Yamaha RAPTOR 80 User Manual
READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YFM80WR
w
LIT-11626-16-07
This ATV should not be ridden by anyone under 12 years of age.
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 infor-
mation. 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:
8 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COM-
PLETELY BEFORE OPERATING YOUR MACHINE. MAKE SURE YOU UNDERSTAND ALL
INSTRUCTIONS.
8 PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MACHINE.
8 NEVER 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.
8 THIS 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
w
cC
NOTE: A NOTE provides key information to make procedures easier or clearer.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
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.
A CAUTION indicates special precautions that must be taken to avoid damage
to the machine.
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
AFFIX DEALER
LABEL HERE
YFM80WR
OWNER’S MANUAL
©2002 by Yamaha Motor Corporation,
U.S.A.
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
LOCATION OF THE WARNING AND
1
SPECIFICATION LABELS.......................1-1
2
SAFETY INFORMATION.........................2-1
DESCRIPTION AND MACHINE
3
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
4
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
5
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
Switches ...............................................5-6
Battery ..................................................5-6
Tires .....................................................5-7
How to measure tire pressure ..............5-8
Tire wear limit .......................................5-9
OPERATION............................................6-1
6
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
7
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
8
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
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
9
A. Cleaning ...........................................9-1
B. Storage ............................................9-3
10
SPECIFICATIONS .................................10-1
11
NOISE REGULATION............................11-1
MAINTENANCE RECORD.....................12-1
12
13
ATV LIMITED WARRANTY....................13-1
YAMAHA EXTENDED SERVICE
14
(Y.E.S.)...................................................14-1
EBU00464
1
3
4
2
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
12
q
WARNING
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.
q
WARNING
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 :
9 use 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
1
4EM-21697-31
5FE-21568-11
1-2
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
9
Recommended
:
FRONT
: 20 kPa,
{
0.20
kgf/cm
2
}
2.9 psi
REAR
: 20 kPa,
{
0.20
kgf/cm
2
}
2.9 psi
9
Minimum
:
FRONT
: 17 kPa,
{
0.17
kgf/cm
2
}
2.5 psi
REAR
: 17 kPa,
{
0.17
kgf/cm
2
}
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
q
WARNING
NEVER ride as a
passenger.
Passengers can cause
a loss of control,
resulting in SEVERE
INJURY or DEATH.
5FE-2151H-01
4EM-21696-11
43
5FE-2151H-01
1-3
EBU00928
q
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:
8 Read this manual and all labels carefully and follow the operating procedures described.
8 Never 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.
8 Always 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.
8 Never 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.
8 Never carry a passenger on an ATV.
SAFETY INFORMATION
2-1
2
8 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots
and streets.
8 Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
8 Never 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.
8 Never consume alcohol or drugs before or while operating this ATV.
8 Never 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.
8 Never attempt wheelies, jumps, or other stunts.
8 Always 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.
8 Always keep both hands on the handlebars and both feet on the footrests of the ATV during opera-
tion.
8 Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.
2-2
8 Never 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.
8 Always 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.
8 Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills
before attempting larger hills.
8 Always 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.
8 Always 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.
8 Always 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
8 Always 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.
8 Always 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.
8 Always 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.
8 Never 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.
8 Always use the size and type tires specified in this manual. Always maintain proper tire pressure as
described in this manual.
8 Never modify an ATV through improper installation or use of accessories.
2-4
8 Never 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
q
WARNING
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
q
WARNING
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
q
w
e
ru
t
y
uio
!0 !1 !2 !3
!4!5
!6
!7
DESCRIPTION AND MACHINE IDENTIFICATION
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.
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.
q
1. Key identification number
3
3-2
EBU00036
q
Vehicle identification number
The vehicle identification number is stamped
into the frame.
1. Vehicle identification number
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
NOTE:
The vehicle identification number is used to
identify your machine.
1. Model label
3-3
EBU00039
q
CONTROL FUNCTIONS
EBU00043
Indicator lights
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
EBU00603
Neutral indicator light “N”
This indicator light comes on when the transmission is in neutral.
1. Neutral indicator light “N”
4-1
4
EBU00053
q
w
Handlebar switches
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
q
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.
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.
q
WARNING
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
q
w
a
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.
1. Locknut 2. Adjuster a. 20 mm (0.8 in)
4-4
q
q
WARNING
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.
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
1. Brake pedal
q
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
q
WARNING
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
q
q
3
2
1
N
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.
1. Shift pedal N. Neutral
EBU00092
Fuel tank cap
Remove the fuel tank cap by turning it counterclockwise.
1. Fuel tank cap
4-8
Loading...