Yamaha YFM80GV User manual

OWNER’S MANUAL
2D3-28199-20
YFM80GV
2D3-9-20 hyoshi 3/9/05 6:43 PM Page 1

2D3-9-11 hyoshi 3/9/05 6:02 PM Page 3

EBU01050
INTRODUCTION
Congratulations on your purchase of the
Yamaha YFM80G. It represents the result of
many years of Yamaha experience in the pro-
duction 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 infor-
mation. It provides information about special
techniques and skills necessary to ride your
machine.
It also includes basic maintenance and inspec-
tion 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 COMPLETELY
BEFORE OPERATING YOUR MACHINE.
MAKE SURE YOU UNDERSTAND ALL
INSTRUCTIONS.
8PAY CLOSE ATTENTION TO THE WARN-
ING AND CAUTION LABELS ON THE
MACHINE.
8THIS ATV, AND ANY OTHER ATV OVER
70cc, SHOULD NOT BE OPERATED BY A
CHILD UNDER 12 YEARS OF AGE.
2D3-9-20 ~3 3/9/05 7:56 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 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 contin-
ued 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 restric-
tor plate. Yamaha recommends that all begin-
ners 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 lim-
iter 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 completely 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.
2D3-9-20 ~3 3/9/05 7:56 PM Page 2

EBU00801
IMPORTANT MANUAL
INFORMATION
FAILURE TO FOLLOW THE WARNINGS CON-
TAINED IN THIS MANUAL CAN RESULT IN
SERIOUS INJURY OR DEATH.
Particularly important information is distin-
guished 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 pro-
cedures easier or clearer.
EBU00111
IMPORTANT NOTICE
This ATV is designed and manufactured for use
on UNPAVED surfaces only. It is unsafe to oper-
ate this ATV on any paved surface, paved
street, paved road or motorway.
Please check your local riding laws and regula-
tions before operating this ATV.
EBU001056
YFM80GV
OWNER’S MANUAL
©2005 by Yamaha Motor Co., Ltd.
1st edition, March 2005
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
2D3-9-20 ~3 3/9/05 7:56 PM Page 3

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 .........4-6
Parking brake .......................................4-6
Shift pedal ............................................4-7
Fuel tank cap........................................4-8
Fuel cock ..............................................4-8
Choke lever ..........................................4-9
Seat ......................................................4-9
Carrier ................................................4-10
PRE-OPERATION CHECKS ...................5-1
Front and rear brakes ...........................5-3
Fuel ......................................................5-4
Engine oil..............................................5-5
Final gear oil.........................................5-5
Throttle lever ........................................5-6
Tires .....................................................5-6
How to measure tire pressure ..............5-7
Tire wear limit .......................................5-8
Fittings and fasteners ...........................5-8
Switches ...............................................5-9
Battery ..................................................5-9
EBU00015
CONTENTS
1
2
3
4
5
2D3-9-20 ~3 3/9/05 7:56 PM Page 4

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...................6-5
To decelerate .......................................6-6
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.....................7-2
Ride with care and good
judgement...........................................7-2
Be careful where you ride...................7-10
Turning your ATV ...............................7-15
Climbing uphill ....................................7-16
Riding downhill ...................................7-19
Crossing a slope.................................7-20
Crossing through shallow water .........7-21
Riding over rough terrain....................7-23
Sliding and skidding ...........................7-23
What to do if ......................................7-25
What to do .........................................7-25
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
Cleaning the air filter element.............8-10
Air intake restrictor plate removal.......8-13
Carburetor adjustment........................8-14
Idle speed adjustment ........................8-14
Valve clearance adjustment ...............8-15
Cam chain adjustment........................8-15
Front and rear brake shoe
inspection .........................................8-16
6
7
8
2D3-9-20 ~3 3/9/05 7:56 PM Page 5

Front brake lever free play
adjustment........................................8-17
Rear brake lever and pedal
adjustment........................................8-19
Adjusting the clutch ...........................8-21
Cable inspection and lubrication ........8-22
Brake and shift pedal/brake
lever lubrication ................................8-22
Knuckle shaft and steering shaft
lubrication .........................................8-22
Wheel removal ...................................8-23
Wheel installation ...............................8-23
Battery ................................................8-24
Replenishing the battery fluid .............8-25
Fuse replacement...............................8-26
Troubleshooting..................................8-27
Troubleshooting chart.........................8-28
CLEANING AND STORAGE....................9-1
A. Cleaning ...........................................9-1
B. Storage ............................................9-2
SPECIFICATIONS .................................10-1
Conversion Table...................................11-1
9
10
11
2D3-9-20 ~3 3/9/05 7:56 PM Page 6

