Category Archives: Yamaha

2004-2013 Yamaha YFZ450 Service Repair Manual

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Yamaha YFZ450 Service Repair Manual
2004-2013 Yamaha YFZ450 Service Manual

This is the full Yamaha 2004-2013undreds of detailed pages with full Pictures, Diagrams, and Procedures to cover the YFZ450 ATV from bumper to bumper.

The YFZ450 Service Manual PDF is fully indexed and bookmarked by topic. The PDF can be searched quickly to find what you need and is perfect quality. You can print the entire manual or any pages you want to select. You can also zoom in on any diagram or pictures to easily see every part.

2004-2013 Yamaha YFZ450 Service Repair Manual CONTENTS:
■ GENERAL INFORMATION
■ SPECIFICATIONS
■ PERIODIC CHECKS & ADJUSTMENTS
■ CHASSIS
■ ENGINE
■ COOLING SYSTEM
■ FUEL INJECTION SYSTEM
■ ELECTRICAL SYSTEM
■ TROUBLESHOOTING

PRODUCT DETAILS:
– File Format: PDF
– Total Pages: 572 pages

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1999-2004 YAMAHA BEAR TRACKER 250 / YFM250 SERVICE REPAIR MANUAL

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YAMAHA BEAR TRACKER 250 service manual  YAMAHA YFM250 SERVICE MANUAL

1999-2004 YAMAHA BEAR TRACKER 250 / YFM250 SERVICE REPAIR MANUAL

Instant download of a COMPLETE Official Full Workshop Service and Repair Manual for the Yamaha YFM 250 Bear Tracker atv. Production model years: 1999, 2000, 2001, 2002, 2003, 2004.

MODELS COVERED:
● 2004 Yamaha YFM250XS Bear Tracker 2WD
● 2003 Yamaha YFM250XR Bear Tracker 2WD
● 2002 Yamaha YFM250XP-XHP Bear Tracker 2WD
● 2001 Yamaha YFM250XN-XHN BearTracker RT
● 2000 Yamaha YFM250XM-XMC Bear Tracker 4×2
● 1999 Yamaha YFM250XL-XLC Bear Tracker 2WD

This is the complete factory service repair workshop manual for the 1999-2004 YAMAHA BEAR TRACKER 250 / YFM250 ATV. This Service Manual has easy-to-read text sections with top quality diagrams and instructions.They are specifically written for the do-it-yourselfer as well as the experienced mechanic.With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using.1999-2004 YAMAHA BEAR TRACKER 250 / YFM250 ATV Service Repair Workshop Manual covers every single detail on your machine.provides step-by-step instructions based on the complete disassembly of the machine.

YAMAHA BEAR TRACKER 250 SERVICE REPAIR MANUAL CONTENTS: ■ General information
■ Specifications
■ Periodic Inspections and Adjustments
■ Engine
■ Carburetion
■ Drive train
■ Chassis
■ Electrical
■ Troubleshooting
■ Wiring Diagram

PRODUCT DETAILS:
– File Format: PDF
– Compatible: All Versions of Windows & Mac
– Language: English

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YAMAHA BEAR TRACKER 250 service manual,YAMAHA YFM250 Service manual

2000-2006 Yamaha YFM400 Kodiak 400 ATV Service Repair Manual

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2000-2006 Yamaha YFM400 Kodiak 400 ATV Service Repair Manual

Download Yamaha YFM400 Kodiak 400 ATV Service Repair Manual

This is the Complete Official Workshop Service and Repair Manual for the 2000-2006 Yamaha YFM400 Kodiak 400 ATV.
This is the same type of service manual your local dealer will use when doing a repair. The manual has detailed illustrations and step by step instructions and contains everything you will need to repair, maintain, rebuild, refurbish or restore your ATV. All diagnostic and repair procedures are covered. This Manual is a must for the Do-It-Yourselfer! All pages are printable. Just print it out and take it with you into the garage or workshop. Using this repair manual is an inexpensive way to keep your ATV working properly.

TABLE OF CONTENTS:
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENTS
ENGINE
COOLING SYSTEM
CARBURETION
DRIVE TRAIN
CHASSIS
ELECTRICAL
TROUBLESHOOTING

And A LOT MORE..

File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English

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2002 Yamaha YFM660F(P) Raptor Workshop Service Repair Manual

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2002 Yamaha YFM660F(P) Raptor Workshop Service Repair Manual

This is the Complete Official Workshop Service and Repair Manual for the Yamaha YFM660F(P) Raptor ATV.

