maintenance YAMAHA YFM80R 2007 Owners Manual

EBU17170
INTRODUCTION
EBU17260
Congratulations on your purchase of the Yamaha YFM80RW. This ATV 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.
This manual will provide you with a good basic understanding of the features and operation of this ATV.
This manual includes important safety information. It provides information about special tech-
niques and skills necessary to ride the ATV.
It also includes basic maintenance and inspection proce-
dures. If you have any questions regarding the operation or maintenance of your ATV, please consult a
Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:


READ THIS MANUAL COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDER-
STAND ALL INSTRUCTIONS.

PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.

THIS ATV, AND ANY OTHER ATV OVER 70 cc, SHOULD NOT BE OPERATED BY A CHILD UNDER
12 YEARS OF AGE.
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. Some children may not be able to operate an ATV safely. Parents
should supervise their child’s use of the ATV at all times. Parents should permit continued use only if they
determine that the child has the ability to operate the ATV safely.

RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV.............. 7-2
RIDE WITH CARE AND GOOD
JUDGEMENT ...........................................7-2
BE CAREFUL WHERE YOU RIDE ............ 7-9
TURNING YOUR ATV ............................. 7-13
CLIMBING UPHILL .................................. 7-14
RIDING DOWNHILL................................. 7-17
CROSSING A SLOPE.............................. 7-18
CROSSING THROUGH SHALLOW
WATER ..................................................7-19
RIDING OVER ROUGH TERRAIN .......... 7-20
SLIDING AND SKIDDING ........................ 7-21
WHAT TO DO IF... ................................... 7-22
WHAT TO DO... ....................................... 7-22
PERIODIC MAINTENANCE AND MINOR
REPAIR .......................................................... 8-1
Owner’s manual and tool kit ...................... 8-1
Periodic maintenance and lubrication
chart ........................................................ 8-3
Checking the spark plug ............................ 8-7
Engine oil .................................................. 8-8
Final gear oil ............................................ 8-11
Cleaning the air filter element ................. 8-12
Removing the air intake restrictor plate ... 8-15
Cleaning the spark arrester ..................... 8-16
Adjusting the carburetor .......................... 8-17
Adjusting the engine idling speed ........... 8-17Checking the throttle cable free play ....... 8-18
Timing chain ............................................ 8-19
Valve clearance ....................................... 8-19
Checking the front and rear brake
shoes .....................................................8-19
Adjusting the front brake lever free
play ........................................................8-20
Adjusting the rear brake lever and brake
pedal free play .......................................8-22
Adjusting the clutch free play ................... 8-25
Checking and lubricating the cables ........ 8-25
Checking and lubricating the front and
rear brake levers ....................................8-26
Checking and lubricating the brake and
shift pedals .............................................8-27
Checking the wheel bearings ................... 8-27
Lubricating the knuckle shafts ................. 8-27
Lubricating the steering shaft ................... 8-27
Battery ..................................................... 8-28
Replacing the fuse ................................... 8-31
Removing a wheel ................................... 8-31
Installing a wheel ..................................... 8-32
Troubleshooting ....................................... 8-33
Troubleshooting chart .............................. 8-34
CLEANING AND STORAGE ..........................9-1
Cleaning ..................................................... 9-1
Storage ...................................................... 9-2

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Never operate at speeds too fast for your skills
or the riding conditions. Always go at a speed
that is proper for the terrain, visibility, operating
conditions, and your experience.

Never attempt wheelies, jumps, or other stunts.

Always inspect your ATV each time you use it to
make sure it is in safe operating condition. Al-
ways follow the inspection and maintenance
procedures and schedules described in this
manual.

Always keep both hands on the handlebars and
both feet on the footrests of the ATV during op-
eration.

Always go slowly and be extra careful when op-
erating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the
ATV.

Never operate on excessively rough, slippery or
loose terrain until you have learned and prac-
ticed the skills necessary to control the ATV on
such terrain. Always be especially cautious on
these kinds of terrain.

Always follow proper procedures for turning as
described in this manual. Practice turning at low
speeds before attempting to turn at faster
speeds and never turn at excessive speeds.

