Yamaha RAPTOR YFM80WP, Service Manual

Page 1: ...YFM80WP SUPPLEMENTARY SERVICEMANUAL 4EM AE1 ...

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Page 3: ...es it is necessary to use this Supple mentary Service Manual together with the following manual YFM80 D SERVICE MANUAL 4EM 28197 20 YFM80WP SUPPLEMENTARY SERVICE MANUAL 2001 by Yamaha Motor Co Ltd First Edition September 2001 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...fications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ...

Page 5: ...ntify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy t...

Page 6: ...clearance E Engine speed F Ω V A Illustrated symbols G to M in the exploded diagrams indicate the types of lubricants and lubrication points G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply wheel bearing grease K Apply lightweight lithium soap base grease L Apply molybdenum disulfide grease M Apply silicon grease Illustrated symbols N to O in the exploded diagrams indic...

Page 7: ...IONS 2 MAINTENANCE SPECIFICATIONS 3 ENGINE 3 CHASSIS 5 ELECTRICAL 5 CABLE ROUTING 7 PERIODIC CHECKS AND ADJUSTMENTS 11 INTRODUCTION 11 PERIODIC MAINTENANCE LUBRICATION INTERVALS 11 SEAT FENDERS AND FUEL TANK 12 SEAT AND FRONT PANEL 12 FRONT FENDER 13 REAR FENDER 14 FUEL TANK 15 ENGINE 16 SPEED LIMITER ADJUSTMENT 16 AIR FILTER CLEANING 17 ...

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Page 9: ...ORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 10: ...us 2 400 mm 94 5 in Oil type or grade Engine oil API service SE type or higher Final gear oil SAE 80API GL 4 Hypoid gear oil Fuel Type Unleaded gasoline For Oceania Regular unleaded gasoline For CDN and Europe Tank capacity 6 8 L 1 5 Imp gal 1 8 US gal Reserve amount 0 9 L 0 2 Imp gal 0 2 US gal Spark plug Type Manufacturer CR7HS NGK Gap 0 6 0 7 mm 0 024 0 028 in Tire Front Rear Type Tubeless Tube...

Page 11: ...stment method Manual Rocker arm rocker arm shaft Bearing inside diameter 10 000 10 015 mm 0 3937 0 3943 in Shaft outside diameter 9 981 9 991 mm 0 3930 0 3934 in Arm to shaft clearance 0 009 0 034 mm 0 0004 0 0013 in Limit 0 08 mm 0 0032 in Valve spring Free length IN 28 63 mm 1 13 in EX 28 63 mm 1 13 in Limit IN 25 4 mm 1 00 in EX 25 4 mm 1 00 in Compressed length valve closed IN 24 9 mm 0 980 in...

Page 12: ...2 9 mm 0 114 in Clutch plate Thickness Quantity 1 2 1 6 mm 0 047 0 063 in 5 Warp limit 0 06 mm 0 0024 in Clutch spring Free length Quantity 28 3 mm 1 11 in 8 Clutch release method Inner push cam push Clutch in revolution 2 100 2 300 r min Clutch stall revolution 2 800 3 000 r min Carburetor Type manufacturer quantity VM16SH MIKUNI 1 I D mark 5TH1 00 Main jet M J 76 3 Main air jet M A J ø1 2 Jet ne...

Page 13: ...mm 0 8 1 2 in Model YFM80WP CDI Magneto model manufacturer F2FM MORIC Pickup coil resistance color 264 396 Ω at 20 C 68 F W L W R Source coil resistance color 304 456 Ω at 20 C 68 F G W B R Lighting coil resistance color 0 72 1 08 Ω B W 0 32 0 48 Ω B Y R CDI unit model manufacturer 4EM MORIC Ignition coil Model manufacturer 2JN MORIC Minimum spark gap 6 mm 0 24 in Primary winding resistance 0 184 ...

Page 14: ...e 3 24 4 22 N 330 430 gf Commutator Diameter 16 5 mm 0 65 in Wear limit 15 5 mm 0 61 in Mica undercut 1 0 mm 0 04 in Starter relay Model manufacturer MS5D 611 JIDECO Amperage rating 100A Coil winding resistance 3 87 4 73 Ω at 20 C 68 F Starting circuit cut off relay Model manufacturer ACA12115 3 MATSUSHITA Coil winding resistance 72 88 Ω at 20 C 68 F Diode Yes Circuit breaker Type Fuse Amperage fo...

