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Skoda - Auto - skoda-karoq-2017-110444
Skoda - Auto - skoda-karoq-2017-brukerhandbok-110449
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Skoda - Auto - skoda-karoq-2017-110460
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Skoda - Auto - skoda-karoq-2017-110457
VCRs & Accessories - Hitachi Electronics - VTM171A
Skoda - Auto - skoda-karoq-2017-110431
Skoda - Auto - skoda-karoq-2017-kullan-m-k-lavuzu-110458
1981-1995--Chrysler--Lebaron--4 Cylinders C 2.2L FI Turbo SOHC--31006701
Skoda - Auto - skoda-karoq-2017-110441
1981-1995--Chrysler--Lebaron--4 Cylinders J 2.5L MFI Turbo SOHC--31034803
Skoda - Auto - skoda-karoq-2017-prirocnik-za-lastnika-110456
1981-1995--Chrysler--Lebaron--4 Cylinders J 2.5L MFI Turbo SOHC--31006702
Barossa - Motorcycle - Barossa__Barossa_PYTHON_100cc_parts_5d8a7f921c3648a62136367
Pool Equipment - Haywood-Pool - Super Pump~All Super Pump Models
Skoda - Auto - skoda-karoq-2017-uzivatelska-prirucka-110455
Skoda - Auto - skoda-karoq-2017-instrukcja-obslugi-110450
Skoda - Auto - skoda-karoq-2017-omaniku-kasiraamat-110436
Skoda - Auto - skoda-karoq-2017-ipasnieka-rokasgramata-110447
Skoda - Auto - skoda-karoq-2017-110453
Barossa - Motorcycle - Barossa_PYTHON_100cc_parts
Skoda - Auto - skoda-karoq-2017-manuale-del-proprietario-110445
Sewing Machine - Singer - 14T968DC %7C PROFESSIONAL 5
Skoda - Auto - skoda-karoq-2017-manuel-du-proprietaire-110440
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.2L TBI SOHC--31095601
1981-1995--Chrysler--Lebaron--4 Cylinders B 2.2L 2BL SOHC--31218101
Skoda - Auto - skoda-karoq-2017-agarmanual-110454
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.6L 2BL SOHC--31218102
Skoda - Auto - skoda-karoq-2017-handleiding-110448
Furniture & Storage - Blue Rhino - GAD1375SP
Skoda - Auto - skoda-karoq-2017-kezelesi-utmutato-110443
Skoda - Auto - skoda-karoq-2017-110459
Barossa - Motorcycle - Barossa__Barossa_PYTHON_100cc_parts
Skoda - Auto - skoda-karoq-2017-110432
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Speakers & Audio Accessories - Dual - Dual - SX652 ~ SX692
Skoda - Auto - skoda-karoq-2017-instruktionsbog-110435
Grills & Accessories - Blue Rhino - Blue Rhino WAD996SP
Skoda - Auto - skoda-karoq-2017-vodic-za-korisnike-110442
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.2L TBI SOHC--31034802
Printers & Accessories - Xerox - WorkCentre Pro C2128~C2636~C3545
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Sewing Machine - Brother - Brother BAS-511
Skoda - Auto - skoda-karoq-2017-owner-s-manual-110437
Ducati - Motorcycle - Ducati_M620_ie_Parts_2002
Speaker Systems - JBL - Xtreme
Cameras & Accessories - Nikon - Nikon COOLPIX S203
Video Cameras, Camcorders, & Accessories - Canon - ZR900 Camcorder
Cars & Automotive Accessories - Ford - F-150 2001
Skoda - Auto - skoda-karoq-2017-manual-do-proprietario-110451
Printers & Accessories - Epson - Stylus Pro 9000
Sewing Machine - Brother - Brother DB2-B798
DJ Equipment - Kramer AV - VM-4HDT
Power Tools & Accessories - STIHL - STIHL Trimmer FS 40, FS 50
Printers & Accessories - Epson - WorkForce 40
Summary of Content
1C5-9-10 hyoshi 8/12/03 11:45 AM Page 1 EBU00438 READ THIS MANUAL CAREFULLY! It contains important safety information. qWARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: 9 without proper training or instruction. 9 use proper riding techniques to avoid 9 at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns. 9 on public roads - a collision can occur with 9 avoid paved surfaces - pavement may another vehicle. seriously affect handling and control. 9 with a passenger - passengers affect balance and steering and increase risk of losing control. LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) OWNER’S MANUAL YFM125S w YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.12-1.2x1 ! (E) LIT-11626-17-56 This ATV should not be ridden by anyone under 16 years of age. 1C5-28199-10 1C5-9-10 hyoshi 8/12/03 11:45 AM Page 2 1C5-9-10-1 9/12/03 9:30 AM Page 1 EBU13290 INTRODUCTION Congratulations on your purchase of the Yamaha YFM125. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this ATV. This manual includes important safety information. It provides information about special techniques and skills necessary to ride your ATV. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer. AN IMPORTANT SAFETY MESSAGE: 8 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. 8 PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV. 8 NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMATION. 8 THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE. 1C5-9-10-1 9/12/03 9:30 AM Page 2 EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! w 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. cC A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer. 1C5-9-10-1 9/12/03 9:30 AM Page 3 EBU00011 IMPORTANT NOTICE This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this machine on any public street, road or highway. This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this machine. EBU13330 AFFIX DEALER LABEL HERE YFM125S OWNER'S MANUAL © 2003 by Yamaha Motor Corporation, U.S.A. 1st edition, December 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan. P/N LIT-11626-17-56 1C5-9-10-1 9/12/03 9:30 AM Page 4 EBU00014 w Indicates a potential hazard that could result in serious injury or death. CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS .......................1-1 2 SAFETY INFORMATION .........................2-1 3 DESCRIPTION AND MACHINE IDENTIFICATION.....................................3-1 Identification number records ...............3-2 Key identification number .....................3-2 Vehicle identification number ...............3-3 Model label ...........................................3-3 4 CONTROL FUNCTIONS ..........................4-1 Main switch ...........................................4-1 Indicator lights ......................................4-2 Handlebar switches ..............................4-2 Throttle lever ........................................4-4 Speed limiter ........................................4-5 Front brake lever ..................................4-6 Rear brake lever ...................................4-6 Parking brake .......................................4-7 Drive select lever ..................................4-8 Fuel tank cap ........................................4-8 Fuel cock ..............................................4-9 Starter (choke)....................................4-10 Seat ....................................................4-10 Front carrier ........................................4-11 Rear carrier ........................................4-11 1C5-9-10-1 9/12/03 9:30 AM Page 5 5 PRE-OPERATION CHECKS ...................5-1 Front and rear brakes ...........................5-2 Fuel ......................................................5-3 Engine and transmission oil .................5-5 Chain ....................................................5-6 Throttle lever ........................................5-6 Fittings and fasteners ...........................5-6 Lights ....................................................5-6 Switches ...............................................5-6 Battery ..................................................5-6 Tires .....................................................5-7 How to measure tire pressure ..............5-8 Tire wear limit .......................................5-9 6 OPERATION ............................................6-1 Starting a cold engine...........................6-1 Starting a warm engine ........................6-3 Warming up ..........................................6-3 Drive select lever operation and reverse driving ....................................6-4 Engine break-in ....................................6-6 Parking .................................................6-7 Parking on a slope................................6-8 Accessories and loading ......................6-9 7 Riding Your ATV.......................................7-1 Getting to know your ATV .....................7-3 Ride with care and good judgement...........................................7-4 Be careful where you ride...................7-16 Turning your ATV ...............................7-22 Climbing uphill ....................................7-24 Riding downhill ...................................7-30 Crossing a slope.................................7-32 Crossing through shallow water .........7-34 Riding over rough terrain ....................7-36 Sliding and skidding ...........................7-38 What to do if .......................................7-40 What to do ..........................................7-40 1C5-9-10-1 8 9/12/03 9:30 AM Page 6 PERIODIC MAINTENANCE AND ADJUSTMENT .........................................8-1 Owner’s manual and tool kit .................8-1 Periodic maintenance/Lubrication ........8-3 Engine oil..............................................8-5 Final transmission oil ............................8-7 Spark plug inspection ...........................8-9 Engine air filter element and V-belt case air filter element cleaning .........8-11 Spark arrester cleaning ......................8-16 Idle speed adjustment ........................8-17 Valve clearance adjustment ...............8-18 Throttle lever adjustment ....................8-19 Front and rear brake shoe inspection .........................................8-20 Front brake lever free play adjustment ........................................8-21 Rear brake adjustment .......................8-25 Drive chain slack check ......................8-27 Drive chain slack adjustment..............8-28 Lubricating the drive chain .................8-30 Draining the V-belt compartment........8-31 Cable inspection and lubrication ........8-31 Brake lever lubrication ........................8-32 Knuckle shaft, lower arms and steering shaft lubrication ..................8-32 Wheel removal ...................................8-33 Wheel installation ...............................8-33 Battery ................................................8-34 Replenishing the battery fluid .............8-36 Fuse replacement...............................8-37 Replacing the headlight bulb ..............8-38 Tail/brake light bulb replacement .......8-40 Headlight beam adjustment................8-41 Troubleshooting..................................8-42 Troubleshooting chart.........................8-43 9 CLEANING AND STORAGE ....................9-1 A. CLEANING .......................................9-1 B. STORAGE .......................................9-3 10 SPECIFICATIONS .................................10-1 1C5-9-10-1 9/12/03 9:30 AM Page 7 11 NOISE REGULATION............................11-1 12 MAINTENANCE RECORD ....................12-1 13 ATV LIMITED WARRANTY ...................13-1 14 YAMAHA EXTENDED SERVICE (Y.E.S.)