PW80 (4BCM) EUROPE,JAPAN PW80A (3RVT) OCEANIA,SOUTH AFRICA 1K4BC-300E1

Transcription

1 PW80 () EUROPE,JAPAN PW80A () OCEANIA,SOUTH AFRICA 1K4BC-300E1 ( )

2 PW80/PW80A PARTS CATALOGUE 2010 by Yamaha Motor Co., Ltd. 1st edition, May 2010 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

3 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. 6. The asterisk (*) before a reference number indicates modified items after the first edition. 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 DESCRIPTION Q TY 2F FRONT FLASHER LIGHT ASSY BULB (6V 18W) 1 4. Applicable colours of graphics are represented in the as shown below. PART DESCRIPTION Q TY 2N X5 FUEL TANK COMP. 2 MXR 3J 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.

4 FOREWORD 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

5 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 Colouring Type Code Colour Code Colour Name Abbreviation A 0583 DEEP PURPLISH BLUE SOLID E DPBSE A 0583 DEEP PURPLISH BLUE SOLID E DPBSE (5) Model Code Production Code Number of Model Listed in This Parts Catalogue Model Code Production Code No. 010 Country (destination) AUSTRALIA NEW ZEALAND SOUTH AFRICA AUSTRIA BELGIUM DENMARK FINLAND FRANCE GERMANY GREECE IRELAND ITALY 010 NETHERLANDS NORWAY POLAND PORTUGAL SLOVENIA SPAIN SWEDEN SWITZERLAND UNITED KINGDOM 020 JAPAN Model Code Production Code No. Country (destination)

6 CONTENTS ENGINE CYLINDER... 1 CRANKSHAFT & PISTON... 2 OIL PUMP... 3 INTAKE... 4 CARBURETOR... 5 EXHAUST... 7 CRANKCASE... 8 CRANKCASE COVER STARTER CLUTCH TRANSMISSION SHIFT CAM & FORK SHIFT SHAFT CHASSIS FRAME FRONT FENDER SIDE COVER OIL TANK REAR ARM & SUSPENSION STEERING FRONT FORK FUEL TANK SEAT FRONT WHEEL REAR WHEEL STEERING HANDLE & CABLE STAND & FOOTREST GENERATOR HANDLE SWITCH & LEVER ELECTRICAL INDEX NUMERICAL INDEX... 34

7 FIG. 1 CYLINDER PART DESCRIPTION 1 21W HEAD, CYLINDER W GASKET, CYLINDER HEAD PLUG, SPARK (NGK BPR6HS) PLUG, SPARK (NGK BPR6HS) 1 FOR JPN ABSORBER W ABSORBER E CYLINDER E ABSORBER AW GASKET, CYLINDER BOLT, STUD NUT 4 4 1

8 FIG. 2 CRANKSHAFT & PISTON PART DESCRIPTION 1 4BC CRANKSHAFT ASSY BC CRANK BC PIN, CRANK F2.BEARING BC ROD, CONNECTING BC CRANK BC WASHER O-RING KEY, WOODRUFF WASHER, PLATE NUT COLLAR BEARING OIL SEAL OIL SEAL E PISTON (STD) 1 1 UR 3E PISTON (STD) 1 1 UR 3E PISTON (STD) 1 1 UR 3E PISTON (STD) 1 1 UR 3E PISTON (0.25MM O/S) 1 1 AP 3E PISTON (0.50MM O/S) 1 1 AP PIN, PISTON N PISTON RING SET (STD) N PISTON RING SET (0.25MM O/S) 1 1 AP 14N PISTON RING SET (0.50MM O/S) 1 1 AP CIRCLIP BEARING 1 1 2

9 FIG. 3 OIL PUMP PART DESCRIPTION 1 2T OIL PUMP ASSY O-RING OIL SEAL T GEAR, WORM WHEEL (71T) CIRCLIP PIN, DOWEL SCREW GASKET SHIM PLATE, ADJUSTING NUT BOLT, UNION CLIP SCREW, PAN HEAD SCREW, PAN HEAD GROMMET HOLDER, OIL PIPE F GEAR, PUMP DRIVE O-RING PIPE, DELIVERY

