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Yamaha RAPTOR YFM80RT Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM80RT
w
This ATV should not be ridden by anyone under 12 years of age.
LIT-11626-18-07
5TH-28199-13

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Summary of Contents for Yamaha RAPTOR YFM80RT

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM80RT This ATV should not be ridden by anyone under 12 years of age. LIT-11626-18-07 5TH-28199-13...
  • Page 3 EBU13310 INTRODUCTION Congratulations on your purchase of the Yamaha YFM80R. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 4 Your ATV was delivered with an adjustable speed limiter and also with an air intake restrictor plate. Yamaha recommends that all beginners start off with the speed limiter screw turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn. The limiter screw may be gradually turned out to increase maximum speed as the beginner becomes more familiar with operating the ATV.
  • Page 5 EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or...
  • Page 6 Please check your local riding laws and regulations before operating this ATV. YFM80RT EBU13330 OWNER’S MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st edition, March 2004 AFFIX DEALER All rights reserved. LABEL HERE...

  • Page 7: Table Of Contents

    EBU00014 Indicates a potential hazard that could result in serious injury or death. CONTENTS LOCATION OF THE WARNING AND Speed limiter ........4-4 SPECIFICATION LABELS .......1-1 Front brake lever ........4-5 Brake pedal and rear brake lever ..4-5 SAFETY INFORMATION ......2-1 Parking brake ........4-6 Shift pedal ..........4-8 DESCRIPTION AND MACHINE Fuel tank cap ........4-8...
  • Page 8 Switches ..........5-6 Be careful where you ride....7-16 Battery ..........5-6 Turning your ATV .......7-23 Tires .............5-7 Climbing uphill ........7-25 How to measure tire pressure ....5-8 Riding downhill ........7-30 Tire wear limit ........5-9 Crossing a slope.........7-32 Crossing through shallow water ..7-34 OPERATION ..........6-1 Riding over rough terrain ....7-36 Starting a cold engine......6-1 Sliding and skidding ......7-38...
  • Page 9 Rear brake lever and pedal MAINTENANCE RECORD.....12-1 adjustment ........8-20 Clutch adjustment.......8-23 ATV LIMITED WARRANTY....13-1 Cable inspection and lubrication ..8-24 Brake and shift pedal/brake lever YAMAHA EXTENDED SERVICE lubrication .........8-24 (Y.E.S.) ...........14-1 Knuckle shaft and steering shaft lubrication .........8-25 Wheel removal ........8-25 Wheel installation .......8-25 Battery ..........8-26...

  • Page 10: Location Of The Warning And Specification Labels

    They contain important information for safe and proper operation of your ATV. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replace- ment label is available from your Yamaha dealer.
  • Page 11 WARNING WARNING Improper ATV use can result in SEVERE INJURY or DEATH. UNDER ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR Operating this ATV if you are under NEVER operate : the age of 12 increases your chance 9 without proper training or instruction.
  • Page 12 WARNING WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN NEVER ride as a CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE passenger. INJURY OR DEATH. OPERATING TIRE PRESSURE: Set with tires cold Passengers can cause 9Recommended : FRONT : 20 kPa, { 0.20 kgf/cm } 2.9 psi a loss of control, REAR : 20 kPa, { 0.20 kgf/cm...

  • Page 13: Safety Information

    EBU13390 SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper pre- cautions.
  • Page 14 8 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. 8 Never operate an ATV on any public street, road or highway, even a dirt or gravel one. 8 Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.
  • Page 15 8 Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. 8 Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds.
  • Page 16 8 Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, fol- low the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill.
  • Page 17 8 Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.
  • Page 18 q WARNING When transporting the ATV in another vehicle, be sure it is kept upright and that POTENTIAL HAZARD the fuel cock is in the “OFF” position. Improper handling of gasoline. Otherwise, fuel may leak out of the carbu- WHAT CAN HAPPEN retor or fuel tank.
  • Page 19 q WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation.

