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Yamaha BLASTER YFS200W Owner's Manual

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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFS200W
This A
5VM-28199-64

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Summary of Contents for Yamaha BLASTER YFS200W

  • Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFS200W This A 5VM-28199-64...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN 2006.06-0.7x2 ! (E,F,S)
  • Page 3 OWNER’S MANUAL YFS200W This A 5VM-28199-64-E0...
  • Page 5 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.
  • Page 6 EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury WARNING...
  • Page 7 IMPORTANT NOTICE EBU17370 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Fuel ............4-8 Fuel cock ........... 4-9 Starter (choke) ......... 4-11 LOCATION OF THE WARNING AND Seat ............4-11 SPECIFICATION LABELS ......2-1 Adjusting the front shock absorber assemblies ..........4-12 DESCRIPTION ..........3-1 Adjusting the rear shock absorber Left view .............
  • Page 9 Shifting ............6-2 Autolube pump ......... 8-11 Engine break-in ......... 6-4 Cleaning the air filter element ....8-11 Parking ............6-5 Cleaning the spark arrester ..... 8-14 Parking on a slope ........6-6 Changing the carburetor settings ..... 8-16 Accessories and loading ......6-6 Adjusting the engine idling speed ....
  • Page 10 Adjusting a headlight beam ..... 8-40 Replacing the tail/brake light bulb ... 8-41 Removing a wheel ........8-42 Installing a wheel ........8-43 Troubleshooting ........8-43 Troubleshooting chart ......8-45 CLEANING AND STORAGE......9-1 Cleaning ............ 9-1 Storage ............9-2 SPECIFICATIONS ........

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION SAFETY INFORMATION EBU17591 does not have the abilities to operate it safely. Never carry a passenger on an ATV. AN ATV IS NOT A TOY AND CAN BE HAZARD- Always avoid operating an ATV on any paved OUS TO OPERATE.
  • Page 12 that is proper for the terrain, visibility, operating before attempting larger hills. conditions, and your experience. Always follow proper procedures for climbing Never attempt wheelies, jumps, or other stunts. hills as described in this manual. Check the ter- Always inspect your ATV each time you use it to rain carefully before you start up any hill.
  • Page 13 ing, use the proper gear and maintain a steady Always use the size and type of tires specified in speed when climbing a hill. If you stall or roll this manual. backwards, follow the special procedure for Always maintain proper tire pressure as de- braking described in this manual.
  • Page 14 cock is in the “OFF” position. Otherwise, fuel death within a short time. may leak out of the carburetor or fuel tank. Gasoline is poisonous. If you should swal- low some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, seek medical help immediately.

  • Page 15: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 16 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 replace- ment label from your Yamaha dealer.
  • Page 17 For Europe For Oceania WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. 0.30 kgf/cm 0.25 kgf/cm OPERATING TIRE PRESSURE: Set with tires cold kPa, { 0.30 kgf/cm } 4.4 psi Recommended : FRONT : 30 kPa, { 0.25 kgf/cm...
  • Page 18 For Europe For Oceania WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 5FK-2151H-00 5FE-2151H-01 For Europe YAMAHA MOTOR CO., LTD. SHIZUOKA JAPAN 4GB-2155A-00...
  • Page 19 For Europe For Oceania WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE Before you operate this vehicle, GEAR read the owner’s manual.
  • Page 20 For Europe For Oceania WARNING UNDER < 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 5FK-21697-00 5FE-21697-01...

  • Page 21: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Front shock absorber assembly 1. Seat 2. Fuel cock 2. Fuel tank cap 3. Starter (choke) 3. Headlight 4. Rear shock absorber assembly 4. Brake pedal 5. Tail/brake light 5. Brake light switch 6.

  • Page 22: Controls And Instruments

    EBU17712 Controls and instruments 1. Clutch lever 2. Parking brake lock plate 3. Main switch 4. Front brake lever 5. Throttle lever 6. Handlebar switches NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 23: Instrument And Control Functions

    EBU17731 INSTRUMENT AND CONTROL FUNCTIONS EBU17750 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlight and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.

