2007 YAMAHA YFM80R brake

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

18
*
Crankcase breather
system

Check breather hose for cracks or other damage,
and replace if necessary.
√√√
19 Engine oil

Change.

Check ATV for oil leakage, and correct if neces-
sary.
√ √√√
20 Final gear oil

Change.

Check ATV for oil leakage, and correct if neces-
sary.
√√
21
*
Moving parts and
cables


Lubricate.
√√√√
22
*
Throttle lever hous-
ing and cable


Check operation and correct if necessary.

Check throttle cable free play and have a Yamaha
dealer adjust if necessary.

Lubricate throttle lever housing and cable.
√√√√√
23
*
Exhaust system


Check for leakage and replace gasket(s) if neces-
sary.

Check for looseness and tighten all screw clamps
and joints if necessary.
√√√
24 Spark arrester

Clean.
√√√
25
*
Front and rear brake
switches


Check operation and correct if necessary.
√√√√√
26
*
Battery


Check electrolyte level and specific gravity, and
correct if necessary.

Make sure that the breather hose is properly
routed.
√√√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300

8-19
1
2
3
4
5
6
78
9
10
11

The throttle cable free play should measure 1.0–
3.0 mm (0.04–0.12 in) at the throttle lever. Period-
ically check the throttle cable free play and, if nec-
essary, have a Yamaha dealer adjust it.
EBU24050
Timing chain
The timing chain stretches with use, resulting in im-
proper valve timing and engine noise. To prevent
this from occurring, the timing chain tensioner
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
EBU24060
Valve clearance
The valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
EBU24090
Checking the front and rear brake
shoes
The front and rear brake shoes must be checked
for wear at the intervals specified in the periodic
maintenance and lubrication chart. Each brake is
provided with a wear indicator, which allows you to
check the brake shoe wear without having to dis-
assemble the brake. To check the brake shoe
wear, check the position of the wear indicator while
applying the brake. If a brake shoe has worn to the
point that the wear indicator reaches the wear limit
line or mark, have a Yamaha dealer replace the
brake shoes as a set.
1. Throttle lever free play
1

8-20
1
2
3
4
5
6
78
9
10
11
Front brake Rear brake

EBU24330
Adjusting the front brake lever free
play
The brake lever free play must be checked and, if
necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.NOTE:

Before adjusting the brake lever free play, check
the front brake shoes for wear.
The brake lever free play should measure 10.0–
1. Wear limit line
2. Wear indicator
1
2

1. Wear limit mark
2. Wear indicator
1
2

8-21
1
2
3
4
5
6
78
9
10
11

12.0 mm (0.39–0.47 in) as shown. If the free play
is incorrect, adjust it as follows.
1. Loosen the upper locknut and fully turn in the
upper adjusting bolt.
2. Loosen the lower locknut.
3. Turn the lower adjusting bolt in direction (a) to
increase the free play, and in direction (b) to
decrease it.4. Tighten the lower locknut.
5. While applying the front brake, turn out the up-
per adjusting bolt until the upper and lower ca-
ble lengths are equal. The cable joint will
become vertical.
1. Brake lever free play
1

1. Upper locknut
2. Upper adjusting bolt
3. Lower locknut
4. Lower adjusting bolt
1
2
4
3(a)(b)(a)
(b)

8-22
1
2
3
4
5
6
78
9
10
11

6. Tighten the upper locknut.
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.
EBU24473
Adjusting the rear brake lever and
brake pedal free play
The brake lever and brake pedal free play must be
checked and, if necessary, adjusted at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
NOTE:


Always perform this maintenance completely in
the following order whenever adjusting the rear
brake.

Before adjusting the brake lever and brake pedal
free play, check the rear brake shoes for wear.
Adjusting the brake lever free play
The brake lever free play should measure 5.0–8.0
mm (0.20–0.31 in) as shown. If the free play is in-
correct, adjust it as follows.
1. Cable joint
1

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)

8-26
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)