PW80 (4BCF) EUROPE,SOUTH AFRICA,JAPAN

Transcription

1 PW80 (4BCF) OPE,SOUTH AFRICA,JAPAN 1D4BC-300E1 ( 2D4BC-300E1 ) A2

2 PW80 PARTS CATALOGUE 2004 by Yamaha Motor Co., Ltd. 1st edition, May 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan. A3

3 PW80 A4

4 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. A5

5 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 A6

6 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 (5) Model Code Production Code Number of Model Listed in This Parts Catalogue Model Code 4BCF Production Code No. Country (destination) 010 OPE 090 JAPAN 120 SOUTH AFRICA Model Code Production Code No. Country (destination) (3) Model Label Affixing Location (4) Colouring Information Model Code Colouring Type Code Colour Code Colour Name Abbreviation 4BCF A 0583 DEEP PURPLISH BLUE SOLID E DPBSE A7

7 CONTENTS 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

8 FIG. 1 CYLINDER PART DESCRIPTION 1 21W HEAD, CYLINDER W GASKET, CYLINDER HEAD PLUG, SPARK (NGK BPR6HS) PLUG, SPARK (NGK BPR6HS) ABSORBER W ABSORBER E CYLINDER E ABSORBER AW GASKET, CYLINDER BOLT, STUD NUT B2

9 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 (B6205) OIL SEAL OIL SEAL E PISTON (STD) E PISTON (0.25MM O/S) AP 3E PISTON (0.50MM O/S) AP PIN, PISTON N PISTON RING SET (STD) N PISTON RING SET (0.25MM O/S) AP 14N PISTON RING SET (0.50MM O/S) AP CIRCLIP BEARING B3

10 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 B4

11 FIG. 4 INTAKE PART DESCRIPTION REED VALVE ASSY REED, VALVE STOPPER, REED VALVE SCREW, PAN HEAD WASHER, SPRING 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 WASHER, PLATE B5

12 FIG. 5 CARBURETOR PART DESCRIPTION 1 21W CARBURETOR ASSY GASKET, FLOAT CHAMBER NOZZLE, MAIN JET, MAIN (#125) STD JET, MAIN (#120) UR JET, MAIN (#130) 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 SPRING, PLUNGER PLUNGER, STARTER JET, PILOT (# 15) R CAP B6

13 FIG. 5 CARBURETOR PART DESCRIPTION 26 1M SEAL V INSULATOR HOSE (L120) HOSE (L130) B7

14 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 BC SILENCER, EXHAUST BOLT WASHER, SPRING WASHER, PLATE BC PROTECTER, SILENCER M SCREW, PAN HEAD BC WASHER, PROTECTOR B8

15 FIG. 7 CRANKCASE PART DESCRIPTION 1 1W CRANKCASE PIN, DOWEL SCREW, PAN HEAD SCREW, PAN HEAD SCREW, PAN HEAD W CRANKCASE T DAMPER, ENGINE MOUNT PLUG, STRAIGHT SCREW GASKET HOLDER SCREW, PAN HEAD COVER, OIL PUMP GROMMET SCREW BOLT BOLT, FLANGE GASKET B9

16 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 W PROTECTOR SCREW, PAN HEAD B10

17 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 B11

18 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) UR PLATE, CLUTCH 1 (1.4T) UR PLATE, CLUTCH 1 (1.6T) UR SPRING, COMPRESSION 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 B12

19 FIG. 10 CLUTCH PART DESCRIPTION NUT B13

20 FIG. 11 TRANSMISSION PART DESCRIPTION 1 4BC MAIN AXLE COMP (12T/16T/17T) BEARING BEARING (BK1212V1) PLATE, COVER SCREW, PAN HEAD BC AXLE, DRIVE BC GEAR, 1ST WHEEL (39T/26T) WASHER (0.6T) UR WASHER (0.8T) UR WASHER (1.0T) UR 9 4BC GEAR, 2ND WHEEL (29T) BC GEAR, 3RD WHEEL (22T) BC BALL, BC CIRCLIP BC CIRCLIP BEARING (B6204) OIL SEAL SPROCKET,DRIVE 15T( ) CIRCLIP B14

21 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 B15

22 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 COVER, SHIFT PEDAL C2

23 FIG. 14 FRAME PART DESCRIPTION 1 21W FRAME COMP YB BOLT BOLT, FLANGE NUT, FLANGE WASHER, SPRING P8 WASHER, PLATE C3

24 FIG. 15 FRONT FENDER PART DESCRIPTION 1 3RV FENDER, FRONT SCREW, WITH WASHER BOLT, WITH WASHER RV GRAPHIC ES 2153E 01 EMBLEM, YAMAHA C4