  • Page 20: Description And Machine Identification

    EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1. Spark arrester 10. Rear brake lever 2. Seat 11. Parking brake 3. Front cover 12. Neutral indicator light 4. Brake pedal 13. Front brake lever 5. Fuel cock 14. Throttle lever 6. Rear wheel 15.

  • Page 21: Identification Number Records

    This tion in the spaces provided for assistance when number can be used for ordering a new key. ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: 2.

  • Page 22: Vehicle Identification Number

    The model label is affixed to the location in the into the frame. illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Vehicle identification number NOTE: 1.

  • Page 23: Control Functions

    EBU00039 EBU00043 Indicator lights CONTROL FUNCTIONS EBU00603 Indicates a potential hazard that could result Neutral indicator light “N” in serious injury or death. This indicator light comes on when the transmis- sion is in neutral. EBU00042 Main switch Functions of the respective switch positions are as follows: The engine can be started only at this position.

  • Page 24: Handlebar Switches

    EBU00053 EBU00056 Handlebar switches Start switch “START” The starter motor cranks the engine when this switch is pushed. See starting instructions prior to starting engine (see page 6-1 for details). NOTE: If the starter switch is pushed with the main 1.

  • Page 25: Throttle Lever

    Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. 1. Throttle lever Consult a Yamaha dealer if you can’t find or solve the problem yourself.

  • Page 26: Speed Limiter

    For air intake restrictor plate removal instruc- speed limiter and also with an air intake restric- tions, see page 8-13. tor plate. Yamaha recommends that all begin- ners start off with the speed limiter screw turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn.

  • Page 27: Front Brake Lever

    EBU00070 q WARNING Front brake lever The front brake lever is located on the right han- POTENTIAL HAZARD dlebar. Pull it toward the handlebar to apply the Improper adjustment of the speed limiter front brake. and throttle. WHAT CAN HAPPEN The throttle cable could be damaged.

  • Page 28: Parking Brake

    EBU00074 Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake.
  • Page 29 q WARNING POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake could overheat if you ride the ATV without releasing the parking brake.

  • Page 30: Shift Pedal

    EBU00083 EBU00092 Shift pedal Fuel tank cap This machine is equipped with a constant-mesh Remove the fuel tank cap by turning it counter- 3-speed transmission. The shift pedal is located clockwise. on the left side of the engine. Neutral is at the bottom position.

  • Page 31: Fuel Cock

    EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. With the lever in this position, fuel flows to the carburetor.

  • Page 32: Choke Lever

    EBU00096 EBU00566 Choke lever Seat The choke is used to start a cold engine. Refer To remove the seat, pull the seat lock lever to “Starting a cold engine” for proper operation. upward and pull up the seat at the rear. (See page 6-1.) 1.
  • Page 33 To install the seat, insert the projection on the front of the seat into the seat holder and push down on the seat at the rear. 1. Projection 2. Seat holder NOTE: Make sure that the seat is securely fitted. 4-11...
  • Page 34 EBU00112 Indicates a potential hazard that could result in serious injury or death. 4-12...

  • Page 35: Pre-Operation Checks

    PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE 9 Check operation, condition and free play. Brakes 5-2–5-3, 8-17–8-22 9 Adjust if necessary. 9 Check fuel level. 5-3–5-4 Fuel 9 Fill with fuel if necessary. 9 Check oil level. 5-5, 8-5–8-6 Engine oil 9 Fill with oil if necessary.

  • Page 36: Front And Rear Brakes

    HOW TO AVOID THE HAZARD brakes are applied. If not, have the ATV Always inspect your ATV each time you inspected by a Yamaha dealer. use it to make sure the ATV is in safe operating condition. Brake operation...

  • Page 37: Fuel

    Your Yamaha engine has been designed to use reg- ular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher.
  • Page 38 Fuel expands when it heats up. If the fuel containing methanol is not recommended by tank is overfilled, fuel could spill out due Yamaha because it may cause fuel system to heat from the engine or the sun. damage or vehicle performance problems.