10 FIG. 4 INTAKE PART DESCRIPTION REED VALVE ASSY REED, VALVE STOPPER, REED VALVE W MANIFOLD, INTAKE GASKET, VALVE SEAT GASKET, VALVE SEAT SCREW, PAN HEAD BC JOINT, AIR CLEANER BC BAND CLAMP, HOSE BC JOINT BC W AIR CLEANER CASE COMP BC ELEMENT, AIR CLEANER BC CAP, CLEANER CASE BC GUIDE BC SEAL M SCREW, PAN HEAD WITH WASHER M SCREW, PAN HEAD WITH WASHER BOLT, FLANGE 2 2 4

11 FIG. 5 CARBURETOR PART DESCRIPTION 1 21W CARBURETOR ASSY GASKET, FLOAT CHAMBER NOZZLE, MAIN JET, MAIN (#125) 1 1 STD JET, MAIN (#120) 1 1 UR JET, MAIN (#130) 1 1 UR 5 21W 1490J 00.NEEDLE SET W NEEDLE VALVE SET PIN, FLOAT R PLUG, DRAIN SCREW, PAN HEAD WASHER, SPRING E FLOAT VALVE, THROTTLE SPRING, THROTTLE VALVE GASKET CAP G AIR SCREW SET NUT SCREW, PAN HEAD SCREW, PAN HEAD G THROTTLE SCREW SET W ADJUST SCREW SET COIL, SPRING PLUNGER, STARTER JET, PILOT (# 15) R CAP 1 1 5

12 FIG. 5 CARBURETOR PART DESCRIPTION 26 1M SEAL V INSULATOR HOSE (L120) HOSE (L130) 1 1 6

13 FIG. 6 EXHAUST PART DESCRIPTION 1 21W EXHAUST PIPE ASSY RV GASKET, EXHAUST PIPE BOLT WASHER, SPRING W PROTECTOR ASSY SCREW, PAN HEAD RV WASHER, PROTECTOR X GASKET, MUFFLER CLIP BOLT WASHER, SPRING WASHER, PLATE W SILENCER, EXHAUST BOLT WASHER, SPRING WASHER, PLATE W PROTECTOR, SILENCER SCREW, PAN HEAD RV WASHER, PROTECTOR 4 4 7

14 FIG. 7 CRANKCASE PART DESCRIPTION 1 1W CRANKCASE PIN, DOWEL SCREW, PAN HEAD SCREW, PAN HEAD SCREW, PAN HEAD W CRANKCASE T DAMPER PLUG, STRAIGHT SCREW GASKET HOLDER SCREW, PAN HEAD COVER, OIL PUMP GROMMET SCREW BOLT BOLT, FLANGE GASKET 1 1 8

15 FIG. 8 CRANKCASE COVER 1 PART DESCRIPTION 1 21W COVER, CRANKCASE SCREW, PAN HEAD SCREW, PAN HEAD R COVER, CRANKCASE OIL SEAL PIN, DOWEL AW GASKET, CRANKCASE COVER SCREW, PAN HEAD SCREW, PAN HEAD PLUG, OIL LEVEL O-RING BC PROTECTOR SCREW, PAN HEAD 1 1 9

16 FIG. 9 STARTER PART DESCRIPTION 1 4BC KICK AXLE ASSY BC GEAR, KICK (21T) BC CLIP BC WASHER CIRCLIP BC COVER, SPRING BC SPRING, KICK BC GUIDE, SPRING CIRCLIP WASHER, PLATE (T=1.0) BC KICK CRANK ASSY BC COVER, KICK LEVER BOLT OIL SEAL