This is the same type of service manual your local dealer will use when doing a repair. The manual has detailed illustrations and step by step instructions and contains everything you will need to repair, maintain, rebuild, refurbish or restore Yamaha YFM660F(P) Raptor. All diagnostic and repair procedures are covered. This Manual is a must for the Do-It-Yourselfer! All pages are printable. Just print it out and take it with you into the garage or workshop. Using this repair manual is an inexpensive way to keep your ATV working properly.

2002 Yamaha YFM660F(P) Raptor Workshop Service Repair Manual:
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENTS
ENGINE
COOLING SYSTEM
CARBURETION
DRIVE TRAIN
CHASSIS
ELECTRICAL
TROUBLESHOOTING

And A LOT MORE..

PRODUCT DETAILS:
Total Pages: 431 pages
File Format: PDF
Language: English

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2002 Yamaha YFM660F,Yamaha Raptor,2002 Yamaha YFM660FP,service manual, repair manual, workshop manual, factory manual, manual download, Owners manual, manual free

1985-1989 Yamaha YFM200 Moto-4 200 ATV Service Repair Manual

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This is the Complete Official Workshop Service and Repair Manual for the Yamaha YFM200 Moto-4 200 (Yamaha YFM200N/ Yamaha YFM200DXS/Yamaha YFM200DXT/Yamaha YFM200U) ATV.
Production model years:1985, 1986, 1987, 1988, 1989.

This is the same type of service manual your local dealer will use when doing a repair. The manual has detailed illustrations and step by step instructions and contains everything you will need to repair, maintain, rebuild, refurbish or restore your ATV. All diagnostic and repair procedures are covered. This Manual is a must for the Do-It-Yourselfer! All pages are printable. Just print it out and take it with you into the garage or workshop. Using this repair manual is an inexpensive way to keep your ATV working properly.

TABLE OF CONTENTS:
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENTS
ENGINE
COOLING SYSTEM
CARBURETION
DRIVE TRAIN
CHASSIS
ELECTRICAL
TROUBLESHOOTING

And A LOT MORE..

PRODUCT DETAILS:
File Format: PDF
Language: English

Instant Download

Yamaha YFM200,Yamaha Moto-4 200,Yamaha YFM200N, Yamaha YFM200DXS,Yamaha YFM200DXT,Yamaha YFM200U,service manual, repair manual, workshop manual, factory manual, manual download, Owners manual, manual free

2003-2006 Yamaha Yfm450 Kodiak 450 (YFM45FAR YFM450FAR) ATV Service Repair Manual

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2003-2006 Yamaha Yfm450 Kodiak 450 (YFM45FAR YFM450FAR) ATV Service Repair Workshop Manual

This is the Complete Official Workshop Service and Repair Manual for the Yamaha Yfm450 Kodiak 450 (YFM45FAR YFM450FAR) ATV.
Production model years:2002 2003 2004 2005 2006.
This is the same type of service manual your local dealer will use when doing a repair. The manual has detailed illustrations and step by step instructions and contains everything you will need to repair, maintain, rebuild, refurbish or restore Yamaha Yfm450 Kodiak 450. All diagnostic and repair procedures are covered. This Manual is a must for the Do-It-Yourselfer! All pages are printable. Just print it out and take it with you into the garage or workshop. Using this repair manual is an inexpensive way to keep your ATV working properly.

2003-2006 Yamaha Yfm450 Kodiak 450 (YFM45FAR YFM450FAR) ATV Service Repair Workshop Manual covered:
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENTS
ENGINE
COOLING SYSTEM
CARBURETION
DRIVE TRAIN
CHASSIS
ELECTRICAL
TROUBLESHOOTING

And A LOT MORE..

File Format: PDF
Language: English

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1983-1986 Yamaha YTM200 YFM200 YTM225 ATV Service Repair Manual

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1983-1986 Yamaha YTM200 YFM200 YTM225 ATV Service Repair Workshop Manual 1983 1984 1985 1986

This is the Complete Workshop Service and Repair Manual for the Yamaha YTM200 YFM200 YTM225 All-Terrain Vehicle.
Models Covers:
1983 Yamaha YTM200EK Yamahauler
1983 Yamaha YTM225DXK Tri-Moto
1984 Yamaha YTM200L Tri-Moto
1984 Yamaha YTM225DXL Tri-Moto
1985 Yamaha YFM200N-S Moto-4
1985 Yamaha YTM200N Tri-Moto
1985 Yamaha YTM225DXN Tri-Moto
1986 Yamaha YFM200DXS Moto-4

This is the same type of service manual your local dealer will use when doing a repair. The manual has detailed illustrations and step by step instructions and contains everything you will need to repair, maintain, rebuild, refurbish or restore Yamaha YTM200 YFM200 YTM225 ATV. All diagnostic and repair procedures are covered. This Manual is a must for the Do-It-Yourselfer! All pages are printable. Just print it out and take it with you into the garage or workshop. Using this repair manual is an inexpensive way to keep your Yamaha ATV working properly.