  • Page 24: Indicator Light

    EBU17781 the warning light does not come on for a few sec- Indicator light onds, then go off, have a Yamaha dealer check the electrical circuit. ECB00020 CAUTION: Always make sure there is enough engine oil before starting the engine.

  • Page 25: Throttle Lever

    EBU18070 the throttle lever. 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”.

  • Page 26: Throttle Override System

    ATV or consult a Yamaha dealer. the adjusting screw in direction (a). To de- crease the maximum engine power available and the maximum speed of the ATV, turn the EBU18300 Throttle OverRide System adjusting screw in direction (b).

  • Page 27: Clutch Lever

    turn the adjusting screw out more than 12 mm EBU18411 Brake lever (0.47 in) or the throttle cable could be dam- The brake lever is located at the right handlebar aged. Always make sure the throttle lever free grip. To apply the front brake, pull the brake lever play is adjusted to 4.0–6.0 mm (0.16–0.24 in).

  • Page 28: Parking Brake

    wise, the engine will misfire, preventing normal op- eration. 1. Brake pedal EBU18500 Parking brake 1. Button 2. Parking brake lock plate Use the parking brake before starting the engine or parking the ATV, especially on a slope. Squeeze the clutch lever while pushing the button, then push in the lock plate to apply the parking brake.

  • Page 29: Shift Pedal

    prematurely. EBU18530 Shift pedal This ATV is equipped with a constant-mesh 6- speed transmission. The shift pedal is located on the left side of the engine and is used in combina- tion with the clutch when shifting. 1. Locked position EWB00220 WARNING Always set the parking brake before starting...

  • Page 30: Fuel Tank Cap

    push it down smoothly but forcefully. This model is equipped with a primary kickstarter, allowing the engine to be started in any gear if the clutch is dis- engaged. However, shifting the transmission into the neutral position before starting is recommend- 1.

  • Page 31: Fuel Cock

    of gasoline or higher octane grade. ECB00060 CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the piston rings, as well as to the exhaust system. EWB00310 WARNING Do not overfill the fuel tank. Fuel expands when it heats up.
  • Page 32 The fuel cock lever positions are explained as fol- lows and shown in the illustrations. FUEL FUEL 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel flows 1. Arrow mark positioned over “OFF” to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding.

  • Page 33: Starter (Choke)

    the starter (choke). Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. FUEL 1. Arrow mark positioned over “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

  • Page 34: Adjusting The Front Shock Absorber Assemblies

    1. Seat lock lever 1. Projection 2. Seat holder To install the seat EBU18990 Insert the projections on the front of the seat into Adjusting the front shock absorber the seat holders and push down on the seat at the assemblies rear.

  • Page 35: Adjusting The Rear Shock Absorber Assembly

    1. Loosen the locknut. NOTE: 2. Turn the adjusting nut in direction (a) to in- A special wrench can be obtained at a Yamaha crease the spring preload and thereby harden dealer to make this adjustment. the suspension, and in direction (b) to de-...
  • Page 36 1. Distance A 2. Locknut Spring preload setting: NOTE: Minimum (hard): A special wrench can be obtained at a Yamaha Distance A = 222 mm (8.7 in) dealer to make this adjustment. Standard: The spring preload setting is determined by Distance A = 230 mm (9.1 in)
  • Page 37 3. Tighten the locknut to the specified torque. shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha deal- Tightening torque: er for any service. Locknut: 55 Nm (5.5 m·kgf, 40 ft·lbf) ECB00080 CAUTION: Always tighten the locknut against the adjust- ing nut, and then tighten it to the specified torque.

  • Page 38: Pre-Operation Checks

    Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 39 ITEM ROUTINE PAGE Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear, and replace if necessary. Rear brake 5-4, 8-23, 8-24, 8-26 Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.
  • Page 40 EWB00480 WARNING 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. Failure to inspect increases the possibility of an accident or equipment damage.

  • Page 41: Fuel

    Add oil as necessary. (See Check that there is no free play in the brake le- page 10-1.) ver. If there is free play, have a Yamaha dealer check the brake system. Check for correct brake pedal height. (See...

  • Page 42: Throttle Lever

    Have a Yamaha dealer correct if pipe joints or brake fluid reservoirs. Apply the necessary. brakes firmly for one minute. If there is any leak- age, have a Yamaha dealer check the brake sys- EBU19770 Drive chain tem.