Never operate the ATV on hills too steep for the
ATV or for your abilities. Practice on smaller hills
before attempting larger hills.

Always follow proper procedures for climbing
hills as described in this manual. Check the ter-
rain carefully before you start up any hill. Never
climb hills with excessively slippery or loose sur-
faces. Shift your weight forward. Never open the
throttle suddenly or make sudden gear changes.
Never go over the top of a hill at high speed.

Always follow proper procedures for going down
hills and for braking on hills as described in this
manual. Check the terrain carefully before you
start down any hill. Shift your weight backward.
Never go down a hill at high speed. Avoid going
down a hill at an angle that would cause the ve-
hicle to lean sharply to one side. Go straight
down the hill where possible.

Always follow proper procedures for crossing
the side of a hill as described in this manual.
Avoid hills with excessively slippery or loose sur-
faces. Shift your weight to the uphill side of the
ATV. Never attempt to turn the ATV around on
any hill until you have mastered the turning tech-
nique described in this manual on level ground.
Avoid crossing the side of a steep hill if possible.

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EBU19200
PRE-OPERATION CHECKS
EBU19220
Pre-operation check list
Before operating this ATV, be sure to check the items listed in the following table.
NOTE:

The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic
maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a
Yamaha dealer.
ITEM ROUTINE PAGE
Fuel


Check fuel level in fuel tank, and add recommended fuel if neces-
sary.

Check fuel line for leakage. Correct if necessary.4-7, 5-3
Engine oil

Check oil level in engine, and add recommended oil to specified
level if necessary.

Check ATV for oil leakage. Correct if necessary.5-3, 8-8
Final gear oil

Check ATV for oil leakage. Correct if necessary. 5-3, 8-11
Front brake

Check operation, and correct if necessary.

Lubricate cable if necessary.

Check lever free play, and adjust if necessary.5-3, 8-19, 8-20
Rear brake

Check operation, and correct if necessary.

Lubricate cable if necessary.

Check lever and pedal free play, and adjust if necessary.5-3, 8-19, 8-22
Throttle lever

Make sure that operation is smooth. Lubricate cable and lever hous-
ing if necessary.

Check cable free play, and adjust if necessary.5-4, 8-18
Control cables

Make sure that operation is smooth. Lubricate if necessary. 8-25

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WARNING

EWB00480
Always inspect your ATV each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Owner’s
Manual. Failure to inspect increases the possibility of an accident or equipment damage.
Wheels and tires

Check wheel condition, and replace if damaged.

Check tire condition and tread depth. Replace if necessary.

Check air pressure. Correct if necessary.5-4, 5-5, 5-6
Brake and shift pedals

Make sure that operation is smooth. Lubricate pedal pivoting points
if necessary.8-27
Brake levers

Make sure that operation is smooth. Lubricate lever pivoting points
if necessary.8-26
Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened. 5-6
Instruments and switches

Check operation, and correct if necessary. 5-6
Battery

Check electrolyte level. Fill with distilled water if necessary. 5-6, 8-28
ITEM ROUTINE PAGE

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EBU21652
PERIODIC MAINTENANCE AND MINOR REPAIR
EBU21670
Safety is an obligation of the owner. Periodic in-
spection, adjustment and lubrication will keep your
ATV in the safest and best operating condition
possible. The most important points of inspection,
adjustment, and lubrication are explained on the
following pages.
The intervals given in the periodic maintenance
and lubrication chart should be considered as a
general guide under normal riding conditions.
However, DEPENDING ON THE WEATHER,
TERRAIN, GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORTENED.
WARNING

EWB01840
Never service an engine while it is running.
Moving parts can catch clothing or parts of the
body, causing injury. Electrical components
can cause shocks or start fires. Turn off the en-
gine when performing maintenance unless
otherwise specified. Have a Yamaha dealer
perform the service if you are not familiar with
maintenance work.
EBU27110
Owner’s manual and tool kit
Be sure to put this owner’s manual in the plastic
bag and to always carry it as well as the owner’s
tool kit and the low-pressure tire gauge in their re-
spective compartments under the seat.
1. Owner’s manual
2. Low-pressure tire gauge
3. Owner’s tool kit
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2