1983-1986 Yamaha YTM200 YFM200 YTM225 ATV Service Repair Workshop Manual covers all these sections:
Generali Information
Troubleshooting
Lubrication Manintenance And Tune-Up
Engine
Clutch And Transmission
Fuel And Exhaust Systems
Electrical System
Front Suspension And Steering(Ytm200 And Ytm225)
Front Suspension And Steering(Yfm200)
Rear Suspension And Final Drive
Brakes
Index
Wiring Diagrams

File Format: PDF
Language: English

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YAMAHA YFM7FGPW GRIZZLY 700 ATV 2007-2008 WORKSHOP MANUAL

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2007 2008 YAMAHA YFM7FGPW GRIZZLY 700 ATV SERVICE REPAIR WORKSHOP MANUAL

This is the Complete Official Workshop Service and Repair Manual for the YAMAHA YFM7FGPW GRIZZLY 700 ATV.

2007 Yamaha YFM700FGPDUW Grizzly
2007 Yamaha YFM700FGPHW Grizzly
2007 Yamaha YFM700FGPOHW Grizzly
2007 Yamaha YFM700FGPW Grizzly
2008 Yamaha YFM700FGPSPX Grizzly

This Service and Repair Manual contains everything you will need to repair, maintain, rebuild, refurbish or restore your ATV. All diagnostic and repair procedures are covered. The manual has detailed illustrations and step by step instructions. It is specifically written for the do-it-yourselfer as well as the experienced mechanic. All pages are printable. Just print it out and take it with you into the garage or workshop.

Table of Contents:
1. General Information
2. Specification
3. Periodic Checks and Adjustments
4. Engine
5. Cooling System
6. Fuel Injection System
7. Drive Train
8. Chassis
9. Electrical
10. Troubleshooting

Total Pages: 485 pages
File Format: PDF
Language: English

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2001-2005 Yamaha Raptor 660 YFM660RN YFM660RNC ATV Service Repair Manual

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2001-2005 Yamaha ATV Raptor 660 YFM660RN YFM660RNC Service Repair Workshop Manual

This is the Complete Official Workshop Service and Repair Manual for the Yamaha ATV Raptor 660 YFM660RN YFM660RNC.
Modles: Raptor 660 YFM660RN YFM660RNC
Production model years: 2001 2002 2003 2004 2005.

