YAMAHA YFM80R 2007 Owners Manual

8-23
1
2
3
4
5
6
78
9
10
11

1. Loosen the locknut at the brake lever.
2. Turn the brake lever free play adjusting bolt at
the brake lever in direction (a) to increase the
free play, and in direction (b) to decrease it.
3. Tighten the locknut at the brake lever.
If the specified free play cannot be obtained,
proceed with the following steps.
4. Loosen the locknut at the brake lever.
5. Fully turn the adjusting bolt at the brake lever
in direction (a) to loosen the brake cable.
6. To increase the brake lever free play, turn theadjusting nut on the brake cable at the rear
wheel hub in direction (a), and to decrease it,
turn the nut in direction (b).
7. Tighten the locknut at the crankcase and the
brake lever.NOTE:
If the specified free play cannot be obtained as de-
scribed above or if the rear brake does not operate
correctly, have a Yamaha dealer check the internal
rear brake mechanism.
When adjusting the rear brake lever free play:

Be sure not to step on the brake pedal.
1. Locknut
2. Brake lever free play adjusting bolt
3. Brake lever free play
312
(a)
(b)

1. Brake lever free play adjusting nut
1
(a)
(b)

8-24
1
2
3
4
5
6
78
9
10
11


Make sure the brake pedal does not move.
Adjusting the brake pedal free play
The brake pedal free play should measure 20.0–
30.0 mm (0.79–1.18 in) as shown. If the free play
is incorrect, adjust it as follows.
Turn the brake pedal free play adjusting nut on the
brake rod at the rear wheel hub in direction (a) to
increase the free play, and in direction (b) to de-
crease it.
WARNING
EWB02080
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly and
that the free play is correct.

Make sure the brakes do not drag.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
1. Brake pedal free play
1

1. Brake pedal free play adjusting nut
1
(a)
(b)

8-25
1
2
3
4
5
6
78
9
10
11

EBU24781
Adjusting the clutch free play
The clutch free play must be adjusted periodically.
Adjust the free play as follows.
1. Remove the rubber cap.
2. Loosen the locknut.
3. Slowly turn the adjusting bolt clockwise until
resistance is felt, and then turn it 1/8 counter-
clockwise.
NOTE:

Turning the adjusting bolt in decreases clutch free
play and turning it out increases clutch free play.
4. Tighten the locknut to the specified torque.
NOTE:

When tightening the locknut, hold the adjusting
bolt with a screwdriver so that the adjusting bolt
does not turn together with the locknut.
5. Install the rubber cap securely.
EBU24900
Checking and lubricating the cables
The operation and the condition of all control ca-
bles should be checked before each ride, and the
cables and cable ends should be lubricated if nec-
essary. If a cable is damaged or does not move
smoothly, have a Yamaha dealer check or replace
it.
1. Rubber cap
2. Locknut
3. Adjusting bolt
1
2
3

Tightening torque:
Locknut:
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Recommended lubricant:
Engine oil

8-26
1
2
3
4
5
6
78
9
10
11
WARNING

EWB02130
Inspect cables frequently and replace if dam-
aged. Corrosion can result when the cable
sheaths become damaged, and cables can
also become frayed or kinked, which could re-
strict the operation of controls and lead to an
accident or injury.
EBU24911
Checking and lubricating the front and
rear brake levers
The operation of the front and rear brake levers
should be checked before each ride, and the lever
pivots should be lubricated if necessary.
Front brake lever
Rear brake lever
Recommended lubricant:
Lithium-soap-based grease (all-purpose
grease)

8-27
1
2
3
4
5
6
78
9
10
11

EBU24930
Checking and lubricating the brake and
shift pedals
The operation of the brake and shift pedals should
be checked before each ride, and the pedal pivots
should be lubricated if necessary.
EBU24961
Checking the wheel bearings
The front and rear wheel bearings must be
checked at the intervals specified in the periodic
maintenance and lubrication chart. If there is play
in a wheel hub or if a wheel does not turn smoothly,
have a Yamaha dealer check the wheel bearings.
EBU25070
Lubricating the knuckle shafts
The knuckle shafts must be lubricated at the inter-
vals specified in the periodic maintenance and lu-
brication chart.Lubricate the knuckle shafts using a grease gun.
EBU25090
Lubricating the steering shaft
The steering shaft must be lubricated at the inter-
vals specified in the periodic maintenance and lu-
brication chart. Recommended lubricant:
Lithium-soap-based grease (all-purpose
grease)
Recommended lubricant:
Lithium-soap-based grease