  • Page 39: Engine Oil

    EBU10842 EBU00493 Engine oil Final gear oil Make sure the engine oil is at the specified level. Make sure the final gear oil is at the specified Add oil as necessary. (See page 8-5.) level. Add oil as necessary. (See pages 8-7–8-8 for details.) 8 In order to prevent clutch slippage (since Recommended oil:...

  • Page 40: Throttle Lever

    EBU11620 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. EBU11700 Switches Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation.

  • Page 41: Tires

    The following are mini- mums: 1. The tires listed below have been Front 17 kPa (0.17 kgf/cm , 2.5 psi) approved by Yamaha Motor Co., Ltd. Rear 17 kPa (0.17 kgf/cm , 2.5 psi) for this model. Other tire combinations are not recommended.

  • Page 42: Specifications

    Set pressure with tires cold. 4. Use no more than the following pres- Set tire pressures to the following specifications: sures when seating the tire beads. Front 230 kPa (2.3 kgf/cm , 33 psi) Recommended Minimum Maximum pressure Rear 230 kPa (2.3 kgf/cm , 33 psi) 20 kPa 17 kPa...

  • Page 43: Tire Wear Limit

    EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. Tire wear limit...

  • Page 44: Operation

    2. Turn the fuel cock to “ON”. there is a control or function you do not 3. Turn the main switch to “ON” and the engine understand, ask your Yamaha dealer. stop switch to “RUN”. 4. Shift the transmission into neutral.
  • Page 45 °F 30° 50° 70° 90° Yamaha dealer to inspect it. b. When the transmission is in gear and the rear brake lever is applied. However, it is recommended to shift into neutral before starting the engine. 5. Use the choke lever in reference to the fig- ure: a.

  • Page 46: Starting A Warm Engine

    6. Completely close the throttle lever and start the engine by pushing the start switch. See the “Engine break-in” section prior to NOTE: operating engine for the first time. If the engine fails to start, release the start switch, then push it again. Pause a few seconds EBU00181 before the next attempt.

  • Page 47: Shifting

    EBU00200 Shifting This model has a 3-speed forward transmission Do not coast for long periods with the engine with centrifugal automatic clutch. The transmis- off, and do not tow the machine a long dis- sion allows you to control the amount of power tance.

  • Page 48: To Decelerate

    EBU00207 To decelerate: 4. Once the machine has attained adequate When slowing down or stopping, release the throttle speed, release the throttle lever. and apply the brakes smoothly and evenly. As you 5. Shift into second gear and release the shift slow down, shift to a lower gear.

  • Page 49: Engine Break-In

    EBU02092 If any abnormality is noticed during this period, Engine break-in consult a Yamaha dealer. There is never a more important period in the life of your machine than the period between 0-10 hours: zero and 20 hours. Avoid continuous operation above half throttle.

  • Page 50: Parking

    EBU00211 Parking When parking, stop the engine and shift into neutral. Turn the fuel cock to “OFF” and apply the parking brake. 1. Lock plate 1. Locked position...

  • Page 51: Parking On A Slope

    EBU12960 Parking on a slope 1. Bring the ATV to a stop by applying the brakes in low gear. q WARNING 2. Stop the engine. POTENTIAL HAZARD 3. With the rear brake lever and pedal applied, apply the parking brake and slowly Parking on a hill or other incline.

  • Page 52: Accessories And Loading

    8 Use extra caution when riding an ATV with However, it is not possible for Yamaha to test all non-Yamaha accessories, nor have any accessories. The ATV may handle differently control over the quality or suitability of them.
  • Page 53 EBU00584 8 Tie down cargo securely to the carriers. Make Loading sure cargo in the trailer cannot move around. As originally equipped, this ATV is not designed A shifting load can cause an accident. to carry cargo or tow a trailer. If you choose to 8 Make sure the load does not interfere with add accessories so that you can carry cargo or controls or your ability to see where you are...
  • Page 54 q WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow- ing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
  • Page 55 EBU13541 Indicates a potential hazard that could result in serious injury or death. 6-13...

  • Page 56: Riding Your Atv

    Riding Your...

