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4EM-AE1

1. 2 3PZ 13 2 D 8M 3 5 12 5 90 7 1 1 8 1 2 2 5 4 5 mm 0 10 0 18 in Below carburetor body edge 20 0 22 0 mm 0 79 0 87 in 1 750 1 850 r min 36 kPa 270 mmHg MAINTENANCE SPECIFICATIONS SPEC u CHASSIS YFM80WP Wheel Front wheel type Rear wheel type Front rim size material Rear rim size material Rim runout limit Vertical Lateral Panel wheel Panel wheel 7 x 5 5 AT steel 7 x 6 5 AT steel lt 2 0 mm 0 08 in gt lt 2 0 mm 0 08 in gt Brake lever amp brake pedal Brake lever free play front brake Brake lever free play rear brake Brake pedal free play ELECTRICAL Model 10 12 mm 0 4 0 5 in at lever pivot 5 8 mm 0 20 0 31 in at lever pivot 20 30 mm 0 8 1 2 in YFM80WP CDI Magneto model manufacturer Pickup coil resistance color Source coil resistance color Lighting coil resistance color CDI unit model manufacturer F2FM MORIC 264 396 Q at 20 C 68 F W L W R 304 456 Q at 20 C 68 F G W B R 0 72 1 08 2 B W 0 32 0 48 Q B Y R 4EM MORIC Ignition coil Model manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance 2JN MORIC 6 mm 0 24 in 0 184 0 276 Q at 20 C 68 F 6 32 9 48 Q at 20 C 68 F Rectifier regulator Type Model manufacturer No load regulated voltage Capacity Withstand voltage Semi conductor short circuit SH704 12 SHINDENGEN 14 1
2. 3 105 9 N 8 8 10 8 kgf 86 3 105 9 N 8 8 10 8 kgf lt 2 5 or 1 2 mm 0 047 in gt Direction of winding top view O MAINTENANCE SPECIFICATIONS SPEC u YFM80WP Piston Piston size D Measuring point H Piston over size 2nd Offset Offset direction Piston clearance lt Limit gt Piston pin bore inside diameter Piston pin outside diameter Clutch Friction plate Thickness x Quantity lt Wear limit gt Clutch plate Thickness x Quantity lt Warp limit gt Clutch spring Free length x Quantity Clutch release method Clutch in revolution Clutch stall revolution 46 960 46 975 mm 1 8488 1 8494 in 6 5 mm 0 256 in From bottom line of piston skirt 47 50 mm 1 870 in 48 00 mm 1 890 in 0 75 mm Intake side 0 025 0 045 mm 0 0010 0 0018 in lt 0 15 mm 0 006 in gt 13 002 13 013 mm 0 5119 0 5123 in 12 996 13 000 mm 0 5117 0 5118 in 2 92 3 08 mm 0 115 0 121 in x 6 lt 2 9 mm 0 114 in gt 1 2 1 6 mm 0 047 0 063 in x 5 lt 0 06 mm 0 0024 in gt 28 3 mm 1 11 in x8 Inner push cam push 2 100 2 300 r min 2 800 3 000 r min Carburetor Type manufacturer quantity I D mark Main jet Main air jet Jet needle clip position Needle jet Cutaway Pilot jet Pilot outlet Pilot screw Valve seat Fuel level Float height Engine idling speed Intake vacuum VM16SH MIKUNI 1 5TH1 00 76 3 1
3. US gal Spark plug Type Manufacturer Gap CR7HS NGK 0 6 0 7 mm 0 024 0 028 in Tire Type Size Manufacturer type lt Wear limit gt Front Rear Tubeless AT18 x 8 7 DUNLOP KT587 lt 3 mm 0 12 in gt Tubeless AT18 x 7 7 DUNLOP KT586 lt 3 mm 0 12 in gt Indicator light wattage x quantity NEUTRAL 12V1 7Wx1 MAINTENANCE SPECIFICATIONS SPEC u MAINTENANCE SPECIFICATIONS ENGINE YFM80WP Camshatt Drive method Cam dimensions Intake Exhaust B Camshaft runout limit Cam chain type number of links Cam chain adjustment method Chain drive Left 25 30 25 31 mm 0 996 0 997 in 20 994 21 094 mm 0 827 0 831 in 25 301 25 311 mm 0 996 0 997 in 21 021 21 121 mm 0 828 0 832 in lt 0 03 mm 0 0012 in gt BUSH CHAIN 82 links Manual Rocker arm rocker arm shaft Bearing inside diameter Shaft outside diameter Arm to shaft clearance lt Limit gt 10 000 10 015 mm 0 3937 0 3943 in 9 981 9 991 mm 0 3930 0 3934 in 0 009 0 034 mm 0 0004 0 0013 in lt 0 08 mm 0 0032 in gt Valve spring Free length lt Limit gt Compressed length valve closed IN EX Compressed spring force installed IN EX lt Tilt Limit gt IN amp EX 28 63 mm 28 63 mm lt 25 4 mm lt 25 4 mm 1 13 in 1 13 in 1 00 in gt 1 00 in gt 24 9 mm 0 980 in 24 9 mm 0 980 in 86
4. notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING 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 dam age to the machine NOTE A NOTE provides key information to make procedures easier or clearer EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects See Illustrated symbols 1st title This is the title of the chapter with its symbol in the upper right corner of each page 2nd title This title indicates the section of the chapter and only appears on the first page of each section It is located in the upper left corner of the page 3rd title 3 This title indicates a sub section that is followed by step by step procedures accompa nied by corresponding illustrations EXPLODED DIAGRAMS To help identify 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 Y is provided for removal and disassembly jobs 2 Numbers 6 are given in the order of the jobs in the exploded diagram A number that