  • Page 43: Tires

    25.0 kPa (3.6 psi) (0.250 kgf/cm The tires listed below have been approved Check and adjust tire pressures when the by Yamaha Motor Co., Ltd. for this model. tires are cold. Other tire combinations are not recommend- Tire pressures must be equal on both sides.

  • Page 44: Measuring The Tire Pressure

    Rear: 250 kPa (36 psi) (2.5 kgf/cm Higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully. EBU19820 Measuring the tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as stan- 1.

  • Page 45: Tire Wear Limit

    Recommended pressure: Front 30.0 kPa (4.4 psi) (0.300 kgf/cm Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm Minimum: Front 27.0 kPa (3.9 psi) (0.270 kgf/cm Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm 1. Tire wear limit Maximum: Front EBU19840 33.0 kPa (4.8 psi) (0.330 kgf/cm Chassis fasteners Rear Make sure that all nuts, bolts and screws are prop-...

  • Page 46: Operation

    4. Shift the transmission into neutral. accident or injury. If there is a control or func- 5. Use the starter (choke) in reference to the fig- tion you do not understand, ask your Yamaha ure: dealer. Position (1):...

  • Page 47: Starting A Warm Engine

    Ambient temp./starter (choke) position ECB00160 CAUTION: AMBIENT TEMP. / STARTER (CHOKE) POSITION °C 0° 10° 20° 30° For maximum engine life, always warm the en- gine up before starting off. Never accelerate 90° °F 30° 50° 70° hard when the engine is cold! 8.
  • Page 48 To shift into neutral, return the throttle lever to the may result. closed position, apply the clutch, and then repeat- 2. Pull the clutch lever to disengage the clutch. edly depress the shift pedal until it stops. 3. Shift into first gear. When it stops, it will be in first gear.

  • Page 49: Engine Break-In

    you slow down, shift to a lower gear. Be sure that forced shifting and can be damaged by shift- the engine has sufficiently slowed before engaging ing without using the clutch. a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing con- EBU20672 Engine break-in...

  • Page 50: Parking

    1. Button If any engine trouble should occur during the 2. Parking brake lock plate engine break-in period, immediately have a Yamaha dealer check the ATV. EBU20721 Parking When parking the ATV, stop the engine, shift into first gear, apply the parking brake, and then turn...

  • Page 51: Parking On A Slope

    steep you could not walk up them easily. 1. Bring the ATV to a stop by applying the brakes in first gear. 2. Stop the engine and release the clutch lever. 3. With the rear brake applied, apply the parking brake and slowly release the brake pedal.
  • Page 52 However, judgment as the stability and handling of an ATV it is not possible for Yamaha to test all non- can be changed. When adding accessories, keep Yamaha accessories, nor control over their qual- the following points in mind: ity or suitability.
  • Page 53 The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trail- Allow more braking distance. A heavier ATV takes longer to stop.

  • Page 54: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 55: Getting To Know Your Atv

    EBU21611 Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not at- tempt to operate at maximum performance until GETTING TO KNOW YOUR ATV you are totally familiar with the ATV’s handling and This ATV is intended for recreational use by expe- performance characteristics.
  • Page 56 with engine size greater than 90 cc. Use by chil- harm to you and/or your passenger. dren of ATVs that are not recommended for their age can lead to severe injury or death of the child. Apparel This ATV is designed to carry operator only – Always wear an approved motorcycle helmet that passengers prohibited.
  • Page 57 event of an accident. Operating without protec- tive clothing increases your chances of severe injury in the event of an accident. Do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. 1.
  • Page 58 page 5-1 before riding for proper care of the ATV Do not operate at speeds too fast for your and to ensure safety. skills or the conditions. EWB01430 EWB01450 WARNING WARNING Always inspect your ATV each time you use it Always go at a speed that is proper for the ter- to make sure the ATV is in safe operating con- rain, visibility and operating conditions, and...
  • Page 59 MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 100.0 kg (220 lb) EWB01460 WARNING Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and se- 1. Adjusting screw curely attached. Reduce speed when carrying cargo or pull- Loading and accessories ing a trailer.
  • Page 60 Avoid wheelies and jumping. You may lose control of the ATV or overturn. EWB01480 WARNING Never attempt stunts, such as wheelies or jumps. Don’t try to show off. EWB01470 WARNING Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation.