  • Page 57: Getting To Know Your Atv

    Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV completely and understand the operation of the This ATV is for recreation use. This section, controls. Pay particular attention to the safety Riding your ATV, provides general ATV riding information on pages 2-1–2-7.

  • Page 58: Ride With Care And Good Judgement

    Get training if you are inexperienced. should complete the certified training Beginners should get training from a certified course offered by Yamaha. They should instructor. then regularly practice the skills learned in Become familiar with this ATV at slow speeds the course and the operating techniques first, even if you are an experienced operator.
  • Page 59 Not recommended for children under 12 years of age. q WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not rec- ommended for their age can lead to severe injury or death of the child.
  • Page 60 This ATV is designed to carry operator only - passengers prohibited. q WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an acci- dent, resulting in harm to you and/or your passenger.
  • Page 61 Apparel Operating without protective clothing q WARNING increases your chances of severe injury in the event of an accident. POTENTIAL HAZARD HOW TO AVOID THE HAZARD Operating this ATV without wearing an Always wear an approved motorcycle hel- approved motorcycle helmet, eye protec- met that fits properly.
  • Page 62 Do not operate after consuming alcohol or q WARNING drugs. POTENTIAL HAZARD Operator’s performance capability is reduced by the influence of alcohol or drugs. Operating this ATV after consuming alco- hol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly.
  • Page 63 Pre-operation checks q WARNING Always perform the pre-operation checks listed POTENTIAL HAZARD on page 5-1 before riding for safety and proper care of the ATV. Operating this ATV with improper tires, or with improper or uneven tire pressure. q WARNING WHAT CAN HAPPEN Use of improper tires on this ATV, or oper- POTENTIAL HAZARD...
  • Page 64 WARNING Yamaha recommends that all beginning riders start off with the speed limiter turned in and the air POTENTIAL HAZARD intake restrictor plate installed to limit the amount Operating this ATV at speeds too fast for of speed available while they learn.
  • Page 65 Adjusting for maximum throttle lever movement MAXIMUM LOADING LIMIT without removing the air intake restrictor plate Vehicle loading limit(total weight of will cause the engine to run roughly at higher cargo, rider and accessories): speeds. 95 kg (209 lb) For air intake restrictor plate removal instruc- tions, see page 8-13.
  • Page 66 During operation q WARNING Always keep your feet on the footboards during POTENTIAL HAZARD operation. Otherwise your feet may contact the rear wheels. Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.
  • Page 67 Avoid wheelies and jumping. You may lose con- trol of the ATV or overturn. q WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps.
  • Page 68 Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used accord- ing to instructions. If you have questions, consult an authorized ATV dealer.
  • Page 69 Exhaust system HOW TO AVOID THE HAZARD The exhaust system on the ATV is very hot dur- Do not operate, idle, or park the ATV in dry ing and following operation. To prevent burns, grass or other dry ground cover. avoid touching the exhaust system.

  • Page 70: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of con- trol. q WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect han- dling and control of the ATV, and may cause the vehicle to go out of control.
  • Page 71 Do not ride on any public road, street, or high- way. Riding on public roads can result in colli- sions with other vehicles. q WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or...
  • Page 72 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden haz- ards which may cause the ATV to upset. q WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 73 q WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary...
  • Page 74 When riding in an area where you might not WHAT CAN HAPPEN easily be seen, such as desert terrain, mount a You could be in a collision. You could be caution flag on the ATV. DO NOT use the flag injured.
  • Page 75 Select a large, flat area off-road to become With the engine idling, lift the shift pedal to the familiar with your ATV. Make sure that this area 1st gear position and then release the parking is free of obstacles and other riders. You should brake.
  • Page 76 q WARNING Do not shift gears without releasing the POTENTIAL HAZARD throttle. Damage to the engine or drive train Engaging a lower gear when the engine may occur. speed is too high. WHAT CAN HAPPEN When slowing down or stopping, release the The wheels could stop rotating.

