Pre-Operation Checks. Yamaha YFM80RV, 5TH-28199-15, LIT-11626-19-64

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PRE-OPERATION CHECKS

Before using this machine, check the following points:

ITEM

Brakes

Fuel

Engine oil

Final gear oil

Throttle

Wheels and tires

Fittings and fasteners

Switches

Battery

ROUTINE

9 Check operation, condition and free play.

9 Adjust if necessary.

9 Check fuel level.

9 Fill with fuel if necessary.

9 Check oil level.

9 Fill with oil if necessary.

9 Check for leakage.

9 Check for proper throttle cable operation.

9 Check tire pressure, wear and damage.

9 Check all fittings and fasteners.

9 Check operation.

9 Check fluid level.

9 Fill with distilled water if necessary.

PAGE

5-2–5-3, 8-18–8-23

5-3–5-4

5-5, 8-6–8-7

5-5, 8-8–8-9

5-6

5-6–5-8, 8-26

5-9

5-9

5-9, 8-27–8-29

5

5-1

5TH-9-15-1 6/15/05 2:55 PM Page 4-14 qWARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Increases the possibility of an accident or equipment damage.

HOW TO AVOID THE HAZARD

Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.

EBU04762

Front and rear brakes

Brake levers and brake pedal

8 Check for correct free play in the brake levers and brake pedal. If the free play is incorrect, adjust it. (See pages 8-19–8-23.)

8 Check operation of the brake levers and brake pedal. They should move smoothly and there should be a firm feeling when the brakes are applied. If not, have the ATV inspected by a Yamaha dealer.

Brake operation

Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, inspect the brake linings for wear. (See page 8-18–8-19.)

5-2



Riding with improperly operating brakes.

WHAT CAN HAPPEN

You could lose braking ability, which could lead to an accident.


Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have the ATV inspected by a Yamaha dealer.

EBU13410

Fuel

Make sure there is sufficient gasoline in the tank.

Recommended fuel:

UNLEADED GASOLINE ONLY

Fuel tank capacity:

Total:

6.8 L (1.5 Imp gal, 1.8 US gal)

Reserve:

0.9 L (0.2 Imp gal, 0.2 US gal) c C

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.

5-3

Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number

([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel.

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Unleaded fuel will give you longer spark plug life and reduced maintenance cost.

Gasohol

There are two types of gasohol; gasohol containing ethanol and that containing methanol.

Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by

Yamaha because it may cause fuel system damage or vehicle performance problems.

qWARNING


Improper care when refueling.

WHAT CAN HAPPEN

Fuel can spill, which can cause a fire and severe injury.

Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun.


Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely.

Do not refuel right after the engine has been running and is still very hot.

1. Filler tube 2. Fuel level

5-4

5TH-9-15-1 6/15/05 2:55 PM Page 4-17

EBU10842

Engine oil

Make sure the engine oil is at the specified level.

Add oil as necessary. (See page 8-6.) c C

8 In order to prevent clutch slippage (since

the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY

CONSERVING II” or higher.

8 Make sure that no foreign material enters

the crankcase.

EBU00493

Final gear oil

Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-8–8-9 for details.)

Recommended oil:

SAE80API “GL-4” Hypoid gear oil

If desired, an SAE 80W90 hypoid gear oil may be used for all conditions.

NOTE:

GL-4 is a quality and additive rating, GL-5 or

GL-6 rated hypoid gear oils may also be used.

Recommended engine oil type and quantity:

See page 10-2.

5-5

5TH-9-15-1 6/15/05 2:55 PM Page 4-18

EBU01083

Throttle lever

Check to see that the throttle lever operates correctly. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer repair as necessary for proper operation.

EBU00157

Tires

qWARNING


Operating this ATV with improper tires, or with improper or uneven tire pressure.

WHAT CAN HAPPEN

Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident.


1. The tires listed below have been approved by Yamaha Motor Co., Ltd.

for this model. Other tire combinations are not recommended.

Front

Rear

Manufacturer

DUNLOP

DUNLOP

Size

AT18

× 7–7

AT18

× 8–7

Type

KT586

KT587

5-6

5TH-9-15-1 6/15/05 2:55 PM Page 4-19

2. The tires should be set to the recommended pressure:

8 Recommended tire pressure

Front 20 kPa (0.20 kgf/cm

2

, 2.9 psi)

Rear 20 kPa (0.20 kgf/cm 2 , 2.9 psi)

8 Check and adjust tire pressures when

the tires are cold.

8 Tire pressures must be equal on both

sides.