  • Page 61: Be Careful Where You Ride

    Yamaha or equivalent components de- signed for use on this ATV and should be installed and used according to instructions. Improper installation of accessories or modifi- cation of this ATV may cause changes in han- dling which in some situations could lead to an accident.
  • Page 62 another vehicle. In many areas, it is illegal to operate ATVs on public streets, roads and highways. While riding on unpaved public streets or roads may be legal in your area, such operation can in- Know the terrain where you ride. Ride cautiously in crease the risk of collision with other vehicles.
  • Page 63 EWB01540 WARNING When riding in an area where you might not easily Do not operate on excessively rough, slippery be seen, such as desert terrain, mount a caution or loose terrain until you have learned and flag on the ATV. DO NOT use the flag pole bracket practiced the skills necessary to control the as a trailer hitch.
  • Page 64 Select a large, flat, unpaved area to become famil- iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain.

  • Page 65: Turning Your Atv

    these components. ECB00230 CAUTION: With the engine idling, pull the clutch lever to dis- engage the clutch and shift into 1st gear, and then Do not shift gears without releasing the throt- release the parking brake. Open the throttle grad- tle.
  • Page 66 used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. EWB01570 WARNING 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.

  • Page 67: Climbing Uphill

    Improper riding procedures such as abrupt throttle er hills before attempting large hills. changes, excessive braking, incorrect body move- It is important when climbing a hill to make sure ments, or too much speed for the sharpness of the that your weight is transferred forward on the ATV. turn may cause the ATV to tip.
  • Page 68 Always follow proper procedures as de- scribed in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room...

  • Page 69: Riding Downhill

    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, ap- ply the front brake gradually, or dismount the ATV immediately on the uphill side.

  • Page 70: Crossing A Slope

    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 ob- stacles which may appear. EWB01620 WARNING Always follow proper procedures for going down hills as described in this Owner’s Manu- Note: a special technique is required when braking as you go down a hill.

  • Page 71: Crossing Through Shallow Water

    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. EWB01631 WARNING Never attempt to turn the ATV around on any...
  • Page 72 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 lin- ings. If the ATV is operated through deep or fast flowing water, the tires may float, causing loss of traction and loss of control, which could lead to an accident.

  • Page 73: Riding Over Rough Terrain

    you go over obstacles, always follow proper procedures as described in the Owner’s Manu- SLIDING AND SKIDDING Care should be used when riding on loose or slip- pery surfaces since the ATV may slide. If unex- pected and uncorrected, sliding could lead to an accident.

  • Page 74: What To Do If

    slide. Applying the brakes or accelerating is not On extremely slippery surfaces, such as ice, recommended until you have corrected the slide. go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of control.
  • Page 75 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 –...

  • Page 76: Periodic Maintenance And Minor Repair

    1. Owner’s manual can cause shocks or start fires. Turn off the en- 2. Owner’s tool kit gine when performing maintenance unless 3. Low-pressure tire gauge otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with...
  • Page 77 NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING Never modify this ATV through improper in-...

  • Page 78: Periodic Maintenance And Lubrication Chart

    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.
  • Page 79 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours Check operation and correct if necessary. √ √ √ √ √ Check fluid level and ATV for fluid leakage, and Rear brake correct if necessary.
  • Page 80 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours Shock absorber Check operation and correct if necessary. √ √ √ 16 * assemblies Check for oil leakage and replace if necessary. √...
  • Page 81 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours √ √ √ Spark arrester Clean. Front and rear brake √ √ √ √ √ 27 * Check operation and correct if necessary. switches Check operation and correct if necessary.

  • Page 82: Checking The Spark Plug

    If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not 1. Spark plug cap attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Remove the spark plug as shown, with the...