  • Page 77: Turning Your Atv

    TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off- Always follow proper procedures for turn- road, the two rear wheels are mounted solidly ing as described in this Owner’s Manual. on one axle and turn together at the same Practice turning at low speeds before speed.
  • Page 78 Once you have learned this technique you should be able to perform it at higher speeds or Lean towards in tighter curves. Support your inside of turn weight on the outer footrest Improper riding procedures such as abrupt throt- tle changes, excessive braking, incorrect body movements, or too much speed for the sharp- ness of the turn may cause the ATV to tip.

  • Page 79: Climbing Uphill

    CLIMBING UPHILL HOW TO AVOID THE HAZARD Use proper riding techniques to avoid vehicle Never operate the ATV on hills too steep overturns on hills. Be sure that you can maneu- for the ATV or for your abilities. ver your ATV well on flat ground before attempt- Practice on smaller hills before attempting ing any incline and then practice riding first on large hills.
  • Page 80 q WARNING Never go over the top of any hill at high speed. An obstacle, a sharp drop, or POTENTIAL HAZARD another vehicle or person could be on the Climbing hills improperly. other side of the hill. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.
  • Page 81 If you are climbing a hill and you find that you When crossing the side of a hill: have not properly judged your ability to make it Always follow proper procedures as to the top, you should turn the ATV around while described in the Owner’s Manual.
  • Page 82 If your ATV has stalled or stopped and you q WARNING believe you can continue up the hill, restart care- POTENTIAL HAZARD fully to make sure you do not lift the front wheels Stalling, rolling backwards or improperly which could cause you to lose control. If you are dismounting while climbing a hill.
  • Page 83 When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the proce- dure described in the Owner’s Manual. 7-29...

  • Page 84: Riding Downhill

    RIDING DOWNHILL q WARNING When riding your ATV downhill, shift your weight POTENTIAL HAZARD as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with Going down a hill improperly. your arms straight.
  • Page 85 7-31...

  • Page 86: Crossing A Slope

    CROSSING A SLOPE q WARNING Traversing a sloping surface on your ATV POTENTIAL HAZARD requires you to properly position your weight to maintain proper balance. Be sure that you have Improperly crossing hills or turning on learned the basic riding skills on flat ground hills.
  • Page 87 Shift your weight to the uphill side of the ATV. 7-33...

  • Page 88: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER Remember that wet brakes may have The ATV can be used to cross slow moving, reduced stopping ability. Test your brakes shallow water of up to a maximum of 20 cm (7.9 after leaving water. If necessary, apply inches) in depth.
  • Page 89 Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that After riding your ATV in water, be sure to you have regained proper braking ability. drain the trapped water by removing the check hose at the bottom of the air filter case.

  • Page 90: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN q WARNING Riding over rough terrain should be done with POTENTIAL HAZARD caution. Look out for obstacles which could cause damage to the ATV or could lead to an Improperly operating over obstacles. upset or accident. Be sure to keep your feet WHAT CAN HAPPEN firmly mounted on the footboards at all times.

  • Page 91: Sliding And Skidding

    SLIDING AND SKIDDING If the rear wheels of your ATV start to slide side- Care should be used when riding on loose or ways, control can usually be regained (if there is slippery surfaces since the ATV may slide. If room to do so) by steering in the direction of the unexpected and uncorrected, sliding could lead slide.
  • Page 92 With practice, over a period of time, skill at con- q WARNING trolled sliding can be developed. The terrain POTENTIAL HAZARD should be chosen carefully before attempting Skidding or sliding improperly. such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneu- WHAT CAN HAPPEN vers should always be avoided on extremely You may lose control of this ATV.

  • Page 93: What To Do If

    WHAT TO DO IF ... 8 If your ATV starts to slide sideways: This section is designed to be a reference guide Steer in the direction of the slide if you have only. Be sure to read each section on riding the room.
  • Page 94 8 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.

