Yamaha Offroad Vehicle 43D-F8199-10 User manual

READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YFM90RY
WARNING
LIT-11626-22-13
This A
This ATV should not be ridden by anyone under 12 years of age.
43D-F8199-10
Read this manual carefully before operating this vehicle.This manual should stay with this vehicle if it is sold.
INTRODUCTION
Congratulations on your purchase of the Yamaha YFM90RY. This ATV represents the result of many years
of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the
purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have
made Yamaha a leader in these fields.
This manual will provide you with a good basic understanding of the features and operation of this ATV.
This manual includes important safety information. It provides information about special techniques and skills necessary to ride the ATV. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your ATV, please consult a
Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.
PAY CLOSE ATTENTION TO THE WARNING AND NOTICE LABELS ON THE ATV.
NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS
AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMATION.
THIS ATV, AND ANY OTHER ATV OVER 70 cc, SHOULD NOT BE OPERATED BY A CHILD UNDER
12 YEARS OF AGE.
AN IMPORTANT NOTE TO PARENTS:
This ATV is not a toy. Before you let your child ride this ATV, you should understand the instructions and
warnings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ
in skills, physical abilities and judgment. Some children may not be able to operate an ATV safely. Parents
should supervise their child’s use of the ATV at all times. Parents should permit continued use only if they
determine that the child has the ability to operate the ATV safely.
Your ATV was delivered with an adjustable speed limiter . Yamaha recommends that all beginners start off
to limit the amount of speed available while they learn. The adjusting screw may be gradually turned out
as the beginner becomes more familiar with operating the ATV. Parents should decide when to adjust
the ATV for more power as their youngster’s riding skills improve. Once the ATV rider can operate with
skill at the top speed permitted by adjusting the vehicle speed limiter alone, the engine speed limiter
plate can be removed. Since removal of this limiter will result in a significant increase in power, turn the
vehicle speed limiter adjusting screw completely back in again; adjust it out in stages as done previously.
If your child is a beginner or is inexperienced, he or she should take a training course. See the previous
page for information about the free training available to purchasers of new ATVs.
IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
WARNING
A WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
NOTICE
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
TIP
A TIP provides key information to make procedures easier or clearer.
* Product and specifications are subject to change without notice.
IMPORTANT NOTICE
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.
YFM90RY
OWNER’S MANUAL
©2008 by Yamaha Motor Corporation, U.S.A.
1st edition, July 2008
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Taiwan.
P/N LIT-11626-22-13
WARNING
A WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
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
Handlebar switches ................................... 4-2
Throttle lever ............................................. 4-3
Speed limiters............................................. 4-3
Vehicle speed limiter ................................. 4-4
Engine speed limiter plate.......................... 4-5
Front brake lever ........................................ 4-6
Rear brake lever ....................................... 4-6
Parking brake ............................................ 4-7
Fuel tank cap ............................................ 4-8
Fuel ........................................................... 4-8
Fuel cock .............................................. 4-10
Choke ..................................................... 4-11
Seat ........................................................ 4-11
Kick starter ............................................. 4-12
PRE-OPERATION CHECKS.........................5-1
Pre-operation check list............................5-1
Fuel ........................................................... 5-3
Engine oil .................................................. 5-3
Final transmission oil ................................ 5-3
Front and rear brakes ............................... 5-3
Throttle lever ............................................. 5-4
Tires .......................................................... 5-4
Measuring the tire pressure ...................... 5-5
Tire wear limit ........................................... 5-6
Chassis fasteners ..................................... 5-7
Instruments and switches ......................... 5-7
OPERATION................................................6-1
Starting a cold engine ............................... 6-1
Starting a warm engine ............................. 6-3
Engine break-in ........................................ 6-4
Parking ..................................................... 6-4
Parking on a slope ................................... 6-5
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...........7-11
TURNING YOUR ATV..............................7-15
CLIMBING UPHILL....................................7-17
RIDING DOWNHILL..................................7-20
CROSSING A SLOPE................................7-21
CROSSING THROUGH SHALLOW
WATER ................................................... 7-22
RIDING OVER ROUGH TERRAIN...........7-24
SLIDING AND SKIDDING.........................7-25
WHAT TO DO IF.......................................7-26
WHAT TO DO... ........................................ 7-26
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 ............................. 8-9
Engine oil ................................................. 8-11
Final transmission oil ................................ 8-14
Cleaning the air filter element .................. 8-15
Cleaning the spark arrester ...................... 8-19
Adjusting the carburetor ........................... 8-20
Adjusting the engine idling speed ............ 8-20
Checking the throttle cable free play ....... 8-21
Timing chain ............................................ 8-22
Brakes ..................................................... 8-22
Valve clearance ....................................... 8-22
Checking the front brake shoes................ 8-22
Adjusting the front brake lever free
play ....................................................... 8-23
Checking the rear brake pads ................. 8-25
Checking the brake fluid level ................. 8-25
Changing the rear brake fluid .................. 8-26
Checking the rear brake lever free
play ........................................................8-26
Checking and lubricating the cables........ 8-27
Checking and lubricating the front
and rear brake levers............................... 8-27
Checking the wheel hub bearings ............ 8-28
Battery ..................................................... 8-28
Replacing the fuse ................................... 8-30
Removing a wheel ................................... 8-32
Installing a wheel ..................................... 8-33
Troubleshooting ....................................... 8-34
Troubleshooting chart .............................. 8-35
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
1
SAFETY INFORMATION
– A child under 12 years old should never operate an ATV with engine size greater than 70 cc.
– 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
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
An ATV handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine
maneuvers such as turning and riding on hills or
over obstacles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do
not follow these instructions:
Read this manual and all labels carefully and follow the operating procedures described.
Never operate an ATV without proper training or
instruction.Take a Training Course. Beginners
should receive training from a certified instructor. Contact an authorized ATV dealer or call 1800-887-2887 to find out about the training
courses nearest you.
Always follow the age recommendation:
1-1
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
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.
operating this ATV.
Never operate at speeds too fast for your skills
or the riding conditions. Always go at a speed
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 footrests 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
1-2
1
1
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.
Always use the size and type of tires specified in
this manual.
Always maintain proper tire pressure as described in this manual.
Never modify an ATV through improper installation or use of accessories.
Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s
Safety Hotline at 1-800-852-5344.
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 stalling, 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
WARNING
POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could be
burned.
1-3
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.
HOW TO AVOID THE HAZARD
If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, seek medical help
immediately. If gasoline spills on your skin,
wash with soap and water. If gasoline spills
on your clothing, change your clothes.
1
WARNING
POTENTIAL HAZARD
Starting or running the engine in a closed area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death within a short time.
HOW TO AVOID THE HAZARD
Always operate your ATV in an area with adequate ventilation.
1-4
LOCATION OF THE WARNING AND SPECIFICATION LABELS
2
1
5
2
3
4
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.
2-1
1
2
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2-2
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3
4
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2-3
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DESCRIPTION
Left view
Right view
1
4
1.
2.
3.
4.
1
3
2
2
3
3
Fuel cock
Rear wheel
Footrest
Front wheel
1. Spark arrester
2. Seat
3. Footrest
3-1
Controls and instruments
2
1
TIP
The ATV you have purchased may differ slightly
from the figures shown in this manual.
3
3
8 7
1.
2.
3.
4.
5.
6.
7.
8.
6
5
4
Rear brake lever
Parking brake
Front brake lever
Throttle lever
Main switch
Fuel tank cap
Handlebar switches
Choke
3-2
INSTRUMENT AND CONTROL FUNCTIONS
WARNING
A WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
ON
OFF
OF
The positions of the main switch are as follows:
IG
ON
All electrical systems are supplied with power, and
the engine can be started. The key cannot be removed.
I T ON
N
1. Main switch
OFF
All electrical systems are off. The key can be removed.
4-1
F
I
Main switch
1
4
Handlebar switches
Start switch “START”
Push this switch to crank the engine with the starter. See the starting instructions on page 6-1 prior
to starting the engine.
1
4
2
1. Engine stop switch “ENG. STOP”
2. Start switch “START”
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”.
4-2
Throttle lever
WARNING
Once the engine is running, movement of the throttle 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.
POTENTIAL HAZARD
Malfunction of throttle.
WHAT CAN HAPPEN
The throttle could be hard to operate, making
it difficult to speed up or slow down when
you need to. This could cause an accident.
HOW TO AVOID THE HAZARD
Check the operation of the throttle lever before you start the engine. If it does not work
smoothly, check for the cause. Correct the
problem before riding the ATV. Consult a
Yamaha dealer if you can’t find or solve the
problem yourself.
Speed limiters
1
Your ATV was delivered with two speed limiter
devices. A vehicle speed limiter adjusting screw
and a removable engine speed limiter plate.
Yamaha recommends that all beginning riders start
off with the vehicle speed limiter adjusting screw fully
turned in and the engine speed limiter plate installed
to limit the amount of speed available while they learn.
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.
4-3
4
4 4
The vehicle speed limiter keeps the throttle from fully
opening, even when the throttle lever is pushed to the
maximum. The adjusting screw may be gradually
turned out as the beginner becomes more familiar with
operating the ATV. Parents should decide when to
adjust the ATV for more power as their youngster’s
riding skills improve. Once the ATV rider can operate
with skill at the top speed permitted by adjusting the
vehicle speed limiter alone, the engine speed limiter
plate can be removed. Since removal of this limiter
will result in a significant increase in power, turn the
vehicle speed limiter adjusting screw completely back
in again; adjust it out in stages as done previously.
3
1
(b)
2
1. Locknut
2. Adjusting screw
3. No more than 11 mm (0.4 in)
Vehicle speed limiter
3. Tighten the locknut.
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 decrease
the maximum engine power available and the
maximum speed of the ATV, turn the adjusting
screw in direction (b).
4-4
(a)
4. Tighten the screw.
5. Install the seat.
WARNING
POTENTIAL HAZARD
Improper adjustment of the speed limiter and
throttle.
WHAT CAN HAPPEN
The throttle cable could be damaged. Improper throttle operation could result. The
child could lose control, have an accident or
be injured.
HOW TO AVOID THE HAZARD
Do not turn the adjusting screw out more
than 5 mm (0.2 in).
2
1
Engine speed limiter plate
1. Speed limiter plate
2. Screws
With this plate installed, the engine speed is limited
to 4800 r/min. With this plate removed, top engine
speed (8000 r/min) is available.
Remove the plate as follows.
1. Remove the seat. (See page 4-11.)
2. Loosen the screws.
3. Pull the plate out of its case.
4-5
TIP
Store the speed limiter plate with the owner’s manual
so that it is readily available whenever you want to
reduce the top engine speed.
