Periodic Maintenance and Adjustment. Yamaha YFM80RV, 5TH-28199-15, LIT-11626-19-64

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EBU00515

PERIODIC

MAINTENANCE AND

ADJUSTMENT

Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages.

qWARNING

POTENTIAL HAZARD

Servicing an engine while it is running.

WHAT CAN HAPPEN

Moving parts can catch clothing or parts of the body, causing injury.

Electrical components can cause shocks or can start fires.

HOW TO AVOID THE HAZARD

Turn off the engine when performing maintenance unless otherwise specified.

Have a Yamaha dealer perform service if you are not familiar with machine service.

EBU01221

Owner’s manual and tool kit

You are recommended to put this owner’s manual and low-pressure tire gauge in the vinyl bag and always carry them along with the owner’s tool kit under the seat.

e

8-1

1. Owner’s manual

3. Owner’s tool kit q w

2. Low-pressure tire gauge

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The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the owner’s tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts.

NOTE:

If you do not have a torque wrench available during a service operation requiring one, take your machine to a Yamaha dealer to check the torque settings and adjust them as necessary.

qWARNING

POTENTIAL HAZARD

Operating this ATV with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident.

HOW TO AVOID THE HAZARD

Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized Yamaha ATV dealer.

8

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EBU02611

Periodic maintenance chart for the emission control system

NOTE:

8 For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.

8 For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the

ATV isn’t used for a long period of time, the month maintenance intervals should be followed.

Valves*

ITEM

Cam chain*

Spark plug

Carburetor*

Crankcase breather system*

Exhaust system*

Spark arrester

Fuel line*

ROUTINE

Whichever comes first month km

(mi)

9 Check valve clearance.

9 Adjust if necessary.

9 Check chain tension.

9 Adjust if necessary.

9 Check condition.

9 Adjust gap and clean.

9 Replace if necessary.

9 Check idle speed/choke lever operation.

9 Adjust if necessary.

9 Check breather hose for cracks or damage.

9 Replace if necessary.

9 Check for leakage.

9 Tighten if necessary.

9 Replace gasket if necessary.

9 Clean.

9 Check fuel hose for cracks or damage.

9 Replace if necessary.

hours

1

320

(200)

20

2

2

2

INITIAL

3

1300

(800)

80

6 6

EVERY

12

2500 2500 5000

(1600) (1600) (3200)

160 160 320

2 2 2

2 2 2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

8-3

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General maintenance and lubrication chart

Air filter element

Engine oil

Final gear oil

Brakes*

Clutch*

Wheels*

ITEM

Wheel bearings*

Steering system*

Knuckle shafts/ steering shaft*

Fittings and fasteners*

ROUTINE

Whichever comes first month km

(mi) hours

9 Clean.

9 Replace if necessary.

9 Replace (warm engine before draining).

9 Check oil level/oil leakage.

9 Replace every 12 months.

9 Check operation.

9 Adjust if necessary.

9 Check operation.

9 Adjust if necessary.

9 Check balance/damage/runout.

9 Replace if necessary.

9 Check brearing assemblies for looseness/ damage.

9 Replace if damaged.

9 Check operation.

9 Replace if damaged.

9 Check toe-in.

9 Adjust if necessary.

9 Lubricate every 6 months with Lithium-soap-based grease.

9 Check all chassis fittings and fasteners.

9 Correct if necessary.

1

320

(200)

20

2

INITIAL

3

1300

(800)

6 6

EVERY

12

2500 2500 5000

(1600) (1600) (3200)

320 80 160 160

Every 20–40 hours

(more often in wet or dusty areas)

2 2 2

2 2

2 2 2 2 2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

8-4

5TH-9-15-3 6/15/05 2:56 PM Page 8-5

ITEM ROUTINE

Whichever comes first month km

(mi) hours

1

320

(200)

20

INITIAL

3

1300

(800)

80

6 6

EVERY

12

2500 2500 5000

(1600) (1600) (3200)

160 160 320

Battery*

9 Check specific gravity.

9 Check breather hose for correct routing.

9 Correct if necessary.

2 2 2 2 2

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

w

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

8-5

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EBU08682

Engine oil

Engine oil level measurement

1.

Place the ATV on a level surface.

2.

Warm up the engine for several minutes and stop it.

3.