  • Page 95: Periodic Maintenance And Adjustment

    MAINTENANCE AND Turn off the engine when performing maintenance unless otherwise specified. ADJUSTMENT Have a Yamaha dealer perform service if Periodic inspection, adjustment and lubrication you are not familiar with machine service. will keep your machine in the safest and most efficient condition possible.
  • Page 96 HOW TO AVOID THE HAZARD during a service operation requiring one, take Never modify this ATV through improper your machine to a Yamaha dealer to check the installation or use of accessories. All parts torque settings and adjust them as necessary.

  • Page 97: Periodic Maintenance/Lubrication

    EBU02611 PERIODIC MAINTENANCE/LUBRICATION NOTE: 8 For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. 8 For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
  • Page 98 9 Check breather hose for correct routing. Battery* 9 Correct if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. Indicates a potential hazard that could result in serious injury or death.

  • Page 99: Engine Oil

    EBU08682 Engine oil Engine oil level measurement 1. Place the ATV on a level surface. 2. Warm up the engine for several minutes and stop it. 3. Remove the dipstick and wipe it off with a clean rag. Insert the dipstick in the filler hole without screwing it in.
  • Page 100 Recommended oil type: YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 Recommended oil classification: API Service SE, SF, SG type or higher Oil quantity: Periodic oil change: 0.8 L (0.70 Imp qt, 0.85 US qt) 1.

  • Page 101: Final Gear Oil

    EBU00869 Final gear oil Final gear oil measurement 1. Place the ATV on a level surface. 2. Remove the dipstick and wipe it off with a clean rag. Insert the dipstick in the filler hole without screwing it in. 3. Remove the dipstick and inspect the oil level.
  • Page 102 5. Fill the final gear case with oil. Recommended oil: SAE80API “GL-4” Hypoid gear oil Oil quantity: 0.12L (0.11 Imp qt, 0.13 US qt) Be sure no foreign material enters the final 1. Drain bolt gear case. 4. Install the drain bolt and tighten to specifi- 6.

  • Page 103: Spark Plug Inspection

    Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.

  • Page 104: Air Filter Cleaning

    When installing the spark plug, always clean the gasket surface and its mating surface. Wipe off any grime from the threads and tighten it to the specified torque. Tightening torque: Spark plug: 12.5 Nm (1.25 m0kgf, 9.1 ft0lbf) 1. Check hose 1.
  • Page 105 × 1. Air filter case cover 2. Fastener ( 1. Fastener 2. Air filter element 2. Remove the air filter case cover by 3. Remove the air filter element by unhooking unhooking the fasteners. the fastener. 4. Wash the air filter element gently but thor- oughly in solvent.
  • Page 106 6. Inspect the air filter element. If damaged, replace it. POTENTIAL HAZARD 7. Apply Yamaha foam air filter oil or other Using low flash point solvents or gasoline quality foam air filter oil to the air filter ele- to clean the air filter element.

  • Page 107: Air Intake Restrictor Plate Removal

    EBU01035 Air intake restrictor plate removal NOTE: To obtain full engine performance capability, The air filter element should be cleaned every removing the air intake restrictor plate is 20-40 hours. It should be cleaned and lubricated required. more often if the machine is operated in 1.

  • Page 108: Spark Arrester Cleaning

    EBU13601 Spark arrester cleaning NOTE: Be sure the exhaust pipe and muffler are cool Store the air intake restrictor plate with the before cleaning the spark arrester. owner’s manual so that you can install it when- ever you want to reduce the top speed available. 1.
  • Page 109 2. Remove the tailpipe by pulling it out of the q WARNING muffler. POTENTIAL HAZARD 3. Tap the tailpipe lightly, then use a wire brush to remove any carbon deposits from Improper cleaning of the spark arrester. the spark arrester portion of the tailpipe. Hot exhaust system.

  • Page 110: Carburetor Adjustment

    NOTE: requires very sophisticated adjustment. Most A diagnostic tachometer must be used for this adjusting should be left to a Yamaha dealer who procedure. has the professional knowledge and experience to do so. However, the idling speed may be per- 1.