TABLE OF CONTENTS:
———————————
CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION ……………………………………………………………… 1-1
VEHICLE IDENTIFICATION NUMBER …………………………………………. 1-1
MODEL LABEL ………………………………………………………………………….. 1-1
IMPORTANT INFORMATION …………………………………………………………….. 1-2
PREPARATION FOR REMOVAL PROCEDURES …………………………. 1-2
REPLACEMENT PARTS …………………………………………………………….. 1-2
GASKETS, OIL SEALS AND O-RINGS ………………………………………… 1-2
LOCK WASHERS/PLATES AND COTTER PINS …………………………… 1-3
BEARINGS AND OIL SEALS ………………………………………………………. 1-3
CIRCLIPS …………………………………………………………………………………. 1-3
CHECKING OF CONNECTIONS ………………………………………………………… 1-4
SPECIAL TOOLS ……………………………………………………………………………… 1-5
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ……………………………………………………………. 2-1
MAINTENANCE SPECIFICATIONS ……………………………………………………. 2-4
ENGINE ……………………………………………………………………………………. 2-4
CHASSIS ………………………………………………………………………………… 2-14
ELECTRICAL ………………………………………………………………………….. 2-18
HOW TO USE THE CONVERSION TABLE ……………………………………….. 2-20
GENERAL TORQUE SPECIFICATIONS …………………………………………… 2-20
LUBRICATION POINTS AND LUBRICANT TYPES ……………………………. 2-21
ENGINE ………………………………………………………………………………….. 2-21
COOLANT FLOW DIAGRAMS …………………………………………………………. 2-22
OIL FLOW DIAGRAMS …………………………………………………………………… 2-23
CABLE ROUTING …………………………………………………………………………… 2-27
CHAPTER 3.
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION ………………………………………………………………………………. 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS …………………….. 3-1
SEAT, FENDERS AND FUEL TANK …………………………………………………… 3-3
SEAT, FRONT PANEL, FOOTREST GUARDS
AND ENGINE SKID PLATE ……………………………………………………… 3-3
HEADLIGHTS AND FRONT FENDER ………………………………………….. 3-4
REAR FENDER …………………………………………………………………………. 3-5
FUEL TANK ………………………………………………………………………………. 3-6
ENGINE …………………………………………………………………………………………… 3-8
ADJUSTING THE VALVE CLEARANCE ………………………………………. 3-8
ADJUSTING THE TIMING CHAIN ……………………………………………… 3-11
ADJUSTING THE IDLING SPEED ……………………………………………… 3-11
ADJUSTING THE THROTTLE LEVER FREE PLAY …………………….. 3-12
ADJUSTING THE SPEED LIMITER ……………………………………………. 3-14
ADJUSTING THE STARTER CABLE …………………………………………. 3-15
CHECKING THE SPARK PLUG ………………………………………………… 3-16
CHECKING THE IGNITION TIMING …………………………………………… 3-17
MEASURING THE COMPRESSION PRESSURE ………………………… 3-18
CHECKING THE ENGINE OIL LEVEL ………………………………………… 3-19
CHANGING THE ENGINE OIL ………………………………………………….. 3-20
ADJUSTING THE CLUTCH CABLE ……………………………………………. 3-23
CLEANING THE AIR FILTER …………………………………………………….. 3-24
CHECKING THE COOLANT LEVEL …………………………………………… 3-27
CHANGING THE COOLANT ……………………………………………………… 3-27
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT ….. 3-31
CLEANING THE SPARK ARRESTER ………………………………………… 3-31
CHASSIS ………………………………………………………………………………………. 3-33
ADJUSTING THE FRONT BRAKE …………………………………………….. 3-33
ADJUSTING THE REAR BRAKE ……………………………………………….. 3-33
ADJUSTING THE PARKING BRAKE ………………………………………….. 3-34
CHECKING THE BRAKE FLUID LEVEL ……………………………………… 3-35
CHECKING THE FRONT BRAKE PAD ………………………………………. 3-36
CHECKING THE REAR BRAKE PAD …………………………………………. 3-36
ADJUSTING THE REAR BRAKE LIGHT SWITCH ……………………….. 3-36
CHECKING THE BRAKE HOSE ………………………………………………… 3-37
BLEEDING THE HYDRAULIC BRAKE SYSTEM …………………………. 3-38
ADJUSTING THE SHIFT PEDAL ……………………………………………….. 3-39
ADJUSTING THE REVERSE CONTROL CABLE ………………………… 3-40
ADJUSTING THE DRIVE CHAIN SLACK ……………………………………. 3-40
CHECKING THE STEERING SYSTEM ………………………………………. 3-42
ADJUSTING THE TOE-IN …………………………………………………………. 3-42
ADJUSTING THE FRONT SHOCK ABSORBER ………………………….. 3-44
ADJUSTING THE REAR SHOCK ABSORBER ……………………………. 3-45

