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Skoda - Auto - skoda-karoq-2017-110444
Skoda - Auto - skoda-karoq-2017-brukerhandbok-110449
Cars & Automotive Accessories - Kenwood - C929
Skoda - Auto - skoda-karoq-2017-savininko-vadovas-110446
Toys & Accessories - Lego - DUPLO Town - AROUND THE WORLD - 10805
Skoda - Auto - skoda-karoq-2017-manual-del-propietario-110438
Skoda - Auto - skoda-karoq-2017-navod-k-obsluze-110433
Skoda - Auto - skoda-karoq-2017-omistajan-kasikirja-110439
Skoda - Auto - skoda-karoq-2017-110460
VCRs & Accessories - Hitachi Electronics - VTM171A
Skoda - Auto - skoda-karoq-2017-110457
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-omaniku-kasiraamat-110436
Skoda - Auto - skoda-karoq-2017-instrukcja-obslugi-110450
Barossa - Motorcycle - Barossa_PYTHON_100cc_parts
1981-1995--Chrysler--Lebaron--4 Cylinders J 2.5L MFI Turbo SOHC--31006702
1981-1995--Chrysler--Lebaron--4 Cylinders J 2.5L MFI Turbo SOHC--31034803
Skoda - Auto - skoda-karoq-2017-prirocnik-za-lastnika-110456
Skoda - Auto - skoda-karoq-2017-110453
Skoda - Auto - skoda-karoq-2017-uzivatelska-prirucka-110455
Barossa - Motorcycle - Barossa__Barossa_PYTHON_100cc_parts_5d8a7f921c3648a62136367
Sewing Machine - Singer - 14T968DC %7C PROFESSIONAL 5
Skoda - Auto - skoda-karoq-2017-110459
Skoda - Auto - skoda-karoq-2017-110441
Skoda - Auto - skoda-karoq-2017-ipasnieka-rokasgramata-110447
Pool Equipment - Haywood-Pool - Super Pump~All Super Pump Models
1981-1995--Chrysler--Lebaron--4 Cylinders B 2.2L 2BL SOHC--31218101
Skoda - Auto - skoda-karoq-2017-manuel-du-proprietaire-110440
Skoda - Auto - skoda-karoq-2017-agarmanual-110454
Skoda - Auto - skoda-karoq-2017-manuale-del-proprietario-110445
Skoda - Auto - skoda-karoq-2017-handleiding-110448
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.6L 2BL SOHC--31218102
Skoda - Auto - skoda-karoq-2017-110432
Furniture & Storage - Blue Rhino - GAD1375SP
Skoda - Auto - skoda-karoq-2017-kezelesi-utmutato-110443
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.2L TBI SOHC--31095601
Skoda - Auto - skoda-karoq-2017-vodic-za-korisnike-110442
Skoda - Auto - skoda-karoq-2017-manualul-de-utilizare-110452
Speakers & Audio Accessories - Dual - Dual - SX652 ~ SX692
Skoda - Auto - skoda-karoq-2017-instruktionsbog-110435
Barossa - Motorcycle - Barossa__Barossa_PYTHON_100cc_parts
Cars & Automotive Accessories - Kenwood - DPX-510
Skoda - Auto - skoda-karoq-2017-owner-s-manual-110437
Grills & Accessories - Blue Rhino - Blue Rhino WAD996SP
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.2L TBI SOHC--31034802
Printers & Accessories - Xerox - WorkCentre Pro C2128~C2636~C3545
Sewing Machine - Brother - Brother BAS-511
Video Cameras, Camcorders, & Accessories - Canon - ZR900 Camcorder
Ducati - Motorcycle - Ducati_M620_ie_Parts_2002
Sewing Machine - Brother - Brother DB2-B798
Speaker Systems - JBL - Xtreme
Skoda - Auto - skoda-karoq-2017-manual-do-proprietario-110451
Cameras & Accessories - Nikon - Nikon COOLPIX S203
Printers & Accessories - Epson - Stylus Pro 9000
Cars & Automotive Accessories - Ford - F-150 2001
Power Tools & Accessories - STIHL - STIHL Trimmer FS 40, FS 50
Printers & Accessories - Epson - WorkForce 40
DJ Equipment - Kramer AV - VM-4HDT
Summary of Content
READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM125GY WARNING LIT-11626-22-10 This ATV A should not be ridden by anyone under 16 years of age. 1C5-28199-15 EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. EBU17170 INTRODUCTION EBU17270 Congratulations on your purchase of the Yamaha YFM125GY. This ATV 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 the 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: READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. ● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV. ● 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. ● THIS ATV, AND ANY OTHER ATV OVER 90 cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE. ● EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 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: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. NOTICE A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property. TIP A TIP provides key information to make procedures easier or clearer. * Product and specifications are subject to change without notice. EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV 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 ATV. EBU17381 YFM125GY OWNER’S MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. 1st edition, March 2008 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-11626-22-10 EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17420 TABLE OF CONTENTS SAFETY INFORMATION .............................. 1-1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ............................ 2-1 DESCRIPTION .............................................. 3-1 Left view ..................................................... 3-1 Right view................................................... 3-1 Controls and instruments ........................... 3-2 INSTRUMENT AND CONTROL FUNCTIONS .................................................. 4-1 Main switch ............................................... 4-1 Indicator lights ........................................... 4-2 Handlebar switches ................................... 4-2 Throttle lever ............................................. 4-3 Speed limiter ............................................. 4-4 Front brake lever ........................................ 4-5 Rear brake lever ........................................ 4-5 Parking brake ............................................. 4-6 Drive select lever ....................................... 4-7 Fuel tank cap ............................................. 4-7 Fuel ............................................................ 4-8 Fuel cock ................................................... 4-9 Starter (choke) ......................................... 4-11 Seat ......................................................... 4-11 Front carrier ............................................. 4-12 Rear carrier .............................................. 4-12 PRE-OPERATION CHECKS ..........................5-1 Pre-operation check list ............................. 5-1 Fuel ............................................................ 5-3 Engine oil ................................................... 5-3 Transmission oil ......................................... 5-3 Front and rear brakes ................................ 5-3 Throttle lever .............................................. 5-4 Drive chain ................................................. 5-4 Tires ........................................................... 5-5 Measuring the tire pressure ....................... 5-6 Tire wear limit ............................................ 5-7 Chassis fasteners ...................................... 5-7 Instruments, lights and switches ................ 5-7 Battery ....................................................... 5-7 OPERATION...................................................6-1 Starting a cold engine ................................ 6-1 Starting a warm engine ............................. Operating the drive select lever and driving in reverse ..................................... Engine break-in ......................................... Parking ...................................................... Parking on a slope .................................... Accessories and loading ........................... 6-3 6-3 6-5 6-5 6-6 6-7 RIDING YOUR ATV ...................................... 7-1 GETTING TO KNOW YOUR ATV.............. 7-2 RIDE WITH CARE AND GOOD JUDGEMENT ...........................................7-2 BE CAREFUL WHERE YOU RIDE.......... 7-12 TURNING YOUR ATV ............................. 7-16 CLIMBING UPHILL .................................. 7-17 RIDING DOWNHILL................................. 7-21 CROSSING A SLOPE.............................. 7-22 CROSSING THROUGH SHALLOW WATER ..................................................7-23 RIDING OVER ROUGH TERRAIN .......... 7-25 SLIDING AND SKIDDING........................ 7-25 WHAT TO DO IF... ................................... 7-27 WHAT TO DO... ....................................... 7-27 PERIODIC MAINTENANCE AND MINOR REPAIR .......................................................... 8-1 Owner’s manual and tool kit ...................... 8-1 Periodic maintenance chart for the emission control system .......................... 8-3 General maintenance and lubrication chart ......................................................... 8-5 Checking the spark plug ............................ 8-8 Engine oil ................................................. 8-10 Transmission oil ....................................... 8-13 Cleaning the engine and V-belt case air filter elements ........................................ 8-15 Cleaning the spark arrester ..................... 8-21 V-belt case drain plug .............................. 8-23 Adjusting the carburetor ........................... 8-23 Adjusting the engine idling speed ............ 8-24 Adjusting the throttle cable free play ........ 8-25 Valve clearance ....................................... 8-25 Checking the front and rear brake shoes ..................................................... 8-26 Adjusting the front brake lever free play ........................................................ 8-27 Adjusting the rear brake lever free play .... 8-32 Drive chain slack ...................................... 8-33 Lubricating the drive chain ....................... 8-36 Checking and lubricating the cables ........ 8-37 Checking and lubricating the front and rear brake levers .................................... 8-37 Checking the wheel hub bearings ............ 8-38 Lubricating the upper and lower arm pivots ..................................................... 8-38 Lubricating the front knuckle pivots ......... 8-39 Lubricating the steering shaft ................... 8-40 Battery ..................................................... 8-40 Replacing the fuse .................................. Replacing a headlight bulb ...................... Adjusting a headlight beam ..................... Replacing the tail/brake light bulb ........... Removing a wheel ................................... Installing a wheel ..................................... Troubleshooting ...................................... Troubleshooting chart ............................. 8-44 8-44 8-46 8-47 8-48 8-48 8-49 8-51 CLEANING AND STORAGE.......................... 9-1 Cleaning .................................................... 9-1 Storage ...................................................... 9-2 SPECIFICATIONS ...................................... 10-1 CONSUMER INFORMATION ...................... 11-1 Identification numbers ............................. 11-1 Noise regulation ...................................... 11-3 Maintenance record ................................ 11-4 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY ....... 11-5 YAMAHA EXTENDED SERVICE (Y.E.S.) .................................................. 11-7 EBU17430 SAFETY INFORMATION SAFETY INFORMATION EBU17442 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: ● Read this manual and all labels carefully and follow the operating procedures described. ● 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 1800-887-2887 to find out about the training courses nearest you. ● Always follow the age recommendation: ● ● ● ● ● ● ● 1-1 – A child under 16 years old should never operate an ATV with engine size greater than 90 cc. 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. Never carry a passenger on an ATV. Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. Never operate an ATV on any public street, road or highway, even a dirt or gravel one. 