3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums:

Front 17 kPa (0.17 kgf/cm 2 , 2.5 psi)

Rear 17 kPa (0.17 kgf/cm

2

, 2.5 psi)

4. Use no more than the following pressures when seating the tire beads.

Front 230 kPa (2.3 kgf/cm

2

, 33 psi)

Rear 230 kPa (2.3 kgf/cm

2

, 33 psi)

Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst.

5-7

EBU00159

How to measure tire pressure

Use the low-pressure tire gauge.

NOTE:

The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.

5TH-9-15-1 6/15/05 2:55 PM Page 4-20

Set pressure with tires cold.

Set tire pressures to the following specifications:

Front

Rear

Recommended pressure

20 kPa

(0.20 kgf/cm 2 ,

2.9 psi)

20 kPa

(0.20 kgf/cm 2 ,

2.9 psi)

Minimum

17 kPa

(0.17 kgf/cm 2 ,

2.5 psi)

17 kPa

(0.17 kgf/cm 2 ,

2.5 psi)

Maximum

23 kPa

(0.23 kgf/cm 2 ,

3.3 psi)

23 kPa

(0.23 kgf/cm 2 ,

3.3 psi)

EBU00160

Tire wear limit

When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire.

a q a. Tire wear limit

1. Low-pressure tire gauge

5-8

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EBU11620

Fittings and fasteners

Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service

Manual for correct tightening torque.

EBU11700

Switches

Check the operation of all switches. Have a

Yamaha dealer repair as necessary for proper operation.

EBU00499

Battery

Check fluid level and fill if necessary. Use only distilled water if refilling is necessary. (See pages 8-27–8-29.)

5-9

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EBU00161

OPERATION

w

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

qWARNING


Operating ATV without being familiar with all controls.

WHAT CAN HAPPEN

Loss of control, which could cause an accident or injury.


Read the Owner’s Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer.

EBU00579

Starting a cold engine

qWARNING


Freezing control cables in cold weather.

WHAT CAN HAPPEN

You could be unable to control the ATV, which could lead to an accident or collision.


When riding in cold weather, always make sure all control cables work smoothly before you begin riding.

1. Set the parking brake.

2. Turn the fuel cock to “ON”.

3. Turn the main switch to “ON” and the engine stop switch to “RUN”.

4. Shift the transmission into neutral.

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NOTE:

This model is equipped with an ignition circuit cut-off system.

The engine can be started under the following conditions.

a. When the transmission is in neutral. At this time the neutral indicator light should come on. If the light does not come on, ask a

Yamaha dealer to inspect it.

b. When the transmission is in gear and the rear brake lever is applied. However, it is recommended to shift into neutral before starting the engine.

5. Use the choke lever in reference to the figure:

Position 1: Cold engine startambient temperature below 30°C

(90°F).

Position 2: Warming up position.

Position 3: Cold engine startambient temperature above 25°C

(80°F) and warm engine start position.

AMBIENT TEMP. / CHOKE LEVER POSITION

0

°

10

°

20

°

30

°

°C q

30

°

50

°

70

°

90

° °F e

6

a w

CHOKE

OFF e

ON q a. Choke lever

1. Fully open “ON” 2. Half open (warming up position)

3. Closed “OFF”

6-2

5TH-9-15-1 6/15/05 2:55 PM Page 6-3

6. Completely close the throttle lever and start the engine by pushing the start switch.

NOTE:

If the engine fails to start, release the start switch, then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt.

7. If the engine is started with the starter

(choke) in position 1 , the choke lever should be returned to position 2 to warm up the engine. If the engine is started with the starter (choke) in position 2 , keep the starter (choke) in this position to warm up the engine.

8. Continue warming up the engine until it idles smoothly and return the choke lever to position 3 before riding.

c C

See the “Engine break-in” section prior to operating engine for the first time.

EBU00181

Starting a warm engine

To start a warm engine, refer to the “Starting a cold engine” section. The choke lever should not be used. The throttle should be opened slightly.

EBU00184

Warming up

To get maximum engine life, always warm up the engine before starting off. Never accelerate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally with the choke lever turned off.

6-3

5TH-9-15-1 6/15/05 2:55 PM Page 6-4

EBU00200

Shifting

This model has a 3-speed forward transmission with centrifugal automatic clutch. The transmission allows you to control the amount of power you have available at a given speed or for starting accelerating, climbing, etc. To shift into neutral, return the throttle lever to its original position and repeatedly depress the shift pedal until it stops.

c C

Do not coast for long periods with the engine off, and do not tow the machine a long distance. Even with gears in neutral, the transmission is only properly lubricated when the engine is running. Inadequate lubrication may damage the transmission.

1. Shift pedal

3

2

1

N q

N. Neutral position

EBU00205

To start out and accelerate:

1. Release the throttle lever.

c C

Always close the throttle while shifting gears. Otherwise, damage to the engine and drive train may result.