CHECKING THE TIRE ……………………………………………………………… 3-47
CHECKING THE WHEEL ………………………………………………………….. 3-49
CHECKING AND LUBRICATING THE CABLE …………………………….. 3-49
LUBRICATING THE LEVERS AND PEDAL …………………………………. 3-50
ELECTRICAL …………………………………………………………………………………. 3-51
CHECKING THE BATTERY ………………………………………………………. 3-51
CHECKING THE FUSE …………………………………………………………….. 3-56
ADJUSTING THE HEADLIGHT BEAM ……………………………………….. 3-58
REPLACING THE HEADLIGHT BULB ………………………………………… 3-58
CHAPTER 4.
CHASSIS
FRONT WHEELS ……………………………………………………………………………… 4-1
FRONT WHEELS ………………………………………………………………………. 4-1
CHECKING THE WHEEL ……………………………………………………………. 4-3
CHECKING THE WHEEL HUB ……………………………………………………. 4-3
CHECKING THE BRAKE DISC ……………………………………………………. 4-4
INSTALLING WHEEL HUB …………………………………………………………. 4-5
INSTALLING THE WHEEL ………………………………………………………….. 4-5
REAR WHEELS, WHEEL AXLE AND HUB …………………………………………. 4-6
REAR WHEELS ………………………………………………………………………… 4-6
WHEEL AXLE AND HUB ……………………………………………………………. 4-7
REMOVING THE REAR AXLE …………………………………………………….. 4-9
CHECKING THE WHEEL ………………………………………………………….. 4-10
CHECKING THE WHEEL HUB ………………………………………………….. 4-10
CHECKING THE REAR AXLE …………………………………………………… 4-10
CHECKING THE HUB ………………………………………………………………. 4-11
CHECKING THE BRAKE DISC ………………………………………………….. 4-11
INSTALLING THE NUTS (REAR AXLE) ……………………………………… 4-11
INSTALLING THE WHEEL HUB ………………………………………………… 4-12
INSTALLING THE WHEEL ………………………………………………………… 4-12
FRONT AND REAR BRAKES ………………………………………………………….. 4-13
FRONT BRAKE PADS ……………………………………………………………… 4-13
REAR BRAKE PADS ………………………………………………………………… 4-14
REPLACING THE FRONT BRAKE PAD ……………………………………… 4-15
REPLACING THE REAR BRAKE PAD ……………………………………….. 4-17
FRONT BRAKE MASTER CYLINDER ………………………………………… 4-19
REAR BRAKE MASTER CYLINDER ………………………………………….. 4-21
CHECKING THE MASTER CYLINDER ………………………………………. 4-24
ASSEMBLING THE FRONT
AND REAR BRAKE MASTER CYLINDER ……………………………….. 4-25
INSTALLING THE FRONT BRAKE MASTER CYLINDER ……………… 4-25
INSTALLING THE REAR BRAKE MASTER CYLINDER ……………….. 4-27
FRONT BRAKE CALIPERS ………………………………………………………. 4-29
REAR BRAKE CALIPER …………………………………………………………… 4-31
DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER …….. 4-34

CHECKING THE FRONT AND REAR BRAKE CALIPER ………………. 4-34
ASSEMBLING THE FRONT BRAKE CALIPER ……………………………. 4-35
ASSEMBLING THE REAR BRAKE CALIPER ……………………………… 4-36
INSTALLING THE FRONT BRAKE CALIPER ……………………………… 4-37
INSTALLING THE REAR BRAKE CALIPER ………………………………… 4-38
STEERING SYSTEM ………………………………………………………………………. 4-40
HANDLEBAR …………………………………………………………………………… 4-40
REMOVING THE FRONT BRAKE SWITCH, PARK SWITCH
AND CLUTCH SWITCH ………………………………………………………… 4-42
REMOVING THE HANDLEBAR GRIP ………………………………………… 4-42
CHECKING THE HANDLEBAR …………………………………………………. 4-42
INSTALLING THE HANDLEBAR ……………………………………………….. 4-43
INSTALLING THE HANDLEBAR GRIP ……………………………………….. 4-43
INSTALLING THE CLUTCH LEVER …………………………………………… 4-43
INSTALLING THE BRAKE MASTER CYLINDER …………………………. 4-44
STEERING STEM ……………………………………………………………………. 4-45
REMOVING THE BEARING RETAINER …………………………………….. 4-47
CHECKING THE STEERING STEM …………………………………………… 4-47
INSTALLING THE BEARING RETAINER ……………………………………. 4-47
INSTALLING THE LOCK WASHER ……………………………………………. 4-47
TIE-ROD AND STEERING KNUCKLE ………………………………………… 4-48
REMOVING THE STEERING KNUCKLE ……………………………………. 4-49
CHECKING THE TIE-ROD ………………………………………………………… 4-49
CHECKING THE STEERING KNUCKLE …………………………………….. 4-49
INSTALLING THE TIE-ROD ………………………………………………………. 4-49
FRONT ARMS AND FRONT SHOCK ABSORBERS ………………………….. 4-50
REMOVING THE FRONT ARM …………………………………………………. 4-52
CHECKING THE FRONT ARM ………………………………………………….. 4-52
CHECKING THE FRONT SHOCK ABSORBER …………………………… 4-52
CHECKING THE BALL JOINT …………………………………………………… 4-53
INSTALLING THE FRONT ARM ………………………………………………… 4-54
REAR SHOCK ABSORBER AND RELAY ARM …………………………………. 4-55
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER …………………………………………………………… 4-57
DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER …………………………………………………………… 4-57
REMOVING THE REAR SHOCK ABSORBER …………………………….. 4-58
CHECKING THE REAR SHOCK ABSORBER ……………………………… 4-58
CHECKING THE RELAY ARM AND CONNECTING ARM …………….. 4-58
INSTALLING THE RELAY ARM AND CONNECTING ARM …………… 4-59
INSTALLING THE REAR SHOCK ABSORBER ……………………………. 4-59
SWINGARM AND DRIVE CHAIN ……………………………………………………… 4-60
REMOVING THE SWINGARM …………………………………………………… 4-62
CHECKING THE SWINGARM …………………………………………………… 4-62
CHECKING THE DRIVE CHAIN ………………………………………………… 4-63
INSTALLING THE SWINGARM …………………………………………………. 4-65
INSTALLING THE DRIVE SPROCKET ……………………………………….. 4-65

