Yamaha RAPTOR YFM80WS User manual

OWNER’S MANUAL
READ THIS MANUAL CAREFULLY!
It contains important safety information.
w
LIT-11626-17-12 5TH-28199-12
This ATV should not be ridden by anyone under 12 years of age.
YFM80WS
PRINTED IN JAPAN
2003.4-2.1x1 !
(E)
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.
9 on 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.
EBU00438
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
(For replacement manual, call 1-800-532-1558)
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
5TH-9-12_Hyoshi 4/8/03 6:48 PM Page 1

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EBU13310
INTRODUCTION
Congratulations on your purchase of the Yamaha YFM80W. 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:
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 1-800-887-2887 FOR MORE INFOR-
MATION.
8THIS ATV, AND ANY OTHER ATV OVER 70cc, SHOULD NOT BE OPERATED BY A CHILD
UNDER 12 YEARS OF AGE.
5TH-9-12-1 4/2/03 8:29 PM Page 1

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.
5TH-9-12-1 4/2/03 8:29 PM Page 2

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:
QThe Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY 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.
5TH-9-12-1 4/2/03 8:29 PM Page 3

EBU00011
IMPORTANT NOTICE
This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to oper-
ate this machine on any public street, road or highway.
This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and regula-
tions in effect at the time of manufacture.
Please check your local riding laws and regulations before operating this machine.
AFFIX DEALER
LABEL HERE
EBU13330 YFM80WS
OWNER’S MANUAL
©2003 by Yamaha Motor Corporation, U.S.A.
1st edition, April 2003
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-11626-17-12
5TH-9-12-1 4/2/03 8:29 PM Page 4

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
Rear brake pedal and 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
5TH-9-12-1 4/2/03 8:29 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
Air intake restrictor plate removal.......8-13
Spark arrester cleaning ......................8-14
Carburetor adjustment........................8-16
8
7
6
5TH-9-12-1 4/2/03 8:29 PM Page 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
5TH-9-12-1 4/2/03 8:29 PM Page 7

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 replace-
ment label is available from your Yamaha dealer.
1-1
EBU00464
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1
3
4
2
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1-2
1
12
qWARNING
UNDER
12
Operating this ATV if you are under
the age of 12 increases your chance
of severe injury or death.
NEVER permit children under age 12
to operate this ATV.
4EM-21697-31
Adult supervision required for children
under age 16.
qWARNING
Improper ATV 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 :
9 without proper training or instruction.
9 at speeds too fast for your skills or
the conditions.
9 on public roads-a collision can occur
with another vehicle.
9 with 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 it turns.
9 avoid paved surfaces-pavement may
seriously affect handling and control.
LOCATE AND READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
5FE-21568-11
4EM-21697-31
5FE-21568-11
5TH-9-12-1 4/2/03 8:29 PM Page 9

1-3
43
qWARNING
IMPROPER TIRE PRESSURE OR OVERLOADING CAN
CAUSE LOSS OF CONTROL.
LOSS OF CONTROL CAN RESULT IN SEVERE
INJURY OR DEATH.
OPERATING TIRE PRESSURE: Set with tires cold
9
Recommended : FRONT : 20 kPa, {
0.20 kgf/cm2}2.9 psi
REAR
: 20 kPa, {
0.20 kgf/cm2}2.9 psi
9 Minimum
: FRONT : 17 kPa, {
0.17 kgf/cm2}2.5 psi
REAR
: 17 kPa, {
0.17 kgf/cm2}2.5 psi
9 Never set tire pressure below minimum.
It could cause the tire to dislodge from the rim.
LOADING
9 Maximum Vehicle Load :95 kg, (209 lbs).
Includes weight of operator, cargo and accessories.
4EM-21696-11
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
5FE-2151H-01
5TH-9-12-1 4/2/03 8:29 PM Page 10

2-1
EBU13390
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 pre-
cautions.
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 dealer or call
1-800-887-2887 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 con-
tinued 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.
qSAFETY INFORMATION 2
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2-2
8Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking 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 prop-
er 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 opera-
tion.
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 cautious 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 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. 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 turning technique
described in this manual on level ground. Avoid crossing the side of a steep hill if possible.
5TH-9-12-1 4/2/03 8:29 PM Page 2-3

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, fol-
low 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, following 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 follow
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 manu-
al. 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 pressure as
described in this manual.
8Never modify an ATV through improper installation or use of accessories.
5TH-9-12-1 4/2/03 8:29 PM Page 2-4

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.
5TH-9-12-1 4/2/03 8:29 PM Page 2-5

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 refueling.
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 ATV 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.
5TH-9-12-1 4/2/03 8:29 PM Page 2-6

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 ATV in an area with
adequate ventilation.
qWARNING
5TH-9-12-1 4/2/03 8:29 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. 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 switches
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
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