03-08 Yamaha Raptor 80 Service Manual YFM80 and Owners Manual YFM80 ATV Workshop Shop Repair Manual

OWNER’S MANUAL READ THIS MANUAL CAREFULLY! It contains important safety information. w LIT-11626-18-07 5TH-28199-13 This ATV should not be ridden by anyone under 12 years of age. YFM80RT

EBU13310 INTRODUCTION Congratulations on your purchase of the Yamaha YFM80R. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this machine. This manual includes important safety information. It provides information about special tech- niques and skills necessary to ride your machine. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your machine, please consult a Yamaha dealer. AN IMPORTANT SAFETY MESSAGE: 8 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COM- PLETELY BEFORE OPERATING YOUR MACHINE. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. 8 PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MACHINE. 8 NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFOR- MATION. 8 THIS ATV, AND ANY OTHER ATV OVER 70cc, SHOULD NOT BE OPERATED BY A CHILD UNDER 12 YEARS OF AGE.

AN IMPORTANT NOTE TO PARENTS: This ATV is not a toy. Before you let your child ride this ATV, you should understand the instructions and warnings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ in skills, physical abilities and judgment. Some children may not be able to operate an ATV safely. Parents should supervise their child’s use of the ATV at all times. Parents should permit continued use only if they determine that the child has the ability to operate the ATV safely. Your ATV was delivered with an adjustable speed limiter and also with an air intake restrictor plate. Yamaha recommends that all beginners start off with the speed limiter screw turned in and the air intake restrictor plate installed to limit the amount of speed available 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. Parents 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 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 stages as you did before. If your child is a beginner or is inexperienced, he or she should take a training course. See the previ- ous page for information about the free training available to purchasers of new ATVs.

EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! w Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine. cC A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer.

EBU15000 IMPORTANT NOTICE This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD 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. AFFIX DEALER LABEL HERE EBU13330 YFM80RT OWNER’S MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st edition, March 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan. P/N LIT-11626-18-07

LOCATION OF THE WARNING AND SPECIFICATION LABELS .......................1-1 SAFETY INFORMATION .........................2-1 DESCRIPTION AND MACHINE IDENTIFICATION.....................................3-1 Identification number records ...............3-2 Key identification number .....................3-2 Vehicle identification number ...............3-3 Model label ...........................................3-3 CONTROL FUNCTIONS..........................4-1 Main switch ...........................................4-1 Indicator lights ......................................4-1 Handlebar switches ..............................4-2 Throttle lever ........................................4-3 Speed limiter ........................................4-4 Front brake lever ..................................4-5 Brake pedal and rear brake lever .........4-5 Parking brake .......................................4-6 Shift pedal ............................................4-8 Fuel tank cap ........................................4-8 Fuel cock ..............................................4-9 Choke lever ........................................4-10 Seat ....................................................4-10 PRE-OPERATION CHECKS....................5-1 Front and rear brakes ...........................5-2 Fuel ......................................................5-3 Engine oil .............................................5-5 Final gear oil .........................................5-5 Throttle lever ........................................5-6 Fittings and fasteners ...........................5-6 EBU00014 w Indicates a potential hazard that could result in serious injury or death. CONTENTS 1 2 3 4 5

Switches ...............................................5-6 Battery ..................................................5-6 Tires .....................................................5-7 How to measure tire pressure ..............5-8 Tire wear limit .......................................5-9 OPERATION ............................................6-1 Starting a cold engine ...........................6-1 Starting a warm engine ........................6-3 Warming up ..........................................6-3 Shifting .................................................6-4 To start out and accelerate...................6-4 To decelerate .......................................6-5 Engine break-in ....................................6-6 Parking .................................................6-7 Parking on a slope................................6-8 Accessories and loading ......................6-9 Riding Your ATV ......................................7-1 Getting to know your ATV.....................7-3 Ride with care and good judgement ...........................................7-4 Be careful where you ride...................7-16 Turning your ATV ...............................7-23 Climbing uphill ....................................7-25 Riding downhill ...................................7-30 Crossing a slope.................................7-32 Crossing through shallow water .........7-34 Riding over rough terrain ....................7-36 Sliding and skidding ...........................7-38 What to do if .......................................7-40 What to do ..........................................7-40 PERIODIC MAINTENANCE AND ADJUSTMENT .........................................8-1 Owner’s manual and tool kit .................8-1 Periodic maintenance/lubrication .........8-3 Engine oil ..............................................8-5 Final gear oil .........................................8-7 Spark plug inspection ...........................8-9 Air filter cleaning .................................8-10 Air intake restrictor plate removal .......8-13 Spark arrester cleaning ......................8-14 Carburetor adjustment ........................8-16 8 7 6

Idle speed adjustment ........................8-16 Valve clearance adjustment ...............8-17 Cam chain adjustment ........................8-17 Front and rear brake shoe inspection .........................................8-17 Front brake lever free play adjustment ........................................8-18 Rear brake lever and pedal adjustment ........................................8-20 Clutch adjustment ...............................8-23 Cable inspection and lubrication ........8-24 Brake and shift pedal/brake lever lubrication .........................................8-24 Knuckle shaft and steering shaft lubrication .........................................8-25 Wheel removal ...................................8-25 Wheel installation ...............................8-25 Battery ................................................8-26 Replenishing the battery fluid .............8-28 Fuse replacement ...............................8-29 Troubleshooting..................................8-30 Troubleshooting chart .........................8-31 CLEANING AND STORAGE ....................9-1 A. Cleaning ...........................................9-1 B. Storage ............................................9-3 SPECIFICATIONS .................................10-1 NOISE REGULATION ............................11-1 MAINTENANCE RECORD.....................12-1 ATV LIMITED WARRANTY....................13-1 YAMAHA EXTENDED SERVICE (Y.E.S.) ...................................................14-1 9 10 11 12 13 14

Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 1-1 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 3 4 2

03-08 Yamaha Raptor 80 Service Manual YFM80 and Owners Manual YFM80 ATV Workshop Shop Repair Manual

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