2004 YAMAHA YFM80R clutch

Front brake lever free play
adjustment ........................................8-43
Rear brake lever and pedal
adjustment ........................................8-47
Clutch adjustment ...............................8-51
Cable inspection and lubrication ........8-53
Brake and shift pedal/brake
lever lubrication ................................8-55
Knuckle shaft and steering shaft
lubrication .........................................8-55
Wheel removal ...................................8-57
Wheel installation ...............................8-57
Battery ................................................8-59
Replenishing the battery fluid .............8-63
Fuse replacement ...............................8-67
Troubleshooting ..................................8-69
Troubleshooting chart .........................8-73CLEANING AND STORAGE....................9-1
A. Cleaning ...........................................9-1
B. Storage ............................................9-7
SPECIFICATIONS .................................10-1
Conversion Table ...................................11-19
10
11
5TH-9-62 ~3 4/8/03 6:06 PM Page 18

5-13
cC
8In order to prevent clutch slippage (since
the engine oil also lubricates the clutch),
do not mix any chemical additives. Do not
use oils with a diesel specification of “CD”
or oils of a higher quality than specified. In
addition, do not use oils labeled “ENERGY
CONSERVING
II” or higher.
8Make sure that no foreign material enters
the crankcase.
Recommended engine oil type and quantity:
See page 10-2.
5TH-9-62 4~5 4/8/03 6:07 PM Page 38

6-13
EBU00200
Shifting
This model has a 3-speed forward transmission
with centrifugal automatic clutch. The transmis-
sion allows you to control the amount of power
you have available at a given speed or for start-
ing accelerating, climbing, etc. To shift into neu-
tral, return the throttle lever to its original posi-
tion and repeatedly depress the shift pedal until
it stops.
cC
Do not coast for long periods with the engine
off, and do not tow the machine a long dis-
tance. Even with gears in neutral, the trans-
mission is only properly lubricated when the
engine is running. Inadequate lubrication
may damage the transmission.
q
3
2
1
N
1. Shift pedal N. Neutral position1. Pédale de sélection N. Position de la point mort 1. Pedal del cambio N. Posición del punto muerto
5TH-9-62 6 4/8/03 9:06 PM Page 12

7-37
With the engine idling, lift the shift pedal to the
1st gear position and then release the parking
brake. Apply the throttle slowly and smoothly.
The centrifugal clutch will engage and you will
start to accelerate. Once the ATV has attained
adequate speed, release the throttle and lift the
shift pedal to the 2nd gear position. Release the
shift pedal and apply the throttle smoothly. Use
this same procedure as you move into the high-
er gears. Be sure to coordinate the use of the
throttle and shift pedal properly. If the throttle is
applied too abruptly or if the throttle is not
released during shifting, or if the shift pedal is
not released before applying the throttle, the
front wheels may lift off the ground resulting in a
loss of directional control. Avoid higher speeds
until you are thoroughly familiar with the opera-
tion of your ATV.
5TH-9-62 7 4/8/03 6:10 PM Page 180

8-8 * Since these items require special tools, data and techinical skills, hava a Yamaha dealer perform the service.INITIAL 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 with Lithium-soap-based
222
steering shaft*grease.
Fittings and fasteners*9Check all chassis fittings and fasteners.
22222
9Correct if necessary.
9Check specific gravity.
Battery*9Check breather hose for correct routing.22222
9Correct if necessary.
5TH-9-62 8 4/8/03 9:05 PM Page 8-8

8-51
EBU00872
Clutch adjustment
1. Remove the rubber cap.
2. Loosen the locknut.
3. Slowly turn the adjusting bolt clockwise
until resistance is felt. Then turn it 1/8
counterclockwise.
4. Tighten the locknut to the specified torque.
NOTE:
Turn the adjusting bolt clockwise to decrease
the clutch free play and turn it counterclockwise
to increase the free play.
5. Install the rubber cap securely.
qw
e
1. Rubber cap 2. Locknut 3. Adjusting bolt
1. Bouchon en caoutchouc
2. Contre-écrou 3. Boulon de réglage
1. Tapa de goma 2. Contratuerca 3. Perno de ajuste
Tightening torque:
8 Nm (0.8 m0kgf)
5TH-9-62 8 4/8/03 9:05 PM Page 8-51

10-2
10
MODEL YFM80W
Engine oil:
Type
Recommended engine oil classification: API Service SE, SF, SG type or higher
Quantity:
Periodic oil change 0.80 L
cC
In order to prevent clutch slippage (since the
engine oil also lubricates the clutch), do not
mix any chemical additives. Do not use oils
with a diesel specification of “CD” or oils of a
higher quality than specified. In addition, do
not use oils labeled “ENERGY CONSERVING
II” or higher.
–20° 10° 20° 30° 40°
10W30
10W40
20W40
20W5050°C
0° –10°
5W30
15W40
5TH-9-62 9~ 4/8/03 6:13 PM Page 309

10-3
Model YFM80W
Final gear oil:
Type SAE 80API “GL-4” Hypoid gear oil
Quantity:
Total amount 0.12 L
Air filter: Wet type element
Fuel:
Type For Europe: Regular unleaded gasoline
For Australia: Unleaded fuel only
Tank capacity 6.8 L
Reserve amount 0.9 L
Carburetor:
Type/manufacturer VM16SH/MIKUNI
Spark plug:
Type/manufacturer CR7HS/NGK
Gap 0.6–0.7 mm
Clutch type: Wet, multiple-disc automatic
5TH-9-62 9~ 4/8/03 6:13 PM Page 310