...................................................14-1 1C5-9-10-1 9/12/03 9:30 AM Page 8 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS 6 8 1 5 2 4 3 1-1 7 8 1C5-9-10-1 9/12/03 9:30 AM Page 9 2 Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. 1 Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 1 1C5-21696-00 3 qWARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 5FE-21697-01 5FE-2151H-01 1-2 1C5-9-10-1 9/12/03 9:30 AM Page 10 4 5 DRIVE SELECT LEVER 8 Read owner’s manual carefully before operating. 8 ATV MUST be stopped before shifting select lever. 8 Shifting into reverse is impossible without applying the rear brake. 5YT-2151E-01 6 5kg 11lbs 3LD-24877-A0 7 10kg 22lbs 1C5-24877-A0 8 NEVER sit here. 3MX-24875-A0 5FE-21568-01 1-3 1C5-9-10-1 9/12/03 9:30 AM Page 2-1 EBU13360 q SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: 8 Read this manual and all labels carefully and follow the operating procedures described. 8 Never operate an ATV without proper training or instruction. Take a Training Course. Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1-800-887-2887 to find out about the training courses nearest you. 8 Always follow the age recommendation: - A child under 16 years old should never operate an ATV with engine size greater than 90cc. 8 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely. 8 Never carry a passenger on an ATV. 2-1 2 1C5-9-10-1 9/12/03 9:30 AM Page 2-2 8 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. 8 Never operate an ATV on any public street, road or highway, even a dirt or gravel one. 8 Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. 8 Never consume alcohol or drugs before or while operating this ATV. 8 Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience. 8 Never attempt wheelies, jumps, or other stunts. 8 Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. 8 Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. 8 Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. 2-2 1C5-9-10-1 9/12/03 9:30 AM Page 2-3 8 Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. 8 Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. 8 Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. 8 Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high speed. 8 Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible. 8 Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible. 2-3 1C5-9-10-1 9/12/03 9:30 AM Page 2-4 8 Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. 8 Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. 8 Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. 8 Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings. 8 Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. 8 Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual. 8 Never modify an ATV through improper installation or use of accessories. 2-4 1C5-9-10-1 9/12/03 9:30 AM Page 2-5 8 Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344. 2-5 1C5-9-10-1 9/12/03 9:30 AM Page 2-6 qWARNING Otherwise, fuel may leak out of the carburetor or fuel tank. POTENTIAL HAZARD WHAT CAN HAPPEN Improper handling of gasoline. Gasoline is poisonous and can cause injuries. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling. Never refuel while smoking, or while in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers. When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” position. 2-6 1C5-9-10-1 9/12/03 9:30 AM Page 2-7 qWARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation. 2-7 1C5-9-10-1 9/12/03 9:30 AM Page 3-2 EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1 2 3 5 4 6 7 890 q e w r t 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. y Seat Drive select lever Front cover Headlight Front carrier Starter (choke) Fuel cock Tail/brake light Rear carrier Spark arrester 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Footboard Rear brake lever Parking brake Reverse indicator light Neutral indicator light Front brake lever Throttle lever Main switch Fuel tank cap Handlebar switches NOTE: p o i u 3-1 The machine you have purchased may differ slightly from those shown in the figures of this manual. 1C5-9-10-1 9/12/03 9:30 AM Page 3-3 EBU00600 EBU00035 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: Key identification number The key identification number is stamped on the key as shown in the following illustration. This number can be used for ordering a new key. q 2. VEHICLE IDENTIFICATION NUMBER: 1. Key identification number 3. MODEL LABEL INFORMATION: 1 6 3-2 3 1C5-9-10-1 9/12/03 9:30 AM Page 3-4 EBU00036 EBU00787 Vehicle identification number The vehicle identification number is stamped into the frame. Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1 q 1. Vehicle identification number NOTE: The vehicle identification number is used to identify your machine. 1. Model label 3-3 1C5-9-10-1 9/12/03 9:30 AM Page 4-1 EBU00039 CONTROL FUNCTIONS OFF ON w Indicates a potential hazard that could result in serious injury or death. 4 EBU09420 Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights and taillight come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position. 4-1 1C5-9-10-1 9/12/03 9:30 AM Page 4-2 EBU00043 EBU00053 Indicator lights Handlebar switches 1 2 w q e 1. Reverse indicator light “R” 2. Neutral indicator light “N” 1. Engine stop switch “ENG. STOP” 2. Light switch “LIGHTS” 3. Start switch “START” EBU12500 EBU11580 Reverse indicator light “R” This indicator light comes on when the drive select lever is in the “R” position. Engine stop switch “ENG. STOP” Make sure that the engine stop switch is in the “RUN” position before starting the engine. The engine stop switch controls ignition and can be used at all times to stop the engine, especially in an emergency. The engine will not start or run when the engine stop switch is turned to “OFF”. EBU09720 Neutral indicator light “N” This indicator light comes on when the drive select lever is in the “N” position. 4-2 1C5-9-10-1 9/12/03 9:30 AM Page 4-3 EBU00056 EBU14770 Start switch “START” The starter motor cranks the engine when this switch is pushed. Light switch “LIGHTS” Set the switch to the “LO” position to turn on the low beam and the taillight. Set the switch to the “HI” position to turn on the high beam and the taillight. Set the switch to the “OFF” position to turn off all of the lights. cC See starting instructions prior to starting engine (see page 6-1 for details). cC NOTE: Do not use the headlights with the engine turned off for an extended period of time, otherwise the battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. If the starter switch is pushed with the main switch “ON” and the engine stop switch “OFF”, the starter motor will be activated but the engine will not start. To start the engine, be sure to position the engine stop switch at “RUN”. 4-3 1C5-9-10-1 9/12/03 9:30 AM Page 4-4 EBU00062 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. qWARNING POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident. HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can't find or solve the problem yourself. q 1. Throttle lever 4-4 1C5-9-10-1 9/12/03 9:30 AM Page 4-5 EBU11590 qWARNING Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. w HOW TO AVOID THE HAZARD q Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in). See page 8-19. a 1. Adjusting screw 2. Locknut a. No more than 12 mm (0.47 in) 4-5 1C5-9-10-1 9/12/03 9:30 AM Page 4-6 EBU00070 EBU00072 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. Rear brake lever The rear brake lever is located on the left handlebar. Pull it toward the handlebar to apply the rear brake. q q 1. Front brake lever 1. Rear brake lever 4-6 1C5-9-10-1 9/12/03 9:30 AM Page 4-7 EBU00074 qWARNING Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake could overheat if you ride the ATV without releasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely. HOW TO AVOID THE HAZARD q Always set the parking brake before starting the engine. Always be sure you have released the parking brake before you begin to ride. 1. Lock plate 4-7 1C5-9-10-1 9/12/03 9:30 AM Page 4-8 EBU11060 EBU00092 Drive select lever The drive select lever is used to shift your machine into the forward, neutral and reverse positions. (Refer to page 6-4 for the drive select lever operation.) Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1 1 3 2 1. Fuel tank cap a a. Drive select lever 2. Forward 1. Neutral 3. Reverse 4-8 1C5-9-10-1 9/12/03 9:30 AM Page 4-9 EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES: This indicates reserve. If you run out of fuel while riding, turn the lever to this position. THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY. After refuelling, return the fuel cock lever to the “ON” position. RES OFF ON 4-9 1C5-9-10-1 9/12/03 9:30 AM Page 4-10 EBU00094 EBU00567 Starter (choke) Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to “Starting a cold engine” for proper operation. (See page 6-1.) Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. q A b 1. Seat lock lever a e w q 1. Fully open 3. Closed 2. Half open A. Starter (choke) 4-10 1C5-9-10-1 9/12/03 9:30 AM Page 4-11 EBU05820 To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. Front carrier Maximum load limit: 5 kg (11 lb) EBU05830 Rear carrier Maximum load limit: 10 kg (22 lb) NOTE: Make sure that the seat is securely fitted. EBU00112 w Indicates a potential hazard that could result in serious injury or death. 4-11 1C5-9-10-1 9/12/03 9:30 AM Page 5-2 PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE Brakes • Check operation, condition and free play. • Adjust if necessary. Fuel • Check fuel level. • Fill with fuel if necessary. Engine oil and final transmission oil • Check oil level. • Fill with oil if necessary. Drive chain • Check chain slack and condition. • Adjust if necessary. Throttle • Check for proper throttle cable operation. Wheels and tires • Check tire pressure, wear and damage. Fittings and fasteners • Check all fitting and fasteners. Battery • Check fluid level. • Fill with distilled water if necessary. 5-6, 8-34–8-36 Lights and switches • Check for proper operation. 5-6, 8-38–8-41 5-2–5-3, 8-20–8-26 5-3–5-4 5-5, 8-5–8-9 5-1 5-5, 8-27–8-30 5-6 5-7–5-9, 8-33 5-6 1C5-9-10-1 9/12/03 9:30 AM Page 5-3 EBU04721 qWARNING Front and rear brakes 8 Brake levers Check for correct free play in the brake levers. If the free play is incorrect, adjust it. (See pages 8-21–8-26.) POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. 8 Check operation of the levers. They should move smoothly and there should be a firm feeling when the brake is applied. If not, have the machine inspected by a Yamaha dealer. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. 8 Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, inspect the brakes for wear. (See page 8-20.) 5-2 5 1C5-9-10-1 9/12/03 9:30 AM Page 5-4 EBU13410 qWARNING Fuel Make sure there is sufficient gasoline in the tank. POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have the ATV inspected by a Yamaha dealer. 1. Filler tube 2. Fuel level Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: Total: 7.6 L (1.67 Imp gal, 2.01 US gal) Reserve: 1.3 L (0.29 Imp gal, 0.34 US gal) 5-3 1C5-9-10-1 9/12/03 9:30 AM Page 5-5 cC qWARNING Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost. Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems. HOW TO AVOID THE HAZARD Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely. Do not refuel right after the engine has been running and is still very hot. 5-4 1C5-9-10-1 9/12/03 9:30 AM Page 5-6 EBU11163 Engine and final transmission oil Make sure the engine and final transmission oil is at the specified level. Add oil as necessary. (See page 8-5.) Recommended engine oil type and quantity: See page 10-2. Recommended final transmission oil type and quantity: See page 10-2. cC 8 Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. 8 Be sure no foreign material enters the crankcase. EBU00498 Chain Check the general condition of the chain and check the chain slack before every ride. Lubricate and adjust the chain as necessary. (See pages 8-27–8-30 for details.) 5-5 1C5-9-10-1 9/12/03 9:30 AM Page 5-7 EBU01083 EBU11700 Throttle lever Check to see that the throttle lever operates correctly. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer repair as necessary for proper operation. Switches Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation. EBU00499 Battery Check fluid level and fill if necessary. Use only distilled water if refilling is necessary. (See pages 8-34–8-36.) EBU01162 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. EBU00803 Lights Check the headlight and tail/brake light to make sure they are in working condition. Repair as necessary for proper operation. 5-6 1C5-9-10-1 9/12/03 9:30 AM Page 5-8 EBU00157 Tires 2. The tires should be set to the recommended pressure: 8 Recommended tire pressure Front 20 kPa (0.20 kgf/cm2, 2.9 psi) Rear 25 kPa (0.25 kgf/cm2, 3.6 psi) 8 Check and adjust tire pressures when the tires are cold. 8 Tire pressures must be equal on both sides. 3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums: Front 17 kPa (0.17 kgf/cm2, 2.5 psi) Rear 22 kPa (0.22 kgf/cm2, 3.2 psi) qWARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. HOW TO AVOID THE HAZARD 1. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. Other tire combinations are not recommended. Manufacturer Size Type Front DUNLOP AT20 × 7 - 8 KT536A Rear DUNLOP AT22 × 10 - 8 KT537A 5-7 1C5-9-10-1 9/12/03 9:30 AM Page 5-9 Set pressure with tires cold. Set tire pressures to the following specifications: 4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst. Recommended pressure Minimum Maximum Front 20 kPa (0.20 kgf/cm2, 2.9 psi) 17 kPa (0.17 kgf/cm2, 2.5 psi) 23 kPa (0.23 kgf/cm2, 3.2 psi) Rear 25 kPa (0.25 kgf/cm2, 3.6 psi) 22 kPa (0.22 kgf/cm2, 3.2 psi) 28 kPa (0.28 kgf/cm2, 4.0 psi) EBU00159 How to measure tire pressure Use the low-pressure tire gauge. q NOTE: The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. 1. Low-pressure tire gauge 5-8 1C5-9-10-1 9/12/03 9:30 AM Page 5-10 EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a a. Tire wear limit 5-9 1C5-9-10-1 9/12/03 9:30 AM Page 6-1 EBU00161 EBU00509 Starting a cold engine OPERATION qWARNING w POTENTIAL HAZARD Indicates a potential hazard that could result in serious injury or death. Freezing control cables in cold weather. WHAT CAN HAPPEN qWARNING You could be unable to control the ATV, which could lead to an accident or collision. POTENTIAL HAZARD Operating ATV without being familiar with all controls. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD 1. Set the parking brake. 2. Turn the fuel cock to “ON”. 3. Turn the main switch to “ON” and the engine stop switch to “RUN”. 4. Shift the drive select lever to neutral. Read the Owner’s Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer. 6-1 6 1C5-9-10-1 9/12/03 9:30 AM Page 6-2 NOTE: AMBIENT TEMP./STARTER (CHOKE) POSITION 8 The engine can be started only when the drive select lever is in neutral. 8 When the drive select lever is in neutral, the neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it. 5. Use the starter (choke) in reference to the figure: Position 1: Cold engine startambient temperature below 5°C (40°F). Position 2: Cold engine startambient temperature at 0°C (30°F)–30°C (90°F) and warming up position. Position 3: Cold engine startambient temperature above 25°C (80°F) and warm engine start position. 1. Fully open 3. Closed 2. Half open a. Starter (choke) 6. Completely close the throttle lever and start the engine by pushing the start switch. 6-2 1C5-9-10-1 9/12/03 9:30 AM Page 6-3 NOTE: cC If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. See the “Engine break-in” section prior to operating engine for the first time. EBU00180 Starting a warm engine To start a warm engine, refer to the “Starting a cold engine” section. The starter (choke) should not be used. The throttle should be opened slightly. 7. If the engine is started with the starter (choke) in position 1, the starter (choke) should be returned to position 2 to warm up the engine. If the engine is started with the starter (choke) in position 2 , keep the starter (choke) in this position to warm up the engine. 8. Continue warming up the engine until it idles smoothly and return the starter (choke) to position 3 before riding. EBU00182 Warming up To get maximum engine life, always warm up the engine before starting off. Never accelerate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally with the starter (choke) turned off. 6-3 1C5-9-10-1 9/12/03 9:30 AM Page 6-4 EBU12250 Drive select lever operation and reverse driving 1 3 cC 2 Before shifting, you must stop the machine and return the throttle lever to its closed position. Otherwise, the transmission may be damaged. a a. Drive select lever 2. Forward Shifting: forward 1. Bring the machine to a complete stop and return the throttle lever to the closed position. 2. Shift the gear from neutral to forward and vice versa by moving the drive select lever along the shift guide. 1. Neutral 3. Reverse Shifting: reverse 1. Bring the machine to a complete stop and return the throttle lever to the closed position. 2. Apply the parking brake. 3. Shift the gear from neutral to reverse and vice versa by moving the drive select lever along the shift guide. NOTE: Make sure that the drive select lever is completely shifted into position. 3. Open the throttle lever gradually. 6-4 1C5-9-10-1 9/12/03 9:30 AM Page 6-5 qWARNING NOTE: When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect the ATV. POTENTIAL HAZARD Improper operation in reverse. WHAT CAN HAPPEN 4. Check behind for people or obstacles, then release the parking brake. 5. Open the throttle lever gradually and continue to watch to the rear while backing. You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly. NOTE: If the drive select lever is shifted into reverse while the engine is running, the engine will stop unless the rear brake lever or parking brake is applied. 