Yamaha YFM80GX Owner'S Manual Download

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This A

This ATV should not be ridden by anyone under 12 years of age.

OWNER’S MANUAL

LIT-11626-21-06

2D3-28199-14

YFM80GX

WARNING

READ THIS MANUAL CAREFULLY!

It contains important safety information.

Summary of Contents for YFM80GX

Page 1: ...This A This ATV should not be ridden by anyone under 12 years of age OWNER S MANUAL LIT 11626 21 06 2D3 28199 14 YFM80GX WARNING READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 2: ...EBU17091 ...

Page 3: ...nspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE LY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV NEVER OPERATE AN ATV WITHOUT ...

Page 4: ...le while they learn The limiter screw may be gradually turned out to increase maximum speed as the beginner becomes more familiar with operating the ATV Par ents should decide when to adjust the ATV for more power as their youngster s riding skills improve Once the ATV rider can operate with skill at the top speed permitted by adjusting the speed limiter alone the air intake restrictor plate can b...

Page 5: ...ifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the ATV operator a bystander or a person inspecting or repairing the ATV A CAUTION indicates special precautions that must be taken to avoid damage to the ATV A NOTE provides key information to ...

Page 6: ...D noise level and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17381 AFFIX DEALER LABEL HERE YFM80GX OWNER S MANUAL 2007 by Yamaha Motor Corporation U S A 1st edition April 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation...

Page 7: ...r 4 3 Speed limiter and air intake restrictor plate 4 4 Front brake lever 4 5 Brake pedal and rear brake lever 4 5 Parking brake 4 6 Shift pedal 4 7 Fuel tank cap 4 8 Fuel 4 8 Fuel cock 4 10 Choke 4 11 Seat 4 12 Carrier 4 13 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 5 Measuring the tire pres...

Page 8: ...8 10 Final gear oil 8 13 Cleaning the air filter element 8 14 Removing the air intake restrictor plate 8 18 Cleaning the spark arrester 8 19 Adjusting the carburetor 8 20 Adjusting the engine idling speed 8 20 Checking the throttle cable free play 8 21 Timing chain 8 22 Valve clearance 8 22 Checking the front and rear brake shoes 8 22 Adjusting the front brake lever free play 8 23 Adjusting the re...

Page 9: ...NG AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 Noise regulation 11 3 Maintenance record 11 4 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY 11 5 YAMAHA EXTENDED SERVICE Y E S 11 7 ...

Page 10: ...nd out about the training courses nearest you Always follow the age recommendation A child under 12 years old should never oper ate an ATV with engine size greater than 70 cc A child under 16 years old should never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he...

Page 11: ...nd never turn at excessive speeds Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never op...

Page 12: ...very cautious in order to re duce the chance of skidding or sliding out of con trol Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always use the size and type of tires specified...

Page 13: ...e fuel cock is in the OFF position Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause inju ries HOW TO AVOID THE HAZARD If you should swallow some gasoline or in hale a lot of gasoline vapor or get some gas oline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your ...

Page 14: ...2 1 1 2 3 4 5 6 7 8 9 10 11 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 2 3 4 5 6 ...

Page 15: ... use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and in...

Page 16: ...2 2 9 psi Minimum FRONT 17 kPa 0 17 kgf cm2 2 5 psi REAR 17 kPa 0 17 kgf cm2 2 5 psi Never set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING Maximum Vehicle Load 95 kg 209 lbs Includes weight of operator cargo and accessories WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 4EM 21696 11 5FE 2151H 01 ...

Page 17: ...EBU17680 DESCRIPTION EBU17690 Left view EBU17700 Right view 1 Fuel cock 2 Rear carrier 3 Rear wheel 4 Footboard 5 Shift pedal 6 Choke 7 Front wheel 1 3 4 5 7 2 6 1 Spark arrester 2 Seat 3 Panel 4 Brake pedal 5 Footboard 1 2 3 4 5 ...

Page 18: ...ents NOTE The ATV you have purchased may differ slightly from the figures shown in this manual 1 Rear brake lever 2 Parking brake 3 Neutral indicator light 4 Front brake lever 5 Throttle lever 6 Main switch 7 Fuel tank cap 8 Handlebar switches 1 2 3 4 5 6 7 8 ...