CHAPTER 5.
ENGINE
ENGINE REMOVAL ………………………………………………………………………….. 5-1
MUFFLER AND EXHAUST PIPES ………………………………………………. 5-1
LEFT FOOTREST ……………………………………………………………………… 5-2
LEADS, CABLES AND HOSES …………………………………………………… 5-3
ENGINE MOUNTING BOLTS ……………………………………………………… 5-5
INSTALLING THE ENGINE …………………………………………………………. 5-7
CYLINDER HEAD COVER ………………………………………………………………… 5-8
REMOVING THE CYLINDER HEAD COVER ………………………………. 5-10
CHECKING THE CYLINDER HEAD COVER ………………………………. 5-10
CHECKING THE TAPPET COVER …………………………………………….. 5-11
INSTALLING THE CYLINDER HEAD COVER …………………………….. 5-11
ROCKER ARMS …………………………………………………………………………….. 5-12
REMOVING THE ROCKER ARM ………………………………………………. 5-14
CHECKING THE ROCKER ARM ……………………………………………….. 5-14
INSTALLING THE ROCKER ARM ……………………………………………… 5-15
CAMSHAFT AND CYLINDER HEAD ………………………………………………… 5-16
REMOVING THE CAMSHAFT AND CYLINDER HEAD ………………… 5-18
CHECKING THE CAMSHAFT ……………………………………………………. 5-19
CHECKING THE CAMSHAFT SPROCKET …………………………………. 5-19
CHECKING THE DECOMPRESSION SYSTEM …………………………… 5-19
CHECKING THE TIMING CHAIN GUIDE ……………………………………. 5-20
CHECKING THE TIMING CHAIN TENSIONER ……………………………. 5-20
CHECKING THE CYLINDER HEAD …………………………………………… 5-20
INSTALLING THE CAMSHAFT AND CYLINDER HEAD ……………….. 5-21
VALVES AND VALVE SPRINGS ……………………………………………………… 5-24
REMOVING THE VALVE AND VALVE SPRING ………………………….. 5-25
CHECKING THE VALVE AND VALVE SPRING …………………………… 5-26
INSTALLING THE VALVE AND VALVE SPRING …………………………. 5-30
CYLINDER AND PISTON ………………………………………………………………… 5-32
REMOVING THE PISTON ………………………………………………………… 5-33
CHECKING THE CYLINDER AND PISTON ………………………………… 5-33
CHECKING THE PISTON RING ………………………………………………… 5-35
CHECKING THE PISTON PIN INSPECTION ………………………………. 5-36
INSTALLING THE PISTON ……………………………………………………….. 5-36
INSTALLING THE CYLINDER …………………………………………………… 5-37
AC MAGNETO ……………………………………………………………………………….. 5-38
REMOVING THE AC MAGNETO ROTOR …………………………………… 5-40
CHECKING THE COIL ……………………………………………………………… 5-40
CHECKING THE STARTER CLUTCH ………………………………………… 5-41
INSTALLING THE AC MAGNETO ROTOR …………………………………. 5-42

