Instruction/ maintenance manual of the product 5TH-28199-15 Yamaha
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OWNER’S MANUAL READ THIS MANUAL CAREFULLY! It contains important safety information. w LIT -1 1626-19-64 5TH-28199-15 This A TV should not be ridden by anyone under 12 years of age.
5TH-9-15 hyoshi 7/15/05 1:06 PM Page 2.
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.
AN IMPORTANT NOTE TO PARENTS: This ATV is not a toy. Before you let your child ride this ATV, you should understand the instructions and warnings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abilities and judgment.
EBU00801 IMPORT ANT MANUAL INFORMA TION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manua.
EBU15000 IMPORT ANT NOTICE This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.
LOCATION OF THE WARNING AND SPECIFICATION LABELS .......................1-1 SAFETY INFORMATION .........................2-1 DESCRIPTION AND MACHINE IDENTIFICATION.....................................3-1 Identification number records ...............3-2 Key identification number .
How to measure tire pressure ..............5-7 Tire wear limit .......................................5-8 Fittings and fasteners ...........................5-9 Switches ...............................................5-9 Battery .......................
Air intake restrictor plate removal .......8-14 Spark arrester cleaning ......................8-15 Carburetor adjustment ........................8-17 Idle speed adjustment ........................8-17 Valve clearance adjustment ...............8-18 Cam chain adjustment .
Read and understand all of the labels on your machine. 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.
1-2 1 12 q W ARNING UNDER 12 Operating this ATV if you are under the age of 12 increases your chance of severe injury or death. NEVER permit children under age 12 to operate this ATV. 4EM-21697-31 Adult supervision required for children under age 16 .
1-3 4 3 q W ARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. OPERATING TIRE PRESSURE : Set with tires cold 9 Recommended : FRONT : 20 kPa, { 0.20 kgf/cm 2 } 2.9 psi REAR : 20 kPa, { 0.
2-1 EBU13390 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.
2-2 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.
2-3 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.
2-4 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.
2-5 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.
2-6 POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot.
2-7 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.
3-1 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. Main switch 7. Footrest 16. Fuel tank cap 8. Shift pedal 17.
EBU00600 Identification number records Record the key identification number, vehicle identification number and model label informa- tion in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen.
EBU00036 Vehicle identification number The vehicle identification number is stamped into the frame. 1. Vehicle identification number NOTE: The vehicle identification number is used to identify your machine. EBU00787 Model label The model label is affixed to the location in the illustration.
EBU00039 CONTROL FUNCTIONS w Indicates a potential hazard that could result in serious injury or death. EBU00042 Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position. OFF: All electrical circuits are switched off.
EBU00053 Handlebar switches 1. Engine stop switch “ ENG. STOP ” 2. Start switch “ START ” EBU11580 Engine stop switch “ ENG. STOP ” Make sure that the engine stop switch is in the “ RUN ” position before starting the engine.
EBU00062 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.
EBU15650 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV. Your ATV was delivered with an adjustable speed limiter and also with an air intake restric- tor plate.
4-5 EBU00070 Front brake lever The front brake lever is located on the right han- dlebar. Pull it toward the handlebar to apply the front brake. 1. Front brake lever EBU00732 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar.
1. Brake pedal 1. Rear brake lever 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.
1. Locked position 4-7 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.
EBU00083 Shift pedal This machine is equipped with a constant-mesh 3-speed transmission. The shift pedal is located on the left side of the engine. Neutral is at the bottom position. 1. Shift pedal N. Neutral position EBU00092 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise.
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. ON: With the lever in this position, fuel flows to the carburetor.
EBU00096 Choke lever The choke is used to start a cold engine. Refer to “ Starting a cold engine ” for proper operation. (See page 6-1.) a. Choke lever 1. Fully open “ ON ” 2. Half open (warming up position) 3. Closed “ OFF ” EBU00566 Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear.
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.
4-12 EBU00112 w Indicates a potential hazard that could result in serious injury or death. 5TH-9-15-1 6/15/05 2:55 PM Page 4-12.
5-1 PRE-OPERA TION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE Brakes 9 Check operation, condition and free play. 5-2 – 5-3, 8-18 – 8-23 9 Adjust if necessary. Fuel 9 Check fuel level. 9 Fill with fuel if necessary.
5-2 POTENTIAL HAZARD Failure to inspect the ATV before operat- ing. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
EBU13410 Fuel Make sure there is sufficient gasoline in the tank. c C Us e only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the e xhaust system.
Unleaded fuel will give you longer spark plug life and reduced maintenance cost. Gasohol There are two types of gasohol; gasohol con- taining ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%.
EBU10842 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See page 8-6.) c C 8 In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “ CD ” or oils of a higher quality than specified.
