2002-2007 YAMAHA RAPTOR YFM 80

HOW TO USE THIS MANUAL CONSTRACTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See "Illustrated symbols") This is a chapter with its symbol on the upper right of each page. 1 st title CD : 2nd title ® : This title appears on the upper of each page on the left of the chapter symbol. (For the chapter "Periodic inspection and adjustment" the 3rd title appears.) 3rd title ® : This is a final title. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and 'inspections. A set of particularly important procedure @ is placed between a line of asterisks" *" with each procedure preceded by " • ". IMPORT ANT FEATURES • Data and a special tool are framed in a box preceded by a relevant symbol @ . • An encircled numeral ® indicates a part name, and an encircled alphabetical letter data or an alignment mark (j) , the others being indicated by an alphabetical letter in a box ® . • A condition of a faulty component will precede an arrow symbol and the course of action re- quired the symbol ®. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identif- ying correct disassembly and assembly procedures. 1 2r-~~====~~~~~~~= 3 ~ Use Il'IecrankClIse sepa'II""II 1001 2 It] C"." ......... " •• ,-" YU-Ol1JS INSPECTION AND REPAIR • Ca.bondepOll1S US" a.ounded s(:flPe' NOTE' TakeClI,e'Ohg,dedilmllg,nglhesp.rkp'ug 11'''"H1s Do 1'101 use" shll" ,nltrumenl • ® oCyl,nde,hel4wa.,,-oe ~ --1 _________ O.,.,,,.,,',< .... "~R ...,'.,, l ~w.rp'''lIml' .. ~ 00210110110.00111'11 .... II.Ch.str •• ght.dgll I ."",.th.c"n.· ;------t-i¥-7;..::::~1iiS:-I-H • ::.:= ,:.. =~:::I'nd'f h •• d •• 1 th ..... 'pegII .. out OI,p.c.l.c.t,on. f'· lu,I..:.th.cWhnd.,,...d L-____ --=..::J ·;~:.·U:I= P~.:;O.~'f:.::::Cn:~:::.:: U.,"II.I'guf.· .. ghtUnd,nvo.n.'n NOTE·----- ROt.l.th.h ... , • ., .... lom •• lo • .,o.df. mO"'"IIOO much mit., ... "om 0f'I, s,d. ________ FR_ON_TF_OR_K ICHAS <#erG I , InspecT "Inn",fo'k!u!) .. : • OUle. 1o." luoe ~ SCralCheS Bends Damage .... Replace ~---- Do 1'101 .na.",,1 to sltllglllen I bent 'nnll' Ip'klub ... 'hllm • .,d.nll.·" ... ,y ..... ken • Fork ~p"ng he"'"n!ll~ .. [§] ~. ~ / ----------- fork.pring" •• I_"g,h ~" 418511'111'11165,,,, Min,mumh •• '·"I1'" '...... '------'.'O_mm_''''--''_.,_-----' 6 9 7 8

CD ® I~EF~I~I ISPECI ~~I @ ill Ik~Jlfil ENG \. ® ® ICOOll ~I ICARBI f·1 (j) ® IOR1vl-IG-1 ICHASI~I ® @ I HECI iii I I~~~~I? I (j]) ~ @ ~ @ ~ @ ~ @ ~ @ § @ [mJ @ , CLT) @ 1 ® 1 @ 1 - m e m @ @ ® ~ ~ ~ ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to @ are designed as thumb tabs to indicate the chapter's number and content. CD General information ® Specifications @ Periodic inspection and adjustment ill Engine ® Cooling system ® Carburetion (j) Drive train ® Chassis ® Electrical @ Troubleshooting Illustrated symbols (j]) to @ are used to identify the specifications appearing in the text. (j]) Filling fluid @ Lubricant @ Special tool @ Tightening @ Wear limit, clearance @ Engine speed @o.,V,A Illustrated symbols @ to ® in the exploded diagram indicate grade of lubricant and loca- tion of lubrication point. @ Apply locking agent (Loctite@) @ Apply engine oil ® Apply gear oil @ Apply molybdenum disulfide oil @ Apply wheel bearing grease @ Apply lightweight lithium-soap base grease ® Apply molybdenum disulfide grease

INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING .-. ~ GEN INFO SPEC II!a t---- INSP ADJ ENG • t---- CARB CHAS ELEC ? • t---- TRBL SHTG