Remove the dipstick and wipe it off with a clean rag. Insert the dipstick in the filler hole without screwing it in.

NOTE:

Wait a few minutes until the oil level settles before checking.

4.

Remove the dipstick and inspect the oil level.

5.

The oil level should be between the maximum and minimum marks. If the level is low, add oil to raise it to the specified level.

c C

Be sure no foreign material enters the crankcase.

q w e

1. Dipstick

3. Minimum level mark

2. Maximum level mark

Engine oil replacement

1.

Place the ATV on a level surface.

2.

Warm up the engine for several minutes and stop it.

3.

Place a container under the engine.

4.

Remove the dipstick and drain bolt to drain the oil.

5.

Inspect the O-ring and replace if damaged.

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1. Drain bolt q

6.

Install the drain bolt and tighten to specification.

Recommended oil type:

YAMALUBE 4 (20W40) or SAE 20W40

YAMALUBE 4 (10W30) or SAE 10W30

SAE 5W30

Recommended oil classification:

API Service SE, SF, SG type or higher

Oil quantity:

Periodic oil change:

0.8 L (0.70 Imp qt, 0.85 US qt) c C

Be sure no foreign material enters the crankcase.

Tightening torque

Drain bolt:

20 Nm (2.0 m

0kgf, 14 ft0lbf)

8.

Warm up the engine for several minutes at idle speed. Check for oil leakage while warming up.

7.

Fill the engine with oil and install the dipstick.

8-7 c C

If oil leakage is found, stop the engine immediately and check for the cause.

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EBU00869

Final gear oil

Final gear oil measurement

1. Place the ATV on a level surface.

2. Remove the dipstick and wipe it off with a clean rag. Insert the dipstick in the filler hole without screwing it in.

3. Remove the dipstick and inspect the oil level.

4. The oil level should be between the maximum and minimum marks. If the level is low, add oil to raise it to the proper level.

c C

Be sure no foreign material enters the final gear case.

5. Install the dipstick.

2

3

1

1. Dipstick

3. Minimum level mark

2. Maximum level mark

Final gear oil replacement

1. Place the ATV on a level place.

2. Place a container under the final gear case.

3. Remove the dipstick and drain bolt to drain the oil.

8-8

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1. Drain bolt

4. Install the drain bolt and tighten to specification.

Tightening torque

Drain bolt:

23 Nm (2.3 m

0kgf, 17 ft0lbf)

5. Fill the final gear case with oil.

Recommended oil:

SAE80API “GL-4” Hypoid gear oil

Oil quantity:

0.12L (0.11 Imp qt, 0.13 US qt) c C

Be sure no foreign material enters the final gear case.

6. Install the dipstick.

7. Check for oil leakage. If oil leakage is found, check for the cause.

8-9

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EBU11820

Spark plug inspection

The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine.

For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder. Do not attempt to diagnose such problems yourself.

Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.

If electrode erosion becomes excessive, you should replace the spark plug with one of the proper type.

Standard spark plug:

CR7HSA (NGK)

Before installing the spark plug, measure the electrode gap with a wire thickness gauge and adjust it to specification.

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in) a. Spark plug gap a

8-10

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When installing the spark plug, always clean the gasket surface and its mating surface. Wipe off any grime from the threads and tighten it to the specified torque.

Tightening torque:

Spark plug:

12.5 Nm (1.25 m

0kgf, 9.1 ft0lbf) q

EBU10343

Air filter cleaning

NOTE:

There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case.

1. Check hose

1.

Remove the front cover by removing the bolts.

w w

8-11

1. Front cover q

2. Bolt (

×

2)

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1. Air filter case cover 2. Fastener (

×

4)

2.

Remove the air filter case cover by unhooking the fasteners.

1. Fastener 2. Air filter element

3.

Remove the air filter element by unhooking the fastener.

4.

Wash the air filter element gently but thoroughly in solvent.

8-12

5TH-9-15-3 6/15/05 2:56 PM Page 8-13 qWARNING

POTENTIAL HAZARD

Using low flash point solvents or gasoline to clean the air filter element.

WHAT CAN HAPPEN

Low flash point solvents or gasoline can catch fire or explode.

HOW TO AVOID THE HAZARD

Use parts cleaning solvent to clean the air filter element.

5.

Squeeze the excess solvent out of the air filter element and let it dry.

c C

Do not twist the air filter element when squeezing it.