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, a long-sleeved shirt or a jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the riding conditions. Always go at a speed 1 2 3 4 5 6 7 8 9 10 11 1 2 ● ● 3 4 ● 5 6 ● 7 8 ● 9 10 11 ● ● that is proper for the terrain, visibility, operating conditions, and your experience. Never attempt wheelies, jumps, or other stunts. 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. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. 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. Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds and never turn at excessive speeds. Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills ● ● ● ● 1-2 before attempting larger hills. 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 or make sudden gear changes. Never go over the top of a hill at high speed. 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. 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. Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stall- ● ● ● ● ● ing, use the proper gear and 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. 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. 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. 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. 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. ● Always use the size and type of tires specified in this manual. ● Always maintain proper tire pressure as described in this manual. ● Never modify an ATV through improper installation or use of accessories. ● 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 or pulling a trailer. 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. 1 2 3 4 5 6 7 8 9 10 11 1-3 EWB00021 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, seek medical help immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. WARNING 1 2 3 4 5 6 7 8 9 10 11 POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. 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 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. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. EWB00030 WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. 1-4 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. 1 2 3 4 5 6 7 8 9 10 11 1-5 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 6 8 2 3 4 5 6 7 5 1 2 8 4 3 9 10 11 7 8 2-1 EBU17670 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replacement label from your Yamaha dealer. 1 2 3 1 WARNING 2 UNDER 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. OPERATING TIRE PRESSURE : Set with tires cold Recommended : Front : 2.9 psi , ( 20.0 kPa ) Rear : 3.6 psi , ( 25.0 kPa ) Minimum : Front : 2.5 psi , ( 17.0 kPa ) Rear : 3.2 psi , ( 22.0 kPa ) Never set tire pressure below minimum. It could cause the tire to dislodge from the rim. LOADING Maximum weight capacity : 231 lbs. (105 kg) Includes weight of operator, cargo and accessories. 4 5 6 7 8 1C5-2816M-U0 3 9 WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 4D3-2816L-00 5FE-2151H-01 2-2 10 11 1 2 q WARNING 4 5 Improper ATV use can result in SEVERE INJURY or DEATH. 8 Read owner’s manual carefully before operating. 8 When shifting the drive select lever, always be sure to stop the ATV and apply the rear brake. 3 4 5 6 7 8 9 10 11 ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR DRIVE SELECT LEVER NEVER USE NEVER CARRY NEVER USE ON PUBLIC PASSENGERS WITH DRUGS ROADS OR ALCOHOL 5YT-2151E-30 6 NEVER operate : 9 without proper training or instruction. 9 at speeds too fast for your skills or the conditions. 9 on public roads-a collision can occur with another vehicle. 9 with a passenger-passengers affect balance and steering and increase risk of losing control. 11lbs. (5kg) 3LD-24877-U0 7 ALWAYS : 9 use proper riding techniques to avoid vehicle overturns on hills and rough terrain and it turns. 9 avoid paved surfaces-pavement may seriously affect handling and control. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) 22lbs. (10kg) 1C5-24877-U0 8 5FE-21568-01 5FE-21568-11 NEVER sit here. 3MX-24875-A0 2-3 EBU17680 DESCRIPTION 1 EBU17690 EBU17700 Left view Right view 1 2 3 2 1 4 5 6 2 3 3 4 5 6 7 8 7 1. 2. 3. 4. 5. 6. 7. 1. Seat 2. Drive select lever 3. Headlight Front carrier Starter (choke) Fuel cock Tail/brake light Rear carrier Spark arrester Footboard 9 10 11 3-1 from the figures shown in this manual. EBU17712 Controls and instruments 1 2 1 3 4 5 2 3 4 5 6 9 7 8 9 10 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 8 7 6 Rear brake lever Parking brake Reverse indicator light Neutral indicator light Front brake lever Throttle lever Main switch Fuel tank cap Handlebar switches TIP The ATV you have purchased may differ slightly 3-2 EBU17722 INSTRUMENT AND CONTROL FUNCTIONS 1 EWB00010 WARNING OFF Indicates a potential hazard that could result in serious injury or death. 2 ON 1 EBU17740 3 4 Main switch The positions of the main switch are as follows: 5 ON All electrical systems are supplied with power, and the engine can be started. The key cannot be removed. 6 7 1. Main switch 8 OFF All electrical systems are off. The key can be removed. 9 10 11 4-1 EBU17791 EBU18061 Indicator lights Handlebar switches 1 1 2 3 2 3 4 1 2 5 6 7 1. Reverse indicator light “R” 2. Neutral indicator light “N” 1. Engine stop switch “ENG. STOP” 2. Start switch “START” 3. Light switch “LIGHTS” 8 EBU17830 10 Reverse indicator light “ ” This indicator light comes on when the transmission is in the reverse position. 11 EBU17860 9 EBU18070 Engine stop switch “ENG. STOP” Set this switch to “RUN” before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation. The engine will not start or run when this switch is set to “OFF”. Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. 4-2 tle lever will increase the engine speed. Regulate the speed of the ATV by varying the throttle position. Because the throttle is springloaded, the ATV will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. EBU18090 Start switch “START” Push this switch to crank the engine with the starter. ECB00050 NOTICE See the starting instructions on page 6-1 prior to starting the engine. 1 2 3 4 EBU18140 5 Light switch “LIGHTS” Set this switch to “LO” to turn on the low beams and the taillight. Set the switch to “HI” to turn on the high beams and the taillight. Set the switch to “OFF” to turn off all the lights. 6 7 1 ECB00040 NOTICE 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. 1. 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. EBU18270 Throttle lever Once the engine is running, movement of the throt4-3 8 9 10 11 crease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b). EWB00200 WARNING 1 2 3 4 5 6 7 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. (a) 2 1 EBU18311 10 11 3 1. Adjusting screw 2. Locknut 3. No more than 12 mm (0.47 in) 8 9 (b) Speed limiter Your ATV was delivered with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (a). To de- 3. Tighten the locknut. EWB00190 WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. 4-4 WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. HOW TO AVOID THE HAZARD 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 1.0–3.0 mm (0.04–0.12 in). (See page 8-25.) 1 1 2 3 4 5 EBU18391 Front brake lever 1. Front brake lever 6 The front brake lever is located on the right handlebar. To apply the front brake, pull the brake lever toward the handlebar grip. EBU18401 7 Rear brake lever The rear brake lever is located on the left handlebar. To apply the rear brake, pull the brake lever toward the handlebar grip. 8 9 10 11 4-5 1 1 2 3 4 5 6 7 1 1. Parking brake lock plate 2. Parking brake lever (locked position) 1. Rear brake lever EBU18450 Parking brake 8 9 10 2 EWB00170 WARNING Use the parking brake before starting the engine or parking the ATV, 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. 11 4-6 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 Always set the parking brake before starting the engine. Always be sure you have released the parking brake before you begin to ride. 1 3 1 2 2 3 4 4 1. 2. 3. 4. Neutral “N” Forward “F” Reverse “R” Drive select lever 5 6 7 8 EBU18581 EBU18720 Drive select lever Fuel tank cap 9 The drive select lever is used to shift your ATV into the forward, neutral and reverse positions. See the “Operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation. Remove the fuel tank cap by turning it counterclockwise. 10 11 4-7 1 1 2 3 4 5 6 7 1. Fuel level 2. Fuel tank filler tube 1. Fuel tank cap EBU18730 Fuel 8 9 Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 7.0 L (1.85 US gal, 1.54 Imp.gal) Fuel reserve amount: 1.3 L (0.34 US gal, 0.29 Imp.gal) Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. 10 11 ECB00070 NOTICE Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston 4-8 rings, as well as to the exhaust system. 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. 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. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a 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 the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or ATV performance problems. 1 2 3 4 5 6 7 EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while also filtering it. The fuel cock lever positions are explained as follows and shown in the illustrations. EWB00270 WARNING POTENTIAL HAZARD Improper care when refueling. 8 9 10 11 4-9 OFF ON 1 2 3 4 1 RES RES OFF OFF ON FUEL 1 5 ON FUEL ON 6 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running. With the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding. 7 8 9 10 11 4-10 RES the starter (choke). Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. RES 1 RES 4 OFF ON 2 3 (b) FUEL 1 4 5 (a) 2 3 6 1 1. Arrow mark positioned over “RES” 7 This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to “ON”! 8 1. 2. 3. 4. Fully open Half open Closed Starter (choke) EBU18880 EBU18840 Seat Starter (choke) Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the starter (choke) in direction (a) to turn on To remove the seat Pull the seat lock lever upward and pull up the seat at the rear. 4-11 9 10 11 1 1 2 2 3 4 1 5 6 7 8 9 10 1. Seat lock lever 1. Projection 2. Seat holder 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 TIP Make sure that the seat is securely fitted. ● EBU18961 ● 11 Do not exceed the load limit of 5.0 kg (11 lb) for the front carrier. Do not exceed the maximum load of 105.0 kg (231 lb) for the ATV. EBU18971 Rear carrier ● ● 4-12 Do not exceed the load limit of 10.0 kg (22 lb) for the rear carrier. Do not exceed the maximum load of 105.0 kg (231 lb) for the ATV. EWB00010 WARNING 1 Indicates a potential hazard that could result in serious injury or death. 2 3 4 5 6 7 8 9 10 11 4-13 EBU19200 PRE-OPERATION CHECKS 1 EBU19212 2 3 4 5 6 7 8 9 10 Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table. EWB00470 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. 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 it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. TIP The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer. 11 5-1 ITEM ROUTINE ● Check fuel level in fuel tank, and add recommended fuel if necessary. Check fuel line for leakage. Correct if necessary. Check oil level in engine, and add recommended oil to specified level if necessary. Check ATV for oil leakage. Correct if necessary. Check oil level in transmission case, and add recommended oil to specified level if necessary. Check ATV for oil leakage. Correct if necessary. Check operation, and correct if necessary. Lubricate cable if necessary. Check lever free play, and adjust if necessary. Check operation, and correct if necessary. Lubricate cable if necessary. Check lever free play, and adjust if necessary. Make sure that operation is smooth. Lubricate cable and lever housing if necessary. Check cable free play, and adjust if necessary. Make sure that operation is smooth. Lubricate if necessary. Check chain slack, and adjust if necessary. Check chain condition. Lubricate if necessary. Check wheel condition, and replace if damaged. Check tire condition and tread depth. Replace if necessary. Check air pressure. Correct if necessary. Make sure that operation is smooth. Lubricate lever pivoting points if necessary. Make sure that all nuts, bolts and screws are properly tightened. ● Check operation, and correct if necessary. ● Check electrolyte level. Fill with distilled water if necessary. ● Fuel ● ● Engine oil ● ● Transmission oil ● ● Front brake ● ● ● Rear brake ● ● ● Throttle lever ● Control cables ● ● Drive chain ● ● Wheels and tires ● ● ● Brake levers Chassis fasteners Instruments, lights switches Battery and 5-2 PAGE 4-8, 5-3 1 2 5-3, 8-10 3 5-3, 8-13 5-3, 8-26, 8-27 5-3, 8-26, 8-32 4 5 6 7 5-4, 8-25 8 8-37 5-4, 8-33, 8-36 9 5-5, 5-6, 5-7 10 8-37 5-7 5-7 5-7, 8-40 11 EBU19530 EBU19580 Fuel Transmission oil 1 Make sure that there is sufficient fuel in the tank. (See page 4-8.) Make sure that the transmission oil is at the specified level. Add oil as necessary. (See page 8-13.) 