CONTENTS CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFiCATION ......................................................................... 1-1 VEHICLE IDENTIFICATION NUMBER (For AUS) ................................... 1-1 0". t---- GEN INFO ENGINE SERIAL NUMBER (For USA, OCE and EUR) .......................... 1-1 I---~-=-- ENGINE SERIAL NUMBER ..................................................................... 1-1 IMPORTANT INFORMATION ....................................................................... 1-2 SPEC PREPARATION FOR REMOVAL ............................................................. 1-2· t---- ALL REPLACEMENT PARTS ................................................................... 1-2 ~ GASKETS, OIL SEALS, AND O-RINGS .................................................. 1-2 ~ LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-3 t--IN-S=P- BEARINGS AND OIL SEALS ................................................................... 1-3 ADJ CIRCLIPS .................................................................................................. 1-3 SPECIAL TOOLS ........................................................................................... 1-4 •• FOR TUNE-UP ......................................................................................... 1-4 t------..; FOR ENGINE SERVICE ............................................................................ 1-5 ENG FOR CHASSIS SERVICE .......................................................................... 1-6 t------ FOR ELECTRICAL COMPONENTS ......................................................... 1-7 CHAPTER 2. CARB SPECIFICATIONS GENERAL SPECIFICATIONS ........................................................................ 2-1 MAINTENANCE SPECIFICATIONS .............................................................. 2-3 CHAS ENGINE .................................................................................................... 2-3 t---- CHASSIS .................................................................................................. 2-9 iii ELECTRICAL .......................................................................................... 2-11 GENERAL TORQUE SPECIFICATIONS ...................................................... 2-13 LUBRICATION POINTS AND LUBRICANT TYPE ...................................... 2-14 LUBRICATION DIAGRAM .......................................................................... 2-15 CABLE ROUTING ....................................................................................... 2-17 ELEC ? • 1---- TRBL SHTG

CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ........................................................................................... 3-1 PERIODIC MAINTENANCE/LUBRICATION ................................................ 3-1 FENDERS AND FUEL TANK ........................................................................ 3-2 FRONT FENDER ...................................................................................... 3-2 REAR FENDER AND FUEL TANK ................................................................. 3-2 ENGINE .......................................................................................................... 3-4 CAM CHAIN TENSION ADJUSTMENT .................................................. 3-4 VALVE CLEARANCE ADJUSTMENT ..................................................... 3-5 IDLE SPEED ADJUSTMENT ................................................................... 3-7 THROTTLE LEVER ADJUSTMENT ......................................................... 3-7 SPEED LIMITER ADJUSTMENT ............................................................. 3-8 SPARK PLUG INSPECTION .................................................................... 3-9 IGNITION TIMING CHECK .................................................................... 3-10 COMPRESSION PRESSURE MEASUREMENT ................................... 3-11 AIR FILTER CLEANING ......................................................................... 3-12 ENGINE OIL LEVEL INSPECTION ......................................................... 3-13 ENGINE OIL REPLACEMENT ................................................................ 3-14 OIL STRAINER CLEANING ................................................................... 3-15 CLUTCH ADJUSTMENT ....................................................................... 3-16 CHASSIS ..................................................................................................... 3-18 FRONT BRAKE ADJUSTMENT ............................................................ 3-18 REAR BRAKE LEVER AND PEDAL ADJUSTMENT ............................. 3-18 BRAKE LINING INSPECTION ................................................................ 3-20 FINAL GEAR OIL LEVEL INSPECTION ................................................. 3-20 FINAL GEAR OIL REPLACEMENT ........................................................ 3-21 DRIVE SHAFT DUST BOOT INSPECTION ........................................... 3-22 STEERING SYSTEM INSPECTION ....................................................... 3-22 TOE-IN ADJUSTMENT ......................................................................... 3-23 TIRE INSPECTION .................................................................................. 3-24 WHEEL INSPECTION ............................................................................ 3-26 WHEEL BEARINGS CHECK ................................................................... 3-27 KNUCKLE SHAFT AND STEERING SHAFT LUBRICATION ................ 3-27 ELECTRICAL ................................................................................................ 3-28 BATTERY INSPECTION ..................................................... ;................... 3-28 FUSE INSPECTION ................................................................................ 3-30

