1988 Yamaha BIG Wheel (80cc) Service Repair Maintenance Manual

OYAMAHA LIT-11616-05-23 1 RV-28197-10

BW80S SERVICE MANUAL © 1985 by Yamaha Motor Corporation, U.S.A. 1st Edition, August 1985 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-05-23

NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual so it is assumed that persons using this book to perform maintenance and repairs on Yamaha machines have a basic understanding of the mechanical concepts and procedures inherent in machine repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe. Yamaha Motor Company, ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. TECHNICAL PUBL !CATIONS SERVICE DIVISION MOTORCYCLE OPERATIONS YAMAHA MOTOR CO., LTO. HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation. NOTE: ~;%11t.fiti~~i)· WARNING: A NOTE provides key information to make procedures easier or clearer. A CAUTION indicates special procedures that must be followed to avoid damage to the machine. A WARNING indicates special procedures that must be followed to avoid injury to a machine operator or person inspecting or repairing the machine. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings Pitting/Damage --+ Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

CD 0 l~%l.~eal l~&.fl§ll 0 0 I ENG l'-1 ~KI ® ® PRBifl jcHASI cfJol 0 ® jELECI iii I IAPPxl~ 'I ® ~ @) ~ @ ~ @ ~ @ [0] @ [mJ @ 1 @ 1 @ 1 - a - m B @) @) @ ~ ~ ~ @ A ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbolsCDto@are designed as thumb tabs to indicate the chapter's number and content. CD General information ® Periodic inspection and adjustment @Engine @ Cooling system @ Carburetion ®Chassis (J) Electrical ® Appendices Illustrated symbols ®to ® are used to identify the specifications appearing in the text. ® Filling fluid (j]) Lubricant @ Tightening @ Wear limit, clearance @ Engine speed @rl.,V,A Illustrated symbols @to® in the exploded diagram indicate grade of lubricant and location of lubrication point. @ Apply engine oil @ Apply gear oil @.Apply molybdenum disulfide oil @) Apply wheel bearing grease (j]) Apply lightweight lithium-soap base grease ® Apply molybdenum disulfide grease @ Apply locking agent (LOCTITE®)

INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE CARBURETION CHASSIS ELECTRICAL APPENDICES . '- ENG Iii ELEC ~' APPX

CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION .................................... 1-1 VEHICLE IDENTIFICATION NUMBER ......................... 1-1 ENGINE SERIAL NUMBER .................................. 1-1 IMPORTANT INFORMATION .................................... 1-2 ALL REPLACEMENT PARTS ................................. 1-2 GASKETS, OIL SEALS, AND 0-RINGS ........................ 1-2 LOCK WASHERS/PLATES AND COTTER PINS .................. 1-2 BEARINGS AND OIL SEALS ................................ 1-2 Cl RCLIPS ................................................. 1-3 SPECIAL TOOLS .............................................. 1-3 FOR TUNE-UP ............................................. 1-3 FOR ENGINE SERVICE ..................................... 1-4 FOR CHASSIS SERVICE ...................................... 1-4 FOR ELECTRICAL COMPONENTS ............................. 1-5

1-1 GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number CD is stamped into the steering head pipe. NOTE:------------- The vehicle identification number is used to identify your machine and may be used to register your machine with the licensing autho- rity in your state. Starting Serial Number: JYA1RYOO * GC000101 ENGINE SERIAL NUMBER The engine serial number CD is stamped into the left side of the engine. NOTE:------------------------- The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. Starting Serial Number: 1RY-000101 NOTE:------------------ Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION ~~lj:.~~~~ IMPORTANT INFORMATION All REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. GASKETS, OIL SEALS, AND 0-RINGS 1. All gaskets, seals, and 0-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and 0-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates CD and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has b{!en properly tightened. BEARINGS AND OIL SEALS 1. Install the bearing(s) CD and oil seal (s) ® with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces. 1-2 n

SPECIAL TOOLS 1-3 CIRCLIPS 1. All circlips should be inspected carefully before reassembly_ Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip CD , make sure that the sharp-edged corner ® is positioned opposite to the thrust ® it receives. See the sectional view. @ Shaft SPECIAL TOOLS The proper special tools are necessary for com- plete and accurate tune-up and assembly. Using the correct sp~cial tool will help prevent damage caused by the use of improper tools or im- provised techniques. FOR TUNE UP 1. Inductive Tachometer P/N YU-08036 This tool is needed for detecting engine rpm. 2. Inductive Timing Light P/N YM-33277 This tool is necessary for checking ignition timing. 3. Fuel Level Gauge P/N YM-01312 This gauge is used to measure the fuel level in the float chamber.

SPECIAL TOOLS FOR ENGINE SERVICE 1. Rotor Holding Tool P/N YU-01235 This tool is used to hold the clutch when removing or installing the clutch boss locknut. 2. Rotor Puller P/N YM-01189 This tool is needed to remove the flywheel magneto. 3. Crankcase Separating Tool P/N YU-01135 This tool is needed to separate the crankcases. 4. Piston Pin Puller P/N YU-01304 This tool is used to remove the piston pin. FOR CHASSIS SERVICE 1. T-Handle P/N YM-01326- CD Damper Rod Holder P/N YM-01300-1- ® This tool is used to loosen and tighten the front fork cylinder holding bolt. 1-4

1988 Yamaha BIG Wheel (80cc) Service Repair Maintenance Manual

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