6-5 1C5-9-10-1 9/12/03 9:30 AM Page 6-6 EBU02091 Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r/min so the engine can rid itself of the temporary build up of heat. If any abnormality is noticed during this period, consult a Yamaha dealer. Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided. However, momentary (2–3 seconds maximum) full throttle operation under load does not harm the engine. 0–10 hours: 8 Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of operation. Vary the speed of the machine from time to time. Do not operate it at one set throttle position. 6-6 1C5-9-10-1 9/12/03 9:30 AM Page 6-7 EBU00211 10–20 hours: 8 Avoid prolonged operation above 3/4 throttle. Rev the machine freely through the gears but do not use full throttle at any time. Parking When parking, stop the engine and shift into neutral. Turn the fuel cock to “OFF” and apply the parking brake. After break-in: 8 Avoid prolonged full throttle operation. Vary speeds occasionally. 1 1. Locked position 6-7 1C5-9-10-1 9/12/03 9:30 AM Page 6-8 EBU00215 Parking on a slope 1. Bring the machine to a stop by applying the brakes. 2. Stop the engine. 3. With the rear brake applied, apply the parking brake. qWARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the machine transversely across the incline, apply the parking brake, and block the front and rear wheels with rocks or other objects. Do not park the ATV at all on hills that are so steep you could not walk up them easily. 6-8 1C5-9-10-1 9/12/03 9:30 AM Page 6-9 EBU00221 8 Do not mount an accessory where it could interfere with your ability to control the ATV. Examples include (but are not limited to) a heavy or bulky object attached to the handlebars which could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view. 8 Use extra caution when riding an ATV with accessories. The ATV may handle differently than it does without accessories. Accessories and loading EBU00222 Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. 8 Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market. However, it is not possible for Yamaha to test all non-Yamaha accessories, nor have any control over the quality or suitability of them. Choose a genuine Yamaha accessory, or one that is equivalent in design and quality. 8 Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV. 6-9 1C5-9-10-1 9/12/03 9:30 AM Page 6-10 EBU14780 8 Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident. 8 Make sure the load does not interfere with controls or your ability to see where you are going. 8 Ride more slowly than you would without a load. The more weight you carry, the slower you should go. 8 Allow more braking distance. A heavier vehicle takes longer to stop. 8 Avoid making sharp turns unless at very slow speeds. 8 Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV. Loading As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. Keep the following points in mind: 8 Never exceed the weight limits shown. An overloaded ATV can be unstable. MAXIMUM LOADING LIMIT 8 Vehicle loading limit (total weight of cargo, rider and accessories): 105 kg (231 lb) 8 Front carrier: 5 kg (11 lb) 8 Rear carrier: 10 kg (22 lb) 8 Load cargo on the carriers as close to the center of the vehicle as possible. Put cargo at the rear of the front carrier and at the front of the rear carrier. Center the load from side to side. 6-10 1C5-9-10-1 9/12/03 9:30 AM Page 6-11 qWARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. 6-11 1C5-9-10-1 9/12/03 9:30 AM Page 6-12 EBU14870 w Indicates a potential hazard that could result in serious injury or death. 6-12 1C5-9-10-2 3/12/03 6:32 PM Page 7-1 Riding Your ATV 7-1 7 1C5-9-10-2 3/12/03 6:32 PM Page 7-2 7-2 1C5-9-10-2 3/12/03 6:32 PM Page 7-3 w Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use. This section, Riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your ATV requires special skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers. this Owner’s Manual completely and understand the operation of the controls. Pay particular attention to the safety information on pages 2-1–2-7. Please also read all caution and warning labels on your ATV. Riding your new ATV can be a very enjoyable activity, providing you with hours of pleasure. But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely. Before you begin to ride, be sure you have read 7-3 1C5-9-10-2 3/12/03 6:32 PM Page 7-4 RIDE WITH CARE AND GOOD JUDGEMENT HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating techniques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Get training if you are inexperienced. Beginners should get training from a certified instructor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum performance until you are totally familiar with the ATV’s handling and performance characteristics. qWARNING Riding your ATV requires skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers. POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. 7-4 1C5-9-10-2 3/12/03 6:32 PM Page 7-5 Not recommended for children under 16 years of age. qWARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc. 7-5 1C5-9-10-2 3/12/03 6:32 PM Page 7-6 This ATV is designed to carry operator and cargo only - passengers prohibited. qWARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers. 7-6 1C5-9-10-2 3/12/03 6:32 PM Page 7-7 Apparel Operating without protective clothing increases your chances of severe injury in the event of an accident. qWARNING POTENTIAL HAZARD HOW TO AVOID THE HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. Protective clothing Helmet Goggles Gloves Boots 7-7 1C5-9-10-2 3/12/03 6:32 PM Page 7-8 Do not operate after consuming alcohol or drugs. Operator’s performance capability is reduced by the influence of alcohol or drugs. qWARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV. 7-8 1C5-9-10-2 3/12/03 6:32 PM Page 7-9 Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the ATV. qWARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. qWARNING WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident. POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. HOW TO AVOID THE HAZARD WHAT CAN HAPPEN Always use the size and type tires specified in the Owner’s Manual for this vehicle on pages 5-7–5-8. Always maintain proper tire pressure as described in the Owner’s Manual on page 5-8. Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. 7-9 1C5-9-10-2 3/12/03 6:32 PM Page 7-10 w Speed limiter For riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits the power and top speed of the ATV. Turning the screw in decreases top speed, and turning it out increases top speed. Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions qWARNING w POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN q Increases your chances of losing control of the ATV, which can result in an accident. 1. Adjusting screw HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience. 7-10 2. Locknut 1C5-9-10-2 3/12/03 6:32 PM Page 7-11 Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Reduce your speed when adding additional loads. qWARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. MAXIMUM LOADING LIMIT 8 Vehicle loading limit (total weight of cargo, rider and accessories): 105 kg (231 lb) 8 Front carrier: 5 kg (11 lb) 8 Rear carrier: 10 kg (22 lb) HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in your Owner’s Manual for carrying cargo or pulling a trailer. 7-11 1C5-9-10-2 3/12/03 6:32 PM Page 7-12 During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. qWARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident. HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation. 7-12 1C5-9-10-2 3/12/03 6:32 PM Page 7-13 Avoid wheelies and jumping. You may lose control of the ATV or overturn. qWARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off. 7-13 1C5-9-10-2 3/12/03 6:32 PM Page 7-14 Modifications qWARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer. 7-14 1C5-9-10-2 3/12/03 6:32 PM Page 7-15 Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV in dry grass or other dry ground cover. Keep the engine area free of dry grass, brush, or other combustible material. Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it. qWARNING POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire. Someone touching the exhaust system during or after operation could be burned. 7-15 1C5-9-10-2 3/12/03 6:32 PM Page 7-16 BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. qWARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets. 7-16 1C5-9-10-2 3/12/03 6:32 PM Page 7-17 Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. qWARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways. 7-17 1C5-9-10-2 3/12/03 6:32 PM Page 7-18 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. qWARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. 7-18 1C5-9-10-2 3/12/03 6:32 PM Page 7-19 qWARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. 7-19 1C5-9-10-2 3/12/03 6:32 PM Page 7-20 When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. WHAT CAN HAPPEN You could be in a collision. You could be injured. HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles. Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. qWARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off-road vehicles. 7-20 1C5-9-10-2 3/12/03 6:32 PM Page 7-21 With the engine idling, return the starter knob to the closed position and shift the drive select lever into the forward position. Then release the parking brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is applied too abruptly, the front wheels may lift off the ground resulting in a loss of directional control. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Always avoid riding on paved surfaces: the ATV is designed for off-road use only, and handling maneuvers are more difficult to perform on pavement. Set the parking brake and follow the instruction on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your ATV. Remember that the engine and exhaust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components. When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. Improper use of the brakes can cause the tires to lose traction, reducing control and increasing the possibility of an accident. 7-21 1C5-9-10-2 3/12/03 6:32 PM Page 7-22 TURNING YOUR ATV To achieve maximum traction while riding offroad, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner’s Manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions. As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the footboard to the outside of the turn (opposite your desired direction) and lean your upper body into the turn. Use the throttle to maintain an even speed through the turn. This maneuver will let the wheel on the inside of the turn slip slightly, allowing the ATV to make the turn properly. qWARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. 7-22 1C5-9-10-2 3/12/03 6:32 PM Page 7-23 Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over. Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. Lean towards inside of turn. Support your weight on the outer footboard This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesn’t turn, come to a stop and then practice the procedure again. If the riding surface is slippery or loose, it may help to position more of your weight over the front wheels by moving forward on the seat. 7-23 1C5-9-10-2 3/12/03 6:32 PM Page 7-24 CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control. qWARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting large hills. It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars. 7-24 1C5-9-10-2 3/12/03 6:32 PM Page 7-25 qWARNING An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner’s Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards. Never go over the top of any hill at high speed. 7-25 1C5-9-10-2 3/12/03 6:32 PM Page 7-26 If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. qWARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. 7-26 1C5-9-10-2 3/12/03 6:32 PM Page 7-27 7-27 1C5-9-10-2 3/12/03 6:32 PM Page 7-28 If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then descend the hill. qWARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD If you start to roll backwards, DO NOT use the rear brake to stop. The ATV could easily tip over backwards. Instead, dismount the ATV immediately on the uphill side. Maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Lock the parking brake, after you are stopped. If you begin rolling backwards: Keep weight uphill. Never apply the rear brake while rolling backwards. Apply the front brake. 7-28 1C5-9-10-2 3/12/03 6:32 PM Page 7-29 When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner’s Manual. 7-29 1C5-9-10-2 3/12/03 6:32 PM Page 7-30 RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. Whenever possible, ride your ATV straight downhill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear. qWARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owner’s Manual. Note: a special technique is required when braking as you go down a hill. Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible. 7-30 1C5-9-10-2 3/12/03 6:32 PM Page 7-31 7-31 1C5-9-10-2 3/12/03 6:32 PM Page 7-32 CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. qWARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes be sure not to make sharp turns either up or down hill. Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of a hill: If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you wish to travel. Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. 7-32 1C5-9-10-2 3/12/03 6:32 PM Page 7-33 Shift your weight to the uphill side of the ATV. 7-33 1C5-9-10-2 3/12/03 6:33 PM Page 7-34 CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 20 cm (7.9 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and carefully. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings. qWARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual. 7-34 1C5-9-10-2 3/12/03 6:33 PM Page 7-35 cC Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. q 1. Check hose 7-35 1C5-9-10-2 3/12/03 6:33 PM Page 7-36 RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. qWARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual. 7-36 1C5-9-10-2 3/12/03 6:33 PM Page 7-37 7-37 1C5-9-10-2 3/12/03 6:33 PM Page 7-38 SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help. If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide. 7-38 1C5-9-10-2 3/12/03 6:33 PM Page 7-39 With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost. qWARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. 7-39 1C5-9-10-2 3/12/03 6:33 PM Page 7-40 WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. 8 If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See pages 7-38–7-39.) WHAT TO DO ... 8 If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See pages 7-22– 7-23.) 8 If your ATV can’t make it up a hill you are trying to climb: Turn the ATV around if you still have forward speed. If not, stop, dismount on the uphill side of the ATV and physically turn the ATV around. If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE - the ATV may tip over on top of you. Dismount the ATV on the uphill side. (See pages 7-24–7-29.) 8 If your ATV begins to tip while turning: Lean more into the turn to regain balance. If necessary, gradually let off the throttle and/or steer to the outside of the turn. (See pages 7-22–7-33.) 7-40 1C5-9-10-2 3/12/03 6:33 PM Page 7-41 8 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 7-32–7-33.) 8 If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See pages 7-34– 7-35.) w Indicates a potential hazard that could result in serious injury or death. 7-41 1C5-9-10-3 11/12/03 9:53 AM Page 8-2 EBU00515 Have a Yamaha dealer perform service if you are not familiar with machine service. PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages. EBU12210 Owner’s manual and tool kit You are recommended to put this owner’s manual and low-pressure tire gauge in the vinyl bag and always carry them along with the owner’s tool kit under the seat. qWARNING POTENTIAL HAZARD 1 Servicing an engine while it is running. WHAT CAN HAPPEN 3 Moving parts can catch clothing or parts of the body, causing injury. Electrical components can cause shocks or can start fires. 1. Owner’s manual 3. Owner’s tool kit HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified. 8-1 2 2. Low-pressure tire gauge 1C5-9-10-3 11/12/03 9:53 AM Page 8-3 The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the owner’s tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts. qWARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. NOTE: If you do not have a torque wrench available during a service operation requiring one, take your machine to a Yamaha dealer to check the torque settings and adjust them as necessary. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized Yamaha ATV dealer. 8-2 8 1C5-9-10-3 11/12/03 9:53 AM Page 8-4 EBU00261 PERIODIC MAINTENANCE/LUBRICATION INITIAL ITEM ROUTINE EVERY 1 3 6 6 month months months months Valves* • Check valve clearance. • Adjust if necessary. 1 Spark plug • Check condition. • Adjust gap and clean. • Replace if necessary. 1 Air filter element (for engine and V-belt case) • Clean. • Replace if necessary. Carburetor* • Check idle speed/starter operation. • Adjust if necessary. Cylinder head cover breather system* Exhaust system* 1 1 year 1 1 1 1 1 1 Every 20 – 40 hours (more often in wet or dusty areas) 1 1 1 • Check breather hose for cracks or damage. • Replace if necessary. 1 1 1 • Check leakage. • Retighten if necessary. • Replace gasket if necessary. 1 1 1 Spark arrester • Clean. 1 1 1 Fuel line* • Check fuel hose for cracks or damage. • Replace if necessary. 1 1 1 Engine oil • Replace (warm engine before draining). 1 1 1 1 Oil strainer* • Clean. • Replace if necessary. 1 1 Drive chain • Check and adjust slack/alignment/clean/lube. 1 Final transmission oil • Check oil level/oil leakage. • Replace every 12 months. 1 8-3 1 1 1 1 1 1 1 1C5-9-10-3 11/12/03 9:53 AM Page 8-5 INITIAL ITEM * ROUTINE EVERY 1 3 6 6 month months months months 1 year Brakes* • Check operation. • Adjust if necessary. 1 V-belt* • Check operation • Replace if damage or excessive wear. 1 Wheels* • Check balance/damage/runout. • Replace if necessary. 1 1 1 1 Wheel bearings* • Check bearing assembly for looseness/damage. • Replace if damaged. 1 1 1 1 Steering system* • • • • 1 1 1 1 Knuckle shafts/ steering shaft* • Lubricate every 6 months with lithium-soap-based grease. 1 1 1 Fittings and fasteners* • Check all chassis fittings and fasteners. • Correct if necessary. 1 1 1 1 1 Battery* • Check specific gravity. • Check breather hose for correct routing. • Correct if necessary. 1 1 1 1 1 Check operation. Replace if damaged. Check toe-in. Adjust if necessary. 1 1 1 1 1 1 It is recommended that these items be serviced by a Yamaha dealer. w Indicates a potential hazard that could result in serious injury or death. 8-4 1C5-9-10-3 11/12/03 9:53 AM Page 8-6 EBU08963 Engine oil The engine oil level should be checked before each ride. In addition, the oil must be changed at the intervals specified in the periodic maintenance and lubrication chart. Engine oil level measurement 1. Place the machine on a level surface. 