Yamaha Badger YFM80M User manual

w This ATV should not be ridden by anyone under 12 years of age.
OWNER’S MANUAL
4EM-28199-1A
YFM80M(C)
READ THIS MANUAL CAREFULLY!
It contains important safety information.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN LIT-11626-13-28
99·8–0.2×1 !(E)
YAMAHA MOTOR CO.,LTD.
Improper ATV use can result in SEVERE INJURY or DEATH.
qWARNING
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate:
9without proper training or instruction.
9at speeds too fast for your skills or the
conditions.
9on public roads - a collision can occur
with another vehicle.
9with a passenger - passengers affect
balance and steering and increase risk
of losing control.
ALWAYS:
9use proper riding techniques to avoid
vehicle overturns on hills and rough
terrain and in turns.
9avoid paved surfaces - pavement may
seriously affect handling and control.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
(For replacement manual, call 1-800-532-1558)
EBU00438

EBU00004
INTRODUCTION
Congratulations on your purchase of the Yamaha YFM80. 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 crafts-
manship 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 techniques and skills necessary to ride your machine. It also includes basic mainte-
nance and inspection procedures. If you have any questions regarding the operation or mainte-
nance of your machine, please consult a Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
8READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COM-
PLETELY BEFORE OPERATING YOUR MACHINE. MAKE SURE YOU UNDERSTAND ALL
INSTRUCTIONS.
8PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MACHINE.
8NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING
IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-447-4700 FOR MORE
INFORMATION.
8THIS ATV, AND ANY OTHER ATV OVER 70cc, SHOULD NOT BE OPERATED BY A CHILD
UNDER 12 YEARS OF AGE.
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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 judgement. 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.
If your child is a beginner or is inexperienced, he or she should take a training course. See the
previous page for information about the free training available to purchasers of new ATVs.
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EBU00010
IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERI-
OUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
QThe Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE-
TY IS INVOLVED!
wFailure 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.
cCA 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.
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EBU00011
IMPORTANT NOTICE
This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to
operate this machine on any public street, road or highway.
This machine 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 machine.
AFFIX DEALER
LABEL HERE
EBU00012 YFM80M(C)
OWNER’S MANUAL
©1999 by Yamaha Motor Corporation,
U.S.A.
1st Edition, August 1999
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-11626-13-28
4EM91A_a 9/28/99 2:49 PM Page 4

LOCATION OF THE WARNING AND
SPECIFICATION LABELS........................1-1
SAFETY INFORMATION.........................2-1
DESCRIPTION AND MACHINE
IDENTIFICATION.....................................3-1
Identification numbers record ...........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
Rear brake pedal and lever ................4-5
Parking brake ......................................4-6
Shift pedal ...........................................4-7
Fuel tank cap .......................................4-8
Fuel cock..............................................4-8
Choke lever .........................................4-9
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
4EM91A_a 9/28/99 2:49 PM Page 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
Spark arrester cleaning ....................8-13
Carburetor adjustment.....................8-15
Idle speed adjustment......................8-15
8
7
6
4EM91A_a 9/28/99 2:49 PM Page 6

Valve clearance adjustment.............8-16
Cam chain adjustment .....................8-16
Front and rear brake shoe
inspection..........................................8-16
Front brake lever free play
adjustment ........................................8-17
Rear brake lever and pedal
adjustment ........................................8-19
Clutch adjustment ............................8-22
Cable inspection and lubrication.....8-23
Brake and shift pedals/brake lever
lubrication .........................................8-23
Knuckle shaft and stering shaft
lubrication .........................................8-24
Wheel removal..................................8-24
Wheel installation.............................8-24
Battery ...............................................8-25
Replenishing the battery fluid .........8-27
Fuse replacement .............................8-28
Troubleshooting ...............................8-29
Troubleshooting chart......................8-30
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
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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
q
w
t
r
e
4EM91A_a 9/28/99 2:49 PM Page 8

1-2
1
1 3
2
4EM-21697-31
4EM-21578-A0
5FE-21568-01
4EM91A_a 9/28/99 2:50 PM Page 9

1-3
4 5 qWARNING
NEVER ride as a
passenger.
Passengers can cause
a loss of control,
resulting in SEVERE
INJURY or DEATH.
5FE-2151H-01
4EM-21696-11
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2-1
EBU00029
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently
from other vehicles including motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail
to take proper precautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
8Read this manual and all labels carefully and follow the operating procedures described.
8Never operate an ATV without proper training or instruction. Take a Training Course.
Beginners should receive training from a certified instructor. Contact an authorized ATV deal-
er or call 1-800-447-4700 to find out about the training courses nearest you.
8Always follow the age recommendation:
- A child under 12 years old should never operate an ATV with engine size greater than 70cc.
- A child under 16 years old should never operate an ATV with engine size greater than 90cc.
8Never 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 or she does not have the abilities to operate it
safely.
8Never carry a passenger on an ATV.
q SAFETY INFORMATION 2
4EM91A_a 9/28/99 2:50 PM Page 2-1

