Yamaha Grizzly 80 (YFM80GT) ATV Service Manual Set, 2005–2008 (P/N LIT-11616-18-47)
252 Pages • ZIP Download: Printable PDF • 31.19 MB
Yamaha Models Covered & Key Technical Specifications
Model & Model Codes: Grizzly 80 (YFM80GT, 2D31)
Model Years: 2005–2008 (2005, 2006, 2007, 2008)
Sub-models / Variants: Included reference manuals cover Badger (YFM80M/YFM80MC, 4EMT outside California, 4EMS for California) and YFM80(D) (4EM 1 for USA and OCE, 4EM 2 for EUR).
YFM80(D) starting serial numbers: Frame and engine: 4EM-000101 (USA and OCE), 4EM-016101 (EUR). Australian starting VIN: JY44EMW0*NA000101 (AUS).
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Engine displacement: 79 cc (YFM80(D))
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Engine type: Air cooled, 4-stroke, SOHC, single cylinder (YFM80(D))
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Starter system: Electric
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Transmission type: Constant mesh, 3-speed (YFM80(D))
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Brake type: Drum (front and rear, YFM80(D))
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Tire size: AT18 x 7-7 (front, YFM80(D) and YFM80M/YFM80MC), AT18 x 8-7 (rear, YFM80M/YFM80MC), AT20 x 9-8 (rear, YFM80(D))
Yamaha Manual Features & Selected Content Preview
| Publication | Pages |
|---|---|
| Grizzly 80 YFM80GT Supplementary Service Manual (model code 2D31, first edition, August 2004, P/N LIT-11616-18-47, Yamaha document code 2D3-28197-10) | 34 |
| Badger YFM80M/YFM80MC Supplementary Service Manual (first edition, September 1999, P/N LIT-11616-13-28, Yamaha document code 4EM-28197-21) | 15 |
| YFM80(D) Service Manual (first edition, September 1991, P/N LIT-11616-08-19, Yamaha document code 4EM-28197-20) | 203 |
Yamaha directs technicians to use the GT supplement with both earlier publications. The supplement gives the GT-specific updates, while the base manual supplies the underlying repair and diagnostic procedures.
PDF Search, Bookmarks, and Wiring Sheets
Search and navigation: Text search covers the GT supplement. Bookmarks jump to sections in all three publications and to both wiring sheets. Zoom in to read the small wire-color codes and connector labels.
The ZIP download contains one printable PDF with 252 pages. The total includes six front and back cover pages and two foldout wiring sheets, one for YFM80(D) and one for YFM80M/YFM80MC.
GT Service Updates, Engine Overhaul, and Electrical Tests
These selected workshop topics give a preview of the set. Other procedures include drive-shaft dust boot inspection and engine oil strainer cleaning.
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GT service updates: Machine identification, revised service specifications, cable and hose routing, front and rear body panel removal, speed limiter adjustment, air filter service, spark arrester cleaning, and handlebar installation.
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Periodic maintenance: Cam chain tension, valve clearance, ignition timing, compression, clutch and brake adjustment, brake lining wear, final gear oil, toe-in, wheel bearings, battery inspection, and fuse checks.
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Engine and transmission overhaul: Engine removal, cylinder head and cylinder disassembly, piston and valve train inspection, cam chain service, crankshaft inspection, crankcase work, and transmission and shift mechanism service.
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Carburetor service: Removal, disassembly, component inspection, and fuel level adjustment, with separate specifications for the carburetor used on the GT.
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Chassis and shaft drive: Front and rear brakes, wheels and bearings, steering, front shocks and lower arms, rear shock and swingarm, and final drive removal, inspection, and installation.
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Electrical diagnosis: Switch and bulb checks, CDI ignition tests, starter motor and starting circuit diagnosis, charging tests, and neutral indicator troubleshooting.
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Factory reference data: Component torque tables, lubricant grades and capacities, inspection limits, clearances, exploded assembly views, job charts, and Yamaha special-tool numbers.
This set is intended for technicians and experienced home mechanics. Brake, steering, engine, and electrical work calls for the specified tools and suitable experience, or review by a qualified technician before the ATV returns to service.
Assembly Checks and Special Tools
Exploded views and job charts identify parts, quantities, and assembly order before disassembly. The engine chapter covers the starter clutch, oil pump, CDI magneto, and middle gear, including a chart for selecting the driven gear shims.
The crankcase section calls for a shift operation check before final tightening. The clutch diagrams identify the positions of the black friction plate and bent clutch plate, and the oil pump section warns of engine damage if the pump passages are left dry during assembly.
Yamaha lists the compression gauge (90890-03081) and adapter (90890-04082), universal clutch holder (90890-04086), rotor puller (90890-01189), and pocket tester (90890-03112).
Wiring and Fault Diagnosis
The starting circuit tests help isolate a no-crank fault among the starter motor, relay, cut-off relay, and switch circuit. The base manual also lists possible causes of hard starting, poor running, driveline or shifting faults, clutch slip or drag, overheating, weak braking, shock absorber faults, and unstable handling.
The GT supplement provides cable and hose routing drawings and electrical specifications. The foldout wiring diagrams belong to the YFM80(D) and YFM80M/YFM80MC publications.
Carburetor and Ignition Specification Preview
For the YFM80GT carburetor, Yamaha lists a fuel level of 2.5–4.5 mm below the carburetor body edge and a float height of 20.0–22.0 mm. The two specifications distinguish the fuel level measurement from the float setting.
The GT ignition specifications give a pickup coil resistance of 264–396 Ω at 20°C between the white/blue and white/red leads.
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