CHAPTER 4. ENGINE OVERHAUL ENGINE REMOVAL ...................................................................................... 4-1 ._. ENGINE OIL ............................................................................................. 4-1 1-- ....... --- SEAT AND REAR FENDER ...................................................................... 4-1 ~~~ MUFFLER ................................................................................................. 4-1 CARBURETOR ......................................................................................... 4-1 I---~~-- STARTER MOTOR ................................................................................... 4-2 LEADS AND HOSE .................................................................................. 4-2 1------.; CRANKCASE COVER (LEFT) ................................................................... 4-2 SPEC ENGINE REMOVAL ................................................................................. 4-2 1-- __ DISASSEMBLY ............................................................................................. 4-3 fi INTAKE MANIFOLD ................................................................................ 4-3 I--IN-S=--P- CYLINDER HEAD AND CYLINDER ......................................................... 4-3 ADJ PISTON .................................................................................................... 4-4 1------- CLUTCH ................................................................................................... 4-5 ...... SHIFT SHAFT ........................................................................................... 4-7 .., DRIVE GEAR AND STARTER CLUTCH .................................................. 4-7 1------.; Ol~ PUMP AND OIL STRAINER .............................................................. 4-8 ENG CDI MAGNETO ........................................................................................ 4-9 1------ MIDDLE GEAR ......................................................................................... 4-9 CRANKCASE .......................................................................................... 4-11 TRANSMISSION .................................................................................... 4-12 CRANKSHAFT ....................................................................................... 4-12 ROCKER ARM AND CAMSHAFT .......................................................... 4-12 VALVE .................................................................................................... 4-13 INSPECTION AND REPAIR ......................................................................... 4-14 CYLINDER HEAD ................................................................................... 4-14 VALVE AND VALVE GUIDE .................................................................. 4-15 VALVE SEAT .......................................................................................... 4-16 VALVE SPRING ...................................................................................... 4-20 CAMSHAFT ............................................................................................ 4-20 ROCKER ARM AND ROCKER ARM SHAFT ......................................... 4-21 CAM CHAIN AND CAM SPROCKET ..................................................... 4-21 CAM CHAIN GUIDE .~ ............................................................................. 4-22 CAM CHAIN TENSIONER ..................................................................... 4-23 CYLINDER AND PISTON ....................................................................... 4-23 PISTON RING ........................................................................................ 4-25 PISTON PIN ........................................................................................... 4-26 CLUTCH ................................................................................................. 4-26 OIL PUMP .............................................................................................. 4-29 TRANSMISSION AND SHIFTER ........................................................... 4-29 SHIFT SHAFT AND STOPPER LEVER .................................................. 4-31 PRIMARY DRIVE .................................................................................... 4-31 STARTER DRIVE .................................................................................... 4-31 CRANKSHAFT ....................................................................................... 4-32 MIDDLE GEAR ....................................................................................... 4-33 • 1---- CARB CHAS ELEC ? • 1---- TRBL SHTG

ENGINE ASSEMBLY AND ADJUSTMENT ............................................... 4-34 VALVE .................................................................................................... 4-35 ROCKER ARM AND CAMSHAFT .......................................................... 4-35 CRANKSHAFT ....................................................................................... 4-37 TRANSMISSION .................................................................................... 4-37 CRANKCASE .......................................................................................... 4-38 MIDDLE GEAR ....................................................................................... 4-39 COl MAGNETO ...................................................................................... 4-41 OIL PUMP AND OIL STRAINER ............................................................ 4-42 DRIVE GEAR AND STARTER CLUTCH ................................................ 4-42 SHIFT SHAFT .............................................................................................. 4-43 CLUTCH ................................................................................................. 4-45 PISTON .................................................................................................. 4-50 CYLINDER AND CYLINDER HEAD .......................................................4-50 INTAKE MANIFOLD .............................................................................. 4-54 REMOUNTING ENGINE ........................................................................ 4-54 CHAPTER 5. CARBURETION CARBURETOR ............................................................................................... 5-1 REMOVAL ................................................................................................ 5-2 DISASSEMBLY ........................................................................................ 5-2 INSPECTION ............................................................................................ 5-3 ASSEMBLY .............................................................................................. 5-4 INSTALLATION ....................................................................................... 5-5 FUEL LEVEL ADJUSTMENT ................................................................... 5-6 CHAPTER 6. CHASSIS FRONT WHEEL AND FRONT BRAKE .......................................................... 6-1 REMOVAL ................................................................................................ 6-2 INSPECTION ............................................................................................ 6-3 INSTALLATION ....................................................................................... 6-5 REAR WHEEL ................................................................................................ 6-7 REMOVAL ................................................................................................ 6-8 INSPECTION ............................................................................................ 6-8 INSTALLATION ....................................................................................... 6-9 REAR BRAKE .............................................................................................. 6-1 0 REMOVAL .............................................................................................. 6-11 INSPECTION .......................................................................................... 6-11 INSTALLATION ...................................................................................... 6-12