2 EWB00500 WARNING 3 4 5 6 7 8 9 10 EBU19640 Front and rear brakes 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. 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. Brake levers ● Check for correct free play in the brake levers. If the free play is incorrect, adjust it. (See pages 8-27 and 8-32.) ● 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 ATV checked by a Yamaha dealer. 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, check the brakes for wear. (See page 8-26.) 11 EWB00530 WARNING EBU19560 Engine oil POTENTIAL HAZARD Riding with improperly operating brakes. Make sure that the engine oil is at the specified level. Add oil as necessary. (See page 8-10.) 5-3 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 checked by a Yamaha dealer. 1 2 3 4 5 EBU19761 6 Throttle lever Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary. 7 8 9 EBU19770 Drive chain 10 Check the condition of the drive chain and check the drive chain slack. Lubricate and adjust the drive chain as necessary. (See page 8-33.) 11 5-4 EBU19782 Tires 1 EWB00562 WARNING 2 3 4 5 6 7 8 9 10 11 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 ● The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. Other tire combinations are not recommended. Front: Manufacturer/model: DUNLOP/KT536A Size: AT20 x 7-8 Type: Tubeless ● Rear: Manufacturer/model: DUNLOP/KT537A Size: AT22 x 10-8 Type: Tubeless The tires should be set to the recommended pressure: Recommended tire pressure: Front: 20.0 kPa (0.200 kgf/cm2, 2.9 psi) Rear: 25.0 kPa (0.250 kgf/cm2, 3.6 psi) Check and adjust tire pressures when the tires are cold. Tire pressures must be equal on both sides. ● ● 5-5 ● ● ● dirt in the gauge could cause the first reading to be incorrect. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure: Front: 17.0 kPa (0.170 kgf/cm2, 2.5 psi) Rear: 22.0 kPa (0.220 kgf/cm2, 3.2 psi) Use no more than the following pressures when seating the tire beads. Maximum tire seating pressure: Front: 250 kPa (2.5 kgf/cm2, 36 psi) Rear: 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully. 1 2 1 3 4 5 6 7 1. Low-pressure tire gauge 8 Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: EBU19820 9 10 Measuring the tire pressure Use the low-pressure tire gauge. 11 TIP The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or 5-6 1 2 3 4 5 6 7 8 Recommended pressure: Front 20.0 kPa (0.200 kgf/cm2, 2.9 psi) Rear 25.0 kPa (0.250 kgf/cm2, 3.6 psi) Minimum: Front 17.0 kPa (0.170 kgf/cm2, 2.5 psi) Rear 22.0 kPa (0.220 kgf/cm2, 3.2 psi) 1. Tire wear limit EBU19830 EBU19840 Tire wear limit Chassis fasteners Replace the tire when the tire groove decreases to 3 mm (0.12 in). Make sure that all nuts, bolts and screws are properly tightened. 9 EBU19850 10 Instruments, lights and switches 11 Check that all instruments, lights and switches are working properly. Correct if necessary. EBU19860 Battery Check the fluid level in the battery. Fill with distilled water if necessary. (See page 8-40.) 5-7 EBU19870 OPERATION 1 EWB00010 EBU20061 Starting a cold engine WARNING 2 EWB00620 Indicates a potential hazard that could result in serious injury or death. WARNING POTENTIAL HAZARD Frozen control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or collision. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding. EBU19890 EWB00610 WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner’s Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer. 3 4 5 6 7 8 ECB00150 NOTICE See the “Engine break-in” section on page 6-5 prior to operating the engine for the first time. 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 into the neutral position. The neutral indicator light should come 6-1 9 10 11 on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 1 2 3 4 5 6 7 8 Ambient temp./starter (choke) position 1 TIP The engine can be started only when the drive select lever is in the neutral position. 4 5. Use the starter (choke) in reference to the figure: 1 Position (1): ● Cold engine start with ambient temperature below 5 °C (40 °F). 1 1. 2. 3. 4. Position (2): Cold engine start with ambient temperature between 0 °C (30 °F) and 30 °C (90 °F). ● 2 3 2 3 Fully open Half open Closed Starter (choke) 6. Completely close the throttle lever and start the engine by pushing the start switch. 9 10 3 2 Position (3): ● Cold engine start with ambient temperature above 25 °C (80 °F). TIP If the engine fails to start, release the start switch, then push it 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 11 6-2 attempt. EBU20350 Operating the drive select lever and driving in reverse 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. 1 ECB00170 NOTICE Before shifting, stop the ATV, otherwise the transmission may be damaged. ECB00160 2 3 4 NOTICE Shifting: Forward 1. Bring the ATV to a complete stop. 2. Shift from neutral to forward and vice versa by moving the drive select lever along the shift guide. For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold! 8. Continue warming up the engine until it idles smoothly, then return the starter (choke) to position (3) before riding. TIP Make sure that the drive select lever is completely shifted into position. TIP The engine is warm when it responds normally to the throttle with the starter (choke) turned off. 5 6 7 8 9 10 11 EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. 6-3 come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 1 1 3 2 4. Check behind for people or obstacles, and then release the parking brake. 5. Open the throttle lever gradually and continue to watch to the rear while backing. 2 3 TIP 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. 4 4 5 6 7 1. 2. 3. 4. Neutral “N” Forward “F” Reverse “R” Drive select lever EWB00670 WARNING POTENTIAL HAZARD Improper operation in reverse. WHAT CAN HAPPEN You could hit an obstacle or even a person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no people or obstacles behind you. When it is safe to proceed, go slowly. 8 9 10 11 3. Open the throttle lever gradually. Shifting: Reverse 1. Bring the ATV to a complete stop. 2. Apply the parking brake. 3. Shift from neutral to reverse and vice versa by moving the drive select lever along the shift guide. TIP When in reverse, the reverse indicator light should 6-4 160–320 km (100–200 mi) or 10–20 hours Avoid prolonged operation above 3/4 throttle. Rev the engine freely, but do not use full throttle at any time. EBU20682 Engine break-in TIP ● For ATVs equipped with an odometer or an hour meter, follow the figures given in km (mi) or the figures given in hours. ● For ATVs not equipped with an odometer or hour meter, follow the figures given in hours. 1 2 320 km (200 mi) or 20 hours and beyond The ATV can now be operated normally. 3 ECB00220 NOTICE If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV. There is never a more important period in the life of your engine than the first 320 km (200 mi) or 20 hours of riding. For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 320 km (200 mi) or 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 that might result in engine overheating must be avoided. EBU20700 Parking When parking the ATV, stop the engine, shift the drive select lever into the forward position, apply the parking brake, and then turn the fuel cock to “OFF”. 4 5 6 7 8 9 10 11 0–160 km (0–100 mi) or 0–10 hours Avoid prolonged operation above 1/2 throttle. Vary the speed of the ATV regularly. Do not operate it at one set throttle position. 6-5 HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the ATV transversely across the incline, shift the drive select lever to the forward position, stop the engine, apply the parking brake, and then 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. 1 2 3 4 1 5 6 1. Bring the ATV to a stop by applying the brakes in the forward position. 2. Stop the engine. 3. With the rear brake applied, apply the parking brake. 1. Locked position 7 EBU20730 8 EWB00760 Parking on a slope 9 10 11 WARNING 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. 6-6 EBU20910 Accessories and loading ● EBU20920 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. ● 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 nonYamaha accessories, nor control over their quality or suitability. Choose a genuine Yamaha accessory, or one that is equivalent in design and quality. ● 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. ● 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. Use extra caution when riding an ATV with accessories. The ATV may handle differently than it does without accessories. EBU21070 Loading As originally equipped, this ATV is not designed to tow a trailer. If you choose to add accessories so that you can tow a trailer, you must use common sense and good judgment as the stability and handling of an ATV can be changed. When adding accessories, keep the following points in mind: ● Never exceed the weight limits shown. An overloaded ATV can be unstable. MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, cargo, accessories, and tongue): 105.0 kg (231 lb) Front carrier: 5.0 kg (11 lb) Rear carrier: 10.0 kg (22 lb) ● 6-7 If you are carrying cargo and towing a trailer, in- 1 2 3 4 5 6 7 8 9 10 11 1 ● 2 3 ● 4 5 ● 6 ● 7 ● 8 ● 9 ● 10 11 clude the tongue weight in the maximum ATV load limit. Load cargo on the carriers as close to the center of the ATV as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, and center it. Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident. Make sure the load does not interfere with controls or your ability to see where you are going. Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Allow more braking distance. A heavier ATV takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV. WHAT CAN HAPPEN Could cause changes in ATV 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. EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EWB00750 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. 6-8 EBU21131 RIDING YOUR ATV 1 2 3 4 5 6 7 8 9 10 11 7-1 labels on your ATV. EWB00010 WARNING 1 2 RIDE WITH CARE AND GOOD JUDGEMENT Indicates a potential hazard that could result in serious injury or death. 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. EBU21293 3 4 5 6 7 8 9 10 11 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. 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 this Owner’s Manual completely and understand the operation of the controls. Pay particular attention to the safety information on pages 1-1–1-5. Please also read all caution and warning EWB01280 WARNING 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. 7-2 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. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc. 1 2 3 4 5 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. 6 7 Not recommended for children under 16 years of age. 8 EWB00901 9 WARNING 10 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. 11 7-3 This ATV is designed to carry operator and cargo only – passengers prohibited. 1 EWB00910 WARNING 2 3 4 5 6 7 8 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. 9 10 11 7-4 Apparel HOW TO AVOID THE HAZARD 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 EWB00920 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. 