2007 YAMAHA YFM80R engine oil

EBU17420
TABLE OF CONTENTS
SAFETY INFORMATION .............................. 1-1
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 2-1
DESCRIPTION .............................................. 3-1
Left view ..................................................... 3-1
Right view................................................... 3-1
Controls and instruments ........................... 3-2
INSTRUMENT AND CONTROL
FUNCTIONS .................................................. 4-1
Main switch ............................................... 4-1
Indicator light ............................................. 4-1
Handlebar switches ................................... 4-2
Throttle lever ............................................. 4-2
Speed limiter and air intake restrictor
plate ........................................................ 4-3
Front brake lever ....................................... 4-4
Brake pedal and rear brake lever .............. 4-5
Parking brake ............................................ 4-6
Shift pedal ................................................. 4-6
Fuel tank cap ............................................. 4-7
Fuel ........................................................... 4-7
Fuel cock ................................................... 4-8Choke ...................................................... 4-10
Seat ......................................................... 4-10
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ............................. 5-1
Fuel ............................................................ 5-3
Engine oil ................................................... 5-3
Final gear oil .............................................. 5-3
Front and rear brakes ................................ 5-3
Throttle lever .............................................. 5-4
Tires ........................................................... 5-4
Measuring the tire pressure ....................... 5-5
Tire wear limit ............................................ 5-6
Chassis fasteners ...................................... 5-6
Instruments, lights and switches ................ 5-6
Battery ....................................................... 5-6
OPERATION...................................................6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-3
Shifting ....................................................... 6-3
Engine break-in .......................................... 6-4
Parking ....................................................... 6-5
Parking on a slope ..................................... 6-6
Accessories and loading ............................ 6-6

RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV.............. 7-2
RIDE WITH CARE AND GOOD
JUDGEMENT ...........................................7-2
BE CAREFUL WHERE YOU RIDE ............ 7-9
TURNING YOUR ATV ............................. 7-13
CLIMBING UPHILL .................................. 7-14
RIDING DOWNHILL................................. 7-17
CROSSING A SLOPE.............................. 7-18
CROSSING THROUGH SHALLOW
WATER ..................................................7-19
RIDING OVER ROUGH TERRAIN .......... 7-20
SLIDING AND SKIDDING ........................ 7-21
WHAT TO DO IF... ................................... 7-22
WHAT TO DO... ....................................... 7-22
PERIODIC MAINTENANCE AND MINOR
REPAIR .......................................................... 8-1
Owner’s manual and tool kit ...................... 8-1
Periodic maintenance and lubrication
chart ........................................................ 8-3
Checking the spark plug ............................ 8-7
Engine oil .................................................. 8-8
Final gear oil ............................................ 8-11
Cleaning the air filter element ................. 8-12
Removing the air intake restrictor plate ... 8-15
Cleaning the spark arrester ..................... 8-16
Adjusting the carburetor .......................... 8-17
Adjusting the engine idling speed ........... 8-17Checking the throttle cable free play ....... 8-18
Timing chain ............................................ 8-19
Valve clearance ....................................... 8-19
Checking the front and rear brake
shoes .....................................................8-19
Adjusting the front brake lever free
play ........................................................8-20
Adjusting the rear brake lever and brake
pedal free play .......................................8-22
Adjusting the clutch free play ................... 8-25
Checking and lubricating the cables ........ 8-25
Checking and lubricating the front and
rear brake levers ....................................8-26
Checking and lubricating the brake and
shift pedals .............................................8-27
Checking the wheel bearings ................... 8-27
Lubricating the knuckle shafts ................. 8-27
Lubricating the steering shaft ................... 8-27
Battery ..................................................... 8-28
Replacing the fuse ................................... 8-31
Removing a wheel ................................... 8-31
Installing a wheel ..................................... 8-32
Troubleshooting ....................................... 8-33
Troubleshooting chart .............................. 8-34
CLEANING AND STORAGE ..........................9-1
Cleaning ..................................................... 9-1
Storage ...................................................... 9-2

5-1
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7
8
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10
11

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PRE-OPERATION CHECKS
EBU19220
Pre-operation check list
Before operating this ATV, be sure to check the items listed in the following table.
NOTE:

The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic
maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a
Yamaha dealer.
ITEM ROUTINE PAGE
Fuel


Check fuel level in fuel tank, and add recommended fuel if neces-
sary.

Check fuel line for leakage. Correct if necessary.4-7, 5-3
Engine oil

Check oil level in engine, and add recommended oil to specified
level if necessary.

Check ATV for oil leakage. Correct if necessary.5-3, 8-8
Final gear oil

Check ATV for oil leakage. Correct if necessary. 5-3, 8-11
Front brake

Check operation, and correct if necessary.

Lubricate cable if necessary.

Check lever free play, and adjust if necessary.5-3, 8-19, 8-20
Rear brake

Check operation, and correct if necessary.