CLUTCH ………………………………………………………………………………………… 5-43
REMOVING THE CLUTCH ……………………………………………………….. 5-47
REMOVING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEAR …………………………………………… 5-47
CHECKING THE FRICTION PLATE …………………………………………… 5-48
CHECKING THE CLUTCH PLATE …………………………………………….. 5-48
CHECKING THE CLUTCH SPRING …………………………………………… 5-49
CHECKING THE CLUTCH HOUSING ………………………………………… 5-49
CHECKING THE CLUTCH BOSS ………………………………………………. 5-49
CHECKING THE PRESSURE PLATE ………………………………………… 5-49
CHECKING THE PULL LEVER SHAFT AND PULL ROD ……………… 5-50
CHECKING THE PRIMARY DRIVE ……………………………………………. 5-50
CHECKING THE BALANCER DRIVE …………………………………………. 5-50
INSTALLING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEAR …………………………………………… 5-51
INSTALLING THE CLUTCH ………………………………………………………. 5-52
OIL PUMP ……………………………………………………………………………………… 5-54
CHECKING THE OIL PUMP ……………………………………………………… 5-56
ASSEMBLING THE OIL PUMP…………………………………………………… 5-56
SHIFT SHAFT ………………………………………………………………………………… 5-57
CHECKING THE SHIFT SHAFT ………………………………………………… 5-59
CHECKING THE STOPPER LEVER ………………………………………….. 5-59
CHECKING THE SHIFT GUIDE AND SHIFT LEVER ……………………. 5-59
CHECKING THE SEGMENT ……………………………………………………… 5-59
INSTALLING THE SHIFT LEVER ………………………………………………. 5-59
INSTALLING THE STOPPER LEVER ………………………………………… 5-60
INSTALLING THE SHIFT SHAFT ………………………………………………. 5-61
CRANKCASE …………………………………………………………………………………. 5-62
TIMING CHAIN AND SPEED SENSOR ROTOR ………………………….. 5-62
CRANKCASE ………………………………………………………………………….. 5-64
CRANKCASE BEARING …………………………………………………………… 5-65
SEPARATING THE CRANKCASE………………………………………………. 5-66
CHECKING THE TIMING CHAIN AND GUIDE …………………………….. 5-66
CHECKING THE OIL STRAINER ………………………………………………. 5-66
CHECKING THE CRANKCASE …………………………………………………. 5-67
CHECKING THE BEARINGS …………………………………………………….. 5-67
ASSEMBLING THE CRANKCASE ……………………………………………… 5-67
CRANKSHAFT AND BALANCER …………………………………………………….. 5-69
REMOVING THE CRANKSHAFT ………………………………………………. 5-70
CHECKING THE CRANKSHAFT ……………………………………………….. 5-70
INSTALLING THE CRANKSHAFT ……………………………………………… 5-71

TRANSMISSION …………………………………………………………………………….. 5-72
MAIN AXLE …………………………………………………………………………….. 5-74
DRIVE AXLE …………………………………………………………………………… 5-75
CHECKING THE SHIFT FORK ………………………………………………….. 5-77
CHECKING THE SHIFT DRUM …………………………………………………. 5-77
CHECKING THE TRANSMISSION …………………………………………….. 5-77
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE …………………….. 5-78
INSTALLING THE TRANSMISSION …………………………………………… 5-79
CHAPTER 6.
COOLING SYSTEM
RADIATOR ………………………………………………………………………………………. 6-1
CHECKING THE RADIATOR ………………………………………………………. 6-3
INSTALLING THE RADIATOR …………………………………………………….. 6-4
THERMOSTAT …………………………………………………………………………………. 6-5
CHECKING THE THERMOSTAT …………………………………………………. 6-7
ASSEMBLING THE THERMOSTAT …………………………………………….. 6-7
WATER PUMP …………………………………………………………………………………. 6-8
DISASSEMBLING THE WATER PUMP ………………………………………. 6-11
CHECKING THE WATER PUMP ……………………………………………….. 6-11
ASSEMBLING THE WATER PUMP ……………………………………………. 6-12
CHAPTER 7.
CARBURETION
CARBURETORS ………………………………………………………………………………. 7-1
DISASSEMBLING THE CARBURETOR ……………………………………….. 7-5
CHECKING THE CARBURETOR ………………………………………………… 7-5
ASSEMBLING THE CARBURETOR …………………………………………….. 7-7
ADJUSTING THE FUEL LEVEL …………………………………………………… 7-8