6.

Inspect the air filter element. If damaged, replace it.

7.

Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter element.

NOTE:

The air filter element should be wet but not dripping.

8.

Install the air filter element.

9.

Install the air filter case cover by hooking the fasteners onto the air filter case.

10. Install the front cover by installing the bolts.

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NOTE:

The air filter element should be cleaned every

20-40 hours. It should be cleaned and lubricated more often if the machine is operated in extremely dusty areas. Each time air filter element maintenance is performed, check the air inlet of the air filter case for obstructions. Check the air cleaner rubber joint to the carburetor and manifold fittings for an airtight seal. Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine.

EBU01035

Air intake restrictor plate removal

To obtain full engine performance capability, removing the air intake restrictor plate is required.

1. Remove the air filter element. (See page

8-11 for removal and installation procedures.)

2. Remove the air intake restrictor plate.

c C

Never operate the engine with the air filter element removed. This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage.

Additionally, operation without the filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating.

8-14

1. Air intake restrictor plate q

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NOTE:

Store the air intake restrictor plate with the owner’s manual so that you can install it whenever you want to reduce the top speed available.

3. Install the air filter element.

EBU13600

Spark arrester cleaning

Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester.

1.

Remove the screws.

q

1. Screw (

×

2)

8-15

5TH-9-15-3 6/15/05 2:56 PM Page 8-16

2.

Remove the tailpipe by pulling it out of the muffler.

3.

Tap the tailpipe lightly, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe.

q e w

1. Tailpipe

3. Screw (

×

2)

2. Spark arrester

4.

Insert the tailpipe into the muffler and align the screw holes.

5.

Install the screws and tighten them.

qWARNING

POTENTIAL HAZARD

Improper cleaning of the spark arrester.

Hot exhaust system

WHAT CAN HAPPEN

Could injure the eyes.

Could cause burns.

Could cause carbon monoxide poisoning, possibly leading to death.

Could start a fire.

HOW TO AVOID THE HAZARD

When cleaning the spark arrester:

Always let the exhaust system cool prior to touching exhaust components.

Do not start the engine when cleaning the exhaust system.

8-16

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EBU00296

Carburetor adjustment

The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine.

c C

The carburetor was set at the Yamaha factory after many tests. If the settings are disturbed by someone without sufficient technical knowledge, poor engine performance and damage may result.

EBU13020

Idle speed adjustment

NOTE:

A diagnostic tachometer must be used for this procedure.

1.

Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle.

8-17

5TH-9-15-3 6/15/05 2:56 PM Page 8-18

2.

Connect the tachometer to the spark plug lead, and then set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw in direction a to increase the engine speed, and in direction b to decrease the engine speed.

Specified idle speed:

1,750–1,850 r/min

1. Throttle stop screw b a q

EBU00303

Valve clearance adjustment

The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician.

EBU00304

Cam chain adjustment

The cam chain becomes loose with use, resulting in improper valve timing and engine noise.

To prevent this, the cam chain tensioner must be adjusted regularly. This adjustment should be left to a Yamaha service technician.

EBU01218

Front and rear brake shoe inspection

A wear indicator is provided on each brake. The indicators allows checking of brake shoe wear without disassembling the brake. Apply the brake and check the position of the indicator. If the indicator reaches the wear limit line or mark, ask a

8-18

Yamaha dealer to replace the shoes as a set.

5TH-9-15-3 6/15/05 2:56 PM Page 8-19

Front

1. Wear limit line

Rear

w

2. Wear indicator q

EBU00323

Front brake lever free play adjustment

NOTE:

Before adjusting the brake, inspect the front brake shoes.

The front brake lever free play should be adjusted to 10–12 mm (0.4–0.5 in) at the brake lever pivot. If the free play is incorrect, adjust as follows: a q

1. Wear limit mark w

2. Wear indicator

8-19 a. Free play

5TH-9-15-3 6/15/05 2:56 PM Page 8-20

1. Loosen the upper locknut and fully turn in the adjusting bolt.

2. Loosen the lower locknut.

3. Turn the lower adjusting bolt until specified free play is obtained.

q w

5. While applying the front brake, turn out the upper adjusting bolt until the upper and lower cable lengths are equal. The cable joint will become vertical.

a=a’ q a a’

1. Upper locknut

3. Lower locknut

Specified free play:

10–12 mm (0.4–0.5 in) e r

2. Upper adjusting bolt

4. Lower adjusting bolt

4. Tighten the lower locknut.

1. Cable joint

6. Tighten the upper locknut.

8-20

5TH-9-15-3 6/15/05 2:56 PM Page 8-21 qWARNING

POTENTIAL HAZARD

Operating with improperly serviced or adjusted brakes.

