2007 Yamaha PW80 (W) Service Manual
Complete 2007 PW80 (W) documentation with carburetor specifications, autolube pump calibration, transmission oil capacity 0.75L, and CDI ignition timing 20.6 degrees BTDC. Ref: 4BC-28197-E0
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Models Covered & Key Technical Specifications
Yamaha PW80 (W) (3RVL/4BCH) — 2007 Automotive Engineering Vault | PW80 Series Repository.
- Prescribed Speed Rating: 1650–1750 r/min is established at the engine idle operation Bounds.
- Documented Travel Rate: For optimal suspension performance, 110.0 mm (4.33 in) dictates the front fork compression travel Matrix.
- Core Net Mass: 61.0 kg (134 lb) corresponds to the vehicle weight with oil and fuel Standards.
- Rated Assembly Torques: The cylinder head nut requires 10 Nm (1.0 m·kg, 7.2 ft·lb) fastening specification Margin.
- Technical Adjustment Range: Spark plug gap yields 0.6–0.7 mm (0.024–0.028 in) clearance Protocol.
- Advanced Cold Start Limits: Fuel tank capacity is set to 4.9 L (1.29 US gal) operational Parameters.
Professional Workshop Service Manual & Technical Specifications
Standard Service Training Manual: Yamaha PW80 (W) 2007 - Essential Service & Maintenance Manual Electrical-Reference
Design-Core: Yamaha PW80 (W) (2007) // Repair-Classification: Service Operations / Ignition Logic // Design-Core: Crankcase separating tool (90890-01135), fork seal driver attachment (90890-01186), rotor holding tool (90890-01235).
| Component Category | Procedural Scope | Documentation Status |
|---|---|---|
| Engine Systems | 2-stroke air-cooled single cylinder configuration | Complete specifications provided |
| Transmission Assembly | Constant mesh 3-speed with helical gear primary reduction | Documented |
| Chassis Framework | Steel tube backbone suspension with drum brakes | See Chapter 4 |
Outlining the operational framework across engine and transmission systems, the document addresses periodic checks and adjustments, establishes chassis maintenance protocols, details carburetor configuration, coordinates electrical component verification, covers ignition timing procedures, and examines troubleshooting logic for starting failures and performance issues.
Systematic Logic-Path
Technically requiring comprehensive technical data, the manual provides detailed specifications for engine displacement (79.0 cm³), compression ratio (6.60:1), and fuel system parameters including tank capacity and reserve amounts. The document includes systematic reference data for piston-to-cylinder clearance measurements, ring end gap limits, and crankshaft runout specifications. Spark plug gap reference information (0.6-0.7 mm) and ignition timing data at 4000 r/min are documented throughout the periodic maintenance sections.
Precise Topology
Electrical system documentation covers CDI magneto configuration, ignition coil resistance ranges (primary: 0.32-0.48 Ω; secondary: 5.68-8.52 kΩ), and spark plug cap specifications (5.0 kΩ). The manual documents charge coil resistance parameters (200-300 Ω) and provides wiring diagrams for the ignition circuit with color-coded lead identification. Switch continuity checking procedures and troubleshooting logic for electrical system failures are included with continuity test methodology.
Engineered Interface
Suspension service documentation covers front fork assembly with telescopic design, coil spring configuration, and oil damper specifications. The layout details rear shock absorber nitrogen gas tank handling, spring preload adjustment procedures using circlip positioning, and swingarm pivot point measurement protocols. Brake system documentation includes drum brake inside diameter specifications, lining thickness references, and shoe spring free length data for both front and rear brake assemblies.
Precise Logic-Path
Disassembly instructions are documented for engine removal, cylinder head separation, piston extraction, clutch configuration, and crankcase separation using specialized tools. The manual provides sequential removal and installation procedures for drive chain components, sprocket alignment data, and transmission gear assembly. Detailed exploded diagrams accompany each major disassembly section with numbered steps and torque specification references for component reassembly.
Structured Threshold
Wear limits are specified for cylinder bore (47.100 mm maximum), piston skirt diameter tolerance (0.10 mm limit), and clutch friction plate thickness (2.70 mm minimum wear threshold). The document references ball bearing inspection procedures, oil seal lip condition checking, and crankshaft bearing clearance verification. Drive chain 15-link section maximum wear limit (194.3 mm) and tire minimum tread depth (0.8 mm) are documented with corresponding replacement criteria.
The manual documents torque specifications for the crankshaft installation and primary drive gear assembly to ensure proper fastener preload and component alignment.
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