Yamaha YFM80WP Service Manual
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Yamaha YFM80WP Service Manual

Yamaha YFM80WP Service Manual

Yamaha atv
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YFM80WP
4EM-AE1
SUPPLEMENTARY
SERVICE MANUAL

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Summary of Contents for Yamaha YFM80WP

  • Page 1 YFM80WP 4EM-AE1 SUPPLEMENTARY SERVICE MANUAL...
  • Page 3 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM80WP. For complete information on service procedures, it is necessary to use this Supple- mentary Service Manual together with the following manual. YFM80(D) SERVICE MANUAL: 4EM-28197-20...

  • Page 4: Important Information

    EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair.

  • Page 5: How To Use This Manual

    EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.
  • Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the SPEC top right of each page and indicate the subject INFO of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical...

  • Page 7: Table Of Contents

    CONTENTS GENERAL INFORMATION ................1 MACHINE IDENTIFICATION ..............1 VEHICLE IDENTIFICATION NUMBER ..........1 MODEL LABEL ..................1 SPECIFICATIONS ....................2 GENERAL SPECIFICATIONS ..............2 MAINTENANCE SPECIFICATIONS ............3 ENGINE ....................3 CHASSIS ....................5 ELECTRICAL ..................5 CABLE ROUTING ..................7 PERIODIC CHECKS AND ADJUSTMENTS ..........11 INTRODUCTION ..................11 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ......11 SEAT, FENDERS AND FUEL TANK ............12 SEAT AND FRONT PANEL ..............12 FRONT FENDER ................13...

  • Page 9: General Information

    MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.

  • Page 10: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YFM80WP Model code number: 5TH1 (For Oceania) 5TH2 (For CDN) 5TH3 (For Europe) Dimensions: Overall length 1,537 mm (60.5 in) Overall width 841 mm (33.1 in) Overall height 940 mm (37 in) Seat height 669 mm (26.3 in)

  • Page 11: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model YFM80WP Camshaft: Drive method Chain drive (Left) Cam dimensions: Intake: “A” 25.30 ~ 25.31 mm (0.996 ~ 0.997 in) “B” 20.994 ~ 21.094 mm (0.827 ~ 0.831 in) Exhaust: “A” 25.301 ~ 25.311 mm (0.996 ~ 0.997 in) “B”...
  • Page 12 SPEC MAINTENANCE SPECIFICATIONS Model YFM80WP Piston: Piston size “D” 46.960 ~ 46.975 mm (1.8488 ~ 1.8494 in) Measuring point “H” 6.5 mm (0.256 in) (From bottom line of piston skirt) Piston over size: 2nd 47.50 mm (1.870 in) 48.00 mm (1.890 in) Offset 0.75 mm...

  • Page 13: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model YFM80WP Wheel: Front wheel type Panel wheel Rear wheel type Panel wheel 7 × 5.5 AT/steel Front rim size/material 7 × 6.5 AT/steel Rear rim size/material Rim runout limit: Vertical <2.0 mm (0.08 in)> Lateral <2.0 mm (0.08 in)>...
  • Page 14 SPEC MAINTENANCE SPECIFICATIONS Model YFM80WP Electric starter system: Type Constant mesh type Starter motor: Model/manufacturer ADB4A5/DENSO Out put 0.2 kW 0.0288 ~ 0.0352 Ω at 20°C (68°F) Armature coil resistance Brush: Overall length 6 mm (0.24 in) <Limit> <3.5 mm (0.14 in)>...

  • Page 15: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Throttle cable A Battery breather hose 2 Fuel tank breather hose B CDI magneto lead 3 Carburetor ventilation hose C Carburetor overflow hose 4 Final gear case breather hose D Front brake cable (right) 5 Crankcase breather hose E Front brake cable (left) 6 Fuel hose...
  • Page 16 SPEC CABLE ROUTING 1 Rear brake cable C Throttle cable 2 Band 3 Wireharness 4 Ignition coil 5 Handlebar switch lead 6 Rear brake switch lead 7 “NEUTRAL” indicator light lead 8 Main switch 9 CDI unit 0 Fuel hose A Front brake cable B Fuel tank breather hose –...
  • Page 17 SPEC CABLE ROUTING 1 Fuel tank breather hose 2 Throttle cable 3 Front brake cable (left) 4 Front brake cable (right) 5 Air filter joint 6 Rear brake switch lead 7 Handlebar switch lead 8 “NEUTRAL” indicator light lead 9 Rear brake cable –...
  • Page 18 SPEC CABLE ROUTING 1 Front brake cable È Pass the leads through the hole. 2 Throttle cable 3 Fuel tank breather hose 4 Battery negative lead 5 Fuse 6 Battery positive lead 7 Band 8 Handlebar switch 9 Rear brake switch 0 Rear brake cable –...

  • Page 19: Periodic Checks And Adjustments

    • Check all chassis fittings and fasteners. ers* • Correct if necessary. • Check specific gravity. Battery* • Check breather hose for correct routing. • Correct if necessary. It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease. – 11 –...

  • Page 20: Seat, Fenders And Fuel Tank

    SEAT, FENDERS AND FUEL TANK SEAT, FENDERS AND FUEL TANK SEAT AND FRONT PANEL Order Job name/Part name Q’ty Remarks Removing the seat and front panel Remove the parts in the order below. Seat NOTE: Pull back the seat lock lever, than pull up on the rear of the seat.

  • Page 21: Front Fender

    SEAT, FENDERS AND FUEL TANK FRONT FENDER 7 Nm (0.7 m kg, 5.1 ft • • Order Job name/Part name Q’ty Remarks Removing the front fender Remove the parts in the order below. Seat and front panel Refer to “SEAT AND FRONT PANEL”. Fuel tank top panel Air cleaner joint clamp screw Loosen...

  • Page 22: Rear Fender

    SEAT, FENDERS AND FUEL TANK REAR FENDER 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • Order Job name/Part name Q’ty Remarks Removing the rear fender Remove the parts in the order below. Seat Refer to “SEAT AND FRONT PANEL”.

  • Page 23: Fuel Tank

    SEAT, FENDERS AND FUEL TANK FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • Order Job name/Part name Q’ty Remarks Removing the fuel tank Remove the parts in the order below. Seat and front panel Refer to “SEAT AND FRONT PANEL”. Front fender Refer to “FRONT FENDER”.

  • Page 24: Engine

    SPEED LIMITER ADJUSTMENT ENGINE SPEED LIMITER ADJUSTMENT The speed limiter keeps the carburetor throttle from becoming fully-opened even when the throttle lever is applied to the maximum posi- tion. Screwing in the adjuster stops the engine speed from increasing. 1.Check: Speed limiter length a Out of specification →...

  • Page 25: Air Filter Cleaning

    SPEED LIMITER ADJUSTMENT/ AIR FILTER CLEANING Air intake restrictor plate removal Refer to “AIR FILTER CLEANING”. NOTE: To obtain full engine performance capability, removing the air intake restrictor plate 1 is required. Since removal of this plate will result in a significant increase in power, turn the speed limiter completely back in again.
  • Page 26 AIR FILTER CLEANING 6.Check: Air filter element Damage → Replace. 7.Clean: Air filter element *********************************************** Cleaning steps: Wash the element gently, but thoroughly in solvent. WARNING Never use low flash point solvents such as gasoline to clean the air filter element. Such solvent may lead to a fire or explo- sion.

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