  • Page 83: Transmission Oil

    2. Check the spark plug for electrode erosion 2. Clean the surface of the spark plug gasket and excessive carbon or other deposits, and and its mating surface, and then wipe off any replace it if necessary. grime from the spark plug threads. 3.
  • Page 84 To check the transmission oil level 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Wait a few minutes until the oil settles, and then check the oil level through the check win- dow located at the right side of the crankcase.
  • Page 85 3. Place an oil pan under the transmission to col- en the oil filler cap. lect the used oil. Recommended transmission oil: 4. Remove the oil filler cap and the drain bolt to See page 10-1. drain the oil from the transmission. Oil quantity: 0.6 L (0.69 US qt) (0.57 Imp.qt) ECB00430...

  • Page 86: Autolube Pump

    Any adjusting should be left to a Yamaha dealer who has the pro- fessional knowledge and experience to do so. EBU23781...
  • Page 87 1. Air filter case cover 1. Sponge material 2. Screw 2. Air filter element frame 3. Remove the screw and washer. 6. Wash the sponge material gently but thor- 4. Remove the air filter element out of the air fil- oughly in solvent.
  • Page 88 ECB00440 CAUTION: Do not twist the sponge material when squeez- ing it. 1. Sponge material 11. Install the air filter element into the air filter case. 12. Install the washer and screw. 8. Check the sponge material and replace it if ECB00451 damaged.

  • Page 89: Cleaning The Spark Arrester

    tings securely to avoid the possibility of unfiltered air entering the engine. ECB00460 CAUTION: Make sure that the air filter element is prop- erly seated in the air filter case. Never operate the engine with the air filter el- ement removed. This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage.
  • Page 90 1. Screw 1. Tailpipe 2. Spark arrester 2. Remove the tailpipe by pulling it out of the 3. Gasket muffler. 4. Make sure the gasket is properly positioned, 3. Tap the tailpipe lightly, and then use a wire then insert the tailpipe into the muffler and brush to remove any carbon deposits from the align the screw holes.

  • Page 91: Changing The Carburetor Settings

    Carburetor adjustments should only be per- formed by a Yamaha dealer. Do not attempt 1. Main jet number to perform these procedures unless you have mechanical knowledge and the neces- sary tools.
  • Page 92 2. Loosen the carburetor float bowl drain screw and drain the fuel. 1. Standard position: Groove 2 Carburetor setting chart 1. Carburetor float bowl drain screw Pilot air Temperature Main jet Jet needle screw 3. Disconnect the fuel hose and the oil hose. Above 0°C (32°F) 1 1/2 #230...
  • Page 93 1. Clamp screw 2. Mixing chamber cap securing plate 1. Fuel hose 3. Screw 2. Oil hose 4. Mixing chamber cap 4. Loosen the clamp screw on each side of the 7. Disconnect the throttle cable from the throttle carburetor, and then remove the carburetor. valve by removing the holder screws and 5.
  • Page 94 8. Remove the float chamber by removing the 1. Mixing chamber cap screws. 2. Throttle valve 3. Throttle cable holder 4. Screw 5. Throttle cable 1. Float chamber 2. Screw 8-19...
  • Page 95 1. Float 2. Float pin 3. Needle valve 4. Float arm 5. Main jet NOTE: An optional main jet can be obtained at a Yamaha dealer. 8-20...

  • Page 96: Adjusting The Engine Idling Speed

    NOTE: A diagnostic tachometer is needed to make this adjustment. 1. Start the engine and warm it up. NOTE: The engine is warm when it quickly responds to the throttle. 2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if neces- sary, adjust it to specification by turning the throttle stop screw at the carburetor.

  • Page 97: Adjusting The Throttle Cable Free Play

    (b). 1450–1550 r/min NOTE: If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. EBU24043 Adjusting the throttle cable free play The throttle cable free play should be checked...

  • Page 98: Checking The Front And Rear Brake Pads

    1.0 mm (0.04 in), have a Yamaha dealer replace the brake pads as a set. 1. Throttle lever free play adjusting bolt 2. Locknut 3. Throttle lever free play 1. Lining thickness 3.

  • Page 99: Checking The Brake Fluid Level

    Front brake 1. Wear indicator 1. Minimum level mark EBU24251 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary.