5. 5V 13 14V 5A 8A 200 V MAINTENANCE SPECIFICATIONS SPEC u Model YFM80WP Electric starter system Type Starter motor Model manufacturer Out put Armature coil resistance Brush Overall length lt Limit gt Spring pressure Diameter lt Wear limit gt Mica undercut Model manufacturer Amperage rating Coil winding resistance Commutator Starter relay Constant mesh type ADB4A5 DENSO 0 2 kW 0 0288 0 0352 Q at 20 C 68 F 6 mm 0 24 in lt 3 5 mm 0 14 in gt 3 24 4 22 N 330 430 gf 16 5 mm 0 65 in lt 15 5 mm 0 61 in gt 1 0 mm 0 04 in MS5D 611 JIDECO 100A 3 87 4 73 Q at 20 C 68 F Starting circuit cut off relay Model manufacturer Coil winding resistance Diode ACA12115 3 MATSUSHITA 72 88 Q at 20 C 68 F Yes Circuit breaker Type Amperage for individual circuit quantity Main Reserve Fuse 5Ax1 5Ax1 CABLE ROUTING SPEC u CABLE ROUTING Throttle cable Battery breather hose Fuel tank breather hose 42 CDI magneto lead Carburetor ventilation hose 3 Carburetor overflow hose Final gear case breather hose Front brake cable right Crankcase breather hose 3 Front brake cable left Fuel hose Band A Pass the final gear case breather hose through Starter relay the guide Starting circuit cut off relay B Pass the battery breather hose through the hole Rectifier regulator Ey WA Yo N T
6. INTERVALS INITIAL ROUTINE INTRODUCTION PERIODIC MAINTENANCE CHK LUBRICATION INTERVALS ADJ PERIODIC CHECKS AND ADJUSTMENTS Q EVERY 3 months 6 6 months 1 months year Valves e Check valve clearance e Adjust if necessary O Cam chain e Check chain tension e Adjust if necessary O Spark plug e Check condition e Adjust gap and clean e Replace if necessary O O Air filter element e Clean e Replace if necessary Every 20 40 hours more often in wet or dusty areas Carburetor e Check idle speed choke lever operation e Adjust if necessary O O O Crankcase breather system e Check breather hose for cracks or damage e Replace if necessary Exhaust system e Check for leakage e Retighten if necessary e Replace gasket if necessary Fuel line e Check fuel hose for cracks or damage e Replace if necessary Engine oil e Replace warm engine before draining Final gear oil e Check oil level oil leakage e Replace every 12 months Brakes e Check operation e Adjust if necessary Clutch e Check operation e Adjust if necessary Wheels e Check balance damage runout e Replace if necessary Wheel bearings e Check bearing assemblies for looseness damage e Replace if damaged OTOOTO O Oe OTE OOOO Steering system e Check operation e Repair if damage
7. IZ e i Y A Remarks Removing the rear fender Seat Front fender Battery band Main fuse Battery lead Battery breather hose Battery Rear fender die Remove the parts in the order below Refer to SEAT AND FRONT PANEL Refer to FRONT FENDER Disconnect ect the negative lead then disconnect the positive lead For installation reverse the removal procedure CHK SEAT FENDERS AND FUEL TANK FUEL TANK Job name Part name 4 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 Fuel hose NOTE Before disconnecting the fuel hose turn the fuel cock to OFF Fuel tank For installation reverse the removal procedure 45 CHK SPEED LIMITER ADJUSTMENT ENGINE SPEED LIMITER ADJUSTMENT The speed limiter keeps the carburetor throttle from becoming fully opened even when the throttle lever is applied to the maximum posi tion Screwing in the adjuster stops the engine speed from increasing 1 Check e Speed limiter length Out of specification gt Adjust Speed limiter length Less than 20 mm 0 8 in 2 Adjust e Speed limiter length kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Speed limiter length adjustment steps e Loosen the locknut e Turn the adjuster in or out until the speci fied speed l
