2002 YAMAHA YFM80 battery

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 ................................4-11Rear brake pedal and lever ................4-13
Parking brake .....................................4-15
Shift pedal ..........................................4-17
Fuel tank cap ......................................4-17
Fuel cock ............................................4-19
Choke lever ........................................4-21
Seat ....................................................4-23
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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Front brake lever free play
adjustment ........................................8-41
Rear brake lever and pedal
adjustment ........................................8-45
Clutch adjustment ...............................8-49
Cable inspection and lubrication ........8-51
Brake and shift pedal/brake
lever lubrication ................................8-53
Knuckle shaft and steering shaft
lubrication .........................................8-53
Wheel removal ...................................8-55
Wheel installation ...............................8-55
Battery ................................................8-57
Replenishing the battery fluid .............8-61
Fuse replacement ...............................8-65
Troubleshooting ..................................8-67
Troubleshooting chart .........................8-71
CLEANING AND STORAGE....................9-1
A. Cleaning ...........................................9-1
B. Storage ............................................9-7SPECIFICATIONS .................................10-1
HOW TO USE THE CONVERSION
TABLE ....................................................11-1
9
10
11
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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, 8-39 ~ 8-47
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, 8-55
Fittings and fasteners9Check all fittings and fasteners. 5-17
Battery9Check fluid level.
5-17, 8-57 ~ 8-63
9Fill with distilled water if necessary.
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5-17
EBU00151
Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
idle position when released. Repair as neces-
sary for proper operation.
EBU00152
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.
EBU00154
Switches
Check the operation of the start switch, engine
stop switch and any other switches. Repair as
necessary for proper operation.
EBU00499
Battery
Check fluid level and fill if necessary. Use only
distilled water if refilling is necessary. (See
pages 8-57 ~ 8-63.)
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6-7
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. Do not crank the engine more than 10 sec-
onds on each attempt.
7. If the engine is started with the starter
(choke) in position 1, the choke lever
should be returned to position 2to warm
up the engine. If the engine is started with
the starter (choke) in position 2, keep the
starter (choke) in this position to warm up
the engine.
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8-8 * : It is recommended that these items be serviced by a Yamaha dealer.
** : Lithium soap base greaseINITIAL EVERY
ITEM ROUTINE 1 3 6 6 1
month months months months year
Clutch*9Check operation.
2222
9Adjust if necessary.
Wheels*9Check balance/damage/runout.
2222
9Replace if necessary.
9Check bearing assemblies for looseness/
Wheel bearings*damage.2222
9Replace if damaged.
9Check operation.
Steering system*9Replace if damage.
22222
9Check toe-in
9Adjust if necessary.
Knuckle shafts/
9Lubricate every 6 months. **
222
Steering shaft*
Fittings and Fasteners*9Check all chassis fittings and fasteners.
22222
9Correct if necessary.
9Check specific gravity.
Battery*9Check breather hose for porper operation.22222
9Correct if necessary.
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8-57
EBU00379
Battery
Check the level of the battery fluid and see if the
terminals are tight. Add distilled water if the fluid
level is low.
cC
Do not leave or store the battery on its side.
When inspecting the battery, be sure the
breather hose is routed correctly. If it touch-
es the frame or exists in such a way as to
cause battery electrolyte or gas to exit onto
the frame, structural and cosmetic damage
to the machine can occur.
q
w
1. Battery 2. Battery breather hose1. Batterie 2. Reniflard de batterie1. Batería 2.Manguera del respiradero de batería
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8-59
w
Battery electrolyte is poisonous and danger-
ous, causing severe burns, etc. It contains
sulfuric acid. Avoid contact with skin, eyes
or clothing.
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 imme-
diately.
EYES: Flush with water for 15 minutes and
get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes or other sources of
ignition away. Ventilate when charging or
using in an enclosed space. Always shield
your eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
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