25 FIG. 16 SIDE COVER PART DESCRIPTION 1 3RV COVER, SIDE W FLAP SCREW, WITH WASHER RV 2173L 60 GRAPHIC SET W GROMMET ES 2153E 01 EMBLEM, YAMAHA C5

26 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 C6

27 FIG. 18 REAR ARM & SUSPENSION PART DESCRIPTION 1 21W REAR ARM COMP SL 2 4BC BUSH R SEAL, GUARD BOLT, FLANGE NUT, SELF-LOCKING W SUPPORT, CHAIN BOLT, WITH WASHER W CASE, CHAIN RV SHOCK ABSORBER ASSY, REAR 1 1 3RV SHOCK ABSORBER ASSY, REAR M BUSH, REAR SHOCK ABSORBER PIN, CLEVIS PIN, CLEVIS H5 WASHER, PLATE PIN, COTTER WASHER, PLATE C7

28 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 SL BOLT, HEXAGON WASHER NUT WASHER, SPRING CLAMP BOLT SEAL, STEERING C8

29 FIG. 20 FRONT FORK PART DESCRIPTION 1 3RV FRONT FORK ASSY (L.H) RV TUBE, OUTER (LEFT) M OIL SEAL M CLIP, OIL SEAL 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 WITH WASHER 14 3M SEAT, SPRING UPPER RV FRONT FORK ASSY (R.H) RV TUBE, OUTER (RIGHT) M OIL SEAL M CLIP, OIL SEAL 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 WITH WASHER C9

30 FIG. 20 FRONT FORK PART DESCRIPTION 28 3M SEAT, SPRING UPPER HN UNDER BRACKET COMP R HOLDER, CABLE BOLT WASHER, SPRING C10

31 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 AJ VALVE PACKING WASHER, PLATE SCREW HOSE (L150) W DAMPER, LOCATING X DAMPER, LOCATING CLIP RV B0 GRAPHIC SET WASHER, PLATE C11

32 FIG. 22 SEAT PART DESCRIPTION 1 3RV SEMI-DOUBLE SEAT ASSY RV COVER, SEAT NUT RV BAND, SEAT C12

33 FIG. 23 FRONT WHEEL PART DESCRIPTION HUB, FRONT LGB SPACER BEARING (B6200) OIL SEAL BEARING (B6200RS) E FLANGE, SPACER R PLATE, BRAKE SHOE LGB 8 3EC W253A 00 BRAKE SHOE KIT SPRING, TENSION YT CAMSHAFT LEVER, CAMSHAFT BOLT NUT A6 TIRE ( PR) CHENG SHIN TUBE (2.25/ TR4) CHENG SHIN BAND, RIM ( ) CHENG SHIN RIM ( ) R SPOKE SET, FRONT HN AXLE, WHEEL WASHER, PLAIN NUT, U FLANGE COLLAR COVER, HUB DUST C13

34 FIG. 24 REAR WHEEL PART DESCRIPTION 1 21W HUB, REAR LGB SPACER FLANGE, SPACER BEARING W DAMPER O-RING J PLATE, BRAKE SHOE LGB 8 4BE W253E 00 BRAKE SHOE KIT SPRING, TENSION Y CAMSHAFT LEVER, CAMSHAFT BOLT NUT CLUTCH, HUB LGB 15 21W AXLE, SPROCKET OIL SEAL BEARING (B6004RS) W SPROCKET, DRIVEN (32T) BOLT AW WASHER NUT G3 COLLAR A7 TIRE ( PR) CHENG SHIN TUBE (2.75/ TR4) CHENG SHIN BAND, RIM ( ) CHENG SHIN RIM ( ) W SPOKE SET, REAR C14

35 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 PULLER, CHAIN NUT NUT A5 WASHER, PLATE GL PULLER, CHAIN C15

36 FIG. 25 STEERING HANDLE & CABLE PART DESCRIPTION 1 3RV HANDLEBAR N GRIP 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 CABLE, BRAKE BOLT NUT W PROTECTOR, HANDLEBAR BAND, SWITCH CORD D2

37 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 WASHER, SPRING D3

38 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 D4

39 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 BAND, SWITCH CORD V WIRE, EARTH LEAD D5