2-2
8Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, park-
ing lots and streets.
8Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
8Never operate an ATV without wearing an approved motorcycle helmet that fits properly.
You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved
shirt or jacket, and long pants.
8Never consume alcohol or drugs before or while operating this ATV.
8Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is
proper for the terrain, visibility and operating conditions, and your experience.
8Never attempt wheelies, jumps, or other stunts.
8Always inspect your ATV each time you use it to make sure it is in safe operating
condition.Always follow the inspection and maintenance procedures and schedules
described in this manual.
8Always keep both hands on the handlebars and both feet on the footrests of the ATV during
operation.
8Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert
to changing terrain conditions when operating the ATV.
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2-3
8Never operate on excessively rough, slippery or loose terrain until you have learned and
practiced the skills necessary to control the ATV on such terrain. Always be especially cau-
tious on these kinds of terrain.
8Always follow proper procedures for turning as described in this manual. Practice turning at
low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
8Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller
hills before attempting larger hills.
8Always 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
surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear
changes. Never go over the top of a hill at high speed.
8Always follow proper procedures for going down hills and for braking on hills as described in
this manual. Check the terrain carefully before you start down any hill. Shift your weight
backward. Never go down a hill at high speed. Avoid going down a hill at an angle that
would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.
8Always follow proper procedures for crossing the side of a hill as described in this manual.
Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of
the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turn-
ing technique described in this manual on level ground. Avoid crossing the side of a steep
hill if possible.
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2-4
8Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid
stalling, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll
backwards, follow the special procedure for braking described in this manual. Dismount on
the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, fol-
lowing the procedure described in this manual.
8Always check for obstacles before operating in a new area.
Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always fol-
low proper procedures when operating over obstacles as described in this manual.
8Always be careful when skidding or sliding. Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such
as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out
of control.
8Never 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.
8Always use the size and type tires specified in this manual.Always maintain proper tire pres-
sure as described in this manual.
8Never modify an ATV through improper installation or use of accessories.
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2-5
8Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety
Commission at 1-800-638-2772, or the ATV Distributor's Safety Hotline at 1-800-852-5344.
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2-6
POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could be
burned.
HOW TO AVOID THE HAZARD
Always turn off the engine when refuel-
ing.
Do not refuel right after the engine has
been running and is still very hot.
Do not spill gasoline on the engine or
exhaust pipe/muffler when refueling.
Never refuel while smoking, or while in
the vicinity of sparks, open flames, or
other sources of ignition such as the pilot
lights of water heaters and clothes dryers.
qWARNING When transporting the machine in another
vehicle, be sure it is kept upright and that
the fuel cock is in the “OFF” position.
Otherwise, fuel may leak out of the carbu-
retor or fuel tank.
WHAT CAN HAPPEN
Gasoline is poisonous and can cause
injuries.
HOW TO AVOID THE HAZARD
If you should swallow some gasoline or
inhale a lot of gasoline vapor, or get some
gasoline in your eyes, see your doctor
immediately.
If gasoline spills on your skin, wash with
soap and water. If gasoline spills on your
clothing, change your clothes.
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2-7
POTENTIAL HAZARD
Starting or running the engine in a closed
area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
HOW TO AVOID THE HAZARD
Always operate your machine in an area
with adequate ventilation.
qWARNING
4EM91A_a 9/28/99 2:50 PM Page 2-7

3-1
1. Spark arrester 10. Rear brake lever
2. Seat 11. Parking brake
3. Front cover 12. Neutral indicator light
4. Rear brake pedal 13. Front brake lever
5. Fuel cock 14. Throttle lever
6. Rear wheel 15. Main switch
7. Footrest 16. Fuel tank cap
8. Shift pedal 17. Handlebar switch
9. Front wheel
NOTE:
The machine you have purchased may differ
slightly from those shown in the figures of
this manual.
EBU00032
DESCRIPTION AND MACHINE IDENTIFICATION
w e
r
q
u
o i uy
t
!0 !1 !2 !3
!4!5
!6
!7
4EM91A_a 9/28/99 2:50 PM Page 2-8

EBU00033
Identification numbers record
Record the key identification number, vehicle
identification number and model label infor-
mation in the spaces provided for assistance
when ordering spare parts from a Yamaha
dealer or for reference in case the vehicle is
stolen.
1. KEY IDENTIFICATION NUMBER:
2. VEHICLE IDENTIFICATION NUMBER:
3. MODEL LABEL INFORMATION:
EBU00035
Key identification number
The key identification number is stamped on
the key as shown in the following illustration.
This number can be used for ordering a new
key.
1. Key identification number
3-2
1
6
q
3
4EM91A_a 9/28/99 2:50 PM Page 2-9