Page 19: ... hazard that could result in serious injury or death EBU17740 Main switch The positions of the main switch are as follows ON All electrical systems are supplied with power and the engine can be started The key cannot be re moved OFF All electrical systems are off The key can be re moved 1 Main switch OFF ON 1 ...

Page 20: ...itches EBU18070 Engine stop switch ENG STOP Set this switch to RUN before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run when this switch is set to OFF 1 Neutral indicator light N 1 1 Engine stop switch ENG STOP 2 Start switch START 1 2 ...

Page 21: ...ovement of the throt tle lever will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV 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 positio...

Page 22: ... removed Since re moval of this plate will result in a significant in crease in power turn the adjusting screw completely back in again adjust it out in stages as done previously 1 Loosen the locknut 2 To increase the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction a To de crease the maximum engine power available and the maximum speed of the ...

Page 23: ...ed on the right side of the ATV and the rear brake lever is located on the left 1 Locknut 2 Adjusting screw 3 No more than 20 mm 0 8 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Im proper throttle operation could result The child could lose control have an accident or be injured 3 1 2 b a HOW TO AVOID THE HAZA...

Page 24: ...toward the handlebar grip EBU18450 Parking brake Use the parking brake before starting the engine or parking the ATV especially on a slope Apply the rear brake lever and push down the lock plate to apply the parking brake Squeeze the rear brake lever to release the parking brake 1 Brake pedal 1 1 Rear brake lever 1 ...

Page 25: ... HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before start ing the engine This could cause loss of con trol or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking...

Page 26: ...ap Remove the fuel tank cap by turning it counter clockwise EBU18730 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Shift pedal 2 Neutral position 1 N 2 3 2 1 1 Fuel tank cap 1 ...

Page 27: ... different brand of gasoline or premi um unleaded fuel Unleaded fuel will give you long er spark plug life and reduced maintenance cost Gasohol There are two types of gasohol gasohol contain ing ethanol and that containing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recommended by Yamaha be cause it can cause damage ...

Page 28: ...RNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and se vere injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immed...

Page 29: ... this position the fuel reserve is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18860 Choke The choke is used to start a cold engine Move the choke in direction a to turn on the choke 1 Arrow mark positioned over ON ON FUEL RES OFF ON 1 1 Arrow mark posi...

Page 30: ...Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear To install the seat Insert the projection on the front of the seat into the seat holder and push down on the seat at the rear NOTE Make sure that the seat is securely fitted 1 Fully open ON 2 Half open warming up position 3 Closed OFF 4 Choke 4 1 2 3 b a 1 Seat lock lever 1 ...

Page 31: ...r Do not exceed the load limit of 5 0 kg 11 lb for the carrier Do not exceed the maximum load of 95 0 kg 209 lb for the ATV WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death 1 Projection 2 Seat holder 2 1 ...

Page 32: ...intenance charts on page 8 3 to determine which service should be performed by a Yamaha dealer WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition Always...

Page 33: ...adjust if necessary 5 3 8 22 8 25 Throttle lever Make sure that operation is smooth and check cable free play Lubricate cable and lever housing if necessary 5 4 8 21 Control cables Make sure that operation is smooth Lubricate if necessary 8 29 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necess...

Page 34: ...e 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 22 EWB00530 WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and se vere injury...

Page 35: ...Yamaha dealer correct if necessary WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any prob lem with the brakes If a problem cannot be corrected by the adjustment procedures pro vided in this manual have the ATV checked by a Yamaha dealer ...

Page 36: ...HOW TO AVOID THE HAZARD The tires listed below have been approved by Yamaha Motor Co Ltd for this model Other tire combinations are not recom mended Front Manufacturer model DUNLOP KT586 Size AT18 x 7 7 Type Tubeless Rear Manufacturer model DUNLOP KT587 Size AT18 x 8 7 Type Tubeless The tires should be set to the recommend ed pressure Recommended tire pressure Front 20 0 kPa 2 9 psi 0 20 kgf cm2 R...

Page 37: ...he tire pressures to the following specifications Tire pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 17 0 kPa 2 5 psi 0 17 kgf cm2 Rear 17 0 kPa 2 5 psi 0 17 kgf cm2 Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 36 psi 2 5 kgf cm2 Rear ...