2. Shift into first gear and release the shift pedal.

3. Open the throttle gradually.

6-4

5TH-9-15-1 6/15/05 2:55 PM Page 6-5

4. Once the machine has attained adequate speed, release the throttle lever.

5. Shift into second gear and release the shift pedal.

6. Open the throttle gradually.

7. Follow the same procedure when shifting to the next higher gear.

qWARNING


Opening the throttle before releasing the shift pedal.

WHAT CAN HAPPEN

The machine could wheelie. This would increase the chance of an accident, including overturn.


Release the shift pedal before opening the throttle. Open the throttle gradually.

EBU00207

To decelerate:

When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident.

qWARNING


Engaging a lower gear when the engine speed is too high.

WHAT CAN HAPPEN

The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage.


Make sure the engine has sufficiently slowed before shifting to a lower gear.

6-5

5TH-9-15-1 6/15/05 2:55 PM Page 6-6

EBU02092

Engine break-in

There is never a more important period in the life of your machine than the period between zero and 20 hours.

For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances.

During this period, prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided. However, momentary (2-3 seconds maximum) full throttle operation under load does not harm the engine.

Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r/min so the engine can rid itself of the temporary build up of heat.

If any abnormality is noticed during this period, consult a Yamaha dealer.

0-10 hours:

Avoid continuous operation above half throttle.

Allow a cooling off period of five to ten minutes after every hour of operation. Vary the speed of the machine from time to time. Do not operate it at one set throttle position.

10-20 hours:

Avoid prolonged operation above 3/4 throttle.

Rev the machine freely through the gears but do not use full throttle at any time.

After break-in:

Avoid prolonged full throttle operation. Vary speeds occasionally.

6-6

5TH-9-15-1 6/15/05 2:55 PM Page 6-7

EBU02111

Parking

When parking, stop the engine and shift into first gear. Turn the fuel cock to “OFF” and apply the parking brake.

q

1. Lock plate

6-7

1. Locked position q

5TH-9-15-1 6/15/05 2:55 PM Page 6-8

EBU12960

Parking on a slope

qWARNING


Parking on a hill or other incline.

WHAT CAN HAPPEN

The ATV could roll out of control, increasing the chance of an accident.


Avoid parking on hills or other inclines. If you must park on an incline, put the ATV in low gear, apply the parking brake, and block the front and rear wheels with rocks or other objects.

Do not park the ATV at all on hills that are so steep you could not walk up them easily.

1.

Bring the ATV to a stop by applying the brakes in low gear.

2.

Stop the engine.

3.

With the rear brake lever and pedal applied, apply the parking brake and slowly release the brake pedal.

6-8

5TH-9-15-1 6/15/05 2:55 PM Page 6-9

EBU00221

Accessories and loading

EBU00222

Accessories

Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories.

8 Choose only accessories designed for your

ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market.

However, it is not possible for Yamaha to test all non-Yamaha accessories, nor have any control over the quality or suitability of them.

Choose a genuine Yamaha accessory, or one that is equivalent in design and quality.

8 Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV.

8 Do not mount an accessory where it could interfere with your ability to control the ATV.

Examples include (but are not limited to) a heavy or bulky object attached to the handlebars which could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view.

8 Use extra caution when riding an ATV with accessories. The ATV may handle differently than it does without accessories.

6-9

5TH-9-15-1 6/15/05 2:55 PM Page 6-10

EBU00584

Loading

As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. Keep the following points in mind:

8 Never exceed the weight limits shown. An overloaded ATV can be unstable.

MAXIMUM LOADING LIMIT

Vehicle loading limit (total weight of cargo, rider and accessories):

95 kg (209 lb)

8 Load cargo on the carriers as close to the center of the vehicle as possible. Put cargo at the rear of the front carrier and at the front of the rear carrier. Center the load from side to side.

8 Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around.

A shifting load can cause an accident.

8 Make sure the load does not interfere with controls or your ability to see where you are going.

8 Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trailer.

8 Allow more braking distance. A heavier vehicle takes longer to stop.

8 Avoid making sharp turns unless at very slow speeds.

8 Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV.

6-10



Overloading this ATV or carrying or towing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in vehicle handling which could lead to an accident.


Never exceed the stated load capacity for this ATV.

Cargo should be properly distributed and securely attached.

Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.

6-11

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EBU13541 w

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

6-13

Pre-Operation Checks. Yamaha YFM80RV, 5TH-28199-15, LIT-11626-19-64

PRE-OPERATION CHECKS

OPERATION

Related manuals

Table of contents

Pre-Operation Checks. Yamaha YFM80RV, 5TH-28199-15, LIT-11626-19-64