  • Page 111: Valve Clearance Adjustment

    Apply the brake and check the position of the indicator. If the indi- 1. Throttle stop screw cator reaches the wear limit line or mark, ask a Yamaha dealer to replace the shoes as a set. 8-17...

  • Page 112: Front Brake Lever Free Play Adjustment

    EBU00323 Front Front brake lever free play adjustment NOTE: Before adjusting the brake, inspect the front brake shoes. The front brake lever free play should be adjust- ed to 10–12 mm (0.4–0.5 in) at the brake lever pivot. If the free play is incorrect, adjust as fol- 1.
  • Page 113 1. Loosen the upper locknut and fully turn in 5. While applying the front brake, turn out the the adjusting bolt. upper adjusting bolt until the upper and 2. Loosen the lower locknut. lower cable lengths are equal. The cable 3.

  • Page 114: Rear Brake Lever And Pedal Adjustment

    8 Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a. Free play Yamaha dealer. 1. Locknut 2. Adjusting bolt 8-20...
  • Page 115 Brake pedal free play adjustment NOTE: Turn the brake rod adjusting nut at the rear If specified free play cannot be obtained, tighten wheel hub until brake pedal free play is 20– the brake cable adjusting nut at the rear wheel 30 mm (0.8–1.2 in).
  • Page 116 8 Make sure the brakes operate smooth- ly and that the free play is correct. 8 Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. 8-22...

  • Page 117: Clutch Adjustment

    EBU00872 Clutch adjustment NOTE: 1. Remove the rubber cap. Turn the adjusting bolt clockwise to decrease 2. Loosen the locknut. the clutch free play and turn it counterclockwise 3. Slowly turn the adjusting bolt clockwise to increase the free play. until resistance is felt.

  • Page 118: Cable Inspection And Lubrication

    WARNING Yamaha dealer to replace them. POTENTIAL HAZARD Recommended lubricant: Damaged control cables. Yamaha chain and cable lube or WHAT CAN HAPPEN SAE 10W30 motor oil Corrosion can result when the outer cov- ering of control cables becomes damaged.

  • Page 119: Knuckle Shaft And Steering Shaft Lubrication

    EBU01220 Rear Knuckle shaft and steering shaft lubrication Front Lubricate the pivot points using a grease gun. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) × × 1. Wheel nut ( 2. Wheel nut ( EBU00871 Wheel installation When installing the wheel, reverse the removal procedure.

  • Page 120: Battery

    EBU00378 Battery Check the level of the battery fluid and see if the terminals are tight. Add distilled water if the fluid level is low. Do not leave or store the battery on its side. When inspecting the battery, be sure the breather hose is routed correctly.
  • Page 121 q WARNING EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batter- POTENTIAL HAZARD ies away from sparks, flames, cigarettes Failure to handle batteries or battery elec- or other sources of ignition. Ventilate trolyte carefully. when charging or using in a closed space. WHAT CAN HAPPEN You could be poisoned.

  • Page 122: Replenishing The Battery Fluid

    EBU11950 Replenishing the battery fluid A poorly maintained battery will corrode and dis- Normal tap water contains minerals which charge quickly. The battery fluid should be are harmful to a battery. Therefore, refill only checked at least once a month. with distilled water.

  • Page 123: Fuse Replacement

    WHAT CAN HAPPEN amperage. Then turn on the switches. If the fuse immediately blows again, consult An improper fuse can cause damage to a Yamaha dealer. the electrical system which could lead to a fire. Specified fuse: 5 A HOW TO AVOID THE HAZARD Always use a fuse of the specified rating.

  • Page 124: Troubleshooting

    Fuel can ignite or explode, causing severe procedure for making checks. If your machine injury or property damage. requires any repair, take it to a Yamaha dealer. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys- The skilled technicians at a Yamaha dealership tem.

  • Page 125: Troubleshooting Chart

    2. Compression Use electric starter There is compresson Compression normal to see if there is compression No compression Ask a Yamaha dealer to inspect Wipe clean with dry 3. Ignition cloth Remove spark Spark good Ignition system normal plug and check...