Page 38: ...that all instruments lights and switches are working properly Correct if necessary EBU19860 Battery Check the fluid level in the battery Fill with distilled water if necessary See page 8 31 Recommended pressure Front 20 0 kPa 2 9 psi 0 20 kgf cm2 Rear 20 0 kPa 2 9 psi 0 20 kgf cm2 Minimum Front 17 0 kPa 2 5 psi 0 17 kgf cm2 Rear 17 0 kPa 2 5 psi 0 17 kgf cm2 Maximum Front 23 0 kPa 3 3 psi 0 23 kgf...

Page 39: ...to neutral The neutral indicator light should come on If the indicator WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an acci dent or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer WARNING POTENTIAL HAZARD Frozen control...

Page 40: ...rence to the figure Position 1 Cold engine start with ambient temperature be low 30 C 90 F Position 2 Warming up position Position 3 Cold engine start with ambient temperature above 25 C 80 F Ambient temp choke position 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 sec...

Page 41: ...e is warm when it responds normally to the throttle with the choke turned off EBU20301 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the choke is not re quired when the engine is warm Instead start the engine with the throttle slightly open EBU20550 Shifting This ATV has a 3 speed forward transmission with a centrifugal automatic clutch The ...

Page 42: ...roper use of the brakes or shifting can cause the tires to lose traction reducing con trol and increasing the possibility of an accident EWB00650 CAUTION ECB00190 Even with the transmission in the neutral posi tion do not coast for long periods of time with WARNING POTENTIAL HAZARD Opening the throttle before releasing the shift pedal WHAT CAN HAPPEN The ATV could wheelie This would increase the c...

Page 43: ... km 200 mi or 20 hours The various parts in the engine wear and polish themselves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in en gine overheating must be avoided 0 160 km 0 100 mi or 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set throttle pos...

Page 44: ... WARNING POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the ATV trans versely across the incline shift into first gear stop the engine apply the parking brake and then block the front and rear wheels with r...

Page 45: ...ch can shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits...

Page 46: ...ying heavier loads or when towing a trail er Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV EWB00750 WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death MAXIMUM LOADING LIMIT ATV ...

Page 47: ...7 1 1 2 3 4 5 6 7 8 9 10 11 EBU21131 RIDING YOUR ATV ...

Page 48: ...to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 1 1 1 4 Please also read all caution and warning labels on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get ...

Page 49: ...complete the certified training course offered by Yamaha They should then regu larly practice the skills learned in the course and the operating techniques described in this Owner s Manual For more information about the training course contact an autho rized ATV dealer or call 1 800 887 2887 WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Use by chil...

Page 50: ...HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passen ger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying pas sengers ...

Page 51: ...of an acci dent Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing in creases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield ...

Page 52: ...ously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment dam...

Page 53: ... intake restrictor plate to limit the amount of engine power available WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or opera tion of this ATV with improper or uneven tire pressure may cause loss of control increas ing your risk of an accident HOW TO AVOID THE HAZARD Always use the size and...

Page 54: ...e restrictor plate can be removed Since removal of this plate will result in a significant increase in power turn the speed limiter back in again adjust it out in stag es as you did before Adjusting for maximum throttle lever movement without removing the air intake restrictor plate will cause the engine to run roughly at higher speeds For air intake restrictor plate removal instructions see page ...

Page 55: ...g cargo improperly WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own er s Manual for carrying car...

Page 56: ... the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident inc...

Page 57: ...sories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV dealer WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible ma terial accumulated around the engine area could catch fire Someone touching the...

Page 58: ...WB01030 WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect han dling and control of the ATV and may cause the ATV to go out of control HOW TO AVOID THE HAZARD Always avoid paved surfaces including side walks driveways parking lots and streets WARNING POTENTIAL HAZARD Operating this ATV on public ...

Page 59: ...rt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra carefu...

Page 60: ...re to use extra care when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Could cause loss of traction or ATV control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slip pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especial ly...

Page 61: ... avoid riding on paved surfaces the ATV is designed for off road use only and handling maneuvers are more difficult to perform on pavement Set the parking brake and follow the instruction on page 6 1 to start the engine Once it has warmed up you are ready to begin riding your ATV As you get on the ATV be sure not to accidentally move WARNING POTENTIAL HAZARD Operating in areas where you might not ...

Page 62: ...of directional control Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CAUTION ECB00230 Do not shift gears without releasing the throt tle Damage to the engine or drive train may oc cur When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly As you slow down shift to a lower gear Be sure that the engine has sufficiently slow...