Lubricate cable if necessary.

Check lever and pedal free play, and adjust if necessary.5-3, 8-19, 8-22
Throttle lever

Make sure that operation is smooth. Lubricate cable and lever hous-
ing if necessary.

Check cable free play, and adjust if necessary.5-4, 8-18
Control cables

Make sure that operation is smooth. Lubricate if necessary. 8-25

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EBU19540
Fuel
Make sure that there is sufficient fuel in the tank.
(See page 4-7.)
WARNING

EWB00520

Do not overfill the fuel tank. Fuel expands
when it heats up. If the fuel tank is overfilled,
fuel could spill out due to heat from the en-
gine or the sun.

Be careful not to spill fuel, especially on the
engine or exhaust pipe which can cause a
fire and severe injury. Wipe up any spilled
fuel immediately.

Do not refuel right after the engine has been
running and is still very hot.

Be sure the fuel tank cap is closed securely.
EBU19560
Engine oil
Make sure that the engine oil is at the specified lev-
el. Add oil as necessary. (See page 8-8.)
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Final gear oil
Make sure that the final gear oil is at the specified
level. Add oil as necessary. (See page 8-11.)
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Front and rear brakes
Brake levers and brake pedal

Check for correct free play in the brake levers
and brake pedal. If the free play is incorrect, ad-
just it. (See pages 8-20 and 8-22.)

Check operation of the brake levers and brake
pedal. They should move smoothly and there
should be a firm feeling when the brakes are ap-
plied. If not, have the ATV checked by a Yamaha
dealer.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, check
the brake linings for wear. (See page 8-19.)
WARNING

EWB00570
Always check the brakes at the start of every
ride. Do not ride the ATV if you find any prob-
lem with the brakes or you could lose braking
ability, which could lead to an accident. If a
problem cannot be corrected by the adjust-
ment procedures provided in this manual, have

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4
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7
*
Rear brake

Check operation and correct if necessary.

Check brake lever and pedal free play, and adjust
if necessary.
√√√√√

Replace brake shoes. Whenever worn to the limit
8
*
Wheels

Check runout and for damage, and replace if nec-
essary.
√ √√√
9
*
Tires


Check tread depth and for damage, and replace if
necessary.

Check air pressure and balance, and correct if
necessary.
√ √√√
10
*
Wheel bearings

Check for looseness or damage, and replace if
necessary.
√ √√√
11
*
Drive shaft univer-
sal joint

Lubricate with lithium-soap-based grease.
√√√
12
*
Chassis fasteners

Make sure that all nuts, bolts, and screws are
properly tightened.
√√√√√
13
*
Shock absorber
assemblies

Check operation and correct if necessary.

Check for oil leakage and replace if necessary.
√√√
14
*
Knuckle shafts


Lubricate with lithium-soap-based grease.
√√√
15
*
Steering shaft


Lubricate with lithium-soap-based grease.
√√√
16
*
Steering system


Check operation and repair or replace if damaged.

Check toe-in and adjust if necessary.
√√√√√
17
*
Carburetor


Check choke operation and correct if necessary.

Check engine idling speed and adjust if neces-
sary.
√√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth 1 3 6 6 12
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300

8-5
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3
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5
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78
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10
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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

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

2. Check the spark plug for electrode erosion
and excessive carbon or other deposits, and
replace it if necessary.
To install the spark plug
1. Measure the spark plug gap with a wire thick-
ness gauge and, if necessary, adjust the gap
to specification.2. Clean the surface of the spark plug gasket
and its mating surface, and then wipe off any
grime from the spark plug threads.
3. Install the spark plug with the spark plug
wrench, and then tighten it to the specified
torque.NOTE:

If a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque as
soon as possible.
4. Install the spark plug cap.
EBU23251
Engine oil
The engine oil level should be checked before
each ride. In addition, the oil must be changed at
the intervals specified in the periodic maintenance
and lubrication chart. Specified spark plug:
NGK/CR7HSA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
1. Spark plug gap
Tightening torque:
Spark plug:
12.5 Nm (1.3 m·kgf, 9.0 ft·lbf)

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To check the engine oil level
1. Place the ATV on a level surface.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Wait a few minutes until the oil settles before
checking.
4. Remove the engine oil filler cap, and then
wipe the dipstick off with a clean rag.
5. Insert the dipstick into the filler hole (without
screwing it in), and then remove it again to
check the oil level.NOTE:
The engine oil should be between the minimum
and maximum level marks.
6. If the engine oil is at or below the minimum
level mark, add sufficient oil of the recom-
mended type to raise it to the correct level.
7. Insert the dipstick into the oil filler hole, and
then tighten the engine oil filler cap.
To change the engine oil
1. Place the ATV on a level surface.
2. Start the engine, warm it up for several min-
1. Dipstick
1

1. Maximum level mark
2. Minimum level mark
1
2