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SERVICE
INFORMATION
FOREWORD
This Service Information has been prepared to introduce new service and data for the YFM80GT.
For complete service information procedures it is necessary to use this Service Information together
with the following manual.
YFM80GT
SERVICE INFORMATION
©2004 by Yamaha Motor Co., Ltd.
First edition, August 2004
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in the Netherlands
EBS00002
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:
_
EBS00003
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING Failure to follow WARNING instructions could result in severe injury or death
to the machine operator, a bystander or a person checking or repairing the
machine.
CAUTION: 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.
EB003000
1 2 ILLUSTRATED SYMBOLS
GEN Illustrated symbols 1 to 9 are printed on the
INFO SPEC top right of each page and indicate the subject
of each chapter.
3 4 1 General information
2 Specifications
CHK 3 Periodic checks and adjustments
ADJ ENG 4 Engine
5 Carburetion
5 6 6 Drive train
7 Chassis
8 Electrical
CARB DRIV 9 Troubleshooting
7 8
– +
CHAS ELEC
9 0 Illustrated symbols 0 to F are used to identify
the specifications appearing in the text.
TRBL 0 Filling fluid
A Lubricant
SHTG B Special tool
A B C Torque
D Wear limit, clearance
E Engine speed
F Ω, V, A
C D
T.
R.
E F
SPECIFICATIONS ............................................................................................2
GENERAL SPECIFICATIONS ..................................................................2
MAINTENANCE SPECIFICATIONS .........................................................4
ENGINE ................................................................................................4
CHASSIS ..............................................................................................7
ELECTRICAL ........................................................................................7
CABLE ROUTING ....................................................................................9
GEN
MACHINE IDENTIFICATION INFO
EBS00009
GENERAL INFORMATION
MACHINE IDENTIFICATION
EBS00010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the left side of the frame.
1
EBS00011
MODEL LABEL
The model label 1 is affixed to the frame. This
information will be needed to order spare
parts.
–1–
–2–
SAE 5W30
–2–
–3–
–3–
–4–
Model YFM80GT
Camshaft:
Drive method Chain drive (Left)
Cam dimensions:
Intake: “A” 25.300 ~ 25.310 mm (0.9961 ~ 0.9965 in)
“B” 20.994 ~ 21.094 mm (0.8265 ~ 0.8305 in)
Exhaust: “A” 25.301 ~ 25.311 mm (0.9961 ~ 0.9965 in)
A
“B” 21.021 ~ 21.121 mm (0.8276 ~ 0.8315 in)
Direction of winding:
(top view) IN Clockwise
EX Clockwise
–4–
–5–
H
D
–5–
–6–
Tightening torques
Bolt M8 4 20 2.0 14
Neutral switch — M10 1 20 2.0 14
–6–
–7–
Model YFM80GT
Brake lever and brake pedal:
Front brake lever free play (pivot) 10.0 ~ 12.0 mm (0.39 ~ 0.47 in)
Rear brake lever free play (pivot) 5.0 ~ 8.0 mm (0.20 ~ 0.31 in)
Brake pedal free play 20.0 ~ 30.0 mm (0.79 ~ 1.18 in)
Throttle lever free play 3.0 ~ 5.0 mm (0.118 ~ 0.197 in)
Tightening torques
Tightening torque
Part to be tightened Thread size Remarks
Nm m · kg ft · lb
Lower arm and frame M12 60 6.0 43
Tie-rod and locknut M10 15 1.5 11
Steering shaft and frame M10 35 3.5 25
Steering shaft and handlebar holder M8 20 2.0 14
Front brake camshaft lever M6 9 0.9 6.5
Rear brake camshaft lever M6 9 0.9 6.5
Rear wheel and wheel hub M8 28 2.8 20
Footrest, brake pedal and frame M8 16 1.6 11
Front bumper and front fender M6 7 0.7 5.1
Front bumper and frame M8 23 2.3 17
Front fender and front grill M6 7 0.7 5.1
Front fender and frame M6 7 0.7 5.1
Rear carrier and frame M8 23 2.3 17
Footrest board and footrest bracket M6 10 1.0 7.2
