repairs86
Preparation For Service86
Engine Carburetor88
Replacement Of Main Jet88
Reed Valve94
Valve Stopper Height94
Reed Valve Bending Limit94
Cylinder104
Piston104
Piston Clearance104
Cylinder Bore Measurement104
Piston Outside Diameter Measurement106
Piston Rings106
Ring Groove Clearance108
Piston Pin Bearing And Connecting Rod108
Connecting Rod/Crank Side Clearance110
Clutch Plate Warm Allowance114
Kick Starter Removal116
Kick Starter Inspection116
Clutch Adjustment Gap116
Shifter118
Chassis124
Front Wheel124
Rear Wheel124
Brake Shoe Inspection128
Axle Nut Torque128
Tension Bar Nut128
Brake Drum Inspection130
Tire130
Replacing Wheel Bearings134
Checking Rim134
Swingarm Inspection138
Lubrication Of Lever, Pedals, Etc.138
Cable Inspection And Lubrication140
Throttle Cable And Grip140
Miscellaneous144
Electrical Components144
Color Code144
Wiring Diagram144
Troubleshooting146
Spark Gap Test148
Engine Stop Switch Inspection148
Ignition Coil Inspection150
Cdi Magneto Inspection152
Cleaning158
Storage160
Specifications164
Tightening Torque168
Electrical170
Torque Specifications184
Definition Of Units186
Cable Routing187