EBU01083 Throttle lever Check to see that the throttle lever operates cor- rectly. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer repair as necessary for proper operation. EBU00157 Tires 5-6 POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure.
5-7 EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as stan- dard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.
Set pressure with tires cold. Set tire pressures to the following specifications: 1. Low-pressure tire gauge 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 5-8 20 kPa (0.20 kgf/cm 2 , 2.
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.
EBU00161 OPERA TION w Indicates a potential hazard that could result in serious injury or death. EBU00579 Starting a cold engine 1. Set the parking brake. 2. Turn the fuel cock to “ ON ” . 3. Turn the main switch to “ ON ” and the engine stop switch to “ RUN ” .
6-2 NOTE: This model is equipped with an ignition circuit cut-off system. The engine can be started under the following conditions. a. When the transmission is in neutral. At this time the neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it.
6. Completely close the throttle lever and start the engine by pushing the start switch. NOTE: If the engine fails to start, release the start switch, then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery ener- gy.
EBU00200 Shifting This model has a 3-speed forward transmission with centrifugal automatic clutch. The transmis- sion allows you to control the amount of power you have available at a given speed or for start- ing accelerating, climbing, etc.
4. Once the machine has attained adequate speed, release the throttle lever. 5. Shift into second gear and release the shift pedal. 6. Open the throttle gradually. 7. Follow the same procedure when shifting to the next higher gear. EBU00207 To decelerate: When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly.
6-6 EBU02092 Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running.
EBU02111 Parking When parking, stop the engine and shift into first gear. Turn the fuel cock to “ OFF ” and apply the parking brake. 1. Lock plate 1.
EBU12960 Parking on a slope 1. Bring the ATV to a stop by applying the brakes in low gear. 2. Stop the engine. 3 . With the rear brake lever and pedal applied, apply the parking brake and slowly release the brake pedal. 6-8 POTENTIAL HAZARD Parking on a hill or other incline.
EBU00221 Accessories and loading EBU00222 Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. 8 Choose only accessories designed for your ATV.
EBU00584 Loading As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. Keep the following points in mind: 8 Never exceed the weight limits shown.
6-11 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. Cargo should be properly distributed and securely attached.
EBU13541 w Indicates a potential hazard that could result in serious injury or death. 6-13 5TH-9-15-1 6/15/05 2:55 PM Page 6-13.
Riding Y our AT V 7 7-1 OK OK OK OK 5TH-9-15-2 6/15/05 2:55 PM Page 7-1.
GETTING TO KNOW YOUR ATV This ATV is for recreation use. This section, Riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding.
7-4 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. Beginners should get training from a certified instructor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator.
7-5 Not recommended for children under 12 years of age. 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.
7-6 This ATV is designed to carry operator only - passengers prohibited. 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.
Apparel 7-7 POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protec- tion and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident.
7-8 Do not operate after consuming alcohol or drugs. Operator ’ s performance capability is reduced by the influence of alcohol or drugs. POTENTIAL HAZARD Operating this ATV after consuming alco- hol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment.
7-9 Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the ATV. POTENTIAL HAZARD Failure to inspect the ATV before operat- ing. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage.
w Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. Speed limiter For riders inexperienced with this model, this model is equipped with a speed limiter in the throt- tle lever housing.
Adjusting for maximum throttle lever movement without removing the air intake restrictor plate will cause the engine to run roughly at higher speeds. For air intake restrictor plate removal instruc- tions, see page 8-14.
7-12 During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation.
7-13 Avoid wheelies and jumping. You may lose con- trol of the ATV or overturn. 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.
7-14 Modifications POTENTIAL HAZARD Operating this ATV with improper modifi- cations. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situa- tions could lead to an accident.
Exhaust system The exhaust system on the ATV is very hot dur- ing and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. 7-15 POTENTIAL HAZARD Hot exhaust system.
7-16 BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of con- trol. POTENTIAL HAZARD Operating this ATV on paved surfaces.
7-17 Do not ride on any public road, street, or high- way. Riding on public roads can result in colli- sions with other vehicles. POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle.
7-18 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. POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
7-19 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.
7-20 When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. Do not ride in areas posted “ no trespassing ” . Do not ride on private property without getting per- mission.
7-21 Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain.
7-22 c C Do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear.
7-23 TURNING YOUR ATV To achieve maximum traction while riding off- road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning.
7-24 This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesn ’ t turn, come to a stop and then practice the procedure again.
7-25 CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneu- ver your ATV well on flat ground before attempt- ing any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill.
7-26 POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner’s Manual. Always check the terrain carefully before you start up any hill.
7-27 If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. POTENTIAL HAZARD Improperly crossing hills or turning on hills.