17 FIG. 10 CLUTCH PART DESCRIPTION 1 56H PRIMARY DRIVE GEAR ASSY KEY, STRAIGHT WASHER WASHER, CONICAL SPRING NUT BC PRIMARY DRIVEN GEAR COMP CLIP BALL PLATE, THRUST WEIGHT E PLATE, FRICTION PLATE, CLUTCH 1 (1.2T) 5 5 UR PLATE, CLUTCH 1 (1.4T) 5 5 UR PLATE, CLUTCH 1 (1.6T) 5 5 UR SPRING, COMPRESSION 4 4 PINK PRESSURE PLATE ASSY SPRING, COMPRESSION PLATE, PRESSURE CIRCLIP CIRCLIP ONE WAY BOSS COMP PAWL, KICK T SPRING, PAWL BOSS, CLUTCH O-RING PLATE, THRUST SPACER WASHER, CONICAL SPRING

18 FIG. 10 CLUTCH PART DESCRIPTION NUT

19 FIG. 11 TRANSMISSION PART DESCRIPTION 1 4BC MAIN AXLE COMP. 1 1 (12T/16T/17T) BEARING BEARING PLATE, COVER SCREW, PAN HEAD BC AXLE, DRIVE BC GEAR, 1ST WHEEL 1 1 (39T/26T) WASHER (0.6T) 1 1 UR WASHER (0.8T) 1 1 UR WASHER (1.0T) 1 1 UR 9 4BC GEAR, 2ND WHEEL (29T) BC GEAR, 3RD WHEEL (22T) BC BALL, BC CIRCLIP BC CIRCLIP BEARING OIL SEAL SPROCKET,DRIVE 15T( ) CIRCLIP

20 FIG. 12 SHIFT CAM & FORK PART DESCRIPTION 1 21W SHIFT CAM ASSY PIN, DOWEL PLATE, SIDE CIRCLIP BEARING PLATE, STOPPER SCREW, PAN HEAD W FORK, SHIFT W FORK, SHIFT PIN, DOWEL N BAR, SHIFT FORK GUIDE CIRCLIP O-RING STOPPER LEVER ASSY F6 BOLT SPRING, TENSION HOOK, SPRING

21 FIG. 13 SHIFT SHAFT PART DESCRIPTION 1 58H SHIFT SHAFT ASSY SPRING, TENSION SPRING, TORSION STOPPER, SCREW OIL SEAL WASHER, PLATE CIRCLIP W PEDAL, SHIFT BOLT, HEXAGON COVER, SHIFT PEDAL

22 FIG. 14 FRAME PART DESCRIPTION 1 21W FRAME COMP. 1 1 YB BOLT BOLT, FLANGE NUT, FLANGE WASHER, SPRING P8 WASHER, PLATE HA PROTECTOR, FUEL TANK

23 FIG. 15 FRONT FENDER PART DESCRIPTION 1 3RV FENDER, FRONT BOLT, WITH WASHER BOLT, WITH WASHER RV GRAPHIC,

24 FIG. 16 SIDE COVER PART DESCRIPTION 1 3RV COVER, SIDE W FLAP SCREW, WITH WASHER EM C0 EMBLEM 1 FOR JPN 5 5PG 2816R 00 LABEL, WARNING GENERAL INFO. 1 UR FOR EUR 5PA 2118K 20 LABEL, CAUTION 1 UR FOR JPN 3PT 2118K A1 LABEL, CAUTION 1 6 3RV 2173L 80 GRAPHIC SET ES 2153E 01 EMBLEM, YAMAHA W GROMMET

25 FIG. 17 OIL TANK PART DESCRIPTION 1 21W TANK, OIL R BODY, CAP DAMPER, LOCATING W PIPE, OIL BOLT, WITH WASHER W BAND X TOOL KIT CLIP

26 FIG. 18 REAR ARM & SUSPENSION PART DESCRIPTION 1 21W REAR ARM COMP. 1 1 SL 2 4BC BUSH R SEAL, GUARD BOLT, FLANGE WASHER, PLATE NUT, SELF-LOCKING W SUPPORT, CHAIN BOLT, WITH WASHER W CASE, CHAIN XJ LABEL, TIRE 1 FOR JPN 3RV A0 LABEL, TIRE RV SHOCK ABSORBER ASSY, REAR 1 1 EXCEPT FOR JPN 3RV SHOCK ABSORBER ASSY, REAR 1 FOR JPN 12 3M BUSH, REAR SHOCK ABSORBER AA LABEL, WARNING 1 1 EXCEPT FOR JPN 4AA LABEL, WARNING 1 FOR JPN PIN, CLEVIS PIN, CLEVIS H5 WASHER, PLATE PIN, COTTER