4
Front brake lever
Rear 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.
The rear brake lever is located on the left handlebar. To apply the rear brake, pull the brake lever toward the handlebar grip.
1
1
4
1. Rear brake lever
1. Front brake lever
4-6
Parking brake
WARNING
Use the parking brake before starting the engine or
parking the ATV, especially on a slope. Apply the
front bake lever and push down the lock button to
apply the parking brake. Squeeze the front brake
lever to release the parking brake.
POTENTIAL HAZARD
Improper use of the parking brake.
WHAT CAN HAPPEN
The ATV could start moving unexpectedly if
the parking brake is not applied before starting the engine. This could cause loss of control or a collision.
The brake could overheat if you ride the ATV
without releasing the parking brake. You
could lose braking performance which could
cause an accident. You could also wear out
the brakes prematurely.
HOW TO AVOID THE HAZARD
Always set the parking brake before starting
the engine.
Always be sure you have released the parking brake before you begin to ride.
1
1. Parking brake lock button
4-7
4
Fuel tank cap
1
Remove the fuel tank cap by turning it counterclockwise.
2
1
4
1. Fuel level
2. Filler tube
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
4.8 L (1.27 US gal) (1.06 Imp.gal)
1. Fuel tank cap
Fuel reserve amount:
1.0 L (0.26 US gal) (0.22 Imp.gal)
Fuel
Make sure that there is sufficient fuel in the tank.
Fill the fuel tank to the bottom of the filler tube as
shown.
4-8
NOTICE
WARNING
Use only unleaded gasoline. The use of leaded
gasoline will cause severe damage to internal
engine parts, such as the valves and piston
rings, as well as to the exhaust system.
POTENTIAL HAZARD
Improper care when refueling.
WHAT CAN HAPPEN
Fuel can spill, which can cause a fire and severe injury.
Fuel expands when it heats up. If the fuel
tank is overfilled, fuel could spill out due to
heat from the engine or the sun.
HOW TO AVOID THE HAZARD
Do not overfill the fuel tank. Be careful not to
spill fuel, especially on the engine or exhaust
pipe. Wipe up any spilled fuel immediately.
Be sure the fuel tank cap is closed securely.
Do not refuel right after the engine has been
running and is still very hot.
Your Yamaha engine has been designed to use
regular unleaded gasoline with a pump octane
number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If knocking or pinging
occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost.
Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol
containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing
methanol is not recommended by Yamaha because it can cause damage to the fuel system or
ATV performance problems.
4-9
4
RES
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.
RES
1
RE S
OFF
OFF
RE S
OFF
54
RES
1
NO
1. Lever positioned over “OFF”
FUEL
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
NO
1. Lever positioned over “ON”
FUEL
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”!
OFF
RE S
1. Lever positioned over “RES”
NO
OFF
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.
FUEL
1
ON
4-10
Choke
Seat
The choke is used to start a cold engine.
Move the choke in direction (a) to turn on the
choke.
Move the choke in direction (b) to turn off the
choke.
See the “Starting a cold engine” section on page
6-1 for proper operation.
To remove the seat
Pull the seat lock lever upward and pull up the seat
at the rear.
4
1
(a) 1 2 3 (b)
1.
2.
3.
4.
1. Seat lock lever
4
Fully open “ON”
Half open (warming up position)
Closed “OFF”
Choke
4-11
To install the seat
Insert the projection on the front of the seat into the
seat holder and push down on the seat at the rear.
2. Move the kickstarter lever down lightly with your
foot until the gears engage, and then push it
down smoothly but forcefully.
TIP
Make sure that the seat is securely fitted.
4
1
1
2
1. Kickstarter
NOTICE
1. Projection
2. Seat holder
Do not use the kickstarter if there is no battery
installed or if the battery leads are disconnected.
Kickstarter
A kickstarter lever is located under the seat to use
if the battery is discharged.
1. Install the kickstarter lever.
WARNING
A WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
4-12
PRE-OPERATION CHECKS
Pre-operation check list
Before operating this ATV, be sure to check the items listed in the following table.
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident or equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual.
TIP
The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the "Periodic
maintenance and lubrication charts" on page 8-3 to determine which service should be performed by a
Yamaha dealer.
5-1
5
ITEM
T
Fuel
Engine oil
Final transmission oil
9
9
2
5
Front brake
Rear brake
Throttle lever
Control cables
Wheels and tires
Brake levers
Chassis fasteners
Instruments and switches
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 A TV for oil leakage. Correct if necessary.
Check ATV for oil leakage. Correct if necessary.
Check operation, and correct if necessary.
Lubricate cable if necessary.
Check lever free play, and adjust if necessary.
Check operation. If soft or spongy, have Yamaha dealer bleed
hydraulic system.
Check brake pads for wear, and replace if necessary.
Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.
Check hydraulic system for leakage. Correct if necessary.
Make sure that operation is smooth, and check cable free play.
Lubricate cable and lever housing if necessary.
Make sure that operation is smooth. Lubricate if necessary.
Check wheel condition, and replace if damaged.
Check tire condition and tread depth. Replace if necessary.
Check air pressure. Correct if necessary.
Make sure that operation is smooth. Lubricate lever pivoting points
if necessary.
Make sure that all nuts, bolts and screws are properly tightened.
Check operation, and correct if necessary.
5-2
PAGE
4-8, 5-3
5-3, 8-11
5-3, 8-14
5-3, 8-22, 8-23
5-3, 8-25, 8-26
5-4, 8-21
8-27
5-4, 5-5, 5-6
8-27
5-7
5-7
Final transmission oil
Fuel
Make sure that the final transmission oil is at the
specified level. Add oil as necessary.
(See page 8-14.)
Make sure that there is sufficient fuel in the tank.
(See page 4-8.)
Front and rear brakes
WARNING
Brake levers
Check for correct free play in the brake levers. If
the free play is incorrect, adjust it. (See pages
8-23 and 8-26.)
6
513
Check operation of the levers. They should
move smoothly and there should be a firm feeling when the brakes are applied. If not, have the
ATV checked by a Yamaha dealer.
POTENTIAL HAZARD
Improper care when refueling.
WHAT CAN HAPPEN
Fuel can spill, which can cause a fire and severe injury.
Fuel expands when it heats up. If the fuel
tank is overfilled, fuel could spill out due to
heat from the engine or the sun.
HOW TO AVOID THE HAZARD
Do not overfill the fuel tank. Be careful not to
spill fuel, especially on the engine or exhaust
pipe. Wipe up any spilled fuel immediately.
Be sure the fuel tank cap is closed securely.
Do not refuel right after the engine has been
running and is still very hot.
Brake fluid level
Check the brake fluid level. Add fluid if necessary.
(See page 8-25.)
Recommended brake fluid:
DOT4
Brake fluid leakage
Check to see if any brake fluid is leaking out of the
pipe joint or brake fluid reservoir. Apply the brake
firmly for one minute. If there is any leakage, have a
Yamaha dealer check the brake system.
Engine oil
Make sure that the engine oil is at the specified level. Add oil as necessary. (See page 8-11.)
5-3
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 pages 8-22 and 8-25.)
Tires
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires, or
with improper or uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire
pressure, may cause loss of control, increasing your risk of accident.
HOW TO AVOID THE HAZARD
The tires listed below have been approved
by Yamaha Motor Co., Ltd. for this model.
Other tire combinations are not recommended.
Front:
Manufacturer/model:
MAXXIS/M939
Size:
AT18 x 7-8
Type:
Tubeless
WARNING
5
POTENTIAL HAZARD
Riding with improperly operating brakes.
WHAT CAN HAPPEN
You could lose braking ability, which could
lead to an accident.
HOW TO AVOID THE HAZARD
Always check the brakes at the start of every
ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be
corrected by the adjustment procedures provided in this manual, have the ATV checked
by a Yamaha dealer.
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.
5-4
Rear:
Manufacturer/model:
MAXXIS/M940
Size:
AT18 x 9-8
Type:
Tubeless
The tires should be set to the recommended pressure:
Recommended tire pressure:
Front:
25 kPa (3.6 psi) (0.25 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.
Tire pressure below the minimum specified could cause the tire to dislodge from
the rim under severe riding conditions.
Minimum tire pressure:
Front:
22 kPa (3.2 psi) (0.22 kgf/cm2)
Rear:
22 kPa (3.2 psi) (0.22 kgf/cm2)
Use no more than the following pressures
when seating the tire beads.
Maximum tire seating pressure:
Front:
250 kPa (36 psi) (2.5 kgf/cm2)
Rear:
250 kPa (36 psi) (2.5 kgf/cm2)
Higher pressures and fast inflation may
cause a tire to burst. Inflate the tires very
slowly and carefully.
Measuring the tire pressure
Use the low-pressure tire gauge.
TIP
The low-pressure tire gauge is included as standard equipment. Make two measurements of the
tire pressure and use the second reading. Dust or
5-5
5
dirt in the gauge could cause the first reading to be
incorrect.
Recommended pressure:
Front
25 kPa (3.6 psi) (0.25 kgf/cm2)
Rear
25 kPa (3.6 psi) (0.25 kgf/cm2)
Minimum:
Front
22 kPa (3.2 psi) (0.22 kgf/cm2)
Rear
22 kPa (3.2 psi) (0.22 kgf/cm2)
1
5
1. Low-pressure tire gauge
Tire wear limit
Set the tire pressure when the tires are cold. Set
the tire pressures to the following specifications:
Replace the tire when the tire groove decreases to
3 mm (0.12 in).
5-6
5
1. Tire wear limit
Chassis fasteners
Make sure that all nuts, bolts and screws are properly tightened.
Instruments and switches
Check that all instruments and switches are
working properly. Correct if necessary.
5-7
OPERATION
Starting a cold engine
WARNING
A WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
WARNING
POTENTIAL HAZARD
Frozen control cables in cold weather.
WHAT CAN HAPPEN
You could be unable to control the ATV,
which could lead to an accident or collision.
HOW TO AVOID THE HAZARD
When riding in cold weather, always make
sure all control cables work smoothly before
you begin riding.
WARNING
6
POTENTIAL HAZARD
Operating ATV without being familiar with all
controls.
WHAT CAN HAPPEN
Loss of control, which could cause an accident or injury.
HOW TO AVOID THE HAZARD
Read the Owner’s Manual carefully. If there is
a control or function you do not understand,
ask your Yamaha dealer.
NOTICE
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”.
6-1
Ambient temp./choke position
TIP
This model is equipped with an ignition circuit cutoff system. The engine can be started only when
the rear brake lever is applied.