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The service information included in this manual
and the tools provided in the owner’s tool kit are in-
tended to assist you in the performance of preven-
tive maintenance and minor repairs. However,
additional tools such as a torque wrench may be
necessary to perform certain maintenance work
correctly.
NOTE:

If you do not have the tools or experience required
for a particular job, have a Yamaha dealer perform
it for you.
WARNING

EWB01850
Never modify this ATV through improper in-
stallation or use of accessories, as it may
cause changes in handling, which in some sit-
uations could lead to an accident. All parts and
accessories added to this ATV should be gen-
uine Yamaha or equivalent components de-
signed for use on this ATV and should be
installed and used according to instructions. If
you have questions, consult an authorized
Yamaha ATV dealer.

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EBU22401
Periodic maintenance and lubrication chart
NOTE:


For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.

For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-
vals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance
intervals should be followed.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 3001
*
Fuel line


Check fuel hoses for cracks or other damage, and
replace if necessary.
√√√
2 Spark plug

Check condition and clean, regap, or replace if
necessary.
√√√√√
3
*
Valves


Check valve clearance and adjust if necessary.
√ √√√
4
*
Timing chain


Check chain tension.

Adjust if necessary.
√ √√√
5 Air filter element

Clean and replace if necessary.Every 20–40 hours (more often in wet or
dusty areas)
6
*
Front brake

Check operation and correct if necessary.

Check brake lever free play and adjust if neces-
sary.
√√√√√

Replace brake shoes. Whenever worn to the limit

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7
*
Rear brake

Check operation and correct if necessary.

Check brake lever and pedal free play, and adjust
if necessary.
√√√√√

Replace brake shoes. Whenever worn to the limit
8
*
Wheels

Check runout and for damage, and replace if nec-
essary.
√ √√√
9
*
Tires


Check tread depth and for damage, and replace if
necessary.

Check air pressure and balance, and correct if
necessary.
√ √√√
10
*
Wheel bearings

Check for looseness or damage, and replace if
necessary.
√ √√√
11
*
Drive shaft univer-
sal joint

Lubricate with lithium-soap-based grease.
√√√
12
*
Chassis fasteners

Make sure that all nuts, bolts, and screws are
properly tightened.
√√√√√
13
*
Shock absorber
assemblies

Check operation and correct if necessary.

Check for oil leakage and replace if necessary.
√√√
14
*
Knuckle shafts


Lubricate with lithium-soap-based grease.
√√√
15
*
Steering shaft


Lubricate with lithium-soap-based grease.
√√√
16
*
Steering system


Check operation and repair or replace if damaged.

Check toe-in and adjust if necessary.
√√√√√
17
*
Carburetor


Check choke operation and correct if necessary.

Check engine idling speed and adjust if neces-
sary.
√√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth 1 3 6 6 12
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300

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18
*
Crankcase breather
system

Check breather hose for cracks or other damage,
and replace if necessary.
√√√
19 Engine oil

Change.

Check ATV for oil leakage, and correct if neces-
sary.
√ √√√
20 Final gear oil

Change.

Check ATV for oil leakage, and correct if neces-
sary.
√√
21
*
Moving parts and
cables


Lubricate.
√√√√
22
*
Throttle lever hous-
ing and cable


Check operation and correct if necessary.

Check throttle cable free play and have a Yamaha
dealer adjust if necessary.

Lubricate throttle lever housing and cable.
√√√√√
23
*
Exhaust system


Check for leakage and replace gasket(s) if neces-
sary.

Check for looseness and tighten all screw clamps
and joints if necessary.
√√√
24 Spark arrester

Clean.
√√√
25
*
Front and rear brake
switches


Check operation and correct if necessary.
√√√√√
26
*
Battery


Check electrolyte level and specific gravity, and
correct if necessary.

Make sure that the breather hose is properly
routed.
√√√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300