Yamaha Badger Raptor 80 Manual
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– 5 – SPEC CABLE ROUTING 1Throttle cable 2Fuel tank breather hose 3Carburetor ventilation hose 4Final gear case breather hose 5Crankcase breather hose 6Fuel hose 7Band 8Starter relay 9Starting circuit cut-off relay 0Rectifier/regulatorABattery breather hose BCDI magneto lead CCarburetor overflow hose DFront brake cable (right) EFront brake cable (left) ÈPass the final gear case breather hose through the guide. ÉPass the battery breather hose through the hole. CABLE ROUTING
– 6 – SPEC 1Rear brake cable 2Band 3Wireharness 4Ignition coil 5Handlebar switch lead 6Rear brake switch lead 7“NEUTRAL” indicator light lead 8Main switch 9CDI unit 0Fuel hose AFront brake cable BFuel tank breather hoseCThrottle cable CABLE ROUTING
– 7 – SPEC 1Fuel tank breather hose 2Throttle cable 3Front brake cable (left) 4Front brake cable (right) 5Air filter joint 6Rear brake switch lead 7Handlebar switch lead 8“NEUTRAL” indicator light lead 9Rear brake cable CABLE ROUTING
– 8 – SPEC 1Front brake cable 2Throttle cable 3Fuel tank breather hose 4Battery negative lead 5Fuse 6Battery positive lead 7Band 8Handlebar switch 9Rear brake switch 0Rear brake cableÈPass the leads through the hole. CABLE ROUTING
– 9 – CHK ADJINTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS EB300000 PERIODIC CHECKS AND ADJUSTMENTS 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 INTERVALS * It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease. ITEM ROUTINEINITIAL EVERY1 month3 months6 months6 months1 year Valves*Check valve clearance. Adjust if necessary. Cam chain*Check chain tension. Adjust if necessary. Spark plugCheck condition. Adjust gap and clean. Replace if necessary. Air filter elementClean. 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. Spark arresterClean. Fuel line*Check fuel hose for cracks or damage. Replace if necessary. Engine oilReplace (warm engine before draining). Final gear oilCheck oil level/oil leakage. Replace every 12 months. Brakes*Check operation. Adjust if necessary. Clutch*Check operation. Adjust if necessary. Wheels*Check balance/damage/runout. Replace if necessary. Wheel bearings*Check bearing assemblies for looseness/damage. Replace if damaged. Steering system*Check operation. Repair if damaged. Check toe-in. Adjust if necessary. Knuckle shafts/ steering shaft*Lubricate every 6 months.** Fittings and fasten- ers*Check all chassis fittings and fasteners. Correct if necessary. Battery*Check specific gravity. Check breather hose for correct routing. Correct if necessary.
– 10 – CHK ADJ SEAT, FENDERS AND FUEL TANK SEAT, FENDERS AND FUEL TANK SEAT AND FRONT PANEL 1 3 4 5 2 Order Job name/Part name Q’ty Remarks Removing the seat and front panel Remove the parts in the order below. 1Seat 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.
– 11 – CHK ADJ SEAT, FENDERS AND FUEL TANK FRONT FENDER T R..7 Nm (0.7 m kg, 5.1 ft Ib) 41 2 3 Order 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.
– 12 – CHK ADJ SEAT, FENDERS AND FUEL TANK REAR FENDER 1 5 4 2 3 3 6 T R..7 Nm (0.7 m kg, 5.1 ft Ib)T R..7 Nm (0.7 m kg, 5.1 ft Ib) Order Job name/Part name Q’ty Remarks Removing 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.
– 13 – CHK ADJ SEAT, FENDERS AND FUEL TANK FUEL TANK 2 1 T R..10 Nm (1.0 m kg, 7.2 ft Ib) Order Job name/Part 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.
– 14 – CHK ADJ 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: Speed limiter length a Out of specification → Adjust. Speed limiter length: Less than 20 mm (0.8 in)a 2.Adjust: Speed limiter length *********************************************** Speed limiter 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 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). *********************************************** Turning in Speed limiter length is decreased. Turning out Speed limiter length is increased. 1 2