CHAPTER 8.
ELECTRICAL
ELECTRICAL COMPONENTS …………………………………………………………… 8-1
CHECKING THE SWITCH …………………………………………………………………. 8-2
CHECKING THE SWITCH ………………………………………………………….. 8-2
CHECKING A SWITCH SHOWN IN THE MANUAL ……………………….. 8-2
CHECKING THE SWITCH CONTINUITY ……………………………………… 8-3
IGNITION SYSTEM …………………………………………………………………………… 8-5
CIRCUIT DIAGRAM …………………………………………………………………… 8-5
TROUBLESHOOTING ……………………………………………………………….. 8-6
ELECTRIC STARTING SYSTEM ……………………………………………………… 8-11
CIRCUIT DIAGRAM …………………………………………………………………. 8-11
STARTING CIRCUIT OPERATION …………………………………………….. 8-12
TROUBLESHOOTING ……………………………………………………………… 8-13
STARTER MOTOR ………………………………………………………………….. 8-16
CHECKING THE STARTER MOTOR …………………………………………. 8-17
ASSEMBLING THE STARTER MOTOR ……………………………………… 8-18
CHARGING SYSTEM ……………………………………………………………………… 8-19
CIRCUIT DIAGRAM …………………………………………………………………. 8-19
TROUBLESHOOTING ……………………………………………………………… 8-20
LIGHTING SYSTEM ………………………………………………………………………… 8-22
CIRCUIT DIAGRAM …………………………………………………………………. 8-22
TROUBLESHOOTING ……………………………………………………………… 8-23
CHECKING THE LIGHTING SYSTEM ………………………………………… 8-25
SIGNAL SYSTEM …………………………………………………………………………… 8-27
CIRCUIT DIAGRAM …………………………………………………………………. 8-27
TROUBLESHOOTING ……………………………………………………………… 8-28
CHECKING THE SIGNAL SYSTEM …………………………………………… 8-30
COOLING SYSTEM ………………………………………………………………………… 8-36
CIRCUIT DIAGRAM …………………………………………………………………. 8-36
TROUBLESHOOTING …………………………………………………………….. 8-37
CHAPTER 9.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING …………………………………………….. 9-1
FUEL SYSTEM ………………………………………………………………………….. 9-1
ELECTRICAL SYSTEM ………………………………………………………………. 9-1
COMPRESSION SYSTEM ………………………………………………………….. 9-2
POOR IDLE SPEED PERFORMANCE ……………………………………………….. 9-2
POOR IDLE SPEED PERFORMANCE …………………………………………. 9-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE …………………………. 9-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ………………….. 9-2
FAULTY GEAR SHIFTING ………………………………………………………………… 9-3
HARD SHIFTING ……………………………………………………………………….. 9-3
SHIFT PEDAL DOES NOT MOVE ……………………………………………….. 9-3
JUMP-OUT GEAR ……………………………………………………………………… 9-3
CLUTCH SLIPPING/DRAGGING ……………………………………………………….. 9-3
CLUTCH SLIPPING …………………………………………………………………… 9-3
CLUTCH DRAGGING ………………………………………………………………… 9-3
OVERHEATING ……………………………………………………………………………….. 9-4
OVERHEATING ………………………………………………………………………… 9-4
OVER COOLING ………………………………………………………………………………. 9-4
COOLING SYSTEM …………………………………………………………………… 9-4
FAULTY BRAKE ………………………………………………………………………………. 9-4
POOR BRAKING EFFECT ………………………………………………………….. 9-4
SHOCK ABSORBER MALFUNCTION ………………………………………………… 9-5
MALFUNCTION …………………………………………………………………………. 9-5
UNSTABLE HANDLING ……………………………………………………………………. 9-5
UNSTABLE HANDLING ……………………………………………………………… 9-5
LIGHTING SYSTEM ………………………………………………………………………….. 9-5
HEADLIGHT DARK ……………………………………………………………………. 9-5
BULB BURNT OUT ……………………………………………………………………. 9-5

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1992-2001 Yamaha Badger/raptor 80 Yfm80 Yfm80wp Yfm80M(C) Yfm80D Atv Service Repair Workshop Manual

Have a problem? Instant download 1992-2001 Yamaha Badger/raptor 80 Yfm80 Yfm80wp Yfm80M(C) Yfm80D Atv Service Repair Workshop Manual, Fix it! Keep Your All-Terrain Vehicle Running Smoothly.

1992-2001 Yamaha Badger/raptor 80 Yfm80 Yfm80wp Yfm80M(C) Yfm80D Atv Service Repair Workshop Manual

This is the Complete Official Workshop Service and Repair Manual for the Yamaha Badger/raptor 80 Yfm80 Yfm80wp Yfm80M(C) Yfm80D Atv.
Production model years: 1992-2001.
This Complete Service and Repair Manual contains everything you will need to repair, maintain, rebuild, refurbish or restore your Atv. All diagnostic and repair procedures are covered. The manual has detailed illustrations and step by step instructions. It is specifically written for the do-it-yourselfer as well as the experienced mechanic. All pages are printable. Just print it out and take it with you into the garage or workshop.

This Service Repair Manual Covers:

*General Information
*Specifications
*Periodic Checks And Adjustments
*Engine Overhaul
*Carburetion
*Chassis
*Electrical
*Troubleshooting

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