7-28 If your ATV has stalled or stopped and you believe you can continue up the hill, restart care- fully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side.
7-29 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.
7-30 RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the engine compression to do most of the braking for you.
7-31 OK OK 5TH-9-15-2 6/15/05 2:55 PM Page 7-31.
7-32 CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface.
7-33 Shift your weight to the uphill side of the ATV. OK OK 5TH-9-15-2 6/15/05 2:55 PM Page 7-33.
7-34 CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 20 cm (7.9 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV.
7-35 Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. c C After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case.
7-36 RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times.
7-38 SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help.
7-39 With practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneu- vers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost.
7-40 WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. WHAT TO DO ... 8 If your ATV doesn ’ t turn when you want it to: Bring the ATV to a stop and practice the turn- ing maneuvers again.
7-41 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.
8-1 EBU00515 PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obliga- tion of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages.
8-2 The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the owner’s tool kit are suffi- cient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts.
8-3 EBU02611 Periodic maintenance chart for the emission control system 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.
General maintenance and lubrication chart 8-4 INITIAL EVERY month 1 3 6 6 12 ITEM ROUTINE Whichever km 320 1300 2500 2500 5000 comes first (mi) (200) (800) (1600) (1600) (3200) hours 20 80 160 160 320 Air filter element 9 Clean. Every 20–40 hours 9 Replace if necessary.
8-5 * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. w Indicates a potential hazard that could result in serious injury or death.
8-6 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.
8-7 1. Drain bolt 6. Install the drain bolt and tighten to specifi- cation. 7. Fill the engine with oil and install the dip- stick. c C Be sure no foreign material enters the crankcase. 8. Warm up the engine for several minutes at idle speed. Check for oil leakage while warming up.
8-8 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.
8-9 1. Drain bolt 4. Install the drain bolt and tighten to specifi- cation. 5. Fill the final gear case with oil. c C Be sure no foreign material enters the final gear case. 6. Install the dipstick. 7 . Check for oil leakage. If oil leakage is found, check for the cause.
8-10 EBU11820 Spark plug inspection The spark plug is an important engine compo- nent and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder.
8-11 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. EBU10343 Air filter cleaning NOTE: There is a check hose at the bottom of the air fil- ter case.
8-12 1. Air filter case cover 2. Fastener ( × 4) 2 . Remove the air filter case cover by unhooking the fasteners. 1. Fastener 2. Air filter element 3. Remove the air filter element by unhooking the fastener. 4. Wash the air filter element gently but thor- oughly in solvent.
8-13 5. Squeeze the excess solvent out of the air filter element and let it dry. c C Do not twist the air filter element when squeezing it. 6. Inspect the air filter element. If damaged, replace it. 7. Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter ele- ment.
NOTE: The air filter element should be cleaned every 20-40 hours. It should be cleaned and lubricated more often if the machine is operated in extremely dusty areas. Each time air filter ele- ment maintenance is performed, check the air inlet of the air filter case for obstructions.
8-15 NOTE: Store the air intake restrictor plate with the owner’s manual so that you can install it when- ever you want to reduce the top speed available. 3. Install the air filter element. EBU13600 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester.
8-16 POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death.
8-17 EBU00296 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idling speed may be per- formed by the owner as a part of the usual main- tenance routine.
8-18 2. Connect the tachometer to the spark plug lead, and then set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw in direction a to increase the engine speed, and in direction b to decrease the engine speed.
8-19 1. Wear limit line 2. Wear indicator 1. Wear limit mark 2. Wear indicator EBU00323 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.
8-20 1. Loosen the upper locknut and fully turn in the adjusting bolt. 2. Loosen the lower locknut. 3. Turn the lower adjusting bolt until specified free play is obtained. 1. Upper locknut 2. Upper adjusting bolt 3. Lower locknut 4. Lower adjusting bolt 4.
8-21 EBU03351 Rear brake lever and brake pedal adjustment Brake lever free play adjustment 1. Loosen the brake cable locknut. 2. Turn the adjusting bolt at the brake lever until brake lever free play is 5–8 mm (0.20–0.30 in). 3. Tighten the locknut.
8-22 NOTE: If specified free play cannot be obtained, tighten the brake cable adjusting nut at the rear wheel hub until brake lever free play is 5–8 mm (0.20–0.30 in). 1. Brake cable adjusting nut Brake pedal free play adjustment Turn the brake rod adjusting nut at the rear wheel hub until brake pedal free play is 20– 30 mm (0.
8-23 1. Brake rod adjusting nut q POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: 8 Make sure the brakes operate smooth- ly and that the free play is correct.