  • Page 100: Changing The Brake Fluid

    Yamaha dealer check the cause. EBU24290 1. Minimum level mark Changing the brake fluid Have a Yamaha dealer change the brake fluid at Observe these precautions: the intervals specified in the NOTE after the peri- When checking the fluid level, make sure that odic maintenance and lubrication chart.

  • Page 101: Checking The Brake Pedal Position

    Make sure the brakes are not spongy. All air free play of zero mm (zero in) as shown. If the free must be bled from the brake system. play is incorrect, have a Yamaha dealer check the Replacement of brake components requires brake system.

  • Page 102: Adjusting The Parking Brake Free Play

    Yamaha dealer. EBU24670 Adjusting the parking brake free play The parking brake free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. Cable length “A” should measure 64–68 mm (2.52–2.68 in).
  • Page 103 If the cable length cannot be adjusted to specifica- ECB00520 CAUTION: tion, consult a Yamaha dealer. When tightening the locknut, hold the adjust- 5. Tighten the locknut at the clutch lever. ing bolt with a wrench so that it does not turn 6.

  • Page 104: Brake Light Switches

    The brake light switch for the brake pedal can be adjusted as follows, but the other brake light EBU24810 switches should be adjusted by a Yamaha dealer. Adjusting the clutch lever free play NOTE: The clutch lever free play must be checked and, if...

  • Page 105: Drive Chain Slack

    (0.08–0.12 in) as shown. If the free play is in- rectly, have a Yamaha dealer check the internal correct, adjust it as follows. clutch mechanism. EBU24851 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary.
  • Page 106 1. Drive chain slack 1. Axle holding nut (upper) 2. Axle holding nut (lower) 3. If the drive chain slack is incorrect, adjust it as 2. Loosen the locknut on each side of the swing- follows. arm. To tighten the drive chain, turn the ad- To adjust the drive chain slack justing bolts in direction (a).

  • Page 107: Lubricating The Drive Chain

    Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 11 ft·lbf) Axle holding nut (upper): 50 Nm (5.0 m·kgf, 36 ft·lbf) Axle holding nut (lower): 50 Nm (5.0 m·kgf, 36 ft·lbf) EBU24880 Lubricating the drive chain 1. Locknut The drive chain must be cleaned and lubricated at 2.

  • Page 108: Checking And Lubricating The Cables

    If a cable is damaged or does not move ECB00560 CAUTION: smoothly, have a Yamaha dealer check or replace The drive chain must be lubricated after wash- ing the ATV or riding in the rain. Recommended lubricant: 1.

  • Page 109: Checking And Lubricating The Brake And Clutch Levers

    If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. EBU24992 Lubricating the swingarm pivots...

  • Page 110: Lubricating The Upper And Lower Arm Pivots

    EBU25030 Right side Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Lubricate the pivoting points using a grease gun. Recommended lubricant: Lithium-soap-based grease Left side 1.

  • Page 111: Replacing The Headlight Bulb

    1. Panel 1. Grease nipple 2. Screw EBU25340 Replacing the headlight bulb 2. Remove the headlight beam adjusting screw, If the headlight bulb burns out, replace it as follows. the washer, the spring and the nut. 1. Remove the panel shown by removing the NOTE: screws.
  • Page 112 1. Main switch lead 1. Headlight beam adjusting screw 2. Washer 3. Spring 4. Remove the headlight unit from the headlight 4. Nut assembly by removing the screws. 3. Disconnect the main switch leads. 8-37...
  • Page 113 1. Headlight bulb holder cover 2. Headlight bulb holder 1. Headlight unit 2. Screw 5. Remove the headlight bulb holder cover. 6. Remove the headlight bulb holder by turning it counterclockwise, and then remove the defec- tive bulb. 8-38...
  • Page 114 1. Headlight bulb holder 1. Do not touch the glass part of the bulb. 2. Headlight bulb ECB00650 CAUTION: EWB02200 WARNING Do not touch the glass part of the headlight A headlight bulb is hot when it is on and imme- bulb to keep it free from oil, otherwise the diately after it is turned off.

  • Page 115: Adjusting A Headlight Beam

    13. Adjust the headlight beam. EBU25550 1. Headlight unit Adjusting a headlight beam 2. Screw ECB00690 CAUTION: 10. Install the headlight beam adjusting screw, It is advisable to have a Yamaha dealer make the washer, the spring and the nut. this adjustment. 8-40...

  • Page 116: Replacing The Tail/Brake Light Bulb

    To raise a headlight beam, turn the adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b). 1. Tail/brake light bulb holder 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 1.

  • Page 117: Removing A Wheel

    Front 1. Tail/brake light bulb holder 1. Wheel nut 2. Tail/brake light bulb 3. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 4. Install the bulb holder (together with the bulb) by turning it clockwise.

  • Page 118: Installing A Wheel

    3. Remove the nuts from the wheel. systems yourself. However, should your ATV re- 4. Remove the wheel. quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- EBU25660 Installing a wheel rience, and know-how to service the ATV properly.
  • Page 119 EWB02280 WARNING Do not smoke when checking the fuel system. Fuel can ignite or explode, causing severe inju- ry or property damage. Make sure there are no open flames or sparks in the area, including pi- lot lights from water heaters or furnaces. 8-44...

  • Page 120: Troubleshooting Chart

    Wipe off with a dry cloth and correct the the kickstarter. spark plug gap, or replace the spark plug. Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Have a Yamaha dealer check the ATV. 8-45...

  • Page 121: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25900 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.

  • Page 122: Storage

    EWB02310 Long-term WARNING Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” Wet brakes may have reduced stopping ability, section of this chapter. increasing the chance of an accident. Test the 2. Turn the fuel cock lever to “OFF”. brakes after washing.
  • Page 123 the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder wall with oil.) e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. 6.

  • Page 124: Specifications

    Starting system: 1735 mm (68.3 in) Kickstarter Overall width: Lubrication system: 1035 mm (40.7 in) Separate lubrication (Yamaha autolube) Overall height: Type: 1040 mm (40.9 in) YAMALUBE 2-cycle oil or 2-stroke engine oil (AUS)(NZL) Seat height: YAMALUBE 2-cycle oil or 2-stroke engine oil (JASO FC 740 mm (29.1 in)
  • Page 125 Carburetor: 3rd: 25/15 (1.667) Manufacturer: 4th: MIKUNI 20/16 (1.250) Type x quantity: 5th: VM26SS x 1 19/18 (1.056) Spark plug (s): 6th: Manufacturer/model: 19/21 (0.905) NGK/BR8ES Chassis: Spark plug gap: Frame type: 0.7–0.8 mm (0.028–0.031 in) Steel tube frame Clutch: Caster angle: Clutch type: 9.0 °...
  • Page 126 Manufacturer/model: Rim size: CHENG SHIN/C-874N 8 x 8.0AT Loading: Front brake: Maximum loading limit: Type: 100.0 kg (220 lb) Dual disc brake (Total weight of rider, cargo, accessories, and tongue) Operation: Tire air pressure (measured on cold tires): Right hand operation Recommended fluid: Recommended: DOT 4...
  • Page 127 Electrical system: Ignition system: Charging system: Flywheel magneto Headlight: Bulb type: Halogen bulb Bulb voltage, wattage x quantity: Headlight: 12 V, 35.0/36.5 W × 1 Tail/brake light: 12 V, 5.0/21.0 W × 1 Oil level warning light: 12 V, 3.4 W × 1 10-4...

  • Page 128: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 129 EBU26050 Model label The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- 11-2...
  • Page 130 INDEX Drive chain slack ............8-30 Accessories and loading ..........6-6 Air filter element, cleaning..........8-11 Engine break-in .............. 6-4 Autolube pump ............. 8-11 Engine, cold start ............6-1 Engine idling speed............8-21 Engine, starting a warm ..........6-2 Brake and clutch levers, checking and lubricating ..8-34 Engine stop switch ............
  • Page 131 Swingarm pivots, lubricating ........8-34 Main switch ..............4-1 Model label..............11-2 Tail/brake light bulb, replacing ........8-41 Throttle cable free play, adjusting ........ 8-22 Throttle lever ............4-3 Owner’s manual and tool kit..........8-1 Throttle OverRide System..........4-4 Tire pressure, measuring ..........5-7 Parking................6-5 Tires ................
  • Page 132 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2006.06-0.7x2 !

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