Yamaha RAPTOR 80 Manual

READ THIS MANUAL CAREFULLY!

It contains important safety information.

OWNER’S MANUAL

YFM80WR

w This ATV should not be ridden by anyone under 12 years of age.

LIT-11626-16-07 5TH-28199-11

EBU01031

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 techniques 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 COMPLETELY 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 INFORMATION.

8THIS 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 this 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 previous 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 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.

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.

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.

EBU00981				YFM80WR
				OWNER’S MANUAL
				©2002 by Yamaha Motor Corporation,
	AFFIX DEALER			U.S.A.
	LABEL HERE			1st edition, April 2002
				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-11626-16-07

EBU00014

w

Indicates a potential hazard that could result in serious injury or death.

CONTENTS

1

2

3

4

LOCATION OF THE WARNING AND			Speed limiter ........................................	4-4
SPECIFICATION LABELS .......................	1-1		Front brake lever ..................................	4-5
			Rear brake pedal and lever ..................	4-5
SAFETY INFORMATION .........................	2-1		Parking brake .......................................	4-6
			Shift pedal ............................................	4-8
DESCRIPTION AND MACHINE			Fuel tank cap........................................	4-8
IDENTIFICATION.....................................	3-1		Fuel cock ..............................................	4-9
Identification number records ...............	3-2		Choke lever ........................................	4-10
Key identification number .....................	3-2		Seat ....................................................	4-10
Vehicle identification number ...............	3-3
Model label	3-3		PRE-OPERATION CHECKS	5-1
		5
			Front and rear brakes ...........................	5-2
CONTROL FUNCTIONS..........................	4-1		Fuel ......................................................	5-3
Main switch...........................................	4-1		Engine oil.............................................	5-5
Indicator lights ......................................	4-1		Final gear oil.........................................	5-5
Handlebar switches ..............................	4-2		Throttle lever ........................................	5-6
Throttle lever ........................................	4-3		Fittings and fasteners ...........................	5-6

6

7

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

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

9	....................CLEANING AND STORAGE	9-1
	...........................................A. Cleaning	9-1
	B. Storage ............................................	9-3
10	.................................SPECIFICATIONS	10-1
11	............................NOISE REGULATION	11-1
12	.....................MAINTENANCE RECORD	12-1
13	....................ATV LIMITED WARRANTY	13-1
	YAMAHA EXTENDED SERVICE
14
	(Y.E.S.)...................................................	14-1

EBU00464

1

2

3

4

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.

1-1

1

q WARNING

2	q WARNING	1

Improper ATV use can result in SEVERE

INJURY or DEATH.

Operating this ATV if you are under the age of 12 increases your chance of severe injury or death.

Adult supervision required for children under age 16.

NEVER permit children under age 12 to operate this ATV.

ALWAYS USE	NEVER USE	NEVER CARRY	NEVER USE
AN APPROVED	ON PUBLIC	PASSENGERS	WITH DRUGS
HELMET AND	ROADS		OR ALCOHOL
PROTECTIVE
GEAR

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.

4EM-21697-31-31 ALWAYS:

9use proper riding techniques to avoid vehicle overturns on hills and rough terrain and it turns.

9avoid 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

1-2

3	q WARNING	4	q WARNING

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

9Recommended : FRONT : 20		kPa, {0.20	kgf/cm2	}	2.9 psi
	REAR : 20	kPa, {0.20	kgf/cm2	}	2.9 psi
9Minimum	: FRONT : 17	kPa, {0.17	kgf/cm2	}	2.5 psi
	REAR : 17	kPa, {0.17	kgf/cm2	}	2.5 psi
9Never set tire pressure below minimum.
It could cause	the tire to dislodge from the rim.

NEVER ride as a passenger.

Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.

LOADING			5FE5FE-2151H-2151H-01-01
9Maximum Vehicle Load : 95 kg, (209 lbs).
Includes weight of operator, cargo and accessories.
	4EM4EM-21696696- -11-11

1-3

EBU00928

q SAFETY INFORMATION	2

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 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 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.

2-1

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 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.

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.

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.

2-3

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, 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 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 pressure as described in this manual.