8. Ss LS CABLE ROUTING SPEC y Rear brake cable 43 Throttle cable Band Wireharness Ignition coil Handlebar switch lead Rear brake switch lead NEUTRAL indicator light lead Main switch CDI unit Fuel hose Front brake cable 2 Fuel tank breather hose SN AY i SS A SS O mo oe Fuel tank breather hose Throttle cable Front brake cable left Front brake cable right Air filter joint Rear brake switch lead Handlebar switch lead NEUTRAL indicator light lead Rear brake cable CABLE ROUTING SPEC y CABLE ROUTING SPEC u Front brake cable Pass the leads through the hole Throttle cable Fuel tank breather hose Battery negative lead Fuse Battery positive lead Band Handlebar switch Rear brake switch Rear brake cable EB300000 INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust ments These preventive maintenance procedures if followed will ensure more reliable vehicle operation and a longer service life The need for costly overhaul work will be greatly reduced This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale All service technicians should be familiar with this entire chapter EB301000 PERIODIC MAINTENANCE LUBRICATION
9. YAMAHA TEMU WP 4EM AE1 OUPPLEMENTARY OERVIGE MANUAL FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM80WP For complete information on service procedures 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 O 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 EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics It is not possible to include all the knowledge of a mechanic in one manual so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use Yamaha Motor Company Ltd is continually striving to improve all its models Modifications 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
10. aa 12 SEAT AND ERONT PANEL adaa na Kan lo doo 12 FRONT FENDER sata a 13 REAR FENDER aora dai 14 FUEL TANK ta 15 ENGINE 00d ra naga Bag O A ALN 16 SPEED LIMITER ADJUSTMENT 0aenenene ane ne anna anana n nanam nn anna 16 AIR FILTER CLEANING MACHINE IDENTIFICATION KA 0 6 GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the left side of the frame MODEL LABEL The model label is affixed to the frame This information will be needed to order spare parts GENERAL SPECIFICATIONS SPEC y SPECIFICATIONS GENERAL SPECIFICATIONS Model YFM80WP Model code number 5TH1 For Oceania 5TH2 For CDN 5TH3 For Europe Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 1 537 mm 60 5 in 841 mm 33 1 in 940 mm 37 in 669 mm 26 3 in 1 030 mm 40 6 in 100 mm 3 9 in 2 400 mm 94 5 in Oil type or grade Engine oil o Ng 30 50 a 90 LOs 10 F a HE YAMALUBE 4 20W40 or SAE 20W40 YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 Final gear oil API service SE type or higher SAE 80API GL 4 Hypoid gear oil Fuel Type Tank capacity Reserve amount Unleaded gasoline For Oceania Regular unleaded gasoline For CDN and Europe 6 8 L 1 5 Imp gal 1 8 US gal 0 9 L 0 2 Imp gal 0 2
11. d e Check toe in e Adjust if necessary O Knuckle shafts steering shaft e Lubricate every 6 months Fittings and fasten ers e Check all chassis fittings and fasteners e Correct if necessary Battery e Check specific gravity e Check breather hose for correct routing e Correct if necessary It is recommended that these items be serviced by a Yamaha dealer Lithium soap based grease AA CHK SEAT FENDERS AND FUEL TANK ADJ SEAT FENDERS AND FUEL TANK SEAT AND FRONT PANEL Job name Part name f Remarks Removing the seat and front panel Remove the parts in the order below Seat NOTE Pull back the seat lock lever than pull up on the rear of the seat Front panel Fuel tank breather hose Handlebar cover Neutral indicator light leads Disconnect For installation reverse the removal procedure 12 CHK SEAT FENDERS AND FUEL TANK FRONT FENDER Job name Part name f Remarks Removing the front fender Remove the parts in the order below Seat and front panel Refer to SEAT AND FRONT PANEL Fuel tank top panel Air cleaner joint clamp screw Loosen Main switch Front fender For installation reverse the removal procedure 13 CHK SEAT FENDERS AND FUEL TANK REAR FENDER 7 Nm 0 7 m kg 5 1ft 1b Job name Part name A N E NI NS AN le VEZ TI y amp Y LA L
