Yamaha Badger 80 service manual repair 1985-1988 YFM80

CD (3) I~IJ=~I'-I INSP fA An .• @) 0 1 ENG 1'-1 ~~I ® ® ~RBI , 1 ~H~~I 0 ® IELECI iii I IAPpxl·'1 ® ~ @ ~ @ ~ @ ~ @ [0] @ [mJ @ 1 @ 1 @ 1 - a - m G @) @) @ ~ ~ ~ @ a ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbolsCDto@are designed as thumb tabs to indicate the chapter's number and content. CD General information @ Periodic inspection and adjustment @ Engine ® Cooling system @ Carburetion ® Chassis (j) Electrical @ Appendices Illustrated symbols ®to @ are used to identify the specifications appearing in the text. ® Filling fluid' @ Lubricant @ Tightening @ Wear limit, clearance @ Engine speed @n,V,A Illustrated symbols @to ® in the exploded dia- gram indicate grade of lubricant and location of lubrication point. @ Apply engine oil @ Apply gear oil @ Apply molybdenum disulfide oil @ Apply wheel bearing grease @ Apply lightweight lithium·soap base grease ® Apply molybdenum disulfide grease ® Apply locking agent (LOCTITE@)

INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE CARBURETION CHASSIS ELECTRICAL APPENDICES ~ CHAS Iii ELEC ~, APPX

CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ...................................... 1-1 VEHICLE IDENTIFICATION NUMBER ........................... 1-1 ENGINE SERIAL NUMBER ..................................... 1-1 IMPORTANT INFORMATION ...................................... 1-2 ALL REPLACEMENT PARTS ................................... 1-2 GASKETS, OIL SEALS, AND O-RINGS .... " ..... '" .. " ...... , .. 1-2 LOCK WASHERS/PLATES AND COTTER PINS ..................... 1-2 BEARINGS AND OIL SEALS ....... , " ........... , ............. 1-2 CIRCLIPS ................................................... 1-3 SPECIAL TOOLS ................................................ 1-3 FOR TUNE-UP ............................................. : . 1-3 FOR ENGINE SERVICE ................................... ; .... 1-4 FOR CHASSIS SERVICE ....................................... 1-7 FOR ELECTRICAL COMPONENTS ...... , ........ " , ............ 1-7

I~l-~Iditol MACHINE IDENTIFICATION ,., GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number CD is stamped into the left side of the frame. NOTE: ________________________ __ The Vehicle identification number is used to identify your machine and may be used to register your machine with the licensing outhority in your state. Starting Serial Number: JY A55XOO * FC000101 ENGINE SERIAL NUMBER The engine serial number CD is stamped into the left side of the engine. NOTE: ________________________ __ The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. Starting Serial Number: 55X-000101 NOTE: ________________________ __ Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION I~l-~I ...I IMPORTANT INFORMATION ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. GASKETS, OIL SEALS, AND a-RINGS 1. All gaskets, seals, and a-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and a-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates CD and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened. BEARINGS AND OIL SEALS 1. Install the bearing(s) CD and oil seal(s) 00 with their manufacturer's marksor numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

1~l-~lfIitol SPECIAL TOOLS 1-3 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip CD , make sure that the sharp-edged corner @ is positioned opposite' to the thrust ® it receives. See the sectional view. @ Shaft SPECIAL TOOLS The proper special tools are necessary for com- plete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvis- ed techniques. FOR TUNE UP 1. Inductive Tachometer PIN YU-08036 This tool is needed for detecting engine rpm. 2. Inductive Timing Light PIN YM-33277 This tool is necessary for checking ignition timing. 3. Compression Gauge PIN YU-33223 This gauge is used to measure the engine compression.

o SPECIAL TOOLS 4. Fuel Level Gauge PIN YM-01312 This gauge is used to measure the fuel level in the float chamber. 5. Valve Adjusting Tool PIN YM-08035 This tool is necessary for adjusting the valve clearance. FOR ENGINE SERVICE 1. Clutch Holder PIN YM-91 042 This tool is used to hold the clutch whi:m removing or installing the clutch boss locknut. 2. Valve Spring Compressor PIN YM-04019 - CD Attachment PIN YM-4108 - @ This tool is needed to remove and install the valve assemblies. 3. Slide Hammer Set PIN YU-01083 These tools are used when removing the rocker arm shaft and camshaft. 1-4

I~IJ=~I"'I SPECIAL TOOLS F""'I b bJ 1f1[][][] /HrS 1-5 4. Flywheel Puller PIN YM-01189 This tool is used to remove the flywheel magneto. 5. Valve Guide Remover (5.0 mm) PIN YM-4097 This tool is used to remove the valve guides. 6. Valve Guide Reamer (5.0 mm) PIN YM-4099 This tool is used to rebore the new valve guide. 7. Valve Guide Installer PIN YM-4098 This tool is needed to install the valve guides properly. 8. Valve Seat Cutter Set PIN YM-91 043 This tool is needed to resurface the valve seat.

SPECIAL TOOLS 1fUJ=~I~1 9. Piston Pin Puller PIN YU-01304 This tool is used to remove the piston pin. 10. Hexagon Wrench (27 mm) PIN YM-01388 This tool is used to loosen or tighten the middle- drive-shaft-bearing retainer nut. 11. Rotor Holder PIN YM-01235 This tool is used to hold the flywheel magneto when removing or installing the flywheel magneto securing nut. 12. Sealant (Quick Gasket®) PIN A CC-11 001 -05-01 This sealant (bond) is used for crankcase mating surfaces, etc. FOR CHASSIS SERVICE 1. Hexagon Wrench (32 mm) PIN YM-01364 This tool is used to loosen and tighten the final- drive-shaft retainer nut. 1-6

1~Ef=~I0'81 SPECIAL TOOLS 1-7 2_ Ring Nut Wrench PIN YU-33975 This tool is used to loosen and tighten the steering ring nut_ 3. Crankcase Separating Tool PIN YU-01135 This tool is needed to disassemble and reassemble the shaft drive assembly. FOR ELECTRICAL COMPONENTS 1. Electro Tester PIN YU-33260 -CD This instrument is necessary for checking the ignition system components. 2. Pocket Tester PIN YU-33263 -®or PIN YU-03112 -@ This instrument is invaluable for checking the electrical system.

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Yamaha Badger 80 service manual repair 1985-1988 YFM80

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