WHAT CAN HAPPEN

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

HOW TO AVOID THE HAZARD

After servicing:

8 Make sure the brakes operate smooth-

ly and that the free play is correct.

8 Make sure the brakes do not drag.

Replacement of brake components requires professional knowledge. These procedures should be performed by

Yamaha dealer.

EBU03351

Rear brake lever and brake pedal adjustment

Brake lever free play adjustment

1. Loosen the brake cable locknut.

2. Turn the adjusting bolt at the brake lever until brake lever free play is 5–8 mm

(0.20–0.30 in).

3. Tighten the locknut.

a q w a. Free play

1. Locknut 2. Adjusting bolt

8-21

5TH-9-15-3 6/15/05 2:56 PM Page 8-22

NOTE:

If specified free play cannot be obtained, tighten the brake cable adjusting nut at the rear wheel hub until brake lever free play is 5–8 mm

(0.20–0.30 in).

Brake pedal free play adjustment

Turn the brake rod adjusting nut at the rear wheel hub until brake pedal free play is 20–

30 mm (0.8–1.2 in).

a a. Free play q

1. Brake cable adjusting nut

8-22

5TH-9-15-3 6/15/05 2:56 PM Page 8-23

1. Brake rod adjusting nut q

8-23 qWARNING

POTENTIAL HAZARD

Operating with improperly serviced or adjusted brakes.

WHAT CAN HAPPEN

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

HOW TO AVOID THE HAZARD

After servicing:

8 Make sure the brakes operate smooth-

ly and that the free play is correct.

8 Make sure the brakes do not drag.

Replacement of brake components requires professional knowledge. These procedures should be performed by a

Yamaha dealer.

5TH-9-15-3 6/15/05 2:56 PM Page 8-24

EBU00872

Clutch adjustment

1. Remove the rubber cap.

2. Loosen the locknut.

3. Slowly turn the adjusting bolt clockwise until resistance is felt. Then turn it 1/8 counterclockwise.

NOTE:

Turn the adjusting bolt clockwise to decrease the clutch free play and turn it counterclockwise to increase the free play.

5. Install the rubber cap securely.

q w e

1. Rubber cap 2. Locknut 3. Adjusting bolt

4. Tighten the locknut to the specified torque.

Tightening torque:

8 Nm (0.8 m

0kgf, 5.8 ft0lbf)

8-24

5TH-9-15-3 6/15/05 2:56 PM Page 8-25

EBU00356

Cable inspection and lubrication

qWARNING

POTENTIAL HAZARD

Damaged control cables.

WHAT CAN HAPPEN

Corrosion can result when the outer covering of control cables becomes damaged.

Cables can also become frayed or kinked.

Operation of controls could be restricted, which could cause an accident or injury.

HOW TO AVOID THE HAZARD

Inspect cables frequently. Replace damaged cables.

Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a

Yamaha dealer to replace them.

Recommended lubricant:

Yamaha chain and cable lube or

SAE 10W30 motor oil

EBU00727

Brake and shift pedal/brake lever lubrication

Lubricate the pivoting parts of each lever and pedal.

Recommended lubricant:

Lithium-soap-based grease

(all-purpose grease)

8-25

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EBU01220

Knuckle shaft and steering shaft lubrication

Lubricate the pivot points using a grease gun.

Recommended lubricant:

Lithium-soap-based grease

(all-purpose grease)

Front

q

Rear

w q

1

1

1. Wheel nut (

×

4) 2. Wheel nut (

×

3)

EBU00871

Wheel installation

When installing the wheel, reverse the removal procedure.

Tighten the wheel nuts to the specified torques.