Page 63: ... turn properly This procedure should be practiced at slow speed many times in a large off road area with no obsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the proce dure again If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on th...

Page 64: ...fore attempting any in cline and then practice riding first on gentle slopes Try more difficult climbs only after you have devel oped your skill In all cases avoid inclines with slip pery or loose surfaces or obstacles that might cause you to lose control EWB01090 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by leanin...

Page 65: ...AZARD Always follow proper procedures for climb ing hills as described in this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle...

Page 66: ...ad ap ply the front brake gradually or dismount the ATV immediately on the uphill side WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level groun...

Page 67: ...V straight down hill Avoid sharp angles which could allow the ATV WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dis mounting while climbing a hill WHAT CAN HAPPEN Could result in the ATV overturning HOW TO AVOID THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking brake...

Page 68: ...cross a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loose surfaces by pointing WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owner s Man ual Note a special techn...

Page 69: ... in in depth Before entering the water choose your path WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning ...

Page 70: ...r braking ability WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an acci dent HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember that wet brakes may have re duced stopping ability Te...

Page 71: ...t has been operated in salt water or muddy conditions RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau tion Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult 1 Air filter case ch...

Page 72: ...ide side ways control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in ...

Page 73: ...turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight over the front wheels for better control See page 7 16 If your ATV begins to tip while turning WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may a...

Page 74: ... top of you Instead apply the front brake or dis mount the ATV on the uphill side See page 7 18 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that the ATV is going to tip over di...

Page 75: ...RAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED EWB01820 EBU27100 Owner s manual and tool kit Be sure to put this owner s manual in the plastic bag and to always carry it as well as the owner s tool kit and the low pressure tire gauge in their re spective compartments under the seat WARNING POTENTIAL HAZARD Servicing an engine while it is running W...

Page 76: ...1830 1 Owner s manual 2 Low pressure tire gauge 3 Owner s tool kit 1 2 3 WARNING POTENTIAL HAZARD Operating this ATV with improper modifica tions WHAT CAN HAPPEN Improper installation of accessories or mod ification of this ATV may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of acce...

Page 77: ...performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3...

Page 78: ...ket s if neces sary Check for looseness and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 ...

Page 79: ...nt brake Check operation and correct if necessary Check brake lever free play and adjust if neces sary Replace brake shoes Whenever worn to the limit 5 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 6 Wheels Check runout and for damage and replace if nec essary 7 Tires Check tread dept...

Page 80: ...l Change Check ATV for oil leakage and correct if neces sary 16 Moving parts and cables Lubricate 17 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 18 Front and rear brake switches Check operation and correct if necessary 19 Battery Check electrolyte le...

Page 81: ...8 7 1 2 3 4 5 6 7 8 9 10 11 EBU23060 NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas ...

Page 82: ...ince heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accor dance with the periodic maintenance and lubrica tion chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s to...

Page 83: ...operly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 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 1 Spark p...

Page 84: ...ld be checked before each ride In addition the oil must be changed at the intervals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the ATV on a level surface 2 Check the engine oil level on a cold engine NOTE If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until ...

Page 85: ...To change the engine oil 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 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase 5 Check the O ring for damage and replace it if necessary 6 Install the engine oil drain bolt ...

Page 86: ...y than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher Make sure that no foreign material enters the crankcase 8 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 9 Turn the engine off wait at least ten minutes and then check the oil level and correct it...

Page 87: ...dipstick off with a clean rag insert it back into the oil filler hole without screwing it in and then remove it again to check the oil level NOTE The final gear oil should be between the minimum and maximum level marks 3 If the oil is at or below the minimum level mark add sufficient oil of the recommended type to raise it to the correct level 4 Insert the dipstick into the oil filler hole and the...

Page 88: ...Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean the air filter element more frequently if you are riding in unusually wet or dusty areas NOTE There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and...

Page 89: ...8 15 1 2 3 4 5 6 7 8 9 10 11 ter case 1 Remove the quick fasteners 2 Remove the panel by sliding it forward and pulling it off as shown 1 Air filter case check hose 1 1 Quick fastener 1 1 ...

Page 90: ...e the air filter case cover by unhooking the holders 4 Unhook the holder holding the air filter ele ment and then pull out the sponge material from the air filter element 1 Panel 1 1 1 Air filter case cover 2 Air filter case holder 1 2 2 ...