STEERING SYSTEM .................................................................................. 6-14 REMOVAL ..............................................................................................6-15 INSPECTION .......................................................................................... 6-16 INSTALLATION ..................................................................................... 6-17 FRONT SHOCK ABSORBER AND LOWER ARM ...................................... 6-21 REMOVAL .............................................................................................. 6-22 INSPECTION .......................................................................................... 6-23 INSTALLATION ..................................................................................... 6-23 REAR SHOCK ABSORBER AND SWINGARM .......................................... 6-25 REMOVAL .............................................................................................. 6-26 INSPECTION .......................................................................................... 6-27 INSTALLATION ..................................................................................... 6-28 SHAFT DRIVE ............................................................................................. 6-30 REMOVAL .............................................................................................. 6-31 INSPECTION .......................................................................................... 6-32 INSTALLATION ..................................................................................... 6-33 CHAPTER 7. ELECTRICAL YFM80(D) WIRING DIAGRAM ...................................................................... 7-1 COLOR CODE .......................................................................................... 7-2 ELECTRICAL COMPONENTS ....................................................................... 7-3 CHECKING OF SWITCHES .......................................................................... 7-4 SWITCH CONNECTION AS SHOWN IN MANUAL ............................... 7-4 CHECKING SWITCH FOR TERMINAL CONNECTION ........................... 7-5 CHECKING OF BULBS (FOR HEAD LIGHT, TAIL/BRAKE LIGHT, FLASHER LIGHT, METER LIGHT, ETC.) ..................................................................... 7-8 CHECKING BULB CONDITION ............................................................... 7-8 IGNITION SYSTEM .................................................................................... 7-10 CIRCUIT DIAGRAM ............................................................................... 7-10 TROUBLESHOOTING ............................................................................ 7-11 ELECTRICAL STARTING SYSTEM ............................................................. 7-16 CIRCUIT DIAGRAM ............................................................................... 7-16 TROUBLESHOOTING .............. ;............................................................. 7-17 STARTER MOTOR .................................................................................. 7-22 CHARGING SYSTEM ................................................................................. 7-26 CIRCUIT DIAGRAM ............................................................................... 7-26 TROUBLESHOOTING ............................................................................ 7-27 0". t----- GEN INFO SPEC pjJ t---~- INSP ADJ •• t----- ENG • t----- CARB CHAS ELEC ? • t----- TRBL SHTG

SIGNAL SYSTEM ....................................................................................... 7-29 CIRCUIT DIAGRAM ............................................................................... 7-29 TROUBLESHOOTING ............................................................................ 7-30 SIGNAL SYSTEM CHECK ..................................................................... 7-32 CHAPTER 8. TROUBLESHOOTING STARTING FAILURE/HARD STARTING ...................................................... 8-1 FUEL SYSTEM ......................................................................................... 8-1 ELECTRICAL SYSTEM ............................................................................ 8-1 COMPRESSION SYSTEM ....................................................................... 8-2 POOR IDLE SPEED PERFORMANCE ........................................................... 8-2 POOR IDLE SPEED PERFORMANCE ...................................................... 8-2 POOR MEDIUM AND HIGH SPEED PERFORMANCE ................................ 8-2 POOR MEDIUM AND HIGH SPEED PERFORMANCE ........................... 8-2 FAUL TV DRIVE TRAIN ................................................................................. 8-3 FAUL TV GEAR SHIFTING ............................................................................ 8-3 HARD SHIFTING ...................................................................................... 8-3 CHANGE PEDAL DOES NOT MOVE ...................................................... 8-3 JUMP-OUT GEAR ................................................................................... 8-4 CLUTCH SLIPPING/DRAGGING .................................................................. 8-4 CLUTCH SLIPPING .................................................................................. 8-4 CLUTCH DRAGGING ............................................................................... 8-4 OVERHEATING ............................................................................................. 8-4 OVERHEATING ........................................................................................ 8-4 FAUL TV BRAKE ............................................................................................ 8-5 POOR BRAKING EFFECT ........................................................................ 8-5 SHOCK ABSORBER MALFUNCTION .......................................................... 8-5 MALFUNCTION ....................................................................................... 8-5 INSTABLE HANDLING ................................................................................. 8-5 INSTABLE HANDLING ............................................................................ 8-5 YFM80(D) WIRING DIAGRAM ...................................................................... 8-6

MACHINE IDENTIFICATION I~EF~I"'I 1-1 GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER (For AUS} D The vehicle identification number CD is stamped into the left side of the frame. Starting serial number: JV44EMWO*NA000101 (For AUS) NOTE: ____________________ __ The vehicle identification number is used to identify your machine and may be used to register your machine with the licensing in your state. FRAME SERIAL NUMBER (For USA, OCE and EUR) The frame serial number CD is stamped into the left side of the frame. Starting serial number: 4EM-000101 (For USA and OCE) 4EM-016101 (For EUR) NOTE: ____________________ __ The firstthree digits ofthese numbers are for model identifications; the remaining digits are the unit production number. ENGINE SERIAL NUMBER The engine serial number CD is stamped into the left of the engine. Starting serial number: 4EM-000101 (For USA and OCE) 4EM-016101 (For EUR) NOTE: ____________________ __ • The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. • Designs and specifications are subject to change without notice.

2002-2007 YAMAHA RAPTOR YFM 80

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