1
0°
10°
20°
30° °C
30°
50°
70°
90°
°F
3
4. Use the choke in reference to the figure:
Position (1):
Cold engine start with ambient temperature below 30 °C (90 °F).
1
Position (2):
Warming up position.
1.
2.
3.
4.
Position (3):
Cold engine start with ambient temperature
above 25 °C (80 °F).
2
4
3
Fully open “ON”
Half open (warming up position)
Closed “OFF”
Choke
5. Completely close the throttle lever and start
the engine by pushing the start switch.
TIP
If the engine fails to start, release the start switch,
then push it again. Pause a few seconds before
the next attempt. Each cranking should be as short
as possible to preserve battery energy. Do not
6-2
6
6
crank the engine more than 10 seconds on each
attempt.
To start out and accelerate
1. Squeeze the front brake lever to release the
parking brake.
2. Gradually open the throttle while slowly releasing the rear brake lever.
6. If the engine is started with the choke in position (1), the choke should be returned to position (2) to warm up the engine. If the engine is
started with the choke in position (2), keep the
choke in this position to warm up the engine.
NOTICE
6
WARNING
For maximum engine life, always warm the engine up before starting off. Never accelerate
hard when the engine is cold!
POTENTIAL HAZARD
Opening the throttle before releasing the
parking brake.
WHAT CAN HAPPEN
The ATV could wheelie. This would increase
the chance of an accident, including overturn.
HOW TO AVOID THE HAZARD
Release the parking brake before opening
the throttle. Open the throttle gradually.
7. Continue warming up the engine until it idles
smoothly, then return the choke to position (3)
before riding.
TIP
The engine is warm when it responds normally to
the throttle with the choke turned off.
To decelerate
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.
Starting a warm engine
Follow the same procedure as for starting a cold
engine, with the exception that the choke is not required when the engine is warm. Instead, start the
engine with the throttle slightly open.
6-3
0–160 km (0–100 mi) or 0–10 hours
Avoid prolonged operation above 1/2 throttle. Vary
the speed of the ATV regularly. Do not operate it at
one set throttle position.
160–320 km (100–200 mi) or 10–20 hours
Avoid prolonged operation above 3/4 throttle. Rev
the engine freely, but do not use full throttle at any
time.
320 km (200 mi) or 20 hours and beyond
The ATV can now be operated normally.
NOTICE
Do not tow the ATV for long distances. The
transmission is properly lubricated only when
the engine is running. Inadequate lubrication
may damage the transmission.
Engine break-in
6
There is never a more important period in the life of
your engine than the first 320 km (200 mi) or 20
hours of riding. For this reason, you should read
the following material carefully.
Since the engine is brand new, do not put an excessive load on it for the first 320 km (200 mi) or 20
hours. The various parts in the engine wear and
polish themselves to the correct operating clearances. During this period, prolonged full-throttle
operation or any condition that might result in engine overheating must be avoided.
NOTICE
If any engine trouble should occur during the
engine break-in period, immediately have a
Yamaha dealer check the ATV.
Parking
When parking the ATV, stop the engine, shift the
drive select lever into the drive position, apply the
parking brake, and then turn the fuel cock to “OFF”.
6-4
Parking on a slope
1
WARNING
6
POTENTIAL HAZARD
Parking on a hill or other incline.
WHAT CAN HAPPEN
The ATV could roll out of control, increasing
the chance of an accident.
HOW TO AVOID THE HAZARD
Avoid parking on hills or other inclines. If you
must park on an incline, place the ATV transversely across the incline, 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. Parking brake lock button
1. Bring the ATV to a stop by applying the brakes
in the drive position.
2. Stop the engine.
3. Apply the parking brake.
1
1. Locked position
6-5
Yamaha accessories, nor control over their quality or suitability. Choose a genuine Yamaha accessory, or one that is equivalent in design and
quality.
Accessories should be rigidly and securely
mounted. An accessory which can shift position
or come off while you are riding could affect your
ability to control the ATV.
Do not mount an accessory where it could interfere with your ability to control the ATV. Examples include (but are not limited to) a heavy or
bulky object attached to the handlebars which
could make steering difficult, an accessory that
limits your ability to move around on the seat, or
one that limits your view.
Use extra caution when riding an ATV with accessories. The ATV may handle differently than
it does without accessories.
Accessories and loading
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-
Loading
As originally equipped, this ATV is not designed to
carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good
judgment as the stability and handling of an ATV
can be changed. When adding accessories, keep
6-6
6
speeds.
Avoid hills and rough terrain. Choose terrain
carefully. Added weight affects the stability and
handling of the ATV.
the following points in mind:
Never exceed the weight limits shown. An overloaded ATV can be unstable.
MAXIMUM LOADING LIMIT
ATV loading limit (total weight of rider, cargo,
accessories, and tongue):
70.0 kg (154 lb)
6
WARNING
POTENTIAL HAZARD
Overloading this ATV or carrying or towing
cargo improperly.
WHAT CAN HAPPEN
Could cause changes in ATV handling which
could lead to an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity for
this ATV.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.
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
takes longer to stop.
Avoid making sharp turns unless at very slow
WARNING
A WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
6-7
RIDING YOUR ATV
7
7-1
RIDE WITH CARE AND GOOD JUDGEMENT
WARNING
A WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
7
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.
GETTING TO KNOW YOUR ATV
This ATV is for recreation 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
1-1–1-4. Please also read all notice and warning
labels on your ATV.
7-2
Not recommended for children under 12 years
of age.
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if
the operator does not know how to operate
the ATV properly in different situations and
on different types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators
should complete the certified training course
offered by Yamaha. They should then regularly practice the skills learned in the course
and the operating techniques described in
this Owner’s Manual. For more information
about the training course, contact an authorized ATV dealer or call 1-800-887-2887.
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations
for this ATV.
WHAT CAN HAPPEN
Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child.
HOW TO AVOID THE HAZARD
A child under 12 should never operate an ATV
with engine size greater than 70 cc.
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.
7-3
7
This ATV is designed to carry operator only –
passengers prohibited.
WARNING
7
POTENTIAL HAZARD
Carrying a passenger on this ATV.
WHAT CAN HAPPEN
Greatly reduces your ability to balance and
control this ATV. Could cause an accident,
resulting in harm to you and/or your passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The long seat is to
allow the operator to shift position as needed
during operation. It is not for carrying passengers.
7-4
Apparel
HOW TO AVOID THE HAZARD
Always wear an approved motorcycle helmet
that fits properly.
You should also wear:
eye protection (goggles or face shield)
gloves
boots
long-sleeved shirt or jacket
long pants
WARNING
POTENTIAL HAZARD
Operating this ATV without wearing an approved motorcycle helmet, eye protection
and protective clothing.
WHAT CAN HAPPEN
Operating without an approved motorcycle
helmet increases your chances of a severe
head injury or death in the event of an accident.
Operating without eye protection can result
in an accident and increases your chances of
a severe injury in the event of an accident.
Operating without protective clothing increases your chances of severe injury in the
event of an accident.
7
1.
2.
3.
4.
5.
7-5
Protective clothing
Goggles
Gloves
Boots
Helmet
Do not operate after consuming alcohol or
drugs.
The operator’s performance capability is reduced
by the influence of alcohol or drugs.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or
while driving this ATV.
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.
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident or
equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV each time you use
it to make sure the ATV is in safe operating
condition.
Always follow the inspection and maintenance procedures and schedules described
in the Owner’s Manual.
7
WARNING
POTENTIAL HAZARD
Operating this ATV after consuming alcohol
or drugs.
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
7-6
WARNING
WARNING
POTENTIAL HAZARD
Operating this ATV at speeds too fast for
your skills or the conditions.
WHAT CAN HAPPEN
Increases your chances of losing control of
the ATV, which can result in an accident.
HOW TO AVOID THE HAZARD
Always go at a speed that is proper for the
terrain, visibility and operating conditions,
and your experience.
POTENTIAL HAZARD
Operating this ATV with improper tires, or
with improper or uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire
pressure, may cause loss of control, increasing your risk of an accident.
HOW TO AVOID THE HAZARD
Always use the size and type tires specified
in the Owner’s Manual for this ATV on page
5-4.
Always maintain proper tire pressure as described in the Owner’s Manual on page 5-5.
Speed limiters
For riders less experienced with this model, the
throttle lever housing is equipped with a vehicle
speed limiter. This 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 pages 4-3 and 4-4.)
This model also has an engine speed limiter plate
to limit the amount of engine power available.
Yamaha recommends that all beginning riders start
off with the vehicle speed limiter turned in and the
WARNING
A WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
Do not operate at speeds too fast for your
skills or the conditions.
7-7
7
7
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.
engine speed limiter plate installed to limit the amount
of speed available while they learn. The vehicle speed
limiter may be gradually adjusted to increase maximum
speed as the beginner becomes more familiar with
operating the ATV. Parents should decide when to
adjust the ATV for more power as their youngster’s
riding skills improve. Once the ATV rider can operate
with skill at the top speed permitted by adjusting the
vehicle speed limiter alone, the engine speed limiter
plate can be removed. Since removal of this plate will
result in a significant increase in power, turn the vehicle
speed limiter adjusting screw back in again; adjust it
out in stages as you did before. For engine speed
limiter plate removal instructions, see page 4-4.
MAXIMUM LOADING LIMIT
ATV loading limit (total weight of cargo, rider,
accessories, and tongue):
70.0 kg (154 lb)
WARNING
POTENTIAL HAZARD
Overloading this ATV or carrying or towing
cargo improperly.
WHAT CAN HAPPEN
Could cause changes in ATV handling which
could lead to an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity for
this ATV.
1
2
1. Locknut
2. Adjusting screw
7-8
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.
WARNING
POTENTIAL HAZARD
Removing hands from handlebars or feet
from footboards during operation.
WHAT CAN HAPPEN
Removing even one hand or foot can reduce
your ability to control the ATV or could cause
you to lose your balance and fall off of the
ATV. If you remove a foot from a footboard,
your foot or leg may come into contact with
the rear wheels, which could injure you or
cause an accident.
HOW TO AVOID THE HAZARD
Always keep both hands on the handlebars
and both feet on the footboards of your ATV
during operation.
During operation
Always keep your feet on the footboards during operation, otherwise they may contact the rear
wheels.
Avoid wheelies and jumping. You may lose control
of the ATV or overturn.
7-9
7
Modifications
WARNING
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps, and other
stunts.
WHAT CAN HAPPEN
Increases the chance of an accident, including an overturn.
HOW TO AVOID THE HAZARD
Never attempt stunts, such as wheelies or
jumps. Don’t try to show off.
POTENTIAL HAZARD
Operating this ATV with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or modification of this ATV may cause changes in
handling which in some situations could lead
to an accident.
HOW TO AVOID THE HAZARD
Never modify this ATV through improper installation or use of accessories. All parts and
accessories added to this ATV should be
genuine Yamaha or equivalent components
designed for use on this ATV and should be
installed and used according to instructions.
If you have questions, consult an authorized
ATV dealer.
7
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.
7-10
WARNING
POTENTIAL HAZARD
Hot exhaust system.
WHAT CAN HAPPEN
Dry grass or brush or other combustible material accumulated around the engine area
could catch fire.
Someone touching the exhaust system during or after operation could be burned.
HOW TO AVOID THE HAZARD
Do not operate, idle, or park the ATV in dry
grass or other dry ground cover.
Keep the engine area free of dry grass,
brush, or other combustible material.
Do not touch the hot exhaust system.
Do not park the ATV in a place where others
might be likely to touch it.
BE CAREFUL WHERE YOU RIDE
This ATV is designed for off-road use only. Riding
on paved surfaces can cause loss of control.
WARNING
POTENTIAL HAZARD
Operating this ATV on paved surfaces.
WHAT CAN HAPPEN
ATVs are designed for off-road use only.
Paved surfaces may seriously affect handling and control of the ATV, and may cause
the ATV to go out of control.
7-11
7
HOW TO AVOID THE HAZARD
Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.
WARNING
POTENTIAL HAZARD
Operating this ATV on public streets, roads
or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate this ATV on any public street,
road or highway, even a dirt or gravel one. In
many states it is illegal to operate ATVs on
public streets, roads and highways.
7
Do not ride on any public road, street, or highway.
Riding on public roads can result in collisions with
other vehicles.
7-12
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.
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating this
ATV on unfamiliar terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks, bumps, or
holes, without enough time to react. Could
result in the ATV overturning or going out of
control.
HOW TO AVOID THE HAZARD
Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating
the ATV.
7
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating on
excessively rough, slippery or loose terrain.
WHAT CAN HAPPEN
Could cause loss of traction or ATV control,
which could result in an accident, including
an overturn.
7-13
HOW TO AVOID THE HAZARD
Do not operate on excessively rough, slippery or loose terrain until you have learned
and practiced the skills necessary to control
the ATV on such terrain. Always be especially cautious on these kinds of terrain.
7
WARNING
POTENTIAL HAZARD
Operating in areas where you might not be
seen by other off-road vehicles.
WHAT CAN HAPPEN
You could be in a collision. You could be injured.
HOW TO AVOID THE HAZARD
Always mount a caution flag on the ATV to
make you more visible. Watch carefully for
other vehicles.
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
member that the engine and exhaust pipe will be
hot when riding and afterwards; do not allow skin
or clothing to come in contact with these components.
With the engine idling, release the parking brake.
Apply the throttle slowly and smoothly. 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.
Do not ride in areas posted “no trespassing”.
Do not ride on private property without getting permission.
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, 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. Re-
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
easily. It is essential that this skill be learned first at
7-15
7
low speed.
1
WARNING
7
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
The ATV could go out of control, causing a
collision or overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for turning
as described in this Owner’s Manual. Practice turning at low speeds before attempting
to turn at faster speeds. Do not turn at
speeds too fast for your skills or the conditions.
2
1. Lean towards inside of turn.
2. Support your weight on the outer footboard.
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.
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
7-16
curves.
Improper riding procedures such as abrupt throttle
changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the
turn may cause the ATV to tip. If the ATV begins to
tip over to the outside while negotiating a turn, lean
more to the inside. It may also be necessary to
gradually let off on the throttle and steer to the outside of the turn to avoid tipping over.
Remember: Avoid higher speeds until you are
thoroughly familiar with the operation of your ATV.
WHAT CAN HAPPEN
The ATV can overturn more easily on extremely steep hills than on level surfaces or
small hills.
HOW TO AVOID THE HAZARD
Never operate the ATV on hills too steep for
the ATV or for your abilities. Practice on
smaller hills before attempting large hills.
It is important when climbing a hill to make sure
that your weight is transferred forward on the ATV.
This can be accomplished by leaning forward and,
on steeper inclines, standing on the footboards
and leaning forward over the handlebars.
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.
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause the ATV
to overturn.
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
7-17
7
7
HOW TO AVOID THE HAZARD
Always follow proper procedures for climbing hills as described in this Owner’s Manual.
Always check the terrain carefully before you
start up any hill.
Never climb hills with excessively slippery or
loose surfaces.
Shift your weight forward.
Never open the throttle suddenly. The ATV
could flip over backwards.
Never go over the top of any hill at high
speed. An obstacle, a sharp drop, or another
vehicle or person could be on the other side
of the hill.
OK
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.
7-18
WARNING
OK
POTENTIAL HAZARD
Improperly crossing hills or turning on hills.
WHAT CAN HAPPEN
Could cause loss of control or cause the ATV
to overturn.
HOW TO AVOID THE HAZARD
Never attempt to turn the ATV around on any
hill until you have mastered the turning technique as described in the Owner’s Manual on
level ground. Be very careful when turning
on any hill.
Avoid crossing the side of a steep hill if possible.
When crossing the side of a hill:
Always follow proper procedures as described in the Owner’s Manual.
Avoid hills with excessively slippery or loose
surfaces.
Shift your weight to the uphill side of the
ATV.
If your ATV has stalled or stopped and you believe
you can continue up the hill, restart carefully to
make sure you do not lift the front wheels which
could cause you to lose control. If you are unable
to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then
descend the hill.
If you start to roll backwards, DO NOT apply the
rear brake to stop or try to put the ATV in gear. The
ATV could easily tip over backwards. Instead, apply the front brake gradually, or dismount the ATV
immediately on the uphill side.
7-19
7
WARNING
7
POTENTIAL HAZARD
Stalling, rolling backwards or improperly dismounting while climbing a hill.
WHAT CAN HAPPEN
Could result in the ATV overturning.
HOW TO AVOID THE HAZARD
Maintain a steady speed when climbing a hill.
If you lose all forward speed:
Keep weight uphill.
Apply the brakes.
Lock the parking brake after you are
stopped.
If you begin rolling backwards:
Keep weight uphill.
Never apply the rear brake while rolling
backwards.
Apply the front brake.
When fully stopped, apply the rear brake
as well, and then lock the parking brake.
Dismount on uphill side or to a side if pointed
straight uphill. Turn the ATV around and remount, following the procedure described in
the Owner’s Manual.
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. Allow the engine compression to do most
of the braking for you. 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 down7-20
hill. Avoid sharp angles which could allow the ATV
to tip or roll over. Carefully choose your path and
ride no faster than you will be able to react to obstacles which may appear.
OK
WARNING
POTENTIAL HAZARD
Going down a hill improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause the ATV
to overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for going
down hills as described in this Owner’s Manual.
TIP: 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.
7
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
the front wheels slightly uphill. When riding on
7-21
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.
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.
WARNING
7
POTENTIAL HAZARD
Improperly crossing hills or turning on hills.
WHAT CAN HAPPEN
Could cause loss of control or cause the ATV
to overturn.
HOW TO AVOID THE HAZARD
Never attempt to turn the ATV around on any
hill until you have mastered the turning technique as described in the Owner’s Manual on
level ground. Be very careful when turning
on any hill. Avoid crossing the side of a steep
hill if possible.
OK
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
7-22
carefully. Enter where there is no sharp drop off,
and avoid rocks or other obstacles which may be
slippery or upset the ATV. Drive slowly and carefully.
WARNING
POTENTIAL HAZARD
Operating this ATV through deep or fast
flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction and
loss of control, which could lead to an accident.
HOW TO AVOID THE HAZARD
Never operate this ATV in fast flowing water
or in water deeper than that specified in your
Owner’s Manual.
Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them
several times to let friction dry out the linings.
7
Test your brakes after leaving the water. Do not
continue to ride your ATV without verifying that you
have regained proper braking ability.
7-23
1
1. Air filter case check hose
7
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.
NOTICE
After riding your ATV in water, be sure to drain
the trapped water by removing the check hose
at the bottom of the air filter case. Wash the
ATV in fresh water if it has been operated in
salt water or muddy conditions.
7-24
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Could cause loss of control or a collision.
Could cause the ATV to overturn.
HOW TO AVOID THE HAZARD
Before operating in a new area, check for obstacles.
Never attempt to ride over large obstacles,
such as large rocks or fallen trees. When you
go over obstacles, always follow proper procedures as described in the Owner’s Manual.
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.
SLIDING AND SKIDDING
Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an
accident.
To reduce the tendency for the front wheels to slide
in loose or slippery conditions, positioning your
weight over the front wheels will sometimes help.
7-25
7
WHAT CAN HAPPEN
You may lose control of this ATV. You may
also regain traction unexpectedly, which
may cause the ATV to overturn.
HOW TO AVOID THE HAZARD
Learn to safely control skidding or sliding by
practicing at low speeds and on level,
smooth terrain.
On extremely slippery surfaces, such as ice,
go slowly and be very cautious in order to reduce the chance of skidding or sliding out of
control.
7
WHAT TO DO IF...
This section is designed to be a reference guide
only. Be sure to read each section on riding techniques completely.
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.
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 7-15.)
If your ATV begins to tip while turning:
WARNING
POTENTIAL HAZARD
Skidding or sliding improperly.
7-26
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 7-15.)
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. Instead, apply the front brake or 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 7-21.)
If your ATV encounters shallow water:
Ride slowly and carefully through slow moving
water, watching for obstacles. Be sure to let water drain from the ATV and CHECK YOUR
BRAKES FOR PROPER OPERATION when
you come out of the water. Do not continue to
ride your ATV until you have regained adequate
braking ability. (See page 7-22.)
WARNING
A WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
7
7-27
PERIODIC MAINTENANCE AND MINOR REPAIR
8
HOW TO AVOID THE HAZARD
Turn off the engine when performing maintenance unless otherwise specified. Have a
Yamaha dealer perform the service if you are
not familiar with maintenance work.
Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your
ATV in the safest and best operating condition
possible. The most important points of inspection,
adjustment, and lubrication are explained on the
following pages.
The intervals given in the periodic maintenance
and lubrication chart should be considered as a
general guide under normal riding conditions.
However, DEPENDING ON THE WEATHER,
TERRAIN, GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTENANCE INTERVALS MAY NEED TO BE SHORTENED.
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.
WARNING
POTENTIAL HAZARD
Servicing an engine while it is running.
WHAT CAN HAPPEN
Moving parts can catch clothing or parts of
the body, causing injury.
Electrical components can cause shocks or
start fires.
8-1
TIP
3
If you do not have the tools or experience required
for a particular job, have a Yamaha dealer perform
it for you.
1
WARNING
W
Y! n.
io
ULL at
REF form
CA in
L ty
UA safe
AN t
M an
IS rt
TH po
D im
ns
REAntai
co
It
POTENTIAL HAZARD
Operating this ATV with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or modification of this ATV may cause changes in
handling which in some situations could lead
to an accident.
HOW TO AVOID THE HAZARD
Never modify this ATV through improper installation or use of accessories. All parts and
accessories added to this ATV should be
genuine Yamaha or equivalent components
designed for use on this ATV and should be
installed and used according to instructions.
If you have questions, consult an authorized
Yamaha ATV dealer.
G
8
1-3
-2
26
16
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an
2
1. Owner ’s manual
2. Low-pressure tire gauge
3. Owner ’s tool kit
The service information included in this manual
and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However,
additional tools such as a torque wrench may be
necessary to perform certain maintenance work
correctly.
8-2
8
Periodic maintenance chart for the emission control system
TIP
For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance
intervals should be followed.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
INITIAL
NO.
ITEM
Whichev- month
CHECK OR MAINTENANCE
er comes
km
JOB
first
(mi)
hours
8
1
*
2
Fuel line
Spark plug
3
*
Valves
4
*
Carburetor
5
*
Crankcase breather
system
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 choke operation and correct if necessary.
Check engine idling speed and adjust if necessary.
Check breather hose for cracks or other damage,
and replace if necessary.
8-3
EVERY
1
3
6
6
12
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
20
80
160
160
320
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
INITIAL
NO.
ITEM
Whichev- month
CHECK OR MAINTENANCE
er comes
km
JOB
first
(mi)
hours
6
7
*
Exhaust system
Spark arrester
Check for leakage and replace gasket(s) if necessary.
Check for looseness and tighten all screw clamps
and joints if necessary.
Clean.
EVERY
1
3
6
6
12
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
20
80
160
160
320
√
√
√
√
√
√
8
8-4
General maintenance and lubrication chart
INITIAL
NO.
1
*
2
3
4
*
*
ITEM
Timing chain
Check chain tension.
Adjust if necessary.
Air filter element
Clean and replace if necessary.
Clutch
Check operation.
Front brake
8
5
6
*
WhichevCHECK OR MAINTENANCE
er comes
JOB
first
Rear brake
*
Brake hoses
7
*
Wheels
8
*
Tires
1
3
6
6
12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours
20
80
160
160
320
√
√
√
√
Every 20–40 hours (more often in wet or
dusty areas)
√
Check operation and correct if necessary.
Check brake lever free play and adjust if necessary.
Replace brake shoes.
Check operation and correct if necessary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.
Replace brake pads.
Check for cracks or other damage, and replace if
necessary.
Replace.
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.
8-5
EVERY
month
√
√
√
√
√
√
√
√
Whenever worn to the limit
√
√
√
√
√
Whenever worn to the limit
√
√
√
√
Every 4 years
√
√
√
√
√
√
√
√
INITIAL
NO.
ITEM
9
*
Wheel hub bearings
10
*
Chassis fasteners
11
*
12
*
13
*
Shock absorber
assemblies
Front knuckle pivots
Steering shaft
14
*
Steering system
15
Engine oil
16
Engine oil strainer
17
18
*
1
3
6
6
12
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
20
80
160
160
320
√
√
√
√
√
√
√
√
√
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.
√
√
√
√
√
√
√
√
√
√
√
√
CHECK OR MAINTENANCE
JOB
Whichev- month
er comes
km
first
(mi)
EVERY
hours
Check for looseness or damage, and replace if
necessary.
Make sure that all nuts, bolts, and screws are
properly tightened.
Check operation and correct if necessary.
Check for oil leakage and replace if necessary.
Final transmission oil
Change.
Check ATV for oil leakage, and correct if necessary.
Moving parts and
cables
Lubricate.
√
√
√
√
√
√
√
√
8-6
√
√
√
√
8
INITIAL
NO.
8
ITEM
19
*
Drive select lever
safety system cable
20
*
Throttle lever housing and cable
21
*
Front and rear brake
switches
22
*
Lights and switches
23 *
V-belt
CHECK OR MAINTENANCE
JOB
Whichever comes
first
month
1
3
km
(mi)
320
(200)
1300
(800)
hours
20
80
• Check operation and adjust or replace if necessary.
• Check operation and correct if necessary.
• Check throttle cable free play and adjust if necessary.
• Lubricate throttle lever housing and cable.
EVERY
6
6
12
2500
2500
5000
(1600) (1600) (3200)
160
160
320
√
√
√
√
√
√
√
√
• Check operation and correct if necessary.
√
√
√
√
√
• Check operation and correct if necessary.
• Adjust headlight beams.
Check operation
Check for wear, cracks or other damage, and replace
if necessary.
√
√
√
√
√
8-7
√
√
√
√
TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
8
8-8
1
WARNING
A WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
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.
8
1. Spark plug cap
2. Remove the spark plug as shown, with the
spark plug wrench included in the owner’s tool
kit.
To remove the spark plug
1. Remove the spark plug cap.
8-9
replace it if necessary.
Specified spark plug:
NGK/CR7HSA
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)
1
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).
8
TIP
If the spark plug shows a distinctly different color,
the engine could be operating improperly. Do not
attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the ATV.
1. Spark plug gap
2. Check the spark plug for electrode erosion
and excessive carbon or other deposits, and
8-10
To check the engine oil level
1. Place the ATV on a level surface.
2. Check the engine oil level on a cold engine.
2. Clean the surface of the spark plug gasket
and its mating surface, and then wipe off any
grime from the spark plug threads.
3. Install the spark plug with the spark plug
wrench, and then tighten it to the specified
torque.
TIP
If the engine was started before checking the oil
level, be sure to warm up the engine sufficiently,
and then wait at least ten minutes until the oil settles for an accurate reading.
Tightening torque:
Spark plug:
12.0 Nm (1.20 m·kgf, 8.9 ft·lbf)
3. Remove the engine oil filler cap, and then
wipe the dipstick off with a clean rag.
TIP
8
If a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque as
soon as possible.
1
2
4. Install the spark plug cap.
Engine oil
The engine oil level should be checked before
each ride. In addition, the oil must be changed at
the intervals specified in the periodic maintenance
and lubrication chart.
1. Engine oil filler cap
2. Dipstick
8-11
To change the engine oil
1. Place the ATV on a level surface.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Place an oil pan under the 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.
4. Insert the dipstick into the filler hole (without
screwing it in), and then remove it again to
check the oil level.
1
2
4
1. Maximum level mark
2. Minimum level mark
3
TIP
The engine oil should be between the minimum
and maximum level marks.
1.
2.
3.
4.
5. If the engine oil is at or below the minimum
level mark, add sufficient oil of the recommended type to raise it to the correct level.
6. Insert the dipstick into the oil filler hole, and
then tighten the engine oil filler cap.
Engine oil drain bolt
O-ring
Spring
Oil filter element
8
2
1
5. Check the washer for damage and replace it if
necessary.
6. Install the engine oil drain bolt, and then tighten
it to the specified torque.
8-12
minutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
check for the cause.
9. Turn the engine off, wait at least ten minutes,
and then check the oil level and correct it if
necessary.
Tightening torque:
Engine oil drain bolt:
8 Nm (0.8m·kgf, 5.8 ft·lbf)
7. 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:
0.8 L (0.84 US qt) (0.70 Imp.qt)
8
NOTICE
Do not mix any chemical additives. Do
not use oils with a diesel specification
of "CD" or oils of a higher quality than
specified. In addition, do not use oils
labeled "ENERGY CONSERVING II" or
higher.
Make sure that no foreign material enters
the crankcase.
8. Start the engine, and then let it idle for several
8-13
1
Final transmission oil
The final transmission case must be checked for
oil leakage before each ride. If any leakage is
found, have a Yamaha dealer check and repair the
ATV. In addition, the final transmission oil must be
changed at the intervals specified in the periodic
maintenance and lubrication chart.
To change the final transmission oil
1. Place the ATV on a level surface.
2. Place an oil pan under the final transmission.
3. Remove the final transmission oil filler cap and
the drain bolt to drain the oil from the final
transmission oil case.
4. Install the drain bolt, and then tighten it to the
specified torque.
1. Final transmission oil filler cap
8
1
1. Final transmission oil drain bolt
8-14
Tightening torque:
Final transmission oil drain bolt:
15 Nm (1.5 m·kgf, 10.8 ft·lbf)
5. Add the specified amount of the recommended final transmission oil, and then check the
oil level.
Recommended final transmission oil:
See page 10-1.
Oil quantity:
0.30 L (0.32 US qt) (0.27 Imp.qt)
8
Cleaning the air filter element
The air filter element should be cleaned at the intervals specified in the periodic maintenance and
lubrication chart. Clean the air filter element more
frequently if you are riding in unusually wet or dusty
areas.
TIP
There are check hoses at the bottom of the air filter
case. If dust or water collects in these hoses, empty
them and clean the air filter element and air filter
case.
NOTICE
Be sure no foreign material enters the final
transmission case.
6. Install and tighten the oil filler cap.
7. Check the final transmission case for oil leakage.
If oil is leaking, check for the cause.
1
1. Air filter case check hose (left)
8-15
1
2
2
1
2
1. Air filter case check hose (right)
1. Air filter case cover (right)
2. Bolts
1. Remove the air filter case cover by removing the bolts.
2
2
8
1
2
1. Air filter case cover (left)
2. Bolts
8-16
2. Remove the air filter element by removing the
screw, and then pull off the sponge material
from the air filter element holder.
WHAT CAN HAPPEN
Low-flash-point solvents or gasoline can
catch fire or explode.
HOW TO AVOID THE HAZARD
Use parts cleaning solvent to clean the
sponge material.
2
1
4. Squeeze the excess solvent out of the sponge
material and let it dry.
NOTICE
Do not twist the sponge material when squeezing it.
8
1. Air filter element holder
2. Sponge material
3. Wash the sponge material gently but thoroughly in solvent.
WARNING
POTENTIAL HAZARD
Using low-flash-point solvents or gasoline to
clean the sponge material.
5. Check the sponge material and replace it if
damaged.
8-17
ement 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.
6. Apply Yamaha foam air filter oil or other quality foam air filter oil to the sponge material.
TIP
The sponge material should be wet but not dripping.
7. Install the sponge material onto the air filter
element holder.
8. Place the air filter element in the original position,
and then install the screw.
9. Install the air filter case cover by installing the
bolts.
TIP
The air filter element should be cleaned every 20–
40 hours. It should be cleaned and lubricated more
often if the ATV is operated in extremely dusty areas. Each time the air filter element maintenance
is performed, check the air inlet of the air filter case
for obstructions.
8
NOTICE
Make sure that the air filter element is properly seated in the air filter case.
Never operate the engine with the air filter el8-18
Cleaning the spark arrester
2. Remove the spark arrester by pulling it out
of the muffler.
3. Tap the spark arrester lightly, and then use
a wire brush to remove any carbon deposits.
4. Insert the spark arrester into the muffler and
align the screw holes.
5. Install the screw and nut, and then tighten the
nut.
Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester.
1. Remove the screw and nut.
2
1
8
3
1. Spark arrester
2. Screw
3. Nut
8-19
Adjusting the carburetor
WARNING
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.
POTENTIAL HAZARD
Improper cleaning of the spark arrester.
Hot exhaust system.
WHAT CAN HAPPEN
Could injure the eyes.
Could cause burns.
Could cause carbon monoxide poisoning,
possibly leading to death.
Could start a fire.
HOW TO AVOID THE HAZARD
When cleaning the spark arrester:
Always let the exhaust system cool prior to
touching exhaust components.
Do not start the engine when cleaning the exhaust system.
NOTICE
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.
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 lubrica8-20
8
tion chart.
TIP
A diagnostic tachometer is needed to make this
adjustment.
(a)
(b)
1
1. Start the engine and warm it up.
TIP
The engine is warm when it quickly responds to the
throttle.
8
2. Attach the tachometer to the spark plug lead.
3. Check the engine idling speed and, if necessary, adjust it to specification by turning the
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. Throttle stop screw
Engine idling speed:
1600–1800 r/min
TIP
If the specified idling speed cannot be obtained as
described above, have a Yamaha dealer make the
adjustment.
Checking the throttle cable free play
The throttle cable free play should be checked at
the intervals specified in the periodic maintenance
and lubrication chart.
8-21
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, have a Yamaha dealer adjust it.
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.
Brakes
Replacement of brake components requires
professional knowledge.Brake service should be
performed by a Yamaha dealer.
1
1. Throttle lever free play
Timing chain
WARNING
Operating with improperly serviced or adjusted
brakes could lead to a loss in braking ability
and an accident.
The timing chain stretches with use, resulting in improper valve timing and engine noise. To prevent
this from occurring, the timing chain tensioner
must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
Checking the front brake shoes
The front brake shoes must be checked for wear at
the intervals specified in the periodic maintenance
and lubrication chart. Front brake is provided with a
wear indicator on front brake lever, which allows you
8-22
8
to check the brake shoe wear without having to
disassemble the brake. To check the brake shoe
wear, there are two adjusting bolts to indicate brake
shoe wear. If the positions of adjusting bolts reach to
12mm (0.47in), the brake shoes should be replaced
as a set by Yamaha dealer.
3
TIP
Before adjusting the brake lever free play, check
the front brake shoes for wear.
The brake lever free play should measure 4.0–
6.0 mm (0.16–0.24 in) as shown. If the free play
is incorrect, adjust it as follows.
1
1
2
8
1. Upper adjusting bolt
2. Lower adjusting bolt
3. No more than 12 mm (0.47 in)
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.
1. Brake lever free play
1. Loosen the upper locknut and fully turn in the
upper adjusting bolt.
2. Loosen the lower locknut.
3. Turn the lower adjusting bolt in direction (a) to
increase the free play, and in direction (b) to
decrease it.
8-23
1 2
1
(a)
(b)
(a)
(b)
3 4
1.
2.
3.
4.
1. Cable joint
Upper locknut
Upper adjusting bolt
Lower locknut
Lower adjusting bolt
6. Tighten the upper locknut.
WARNING
4. Tighten the lower locknut.
5. While applying the front brake, turn out the upper adjusting bolt until the upper and lower cable lengths are equal. The cable joint will
become vertical.
POTENTIAL HAZARD
Operating with improperly serviced or adjusted brakes.
WHAT CAN HAPPEN
You could lose braking ability, which could
lead to an accident.
8-24
8
HOW TO AVOID THE HAZARD
After servicing:
Make sure the brakes operate smoothly
and that the free play is correct.
Make sure the brakes do not drag.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
1
1. Wear indicator groove
Checking the rear brake pads
8
The rear brake pads must be checked for wear at the
intervals specified in the periodic maintenance and
lubrication chart. Each brake pad is provided with
wear indicator grooves, which allow you to check the
brake pad wear without having to disassemble the
brake. If a brake pad has worn to the point that the
wear indicator grooves have almost disappeared,
have a Yamaha dealer replace the brake pads as a
set.
Checking the brake fluid level
Insufficient brake fluid may allow air to enter the brake
system, possibly causing it to become ineffective.
Before riding, check that the brake fluid is above the
minimum level mark and replenish if necessary.
A low brake fluid level may indicate worn brake pads
and/or brake system leakage. If the brake fluid level
is low, be sure to check the brake pads for wear and
the brake system for leakage.
8-25
Checking the rear brake lever free play
LOWER
The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever free play should
measure 0 –1.5 mm (0 –0.06 in) as shown. If
the free play is incorrect, have a Yamaha dealer
check the brake system.
1
1. Minimum level mark
1
Changing the rear brake fluid
Have a Yamaha dealer change the rear brake fluid
at the intervals specified in the TIP after the periodic
maintenance and lubrication chart. In addition,
have the oil seals of the master cylinders and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are damaged
or leaking.
Oil seals: Replace every two years.
Brake hoses: Replace every four years.
8
1. Brake lever free play
Recommended brake fluid:
DOT4
8-26
WARNING
POTENTIAL HAZARD
Recommended lubricant:
Engine oil
Operating with improperly serviced or adjusted brakes.
WARNING
POTENTIAL HAZARD
WHAT CAN HAPPEN
You could lose braking ability, which could
lead to an accident.
Damaged control cables.
WHAT CAN HAPPEN
HOW TO AVOID THE HAZARD
8
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.
After servicing:
Make sure the brakes operate smoothly
and that the free play is correct.
Make sure the brakes do not drag.
Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
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.
HOW TO AVOID THE HAZARD
Inspect cables frequently. Replace damaged
cables.
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.
8-27
Battery
Recommended lubricant:
Front brake lever:
Lithium-soap-based grease
Rear brake lever:
Silicone grease
This model is equipped with a VRLA (Valve
Regulated Lead Acid) battery. There is no need to
check the electrolyte or to add distilled water.
However, the battery lead connections need to be
checked and, if necessary, tightened.
NOTICE
1
Never attempt to remove the battery cell seals,
as this would permanently damage the battery.
WARNING
1. Lever pivot
Checking the wheel hub bearings
The front and rear wheel hub bearings must be
checked at the intervals specified in the periodic
maintenance and lubrication chart. If there is play
in a wheel hub or if a wheel does not turn smoothly,
have a Yamaha dealer check the wheel hub bearings.
8-28
POTENTIAL HAZARD
Failure to handle batteries or battery electrolyte carefully.
WHAT CAN HAPPEN
You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases.
HOW TO AVOID THE HAZARD
8
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
1. If the ATV will not be used for more than one
month, remove the battery, fully charge it, and
then place it in a cool, dry place.
2. If the battery will be stored for more than two
months, check it at least once a month and fully
charge it if necessary.
To install the battery
TIP
Be sure the battery is fully charged.
1. Place the battery in its compartment.
2. Make sure to properly connect the battery
leads to the battery terminals.
8
To charge the battery
Have a Yamaha dealer charge the battery as soon
as possible if it seems to have discharged. Keep in
mind that the battery tends to discharge more quickly
if the ATV is equipped with optional electrical
accessories.
3
1
2
1. Battery
2. Negative lead
3. Positive lead
8-29
NOTICE
Always keep the battery charged. Storing a
discharged battery can cause permanent
battery damage.
To charge a VRLA (Valve Regulated Lead Acid)
battery, a special (constant-voltage) battery
charger is required. Using a conventional
battery charger will damage the battery. If you
do not have access to a constant-voltage
battery charger, have a Yamaha dealer charge
your battery.
(See page 4-11.)
If the fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off all electrical
circuits.
NOTICE
To prevent accidental short-circuiting, turn off
the main switch when checking or replacing a
fuse.
2. Remove the blown fuse, and then install a
new fuse of the specified amperage.
Specified fuse:
10 A
Replacing the fuse
8
WARNING
1
POTENTIAL HAZARD
Using an improper fuse.
WHAT CAN HAPPEN
An improper fuse can cause damage to the
electrical system, which could lead to a fire.
HOW TO AVOID THE HAZARD
Always use a fuse of the specified rating.
Never use a material in place of the proper
fuse.
2
1. Fuse
2. Spare fuse
The fuse holder is located under the seat.
8-30
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.
8
8-31
Removing a wheel
2. Elevate the ATV and place a suitable stand
under the frame.
3. Remove the nuts from the wheel.
4. Remove the wheel.
1. Loosen the wheel nuts.
1
8
1. Wheel nuts
1
8-32
Installing a wheel
2. Lower the ATV to the ground.
3. Tighten the wheel nuts to the specified
torques.
1. Install the wheel and the nuts.
TIP
When installing the wheel, make sure its arrow
mark
points toward the rotating direction of the
wheel.
Front
1
8
1. Arrow mark
8-33
Tightening torques:
Front wheel nut:
45 Nm (4.5 m·kgf, 33 ft·lbf)
Rear wheel nut:
45 Nm (4.5 m·kgf, 33 ft·lbf)
HOW TO AVOID THE HAZARD
Do not smoke when checking the fuel system. Make sure there are no open flames or
sparks in the area, including pilot lights from
water heaters or furnaces.
Troubleshooting
Although Yamaha ATVs receive a thorough inspection before shipment from the factory, trouble
may occur during operation. Any problem in the fuel, compression, or ignition systems, for example,
can cause poor starting and loss of power.
The following troubleshooting chart represents a
quick and easy procedure for checking these vital
systems yourself. However, should your ATV require any repair, take it to a Yamaha dealer, whose
skilled technicians have the necessary tools, experience, and know-how to service the ATV properly.
Use only genuine Yamaha replacement parts. Imitation parts may look like Yamaha parts, but they
are often inferior, have a shorter service life and
can lead to expensive repair bills.
8
WARNING
POTENTIAL HAZARD
Checking the fuel system while smoking or
near an open flame.
WHAT CAN HAPPEN
Fuel can ignite or explode, causing severe injury or property damage.
8-34
Troubleshooting chart
1. Fuel
There is enough fuel.
Check the compression.
There is no fuel.
Supply fuel.
There is compression.
Check the ignition.
There is no compression.
Have a Yamaha dealer
check the ATV.
Check the fuel level in
the fuel tank.
The engine does not start.
Check the compression.
2. Compression
Operate the electric starter.
3. Ignition
8
Wet
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Open the throttle halfway and operate
the electric starter.
Dry
Have a Yamaha dealer check the ATV.
The engine does not start.
Check the battery.
Remove the spark plug
and check the electrodes.
4. Battery
The engine turns over
quickly.
The battery is good.
The engine turns over
slowly.
Check the battery lead connections, and
charge the battery if necessary.
Operate the electric starter.
8-35
The engine does not start.
Have a Yamaha dealer
check the ATV.
CLEANING AND STORAGE
applications such as those available in coinoperated car washers.
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 wheel axles.
3. Rinse the dirt and degreaser off with a garden
hose. Use only enough pressure to do the job.
4. Once most of the dirt has been hosed off,
wash all surfaces with warm water and mild,
detergent-type soap. An old toothbrush or bottle brush is handy for hard-to-reach places.
5. Rinse the ATV off immediately with clean water and dry all surfaces with a chamois, clean
towel or soft absorbing cloth.
6. Clean the seat with a vinyl upholstery cleaner
to keep the cover pliable and glossy.
7. 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.
NOTICE
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
9-1
9
nia) and areas where strong chemicals are
stored.
WARNING
POTENTIAL HAZARD
Operation with wet brakes after washing.
WHAT CAN HAPPEN
Wet brakes may have reduced stopping ability, increasing the chance of an accident.
HOW TO AVOID THE HAZARD
Test the brakes after washing. Apply the
brakes several times at slow speeds to let
friction dry out the linings.
Long-term
Before storing your ATV for several months:
1. Follow all the instructions in the “Cleaning”
section of this chapter.
2. Turn the fuel cock lever to “OFF”.
3. Drain the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits
from building up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel stabilizer (if
available) to prevent the fuel from deteriorating.
Storage
9
Short-term
Always store your ATV in a cool, dry place and, if
necessary, protect it against dust with a porous
cover.
Specified amount:
7.5 ml of stabilizer to each liter of fuel (or 1 oz
of stabilizer to each gallon of fuel)
NOTICE
5. Perform the following steps to protect the cylinder, piston rings, etc. from corrosion.
a. Remove the spark plug cap and spark
plug.
b. Pour a teaspoonful of engine oil into the
spark plug bore.
c. Install the spark plug cap onto the spark
Storing the ATV in a poorly ventilated room
or covering it with a tarp while it is still wet,
will allow water and humidity to seep in and
cause rust.
To prevent corrosion, avoid damp cellars,
stables (because of the presence of ammo9-2
6.
7.
8.
9.
plug, and then place the spark plug on the
cylinder head so that the electrodes are
grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times with
the starter. (This will coat the cylinder wall
with oil.)
e. Remove the spark plug cap from the spark
plug, and then install the spark plug and
the spark plug cap.
Lubricate all control cables and the pivoting
points of all levers and pedals.
Check and, if necessary, correct the tire air
pressure, and then block up the ATV so that
all of its wheels are off the ground. Alternatively, turn the wheels a little every month in order
to prevent the tires from becoming degraded
in one spot.
Cover the muffler outlet with a plastic bag to
prevent moisture from entering it.
Remove the battery and fully charge it. Store
it in a cool, dry place and charge it once a
month. Do not store the battery in an excessively cold or warm place [less than 0 °C (30
°F) or more than 30 °C (90 °F)]. For more information on storing the battery, see page 8-28.
TIP
Make any necessary repairs before storing the
ATV.
9
9-3
SPECIFICATIONS
Compression ratio:
Dimensions:
10.2 : 1
Overall length:
1490 mm (58.7 in)
Overall width:
885 mm (34.8 in)
Overall height:
910 mm (35.8 in)
Seat height:
654 mm (25.7 in)
Wheelbase:
1010 mm (39.8 in)
Ground clearance:
100 mm (3.9 in)
Minimum turning radius:
2900 mm (114 in)
Starting system:
Electric starter & kickstarter
Lubrication system:
Wet sump
Engine oil:
Type:
YAMALUBE 4, SAE5W-30 or SAE10W-40 or SAE20W-50
10
0
30
Weight:
70
90
110
130 F
YAMALUBE 4 (20W-50) or SAE 20W-50
With oil and fuel:
120.0 kg (264 lb)
10
50
YAMALUBE 4 (10W-40) or SAE 10W-40
Engine:
Engine type:
Forced air cooled 4-stroke
Cylinder arrangement:
Single cylinder
Displacement:
88 cm3 (5.37 cu. in)
Bore × stroke:
47.0 × 51.0 mm (1.85 x 2.0 in)
SAE 5W-30
-20
-10
0
10
20
30
40
50 C
Recommended engine oil grade:
API service SG type or higher, JASO standard MA
10-1
Transmission:
Engine oil quantity:
Periodic oil change:
0.8 L (0.84 US qt) (0.70 Imp.qt)
Primary reduction system:
V-belt
Primary reduction ratio:
2.47-0.61:1
Secondary reduction system:
Spur
Secondary reduction ratio:
41/15 × 45/13 (9.462)
Third reduction system:
Chain drive
Third reduction ratio:
28/13(2.154)
Transmission type:
V-belt automatic
Final transmission oil:
Type:
SAE80 API GL-4 Hypoid gear oil
Quantity:
0.30 L (0.32 US qt) (0.27 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Unleaded gasoline only
Fuel tank capacity:
4.8 L (1.27 US gal) (1.06 lmp.gal)
Fuel reserve amount:
1.0l(0.26 US gal) (0.22 Imp.gal)
Chassis:
Frame type:
Steel tube frame
Caster angle:
4.0 °
Trail:
16 mm (0.63 in)
Carburetor:
Manufacturer:
TK
Type x quantity:
SVR 22-1G x 1
Spark plug (s):
Manufacturer/model:
NGK/CR7HSA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Front tire:
Type:
Tubeless
Size:
AT18 x 7-8
Manufacturer/model:
MAXXIS/M939
Clutch:
Clutch type:
Dry, centrifugal automatic
10-2
10
Front wheel:
Rear tire:
Wheel type:
Panel wheel
Rim size:
8 x 5.5AT
Type:
Tubeless
Size:
AT18 x 9-8
Manufacturer/model:
MAXXIS/M940
Rear wheel:
Wheel type:
Panel wheel
Rim size:
8 x 7AT
Loading:
Maximum loading limit:
70.0 kg (154 lb)
(Total weight of rider, cargo, accessories, and tongue)
Front brake:
Type:
Drum brake
Operation:
Right hand operation
Tire air pressure (measured on cold tires):
Recommended:
Front:
25 kPa (3.6 psi) (0.25 kgf/cm2)
Rear:
25 kPa (3.6 psi) (0.25 kgf/cm2)
Minimum:
Front:
22 kPa (3.2 psi) (0.22 kgf/cm2)
Rear:
22 kPa (3.2 psi) (0.22 kgf/cm2)
Rear brake:
Type:
Single disc brake
Operation:
Left hand operation
Recommended fluid:
DOT4
Front suspension:
10
Type:
Double wishbone
Spring/shock absorber type:
Coil spring/oil damper
10-3
Wheel travel:
111 mm (4.4 in)
Rear suspension:
Type:
Swingarm
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
83 mm (3.3 in)
Electrical system:
Ignition system:
CDI
Charging system:
AC magneto
Battery:
Model:
GTX5L-BS
Voltage, capacity:
12 V, 4.0 AH
Fuses:
Main fuse:
10 A
10
10-4
CONSUMER INFORMATION
Identification numbers
Key identification number
The key identification number is stamped into the
key. Record this number in the space provided and
use it for reference when ordering a new key.
Record the key identification number, vehicle identification number and model label information in
the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen.
KEY IDENTIFICATION NUMBER:
1
VEHICLE IDENTIFICATION NUMBER:
1. Key identification number
MODEL LABEL INFORMATION:
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Vehicle identification number
The vehicle identification number is stamped into
the frame.
11-1
1
1
1. Vehicle identification number
1. Model label
TIP
The vehicle identification number is used to identify your ATV.
Model label
The model label is affixed at the location in the illustration. Record the information on this label in
the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
11
11-2
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
11
11-3
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
month
km (mi)
hours
1
3
6
12
18
24
30
36
42
48
54
60
320 (200)
1300 (800)
2500 (1600)
5000 (3200)
7500 (4800)
10000 (6400)
12500 (8000)
15000 (9600)
17500 (11200)
20000 (12800)
22500 (14400)
25000 (16000)
20
80
160
320
480
640
800
960
1120
1280
1440
1600
DATE OF
SERVICE
MILEAGE
SERVICING DEALER
NAME AND ADDRESS
REMARKS
11
11-4
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.
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SPECIFIC EXCLUSIONS from this warranty shall
include parts replaced due to normal wear or routine
maintenance, such as spark plugs, oil, oil filter, air filter,
and brake shoes.
THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to:
1. Operate and maintain the ATV as specified in the
appropriate owner’s manual;
2. Give notice to an authorized Yamaha ATV dealer
of any and all apparent defects within ten (10) days
after discovery, and make the machine available at
that time for inspection and repairs at such dealer’s
place of business.
WARRANTY TRANSFER: To transfer the warranty
from the original purchaser to any subsequent purchaser(s), it is imperative that the machine be
inspected and registered for warranty by an authorized Yamaha ATV dealer. In order for this warranty
to remain in effect, this inspection and registration
must take place within ten (10) days after transfer. An
inspection and registration fee will be charged for this
service.
EMISSION CONTROL SYSTEM WARRANTY
Yamaha Motor Corporation, USA also warrants to
the ultimate purchaser and each subsequent purchaser of each 2006 and later model Yamaha
ATV covered by this warranty that the vehicle is
designed, built, and equipped so as to conform at the
time of sale with all U.S. emissions standards
applicable at the time of manufacture and that it is
free from defects in materials and workmanship
which would cause it not to meet these standards
11-5
within the period listed immediately below. Failures
other than those resulting from defects in material or
workmanship which arise solely as a result of owner
abuse and/or lack of proper maintenance are not
covered by this warranty.