1. Grease nipple

EBU01112

Wheel removal

1. Loosen the wheel nuts.

2. Elevate the ATV and place a suitable stand under the frame.

3. Remove the nuts from the wheel.

4. Remove the wheel.

8-26

Tightening torque:

Wheel nut:

Front: 28 Nm (2.8 m

0kgf, 20 ft0lbf)

Rear: 28 Nm (2.8 m

0kgf, 20 ft0lbf)

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EBU00378

Battery

Check the level of the battery fluid and see if the terminals are tight. Add distilled water if the fluid level is low.

c C

Do not leave or store the battery on its side.

When inspecting the battery, be sure the breather hose is routed correctly. If it touches the frame or exists in such a way as to cause battery electrolyte or gas to exit onto the frame, structural and cosmetic damage to the machine can occur.

1. Battery q w

2. Battery breather hose

8-27

5TH-9-15-3 6/15/05 2:56 PM Page 8-28 qWARNING

POTENTIAL HAZARD

Failure to handle batteries or battery electrolyte carefully.

WHAT CAN HAPPEN

You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte.

Batteries produce explosive gases.

HOW TO AVOID THE HAZARD

Avoid contact with skin, eyes or clothing.

Always shield eyes when working near batteries. Keep out of reach of children.

Antidote:

EXTERNAL: Flush with water.

INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Get prompt medical attention.

8-28

EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batteries away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed space.

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EBU11950

Replenishing the battery fluid

A poorly maintained battery will corrode and discharge quickly. The battery fluid should be checked at least once a month.

1.

The level should be between the maximum and minimum level marks. Use only distilled water if refilling is necessary.

e q w r

1. Maximum level mark

3. Negative lead

2. Minimum level mark

4. Positive lead

2.

Disconnect the negative (–) lead.

3.

Disconnect the positive (+) lead, and then remove the battery.

8-29 c C

Normal tap water contains minerals which are harmful to a battery. Therefore, refill only with distilled water.

4.

When the machine is not to be used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before using.

5.

If the battery is to be stored for a longer period than the above, check the specific gravity at least once a month and recharge the battery when it is too low.

6.

Always make sure the connections are correct when putting the battery back in the machine. Make sure the breather hose is properly connected and is not damaged or obstructed.

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EBU00390

Fuse replacement

1. The fuse case is located under the seat.

2. If the fuse is blown, turn off the main switch and install a new fuse of the specified amperage. Then turn on the switches. If the fuse immediately blows again, consult a Yamaha dealer.

Specified fuse: 5 A

1. Fuse q w

2. Spare fuse qWARNING

POTENTIAL HAZARD

Using an improper fuse.

WHAT CAN HAPPEN

An improper fuse can cause damage to the electrical system which could lead to a fire.

HOW TO AVOID THE HAZARD

Always use a fuse of the specified rating.

Never use a material in place of the proper fuse.

c C

To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse.

8-30

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EBU00412

Troubleshooting

Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer.

The skilled technicians at a Yamaha dealership have the tools, experience, and know-how to properly service your machine. Use only genuine Yamaha parts on your machine. Imitation parts may look like Yamaha parts, but they are often inferior. Consequently, they have a shorter service life and can lead to expensive repair bills.

qWARNING

POTENTIAL HAZARD

Checking the fuel system while smoking or near an open flame.

WHAT CAN HAPPEN

Fuel can ignite or explode, causing severe injury or property damage.

HOW TO AVOID THE HAZARD

Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces.

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EBU00440

Troubleshooting chart

Remove the fuel hose from the fuel cock.

Water or dirt mixed in fuel

Turn the fuel cock to “ON”

Clean the fuel filter and the fuel tank

Check fuel flow No fuel Fuel cock clogged

Clean fuel cock

1. Fuel

Check if there is fuel in the fuel tank

There is fuel

Some fuel

Turn the fuel cock to “OFF”

Turn the fuel cock to “RES”

Supply fuel

Restart engine

2. Compression

Use electric starter to see if there is compression

No fuel

3. Ignition

Remove spark plug and check electrodes

4. Battery

Use electric starter

There is compresson

No compression

Compression normal

Ask a Yamaha dealer to inspect

Wet

Wipe clean with dry cloth

Dry

Attach spark plug cap and ground to chassis

Engine turns over quickly

Engine turns over slowly

Battery good

Use electric starter

Spark good Ignition system normal

Spark weak

No spark

Adjust spark plug gap or replace spark plug

Ask a Yamaha dealer to inspect

Check fluid, recharge, check connections

8-32