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. Operating without protective clothing increases your chances of severe injury in the event of an accident. 1 2 3 4 5 6 7 8 9 10 1. 2. 3. 4. 5. 7-5 Protective clothing Goggles Gloves Boots Helmet 11 1 Do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV. 2 Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety. 3 4 EWB00940 WARNING 5 POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. 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. 6 7 8 9 10 11 EWB00930 WARNING 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. 7-6 EWB00950 WARNING EWB00960 WARNING 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 an accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner’s Manual for this ATV on page 5-5. Always maintain proper tire pressure as described in the Owner’s Manual on page 5-6. POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience. 1 2 3 4 5 6 7 Speed limiter For riders less experienced with this model, the throttle lever housing is equipped with a 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. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (See page 4-4.) EWB00010 WARNING 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. 7-7 8 9 10 11 1 2 MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 105.0 kg (231 lb) Front carrier: 5.0 kg (11 lb) Rear carrier: 10.0 kg (22 lb) 2 3 1 4 5 EWB00970 6 WARNING 1. Adjusting screw 2. Locknut POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. 7 8 9 10 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. 11 7-8 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. 1 2 3 4 5 6 During operation Always keep your feet on the footboards during operation, otherwise they may contact the rear wheels. 7 8 9 10 11 7-9 EWB00980 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. WARNING 1 2 3 4 5 6 7 8 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. 9 10 Avoid wheelies and jumping. You may lose control of the ATV or overturn. Modifications EWB01000 EWB00990 11 WARNING WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. 7-10 WHAT CAN HAPPEN Improper installation of accessories or modification of this ATV 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 ATV 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. 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. 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. 1 2 3 4 5 6 7 8 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. 9 10 11 EWB01010 WARNING POTENTIAL HAZARD Hot exhaust system. 7-11 HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets. 1 2 3 4 5 6 7 8 BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. 9 EWB01020 WARNING 10 11 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 ATV to go out of control. Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. 7-12 unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. EWB01030 WARNING 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. 1 EWB01040 WARNING 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. 2 3 4 5 6 7 8 9 10 11 Know the terrain where you ride. Ride cautiously in 7-13 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. 1 2 3 4 5 6 7 8 EWB01050 9 10 11 WARNING 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 ATV control, which could result in an accident, including an overturn. 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. 7-14 Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. 1 2 3 4 5 6 7 EWB01060 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 WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off-road vehicles. 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. 7-15 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 easily. It is essential that this skill be learned first at low speed. hot when riding and afterwards; do not allow skin or clothing to come in contact with these components. 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. 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. EWB01080 WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. 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. TURNING YOUR ATV To achieve maximum traction while riding off-road, 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 7-16 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. 1 2 CLIMBING UPHILL Use proper riding techniques to avoid ATV 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. 1. Lean towards inside of turn. 2. 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. Once you have learned this technique, you should be able to perform it at higher speeds or in tighter 1 2 3 4 5 6 7 8 9 10 11 7-17 EWB01090 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. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. WARNING 1 2 3 4 5 6 7 8 9 POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The ATV 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. EWB01180 10 11 WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. 7-18 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. 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. 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. 1 2 3 4 5 6 7 8 9 10 EWB01190 11 WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. 7-19 EWB01341 WARNING 1 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 Maintain a 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. ● 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. 2 3 4 5 6 7 8 9 10 11 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. If you start to roll backwards, DO NOT apply the rear brake to stop or try to put the ATV in gear. The ATV could easily tip over backwards. Instead, apply the front brake gradually, or dismount the ATV immediately on the uphill side. 7-20 stacles which may appear. EWB01130 WARNING 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 ATV to lean sharply to one side. Go straight down the hill where possible. 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 ob7-21 1 2 3 4 5 6 7 8 9 10 11 the front wheels slightly uphill. When riding on slopes, be sure not to make sharp turns either up or down 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. 1 2 3 EWB01141 4 WARNING 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. 5 6 7 8 9 10 11 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. 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 7-22 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. 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. 2 EWB01150 WARNING 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. 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. CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 20 cm (8 in) in depth. Before entering the water, choose your path 7-23 1 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 ECB00800 Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. NOTICE 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 and the V-belt case drain plug. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. 9 10 11 7-24 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. 1 EWB01160 WARNING 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. 1. Air filter case check hose 1 SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unex- 1. V-belt case drain plug 7-25 1 2 3 4 5 6 7 8 9 10 11 1 2 pected 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. 3 4 5 6 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. 7 8 9 10 11 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. EWB01170 WARNING POTENTIAL HAZARD Skidding or sliding improperly. 7-26 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. ● ● WHAT TO DO IF... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. ● WHAT TO DO... 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 page 7-16.) ● If your ATV begins to tip while turning: ● ● 7-27 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 page 7-16.) 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 page 7-25.) 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 page 7-17.) 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 page 7-22.) If your ATV encounters shallow water: 1 2 3 4 5 6 7 8 9 10 11 1 2 3 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 page 7-23.) EWB00010 4 5 WARNING Indicates a potential hazard that could result in serious injury or death. 6 7 8 9 10 11 7-28 EBU21647 PERIODIC MAINTENANCE AND MINOR REPAIR 1 EBU21660 HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with maintenance work. Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your ATV in the safest and best operating condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages. The intervals given in the periodic maintenance and lubrication chart should be considered as a general guide under normal riding conditions. However, DEPENDING ON THE WEATHER, TERRAIN, GEOGRAPHICAL LOCATION, AND INDIVIDUAL USE, THE MAINTENANCE INTERVALS MAY NEED TO BE SHORTENED. 2 3 4 EBU27100 Owner’s manual and tool kit Be sure to put this owner’s manual in the plastic bag and to always carry it as well as the owner’s tool kit and the low-pressure tire gauge in their respective compartments under the seat. 5 6 7 8 9 EWB01820 WARNING 10 POTENTIAL HAZARD Servicing an engine while it is running. WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body, causing injury. Electrical components can cause shocks or start fires. 11 8-1 it for you. EWB01830 1 WARNING 1 POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this ATV 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 ATV 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. 2 3 3 2 4 5 6 7 8 9 10 11 1. Owner’s manual 2. Low-pressure tire gauge 3. Owner’s tool kit The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. TIP If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform 8-2 EBU21742 Periodic maintenance chart for the emission control system TIP ● For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. 1 2 3 4 5 INITIAL NO. 1 * 2 ITEM Fuel line Spark plug 3 * Valves 4 * Carburetor 5 * Crankcase breather system CHECK OR MAINTENANCE JOB ● ● ● ● ● ● Whichever comes first month 1 3 6 6 12 6 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) 7 hours 20 80 160 160 320 8 √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ Check fuel hoses for cracks or other damage, and replace if necessary. Check condition and clean, regap, or replace if necessary. Check valve clearance and adjust if necessary. Check starter (choke) operation and correct if necessary. Check engine idling speed and adjust if necessary. Check breather hose for cracks or other damage, and replace if necessary. 8-3 EVERY 9 √ √ √ √ 10 11 INITIAL 1 NO. ITEM CHECK OR MAINTENANCE JOB 2 3 4 5 ● 6 7 * Exhaust system Spark arrester ● ● Whichever comes first month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 √ √ √ √ √ √ Check for leakage and replace gasket(s) if necessary. Check for looseness and tighten all screw clamps and joints if necessary. Clean. 6 7 8 9 10 11 8-4 EVERY EBU21864 General maintenance and lubrication chart INITIAL NO. Engine and V-belt case air filter element 1 2 ITEM * Front brake CHECK OR MAINTENANCE JOB Rear brake * Wheels 5 * Tires 6 * Wheel hub bearings 7 * Upper and lower arm pivots 3 6 6 12 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 ● Check operation and correct if necessary. Check brake lever free play and adjust if necessary. Replace brake shoes. Check operation and correct if necessary. Check brake lever free play and adjust if necessary. Replace brake shoes. Check runout and for damage, and replace if necessary. Check tread depth and for damage, and replace if necessary. Check air pressure and balance, and correct if necessary. Check for looseness or damage, and replace if necessary. ● ● ● 4 1 km (mi) Clean and replace if necessary. ● * month ● ● 3 Whichever comes first ● ● ● ● ● Lubricate with lithium-soap-based grease. 