Page 91: ...t 7 Check the sponge material and replace it if damaged 8 Apply Yamaha foam air filter oil or other qual ity foam air filter oil to the sponge material 1 Unhook 2 Sponge material WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode 1 2 HOW TO AVOID THE HAZARD Use parts cleanin...

Page 92: ...r element maintenance is performed check the air inlet of the air filter case for obstructions CAUTION ECB00460 Make sure that the air filter element is prop erly seated in the air filter case Never operate the engine with the air filter el ement removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Addition ally operation without the air f...

Page 93: ...t pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the screws 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 4 Insert the tailpipe into the muffler and align the screw holes 5 Install the screws and tight...

Page 94: ...ha factory Changing these settings without sufficient technical knowl edge may result in poor performance of or damage to the engine EBU24000 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica tion chart NOTE A diagnostic tachometer is needed to make this adjustment 1 Star...

Page 95: ...rew in direction b NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EBU27071 Checking the throttle cable free play The throttle cable free play should be checked at the intervals specified in the periodic maintenance and lubrication chart The throttle cable free play should measure 1 0 3 0 mm 0 04 0 12 in at the throttle lever Period...

Page 96: ...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 t...

Page 97: ... the brake lever free play check the front brake shoes for wear The brake lever free play should measure 10 0 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 1 Wea...

Page 98: ...lengths are equal The cable joint will become vertical 6 Tighten the upper locknut EWB02020 1 Upper locknut 2 Upper adjusting bolt 3 Lower locknut 4 Lower adjusting bolt 1 2 4 3 a b a b 1 Cable joint WARNING POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident 1 ...

Page 99: ... play is in correct adjust it as follows 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 ...

Page 100: ... 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 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 a...

Page 101: ...y adjusting nut WARNING POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident 1 a b HOW TO AVOID THE HAZARD 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 proc...

Page 102: ...1 8 counter clockwise NOTE Turning the adjusting bolt in decreases clutch free play and turning it out increases clutch free play 5 Tighten the locknut to the specified torque NOTE When tightening the locknut hold the adjusting 1 Footboard 2 Screw 3 Bolt 3 2 1 2 1 Rubber cap 2 Locknut 3 Adjusting bolt Tightening torque Locknut 8 Nm 0 8 m kgf 5 8 ft lbf 1 2 3 ...

Page 103: ...thly have a Yamaha dealer check or replace it EWB02120 EBU24912 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 Tightening torque Footboard bolt 10 Nm 1 0 m kgf 7 2 ft lbf Recommended lubricant Engine oil WARNING POTENTIAL HAZARD Damaged control cables...

Page 104: ... front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bear ings EBU28820 Lubricating the front knuckle pivots The front knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and Rec...

Page 105: ... poorly maintained battery will corrode and dis charge quickly The electrolyte level battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrica tion chart To check the electrolyte level 1 Place the ATV on a level surface 2 Check the electrolyte level in the battery Recommended lubricant Lithium soap b...

Page 106: ...level mark add distilled water to raise it to the maximum level mark CAUTION ECB00590 Use only distilled water as tap water contains minerals that are harmful to the battery EWB02140 1 Battery 2 Battery breather hose 1 2 1 Maximum level mark 2 Minimum level mark WARNING POTENTIAL HAZARD Failure to handle batteries or battery electro lyte carefully 1 2 ...

Page 107: ...c trolyte at least once a month and fully charge WHAT CAN HAPPEN You could be poisoned You could be severe ly burned by the sulfuric acid in battery elec trolyte Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Al ways shield eyes when working near batter ies Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quan...

Page 108: ...e is properly routed in good condition and not obstructed CAUTION ECB00610 If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the battery the frame could suf fer structural and external damages EBU25232 Replacing the fuse The fuse holder is located under the seat See page 4 12 If the fuse is blown replace it as follows 1 Battery 2 Negativ...

Page 109: ...and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU25650 Removing a wheel 1 Loosen the wheel nuts Front Specified fuse 5 0 A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE H...

Page 110: ...on or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself However should your ATV re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacem...

Page 111: ... smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe in jury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys tem Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces ...

Page 112: ...eck the ATV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The batte...

Page 113: ...sure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle bru...

Page 114: ...by loosen ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark ...

Page 115: ...ls 7 Check and if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative ly turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place a...