1. Grease nipple
1

8-28
1
2
3
4
5
6
78
9
10
11

Lubricate the steering shaft using a grease gun.
EBU25121
Battery
A poorly maintained battery will corrode and dis-
charge quickly. The electrolyte level, battery lead
connections and breather hose routing should be
checked before each ride and at the intervals
specified in the periodic maintenance and lubrica-
tion chart.
To check the electrolyte level
1. Place the ATV on a level surface.
2. Check the electrolyte level in the battery.
NOTE:

The electrolyte should be between the minimum
and maximum level marks.
3. If the electrolyte is at or below the minimum
level mark, add distilled water to raise it to the
maximum level mark. Recommended lubricant:
Lithium-soap-based grease
1. Grease nipple
1

1. Maximum level mark
2. Minimum level mark

1
2

8-29
1
2
3
4
5
6
78
9
10
11
CAUTION:

ECB00590
Use only distilled water, as tap water contains
minerals that are harmful to the battery.
WARNING

EWB02160
Battery electrolyte is poisonous and danger-
ous, as it contains sulfuric acid, which can
cause severe burns. Avoid contact with skin,
eyes or clothing. Always shield your eyes
when working near batteries.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg
or vegetable oil. Call a physician immediately.
EYES: Flush with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes or other sources of ig-
nition away. Ventilate when charging or using
in an enclosed space.
KEEP OUT OF REACH OF CHILDREN.
4. Check and, if necessary, tighten the battery
lead connections and correct the breatherhose routing.
To store the battery
If the ATV will not be used for more than one
month, the battery will need to be removed and
stored as follows.
1. Disconnect the negative lead first and then the
positive lead.
2. Remove the battery, fully charge it, and then
place it in a cool, dry place.

1. Battery
2. Negative lead
3. Positive lead
23
1

8-30
1
2
3
4
5
6
78
9
10
11
CAUTION:

ECB00600
Do not leave or store the battery on its side.
3. If the battery will be stored for more than two
months, check the specific gravity of the elec-
trolyte at least once a month and fully charge
the battery whenever necessary.
To install the battery
NOTE:

Be sure the battery is fully charged.
1. Install the battery.
2. Connect the positive lead first, and then con-
nect the negative lead.
3. Make sure that the breather hose is properly
routed, in good condition, and not obstructed.
CAUTION:

ECB00610
If the breather hose is positioned in such a way
that the frame is exposed to electrolyte or gas
expelled from the battery, the frame could suf-
fer structural and external damages.
1. Battery
2. Battery breather hose
1
2

8-31
1
2
3
4
5
6
78
9
10
11

EBU25242
Replacing the fuse
The fuse holder is located under the seat. (See
page 4-10.)
If the fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off all electrical
circuits.
CAUTION:

ECB00640
To prevent accidental short-circuiting, turn off
the main switch when checking or replacing a
fuse.
2. Remove the blown fuse, and then install a
new fuse of the specified amperage.WARNING
EWB02171
Always use a fuse of the specified rating, and
never use a substitute object in place of the
proper fuse. An improper fuse or a substitute
object can cause damage to the electrical sys-
tem, which could lead to a fire.
3. Turn the key to “ON” and turn on the electrical
circuits to check if the devices operate.
4. If the fuse immediately blows again, have a
Yamaha dealer check the electrical system.
EBU25650
Removing a wheel
1. Loosen the wheel nuts.
1. Fuse
2. Spare fuse
1
2

Specified fuse:
5.0 A

8-32
1
2
3
4
5
6
78
9
10
11
Front Rear

2. Elevate the ATV and place a suitable stand
under the frame.
3. Remove the nuts from the wheel.
4. Remove the wheel.
EBU25660
Installing a wheel
1. Install the wheel and the nuts.
2. Lower the ATV to the ground.
3. Tighten the wheel nuts to the specified
torques.
1. Wheel nut
1
1

1. Wheel nut
1