8-5 1 EVERY Every 20–40 hours (more often in wet or dusty areas) √ √ √ √ √ 2 3 4 5 6 Whenever worn to the limit 7 √ √ √ √ √ 8 Whenever worn to the limit √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ 9 10 11 INITIAL 1 NO. ITEM CHECK OR MAINTENANCE JOB 2 3 4 Drive chain 6 7 8 9 10 11 * * * 12 * 13 * V-belt Chassis fasteners Shock absorber assemblies Front knuckle pivots Steering shaft 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 √ √ √ √ √ √ √ √ Lubricate with lithium-soap-based grease. Check operation and repair or replace if damaged. Check toe-in and adjust if necessary. Change. Check ATV for oil leakage, and correct if necessary. Clean. Change. Check ATV for oil leakage, and correct if necessary. √ √ √ √ √ √ √ √ √ √ √ √ ● 15 Engine oil ● 11 16 Engine oil strainer ● ● ● ● Transmission oil 6 Lubricate with lithium-soap-based grease. ● 10 17 6 ● ● 14 Steering system 3 ● ● 9 * 1 ● ● ● 5 month Check chain slack and adjust if necessary. Check rear wheel alignment and correct if necesssary. Clean and lubricate. Check for wear, cracks or other damage, and replace if necessary. Make sure that all nuts, bolts, and screws are properly tightened. Check operation and correct if necessary. Check for oil leakage and replace if necessary. ● 8 Whichever comes first EVERY ● 8-6 √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ INITIAL NO. ITEM CHECK OR MAINTENANCE JOB 18 19 20 * * * Front and rear brake switches Lights and switches * Battery 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 2 3 √ √ √ √ √ ● ● Check operation and correct if necessary. √ √ √ √ √ 5 ● Check operation and correct if necessary. Adjust headlight beams. Check electrolyte level and specific gravity, and correct if necessary. Make sure that the breather hose is properly routed. √ √ √ √ √ 6 √ √ √ √ √ 7 ● ● ● 21 month Check operation and correct if necessary. Check throttle cable free play and adjust if necessary. Lubricate throttle lever housing and cable. ● Throttle lever housing and cable Whichever comes first EVERY ● 4 8 EBU23060 TIP The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 9 10 11 8-7 EWB00010 WARNING 1 2 Indicates a potential hazard that could result in serious injury or death. 1 EBU23211 3 4 5 6 7 8 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plug can reveal the condition of the engine. 1. Spark plug cap 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. To remove the spark plug 1. Remove the spark plug cap. 9 10 11 8-8 replace it if necessary. 1 Specified spark plug: NGK/CR7HSA 1 2 To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) 3 4 5 1. Spark plug wrench 6 To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan (the ideal color when the ATV is ridden normally). 7 TIP If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the ATV. 10 8 9 11 1. Spark plug gap 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and 2. Clean the surface of the spark plug gasket 8-9 1 2 3 4 5 6 7 8 9 2. Check the engine oil level on a cold engine. and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. TIP If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil settles for an accurate reading. Tightening torque: Spark plug: 12.5 Nm (1.3 m·kgf, 9.0 ft·lbf) 3. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag. TIP If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 1 2 4. Install the spark plug cap. EBU23265 10 11 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. 1. Engine oil filler cap 2. Dipstick 4. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level. To check the engine oil level 1. Place the ATV on a level surface. 8-10 utes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil. 4. Remove the engine oil filler cap, and then remove the engine oil drain bolt to drain the oil from the crankcase. 1 2 1 2 3 4 5 1 6 1. Maximum level mark 2. Minimum level mark 7 4 TIP The engine oil should be between the minimum and maximum level marks. 3 2 1 8 9 1. 2. 3. 4. 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. 6. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap. Engine oil drain bolt O-ring Spring Oil strainer ECB00310 NOTICE To change the engine oil 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min- When removing the engine oil drain bolt, the compression spring, oil strainer and O-ring will 8-11 10 11 fall out. Take care not to lose these parts. 1 2 3 ECB00330 NOTICE 5. Clean the oil strainer with solvent. 6. Check the O-ring for damage and replace it if necessary. 7. Install the O-ring, oil strainer, compression spring and drain bolt. Tighten the engine oil drain bolt to the specified torque. 4 ECB00320 5 Before installing the engine oil drain bolt, be sure to install the O-ring, compression spring and oil strainer. ● ● 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. Make sure that no foreign material enters the crankcase. NOTICE 6 7 8 9 10 11 1 Tightening torque: Engine oil drain bolt: 32 Nm (3.2 m·kgf, 23.1 ft·lbf) 2 8. Refill with the specified amount of the recommended engine oil, and then install and tighten the engine oil filler cap. 1. “CD” specification 2. “ENERGY CONSERVING II” Recommended oil: See page 10-1. Oil quantity: 1.25 L (1.32 US qt, 1.10 Imp.qt) 9. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 8-12 10. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary. 3 2 1 2 EBU27023 Transmission oil 3 The transmission oil level should be checked before each ride. In addition, the transmission oil must be changed at the intervals specified in the periodic maintenance and lubrication chart. 4 1 To check the transmission oil level 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Wait a few minutes until the oil settles, and then remove the screw located at the right side of the crankcase. 1. Screw 2. Transmission oil level check window 3. Correct oil level 4. Check the transmission oil level. TIP The transmission oil should be at the brim of the hole. 5. If the transmission oil level is below the brim of the hole, remove the oil filler bolt, add sufficient oil of the recommended type to raise it to the correct level, and then install and tighten the screw and the oil filler bolt. 8-13 5 6 7 8 9 10 11 4. Remove the oil filler bolt and the drain bolt to drain the oil from the transmission case. 1 1 2 3 4 1 5 6 7 8 9 1. Transmission oil filler bolt 1. Transmission oil drain bolt Tightening torque: Screw: 16 Nm (1.6 m·kgf, 11.6 ft·lbf) Oil filler bolt: 23 Nm (2.3 m·kgf, 16.6 ft·lbf) 5. Install the drain bolt, and then tighten it to the specified torque. Tightening torque: Transmission oil drain bolt: 23 Nm (2.3 m·kgf, 16.6 ft·lbf) 10 11 To change the transmission oil 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place an oil pan under the transmission to collect the used oil. 6. Refill with the specified amount of the recommended transmission oil, and then install and tighten the oil filler bolt. 8-14 EBU23832 Cleaning the engine and V-belt case air filter elements Recommended transmission oil: See page 10-1. Oil quantity: 0.6 L (0.63 US qt, 0.53 Imp.qt) Both air filter elements should be cleaned at the specified intervals in the periodic maintenance chart. Tightening torque: Oil filler bolt: 23 Nm (2.3 m·kgf, 16.6 ft·lbf) Engine air filter element NOTICE ● ● Make sure that no foreign material enters the transmission case. Make sure that no oil gets on the tires or wheels. 2 3 4 TIP 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. ECB00790 1 5 6 7 8 1 7. Start the engine, and then let it idle for several minutes while checking the transmission for oil leakage. If oil is leaking, immediately turn off the engine and check for the cause. 8. Turn the engine off, and then check the oil level and correct it if necessary. 9 10 11 1. Check hose 8-15 1 1. Place the ATV on a level surface. 2. Remove the seat. (See page 4-11.) 3. Remove the breather hose, and then loosen the clamp screw. 2 2 1 2 3 4 5 1 2 6 1. Air filter case cover 2. Screw 7 8 9 10 2 2 5. Pull the air filter element out of the air filter case. 6. Remove the bolt and washer shown, and then pull the sponge material off from the air filter element frame. 1. Breather hose 2. Clamp screw 4. Remove the air filter case cover by removing the screws. 11 8-16 4 HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material. 3 2 8. Squeeze the excess solvent out of the sponge material and let it dry. 1 ECB00440 NOTICE Do not twist the sponge material when squeezing it. 1. 2. 3. 4. 1 2 3 4 5 6 Bolt Washer Sponge material Air filter element frame 7 8 7. Wash the sponge material gently but thoroughly in solvent. 9 EWB01900 10 WARNING POTENTIAL HAZARD Using low-flash-point solvents or gasoline to clean the sponge material. WHAT CAN HAPPEN Low-flash-point solvents or gasoline can catch fire or explode. 11 9. Check the sponge material and replace it if damaged. 10. Apply Yamaha foam air filter oil or other quality foam air filter oil to the sponge material. 8-17 1 2 3 14. Install the air filter case cover by installing the screws. 15. Install the breather hose and then tighten the clamp screw. 16. Install the seat. TIP The sponge material should be wet but not dripping. 11. Pull the sponge material over the air filter element frame. 12. Install the washer and bolt. TIP The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty areas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions. Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air-tight seal. Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine. ECB00450 4 5 NOTICE Be sure to install the washer with the bent edge facing upward as shown. 6 1 7 8 9 ECB00460 NOTICE 10 ● 11 ● 1. Washer 13. Install the air filter element into the air filter case. 8-18 Make sure that the air filter element is properly seated in the air filter case. Never operate the engine with the air filter element removed. This will allow unfiltered air to enter the engine, 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 2 1 2 V-belt case air filter element 1. Place the ATV on a level surface. 2. Remove the front carrier by removing the bolts. 3 1 1 4 5 2 1 1. Panel 2. Quick fastener 6 7 4. Disconnect the coupler shown. 8 1 9 1 10 1. Bolt 2. Front carrier 11 3. Remove the panel shown by removing the quick fasteners. 8-19 1 1 2 2 3 2 4 5 6 1 1. Panel 2. Coupler 1. Air filter case cover 2. Screw 7 8 5. Remove the air filter case cover by removing the screw. 6. Remove the air filter element. 9 10 11 8-20 1 2 3 1 4 5 1 1. Air filter element 1. Air filter element 8. Check the air filter element and replace it if damaged. 9. Install the air filter element into the air filter case. 10. Install the air filter case cover by installing the screw. 11. Connect the coupler, and then install the panel by installing the quick fasteners. 12. Install the front carrier by installing the bolts. 7. Tap the air filter element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air as shown. EBU23891 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be8-21 6 7 8 9 10 11 fore cleaning the spark arrester. 1. Remove the screws. 3 1 1 2 4 2 3 1 4 5 6 7 8 9 10 11 1. 2. 3. 4. 1. Screw 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. Screw Gasket Tailpipe Spark arrester 4. Insert the tailpipe into the muffler and align the screw holes. 5. Install the screws and tighten them. EWB01910 WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system. 8-22 WHAT CAN HAPPEN 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. 1 2 1 3 4 5 1. V-belt case drain plug EBU23930 EBU23940 V-belt case drain plug 6 7 Adjusting the carburetor After riding in water deep enough to allow it to enter the V-belt case, remove this plug to drain the water from the case. The carburetor should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment described in the following section, however, may be performed by the owner as part of routine maintenance. TIP If water drains from the V-belt case after removing the plug, have a Yamaha dealer check the ATV as the water may affect other engine parts. 8-23 8 9 10 11 throttle stop screw at the carburetor. To increase the engine idling speed, turn the throttle stop screw in direction (a), and to decrease it, turn the screw in direction (b). ECB00480 NOTICE 1 2 3 The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine. 1 4 (a) EBU24000 5 6 7 8 9 10 11 (b) Adjusting the engine idling speed The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart. TIP A diagnostic tachometer is needed to make this adjustment. 