EBU00872 Clutch adjustment 1. Remove the rubber cap. 2. Loosen the locknut. 3 . Slowly turn the adjusting bolt clockwise until resistance is felt. Then turn it 1/8 counterclockwise. 1. Rubber cap 2. Locknut 3. Adjusting bolt 4. Tighten the locknut to the specified torque.
8-25 EBU00356 Cable inspection and lubrication Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. EBU00727 Brake and shift pedal/brake lever lubrication Lubricate the pivoting parts of each lever and pedal.
8-26 EBU01220 Knuckle shaft and steering shaft lubrication Lubricate the pivot points using a grease gun. 1. Grease nipple EBU01112 Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel.
8-27 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. c C Do not leave or store the battery on its side. When inspecting the battery, be sure the breather hose is routed correctly.
8-28 POTENTIAL HAZARD Failure to handle batteries or battery elec- trolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in bat- tery electrolyte. Batteries produce explosive gases. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing.
EBU11950 Replenishing the battery fluid A poorly maintained battery will corrode and dis- charge quickly. The battery fluid should be checked at least once a month. 1. The level should be between the maximum and minimum level marks. Use only dis- tilled water if refilling is necessary.
8-30 EBU00390 Fuse replacement 1. The fuse case is located under the seat. 2. If the fuse is blown, turn off the main switch and install a new fuse of the specified amperage. Then turn on the switches. If the fuse immediately blows again, consult a Yamaha dealer.
8-31 EBU00412 Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any prob- lem in the fuel, compression, or ignition systems can cause poor starting and loss of power.
EBU00440 Troubleshooting chart 8-32 Check fuel flow 1. Fuel Check if there is fuel in the fuel tank 2. Compression Use electric starter to see if there is compression 3.
EBU00419 CLEANING AND STORAGE A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to prevent water entry.
9-2 5 . Rinse the machine off immediately with clean water and dry all surfaces with a chamois, clean towel or soft absorbent cloth. 6 . Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces.
9-3 EBU00530 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive proce- dures to guard against deterioration. After thor- oughly cleaning the machine, prepare for stor- age as follows: 1.
10-1 EBU00428 SPECIFICA TIONS 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 ( 3.94 in) Minimum turning radius 2,400 mm (94.
10-2 Model YFM80R Engine oil: Type Recommended engine oil classification: API Service SE, SF, SG type or higher c C In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified.
10-3 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.
10-4 Model YFM80R Transmission: Primary reduction system Spur gear Primary reduction ratio 65/20 (3.250) Secondary reduction system Shaft drive Secondary reduction ratio 19/18 × 34/10 (3.588) Transmission type Constant mesh 3-speed Operation Left foot operation Gear ratio: 1st 39/11 (3.
10-5 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.
EBU13640 NOISE REGULA TION 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 oth.
12-1 EBU13653 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.
13-1 EBU26310 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 5TH-9-15-3 6/15/05 2:56 PM Page 8-43.
13-2 13 5TH-9-15-3 6/15/05 2:56 PM Page 8-44.
EBU00435 14-1 5TH-9-15-3 6/15/05 2:56 PM Page 8-45.
14-2 14 5TH-9-15-3 6/15/05 2:56 PM Page 8-46.
EBU00436 w Indicates a potential hazard that could result in serious injury or death. 5TH-9-15-3 6/15/05 2:56 PM Page 8-47.
EBU00437 5TH-9-15-3 6/15/05 2:56 PM Page 8-49.
PRINTED IN JAP AN 2005.7-2.7x1 ! (E) Improper A TV use can result in SEVERE INJUR Y or DEA TH. q W ARNING AL W A YS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARR Y P ASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: 9 without proper training or instruction.
Dear New Y amaha A TV Owner: CONGRA TULA TIONS ON THE PURCHASE OF Y OUR NEW Y AMAHA A TV . Y ou have purchased a quality Y amaha pr oduct that , with proper use and care , will pro vide hours of r iding pleasure.
NO POST AGE NECESSARY IF MAILED IN THE UNITED ST A TES FIRST CLASS PERMIT NO. 4 CYPRESS, CA POST AGE WILL BE P AID BY ADDRESSEE Y AMAHA MOTOR CORPORA TION U.
An important point after buying a device Yamaha 5TH-28199-15 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Yamaha 5TH-28199-15 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Yamaha 5TH-28199-15 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Yamaha 5TH-28199-15 you will learn all the available features of the product, as well as information on its operation. The information that you get Yamaha 5TH-28199-15 will certainly help you make a decision on the purchase.
If you already are a holder of Yamaha 5TH-28199-15, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Yamaha 5TH-28199-15.
However, one of the most important roles played by the user manual is to help in solving problems with Yamaha 5TH-28199-15. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Yamaha 5TH-28199-15 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