8Never modify an ATV through improper installation or use of accessories.

2-4

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.

2-5

qWARNING

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.

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 carburetor 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.

2-6

qWARNING

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.

2-7

EBU00032

DESCRIPTION AND MACHINE IDENTIFICATION

q w

e

t

		u r			o i u y
!0	!1	!2	1.	Spark arrester	10.	Rear brake lever
			!3		11.	Parking brake
			2.	Seat
			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
	!7	!6 !5 !4	manual.
			3-1

EBU00600

Identification number records

Record the key identification number, vehicle identification number and model label information 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

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.	3

q

1. Key identification number

3-2

EBU00036

Vehicle identification number

The vehicle identification number is stamped into the frame.

q

1. Vehicle identification number

NOTE:

The vehicle identification number is used to identify your machine.

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

3-3

EBU00039

EBU00043

CONTROL FUNCTIONS w

Indicates a potential hazard that could result in serious injury or death.

EBU00042

Main switch

Functions of the respective switch positions are as follows:

ON:

The engine can be started only at this position. OFF:

All electrical circuits are switched off. The key can be removed in this position.

OFF ON

4-1

Indicator lights

EBU00603

Neutral indicator light “N”

This indicator light comes on when the transmis-

4

sion is in neutral.

	q
1.	Neutral indicator light “N”

EBU00053

Handlebar switches

q

w

1.Engine stop switch “ENG. STOP”

2.Start switch “START”

EBU00054

Engine stop switch “ENG. STOP”

Make sure that the engine stop switch is in the “RUN” position. The engine stop switch controls ignition and can be used at all times to stop the engine, especially in an emergency. The engine will not start or run when the engine stop switch is turned to “OFF”.

EBU00056

Start switch “START”

The starter motor cranks the engine when this switch is pushed.

cC

See starting instructions prior to starting engine (see page 6-1 for details).

NOTE:

If the starter switch is pushed with the main switch “ON” and the engine stop switch “OFF”, the starter motor will be activated but the engine will not start. To start the engine, be sure to position the engine stop switch at “RUN”.

4-2

EBU00062

Throttle lever

Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.

q

1. Throttle lever

Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released.

qWARNING

POTENTIAL HAZARD

Malfunction of throttle.

WHAT CAN HAPPEN

The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident.

HOW TO AVOID THE HAZARD

Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can’t find or solve the problem yourself.

4-3

EBU01032

Speed limiter

The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV.

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 completely back in again; adjust it out in stages as you did before.

Adjusting for maximum throttle lever movement without removing the air intake restrictor plate will cause the engine to run roughly at higher speeds.

For air intake restrictor plate removal instructions, see page 8-13.

a
	q w
1. Locknut	2. Adjuster	a. 20 mm (0.8 in)

4-4

qWARNING

POTENTIAL HAZARD

Improper adjustment of the speed limiter and throttle.

WHAT CAN HAPPEN

The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured.

HOW TO AVOID THE HAZARD

Do not turn the speed adjuster out more than 20 mm (0.8 in).

EBU00070

Front brake lever

The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake.

q

1. Front brake lever

EBU00073

Rear brake pedal and lever

The brake pedal is located on the right side of the machine and the brake lever is located on the left handlebar. Push down on the pedal or pull the lever toward the handlebar to apply the rear brake.

4-5

q

1. Brake pedal

q

1. Rear brake lever

EBU00074

Parking brake

Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake.

q

1. Lock plate

4-6

qWARNING

POTENTIAL HAZARD

Improper use of the parking brake.

WHAT CAN HAPPEN

The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision.

The brake could overheat if you ride the ATV without releasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely.

HOW TO AVOID THE HAZARD

Always set the parking brake before starting the engine.

Always be sure you have released the parking brake before you begin to ride.

4-7

EBU00083

Shift pedal

This machine is equipped with a constant-mesh 3-speed transmission. The shift pedal is located on the left side of the engine. Neutral is at the bottom position.

		3
		2
		1
		N
		q
1.	Shift pedal	N. Neutral

EBU00092

Fuel tank cap

Remove the fuel tank cap by turning it counterclockwise.

q

1. Fuel tank cap

4-8