1. Throttle stop screw Engine idling speed: 1650–1750 r/min 1. Start the engine and warm it up. TIP The engine is warm when it quickly responds to the throttle. TIP If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if necessary, adjust it to specification by turning the 8-24 EBU24044 1 Adjusting the throttle cable free play The throttle cable free play should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The throttle cable free play should measure 1.0– 3.0 mm (0.04–0.12 in) at the throttle lever. Periodically check the throttle cable free play and, if necessary, adjust it as follows. 1 2 2 (b) 3 (a) 3 4 5 TIP The engine idling speed must be checked, and adjusted if necessary, before adjusting the throttle cable free play. 1. Locknut 2. Throttle cable free play adjusting bolt 3. Throttle cable free play 1. Loosen the locknut. 2. To increase the throttle cable free play, turn the throttle cable free play adjusting bolt in direction (a). To decrease the throttle cable free play, turn the adjusting bolt in direction (b). 3. Tighten the locknut. EBU24060 6 7 8 9 Valve clearance The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. 8-25 10 11 Front brake EBU24090 1 2 3 4 5 6 7 Checking the front and rear brake shoes The front and rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake is provided with a wear indicator, which allows you to check the brake shoe wear without having to disassemble the brake. To check the brake shoe wear, check the position of the wear indicator while applying the brake. If a brake shoe has worn to the point that the wear indicator reaches the wear limit line or mark, have a Yamaha dealer replace the brake shoes as a set. 2 1 1. Wear limit line 2. Wear indicator 8 9 10 11 8-26 mm (0.20–0.31 in) as shown. If the free play is incorrect, adjust it as follows. Rear brake 1 1 2 3 1 4 2 5 6 1. Wear limit line 2. Wear indicator 1. Brake lever free play EBU24360 1. Remove the front carrier by removing the bolts. Adjusting the front brake lever free play The brake lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. 7 8 9 10 11 TIP Before adjusting the brake lever free play, check the front brake shoes for wear. The brake lever free play should measure 5.0–8.0 8-27 2 1 1 2 2 2 3 4 2 2 5 6 1 1. Front carrier 2. Bolt 1. Panel 2. Quick fastener 7 8 9 2. Remove the panel shown by removing the quick fasteners, then disconnect the coupler shown. 10 11 8-28 1 1 1 2 2 3 2 4 1 1. Panel 2. Coupler 1. V-belt air filter element cover 2. Screw 3. Remove the V-belt air filter element cover by removing the screw. 4. Loosen the locknut and fully turn in the adjusting bolt at the brake lever. 5 6 7 8 9 10 11 8-29 2 1 2 1 1 2 a 3 a' a=a' 4 5 6 1. Locknut 2. Brake lever free play adjusting bolt 1. Brake equalizer 2. Cable joint 7 8 9 10 5. Make sure the brake cable joint in the equalizer is straight when the brake is applied. If the cable joint isn’t straight, loosen the locknuts, and then turn the adjusting nuts on the front brake cables until the cable joint becomes straight. 11 8-30 2 1 (b) 2 1 3 2 1 2 3 1 (a) 4 5 1. Locknut 2. Adjusting nut 1. Locknut 2. Brake lever free play adjusting bolt 3. Brake lever free play 6. Tighten the locknut on each brake cable. 7. Turn the adjusting bolt in direction (a) to increase the free play, and in direction (b) to decrease it. 8. Tighten the locknut at the brake lever. 9. Install the V-belt air filter element cover by installing the screw. 10. Connect the coupler, and then install the panel by installing the quick fasteners. 11. Install the front carrier by installing the bolts. 8-31 6 7 8 9 10 11 The brake lever free play should measure 5.0–8.0 mm (0.20–0.31 in) as shown. If the free play is incorrect, adjust it as follows. EWB02020 WARNING 1 2 3 4 5 6 7 8 9 POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct. ● Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. 1 1. Brake lever free play Turn the brake lever free play adjusting nut on the rear wheel hub in direction (a) to increase the free play, and in direction (b) to decrease it. If the correct free play cannot be obtained, have a Yamaha dealer adjust it. EBU24481 Adjusting the rear brake lever free play 10 11 The brake lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. TIP Before adjusting the brake lever free play, check the rear brake shoes for wear. 8-32 HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct. ● Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. (a) (b) EBU24872 1 6 When checking and adjusting the drive chain slack, there should be no weight on the ATV and all tires must be touching the ground. 2. Move the ATV back and forth to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown. 8-33 4 The drive chain slack should be checked before each ride and adjusted if necessary. TIP POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. 3 5 To check the drive chain slack 1. Place the ATV on a level surface. WARNING 2 Drive chain slack 1. Brake lever free play adjusting nut EWB02020 1 7 8 9 10 11 1 Drive chain slack: 30.0 mm (1.18 in) 2 4 3 4 1 5 6 7 1. 2. 3. 4. 1 2 3 Hub stopper bolt Locknut Axle holding bolt (lower) Axle holding bolt (upper) 8 1. Drive chain slack 4. Loosen the chain adjusting bolt 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. 9 10 11 3. If the drive chain slack is incorrect, adjust it as follows. To adjust the drive chain slack 1. Place the ATV on a level surface. 2. Loosen the hub stopper bolt locknut and then the hub stopper bolt. 3. Loosen the axle holding bolts. 8-34 1 Tightening torques: Chain adjusting bolt locknut: 15.5 Nm (1.6 m·kgf, 11.2 ft·lbf) Axle holding bolt (upper): 85 Nm (8.5 m·kgf, 61.5 ft·lbf) Axle holding bolt (lower): 60 Nm (6.0 m·kgf, 43.4 ft·lbf) (a) (b) ECB00550 2 NOTICE 1. Locknut 2. Drive chain slack adjusting bolt If measurement “A” of the drive chain adjusting bolt is less than 27 mm (1.06 in), have a Yamaha dealer replace the drive chain. 1 2 3 4 5 6 7 ECB00541 8 NOTICE Improper drive chain slack will overload the engine as well as other vital parts of the ATV and can lead to drive chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits. 9 10 11 5. Tighten the locknut and the axle holding bolts to the specified torques. 8-35 1 2 1 3 1 4 5 6 7 8 1. Measurement A 1. O-ring 6. Tighten the hub stopper bolt, and then its locknut. ECB00560 NOTICE The drive chain must be lubricated after washing the ATV or riding in the rain. EBU24880 9 10 11 Lubricating the drive chain 1. Clean the drive chain with kerosene and a small soft brush. 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. ECB00570 NOTICE To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate solvents. 2. Wipe the drive chain dry. 8-36 3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant. WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could restrict the operation of controls and lead to an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently. Replace damaged cables. ECB00580 NOTICE Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings. EBU24890 Checking and lubricating the cables 1 2 3 4 5 EBU24912 The operation and the condition of all control cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it. Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Recommended lubricant: Engine oil Recommended lubricant: Silicone grease 6 7 8 9 10 EWB02120 WARNING 11 POTENTIAL HAZARD Damaged control cables. 8-37 Front brake lever EBU24962 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bearings. 1 2 3 4 EBU25032 Lubricating the upper and lower arm pivots 5 6 The upper and lower arm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Lubricate the pivoting points using a grease gun. Rear brake lever 7 8 Recommended lubricant: Lithium-soap-based grease 9 10 11 8-38 Left side Right side 1 1 1 2 1 3 4 1 5 6 1. Grease nipple 1. Grease nipple 7 EBU28821 Lubricating the front knuckle pivots The front knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Lubricate the front knuckle pivots using a grease gun. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 8-39 8 9 10 11 EBU25111 Battery A poorly maintained battery will corrode and discharge quickly. The electrolyte level, battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrication chart. 1 2 3 1 4 To check the electrolyte level 1. Place the ATV on a level surface. 2. Check the electrolyte level in the battery. 5 6 7 1. Grease nipple EBU25102 Lubricating the steering shaft 8 9 10 11 The steering shaft must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease 8-40 1 2 2 1 1 3 4 3 2 1. Maximum level mark 2. Minimum level mark 1. Battery 2. Battery breather hose 3. Guide 5 6 7 ECB00590 NOTICE TIP The electrolyte should be between the minimum and maximum level marks. Use only distilled water, as tap water contains minerals that are harmful to the battery. 8 9 10 3. If the electrolyte is at or below the minimum level mark, add distilled water to raise it to the maximum level mark. 11 8-41 hose routing. EWB02140 WARNING 1 2 3 4 5 6 7 8 9 10 11 To store the battery If the ATV will not be used for more than one month, the battery will need to be removed and stored as follows. 1. Disconnect the negative lead first and then the positive lead. 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. 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. 1 2 3 1. Battery 2. Negative battery lead (black) 3. Positive battery lead (red) 2. Remove the battery, fully charge it, and then place it in a cool, dry place. 4. Check and, if necessary, tighten the battery lead connections and correct the breather 8-42 ECB00600 1 NOTICE 2 1 Do not leave or store the battery on its side. 3. If the battery will be stored for more than two months, check the specific gravity of the electrolyte at least once a month and fully charge the battery whenever necessary. 3 2 3 4 To install the battery 5 TIP Be sure the battery is fully charged. 1. Battery 2. Negative battery lead (black) 3. Positive battery lead (red) 1. Install the battery. 2. Connect the positive lead first, and then connect the negative lead. 3. Make sure that the breather hose is properly routed, in good condition, and not obstructed. ECB00610 NOTICE If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the battery, the frame could suffer structural and external damages. 8-43 6 7 8 9 10 11 fuse. EBU25252 Replacing the fuse 2. Remove the blown fuse, and then install a new fuse of the specified amperage. 1 2 Specified fuse: 15.0 A 2 3 EWB02151 4 WARNING 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. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse. 5 6 1 7 8 9 10 11 1. Fuse 2. Spare fuse The fuse holder is located on the right side of the ATV. If the fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off all electrical circuits. 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. ECB00640 NOTICE EBU25470 Replacing a headlight bulb To prevent accidental short-circuiting, turn off the main switch when checking or replacing a If a headlight bulb burns out, replace it as follows. 8-44 1. Remove the cover at the rear of the headlight by pulling it off. 1 2 2 3 4 1 1 1. Headlight bulb holder cover 2. Headlight bulb holder 5 6 7 1. Cover at the rear of the headlight 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. 4. Remove the defective bulb by pulling it out. 2. Remove the headlight bulb holder cover by pulling it off. 8 9 10 11 8-45 EWB02180 ECB00650 WARNING 1 2 3 4 5 6 7 NOTICE POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. 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 bulb to cool before touching or removing it. Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. 6. Install the bulb holder by pushing it in and turning it clockwise. 7. Install the bulb holder cover and the cover at the rear of the headlight. 5. Insert a new headlight bulb into the bulb holder by pushing it in. ECB00670 NOTICE 8 Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 9 10 1 8. Adjust the headlight beam if necessary. 