Page 15: ...ather hose 6 Fuel hose 7 Band 8 Starter relay 9 Starting circuit cut off relay 0 Rectifier regulator A Battery breather hose B CDI magneto lead C Carburetor overflow hose D Front brake cable right E Front brake cable left È Pass the final gear case breather hose through the guide É Pass the battery breather hose through the hole CABLE ROUTING ...

Page 16: ... Band 3 Wireharness 4 Ignition coil 5 Handlebar switch lead 6 Rear brake switch lead 7 NEUTRAL indicator light lead 8 Main switch 9 CDI unit 0 Fuel hose A Front brake cable B Fuel tank breather hose C Throttle cable CABLE ROUTING ...

Page 17: ...ank breather hose 2 Throttle cable 3 Front brake cable left 4 Front brake cable right 5 Air filter joint 6 Rear brake switch lead 7 Handlebar switch lead 8 NEUTRAL indicator light lead 9 Rear brake cable CABLE ROUTING ...

Page 18: ...ake cable 2 Throttle cable 3 Fuel tank breather hose 4 Battery negative lead 5 Fuse 6 Battery positive lead 7 Band 8 Handlebar switch 9 Rear brake switch 0 Rear brake cable È Pass the leads through the hole CABLE ROUTING ...

Page 19: ...ck condition Adjust gap and clean Replace if necessary Air filter element Clean Replace if necessary Every 20 40 hours more often in wet or dusty areas Carburetor Check idle speed choke lever operation Adjust if necessary Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Retighten if necessary Replace gasket if necessary Fuel l...

Page 20: ...e Q ty Remarks Removing the seat and front panel Remove the parts in the order below 1 Seat 1 NOTE Pull back the seat lock lever than pull up on the rear of the seat 2 Front panel 1 3 Fuel tank breather hose 1 4 Handlebar cover 1 5 Neutral indicator light leads 2 Disconnect For installation reverse the removal procedure ...

Page 21: ...er Job name Part name Q ty Remarks Removing the front fender Remove the parts in the order below Seat and front panel Refer to SEAT AND FRONT PANEL 1 Fuel tank top panel 1 2 Air cleaner joint clamp screw 1 Loosen 3 Main switch 1 4 Front fender 1 For installation reverse the removal procedure ...

Page 22: ...oving the rear fender Remove the parts in the order below Seat Refer to SEAT AND FRONT PANEL Front fender Refer to FRONT FENDER 1 Battery band 1 2 Main fuse 1 3 Battery lead 2 Disconnect CAUTION First disconnect the negative lead then disconnect the positive lead 4 Battery breather hose 1 5 Battery 1 6 Rear fender 1 For installation reverse the removal procedure ...

Page 23: ...name Q ty Remarks Removing the fuel tank Remove the parts in the order below Seat and front panel Refer to SEAT AND FRONT PANEL Front fender Refer to FRONT FENDER 1 Fuel hose 1 NOTE Before disconnecting the fuel hose turn the fuel cock to OFF 2 Fuel tank 1 For installation reverse the removal procedure ...

Page 24: ...iter length adjustment steps Loosen the locknut 1 Turn the adjuster 2 in or out until the speci fied speed limiter length is obtained Tighten the locknut WARNING Particularly for a beginner rider the speed limiter should be screwed in com pletely Screw it out little by little as their riding technique improves Never remove the speed limiter for a beginning rider For proper throttle lever operation...

Page 25: ...e is check hose 1 at the bottom of the air filter case If dust and or water collects in this hose clean the air filter element and air filter case 1 Remove Front panel Refer to SEAT FENDERS AND FUEL TANK 1 2 Remove Air filter cover 1 3 Remove Rubber band 2 4 Pull out the air filter element assembly 5 Remove Guide Air filter element 3 Air intake restrictor plate 4 CAUTION The engine should never be...

Page 26: ... element Such solvent may lead to a fire or explo sion Squeeze the excess solvent out of the ele ment and let dry CAUTION Do not twist the filter element when squeezing the filter element Apply the engine oil Squeeze out the excess oil NOTE The element should be wet but not dripping 8 Install Air filter element NOTE Make sure its sealing surface matches the sealing surface of the case so there is ...