Page 116: ...lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 79 0 cm3 4 82 cu in Bore stroke 47 0 45 6 mm 1 85 1 80 in Compression ratio 9 60 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 SAE5W30 or SAE10W30 or SAE20W40 Recommended engine oil grade API service SE SF SG type or higher 0 10 30 50 70 90 1...

Page 117: ...retor Manufacturer MIKUNI Type x quantity VM16SH x 1 Spark plug s Manufacturer model NGK CR7HSA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet multiple disc automatic Transmission Primary reduction system Spur gear Primary reduction ratio 65 20 3 250 Secondary reduction system Shaft drive Secondary reduction ratio 19 18 34 10 3 588 Transmission type Constant mesh 3 speed Operation...

Page 118: ...0 kgf cm2 Minimum Front 17 0 kPa 2 5 psi 0 17 kgf cm2 Rear 17 0 kPa 2 5 psi 0 17 kgf cm2 Maximum Front 23 0 kPa 3 3 psi 0 23 kgf cm2 Rear 23 0 kPa 3 3 psi 0 23 kgf cm2 Front wheel Wheel type Panel wheel Rim size 7 x 5 5AT Rear wheel Wheel type Panel wheel Rim size 7 x 6 5AT Front brake Type Drum brake Operation Right hand operation Rear brake Type Drum brake Operation Left hand and right foot oper...

Page 119: ... Coil spring oil damper Wheel travel 56 mm 2 2 in Electrical system Ignition system CDI Charging system AC magneto Battery Model 12N7D 3B Voltage capacity 12 V 7 0 Ah Bulb voltage wattage x quantity Neutral indicator light 12 V 1 7 W 1 Fuses Main fuse 5 0 A ...

Page 120: ...rts from a Yamaha dealer or for ref erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26030 Vehicle identification number The vehicle identification number...

Page 121: ... fy your ATV EBU26050 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha deal er 1 Vehicle identification number 1 1 Model label 1 ...

Page 122: ...ted into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modifi...

Page 123: ...inted only as a reminder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 2250...

Page 124: ...rom the original purchaser to any subsequent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY ...

Page 125: ...satis faction at the time of sale and upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Q Is the warranty transferable to second owners A Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain e...

Page 126: ...overed repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency to...

Page 127: ...pires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 Indicates a potential hazard that could result in...

Page 128: ...11 9 1 2 3 4 5 6 7 8 9 10 11 EBU26132 ...

Page 129: ...cating 8 29 Carburetor adjusting 8 20 Carrier 4 13 Chassis fasteners 5 7 Choke 4 11 Cleaning 9 1 Clutch free play adjusting 8 27 E Engine break in 6 5 Engine cold start 6 1 Engine idling speed 8 20 Engine oil 5 3 8 10 Engine starting a warm 6 3 Engine stop switch 4 2 F Final gear oil 5 3 8 13 Front knuckle pivots lubricating 8 30 Fuel 4 8 5 3 Fuel cock 4 10 Fuel tank cap 4 8 Fuse replacing 8 34 H ...

Page 130: ...Spark plug checking 8 8 Specifications 10 1 Speed limiter and air intake restrictor plate 4 4 Start switch 4 3 Steering shaft lubricating 8 31 Storage 9 2 T Throttle cable free play checking 8 21 Throttle lever 4 3 5 4 Timing chain 8 22 Tire pressure measuring 5 6 Tires 5 5 Tire wear limit 5 7 Troubleshooting 8 36 Troubleshooting chart 8 38 V Valve clearance 8 22 Vehicle identification number 11 1...

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Page 132: ...es pavement may seriously affect handling and control Improper ATV use can result in SEVERE INJURY or DEATH NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS USE AN APPROVED HELMET AND P...

Page 133: ...D SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER THAN 90CC 8 TAKE THE FREE HANDS ON TRAINING COURSE OFFERED BY YAMAHA ASK YOUR DEALER FOR DETAILS OR CALL 1 800 887 2887 If you have any questions about these points or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership please fill out the information below...

Page 134: ...E NECESSARY IF MAILED IN THE UNITED STATES FIRST CLASS PERMIT NO 4 CYPRESS CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U S A P O BOX 6555 CYPRESS CALIFORNIA 90630 9989 ATTN SALES ADMINISTRATION ...

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Yamaha YFM80GX, Owner'S Manual

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