Footrest bracket and frame M8 21 2.1 15
Rear fender and frame M6 7 0.7 5.1
ELECTRICAL
Model YFM80GT
C.D.I.:
Magneto model/manufacturer F2FM/MORIC
Pickup coil resistance/color 264 ~ 396 Ω at 20°C (68°F)/
White/Blue–White/Red
Source coil resistance/color 304 ~ 456 Ω at 20°C (68°F)/
Green/White–Black/Red
C.D.I.unit model/manufacturer 4EM/MORIC
Ignition coil:
Model/manufacturer 2JN/MORIC
Minimum spark gap 6.0 mm (0.24 in)
Primary winding resistance 0.18 ~ 0.28 Ω at 20°C (68°F)
Secondary winding resistance 6.32 ~ 9.48 Ω at 20°C (68°F)
–7–
–8–
–8–
–9–
CABLE ROUTING
1 Rear brake cable 0 Positive battery lead I Left front brake cable
2 Throttle cable A Wire harness J Frame
3 Fuel tank breather hose B Negative battery lead
4 Carburetor air vent hose C Rectifier/regulator
5 Crankcase breather hose D Battery breather hose
6 Final gear case breather hose E Starter motor lead
7 Fuel hose F C.D.I. magnet leads
8 Starter relay G Fuel overflow hose
9 Starting circuit cut-off relay H Right front brake cable
Ø
J
8
×
A-A
É 3
B
Ê
2 4
1
È 5
Ë
Ö 6 C
Í
7
Õ Ì
89 0A
B
A
B A
Ô Î
Ï
D Ð
I Ó FÒ E Ñ
H G
–9–
– 10 –
Ø
J
8
×
A-A
É 3
B
Ê
2 4
1
È 5
Ë
Ö 6 C
Í
7
Õ Ì
89 0A
B
A
B A
Ô Î
Ï
D Ð
I Ó FÒ E Ñ
H G
– 10 –
– 11 –
Ø
J
8
×
A-A
É 3
B
Ê
2 4
1
È 5
Ë
Ö 6 C
Í
7
Õ Ì
89 0A
B
A
B A
Ô Î
Ï
D Ð
I Ó FÒ E Ñ
H G
– 11 –
– 12 –
C 7
B D
8
E
Ñ
Ò
5
1
C-C
Ð A-A 6
B
5
Ë B
Ì 6
34
12 Ê 7
É A Í
È Î
8
C C
A
9 Ï
0
A
– 12 –
– 13 –
C 7
B D
8
E
Ñ
Ò
5
1
C-C
Ð A-A 6
B
5
Ë B
Ì 6
34
12 Ê 7
É A Í
È Î
8
C C
A
9 Ï
0
A
– 13 –
– 14 –
C 7
B D
8
E
Ñ
Ò
5
1
C-C
Ð A-A 6
B
5
Ë B
Ì 6
34
12 Ê 7
É A Í
È Î
8
C C
A
9 Ï
0
A
– 14 –
– 15 –
3
2
1 4
Ì 5
6
Í Î A
A
0
7È
Ë
9
8 B
B
9
7 Ê
B-B É
– 15 –
– 16 –
3
2
1 4
Ì 5
6
Í Î A
A
0
7È
Ë
9
8 B
B
9
7 Ê
B-B É
– 16 –
– 17 –
2 3
9
8 4
5
0
A A
É
Ë
9 3
7
8
1
0
5
Ê
4
A-A
– 17 –
– 18 –
INTRODUCTION/ CHK
PERIODIC MAINTENANCE/LUBRICATION ADJ
EBS00029
INITIAL EVERY
Whichever month 1 3 6 6 12
ITEM ROUTINE comes first km 320 1,200 2,400 2,400 4,800
(mi) (200) (750) (1,500) (1,500) (3,000)
hours 20 75 150 150 300
• Check valve clearance.
Valves*
• Adjust if necessary.
• Check chain tension.
Cam chain*
• Adjust if necessary.
• Check condition.
Spark plug • Adjust gap and clean.
• Replace if necessary.
• Clean. Every 20 ~ 40 hours
Air filter element
• Replace if necessary. (more often in wet or dusty areas)
• Check idle speed/choke lever operation.
Carburetor*
• Adjust if necessary.
Crankcase breather • Check breather hose for cracks or damage.
system* • Replace if necessary.
• Check for leakage.
Exhaust system* • Tighten if necessary.
• Replace gasket if necessary.
• Check fuel hose for cracks or damage.
Fuel line*
• Replace if necessary.
Engine oil • Replace (warm engine before draining).
• Check oil level/oil leakage.
Final gear oil
• Replace every 12 months.
• Check operation.
Brakes*
• Adjust if necessary.
• Check operation.
Clutch*
• Adjust if necessary.
• Check balance/damage/runout.
Wheels*
• Replace if necessary.
• Check bearing assemblies for looseness/damage.
Wheel bearings*
• Replace if damaged.
• Check operation.
• Replace if damaged.
Steering system*
• Check toe-in.
• Adjust if necessary.
Knuckle shafts/ • Lubricate every 6 months with lithium-soap-based
steering shaft* grease.
– 18 –
– 19 –
CHK
PERIODIC MAINTENANCE/LUBRICATION ADJ
INITIAL EVERY
Whichever month 1 3 6 6 12
ITEM ROUTINE comes first km 320 1,200 2,400 2,400 4,800
(mi) (200) (750) (1,500) (1,500) (3,000)
hours 20 75 150 150 300
Fittings and fasten- • Check all chassis fittings and fasteners.
ers* • Correct if necessary.
• Check specific gravity.
Battery* • Check breather hose for correct routing.
• Correct if necessary.
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform
the service.
WARNING
_
– 19 –
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN