Yamaha YFM125GW Owner`s manual

WARNING

LIT-11626-20-07

READ THIS MANUAL CAREFULLY!

It contains important safety information.

OWNER’S MANUAL

YFM125GW

1C5-28199-13

EBU17091

EBU17170

INTRODUCTION

EBU17270

Congratulations on your purchase of the Yamaha YFM125GW. 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 COMPLETE-

LY 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 INFORMA-

●

TION.

THIS ATV, AND ANY OTHER ATV OVER 90 cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16

YEARS OF AGE.

EBU17330

IMPORTANT MANUAL INFORMATION

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FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN-

JURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or repairing the ATV.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the ATV.

NOTE: A NOTE provides key information to make procedures easier or clearer.

* Product and specifications are subject to change without notice.

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IMPORTANT NOTICE

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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

AFFIX DEALER

LABEL HERE

YFM125GW

OWNER’S MANUAL

©2006 by Yamaha Motor Corporation, U.S.A.

1st edition, March 2006

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-11626-20-07

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 ............................. 6-3

Operating the drive select lever and driving in reverse ..................................... 6-3

Engine break-in ......................................... 6-4

Parking ...................................................... 6-5

Parking on a slope .................................... 6-6

Accessories and loading ........................... 6-6

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 ....................................... 8-12

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 bearings ................... 8-38

Lubricating the upper and lower arm pivots .....................................................8-38

Lubricating the knuckle shafts ................. 8-39

Lubricating the steering shaft ................... 8-40

Battery ..................................................... 8-40

Replacing the fuse ................................... 8-44

Replacing a headlight bulb ...................... 8-44

Adjusting a headlight beam ..................... 8-46

Replacing the tail/brake light bulb ........... 8-47

Removing a wheel ................................... 8-48

Installing a wheel ..................................... 8-48

Troubleshooting ...................................... 8-49

Troubleshooting chart ............................. 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

EBU17442

AN ATV IS NOT A TOY AND CAN BE HAZARD-

OUS 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 1-

800-887-2887 to find out about the training courses nearest you.

Always follow the age recommendation:

SAFETY INFORMATION

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– 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

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● 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.

1-3

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●

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 installa●

● tion 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 SAFE-

TY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s

Safety Hotline at 1-800-852-5344.

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EWB00021

WARNING

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.


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.

1-4

EWB00030

WARNING


Starting or running the engine in a closed area.

WHAT CAN HAPPEN

Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.


Always operate your ATV in an area with adequate ventilation.

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LOCATION OF THE WARNING AND SPECIFICATION LABELS

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2-1

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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

WARNING

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.

5FE-21697-01

3

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 : 20 kPa, {0.20 kgf/cm

Minimum

REAR : 25 kPa, {0.25 kgf/cm

: FRONT : 17 kPa, {0.17 kgf/cm

REAR : 22 kPa, {0.22 kgf/cm 2

2

2

2 } 2.9 psi

} 3.6 psi

} 3.2 psi

It could cause the tire to dislodge from the rim.

LOADING

1C5-21696-00

WARNING

NEVER ride as a passenger.

Passengers can cause a loss of control, resulting in SEVERE

INJURY or DEATH.

5FE-2151H-01

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q WARNING

Improper ATV use can result in SEVERE

INJURY or DEATH.

ALWAYS USE NEVER USE NEVER CARRY NEVER USE

AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS

HELMET AND

PROTECTIVE

GEAR

ROADS OR ALCOHOL

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.

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)

2-3

5 DRIVE SELECT LEVER

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.

5YT-2151E-30

6

5kg 11lbs

3LD-24877-A0

7

10kg 22lbs

1C5-24877-A0

8

NEVER

sit here.

3MX-24875-A0

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Left view

1 2 3

DESCRIPTION

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Right view

4 5 6

1 2

1. Front carrier

2. Starter (choke)

3. Fuel cock

4. Tail/brake light

5. Rear carrier

6. Spark arrester

7. Footboard

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1. Seat

2. Drive select lever

3. Headlight

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Controls and instruments

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1. Rear brake lever

2. Parking brake

3. Reverse indicator light

4. Neutral indicator light

5. Front brake lever

6. Throttle lever

7. Main switch

8. Fuel tank cap

9. Handlebar switches

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5

NOTE:

The ATV you have purchased may differ slightly

3-2 from the figures shown in this manual.

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INSTRUMENT AND CONTROL FUNCTIONS

EWB00010

WARNING


OFF ON

EBU17740

Main switch

The positions of the main switch are as follows:

ON

All electrical systems are supplied with power, and the engine can be started. The key cannot be removed.

OFF

All electrical systems are off. The key can be removed.

1. Main switch

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Indicator lights

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1. Reverse indicator light “R”

2. Neutral indicator light “N”

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Reverse indicator light “ ”

This indicator light comes on when the transmission is in the reverse position.

11 EBU17860

Neutral indicator light “ ”

This indicator light comes on when the transmission is in the neutral position.

EBU18060

Handlebar switches

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2

1. Engine stop switch “ENG. STOP”

2. Start switch “START”

3. Light switch “LIGHTS”

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”.

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EBU18090

Start switch “START”

Push this switch to crank the engine with the starter.

ECB00050

CAUTION:

See the starting instructions on page 6-1 prior to starting the engine.

EBU18140

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.

ECB00040

CAUTION:

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.

EBU18270

Throttle lever

Once the engine is running, movement of the throt-

4-3 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.

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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.

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EWB00200

WARNING


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.


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.

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EBU18311

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-

4-4 crease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b).

(a)

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1

(b)

3

1. Adjusting screw

2. Locknut

3. No more than 12 mm (0.47 in)

3. Tighten the locknut.

EWB00190

WARNING


Improper adjustment of the speed limiter and throttle.

WHAT CAN HAPPEN

The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured.


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.)

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Front brake lever

The front brake lever is located on the right handlebar. To apply the front brake, pull the brake lever toward the handlebar grip.

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1. Front brake lever

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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.

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1. Rear brake lever

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Parking brake

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.

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1. Parking brake lock plate

2. Parking brake lever (locked position)

EWB00170

WARNING


Improper use of the parking brake.

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.


Always set the parking brake before starting the engine.

Always be sure you have released the parking brake before you begin to ride.

EBU18581

Drive select lever

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.

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1. Neutral “N”

2. Forward “F”

3. Reverse “R”


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EBU18720

Fuel tank cap

Remove the fuel tank cap by turning it counterclockwise.

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1. Fuel tank cap

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Fuel

Make sure that there is sufficient fuel in the tank.

Fill the fuel tank to the bottom of the filler tube as shown.

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1. Fuel level

2. Fuel tank filler tube

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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)

ECB00070

CAUTION:

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston

rings, as well as to the exhaust system.

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.

EWB00270

WARNING


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.


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.


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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.

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OFF

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OFF

RES

ON

FUEL

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1. Arrow mark positioned over “OFF”

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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.

ON

RES

1

OFF

ON

FUEL

ON

1. Arrow mark positioned over “ON”

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.

4-10

RES

1

OFF

RES

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.

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(b)

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ON

FUEL

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(a)

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1. Arrow mark positioned over “RES”

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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”!

1. Fully open

2. Half open

3. Closed

4. Starter (choke)

EBU18840

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

EBU18880

Seat

4-11

To remove the seat

Pull the seat lock lever upward and pull up the seat at the rear.

8

9

10

11

1

1

4

5

2

3

1

6

1. Seat lock lever

7

8

9

10

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.

NOTE:

Make sure that the seat is securely fitted.

11

2

4-12

1. Projection

2. Seat holder

EBU18960

Front carrier

●

●

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.

EBU18970

Rear carrier

●

●

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

8

9

6

7

10

11

4

5

2

3

4-13

1

2

3

4

5

6

7

8

9

10

11

EBU19200

PRE-OPERATION CHECKS

EBU19210

Pre-operation check list

Before operating this ATV, be sure to check the items listed in the following table.

NOTE:

The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a

Yamaha dealer.

Fuel

Engine oil

Rear brake

ITEM

Transmission oil

Front brake

Throttle lever

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.

●

●


Lubricate cable if necessary.

●

Check lever free play, and adjust if necessary.

●

Make sure that operation is smooth. Lubricate cable and lever hous-

● ing if necessary.

Check cable free play, and adjust if necessary.

5-1

PAGE

4-8, 5-3

5-3, 8-10

5-3, 8-12

5-3, 8-26, 8-27

5-3, 8-26, 8-32

5-4, 8-25

ITEM

Control cables

Drive chain

Wheels and tires

Brake levers

Chassis fasteners

Instruments, lights and switches

Battery

●

● if necessary.

ROUTINE

●

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

Make sure that all nuts, bolts and screws are properly tightened.

●


●

Check electrolyte level. Fill with distilled water if necessary.

PAGE

8-37

5-4, 8-33, 8-36

5-5, 5-6, 5-7

8-37

5-7

5-7

5-7, 8-40

EWB00470

WARNING


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.


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.

1

8

9

6

7

10

11

4

5

2

3

5-2

1

2

3

4

5

6

7

8

9

10

EBU19530

Fuel

Make sure that there is sufficient fuel in the tank.

(See page 4-8.)

EWB00500

WARNING


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.


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.


11

EBU19560

Engine oil

Make sure that the engine oil is at the specified level. Add oil as necessary. (See page 8-10.)

5-3

EBU19580


Make sure that the transmission oil is at the specified level. Add oil as necessary. (See page 8-12.)

EBU19640

Front and rear brakes

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.)

EWB00530

WARNING


Riding with improperly operating brakes.

WHAT CAN HAPPEN

You could lose braking ability, which could lead to an accident.


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.

EBU19761

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.

EBU19770

Drive chain

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.)

5-4

1

8

9

6

7

10

11

4

5

2

3

1

2

3

4

5

6

7

8

9

10

11

EBU19781

Tires

EWB00561

WARNING


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.


● 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 recommend-

●

● ed pressure:

Recommended tire pressure:

Front:

20 kPa (2.9 psi) (0.20 kgf/cm

2

)

Rear:

25 kPa (3.6 psi) (0.25 kgf/cm

2

)

Check and adjust tire pressures when the tires are cold.

Tire pressures must be equal on both sides.

5-5

●

●

●

Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions.

Minimum tire pressure:

Front:

17 kPa (2.5 psi) (0.17 kgf/cm

2

)

Rear:

22 kPa (3.2 psi) (0.22 kgf/cm

2

)

Use no more than the following pressures when seating the tire beads.

Maximum tire seating pressure:

Front:

250 kPa (36 psi) (2.5 kgf/cm

2

)

Rear:

250 kPa (36 psi) (2.5 kgf/cm

2

)

Higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully.

EBU19820

Measuring the tire pressure

Use the low-pressure tire gauge.

NOTE:

The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or

5-6 dirt in the gauge could cause the first reading to be incorrect.

1

1

7

1. Low-pressure tire gauge

8

Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: 9

10

11

4

5

2

3

6

1

2

3

4

5

6

7

8

Recommended pressure:

Front

20 kPa (2.9 psi) (0.20 kgf/cm

2

)

Rear

25 kPa (3.6 psi) (0.25 kgf/cm

2

)

Minimum:

Front

17 kPa (2.5 psi) (0.17 kgf/cm

2

)

Rear

22 kPa (3.2 psi) (0.22 kgf/cm

2

)

Maximum:

Front

23 kPa (3.3 psi) (0.23 kgf/cm

2

)

Rear

28 kPa (4.1 psi) (0.28 kgf/cm

2

)

9

10

11

EBU19830

Tire wear limit

Replace the tire when the tire groove decreases to

3 mm (0.12 in).

1. Tire wear limit

5-7

EBU19840


Make sure that all nuts, bolts and screws are properly tightened.

EBU19850

Instruments, lights and switches

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.)

EBU19870

EWB00010

WARNING


EBU19890

EWB00610

WARNING


Operating ATV without being familiar with all controls.

WHAT CAN HAPPEN

Loss of control, which could cause an accident or injury.


Read the Owner’s Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer.

OPERATION

1

EBU20061

Starting a cold engine

EWB00620

WARNING


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.


When riding in cold weather, always make sure all control cables work smoothly before you begin riding.

2

3

4

5

6

7

8

ECB00150

CAUTION:

See the “Engine break-in” section on page 6-4 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

9

10

11

6-1

1

2

3

4 on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit.

NOTE:

The engine can be started only when the drive select lever is in the neutral position.

5. Use the starter (choke) in reference to the figure:

5

6

Position (1):

● Cold engine start with ambient temperature below 5 °C (40 °F).

7

8

Position (2):

● Cold engine start with ambient temperature between 0 °C (30 °F) and 30 °C (90 °F).

9

10

Position (3):

● Cold engine start with ambient temperature above 25 °C (80 °F).

11

Ambient temp./starter (choke) position

1

4

2

3

1 2 3

1. Fully open

2. Half open

3. Closed

4. Starter (choke)

1

2

3

6. Completely close the throttle lever and start the engine by pushing the start switch.

NOTE:

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

6-2

attempt.

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.

ECB00160

CAUTION:

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.

NOTE:

The engine is warm when it responds normally to the throttle with the starter (choke) turned off.

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

EBU20350

Operating the drive select lever and driving in reverse

ECB00170

CAUTION:

Before shifting, stop the ATV, otherwise the transmission may be damaged.

1

2

3

4

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.

NOTE:

Make sure that the drive select lever is completely shifted into position.

5

6

7

8

9

10

11

1

2

3

4

5

3

1

2

4

6

7

1. Neutral “N”

2. Forward “F”

3. Reverse “R”


8

3. Open the throttle lever gradually.

9

10

11

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.

NOTE:

When in reverse, the reverse indicator light should

6-4 come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit.

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.

NOTE:

If the drive select lever is shifted into reverse while the engine is running, the engine will stop unless the rear brake lever or parking brake is applied.

EWB00670

WARNING


Improper operation in reverse.

WHAT CAN HAPPEN

You could hit an obstacle or even a person behind you, resulting in serious injury.


When you shift into reverse, make sure there are no people or obstacles behind you. When it is safe to proceed, go slowly.

EBU20681

Engine break-in

There is never a more important period in the life of

your engine than the first 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 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.

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.

10–20 hours

Avoid prolonged operation above 3/4 throttle. Rev the engine freely, but do not use full throttle at any time.

20 hours and beyond

The ATV can now be operated normally.

ECB00220

CAUTION:

If any engine trouble should occur during the engine break-in period, immediately have a

6-5

Yamaha dealer check the ATV.

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”.

1

2

3

4

1

1. Locked position

5

6

7

8

9

10

11

1

2

3

4

5

6

7

8

9

10

11

EBU20730

Parking on a slope

EWB00760

WARNING


Parking on a hill or other incline.

WHAT CAN HAPPEN

The ATV could roll out of control, increasing the chance of an accident.


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. 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.

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 non-

Yamaha accessories, nor control over their qual-

●

●

● ity 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 over-

6-7 loaded 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)

1

2

3

4

5

●

●

●

●

●

●

If you are carrying cargo and towing a trailer, include 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

6

7

8

9

10

11

1

2

3

4

5

6

7

8

9

10

11

● 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.

EWB00750

WARNING


Overloading this ATV or carrying or towing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in ATV handling which could lead to an accident.


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


6-8

EBU21131

RIDING YOUR ATV

1

8

9

6

7

10

11

4

5

2

3

7-1

1

EWB00010

WARNING


2

3

4

5

6

7

8

9

10

11

EBU21292

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 labels on your ATV.

7-2

RIDE WITH CARE AND GOOD JUDGEMENT

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.

EWB01280

WARNING


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.


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.

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.

Not recommended for children under 16 years of age.

EWB00901

WARNING


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.

7-3


A child under 16 should never operate an

ATV with engine size greater than 90 cc.

1

7

This ATV is designed to carry operator and cargo only – passengers prohibited.

8

9

10

11

4

5

2

3

6

10

11

8

9

1

2

3

4

5

6

7

EWB00910

WARNING


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.


Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.

7-4

Apparel

EWB00920

WARNING


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.


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

1

8

9

6

7

10

11

4

5

2

3

1. Protective clothing

2. Goggles

3. Gloves

4. Boots

5. Helmet

7-5

5

6

3

4

1

2

Do not operate after consuming alcohol or drugs.

The operator’s performance capability is reduced by the influence of alcohol or drugs.

7

8

9

10

11

EWB00930

WARNING


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.


Never consume alcohol or drugs before or while driving this ATV.

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.

EWB00940

WARNING


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.


Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.

7-6

EWB00950

WARNING


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.


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.

EWB00010

WARNING


Do not operate at speeds too fast for your skills or the conditions.

EWB00960

WARNING


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.


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.)

8

9

10

11

7-7

1

2

4

5

2

3

1

6

1. Adjusting screw

2. Locknut

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

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)

EWB00970

WARNING


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


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.

During operation

Always keep your feet on the footboards during operation, otherwise they may contact the rear wheels.

7-9

1

8

9

6

7

10

11

4

5

2

3

1

2

3

4

5

6

7

8

EWB00980

WARNING


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.


Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation.

9

10

11

Avoid wheelies and jumping. You may lose control of the ATV or overturn.

EWB00990

WARNING


Attempting wheelies, jumps, and other stunts.

WHAT CAN HAPPEN

Increases the chance of an accident, including an overturn.


Never attempt stunts, such as wheelies or jumps. Don’t try to show off.

Modifications

EWB01000

WARNING


Operating this ATV with improper modifications.

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.


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.

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.

EWB01010

WARNING


Hot exhaust system.

WHAT CAN HAPPEN

Dry grass or brush or other combustible material accumulated around the engine area could catch fire.

Someone touching the exhaust system during or after operation could be burned.


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

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10

11

4

5

2

3

7-11

1

4

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2

3

6

7

8

9

10

11

BE CAREFUL WHERE YOU RIDE

This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control.

EWB01020

WARNING


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.

7-12


Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.

Do not ride on any public road, street, or highway.

Riding on public roads can result in collisions with other vehicles.

EWB01030

WARNING


Operating this ATV on public streets, roads or highways.

WHAT CAN HAPPEN

You can collide with another vehicle.


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.

Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset.

EWB01040

WARNING


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.


Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

1

2

3

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5

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7

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11

7-13

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2

3

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8

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10

11

EWB01050

WARNING


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.


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.

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

5

6

3

4

EWB01060

WARNING


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.


Always mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles.

7-15

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

7

8

9

10

11

1

2

3

4

5

6

7

8

9

10

11 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.

easily. It is essential that this skill be learned first at low speed.

EWB01080

WARNING


Turning improperly.

WHAT CAN HAPPEN

ATV could go out of control, causing a collision or overturn.


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.

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

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.

1

2

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

7-17 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

3

4

5

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.

6

7

8

9

10

11

1

2

3

4

5

EWB01090

WARNING


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.


Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting large hills.

6

7

8

9

10

11

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

WARNING


Climbing hills improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV to overturn.


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.

7-18

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.

EWB01190

WARNING


Improperly crossing hills or turning on hills.

WHAT CAN HAPPEN



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.

1

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9

6

7

10

11

4

5

2

3

7-19

1

4

5

2

3

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.

EWB01341

WARNING


Stalling, rolling backwards or improperly dismounting while climbing a hill.

WHAT CAN HAPPEN

●

●

●

Could result in ATV overturning.


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.

7-20

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 ob-

7-21 stacles which may appear.

EWB01130

WARNING


Going down a hill improperly.

WHAT CAN HAPPEN



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.

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7

10

11

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5

2

3

1

2

3

4

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 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.

EWB01141

WARNING


Improperly crossing hills or turning on hills.

WHAT CAN HAPPEN



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.

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 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.

EWB01150

WARNING


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.


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.

1

2

3

4

5

6

7

8

9

10

11

1

4

5

2

3

6

10

11

7

8

Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability.

9

ECB00800

CAUTION:

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.

7-24

1. Air filter case check hose

1

1. V-belt case drain plug

1

7-25

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.

EWB01160

WARNING


Improperly operating over obstacles.

WHAT CAN HAPPEN

Could cause loss of control or a collision.

Could cause the ATV to overturn.


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

2

3

4

5

6

7

8

9

10

11

SLIDING AND SKIDDING

Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unex-

6

7

4

5

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

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.

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.

EWB01170

WARNING


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.


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 7-17.)

If your ATV encounters shallow water:

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9

10

7

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11

1

2

3

4

5

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

WARNING


6

7-28

EBU21640

EBU21660

PERIODIC MAINTENANCE AND MINOR REPAIR

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 INTER-

VALS MAY NEED TO BE SHORTENED.

EWB01820

WARNING


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.

1


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.

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

10

11

8-1

1

1

4

5

2

3

3 2

6

7

1. Owner’s manual

2. Low-pressure tire gauge

3. Owner’s tool kit

8

9

10

11

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.

NOTE:

If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform

8-2 it for you.

EWB01830

WARNING


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.


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.

EBU21741

Periodic maintenance chart for the emission control system

●

●

NOTE:

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

1

2

3

4

5

NO.

*

*

*

*

Spark plug

Valves

ITEM

Fuel line

Carburetor

Crankcase breather system

CHECK OR MAINTENANCE

JOB

Whichever comes first month km

(mi) hours

●

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 nec-

● essary.

Check engine idling speed and adjust if necessary.

●

Check breather hose for cracks or other damage, and replace if necessary.

1

320

(200)

20

INITIAL

3

1300

(800)

80

6

2500

(1600)

160

6

EVERY

12

2500

(1600)

160

5000

(3200)

320

√ √ √

√

√

√ √

√

√

√

√

√

√ √

√

√

√

√

√

6

7

8

9

10

11

8-3

1

8

9

6

7

10

11

4

5

2

3

NO.

ITEM

6 * Exhaust system

7 Spark arrester

Whichever comes first month


JOB km

(mi) hours

●

Check for leakage and replace gasket(s) if necessary.

●

Check for looseness and tighten all screw clamps and joints if necessary.

●

Clean.

1

320

(200)

20

INITIAL

3

1300

(800)

80

6

2500

(1600)

160

6

EVERY

12

2500

(1600)

160

5000

(3200)

320

√

√

√

√

√

√

8-4

EBU21862

General maintenance and lubrication chart

NO.

ITEM


JOB


(mi) hours

1

320

(200)

20

INITIAL

3

1300

(800)

80

6

2500

(1600)

160

6

EVERY

12

2500

(1600)

160

5000

(3200)

320

1

Engine and V-belt case air filter element

●

Clean and replace if necessary.

Every 20–40 hours (more often in wet or dusty areas)

2

3

4

5

6

7

* Front brake

* Rear brake

* Wheels

* Tires

* Wheel bearings

Drive chain

●

Check operation and correct if necessary.

●

Check brake lever free play and adjust if necessary.

●

Replace brake shoes.

●


●

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.

●

Check chain slack and adjust if necessary.

●

Check rear wheel alignment and correct if necesssary.

●

Clean and lubricate.

√

√

√

√

√

√

√

√

Whenever worn to the limit

√ √

√

√ √

Whenever worn to the limit

√

√

√

√

√

√

√

√

√

√

√

√

√

√

8-5

1

8

9

6

7

10

11

4

5

2

3

1

2

3

4

5

6

7

8

9

10

11

8

9

NO.

10

11

12

13

14

15

16

*

*

*

*

*

*

17 *

18 *

19 *

V-belt

ITEM


Shock absorber assemblies

Knuckle shafts

Steering shaft

Steering system

Engine oil

Engine oil strainer


Throttle lever housing and cable

Front and rear brake switches

Lights and switches

Whichever comes first month


JOB km

(mi) hours

●

Check for wear, cracks or other damage, and replace if necessary.

●

Make sure that all nuts, bolts, and screws are properly tightened.

●

●


Check for oil leakage and replace if necessary.

●

Lubricate with lithium-soap-based grease.

●

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.

●


●

Check throttle cable free play and adjust if necessary.

●

Lubricate throttle lever housing and cable.

●


●


●

Adjust headlight beams.

8-6

1

320

(200)

20

INITIAL

3

1300

(800)

80

6

2500

(1600)

160

6

EVERY

12

2500

(1600)

160

5000

(3200)

320

√ √

√ √

√ √

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

NO.

20 * Battery

ITEM


JOB


(mi) hours

●

Check electrolyte level and specific gravity, and correct if necessary.

●

Make sure that the breather hose is properly routed.

1

320

(200)

20

INITIAL

3

1300

(800)

80

6

2500

(1600)

160

6

EVERY

12

2500

(1600)

160

5000

(3200)

320

√ √ √ √ √

EBU23060

NOTE:

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

1

8

9

6

7

10

11

4

5

2

3

8-7

10

11

1

2

3

4

5

6

7

8

EWB00010

WARNING


EBU23210

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.

To remove the spark plug

1. Remove the spark plug cap.

9

1

1. Spark plug cap

2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit.

8-8

1 replace it if necessary.

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

6

1. Spark plug wrench

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).

NOTE:

If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a

Yamaha dealer check the ATV.

2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and

8-9

1. Spark plug gap

2. Clean the surface of the spark plug gasket

7

8

9

10

11

1

2

3

4 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.

Tightening torque:

Spark plug:

12.5 Nm (1.3 m·kgf, 9.0 ft·lbf)

5

6

7

8

NOTE:

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.

4. Install the spark plug cap.

9

10

11

EBU23261

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.

To check the engine oil level

1. Place the ATV on a level surface.

8-10

2. Start the engine, warm it up for several minutes, and then turn it off.

3. Wait a few minutes until the oil settles before checking.

4. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag.

1. Dipstick

1

5. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level.

1

2 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

3

4

1

1. Maximum level mark

2. Minimum level mark

NOTE:

The engine oil should be between the minimum and maximum level marks.

6. 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.

7. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap.

4

1. Engine oil drain bolt

2. O-ring

3. Spring

4. Oil strainer

3 2

1

To change the engine oil


2. Start the engine, warm it up for several min-

8-11

ECB00310

CAUTION:

When removing the engine oil drain bolt, the compression spring, oil strainer and O-ring will

5

6

7

8

9

10

11

1

2

3

4

5

6

7

8

9

10

11 fall out. Take care not to lose these parts.

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.

ECB00320

CAUTION:

Before installing the engine oil drain bolt, be sure to install the O-ring, compression spring and oil strainer.

Tightening torque:

Engine oil drain bolt:

32 Nm (3.2 m·kgf, 23.1 ft·lbf)

8. Add the specified amount of the recommended engine oil, and then install and tighten the engine oil filler cap.

Recommended oil:

See page 10-1.

Oil quantity:

1.25 L (1.32 US qt) (1.10 Imp.qt)

ECB00330

CAUTION:

●

●

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 “EN-

ERGY CONSERVING II” or higher.

Make sure that no foreign material enters the crankcase.

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.

10. Turn the engine off, and then check the oil level and correct it if necessary.

8-12

EBU27021


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.

To check the transmission oil level



3. Wait a few minutes until the oil settles, and then remove the screw located at the right side of the crankcase.

3

2

1

1. Screw

2. Transmission oil level check window

3. Correct oil level

4. Check the transmission oil level.

1

1

1. Transmission oil filler bolt

6

NOTE:

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.

7

8

9

10

11

4

5

2

3

8-13

9

10

11

1

2

3

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)

4

5

6

7

8

To change the transmission oil



3. Place an oil pan under the transmission to collect the used oil.

4. Remove the oil filler bolt and the drain bolt to drain the oil from the transmission case.

1

1. Transmission oil drain bolt

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)

6. Add the specified amount of the recommended transmission oil, and then install and tighten the oil filler bolt.

8-14

Recommended transmission oil:

See page 10-1.

Oil quantity:

0.6 L (0.63 US qt) (0.53 Imp.qt)

Tightening torque:

Oil filler bolt:

23 Nm (2.3 m·kgf,16.6 ft·lbf)

ECB00790

CAUTION:

●

●

Make sure that no foreign material enters the transmission case.

Make sure that no oil gets on the tires or wheels.

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.

EBU23830

Cleaning the engine and V-belt case air filter elements

Both air filter elements should be cleaned at the specified intervals in the periodic maintenance chart.

Engine air filter element

NOTE:

There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case.

1

2

3

4

5

6

7

1

10

11

8

9

8-15

1. Check hose

1

1. Remove the seat. (See page 4-11.)

2. Remove the breather hose, and then loosen the clamp screw.

4

5

2

3

1

6

7

8

1. Breather hose

2. Clamp screw

9

10

2

3. Remove the air filter case cover by removing the screws.

11

2 1

2

2

1. Air filter case cover

2. Screw

2

4. Pull the air filter element out of the air filter case.

5. Remove the bolt and washer shown, and then pull the sponge material off from the air filter element frame.

8-16

1. Bolt

2. Washer

3. Sponge material

4. Air filter element frame

4 3

2 1

6. Wash the sponge material gently but thoroughly in solvent.

EWB01900

WARNING


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.

8-17


Use parts cleaning solvent to clean the sponge material.

7. Squeeze the excess solvent out of the sponge material and let it dry.

ECB00440

CAUTION:

Do not twist the sponge material when squeezing it.

8. Check the sponge material and replace it if damaged.

9. Apply Yamaha foam air filter oil or other quality foam air filter oil to the sponge material.

NOTE:

The sponge material should be wet but not dripping.

10. Pull the sponge material over the air filter element frame.

11. Install the washer and bolt.

ECB00450

CAUTION:

Be sure to install the washer with the bent edge facing upward as shown.

1

2

3

4

5

6

7

8

9

10

11

1

1

4

5

2

3

6

1. Washer

7

8

9

10

11

12. Install the air filter element into the air filter case.

13. Install the air filter case cover by installing the screws.

14. Install the breather hose and then tighten the clamp screw.

15. Install the seat.

NOTE:

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

8-18 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.

ECB00460

CAUTION:

●

●

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.

V-belt case air filter element

1. Remove the front carrier by removing the bolts.

2

1

2 2

1

1

1. Bolt

2. Front carrier

2. Remove the panel shown by removing the quick fasteners.

1

1. Panel

2. Quick fastener

3. Disconnect the coupler shown.

1

1

8

9

6

7

10

11

4

5

2

3

8-19

1

1

2

4

5

2

3

10

11

6

1. Panel

2. Coupler

7

8

4. Remove the air filter case cover by removing the screw.

9

2

1

1. Air filter case cover

2. Screw

5. Remove the air filter element.

8-20

1. Air filter element

1

6. Tap the air filter element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air as shown.

8-21

1

1

1. Air filter element

6

7. Check the air filter element and replace it if damaged.

8. Install the air filter element into the air filter case.

9. Install the air filter case 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.

7

8

9

10

11

EBU23891

Cleaning the spark arrester

Be sure the exhaust pipe and muffler are cool be-

4

5

2

3

1 fore cleaning the spark arrester.

1. Remove the screws.

4

5

2

3

6

1

7

1. Screw

8

9

10

11

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.

4

3

2

1

1. Screw

2. Gasket

3. Tailpipe

4. Spark arrester

4. Insert the tailpipe into the muffler and align the screw holes.

5. Install the screws and tighten them.

EWB01910

WARNING


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.


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.

EBU23930

V-belt case drain plug

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.

NOTE:

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.

1

1

8-23

6

1. V-belt case drain plug

EBU23940

Adjusting the carburetor

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.

7

8

9

10

11

4

5

2

3

1

2

3

4

ECB00480

CAUTION:

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.

sary, adjust it to specification by turning the 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).

1

5

6

7

8

9

10

11

EBU24000

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.

NOTE:

A diagnostic tachometer is needed to make this adjustment.

1. Start the engine and warm it up.

NOTE:

The engine is warm when it quickly responds to the throttle.

2. Attach the tachometer to the spark plug lead.

3. Check the engine idling speed and, if neces-

8-24

1. Throttle stop screw

(a)

Engine idling speed:

1650–1750 r/min

(b)

NOTE:

If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment.

EBU24043

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.

NOTE:

The engine idling speed must be checked, and adjusted if necessary, before adjusting the throttle cable free play.

1. Loosen the locknut.

2. To increase the throttle cable free play, turn the adjusting bolt in direction (a). To decrease the throttle cable free play, turn the adjusting bolt in direction (b).

1

1

2

(b)

(a)

3

1. Locknut

2. Throttle cable free play adjusting bolt

3. Throttle cable free play

6

7

3. Tighten the locknut.

8

EBU24060

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.

9

10

11

4

5

2

3

8-25

10

11

8

9

1

2

3

4

5

6

7

EBU24090

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.

Front brake

1. Wear limit line

2. Wear indicator

2

8-26

1

Rear brake

1

2

1. Wear limit line

2. Wear indicator

EBU24360

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.

NOTE:

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 mm (0.20–0.31 in) as shown. If the free play is incorrect, adjust it as follows.

1

1

7

1. Brake lever free play

1. Remove the front carrier by removing the bolts.

8

9

10

11

4

5

2

3

6

1

1

2

4

5

2

3

2

2

10

11

6

1. Front carrier

2. Bolt

7

8

2. Remove the panel shown by removing the quick fasteners, then disconnect the coupler shown.

9

1

2

1. Panel

2. Quick fastener

8-28

2

1

1

2

1. Panel

2. Coupler

3. Remove the V-belt air filter element cover by removing the screw.

1

2

1

1. V-belt air filter element cover

2. Screw

5

6

7

4. Loosen the locknut and fully turn in the adjusting bolt at the brake lever.

8

9

10

11

2

3

4

8-29

1

2

1

4

5

2

3

6

1. Locknut

2. Brake lever free play adjusting bolt

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 a

2 a=a'

1. Brake equalizer

2. Cable joint

1 a'

8-30

2

1

1

2

1. Locknut

2. Adjusting nut

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.

3

1

(b)

2

1

(a)

1. Locknut

2. Brake lever free play adjusting bolt


6

7

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

9

10

11

4

5

2

3

8-31

1

2

3

4

5

6

7

8

EWB02020

WARNING


Operating with improperly serviced or adjusted brakes.

WHAT CAN HAPPEN



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.

9

10

11

EBU24481

Adjusting the rear 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.

NOTE:

Before adjusting the brake lever free play, check the rear brake shoes for wear.

8-32

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.

1


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.

(a)

(b)

1

1. Brake lever free play adjusting nut

EWB02020

WARNING


Operating with improperly serviced or adjusted brakes.

WHAT CAN HAPPEN



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

2

3

4

EBU24871

Drive chain slack

The drive chain slack should be checked before each ride and adjusted if necessary.

5

6

To check the drive chain slack


NOTE:

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.

7

8

9

10

11

8-33

1 Drive chain slack:

30.0 mm (1.18 in)

4

5

2

3

6

7

1

8

1. Drive chain slack

9

10

3. If the drive chain slack is incorrect, adjust it as follows.

11 To adjust the drive chain slack

1. Loosen the hub stopper bolt locknut and then the hub stopper bolt.

2. Loosen the axle holding bolts.

4

1 2

3

1. Hub stopper bolt

2. Locknut

3. Axle holding bolt (lower)

4. Axle holding bolt (upper)

3. 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.

8-34

(a)

1

(b)

2

1. Locknut

2. Drive chain slack adjusting bolt

ECB00541

CAUTION:

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.

4. Tighten the locknut and the axle holding bolts to the specified torques.

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)

ECB00550

CAUTION:

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

8

9

10

11

8-35

1

4

5

2

3

1

1

6

1. Measurement A 1. O-ring

7

5. Tighten the hub stopper bolt, and then its locknut.

8

9

10

11

EBU24880

Lubricating the drive chain

The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas.

Service the drive chain as follows.

8-36

ECB00560

CAUTION:

The drive chain must be lubricated after washing the ATV or riding in the rain.

1. Clean the drive chain with kerosene and a small soft brush.

ECB00570

CAUTION:

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.

3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant.

ECB00580

CAUTION:

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

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.

Recommended lubricant:

Engine oil

EWB02120

WARNING


Damaged control cables.

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.


Inspect cables frequently. Replace damaged cables.

1

2

3

4

5

EBU24911

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.


Lithium-soap-based grease (all-purpose grease)

6

7

8

9

10

11

8-37

Front brake lever

1

10

11

8

9

4

5

2

3

6

7

Rear brake lever

EBU24961

Checking the wheel bearings

The front and rear wheel 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 bearings.

EBU25030

Lubricating the upper and lower arm pivots

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.


Lithium-soap-based grease

8-38

Left side

1

1. Grease nipple

1

Right side

1

1

1

6

1. Grease nipple

7

EBU25070

Lubricating the knuckle shafts

The knuckle shafts must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.

Lubricate the knuckle shafts using a grease gun.

8

9

10



11

4

5

2

3

8-39

1

4

5

2

3

1

6

1. Grease nipple

7

8

9

10

EBU25090

Lubricating the steering shaft

The steering shaft must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.

Lubricate the steering shaft using a grease gun.

11



1

1. Grease nipple

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.

To check the electrolyte level


2. Check the electrolyte level in the battery.

8-40

2

3

1

1. Battery

2. Battery breather hose

3. Guide

NOTE:

The electrolyte should be between the minimum and maximum level marks.

3. If the electrolyte is at or below the minimum level mark, add distilled water to raise it to the maximum level mark.

1

2

1

1. Maximum level mark

2. Minimum level mark

6

7

ECB00590

CAUTION:

Use only distilled water, as tap water contains minerals that are harmful to the battery.

8

9

10

11

4

5

2

3

8-41

1

2

3

4

5

6

7

8

9

10

11

EWB02140

WARNING


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.


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.

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.

1 2

3 hose routing.

1. Battery

2. Negative lead

3. Positive lead

4. Check and, if necessary, tighten the battery lead connections and correct the breather

8-42

2. Remove the battery, fully charge it, and then place it in a cool, dry place.

ECB00600

CAUTION:

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.

To install the battery

NOTE:

Be sure the battery is fully charged.

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.

1 2

1

3

1. Battery

2. Negative lead

3. Positive lead

6

7

ECB00610

CAUTION:

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

9

10

11

4

5

2

3

8-43

1

2

EBU25252

Replacing the fuse

fuse.

2. Remove the blown fuse, and then install a new fuse of the specified amperage.

Specified fuse:

15.0 A

3

2

4

5

6

1

7

8

1. Fuse

2. Spare fuse

9

10

11

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.

ECB00640

CAUTION:

To prevent accidental short-circuiting, turn off the main switch when checking or replacing a

8-44

EWB02151

WARNING


Using an improper fuse.

WHAT CAN HAPPEN

An improper fuse can cause damage to the electrical system, which could lead to a fire.


Always use a fuse of the specified rating.

Never use a material in place of the proper fuse.

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.

EBU25350

Replacing a headlight bulb

If a headlight bulb burns out, replace it as follows.

1. Remove the cover at the rear of the headlight by pulling it off.

1

1. Cover at the rear of the headlight

2. Remove the bulb holder cover by pulling it off.

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2

1 5

1. Headlight bulb holder cover

2. Headlight bulb holder

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7

3. Remove the bulb holder by pushing it inward and turning it counterclockwise.

4. Remove the defective headlight bulb by pulling it out of the socket.

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EWB02190

WARNING


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.


Wait for the headlight bulb to cool before touching or removing it.

5. Place a new bulb into position.

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1

6. Install the bulb holder by pushing it inward and turning it clockwise.

7. Install the bulb holder cover.

8. Install the cover at the rear of the headlight.

9. Adjust the headlight beam if necessary.

EBU25550

Adjusting a headlight beam

ECB00690

CAUTION:

It is advisable to have a Yamaha dealer make this adjustment.

To raise a headlight beam, turn the adjusting screw in direction (a).

To lower a headlight beam, turn the adjusting screw in direction (b).

1. Headlight bulb

8-46

(b) (a)

1

1. Headlight beam adjusting screw

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.

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1. Tail/brake light bulb holder

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2. Remove the defective bulb by pushing it in and turning it counterclockwise.

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8-47

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6

1. Tail/brake light bulb

2. Tail/brake light bulb holder

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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.

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EBU25650

Removing a wheel

1. Loosen the wheel nuts.

8-48

1

1. Wheel nut

2. Elevate the ATV and place a suitable stand under the frame.

3. Remove the nuts from the wheel.

4. Remove the wheel.

EBU25690

Installing a wheel

1. Install the wheel and the nuts.

NOTE:

Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel.

1

1. Tapered nut

2. Lower the ATV to the ground.

3. Tighten the wheel nuts to the specified torques.

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

Troubleshooting

Although Yamaha ATVs receive a thorough in-

8-49 spection 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.

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EWB02260

WARNING


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.


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

8-50

EBU25791

Troubleshooting chart

1. Fuel

Check the fuel level in the fuel tank.

There is enough fuel.

There is no fuel.

2. Compression

Operate the electric starter.

There is compression.

There is no compression.

3. Ignition

Remove the spark plug and check the electrodes.

Wet

Dry

Check the compression.

Supply fuel.

The engine does not start.

Check the compression.

Check the ignition.

Have a Yamaha dealer check the ATV.

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.


Check the battery.

4. Battery

Operate the electric starter.

The engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the electrolyte level, recharge the battery and check the lead connections.



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8-51

EBU25860

CLEANING AND STORAGE

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EBU25890

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.

ECB00710

CAUTION:

Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high-pressure detergent applications such as those available in coinoperated car washers.

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.

9-1

EWB02300

EBU25932

Storage

WARNING


Operation with wet brakes after washing.

WHAT CAN HAPPEN

Wet brakes may have reduced stopping ability, increasing the chance of an accident.


Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings.

Short-term

Always store your ATV in a cool, dry place and, if necessary, protect it against dust with a porous cover.

ECB00720

CAUTION:

●

●

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,

9-2 stables (because of the presence of ammonia) and areas where strong chemicals are stored.

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.

Specified amount:

7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel)

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.

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2

3 c. Install the spark plug cap onto the spark 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.

6. Lubricate all control cables and the pivoting points of all levers and pedals.

7. 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.

8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it.

9. 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 in-

9-3 formation on storing the battery, see page

8-40.

NOTE:

Make any necessary repairs before storing the

ATV.

EBU25960

EBU25974

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)

Weight:

With oil and fuel:

148.0 kg (326 lb)

Engine:

Engine type:

Air cooled 4-stroke, SOHC

Cylinder arrangement:

Forward-inclined single cylinder

Displacement:

124.0 cm

3

(7.57 cu.in)

Bore

×

stroke:

49.0

×

66.0 mm (1.93

×

2.60 in)

SPECIFICATIONS

Compression ratio:

9.00 :1

Starting system:

Electric starter

Lubrication system:

Wet sump

Engine oil:

Type:

YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40

0˚ 10˚ 30˚ 50˚ 70˚ 90˚ 110˚ 130˚F

YAMALUBE 4 (20W40) or SAE 20W40

YAMALUBE 4 (10W30) or SAE 10W30

SAE 5W30

-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C

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11

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2

3

Recommended engine oil grade:

API service SE, SF, SG type or higher

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Engine oil quantity:

Periodic oil change:

1.25 L (1.32 US qt) (1.10 Imp.qt)

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)

Carburetor:

Manufacturer:

MIKUNI

Type x quantity:

VM18SH x 1

Spark plug (s):

Manufacturer/model:

NGK/CR7HSA

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Clutch:

Clutch type:

Dry, centrifugal automatic

Transmission:

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)

Chassis:

Frame type:

Steel tube frame

Caster angle:

6.0 °

Trail:

15.0 mm (0.59 in)

Front tire:

Type:

Tubeless

Size:

AT20 x 7-8

Manufacturer/model:

DUNLOP/KT536A

10-2

Rear tire:

Type:

Tubeless

Size:

AT22 x 10-8

Manufacturer/model:

DUNLOP/KT537A

Loading:

Maximum load:

105.0 kg (231 lb)

(Total weight of rider, cargo, accessories, and tongue)

Tire air pressure (measured on cold tires):

Recommended:

Front:

20 kPa (2.9 psi) (0.20 kgf/cm

2

)

Rear:

25 kPa (3.6 psi) (0.25 kgf/cm

2

)

Minimum:

Front:

17 kPa (2.5 psi) (0.17 kgf/cm

2

)

Rear:

22 kPa (3.2 psi) (0.22 kgf/cm

2

)

Maximum:

Front:

23 kPa (3.3 psi) (0.23 kgf/cm

2

)

Rear:

28 kPa (4.1 psi) (0.28 kgf/cm

2

)

Front wheel:

Wheel type:

Panel wheel

10-3

Rim size:

8x5.5AT

Rear wheel:

Wheel type:

Panel wheel

Rim size:

8x8.0AT

Front brake:

Type:

Drum brake

Operation:

Right hand operation

Rear brake:

Type:

Drum brake

Operation:

Left hand operation

Front suspension:

Type:

Swing axle

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

70 mm (2.8 in)

Rear suspension:

Type:

Swingarm

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

80 mm (3.1 in)

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Electrical system:

Ignition system:

DC. CDI

Charging system:

AC magneto

Battery:

Model:

12N12C-4A-2

Voltage, capacity:

12 V, 12.0 Ah

Headlight:

Bulb type:

Krypton bulb

Bulb voltage, wattage x quantity:

Headlight:

12 V, 30 W/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

10-4

EBU25981

CONSUMER INFORMATION

EBU26011

Identification numbers

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:

EBU26020

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.