27 FIG. 19 STEERING PART DESCRIPTION RACE, BALL W STAY, PLATE HN BOLT RACE, BALL E 00 RETAINER, BALL BEARING F RACE, BALL F RACE, BALL F 2341E 00 RETAINER, BALL BEARING COVER, BALL RACE NUT BC CROWN, HANDLE BOLT, FLANGE WASHER RV HOLDER, HANDLE UPPER HOLDER, HANDLE LOWER 2 2 SL BOLT, HEXAGON WASHER NUT WASHER, SPRING CLAMP BOLT SEAL, DUST

28 FIG. 20 FRONT FORK PART DESCRIPTION 1 3RV FRONT FORK ASSY (L.H) RV TUBE, OUTER (LEFT) M OIL SEAL M RING, SNAP W INNER TUBE COMP R CYLINDER COMP., FRONT FORK J SPRING, REBOUND J RING, PISTON M SEAL, DUST W SPRING, FRONT FORK J O-RING M BOLT, CAP M BOLT, HEXAGON SOCKET HEAD 1 1 WITH WASHER 14 3M SEAT, SPRING UPPER RV FRONT FORK ASSY (R.H) RV TUBE, OUTER (RIGHT) M OIL SEAL M RING, SNAP W INNER TUBE COMP R CYLINDER COMP., FRONT FORK J SPRING, REBOUND J RING, PISTON M SEAL, DUST W SPRING, FRONT FORK J O-RING M BOLT, CAP M BOLT, HEXAGON SOCKET HEAD 1 1 WITH WASHER 22

29 FIG. 20 FRONT FORK PART DESCRIPTION 28 3M SEAT, SPRING UPPER HN UNDER BRACKET COMP R HOLDER, CABLE BOLT WASHER, SPRING

30 FIG. 21 FUEL TANK PART DESCRIPTION 1 3RV FUEL TANK COMP GROMMET COLLAR BOLT, FLANGE V BAND, TANK FITTING FG CAP ASSY J1 HOSE (L420) X FUEL COCK ASSY X O-RING SCREW, PAN HEAD AJ SEAL, COCK AC VALVE PACKING WASHER, PLATE SCREW HOSE (L150) W DAMPER, LOCATING X DAMPER, LOCATING CLIP RV G0 GRAPHIC SET WASHER, PLATE

31 FIG. 22 SEAT PART DESCRIPTION 1 3RV SEMI-DOUBLE SEAT ASSY RV COVER, SEAT NUT RV BAND, SEAT

32 FIG. 23 FRONT WHEEL PART DESCRIPTION HUB, FRONT 1 1 LGB SPACER BEARING OIL SEAL BEARING E FLANGE, SPACER R PLATE, BRAKE SHOE 1 1 LGB 8 3EC W253A 00 BRAKE SHOE KIT SPRING, TENSION YT CAMSHAFT LEVER, CAMSHAFT BOLT NUT A6 TIRE ( PR) 1 1 CHENG SHIN TUBE (2.25/ TR4) 1 1 CHENG SHIN BAND, RIM ( ) 1 1 CHENG SHIN RIM ( ) R SPOKE SET, FRONT HN AXLE, WHEEL WASHER, PLAIN NUT, U FLANGE COLLAR COVER, HUB DUST

33 FIG. 24 REAR WHEEL PART DESCRIPTION 1 21W HUB, REAR 1 1 LGB SPACER FLANGE, SPACER BEARING W DAMPER O-RING J PLATE, BRAKE SHOE 1 1 LGB 8 4BE W253E 00 BRAKE SHOE KIT SPRING, TENSION Y CAMSHAFT LEVER, CAMSHAFT BOLT NUT CLUTCH, HUB 1 1 LGB 15 21W AXLE, SPROCKET OIL SEAL BEARING BC SPROCKET, DRIVEN (32T) BOLT AW WASHER NUT G3 COLLAR A7 TIRE ( PR) 1 1 CHENG SHIN TUBE (2.75/ TR4) 1 1 CHENG SHIN BAND, RIM ( ) 1 1 CHENG SHIN RIM ( ) W SPOKE SET, REAR