12. imiter length is obtained Speed limiter length is decreased Turning in Speed limiter length is increased Turning out e Tighten the locknut 44 WARNING e 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 e For proper throttle lever operation do not turn out the adjuster more than 20 mm 0 8 in Also always adjust the throttle lever free play to 3 5 mm 0 12 0 20 in kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 16 SPEED LIMITER ADJUSTMENT CHK O AIR FILTER CLEANING ADJ Q e Air intake restrictor plate removal Refer to AIR FILTER CLEANING NOTE To obtain full engine performance capability removing the air intake restrictor plate D is required Since removal of this plate will result in a significant increase in power turn the speed limiter completely back in again AIR FILTER CLEANING NOTE A There is check hose 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 e Front panel Refer to SEAT FENDERS AND FUEL TANK 2 Remove e Air filter cover 3 Remove e Rubber band 4 Pull out the air filter element assembly 5 Remove e Guide e Air filter element e Air intake re
13. is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read way by the use of symbol marks The meanings of the symbol marks are given on the next page 4 A job instruction chart accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 5 For jobs requiring more information the step by step format supplements 3 are given in addition to the exploded diagram and the job instruction chart CHK CHK SEAT FENDERS AND FUEL TANK ADJ AIR FILTER CLEANING ADJ FRONT FENDER y AIR FILTER CLEANING 3 There is check hose at the bottom of the air filter case If dust and or water collects in this D hose clean the air filter element and air filter Front panel Refer to SEAT FENDERS AND FUEL ANK 2 Remove Air filter cover D O 3 Remove D rder al al 4 lemarks ET Rubber band D Removing the front fender Remove the paris in the order below ne NA Soe une air filter element assembly Seat and front panel Refer to SEAT AND FRONT PANEL Plato e Air filter element Loosen For installation reverse the removal procedure 6 Check Air filter element Damage Replace TRBL SHTG ILLUSTRATED SYMBOLS Illustrated symbols to are printed on the top right of each page and indicate the subject of each chapter General information Specifications Periodic checks and adjust
14. ments Engine Carburetion Drive train Chassis Electrical Troubleshooting Illustrated symbols to are used to identify the specifications appearing in the text Filling fluid Lubricant 42 Special tool 43 Torque Wear limit clearance Engine speed O V A Illustrated symbols to in the exploded diagrams indicate the types of lubricants and lubrication points 2 Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight lithium soap base grease 22 Apply molybdenum disulfide grease Apply silicon grease Illustrated symbols to in the exploded diagrams indicate where to apply a locking agent and when to install a new part Apply the locking agent LOCTITE Replace CONTENTS GENERAL INFORMATION 3 rica 1 MACHINE IDENTIFICATION oioo ciat id 1 VEHICLE IDENTIFICATION NUMBER o0oooocccoccccocnnconnnconanncnnncnnnnnnnnnnnnos 1 MODEL LABEL 0d 1 SPECIFICATIONS ikdiena aaia adea iaa inea ea TAA EAn 2 GENERAL SPECIFICATIONS sarita aia 2 MAINTENANCE SPECIFICATIONS 0000 ec eeeeceeeeee cence eeeeeeeeneeeenaeeeeeeeeees 3 ENGINE 0d oo can 3 CHASSIS uan latinas 5 ELECTRICAL Ea aos a 5 GABLE ROUTING 00 cti A daa 7 PERIODIC CHECKS AND ADJUSTMENTS ee 11 INTRODUCTION outside ISA aes 11 PERIODIC MAINTENANCE LUBRICATION INTERVALS 40111 11 SEAT FENDERS AND FUEL TANK 0eeneenene nanem enn anana nana ea
15. strictor plate 4 The engine should never be run without the air filter element excessive piston and or cylinder wear may result E CHK AIR FILTER CLEANING 6 Check e Air filter element Damage gt Replace 7 Clean e Air filter element kkkkxkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Cleaning steps Wash the element gently but thoroughly in solvent A WARNING Never use low flash point solvents such as gasoline to clean the air filter element Such solvent may lead to a fire or explo sion Squeeze the excess solvent out of the ele ment and let dry Do not twist the filter element when squeezing the filter element 11810402 e Apply the engine oil e Squeeze out the excess oil NOTE gt The element should be wet but not dripping kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 8 Install e Air filter element NOTE A A Make sure its sealing surface matches the sealing surface of the case so there is no air leak 18

4EM-AE1

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