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1

7

● VEHICLE IDENTIFICATION NUMBER:

8

● MODEL LABEL INFORMATION:

9

1. Key identification number

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EBU26030

Vehicle identification number

The vehicle identification number is stamped into the frame.

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11-1

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3

1

6

1. Vehicle identification number

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8

NOTE:

The vehicle identification number is used to identify your ATV.

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EBU26050

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.

1. Model label

11-2

1

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

Intake system

●

●

●

Air cleaner case

Air cleaner element

Intake duct

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EBU26080

Maintenance record

Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

MAINTENANCE INTERVAL

DATE OF

SERVICE

MILEAGE

SERVICING DEALER

NAME AND ADDRESS

REMARKS month

18

24

30

36

1

3

6

12

42

48

54

60 km (mi)

320 (200)

1300 (800)

2500 (1600)

5000 (3200)

7500 (4800)

10000 (6400)

12500 (8000)

15000 (9600)

17500 (11200)

20000 (12800)

22500 (14400)

25000 (16000) hours

20

80

160

320

480

640

800

960

1120

1280

1440

1600

10

11

11-4

EBU26501

YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY

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 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

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WARRANTY QUESTIONS AND ANSWERS

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.

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.

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.

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.

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.

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.

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.

CUSTOMER SERVICE

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:

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.

CHANGE OF ADDRESS

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.

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:

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.

11-6

EBU26122

YAMAHA EXTENDED SERVICE (Y.E.S.)

Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Ser vice (Y.E.S.).

Y.E.S. is designed and administered by Yamaha Motor

Corporation to provide maximum owner satisfaction. You get uninterr upted 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. 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 wa r ra n t y. S e e t h e s a m p l e c o n t ra c t a t yo u r Ya m a h a dealer to see how comfor ting uninterr upted factor ybacked protection can be.

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 a y, 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.

1

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 ser vice: 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.

2

3

4

5

Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide.

6

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!

7

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.

8

9

10

11

11-7

1

8

9

6

7

10

11

4

5

2

3

We urge you to act now. You’ll get the excellent benefits of

TRIP coverage r ight away, and you’ll rest easy knowing you’ll have strong factor y-backed protection even after your

Ya m a h a L i m i t e d Wa r ra n t y ex p i r e s. Yo u c a n a l s o s ave 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 Pr imar 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

11-8

WARNING


EBU26132

1

8

9

6

7

10

11

4

5

2

3

11-9

INDEX

A

Accessories and loading ................................................ 6-6

Air filter elements, engine and V-belt filter cleaning ..... 8-15

B

Battery.................................................................. 5-7

,

8-40

Brake lever free play, adjusting the front...................... 8-27

C

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

D

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

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

E

Engine break-in .............................................................. 6-4

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

F

Fuel .........................................................................4-8

,

5-3

Fuel cock........................................................................ 4-9

I

H

Fuel tank cap.................................................................. 4-7

Fuse, replacing............................................................. 8-44

Handlebar switches........................................................ 4-2

Headlight beam, adjusting ........................................... 8-46

Headlight bulb, replacing ............................................. 8-44

Identification numbers .................................................. 11-1

Indicator lights ................................................................ 4-2

Instruments, lights and switches .................................... 5-7

K

L

Key identification number............................................. 11-1

Knuckle shafts, lubricating ........................................... 8-39

Label locations ............................................................... 2-1

Light switch .................................................................... 4-3

M

N

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

O

Owner’s manual and tool kit............................................8-1

P

Neutral indicator light ......................................................4-2

Noise regulation ............................................................11-3

Parking............................................................................6-5

Parking brake..................................................................4-6

Parking on a slope ..........................................................6-6

Part locations ..................................................................3-1

Pre-operation check list ..................................................5-1

R

S

Reverse indicator light ....................................................4-2

Riding your ATV..............................................................7-1

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

,

8-12

Troubleshooting ............................................................8-49

V

Troubleshooting chart ...................................................8-51

W

Valve clearance ............................................................8-25

V-belt case drain plug ...................................................8-23

Vehicle identification number........................................11-1

Warranty, extended ......................................................11-7

Warranty, limited ...........................................................11-5

Wheel bearings, checking.............................................8-38

Wheel, installing............................................................8-48

Wheel, removing...........................................................8-48

EBU26141

WARNING

Improper ATV use can result in SEVERE INJURY or DEATH.

B E E R

B E E R

ALWAYS USE

AN APPROVED

HELMET AND

PROTECTIVE GEAR

NEVER USE

ON PUBLIC

ROADS

NEVER CARRY

PASSENGERS

NEVER USE

WITH DRUGS

OR ALCOHOL

NEVER

operate:

without proper training or instruction.

at speeds too fast for your skills or the

conditions.

on public roads-a collision can occur with

another vehicle.

with a passenger-passengers affect

balance and steering and increase risk

of losing control.

ALWAYS

:

use proper riding techniques to avoid

vehicle overturns on hills and rough

terrain and in turns.

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)

YAMAHA MOTOR CO., LTD.

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN

2006.03-0.6x1 !

(E)

ATV card for US 4/2/03 9:06 AM Page 1

].

[If card is not attached,

Dear New Yamaha ATV Owner:

CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV. You have purchased a quality

Yamaha product that, with proper use and care, will provide hours of riding pleasure. BEFORE YOU

OPERATE YOUR NEW ATV, Yamaha recommends these important points:

8 READ YOUR OWNER’S MANUAL

8 A CHILD UNDER 6 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 50CC OR GREATER

8 A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER

8 A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER

THAN 90CC

8 TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA – ASK YOUR DEALER FOR

DETAILS OR CALL 1-800-887-2887

If you have any questions about these points, or if you purchased your ATV from an authorized Yamaha

dealership and were not informed of the age recommendation for your ATV by the dealership, please fill out the information below and mail this card to yamaha today.

Name: ATV Model: Purchase Date:

Address: Primary I.D. [Engine Number]:

MO. DAY YR.

Dealer Name & Address:

Telephone:

[ ]

ATV card for US 4/2/03 9:06 AM Page 2

FIRST CLASS PERMIT NO. 4 CYPRESS, CA

POSTAGE WILL BE PAID BY ADDRESSEE

YAMAHA MOTOR CORPORATION U.S.A.

P.O. BOX 6555

CYPRESS, CALIFORNIA

90630-9989

ATTN: SALES ADMINISTRATION

NO POSTAGE

NECESSARY

IF MAILED

IN THE

UNITED STATES

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