Yamaha Badger Raptor 80 Manual

							– 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