check engine YAMAHA PW80 2007 User Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
2
3
4
5
67
8
9

EAU21340
Adjusting the engine idling
speed
The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before
making this adjustment.
NOTE:


The engine is warm when it quickly
responds to the throttle.

A diagnostic tachometer is needed
to make this adjustment.
1. Attach the tachometer to the spark
plug lead.
2. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
rection (a). To decrease the en-
gine idling speed, turn the screw in
direction (b).
NOTE:

If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
EAU21370
Adjusting the throttle cable
free play
The throttle cable free play should mea-
sure
3.0–5.0 mm (0.12–0.20 in)
at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, adjust it as follows.
NOTE:

The engine idling speed must be cor-
rectly adjusted before checking and ad-
justing the throttle cable free play.
1. Loosen the locknut.
2. To increase the throttle cable free
play, turn the adjusting nut in direc-
tion (a). To decrease the throttle
1. Throttle stop screw
Engine idling speed:
1650–1750 r/min
1
(a) (b)

1. Throttle cable free play
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
2
3
4
5
67
8
9

EAU41840
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING

EWA10710
Damage to the outer housing of ca-
bles may result in internal rusting
and cause interference with cable
movement. Replace damaged ca-
bles as soon as possible to prevent
unsafe conditions.
EAU23111
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
EAU23120
Adjusting the Autolube pump
The Autolube pump is a vital and so-
phisticated component of the engine,
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil SAE 10W-30 (API SE)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
1
2
3
4
5
6
7
8
9

EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
EAU23290
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
2
3
4
5
67
8
9

EAU24350
Supporting the motorcycle
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
a jack either under each side of theframe in front of the rear wheel or under
each side of the swingarm.

EAU24360
Front wheel
EAU41530
To remove the front wheel
WARNING

EWA10820

It is advisable to have a Yamaha
dealer service the wheel.

Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Remove the brake cable holder by
removing the bolt.
2. Loosen the brake cable locknut
and the brake cable free play ad-
1. Brake cable holder
2. Bolt
2
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
1
2
3
4
5
6
7
8
9

EAU25971
Troubleshooting chart
WARNING

EWA10840
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.1. Fuel
There is
enough fuel.
There is
no fuel.
Supply fuel.
Operate the kickstarter.2. Compression
There is compression.
There is
no compression.Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.3. Ignition
Wet
DryWipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.The engine does not start.
Have a Yamaha dealer check the vehicle.
Open the throttle halfway and operate
the kickstarter.
Check the compression.
The engine does not start.
Check the compression.

MOTORCYCLE CARE AND STORAGE
7-3
2
3
4
5
6
78
9

EAU40651
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
CAUTION:

ECA10810

Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.

To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your motorcycle for sev-
eral months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” posi-
tion: Turn the fuel cock lever to“OFF”.
3. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to pro-
tect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and theninstall the spark plug and the
spark plug cap.
WARNING

EWA10950
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
6. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sidestand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
NOTE:

Make any necessary repairs before
storing the motorcycle.

INDEX
A
Accessories and replacement parts ........6-14
Air filter element, cleaning .........................6-8
Autolube pump, adjusting ........................6-19
B
Brake and shift pedals, checking and
lubricating ..............................................6-20
Brake lever ................................................3-2
Brake lever, checking and lubricating ......6-20
Brake lever free play, adjusting ...............6-14
Brake pedal ...............................................3-2
Brake pedal free play, adjusting ..............6-15
Brake shoes, checking ............................6-16
C
Cables, checking and lubricating .............6-19
Carburetor, adjusting ...............................6-10
Care ...........................................................7-1
D
Drive chain, cleaning and lubricating .......6-18
Drive chain slack .....................................6-16
E
Engine break-in .........................................5-3
Engine idling speed .................................6-11
Engine oil ...................................................3-4
Engine, starting a warm .............................5-2
Engine stop switch.....................................3-1
F
Front fork, checking .................................6-21
Fuel ............................................................3-3
Fuel cock ...................................................3-5
Fuel tank breather hose.............................3-4
Fuel tank cap .............................................3-2
H
Handlebar switch .......................................3-1
I
Identification numbers ............................... 9-1
K
Kickstarter ................................................. 3-6
L
Labels, location of ..................................... 1-4
M
Model label ................................................ 9-1
P
Parking ...................................................... 5-4
Part locations............................................. 2-1
Periodic maintenance and lubrication
chart ........................................................ 6-2
Power reduction plate................................ 3-1
Power reduction plate, removing ............... 6-6
Pre-operation check list ............................. 4-2
S
Safety information ..................................... 1-1
Seat ........................................................... 3-6
Shifting ...................................................... 5-2
Shift pedal ................................................. 3-1
Shock absorber ......................................... 3-7
Sidestand, checking and lubricating ........ 6-21
Spark arrester, cleaning ............................ 6-9
Spark plug, checking ................................. 6-5
Specifications ............................................ 8-1
Starter (choke) lever .................................. 3-6
Starting and warming up a cold engine ..... 5-1
Steering, checking ................................... 6-22
Storage ...................................................... 7-3
Supporting the motorcycle....................... 6-23
T
Throttle cable free play, adjusting ........... 6-11Throttle grip and cable, checking and
lubricating ............................................. 6-19
Tires ........................................................ 6-12
Tool kit....................................................... 6-1
Transmission oil ........................................ 6-7
Troubleshooting ...................................... 6-27
Troubleshooting chart ............................. 6-28
V
Vehicle identification number .................... 9-1
W
Wheel bearings, checking ....................... 6-22
Wheel (front) ........................................... 6-23
Wheel (rear) ............................................ 6-26
Wheels .................................................... 6-13