engine YAMAHA YFM80R 2002 Owners Manual

LOCATION OF THE WARNING AND
SPECIFICATION LABELS .......................1-1
SAFETY INFORMATION .........................2-1
DESCRIPTION AND MACHINE
IDENTIFICATION.....................................3-1
Identification number records ...............3-3
Key identification number .....................3-5
Vehicle identification number ...............3-7
Model label ...........................................3-9
CONTROL FUNCTIONS..........................4-1
Main switch ...........................................4-1
Indicator lights ......................................4-3
Handlebar switches ..............................4-3
Throttle lever ........................................4-7
Speed limiter ........................................4-9
Front brake lever ................................4-13Rear brake pedal and lever ................4-15
Parking brake .....................................4-17
Shift pedal ..........................................4-19
Fuel tank cap ......................................4-19
Fuel cock ............................................4-21
Choke lever ........................................4-23
Seat ....................................................4-25
PRE-OPERATION CHECKS ...................5-1
Front and rear brakes ...........................5-5
Fuel ......................................................5-9
Engine oil ............................................5-11
Final gear oil .......................................5-15
Throttle lever ......................................5-17
Fittings and fasteners .........................5-17
Switches .............................................5-17
Battery ................................................5-17
Tires ...................................................5-19
How to measure tire pressure ............5-23
Tire wear limit .....................................5-25
EBU00015
CONTENTS
1234
5
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OPERATION ............................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine ......................6-11
Warming up ........................................6-11
Shifting ...............................................6-13
To start out and accelerate .................6-15
To decelerate .....................................6-19
Engine break-in ..................................6-21
Parking ...............................................6-25
Parking on a slope ..............................6-27
Accessories and loading ....................6-29
Riding Your ATV ......................................7-1
Getting to know your ATV.....................7-3
Ride with care and good
judgement ...........................................7-5
Be careful where you ride ...................7-27
Turning your ATV ...............................7-41
Climbing uphill ....................................7-45
Riding downhill ...................................7-57
Crossing a slope .................................7-61Crossing through shallow water .........7-65
Riding over rough terrain ....................7-69
Sliding and skidding ...........................7-71
What to do if ......................................7-75
What to do .........................................7-75
PERIODIC MAINTENANCE AND
ADJUSTMENT .........................................8-1
Owner’s manual and tool kit .................8-3
Periodic maintenance/Lubrication ........8-7
Engine oil ............................................8-13
Final gear oil .......................................8-19
Spark plug inspection .........................8-23
Air filter cleaning .................................8-27
Air intake restrictor plate removal .......8-33
Carburetor adjustment ........................8-35
Idle speed adjustment ........................8-37
Valve clearance adjustment ...............8-39
Cam chain adjustment ........................8-39
Front and rear brake shoe
inspection .........................................8-41
67
8
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2-1
EBU01042AN ATV IS NOT A TOY AND CAN BE HAZ
-
ARDOUS TO OPERATE.
An ATV handles dif-
ferently from other vehicles including motorcy-
cles 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 precautions.
SEVERE INJURY OR DEATH can result if you
do not follow these instructions:
8Read this manual and all labels carefully and
follow the operating procedures described.
8Never operate an ATV without proper instruc-
tion.
8Always follow the age recommendation:
–A child under 12 years old should never
operate an ATV with engine size
greater than 70cc.
–A child under 16 years old should never
operate an ATV with engine size
greater than 90cc.
q
SAFETY INFORMATION
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2-15
8Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed
and securely attached. Reduce speed and fol-
low instructions in this manual for carrying
cargo or pulling a trailer. Allow greater dis-
tance for braking.w8Always turn off the engine when refueling.
8Do not refuel right after the engine has
been running and is still very hot.
8Do not spill gasoline on the engine or
exhaust pipe/muffler when refueling.
Never refuel while smoking, or while in the
vicinity of sparks, open flames, or other
sources of ignition such as the pilot lights
of water heaters and clothes dryers.
Gasoline can catch fire. You could be
burned.
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2-17
8When transporting the machine in another
vehicle, be sure it is kept upright and that
the fuel cock is in the "OFF" position.
Otherwise, fuel may leak out of the carbu-
retor or fuel tank.
8Gasoline is poisonous. If you should swal-
low some gasoline or inhale a lot of gaso-
line vapor, or get some gasoline in your
eyes, see your doctor immediately. If
gasoline spills on your skin, wash with
soap and water. If gasoline spills on your
clothing, change your clothes.wAlways operate your ATV in an area with
adequate ventilation. Never start or run the
engine in a closed area. Exhaust fumes are
poisonous and may cause loss of con-
sciousness and death within a short time.
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4-1
EBU00040
CONTROL FUNCTIONS
EBU00042Main 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. The key
can be removed in this position.
OFF ON
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4-3
EBU00043Indicator lightsEBU00603Neutral indicator light “N”
This indicator light comes on when the transmis-
sion is in neutral.EBU00053Handlebar switchesEBU00054Engine stop switch “ENG. STOP”
Make sure that the engine stop switch is in the
“RUN” position. The engine stop switch controls
ignition and can be used at all times to stop the
engine, especially in an emergency. The engine
will not start or run when the engine stop switch
is turned to “OFF”.
q
1. Neutral indicator light “N”1. Témoin de point mort “N”1. Luz de control de punto muerto “N”
q
w
1. Engine stop switch “ENG. STOP”
2. Start switch “START”1. Coupe-circuit du moteur “ENG. STOP”
2. Contacteur du démarreur “START”1. Interruptor de paro del motor “ENG. STOP”
2. Interruptor de arranque “START”
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4-5
EBU00056Start switch “START”
The starter motor cranks the engine when this
switch is pushed.cCSee starting instructions prior to starting
engine (see page 6-3 for details).NOTE:
If the starter switch is pushed with the main
switch “ON” and the engine stop switch “OFF”,
the starter motor will be activated but the engine
will not start. To start the engine, be sure to
position the engine stop switch at “RUN”.
q
w
1. Engine stop switch “ENG. STOP”
2. Start switch “START”1. Coupe-circuit du moteur “ENG. STOP”
2. Contacteur du démarreur “START”1. Interruptor de paro del motor “ENG. STOP”
2. Interruptor de arranque “START”
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4-7
EBU00063Throttle 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.
Before starting the engine, check the throttle to
be sure it is operating smoothly. Make sure it
returns to the idle position as soon as the lever
is released.wMalfunction of the throttle could make it diffi-
cult to speed up or slow down when you
need to. This could cause an accident.
Check the operation of the throttle lever
before you start the engine. If the throttle
does not work smoothly, check for the
cause. Correct the problem before riding the
ATV or consult a Yamaha dealer.
q
1. Throttle lever1. Levier d’accélérateur1. Palanca del aceleración
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4-9
EBU01051Speed 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. 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. The limiter screw may be gradually turned
out to increase maximum speed as the beginner
becomes more familiar with operating the ATV.
Parents should decide when to adjust the ATV
for more power as their youngster’s riding skills
improve. Once the ATV rider can operate with
skill at the top speed permitted by adjusting the
speed limiter alone, the air intake restrictor plate
can be removed.
q
w
a
1. Locknut 2. Adjuster a. 20 mm1. Contre-écrou 2. Dispositif de réglage1. Contratuerca 2. Ajustador
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