MOTORCYCLE SERVICE MANUAL

MODELS COVERED:

PW50 Y-Zinger (1981-1983, 1985-1987, 1990-2002)
PW80 Y-Zinger (1983, 1985, 1991-2002)
BW80 Big Wheel (1986-1988, 1990)

This Yamaha motorcycle manual is 416 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Message to parents / Safety first / Cleaning parts / Handling gasoline safely / Service hints / Serial numbers / Warning labels / Torque specifications / Fasteners / Lubricants/ Sealants, cements and cleaners / Threadlocking compound / Expendable supplies / Basic hand tools / Precision measuring instruments / Test equipment / Special tools / Mechanic's tips / Ball bearing replacement / Seals / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Engine operating principles / Starting the engine / Starting difficulties / Engine starting troubles / Engine performance / Engine / Engine noises / Two-stroke leak down test / Fuel system / Electrical troubleshooting / Ignition system / Clutch and gearshift linkage / Transmission / Kickstarter / Drive train noise (PW50) / Drive train noise (BW80 and PW80) / Oil injection system / Handling/ Brakes / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Service intervals / Tune-up / Engine oil / Transmission oil / Air filter / Spark plug / Carburetor / Exhaust system / Oil pump and engine oil lines / Engine compression check / Ignition timing / Control cable lubrication / Throttle and oil pump cable adjustment / Speed limiter adjustment / Brake lubrication, inspection and cable adjustment / Final gear lubrication PW50 / Drive chain BW80 and PW80 / Front fork oil change BW80 and PW80 / Specifications

CHAPTER FOUR / ENGINE PW50
Engine identification / Engine lubrication / Exhaust system / Cylinder head / Cylinder / Piston, pin and ring / Reed valve assembly / Clutch / Primary drive gear / Kickstarter, oil pump drive gear and kick pinion gear / Transmission / Crankcase and crankshaft / break-in / Specifications

CHAPTER FIVE / ENGINE BW80 AND PW80
Engine identification / Engine lubrication / Exhaust system / Engine / Cylinder head / Cylinder / Piston, piston pin and piston ring / Reed valve assembly / Primary drive gear and oil pump drive gear / Kickstarter / External shift mechanism / Crankcase and crankshaft / Transmission / Break-in / Specifications

CHAPTER SIX / CLUTCH BW80 AND PW80
Right crankcase cover / Clutch service / Specifications

CHAPTER SEVEN / FUEL SYSTEM
Carburetor / Carburetor cleaning and inspection / Carburetor rejetting / Fuel tank and fuel valve / Throttle cables / Choke cable / Specifications

CHAPTER EIGHT / ELECTRICAL SYSTEM
Component testing / Capacitor discharge ignition / Flywheel / CDI unit / Ignition coil / Specifications

CHAPTER NINE / OIL INJECTION SYSTEM
Oil pump cable adjustment / Oil pump bleeding / Oil pump plunger stroke adjustment / Oil pump / Oil hoses / Oil tank / Oil pump output test PW50 / Oil pump output test BW80 and PW80 / Specifications

CHAPTER TEN / FRONT SUSPENSION AND STEERING PW50
Front wheel / Front hub / Tire changing / Handlebar / Steering head / Front forks / Specifications

CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING BW80 AND PW80
Front wheel / Front hub / Handlebar / Steering head / Front forks / Tire change BW80 / Specifications

CHAPTER TWELVE / REAR SUSPENSION AND FINAL DRIVE PW50
Rear wheel / Rear arm / Final drive / Rear shock absorbers / Specifications

CHAPTER THIRTEEN / REAR SUSPENSION BW80 AND PW80
Rear wheel / Rear hub / Final driven flange / Chain and sprockets / Tire changing / Rear shock absorber / Rear swing arm / Specifications

CHAPTER FOURTEEN / BRAKES
Drum brakes / Brake levers and cables PW50 / Front brake cable / Rear brake pedal and rod / Specifications

CHAPTER FIFTEEN / BODY
Seat, side covers and rear fender / Front fender / Rear fender / Specifications

INDEX

WIRING DIAGRAMS