2. Warm up the engine for several minutes and stop it. 3. Wait a few minutes until the oil level settles, remove the oil filler cap, wipe the dipstick clean, and then insert the dipstick in the filler hole without screwing it in. q e 1. Dipstick 3. Minimum level mark 2. Maximum level mark cC Be sure no foreign material enters the crankcase. NOTE: Wait a few minutes until the oil level settles before checking. 4. Remove the dipstick and inspect the oil level. 5. The oil level should be between the maximum and minimum marks. If the level is low, add oil to raise it to the proper level. w Engine oil replacement and oil filter cleaning 1. Place the machine on a level surface. 2. Warm up the engine for several minutes and stop it. 3. Place a container under the engine to collect the used oil. 8-5 1C5-9-10-3 11/12/03 9:53 AM Page 8-7 4. Remove the dipstick and drain bolt to drain the oil. 5. Clean the oil strainer with solvent. 6. Inspect the O-ring and replace it if damaged. 7. Install the O-ring, oil strainer, compression spring and drain bolt. Tighten the drain bolt to specification. q cC r e 1. Drain bolt 3. Compression spring w Before installing the drain bolt, be sure to install the O-ring, compression spring and oil strainer. q 2. O-ring 4. Oil strainer Tightening torque: Drain bolt: 32 Nm (3.2 m0kgf, 23 ft0lbf) cC When removing the drain bolt, the compression spring, oil strainer and O-ring will fall out. Take care not to lose these parts. 8-6 1C5-9-10-3 11/12/03 9:53 AM Page 8-8 EBU14892 8. Fill the engine with oil and install the dipstick. Recommended oil: See page 10-2. Oil quantity: Periodic oil change 1.25 L (1.10 Imp qt, 1.32 US qt) cC Be sure no foreign material enters the crankcase. 9. Warm up the engine for several minutes at idle speed. Check for oil leakage while warming up. Final transmission oil The final transmission case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the machine. In addition, the final transmission oil must be changed at the intervals specified in the periodic maintenance and lubrication chart. Final transmission oil measurement 1. Place the machine on a level surface. 2. Remove the screw and check the oil level. It should be up to the brim of the hole. If the oil level is low, remove the oil filler bolt, and then add sufficient oil of the recommended type to raise it to the proper level. w e cC If oil leakage is found, stop the engine immediately and check for the cause. q 8-7 1. Screw 2. Brim 3. Correct oil level 1C5-9-10-3 11/12/03 9:53 AM Page 8-9 3. Remove the oil filler bolt and drain bolt to drain the oil from the final transmission case. q q 1. Oil filler bolt 3. Install the screw and oil filler bolt, and then tighten them to their specified torques. 1. Drain bolt Tightening torque: Screw: 16 Nm (1.6 m0kgf, 11 ft0lbf) Oil filler bolt: 23 Nm (2.3 m0kgf,17 ft0lbf) 4. Install the drain bolt, and then tighten it to the specified torque. Tightening torque: Drain bolt: 23 Nm (2.3 m0kgf, 17 ft0lbf) Final transmission oil replacement 1. Place the machine on a level surface. 2. Place a container under the engine. 8-8 1C5-9-10-3 11/12/03 9:53 AM Page 8-10 EBU11820 5. Add the specified amount of the recommended oil. Spark plug inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder. Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, you should replace the spark plug with one of the proper type. Recommended oil: See page 10-2. Oil quantity: 0.6 L (0.53 Imp qt, 0.63 US qt) 6. Install the oil filler bolt, and then tighten it to the specified torque. cC 8 Make sure that no foreign material enters the final transmission case. 8 Make sure that no oil gets on the tires or wheels. Standard spark plug: CR7HS (NGK) 8-9 1C5-9-10-3 11/12/03 9:53 AM Page 8-11 Before installing the spark plug, measure the electrode gap with a wire thickness gauge and adjust it to specification. q Spark plug gap: 0.6–0.7 mm (0.02–0.03 in) 1. Spark plug wrench Tightening torque: Spark plug: 12.5 Nm (1.25 m0kgf, 9.1 ft0lbf) a a. Spark plug gap When installing the spark plug, always clean the gasket surface and its mating surface. Wipe off any grime from the threads and tighten it to the specified torque. 8-10 1C5-9-10-3 11/12/03 9:53 AM Page 8-12 EBU14830 1. Remove the seat. 2. Remove the breather hose, and then loosen the clamp screw. 3. Remove the air filter case cover by removing the screws. Engine air filter element and V-belt case air filter element cleaning Both air filter elements should be cleaned at the specified intervals in the periodic maintenance chart. Engine air filter element 2 2 1 NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. 3 2 q 1. Air filter case cover 3. Breather hose 5. Clamp screw 1. Check hose 8-11 4 52 2. Screw (× 4) 4. Clamp 1C5-9-10-3 11/12/03 9:53 AM Page 8-13 4. Remove the air filter element, and separate it from the frame. qWARNING POTENTIAL HAZARD w Using low flash point solvents or gasoline to clean the air filter element. q WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD 1. Air filter element Use parts cleaning solvent to clean the air filter element. 2. Element frame 5. Wash the air filter element gently but thoroughly in solvent. 6. Squeeze the excess solvent out of the air filter element and let it dry. cC Do not twist the air filter element when squeezing it. 8-12 1C5-9-10-3 11/12/03 9:53 AM Page 8-14 7. Inspect the air filter element. If damaged, replace it. 8. Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter element. q NOTE: The air filter element should be wet but not dripping. 1. Washer 9. Install the air filter element on the frame. 10. Install the air filter element into the air filter case. 11. Install the air filter case cover by installing the screws. 12. Tighten the clamp screw, and then install the breather hose. 13. Install the seat. cC Install the washer with the bent edge facing upward as shown. 8-13 1C5-9-10-3 11/12/03 9:53 AM Page 8-15 V-belt case air filter element 1. Remove the front carrier by removing the bolts. NOTE: The air filter element should be cleaned every 20-40 hours. It should be cleaned and lubricated more often if the machine is operated in extremely dusty areas. Each time air filter element maintenance is performed, check the air inlet to the air filter case for obstructions. Check the air cleaner rubber joint to the carburetor and manifold fittings for an airtight seal. Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine. 1 2 2 2 cC 1. Front carrier Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating. 2. Bolt (× 6) 2. Remove the front cover by removing the quick fasteners, then disconnect the coupler shown. 8-14 1C5-9-10-3 11/12/03 9:53 AM Page 8-16 2 2 w 1 q 1. Front cover 2. Quick fastener (× 2) e 1. V-belt air filter element cover 2. Screw 3. Air filter element 1 5. Tap the air filter element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air. If the air filter element is damaged, replace it. 2 NOTE: Be sure the air filter element is seated properly against the case. 1. Front cover 2. Coupler 3. Remove the V-belt air filter element cover by removing the screw. 4. Pull out the air filter element. 8-15 6. Install the air filter element cover by installing the screw. 7. Connect the coupler, and then install the front cover by installing the quick fasteners. 8. Install the front carrier by installing the bolts. 1C5-9-10-3 11/12/03 9:53 AM Page 8-17 EBU13600 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the screws. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe. q w q 1. Screw (× 2) 1. Tailpipe 2. Spark arrester 4. Insert the tailpipe into the muffler and align the screw holes. 5. Install the screws and tighten them. 8-16 1C5-9-10-3 11/12/03 9:53 AM Page 8-18 EBU13020 qWARNING Idle speed adjustment NOTE: POTENTIAL HAZARD A diagnostic tachometer must be used for this procedure. Improper cleaning of the spark arrester. Hot exhaust system WHAT CAN HAPPEN 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components. Do not start the engine when cleaning the exhaust system. 8-17 1C5-9-10-3 11/12/03 9:53 AM Page 8-19 EBU00303 2. Connect the tachometer to the spark plug lead, and then set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw in direction a to increase the engine speed, and in direction b to decrease the engine speed. Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician. Specified idle speed: 1,650–1,750 r/min q a b 1. Throttle stop screw 8-18 1C5-9-10-3 11/12/03 9:53 AM Page 8-20 EBU00307 Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 3–5 mm (0.12–0.20 in). 3. Tighten the locknut. q w a 1. Locknut a. Free play 2. Adjusting bolt 8-19 1C5-9-10-3 11/12/03 9:53 AM Page 8-21 EBU00308 Rear Front and rear brake shoe inspection A wear indicator is provided on each brake. The indicators allows checking of brake shoe wear without disassembling the brake. Apply the brake and check the position of the indicator. If the indicator reaches the wear limit line, ask a Yamaha dealer to replace the shoes as a set. q w Front 1. Wear limit line w q 1. Wear limit line 2. Wear indicator 8-20 2. Wear indicator 1C5-9-10-3 11/12/03 9:53 AM Page 8-22 EBU14822 Front brake lever free play adjustment NOTE: 1 Before adjusting the brake lever free play, inspect the front brake shoes. The front brake lever free play should be adjusted to 5–8 mm (0.2–0.3 in) at the brake lever pivot. If the free play is incorrect, adjust it as follows. 2 2 2 1. Front carrier 2. Bolt (× 6) 2. Remove the front cover by removing the quick fasteners, then disconnect the coupler shown. a 2 2 a. Free play 1 1. Remove the front carrier by removing the bolts. 8-21 1. Front cover 2. Quick fastener (× 2) 1C5-9-10-3 11/12/03 9:53 AM Page 8-23 4. Loosen the locknut and fully turn in the adjusting bolt at the front brake lever. 