40 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 D6

41 NUMERICAL INDEX PART GRID PART GRID PART GRID PART GRID PART GRID PART GRID 21W B B 2 21W B 2 3E B 2 1W B 2 3E B 2 4AW B 2 4BC B 3 4BC B 3 4BC B 3 4BC B 3 14N B 3 14N B 3 14N B 3 3E B B 3 3E B 3 3E B 3 4BC B 3 4BC B 3 2T B 4 2T B B B B B 4 53F B 4 21W B B B B B B 5 21W B 6 12G B 6 12G B 6 21W B B B B B B B B B 6 1R B B B B 6 2E B B 6 12R B B 6 1V B 7 4BC B 5 4BC B 5 4BC B 5 4BC B 5 4BC B 5 4BC B 5 4BC B 5 21W B 6 21W B 8 3RV B 8 21W B 8 4X B 8 4BC B 8 4BC B 8 3RV B 8 4BC B 8 21W 1490J 00 B 6 1M B 7 1W B 9 1W B B 9 5T B B 10 21W B B 9 5R B 10 4AW B 10 21W B 10 4BC B 11 4BC B B 12 2T B 12 4BC B 11 4BC B 11 4BC B 11 4BC B 11 4BC B 11 4BC B 11 4BC B 11 56H B 12 4BC B B B B B 12 3E B B B B B B B 12 4BC B 14 4BC B 14 4BC B 14 4BC B 14 4BC B 14 4BC B 14 4BC B 14 4BC B B 14 58H C 2 21W C C C B 15 1W B 15 1W B 15 2N B 15 21W B B B 15 21W C 3 3RV C 4 4ES 2153E 01 C 4 C 5 3RV C 4 21W C 5 21W C 6 3RV C 5 21W C 5 3RV 2173L 60 C 5 21W C 6 21W C 6 5R C 6 21W C 7 4BC C 7 3R C 7 21W C 7 3RV C 7 3RV C 7 3M C 7 21W C 7 3RV C 9 3RV C 9 21W C 9 3M C 9 3RV C 9 3RV C 9 21W C 9 3M C 9 3M C 9 3M C 9 2J C 9 2J C 9 3M C 9 2J C 9 3R C 9 3M C 9 3R C 10 5HN C C C 8 22F C C 8 22F C C E 00 C 8 22F 2341E 00 C 8 4BC C 8 3RV C C C 8 21W C 8 5HN C 8 3RV C 11 59V C 11 21W C C 6 2X C 11 3RV B0 C 11 4X C 11 4X C 11 3AJ C 11 3AJ C 11 2FG C 11 3RV C 12 3RV C 12 3RV C 12 3R C C 13 2E C C 13 3R C C 13 5HN C 13 21W C 14 21W C C 14 31J C 14 1YT C 13 3Y C C 14 21W C C 14 4BC C 15 5HN C 15 21W C 14 3AC C 15 4GL C 15 4AW C 14 21W C 14 3RV D 2 21W D 2 21W D 2 2N D D 2 4BC D 2 4BC D 2 4BC D 2 4BC D 2 4BC D 2 4BC D 2 4BC D 2 4BC D 2 21W D 3 21W D 3 4BC D 3 21W D D D 3 4X C D 4 4BC D D 6 4V D 5 4BC D 5 4BC D 5 4BC D D D 2 D 5 21W D 5 4BC D 4 4BC D 4 4BC D 6 4BC D 4 4BC W B 5 3EC W253A 00 C 13 4BE W253E 00 C C C B C C C B F6 B D C C D B C C C D B C B D B B B C C D C C B D C B D 2 M1

42 NUMERICAL INDEX PART GRID PART GRID PART GRID PART GRID PART GRID PART GRID B B C C C C A5 C P8 C C H5 C B C A7 C B C B B C B B B B D C C D B B B C C C B G3 C B B B B B B J1 C C B C C 6 C B B B B C B D B B C B C C D D D C C C B C C 15 D D C C B 6 D C B D D 3 D B 8 C 3 D B 5 B 8 C C C D B C B B B B C C B B B B B B C B C C C B B B C B F2 B B B B B B B B B B B B B A6 C A7 C C C C C C C C C B B D C 13 C C 15 D C B D C C 3 C C C C D B 5 B B C B C D M B M B C D B B D B B B B B D B B 9 B B B 9 B B B B M B B B D B 15 C B B B B 9 M2