  • Page 126: Cleaning And Storage

    EBU00419 3. Rinse the dirt and degreaser off with a gar- CLEANING AND STORAGE den hose. Use only enough pressure to do the job. A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will Excessive water pressure may cause water improve its general performance and extend the seepage and deterioration of wheel bearings,...
  • Page 127 5. Rinse the machine off immediately with q WARNING clean water and dry all surfaces with a POTENTIAL HAZARD chamois, clean towel or soft absorbent Operation with wet brakes after washing. cloth. 6. Clean the seat with a vinyl upholstery WHAT CAN HAPPEN cleaner to keep the cover pliable and Wet brakes may have reduced stopping...

  • Page 128: Storage

    (less than the need to drain the fuel system. Consult a 0˚C (30˚F) or more than 30˚C (90˚F). Yamaha dealer if the fuel system needs to be NOTE: drained instead. Make any necessary repairs before storing the 2.

  • Page 129: Specifications

    EBU00428 SPECIFICATIONS Model YFM80R Dimension: Overall length 1,537 mm (60.5 in) Overall width 841 mm (33.1 in) Overall height 940 mm (37.0 in) Seat height 669 mm (26.3 in) Wheel base 1,030 mm (40.6 in) Ground clearance 100 mm ( 3.9 in) Minimum turning radius 2,400 mm (94.5 in) Basic weight:...
  • Page 130 Model YFM80R Engine oil: 0° 10° 30° 50° 70° 90° 110° 130°F Type YAMALUBE 4 (20W40) or SAE20W40 YAMALUBE 4 (10W30) or SAE10W30 SAE 5W30 –20° –10° 0° 10° 20° 30° 40° 50°C Recommended engine oil classification: API Service SE, SF, SG type or higher In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
  • Page 131 Model YFM80R Final gear oil: Type SAE80API “GL-4” Hypoid gear oil Quantity: Total amount 0.12 L (0.11 Imp qt, 0.13 US qt) Air filter: Wet type element Fuel: Type UNLEADED GASOLINE ONLY Tank capacity 6.8 L (1.5 Imp gal, 1.8 US gal) Reserve amount 0.9 L (0.2 Imp gal, 0.2 US gal) Carburetor:...
  • Page 132 Model YFM80R Transmission: Primary reduction system Spur gear Primary reduction ratio 65/20 (3.250) Secondary reduction system Shaft drive 19/18 × 34/10 (3.588) Secondary reduction ratio Transmission type Constant mesh 3-speed Operation Left foot operation Gear ratio: 39/11 (3.545) 35/17 (2.059) 31/22 (1.409) Chassis: Frame type...
  • Page 133 Model YFM80R Brake: Front brake type Drum brake Operation Right hand operation Rear brake type Drum brake Operation Left hand and right foot operation Suspension: Front Leading arm Rear Swingarm Shock Absorber: Front Coil spring/Oil damper Rear Coil spring/Oil damper Wheel travel: Front 57 mm (2.24 in)

  • Page 134: Noise Regulation

    EBU13640 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inopera- tive by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 135: Maintenance Record

    EBU13670 MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work. MAINTENACE DATE OF SERVICING DEALER...
  • Page 136 EBU00432 13-1...
  • Page 137 13-2...
  • Page 138 EBU00435 14-1...
  • Page 139 14-2...
  • Page 140 EBU00436 Indicates a potential hazard that could result in serious injury or death.
  • Page 141 EBU00437...
  • Page 142 9 with a passenger - passengers affect balance and steering and increase risk of losing control. LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2004.4-2.0x1 !
  • Page 143 8 TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA – ASK YOUR DEALER FOR DETAILS OR CALL 1-800-887-2887 If you have any questions about these points, or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership, please fill out the information below and mail this card to yamaha today.
  • Page 144 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES FIRST CLASS PERMIT NO. 4 CYPRESS, CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U.S.A. P.O. BOX 6555 CYPRESS, CALIFORNIA 90630-9989 ATTN: SALES ADMINISTRATION...

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