11 EBU25551 Adjusting a headlight beam ECB00690 NOTICE It is advisable to have a Yamaha dealer make 1. Headlight bulb 8-46 this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b). 1 2 3 4 1 5 1. Tail/brake light bulb holder (a) (b) 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 1 6 7 8 9 1. Headlight beam adjusting screw 10 EBU25610 Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as follows. 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 11 8-47 Front 1 1 1 2 2 3 4 5 1 6 1. Tail/brake light bulb 2. Tail/brake light bulb holder 1. Wheel nut 7 8 9 10 11 3. Elevate the ATV and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. 3. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 4. Install the bulb holder (together with the bulb) by turning it clockwise. EBU25692 EBU25651 Installing a wheel Removing a wheel 1. Place the ATV on a level surface. 2. Elevate the ATV and place a suitable stand under the frame. 3. Install the wheel and the nuts. 1. Place the ATV on a level surface. 2. Loosen the wheel nuts. 8-48 TIP Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel. Tightening torques: Front wheel nut: 55 Nm (5.5 m·kgf, 39.8 ft·lbf) Rear wheel nut: 55 Nm (5.5 m·kgf, 39.8 ft·lbf) EBU25710 1 2 3 4 Troubleshooting Although Yamaha ATVs receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your ATV require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the ATV properly. Use only genuine Yamaha replacement parts. Imitation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills. 1 1. Tapered nut 4. Lower the ATV to the ground. 5. Tighten the wheel nuts to the specified torques. 8-49 5 6 7 8 9 10 11 EWB02260 WARNING 1 2 3 4 5 6 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. 7 8 9 10 11 8-50 EBU25791 Troubleshooting chart 1 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. Check the fuel level in the fuel tank. 2 3 The engine does not start. Check the compression. 4 2. Compression There is compression. Check the ignition. 5 There is no compression. Have a Yamaha dealer check the ATV. 6 Operate the electric starter. 7 3. Ignition Wet Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug. Open the throttle halfway and operate the electric starter. Dry Have a Yamaha dealer check the ATV. The engine does not start. Check the battery. Remove the spark plug and check the electrodes. 4. Battery 8 9 10 The engine turns over quickly. The battery is good. The engine turns over slowly. Check the electrolyte level, recharge the battery and check the lead connections. Operate the electric starter. 8-51 The engine does not start. Have a Yamaha dealer check the ATV. 11 EBU25860 CLEANING AND STORAGE 1 ed from improper high-pressure detergent applications such as those available in coinoperated car washers. EBU25890 2 3 4 5 6 7 8 9 10 11 Cleaning Frequent, thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the ATV: 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 most 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-to-reach places. 5. Rinse the ATV off immediately with clean water and dry all surfaces with a chamois, clean towel or soft absorbing cloth. 6. Dry the chain and lubricate it to prevent it from rusting. 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 cleaning, start the engine and let it idle for several minutes. ECB00710 NOTICE Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have result9-1 nia) and areas where strong chemicals are stored. EWB02300 WARNING 1 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. Long-term Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” section of this chapter. 2. Turn the fuel cock lever to “OFF”. 3. Drain the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank. 4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel from deteriorating. EBU25932 Storage Short-term Always store your ATV in a cool, dry place and, if necessary, protect it against dust with a porous cover. 4 5 6 7 9 10 NOTICE ● 3 8 Specified amount: 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel) ECB00720 ● 2 5. Perform the following steps to protect the cylinder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark plug. b. Pour a teaspoonful of engine oil into the spark plug bore. c. Install the spark plug cap onto the spark Storing the ATV in a poorly ventilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust. To prevent corrosion, avoid damp cellars, stables (because of the presence of ammo9-2 11 1 2 3 4 5 6. 6 7. 7 8 9 8. 10 9. 11 8-40. plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder wall with oil.) e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. Lubricate all control cables and the pivoting points of all levers and pedals. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that all of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an excessively cold or warm place [less than 0 °C (30 °F) or more than 30 °C (90 °F)]. For more information on storing the battery, see page TIP Make any necessary repairs before storing the ATV. 9-3 EBU25960 SPECIFICATIONS 1 Bore × stroke: 49.0 × 66.0 mm (1.93 × 2.60 in) Compression ratio: 9.00 :1 Starting system: Electric starter Lubrication system: Wet sump EBU2597B Dimensions: Overall length: 1700 mm (66.9 in) Overall width: 990 mm (39.0 in) Overall height: 980 mm (38.6 in) Seat height: 685 mm (27.0 in) Wheelbase: 1080 mm (42.5 in) Ground clearance: 145 mm (5.7 in) Minimum turning radius: 2900 mm (114 in) 2 3 4 Engine oil: 5 Type: YAMALUBE 4 5W-30 or 10W-40 or 20W-50, SAE 5W-30 or SAE 10W-40 or SAE 20W-50 0 10 30 50 70 90 110 130 ˚F YAMALUBE 4 (20W-40) or SAE 20W-40 Weight: YAMALUBE 4-CW (5W-30) or SAE 5W-30 Engine: -20 Engine type: Air cooled 4-stroke, SOHC Cylinder arrangement: Forward-inclined single cylinder Displacement: 124.0 cm3 -10 0 10 20 7 8 9 YAMALUBE 4 (10W-30) or SAE 10W-30 With oil and fuel: 152.0 kg (335 lb) 6 10 30 40 50 ˚C 11 Recommended engine oil grade: API service SG type or higher, JASO standard MA 10-1 1 2 3 4 5 6 7 8 9 Transmission: Engine oil quantity: Periodic oil change: 1.25 L (1.32 US qt, 1.10 Imp.qt) Primary reduction system: Helical gear/spur gear Primary reduction ratio: 43/14 × 40/17 (7.226) Secondary reduction system: Chain drive Secondary reduction ratio: 32/12 (2.666) Transmission type: V-belt automatic Operation: Centrifugal automatic type Reverse gear: 49/14 × 49/15 × 40/17 (26.902) Transmission oil: Quantity: 0.6 L (0.63 US qt, 0.53 Imp.qt) Air filter: Air filter element: Wet element Fuel: Recommended fuel: Unleaded gasoline only Fuel tank capacity: 7.0 L (1.85 US gal, 1.54 Imp.gal) Fuel reserve amount: 1.3 L (0.34 US gal, 0.29 Imp.gal) Chassis: Frame type: Steel tube frame Caster angle: 6.0 ° Trail: 15.0 mm (0.59 in) Carburetor: Manufacturer: MIKUNI Type × quantity: VM18SH x 1 Spark plug (s): 10 11 Front tire: Manufacturer/model: NGK/CR7HSA Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) Type: Tubeless Size: AT20 x 7-8 Manufacturer/model: DUNLOP/KT536A Clutch: Clutch type: Dry, centrifugal automatic 10-2 Rear tire: Rim size: 8 x 8.0AT Type: Tubeless Size: AT22 x 10-8 Manufacturer/model: DUNLOP/KT537A Front brake: Type: Drum brake Operation: Right hand operation Loading: Rear brake: Maximum loading limit: 105.0 kg (231 lb) (Total weight of rider, cargo, accessories, and tongue) Type: Drum brake Operation: Left hand operation Tire air pressure (measured on cold tires): 1 2 3 4 5 Front suspension: Recommended: Front: 20.0 kPa (0.200 kgf/cm2, 2.9 psi) Rear: 25.0 kPa (0.250 kgf/cm2, 3.6 psi) Minimum: Front: 17.0 kPa (0.170 kgf/cm2, 2.5 psi) Rear: 22.0 kPa (0.220 kgf/cm2, 3.2 psi) Type: Swing axle Spring/shock absorber type: Coil spring/oil damper Wheel travel: 70 mm (2.8 in) 6 7 8 Rear suspension: Type: Swingarm Spring/shock absorber type: Coil spring/oil damper Wheel travel: 80 mm (3.1 in) Front wheel: Wheel type: Panel wheel Rim size: 8 x 5.5AT Electrical system: Rear wheel: Ignition system: DC. CDI Charging system: AC magneto Wheel type: Panel wheel 10-3 9 10 11 Battery: 1 2 3 4 5 6 7 8 Model: 12N12C-4A-2 Voltage, capacity: 12 V, 12.0 Ah Headlight: Bulb type: Krypton bulb Bulb voltage, wattage × quantity: Headlight: 12 V, 30.0/30.0 W × 2 Tail/brake light: 12 V, 5.0/21.0 W × 1 Neutral indicator light: 12 V, 1.7 W × 1 Reverse indicator light: 12 V, 1.7 W × 1 Fuses: Main fuse: 15.0 A 9 10 11 10-4 EBU25981 CONSUMER INFORMATION 1 EBU26011 EBU26020 Identification numbers Key identification number The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key. Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. ● KEY IDENTIFICATION NUMBER: 2 3 4 5 6 1 ● 7 VEHICLE IDENTIFICATION NUMBER: 8 9 ● MODEL LABEL INFORMATION: 1. Key identification number 10 EBU26030 11 Vehicle identification number The vehicle identification number is stamped into the frame. 11-1 1 1 2 3 4 5 1 6 1. Vehicle identification number 7 8 1. Model label TIP The vehicle identification number is used to identify your ATV. 9 EBU26050 10 11 Model label The model label is affixed at the location in the illustration. Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer. 11-2 EBU26060 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 ● ● ● Muffler Exhaust pipe Silencer 1 2 3 4 5 6 7 Intake system ● ● ● Air cleaner case Air cleaner element Intake duct 8 9 10 11 11-3 EBU26080 Maintenance record 1 2 3 4 5 6 7 8 9 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. MAINTENANCE INTERVAL month km (mi) hours 1 3 6 12 18 24 30 36 42 48 54 60 320 (200) 1300 (800) 2500 (1600) 5000 (3200) 7500 (4800) 10000 (6400) 12500 (8000) 15000 (9600) 17500 (11200) 20000 (12800) 22500 (14400) 25000 (16000) 20 80 160 320 480 640 800 960 1120 1280 1440 1600 DATE OF SERVICE MILEAGE 10 11 11-4 SERVICING DEALER NAME AND ADDRESS REMARKS EBU26501 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 1 Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha ATVs purchased from an authorized Yamaha ATV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations. THE PERIOD OF WARRANTY for Yamaha ATVs shall be six (6) months from the date of purchase. DURING THE PERIOD OF WARRANTY any authorized Yamaha ATV dealer will, free of charge, repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the product’s warranty period. All parts replaced under warranty become property of Yamaha Motor Corp. U.S.A. GENERAL EXCLUSIONS from this warranty shall include any failures caused by: a. Competition or racing use. b. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts. c. Abnormal strain, neglect, or abuse. d. Lack of proper maintenance. e. Accident or collision damage. f. Modification to original parts. g. Damage due to improper transportation. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance, such as spark plugs, oil, oil filter, air filter, and brake shoes. THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the ATV as specified in the appropriate owner’s manual; 2. Give notice to an authorized Yamaha ATV dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer’s place of business. WARRANTY TRANSFER: To transfer the warranty from the original purchaser to any subsequent purchaser(s), it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha ATV dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. An inspection and registration fee will be charged for this service. EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation, USA also warrants to the ultimate purchaser and each subsequent purchaser of each 2006 and later model Yamaha ATV covered by this warranty that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards 11-5 within the period listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty. All Models Thirty (30) months from the original purchase date YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. YAMAHA MOTOR CORPORATION, U.S.A. P.O. Box 6555 Cypress, California 90630 2 3 4 5 6 7 8 9 10 11 WARRANTY QUESTIONS AND ANSWERS 1 2 3 4 5 6 7 8 9 10 11 CUSTOMER SERVICE Q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes. If your machine requires warranty service, you must take it to any authorized Yamaha ATV dealer within the continental United States. Be sure to bring your warranty registration card or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write: Q. What are some examples of “abnormal” strain, neglect, or abuse? A. These terms are general and overlap each other in areas. Specific examples include: Running the machine out of oil, sustained high rpm, full-throttle, operating the machine with a broken or damaged part which causes another part to fail, damage or failure due to improper or careless transportation and or tie-down. If you have any specific questions on operation or maintenance, please contact your dealer for advice. YAMAHA MOTOR CORPORATION U.S.A. CUSTOMER RELATIONS DEPARTMENT P.O. Box 6555 Cypress, California 90630 When contacting Yamaha Motor Corporation, U.S.A. don’t forget to include any important information such as names, addresses, model, V.I.N. (frame number), dates, and receipts. Q. Does the warranty cover incidental costs such as towing or transportation due to a failure? A. No. The warranty is limited to repair of the machine itself. CHANGE OF ADDRESS Q. May I perform any or all of the recommended maintenance shown in the Owner’s Manual instead of having the dealer do them? A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owner’s and Service Manual. We do recommend, however, that items requiring special tools or equipment be done by a Yamaha ATV dealer. The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related defect and recall. This list is compiled from the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase. Q. Will the warranty be void or cancelled if I do not operate or maintain my new ATV exactly as specified in the Owner’s Manual? A. No. The warranty on a new ATV cannot be “voided” or “cancelled.” However, if a particular failure is caused by operation or maintenance other than as described in the Owner’s Manual, that failure may not be covered under warranty. If you should move after you have purchased your new ATV, please advise us of your new address by sending a postcard listing your ATV model name, V.I.N. (frame number), dealer number (or dealer’s name) as it is shown on your warranty card, your name and new mailing address. Mail to: Q. What responsibility does my dealer have under this warranty? A. Each Yamaha ATV dealer is expected to: 1. Completely set up every new machine before sale. 2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request at any later date. 3. Each Yamaha ATV dealer is held responsible for his setup, service and warranty repair work. YAMAHA MOTOR CORPORATION, U.S.A. P.O. Box 6555 Cypress, California 90630 Attention: Warranty Department This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law. Q. Is the warranty transferable to second owners? A. Yes. The remainder of the existing warranty can be transferred upon request. The unit has to be inspected and re-registered by an authorized Yamaha ATV dealer for the policy to remain effective. 11-6 EBU26122 YAMAHA EXTENDED SERVICE (Y.E.S.) 1 Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Ser vice (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost. TRIP gives you up to $150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb coverage goes into effect when you purchase Y.E.S., so it applies to any warranty repairs as well as covered repairs during your entire Y.E.S. plan period. Y.E.S. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get uninterrupted factor y-backed coverage for extra peace of mind. Y. E. S. is flexible. You choose the plan that’s right for you: 12 months, 24 months, or 36 months beyond your warranty period. Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide. Y.E.S. is designed and administered by the same Yamaha people who handle your warranty – and it shows in the comprehensive coverage benefits. There are no mileage limitations. Coverage isn’t limited to “moving par ts” or the “drive train” like many other plans. And Y.E.S. covers manufacturing defects just like the warranty. See the sample contract at your Yamaha dealer to see how comfor ting uninterr upted factor ybacked protection can be. Y.E.S. coverage is transferable to a new owner if you sell or trade in your ATV. That can make your Yamaha much more valuable! This excellent Y.E.S. plan coverage is only available to Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha Extended Service. You don’t have to pay anything for covered repairs. T h e r e ’s n o d e d u c t i b l e t o p ay, a n d r e p a i r s a r e n ’ t “pro-rated.” You don’t have any “out-of-pocket” expenses for covered repairs. 2 3 4 5 6 7 8 9 10 11 11-7 1 2 3 4 5 6 We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. You can also save money: Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O. Box 6555 Cypress, CA 90630 7 8 9 10 11 WARNING Indicates a potential hazard that could result in serious injury or death. 11-8 EBU26132 1 2 3 4 5 6 7 8 9 10 11 11-9 INDEX A E Accessories and loading ................................................ 6-7 Air filter elements, engine and V-belt filter cleaning ..... 8-15 Engine break-in .............................................................. 6-5 Engine, cold start ........................................................... 6-1 Engine idling speed...................................................... 8-24 Engine oil ............................................................. 5-3, 8-10 Engine, starting a warm ................................................. 6-3 Engine stop switch ......................................................... 4-2 B Battery.................................................................. 5-7, 8-40 Brake lever free play, adjusting the front...................... 8-27 Brake lever free play (rear), adjusting .......................... 8-32 Brake lever, front............................................................ 4-5 Brake lever, rear............................................................. 4-5 Brake levers, checking and lubricating......................... 8-37 Brakes, front and rear .................................................... 5-3 Brake shoes, checking the front and rear .................... 8-26 F Front knuckle pivots, lubricating................................... 8-39 Fuel ........................................................................ 4-8, 5-3 Fuel cock........................................................................ 4-9 Fuel tank cap.................................................................. 4-7 Fuse, replacing............................................................. 8-44 C Cables, checking and lubricating ................................. 8-37 Carburetor, adjusting.................................................... 8-23 Carrier, front ................................................................. 4-12 Carrier, rear.................................................................. 4-12 Chassis fasteners........................................................... 5-7 Cleaning ......................................................................... 9-1 H Handlebar switches........................................................ 4-2 Headlight beam, adjusting............................................ 8-46 Headlight bulb, replacing.............................................. 8-44 I Identification numbers .................................................. 11-1 Indicator lights ................................................................ 4-2 Instruments, lights and switches .................................... 5-7 D Drive chain ..................................................................... 5-4 Drive chain, lubricating................................................. 8-36 Drive chain slack .......................................................... 8-33 Drive select lever............................................................ 4-7 Drive select lever and driving in reverse ........................ 6-3 K Key identification number............................................. 11-1 L Label locations ............................................................... 2-1 Light switch .................................................................... 4-3 M Main switch .....................................................................4-1 Maintenance and lubrication chart ..................................8-5 Maintenance chart, emission control system ..................8-3 Maintenance record ......................................................11-4 Model label....................................................................11-2 N Neutral indicator light ......................................................4-2 Noise regulation ............................................................11-3 O Owner’s manual and tool kit............................................8-1 P Parking............................................................................6-5 Parking brake..................................................................4-6 Parking on a slope ..........................................................6-6 Part locations ..................................................................3-1 Pre-operation check list ..................................................5-1 R Reverse indicator light ....................................................4-2 Riding your ATV..............................................................7-1 S Safety information ...........................................................1-1 Seat...............................................................................4-11 Spark arrester, cleaning................................................8-21 Spark plug, checking.......................................................8-8 Specifications................................................................10-1 Speed limiter ...................................................................4-4 Starter (choke) ..............................................................4-11 Start switch .....................................................................4-3 Steering shaft, lubricating .............................................8-40 Storage ...........................................................................9-2 Suspension, lubricating the upper and lower arm pivots ......................................................................... 8-38 T Tail/brake light bulb, replacing ..................................... 8-47 Throttle cable free play, adjusting ................................ 8-25 Throttle lever ...........................................................4-3, 5-4 Tire pressure, measuring ............................................... 5-6 Tires ............................................................................... 5-5 Tire wear limit................................................................. 5-7 Transmission oil ....................................................5-3, 8-13 Troubleshooting ........................................................... 8-49 Troubleshooting chart .................................................. 8-51 V Valve clearance ........................................................... 8-25 V-belt case drain plug .................................................. 8-23 Vehicle identification number ....................................... 11-1 W Warranty, extended...................................................... 11-7 Warranty, limited .......................................................... 11-5 Wheel hub bearings, checking..................................... 8-38 Wheel, installing........................................................... 8-48 Wheel, removing .......................................................... 8-48 EBU26141 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. BEER BEER 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: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns. on public roads-a collision can occur with avoid paved surfaces-pavement may another vehicle. seriously affect handling and control. 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) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2008.03-1.5x2 ! (E)