2006 YAMAHA YFM80R check engine

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 ................................4-13Brake pedal and rear brake 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
Tires ...................................................5-19
How to measure tire pressure ............5-23
Tire wear limit .....................................5-25
Fittings and fasteners .........................5-25
Switches .............................................5-25
Battery ................................................5-25
EBU00015
CONTENTS
1
2
3
4
5
5TH-9-64 ~3 3/1/05 7:49 PM Page 16

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
5TH-9-64 4~5 2/16/05 2:42 PM Page 6

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. 5-25
Switches9Check operation. 5-25
Battery9Check fluid level.
5-25, 8-59–8-65
9Fill with distilled water if necessary.
5TH-9-64 4~5 2/16/05 2:42 PM Page 26

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.
5TH-9-64 6 2/16/05 2:43 PM Page 10

8-8 * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.INITIAL EVERY
month 1 3 6 6 12
ITEM ROUTINEWhichever
km 320 1200 2400 2400 4800 comes first
(mi) (200) (750) (1500) (1500) (3000)
hours 20 75 150 150 300
Engine oil9Replace (warm engine before draining).2222
Final gear oil9Check oil level/oil leakage.
22
9Replace every 12 months.
Brakes*9Check operation.
22222
9Adjust if necessary.
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-9-64 8 2/16/05 2:45 PM Page 8-8

8-13
EBU14181
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 mini-
mum and maximum marks. If the level is
low, add oil to raise it to the specified 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
5TH-9-64 8 2/16/05 2:45 PM Page 8-13

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 type:
20W50, 20W40, 15W40, 10W40,
10W30, 5W30
Recommended oil classification:
API Service SE, SF, SG type or higher
Oil quantity:
Periodic oil change:
0.8 L
5TH-9-64 8 2/16/05 2:45 PM Page 8-17

8-31
NOTE:
The air filter element should be wet but not drip-
ping.
8. Install the air filter element.
9. Install the air filter case cover by hooking
the fasteners onto the air filter case.
10. Install the front cover by installing the bolts.
NOTE:
The air filter element should be cleaned every
20-40 hours. It should be cleaned and lubricated
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 airtight seal. Tighten all
fittings securely to avoid the possibility of unfil-
tered air entering the engine.
5TH-9-64 8 2/16/05 2:45 PM Page 8-31