All Models
Thirty (30) months from the original purchase date
YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO
OTHER WARRANTY OF ANY KIND, EXPRESSED OR
IMPLIED. ALL IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE WHICH EXCEED THE
OBLIGATIONS AND TIME LIMITS STATED
IN THIS WARRANTY ARE HEREBY DISCLAIMED
BY YAMAHA MOTOR CORPORATION, U.S.A. AND
EXCLUDED FROM THIS WARRANTY.
SOME STATES DO NOT ALLOW LIMITATIONS ON
HOW LONG AN IMPLIED WARRANTY LASTS, SO THE
ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO
EXCLUDED FROM THIS WARRANTY ARE ANY
INCIDENTAL OR CONSEQUENTIAL DAMAGES
INCLUDING LOSS OF USE. SOME STATES DO NOT
ALLOW THE EXCLUSION OR LIMITATION OF
INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO
THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL
RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS
WHICH VARY FROM STATE TO STATE.
YAMAHA MOTOR CORPORATION, U.S.A.
P.O. Box 6555
Cypress, California 90630
WARRANTY QUESTIONS AND ANSWERS
CUSTOMER SERVICE
Q. What costs are my responsibility during the warranty period?
A. The customer’s responsibility includes all costs of normal maintenance services,
non-warranty repairs, accident and collision damages, and oil, oil filters, air filters,
spark plugs, and brake shoes.
If your machine requires warranty service, you must take it to any authorized
Yamaha ATV dealer within the continental United States. Be sure to bring
your warranty registration card or other valid proof of the original date of
purchase. If a question or problem arises regarding warranty, first contact
the owner of the dealership. Since all warranty matters are handled at the
dealer level, this person is in the best position to help you. If you are still
not satisfied and require additional assistance, please write:
Q. What are some examples of “abnormal” strain, neglect, or abuse?
A. These terms are general and overlap each other in areas. Specific examples include:
Running the machine out of oil, sustained high rpm, full-throttle, operating the
machine with a broken or damaged part which causes another part to fail, damage
or failure due to improper or careless transportation and or tie-down. If you have
any specific questions on operation or maintenance, please contact your dealer
for advice.
YAMAHA MOTOR CORPORATION U.S.A.
CUSTOMER RELATIONS DEPARTMENT
P.O. Box 6555
Cypress, California 90630
When contacting Yamaha Motor Corporation, U.S.A. don’t forget to include
any important information such as names, addresses, model, V.I.N. (frame
number), dates, and receipts.
Q. Does the warranty cover incidental costs such as towing or transportation due to
a failure?
A. No. The warranty is limited to repair of the machine itself.
CHANGE OF ADDRESS
Q. May I perform any or all of the recommended maintenance shown in the Owner’s
Manual instead of having the dealer do them?
A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owner’s
and Service Manual. We do recommend, however, that items requiring
special tools or equipment be done by a Yamaha ATV dealer.
The federal government requires each manufacturer of a motor vehicle to
maintain a complete, up-to-date list of all first purchasers against the
possibility of a safety-related defect and recall. This list is compiled from
the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the
selling dealer at the time of your purchase.
Q. Will the warranty be void or cancelled if I do not operate or maintain my new ATV
exactly as specified in the Owner’s Manual?
A. No. The warranty on a new ATV cannot be “voided” or “cancelled.” However,
if a particular failure is caused by operation or maintenance other than as described
in the Owner’s Manual, that failure may not be covered under warranty.
If you should move after you have purchased your new ATV, please advise
us of your new address by sending a postcard listing your ATV model
name, V.I.N. (frame number), dealer number (or dealer’s name) as it is
shown on your warranty card, your name and new mailing address. Mail to:
Q. What responsibility does my dealer have under this warranty?
A. Each Yamaha ATV dealer is expected to:
1. Completely set up every new machine before sale.
2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request at any later date.
3. Each Yamaha ATV dealer is held responsible for his setup, service and warranty repair work.
YAMAHA MOTOR CORPORATION, U.S.A.
P.O. Box 6555
Cypress, California 90630
Attention: Warranty Department
This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date
registration record in accordance with federal law.
Q. Is the warranty transferable to second owners?
A. Yes. The remainder of the existing warranty can be transferred upon request. The
unit has to be inspected and re-registered by an authorized Yamaha ATV dealer
for the policy to remain effective.
11-6
11
YAMAHA EXTENDED SERVICE (Y.E.S.)
In addition, Travel and Recreation Interruption Protection
(TRIP) is included at no extra cost. TRIP gives you up to
$150 reimbursement per occurrence for any reasonable
expenses you incur because your Yamaha needs
covered service: replacement vehicle rental, emergency
towing, phone calls, even food and lodging when you are
away from home. This superb coverage goes into effect
when you purchase Y.E.S., so it applies to any warranty
repairs as well as covered repairs during your entire
Y.E.S. plan period.
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 uninterrupted factor y-backed coverage for extra
peace of mind.
Y. E. S. is flexible. You choose the plan that’s right for
you: 12 months, 24 months, or 36 months beyond your
warranty period.
Y.E.S. coverage is honored at any authorized Yamaha
dealer nationwide.
Y.E.S. is designed and administered by the same
Yamaha people who handle your warranty – and it
shows in the comprehensive coverage benefits. There
are no mileage limitations. Coverage isn ’t limited to
“moving par ts” or the “drive train” like many other plans.
And Y.E.S. covers manufacturing defects just like the
warranty. See the sample contract at your Yamaha
dealer to see how comfor ting uninterr upted factor ybacked protection can be.
11
Y.E.S. coverage is transferable to a new owner if you
sell or trade in your ATV. That can make your Yamaha
much more valuable!
This excellent Y.E.S. plan coverage is only available to
Yamaha owners like you, and only while your Yamaha is still
within the Yamaha Limited Warranty period. So visit your
authorized Yamaha dealer to get all the facts. He can show
you how easy it is to protect your investment with Yamaha
Extended Service.
You don’t have to pay anything for covered repairs.
T h e r e ’s n o d e d u c t i b l e t o p ay, a n d r e p a i r s a r e n ’ t
“pro-rated.” You don’t have any “out-of-pocket” expenses
for covered repairs.
11-7
We urge you to act now. You’ll get the excellent benefits of
TRIP coverage right away, and you’ll rest easy knowing
you’ll have strong factory-backed protection even after your
Yamaha Limited Warranty expires. You can also save
money: Y.E.S. costs less within the first 90 days after you
buy your Yamaha. See your dealer today!
A special note:
If visiting your dealer isn’t convenient, contact Yamaha with
your Primar y ID number (your frame number). We’ll be
happy to help you get the Y.E.S. coverage you need.
Yamaha Service Marketing
P.O. Box 6555
Cypress, CA 90630
WARNING
11
A WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
11-8
11
11-9
INDEX
A
Engine oil............................................................5-3, 8-11
Engine, starting a warm................................................6-3
Engine stop switch.......................................................4-2
Engine speed limiter plate............................................ 4-5
Accessories and loading ................................................ 6-6
Air filter element, cleaning............................................ 8-15
B
Battery...........................................................................8-28
Brake lever, front.............................................................4-6
Brake lever, rear............................................................4-6
Brake lever free play, checking the rear........................8-26
Brake lever free play, adjusting the front......................8-23
Brake levers, checking and lubricating ........................8-27
Brakes, front and rear....................................................5-3
Brake shoes, checking the front .................................. 8-22
Brake pads, checking the rear.......................................8-25
Brake fluid level, checking the rear...............................8-25
Brake fluid level, changing the rear..............................8-26
C
Cables, checking and lubricating ................................. 8-27
Carburetor, adjusting.................................................... 8-20
Chassis fasteners........................................................... 5-7
Choke ............................................................................ 4-11
Cleaning..........................................................................9-1
E
Engine break-in .............................................................. 6-4
Engine, cold start...........................................................6-1
Engine idling speed...................................................... 8-20
F
Final transmission oil ........................................... 5-3, 8-14
Fuel........................................................................4-8, 5-3
Fuel cock......................................................................4-10
Fuel tank cap..................................................................4-8
Fuse, replacing.............................................................8-30
H
Handlebar switches........................................................ 4-2
I
Identification numbers .................................................. 11-1
Instruments and switches.............................................5-7
K
Key identification number............................................. 11-1
Kick starter ................................................................. 4-12
L
Label locations...............................................................2-1
M
Main switch .................................................................... 4-1
Maintenance and lubrication chart.................................8-5
Maintenance chart, emission control system.................8-3
Model label...................................................................11-2
O
Owner’s manual and tool kit........................................... 8-1
P
Parking ........................................................................... 6-4
Parking brake ................................................................. 4-7
Parking on a slope ......................................................... 6-5
Part locations ................................................................. 3-1
Pre-operation check list.................................................. 5-1
R
Riding your ATV ............................................................. 7-1
S
Safety information .......................................................... 1-1
Seat .............................................................................. 4-11
Spark arrester, cleaning ............................................... 8-19
Spark plug, checking...................................................... 8-9
Specifications .................................................................. 10-1
Speed limiters.................................................................. 4-3
Start switch..................................................................... 4-2
Storage........................................................................... 9-2
T
Throttle cable free play, checking................................8-21
Throttle lever..........................................................4-3, 5-4
Timing chain.................................................................8-22
Tire pressure, measuring ............................................... 5-5
Tires ............................................................................... 5-4
Tire wear limit................................................................. 5-6
Troubleshooting...........................................................8-34
Troubleshooting chart..................................................8-35
V
Valve clearance............................................................ 8-22
Vehicle identification number ....................................... 11-1
Vehicle speed limiter ...................................................... 4-4
W
Wheel hub bearings, checking ..................................... 8-28
Wheel, installing ........................................................... 8-33
Wheel, removing .......................................................... 8-32
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH.
BEER
BEER
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE GEAR
NEVER operate:
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
ALWAYS:
without proper training or instruction.
use proper riding techniques to avoid
at speeds too fast for your skills or the
vehicle overturns on hills and rough
conditions.
terrain and in turns.
on public roads-a collision can occur with
avoid paved surfaces-pavement may
another vehicle.
seriously affect handling and control.
with a passenger-passengers affect
balance and steering and increase risk
of losing control.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
(For replacement manual, call 1-800-532-1558)
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN TAIWAN
2008.07
(E)
NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES
FIRST CLASS
PERMIT NO. 4
CYPRESS, CA
POSTAGE WILL BE PAID BY ADDRESSEE
YAMAHA MOTOR CORPORATION U.S.A.
P.O. BOX 6555
CYPRESS, CALIFORNIA 90630-9989
ATTN: SALES ADMINISTRATION