1 2 q w 1. Front cover 2. Coupler 3. Remove the V-belt air filter element cover by removing the screw. 1. Locknut w q 1. V-belt air filter element cover 2. Screw 8-22 2. Adjusting bolt 1C5-9-10-3 11/12/03 9:53 AM Page 8-24 5. Make sure the brake cable joint in the equalizer is straight when the brake is applied. If not, loosen the locknut, and then turn the adjusting nuts at the front brake cables until the cable joint becomes straight. w q w q 2 1 1. Locknut (× 2) a 6. Tighten the locknut of each brake cable. a=a’ 1. Equalizer 2. Adjusting nut (× 2) a’ 2. Cable joint 8-23 1C5-9-10-3 11/12/03 9:53 AM Page 8-25 7. Turn the adjusting bolt at the brake lever until the specified free play is obtained. 8. Tighten the locknut at the brake lever. 9. Install the air filter element cover by installing the screw. 10. Connect the coupler, and then install the front cover by installing the quick fasteners. 11. Install the front carrier by installing the bolts. a q w 1. Locknut a. Free play 2. Adjusting bolt Specified free play: 5–8 mm (0.2–0.3 in) 8-24 1C5-9-10-3 11/12/03 9:53 AM Page 8-26 EBU00965 qWARNING Rear brake adjustment Brake lever free play should be 5–8 mm (0.2–0.3 in) at the brake lever pivot. If the free play is incorrect, adjust as follows: POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN a You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: 8 Make sure the brakes operate smoothly and that the free play is correct. 8 Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. a. Free play 8-25 1C5-9-10-3 11/12/03 9:53 AM Page 8-27 qWARNING Turn the adjusting nut on the brake hub in direction a to decrease play, and in direction b to increase play. POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. ba HOW TO AVOID THE HAZARD After servicing: 8 Make sure the brakes operate smoothly and that the free play is correct. 8 Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. q 1. Adjusting nut 8-26 1C5-9-10-3 11/12/03 9:53 AM Page 8-28 EBU01144 Drive chain slack check NOTE: Move the ATV back and forth and find the tightest position of the drive chain. Check and/or adjust the chain slack while it is in this tightest position. a To check the drive chain slack, all tires must be touching the ground and there should be no weight on it. Check the drive chain slack at the position shown in the illustration Normal slack is approximately 30 mm (1.18 in). If the slack exceeds 30 mm (1.18 in), adjust it to specification. a. Drive chain slack 8-27 1C5-9-10-3 11/12/03 9:53 AM Page 8-29 EBU01146 Drive chain slack adjustment 1. Loosen the hub stopper bolt locknut and then the hub stopper bolt. 3. Loosen the locknut. To tighten the drive chain, turn the adjusting bolt in direction a. To loosen the drive chain, turn the adjusting bolt in direction b, and then push the wheels forward. e q w 1. Hub stopper bolt 2. Locknut a e b q 3. Axle holding bolt (× 4) w 2. Loosen the upper and lower axle holding bolts. 1. Locknut 2. Chain adjusting bolt cC Too little of drive chain slack will overload the engine and other important parts. Keep the drive chain slack within the specified limit. 8-28 1C5-9-10-3 11/12/03 9:53 AM Page 8-30 cC 4. After adjusting, be sure to tighten the locknut and the axle holding bolts. If measurement A of the drive chain adjusting bolt is less than 27 mm (1.06 in), ask a Yamaha dealer to replace the drive chain. Tightening torque: Locknut: 15.5 Nm (1.55 m0kgf, 11.2 ft0lbf) Axle holding bolts (upper): 85 Nm (8.5 m0kgf, 61 ft0lbf) Axle holding bolts (lower): 60 Nm (6.0 m0kgf, 43 ft0lbf) A 5. Finger tighten the hub stopper bolt and tighten the hub stopper bolt locknut. Tightening torque: Locknut: 15.5 Nm (1.55 m0kgf, 11.2 ft0lbf) A. Measurement A 8-29 1C5-9-10-3 11/12/03 9:53 AM Page 8-31 EBU00805 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant. Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. cC Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings. cC The drive chain must be lubricated after washing the ATV or riding in the rain. 1. Clean the drive chain with kerosene and a small soft brush. q cC To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate solvents. 1. O-rings 8-30 1C5-9-10-3 11/12/03 9:53 AM Page 8-32 EBU00355 EBU00356 Draining the V-belt compartment If water leaks into the V-belt compartment such as when the machine is driven in water, remove the drain screw on the bottom of compartment and drain the water. Be sure to drive slowly until the V-belt becomes dry. If slipping is noticed, ask a Yamaha dealer to inspect. Cable inspection and lubrication qWARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury. HOW TO AVOID THE HAZARD q Inspect cables frequently. Replace damaged cables. Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. 1. Drain screw Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil 8-31 1C5-9-10-3 11/12/03 9:53 AM Page 8-33 EBU00725 EBU00728 Brake lever lubrication Lubricate the pivoting parts of the brake levers. Knuckle shaft, lower arms and steering shaft lubrication Lubricate the pivot points using a grease gun. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Recommended lubricant: Lithium-soap-based grease 1 1 1 1 1. Grease nipple (×6) 8-32 1C5-9-10-3 11/12/03 9:53 AM Page 8-34 EBU01112 Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified torque. q 1. Tapered wheel nut Tightening torque: Front wheel nut: 55 Nm (5.5 m0kgf, 40 ft0lbf) Rear wheel nut: 55 Nm (5.5 m0kgf, 40 ft0lbf) EBU01150 Wheel installation 1. Install the wheel and the nuts. NOTE: Tapered wheel nuts are used for both front and rear wheels. Install the nut with its tapered side towards the wheel. 8-33 1C5-9-10-3 11/12/03 9:53 AM Page 8-35 EBU00378 Battery Check the level of the battery fluid and see if the terminals are tight. Add distilled water if the fluid level is low. w q cC Do not leave or store the battery on its side. When inspecting the battery, be sure the breather hose is routed correctly. If it touches the frame or exists in such a way as to cause battery electrolyte or gas to exit onto the frame, structural and cosmetic damage to the machine can occur. e 1. Battery 8-34 2. Battery breather hose 3. Guide (× 2) 1C5-9-10-3 11/12/03 9:53 AM Page 8-36 qWARNING EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batteries away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed space. POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Get prompt medical attention. 8-35 1C5-9-10-3 11/12/03 9:53 AM Page 8-37 EBU11950 cC Replenishing the battery fluid A poorly maintained battery will corrode and discharge quickly. The battery fluid should be checked at least once a month. 1. The level should be between the maximum and minimum level marks. Use only distilled water if refilling is necessary. Normal tap water contains minerals which are harmful to a battery. Therefore, refill only with distilled water. 4. When the machine is not to be used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before using. 5. If the battery is to be stored for a longer period than the above, check the specific gravity at least once a month and recharge the battery when it is too low. 6. Always make sure the connections are correct when putting the battery back in the machine. Make sure the breather hose is properly connected and is not damaged or obstructed. e r q w 1. 2. 3. 4. Maximum level mark Minimum level mark Negative (–) lead Positive (+) lead 2. Disconnect the negative (–) lead. 3. Disconnect the positive (+) lead, and then remove the battery. 8-36 1C5-9-10-3 11/12/03 9:53 AM Page 8-38 EBU00388 Fuse replacement 1. The fuse case is located on the right side of the machine. 2. If the fuse is blown, turn off the main switch and install a new fuse of the specified amperage. Then turn on the switches, if the fuse immediately blows again, consult a Yamaha dealer. Specified fuse: 15A qWARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire. w HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse. cC q 1. Fuse To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Spare fuse 8-37 1C5-9-10-3 11/12/03 9:53 AM Page 8-39 EBU14802 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the cover at the rear of the headlight by pulling it off. 2 1 1. Bulb holder cover 1 2. Bulb holder 3. Remove the bulb holder by pushing it inward and turning it counterclockwise. 4. Remove the defective headlight bulb by pulling it out of the socket. 1. Cover 2. Remove the bulb holder cover by pulling it off. 8-38 1C5-9-10-3 11/12/03 9:53 AM Page 8-40 qWARNING 5. Install a new headlight bulb into position. POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. 1 WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the headlight bulb to cool before touching or removing it. 1. Headlight bulb 6. Install the bulb holder by pushing it inward and turning it clockwise. 7. Install the bulb holder cover. 8. Install the cover at the rear of the headlight. 8-39 1C5-9-10-3 11/12/03 9:54 AM Page 8-41 EBU00861 Tail/brake light bulb replacement 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 3. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise. q w 1 1. Bulb 2. Bulb holder 1. Bulb holder 4. Install the bulb holder (together with the bulb). 2. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 8-40 1C5-9-10-3 11/12/03 9:54 AM Page 8-42 EBU10890 Headlight beam adjustment cC It is advisable to have a Yamaha dealer make this adjustment. To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b. a b 1 1. Adjusting screw 8-41 1C5-9-10-3 11/12/03 9:54 AM Page 8-43 EBU00412 qWARNING Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer. POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe injury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces. The skilled technicians at a Yamaha dealership have the tools, experience, and know-how to properly service your machine. Use only genuine Yamaha parts on your machine. Imitation parts may look like Yamaha parts, but they are often inferior. Consequently, they have a shorter service life and can lead to expensive repair bills. 8-42 1C5-9-10-3 11/12/03 9:54 AM Page 8-44 EBU00440 Remove the fuel hose from the fuel cock. Troubleshooting chart Water or dirt mixed in fuel. Turn the fuel cock to “ON”. 1. Fuel Check if there is fuel in the fuel tank. There is fuel. Turn the fuel cock to “OFF”. Some fuel. Turn the fuel cock to “RES”. No fuel. Supply fuel. Clean the fuel filter and the fuel tank. Check fuel flow. No fuel. Fuel cock clogged. Clean fuel cock. Restart engine. 2. Compression Use electric starter to see if there is compression. 3. Ignition There is compresson. Compression normal. No compression. Ask a Yamaha dealer to inspect. Wet Wipe clean with dry cloth. Remove plug and check electrodes. Spark good. Dry Attach plug cap and ground to chassis. Use electric starter. Spark weak. No spark. 4. Battery Engine turns over quickly. Battery good. Engine turns over slowly. Check fluid, recharge, check connections. Ignition system normal. Adjust plug gap or replace plug. Ask a Yamaha dealer to inspect. Use electric starter. 8-43 1C5-9-10-3 11/12/03 9:54 AM Page 9-2 EBU00417 cC CLEANING AND STORAGE Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers. A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may be used. b. Make sure the spark plug and all filler caps are properly installed. 2. If the engine case is excessively greasy, apply degreaser with a paint brush. Do not apply degreaser to the chain, sprockets or wheel axles. 3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure to do the job. 4. Once the majority of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bottle brush is handy for hard-toget-at places. 5. Rinse the machine off immediately with clean water and dry all surfaces with a chamois, clean towel or soft absorbent cloth. 6. Dry the chain and lubricate it to prevent rust. 9-1 9 1C5-9-10-3 11/12/03 9:54 AM Page 9-3 7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes. qWARNING POTENTIAL HAZARD Operation with wet brakes after washing. WHAT CAN HAPPEN Wet brakes may have reduced stopping ability, increasing the chance of an accident. HOW TO AVOID THE HAZARD Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings. 9-2 1C5-9-10-3 11/12/03 9:54 AM Page 9-4 EBU00525 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equivalent product. 3. 4. 5. 6. Specified amount: 1 oz of stabilizer to each gallon of fuel (or 7.5 cc of stabilizer to each liter of fuel) 7. NOTE: 8. Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system. Consult a Yamaha dealer if the fuel system needs to be drained instead. motor oil in the spark plug hole and reinstall the spark plug. Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil. Clean the drive chain thoroughly and lubricate it. (See page 8-25.) Lubricate all control cables. Block up the frame to raise all wheels off the ground. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat cover. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0°C (30°F) or more than 30°C (90°F)). NOTE: 2. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 Make any necessary repairs before storing the machine. 9-3 1C5-9-10-3 11/12/03 9:54 AM Page 10-1 EBU00428 SPECIFICATIONS Model YFM125 Dimension: Overall length Overall width Overall height Seat height Wheel base Ground clearance Minimum turning radius 1,710 mm ( 67.3 in) 990 mm ( 39.0 in) 980 mm ( 38.6 in) 705 mm ( 27.8 in) 1,080 mm ( 42.5 in) 145 mm ( 5.71 in) 2,900 mm (114.2 in) Basic weight: With oil and full fuel tank 152 kg (335 lb) Engine: Type Cylinder arrangement: Displacement Bore × Stroke Compression ratio Starting system Lubrication system: Air cooled, 4-stroke, SOHC Single cylinder, Forward inclined 124 cm3 49 × 66 mm (1.93 × 2.60 in) 9.0 : 1 Electric starter Wet sump 10-1 1C5-9-10-3 11/12/03 9:54 AM Page 10-2 Model YFM125 Engine oil/final transmission oil: Type 0° 10° 30° 50° 70° 90° 110° 130°F YAMALUBE 4 (20W40) or SAE20W40 YAMALUBE 4 (10W30) or SAE10W30 SAE 5W30 –20° Recommended engine oil/final transmission oil classification: –10° 0° 10° 20° 30° 40° 50°C API Service SE, SF, SG type or higher cC 8 Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. 8 Be sure no foreign material enters the crankcase. Quantity Engine oil: Periodic oil change Final transmission oil: 1.25 L (1.10 lmp qt, 1.32 US qt) 0.6 L (0.53 lmp qt, 0.63 US qt) 10-2 10 1C5-9-10-3 11/12/03 9:54 AM Page 10-3 Model YFM125 Air filter: for engine for V-belt case Wet type element Dry type element Fuel: Type Tank capacity Reserve amount UNLEADED GASOLINE ONLY 7.6 L (1.67 Imp gal, 2.01 US gal) 1.3 L (0.29 Imp gal, 0.34 US gal) Carburetor: Type/manufacturer VM18SH/MIKUNI Spark plug: Type/manufacturer Gap CR7HS/NGK 0.6–0.7 mm (0.02–0.03 in) Clutch: Type Dry, centrifugal automatic Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Reverse Helical gear/Spur gear 43/14 × 40/17 (7.226) Chain drive 32/12 (2.666) V-belt automatic 49/14 × 49/15 × 40/17 (26.902) 10-3 1C5-9-10-3 11/12/03 9:54 AM Page 10-4 Model Chassis: Frame type Caster angle Trail YFM125 Steel tube 6° 15 mm (0.59 in) Tire: Type Size: Front Rear Manufacturer/type: Front Rear DUNLOP/KT536A DUNLOP/KT537A Brake: Front brake type Operation Rear brake type Operation Drum brake Right hand operation Drum brake Left hand operation Suspension: Front Rear Swing axle Swingarm Shock absorber: Front Rear Coil spring/Oil damper Coil spring/Oil damper Tubeless AT20 × 7 - 8 AT22 × 10 - 8 10-4 1C5-9-10-3 11/12/03 9:54 AM Page 10-5 Model YFM125 Wheel travel: Front Rear 70 mm (2.8 in) 80 mm (3.2 in) Electrical: Ignition system Charging system Battery type/voltage, capacity DC. C.D.I. A.C. Magneto 12N12C-4A-2/12V, 12Ah Headlight type: Bulb Bulb voltage, wattage × quantity: Headlight Tail/brake light Indicator light: Neutral Reverse Fuse: 12V, 30 W/30 W × 2 12V, 5 W/21W × 1 12V, 1.7 W × 1 12V, 1.7 W × 1 15A 10-5 1C5-9-10-3 11/12/03 9:54 AM Page 11-1 EBU13640 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. "AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW." These acts include tampering with the following systems; i.e., modification, removal, etc. Exhaust system Intake system Muffler Exhaust pipe Silencer Air cleaner case Air cleaner element Intake duct 11-1 11 1C5-9-10-3 11/12/03 9:54 AM Page 12-1 EBU13651 MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work. MAINTENACE INTERVAL DATE OF SERVICE SERVICING DEALER NAME AND ADDRESS 1 Month 3 Months 6 Months 12 Months 18 Months 24 Months 30 Months 36 Months 42 Months 48 Months 54 Months 60 Months 12-1 REMARKS 1C5-9-10-3 11/12/03 9:54 AM Page 12-2 12 12-2 1C5-9-10-3 11/12/03 9:54 AM Page 13-2 EBU00432 13-1 1C5-9-10-3 11/12/03 9:54 AM Page 13-3 13 13-2 1C5-9-10-3 11/12/03 9:54 AM Page 14-2 EBU00435 14-1 1C5-9-10-3 11/12/03 9:54 AM Page 14-3 14 14-2 1C5-9-10-3 11/12/03 9:54 AM Page 14-4 EBU00436 w Indicates a potential hazard that could result in serious injury or death. 1C5-9-10-3 11/12/03 9:54 AM Page 14-5 1C5-9-10-3 11/12/03 9:54 AM Page 14-6 1C5-9-10-3 11/12/03 9:54 AM Page 14-7 1C5-9-10-3 11/12/03 9:54 AM Page 14-8 EBU00437 PROTECT YOUR INVESTMENT 1C5-9-10 hyoshi 8/12/03 11:45 AM Page 2 1C5-9-10 hyoshi 8/12/03 11:45 AM Page 1 EBU00438 READ THIS MANUAL CAREFULLY! It contains important safety information. qWARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: 9 without proper training or instruction. 9 use proper riding techniques to avoid 9 at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns. 9 on public roads - a collision can occur with 9 avoid paved surfaces - pavement may another vehicle. seriously affect handling and control. 9 with a passenger - passengers affect balance and steering and increase risk of losing control. LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) OWNER’S MANUAL YFM125S w YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.12-1.2x1 ! (E) LIT-11626-17-56 This ATV should not be ridden by anyone under 16 years of age. 1C5-28199-10 4/2/03 9:06 AM Page 1 CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV. You have purchased a quality Yamaha product that, with proper use and care, will provide hours of riding pleasure. BEFORE YOU OPERATE YOUR NEW ATV, Yamaha recommends these important points: 8 READ YOUR OWNER’S MANUAL 8 A CHILD UNDER 6 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 50CC OR GREATER 8 A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER 8 A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER THAN 90CC 8 TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA – ASK YOUR DEALER FOR DETAILS OR CALL 1-800-887-2887 If you have any questions about these points, or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership, please fill out the information below and mail this card to yamaha today. Name: ATV Model: Address: Primary I.D. [Engine Number]: Purchase Date: MO. Dealer Name & Address: Telephone: [ ] C A R E F U L LY Dear New Yamaha ATV Owner: DAY YR. READ Dear Yamaha ATV Owner: Please Review this IMPORTANT SAFETY CARD before operating your ATV [If card is not attached, call 1-800-344-6418]. ATV card for US ATV card for US 4/2/03 9:06 AM Page 2 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES FIRST CLASS PERMIT NO. 4 CYPRESS, CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U.S.A. P.O. BOX 6555 CYPRESS, CALIFORNIA 90630-9989 ATTN: SALES ADMINISTRATION