34 FIG. 24 REAR WHEEL PART DESCRIPTION CHAIN (KMC420 84L) JOINT, CHAIN (KMC420) BC BAR, TENSION BOLT BOLT NUT NUT, FLANGE WASHER, PLATE PIN, COTTER HN AXLE, WHEEL NUT, SELF-LOCKING A7 WASHER, PLATE COLLAR AC 2538G 10 PULLER, CHAIN A5.WASHER, PLATE NUT NUT GL 2538G 10 PULLER, CHAIN A5.WASHER, PLATE NUT NUT

35 FIG. 25 STEERING HANDLE & CABLE PART DESCRIPTION 1 3RV HANDLEBAR N GRIP 1 1 BLACK 3 21W GRIP ASSY TUBE, THROTTLE GUIDE BC CONNECTOR, CABLE BC CABLE, THROTTLE BC CABLE, THROTTLE BC CABLE, PUMP BC CAP, CABLE CONNECTOR BC PIECE, CONNECTING SCREW, TAPPING BC CABLE, STARTER BC WIRE, BRAKE BOLT NUT W PROTECTOR, HANDLEBAR BAND, SWITCH CORD

36 FIG. 26 STAND & FOOTREST PART DESCRIPTION 1 21W PEDAL, BRAKE SPRING, TORSION CIRCLIP WASHER, PLATE W ROD, BRAKE WASHER, PLATE PIN, COTTER PIN NUT, WING SPRING, COMPRESSION W FOOTREST YB FOOTREST COVER, FOOTREST PIN, CLEVIS PIN, COTTER SPRING, TORSION BC STAND, SIDE BOLT NUT SPRING, TENSION BOLT, HEXAGON WASHER, SPRING

37 FIG. 27 GENERATOR PART DESCRIPTION 1 4BC STATOR ASSY BC COIL, SOURCE CLAMP SCREW, PAN HEAD WASHER, SPRING SCREW, PAN HEAD WASHER, SPRING BC ROTOR ASSY SCREW, COUNTERSUNK

38 FIG. 28 HANDLE SWITCH & LEVER PART DESCRIPTION 1 4BC HOLDER, LEVER BC HOLDER, LEVER LOWER BOLT BC LEVER BOLT NUT, U W SWITCH, HANDLE BAND, SWITCH CORD M24 CLAMP V WIRE, EARTH LEAD

39 FIG. 29 ELECTRICAL 1 PART DESCRIPTION 1 4BC C.D.I. UNIT ASSY SCREW, PAN HEAD WASHER, SPRING WASHER, PLATE BC IGNITION COIL ASSY BOLT, FLANGE PLUG CAP ASSY

40 NUMERICAL INDEX PART PART PART PART PART PART 21W W E W E AW BC BC BC BC N N N E E E E E E BC BC T T F W W G G W R E R V BC BC BC BC BC BC BC W W RV W X W W RV W 1490J M W W T W R AW BC BC BC T BC BC BC BC BC BC BC H BC E BC BC BC BC BC BC BC BC H W W W N W W PA 2118K PT 2118K A RV ES 2153E RV EM C W W XJ RV A RV W RV 2173L W W R W BC R W RV RV M AA AA W RV RV W M RV RV W M M M J J M J R M R HN F F E F 2341E BC RV W HN RV HA V W X RV G X X AC AJ FG RV RV RV R E R HN W W J YT Y W BC HN W AC 2538G GL 2538G AW BC RV W W N BC BC BC BC BC BC BC BC W W BC W X PG 2816R BC V BC BC BC W BC BC BC BC BC W EC W253A BE W253E F

41 NUMERICAL INDEX PART PART PART PART PART PART A P H A G J M F A A M M