1-1
EBU00464
LOCATION OF THE WARNING
AND SPECIFICATION LABELS
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
3
4
2
56
1
2D3-9-20 ~3 3/9/05 7:56 PM Page 7

1
1-2
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.
4EM-21697-31
2
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
5FE-21568-11
2D3-9-20 ~3 3/9/05 7:56 PM Page 8

1-3
3
qWARNING
NEVER ride as a
passenger.
Passengers can cause
a loss of control,
resulting in SEVERE
INJURY or DEATH.
5FE-2151H-01
5FE-2151H-01
4
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
4EM-21696-11
2D3-9-20 ~3 3/9/05 7:56 PM Page 9

1-4
6
sit here.NEVER
3MX-24875-A0
5
5kg 11lbs
3LD-24877-A0
2D3-9-20 ~3 3/9/05 7:56 PM Page 10

2-1
EBU10421
AN ATV IS NOT A TOY AND CAN BE HAZ-
ARDOUS 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 precau-
tions.
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 instruc-
tion.
8Always follow the age recommendation:
–A child under 12 years old should never
operate an ATV with engine size greater
than 70 cc.
–A child under 16 years old should never
operate an ATV with engine size greater
than 90 cc.
.
qSAFETY INFORMATION
2
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.
8Always avoid operating an ATV on any paved
surfaces, including sidewalks, driveways,
parking lots and paved streets.
8Never operate an ATV on any paved street,
paved road or motorway.
8Watch carefully for other vehicles when oper-
ating on unpaved public streets or roads.
Make sure you know your country’s laws and
regulations before you ride on unpaved public
streets or roads.
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.
2D3-9-20 ~3 3/9/05 7:56 PM Page 11

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 dur-
ing operation.
8Always go slowly and be extra careful when
operating on unfamiliar terrain. Always be
alert to changing terrain conditions when
operating the ATV.
2-2
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.
2D3-9-20 ~3 3/9/05 7:56 PM Page 12

2-3
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.
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 proce-
dure 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.
8Never 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 slid-
ing out of control.
2D3-9-20 ~3 3/9/05 7:56 PM Page 13

2-4
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.
8Always maintain proper tire pressure as
described in this manual.
8Never modify an ATV through improper instal-
lation or use of accessories.
8Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed
and securely attached. Reduce speed and fol-
low instructions in this manual for carrying
cargo or pulling a trailer. Allow greater dis-
tance for braking.
w
8Always turn off the engine when refueling.
8Do not refuel right after the engine has
been running and is still very hot.
8Do 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.
Gasoline can catch fire. You could be
burned.
2D3-9-20 ~3 3/9/05 7:56 PM Page 14

2-5
8When 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.
8Gasoline is poisonous. If you should swal-
low some gasoline or inhale a lot of gaso-
line 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.
w
Always operate your ATV in an area with
adequate ventilation. Never start or run the
engine in a closed area. Exhaust fumes are
poisonous and may cause loss of con-
sciousness and death within a short time.
2D3-9-20 ~3 3/9/05 7:56 PM Page 15

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION
1. Carrier 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. Footboard 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.
123
4
7
0qwe
r
yt
u
5
6
8
97
2D3-9-20 ~3 3/9/05 7:56 PM Page 16

3-2
EBU00600
Identification number records
Record the key identification number, vehicle
identification number and model label informa-
tion 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:
1
6
3
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.
q
1. Key identification number
2D3-9-20 ~3 3/9/05 7:56 PM Page 17

EBU00036
Vehicle identification number
The vehicle identification number is stamped
into the frame.
NOTE:
The vehicle identification number is used to
identify your machine.
1
1. Vehicle identification number
3-3
EBU00787
Model label
The model label is affixed to the location in the
illustration. Record the information on this label
in the space provided. This information will be
needed to order spare parts from your Yamaha
dealer.
1
1. Model label
2D3-9-20 ~3 3/9/05 7:56 PM Page 18