check engine YAMAHA YFM80R 2003 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
1
2
3
4
5
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4-7
EBU00063
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.
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.
w
Malfunction 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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5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Brakes9Check operation, condition and free play.
5-5–5-7, 8-41–8-49
9Adjust if necessary.
Fuel9Check fuel level.
9Fill with fuel if necessary.5-9–5-11
Engine oil9Check oil level.
9Fill with oil if necessary.5-11–5-15, 8-13–8-17
Final gear oil9Check for leakage. 5-15, 8-19–8-21
Throttle9Check for proper throttle cable operation. 5-17
Wheels and tires9Check tire pressure, wear and damage. 5-19–5-25, 8-57
Fittings and fasteners9Check all fittings and fasteners. 5-17
Battery9Check fluid level.
5-17, 8-59–8-65
9Fill with distilled water if necessary.
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6-11
EBU00181
Starting a warm engine
To start a warm engine, refer to the “Starting a
cold engine” section. The choke lever should not
be used. The throttle should be opened slightly.
EBU00184
Warming up
To get maximum engine life, always warm up
the engine before starting off. Never accelerate
hard with a cold engine! To see whether or not
the engine is warm, check if it responds to the
throttle normally with the choke lever turned off.
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8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
INITIAL EVERY
ITEM ROUTINE 1 3 6 6 1
month months months months year
Valves*9Check valve clearance.
9Adjust if necessary.2 222
Cam chain*9Check chain tension.
9Adjust if necessary.2 222
9Check condition.
Spark plug9Adjust gap and clean.22222
9Replace if necessary.
Air filter element9Clean. Every 20–40 hours.
9Replace if necessary. (more often in wet or dusty areas)
Carburetor*9Check idle speed/choke lever operation.
2222
9Adjust if necessary.
Crankcase breather9Check breather hose for cracks or damage.
system*9Replace if necessary.222
9Check for leakage.
Exhaust system*9Tighten if necessary.222
9Replace gasket if necessary.
Fuel line*9Check fuel hose for cracks or damage.
222
9Replace if necessary.
Engine oil9Replace (warm engine before draining).2 222
Final gear oil9Check oil level/oil leakage.
22
9Replace every 12 months.
Brakes*9Check operation.
22222
9Adjust if necessary.
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8-13
EBU00868
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.
NOTE:
Wait a few minutes until the oil level settles
before checking.
4. Remove the dipstick and inspect the oil
level.
5. The oil level should be between the maxi-
mum and minimum marks. If the level is
low, add oil to raise it to the proper level.
cC
Be sure no foreign material enters the
crankcase.
qw
e
1. Dipstick
2. Maximum level mark 3. Minimum level mark
1. Jauge
2. Repère de niveau maximum 3. Repère de niveau minimum
1. Varilla de medición
2. Marca de máximo 3. Marca de mínimo
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8-17
7. Fill the engine with oil and install the dip-
stick.
cC
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.
cC
If oil leakage is found, stop the engine imme-
diately and check for the cause.
Recommended oil: See page 10-2.
Oil quantity:
Periodic oil change:
0.8 L
Total amount:
0.95 L
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8-31
NOTE:
The air filter element should be wet but not dripping.
8. Install the air filter element, the air filter
case cover and the front cover.
NOTE:
The air filter element should be cleaned every
20–40 hours. It should be cleaned and lubricat-
ed 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. Check
the air cleaner rubber joint to the carburetor and
manifold fittings for an air-tight seal. Tighten all
fittings securely to avoid the possibility of unfil-
tered air entering the engine.
cC
Never operate the engine with the air filter
element removed. This will allow unfiltered
air to enter, causing rapid engine wear and
possible engine damage. Additionally, opera-
tion without the filter element will affect car-
buretor jetting with subsequent poor perfor-
mance and possible engine overheating.
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EBU00440
Troubleshooting chart
1. Fuel
Check if there is
fuel in the fuel
tank
2. Compression
Use electric starter
to see if there is
compression
3. Ignition
Remove plug and
check electrodes
WetWipe clean with dry
cloth
DryAttach plug cap and
ground to chassisUse electric
starterSpark weak
Spark goodIgnition system normal
No spark
Ask a Yamaha dealer to inspect
Adjust plug gap or
replace plug
There is compressonCompression normal
Ask a Yamaha dealer to inspectNo compression
There is fuelTurn the fuel
cock to “OFF”
Remove the
fuel hose from
the fuel cock.
Some fuelTurn the fuel
cock to “RES”Restart engine
No fuelSupply fuel
4. Battery
Use electric
starter
Engine turns
over quicklyBattery good
Engine turns
over slowlyCheck fluid, recharge,
check connections
Check fuel flow
Water or dirt
mixed in fuel
Turn the fuel
cock to “ON”No fuelFuel cock clogged
Clean the fuel filter
and the fuel tank
Clean fuel cock
8-73
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