Yamaha YFM80GX Owner's Manual
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Yamaha YFM80GX Owner's Manual

Yamaha YFM80GX Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM80GX
This A
WARNING
This ATV should not be ridden by anyone under 12 years of age.
LIT-11626-21-06
2D3-28199-14

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Summary of Contents for Yamaha YFM80GX

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM80GX This A WARNING This ATV should not be ridden by anyone under 12 years of age. LIT-11626-21-06 2D3-28199-14...
  • Page 2 EBU17091...
  • Page 3 INTRODUCTION EBU17240 Congratulations on your purchase of the Yamaha YFM80GX. 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.
  • Page 4 ATV safely. Your ATV was delivered with an adjustable speed limiter and also with an air intake restrictor plate. Yamaha recommends that all beginners start off with the speed limiter screw turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn.

  • Page 5: Important Manual Information

    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 6: Important Notice

    EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

  • Page 7: Table Of Contents

    EWB00010 Front brake lever ........4-5 WARNING Brake pedal and rear brake lever ....4-5 Parking brake ..........4-6 Indicates a potential hazard that could result in Shift pedal ..........4-7 serious injury or death. Fuel tank cap ..........4-8 Fuel ............
  • Page 8 Engine break-in ......... 6-5 Engine oil ..........8-10 Parking ............6-5 Final gear oil ..........8-13 Parking on a slope ........6-6 Cleaning the air filter element ....8-14 Accessories and loading ......6-7 Removing the air intake restrictor plate ... 8-18 Cleaning the spark arrester .....
  • Page 9 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...

  • Page 10: Safety Information

    EBU17430 SAFETY INFORMATION SAFETY INFORMATION EBU17602 – A child under 12 years old should never oper- ate an ATV with engine size greater than 70 cc. AN ATV IS NOT A TOY AND CAN BE HAZARD- – A child under 16 years old should never oper- OUS TO OPERATE.
  • Page 11 Never operate at speeds too fast for your skills Never operate the ATV on hills too steep for the or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills.
  • Page 12 Always use proper procedures if you stall or roll leaving water. If necessary, apply them several backwards when climbing a hill. To avoid stall- times to let friction dry out the linings. ing, use the proper gear and maintain a steady Always use the size and type of tires specified in speed when climbing a hill.
  • Page 13 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 ex- haust 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 heat-...

  • Page 14: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 15 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. WARNING WARNING Improper ATV use can result in SEVERE INJURY or DEATH.
  • Page 16 WARNING WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN NEVER ride as a CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE passenger. INJURY OR DEATH. OPERATING TIRE PRESSURE: Set with tires cold Passengers can cause Recommended : FRONT : 20 kPa, { 0.20 kgf/cm } 2.9 psi a loss of control, REAR : 20 kPa, { 0.20 kgf/cm...

  • Page 17: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Spark arrester 1. Fuel cock 2. Seat 2. Rear carrier 3. Panel 3. Rear wheel 4. Brake pedal 4. Footboard 5. Footboard 5. Shift pedal 6. Choke 7. Front wheel...

  • Page 18: Controls And Instruments

    EBU17712 from the figures shown in this manual. Controls and instruments 1. Rear brake lever 2. Parking brake 3. Neutral indicator light 4. Front brake lever 5. Throttle lever 6. Main switch 7. Fuel tank cap 8. Handlebar switches NOTE: The ATV you have purchased may differ slightly...

  • Page 19: Instrument And Control Functions

    EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17740 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power, and the engine can be started. The key cannot be re- moved.

  • Page 20: Indicator Light

    EBU17781 EBU18061 Indicator light Handlebar switches 1. Neutral indicator light “N” 1. Engine stop switch “ENG. STOP” 2. Start switch “START” EBU17860 Neutral indicator light “ ” EBU18070 Engine stop switch “ENG. STOP” This indicator light comes on when the transmis- Set this switch to “RUN”...

  • Page 21: Throttle Lever

    EBU18090 Start switch “START” Push this switch to crank the engine with the start- ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. EBU18270 Throttle lever Once the engine is running, movement of the throt- 1.

  • Page 22: Speed Limiter And Air Intake Restrictor Plate

    ATV. Consult a 1. Loosen the locknut. Yamaha dealer if you can’t find or solve the 2. To increase the maximum engine power avail- problem yourself. able and the maximum speed of the ATV, turn the adjusting screw in direction (a).

  • Page 23: Front Brake Lever

    HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 20 mm (0.8 in). EBU18391 Front brake lever The front brake lever is located on the right handle- bar. To apply the front brake, pull the brake lever toward the handlebar grip.

  • Page 24: Parking Brake

    handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip. 1. Rear brake lever EBU18450 Parking brake 1. Brake pedal Use the parking brake before starting the engine or parking the ATV, especially on a slope.

  • Page 25: Shift Pedal

    WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before start- ing the engine. This could cause loss of con- trol or a collision. The brake could overheat if you ride the ATV without releasing the parking brake.

  • Page 26: Fuel Tank Cap

    1. Shift pedal 1. Fuel tank cap 2. Neutral position EBU18730 Fuel EBU18720 Fuel tank cap Make sure that there is sufficient fuel in the tank. Remove the fuel tank cap by turning it counter- Fill the fuel tank to the bottom of the filler tube as clockwise.
  • Page 27 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 oc- tane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premi- um unleaded fuel.

  • Page 28: Fuel Cock

    EWB00270 WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and se- vere injury. Fuel expands when it heats up. If the fuel FUEL tank is overfilled, fuel could spill out due to heat from the engine or the sun.

  • Page 29: Choke

    FUEL FUEL 1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES” With the fuel cock lever in this position, fuel flows This indicates reserve. With the fuel cock lever in to the carburetor. Turn the fuel cock lever to this this position, the fuel reserve is made available.

  • Page 30: Seat

    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. 1. Seat lock lever 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.

  • Page 31: Carrier

    1. Projection 2. Seat holder EBU18950 Carrier Do not exceed the load limit of 5.0 kg (11 lb) for the carrier. Do not exceed the maximum load of 95.0 kg (209 lb) for the ATV. EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death.

  • Page 32: Pre-Operation Checks

    Always follow the inspection and maintenance procedures and schedules described in the Own- er’s Manual. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 33 ITEM ROUTINE PAGE Check fuel level in fuel tank, and add recommended fuel if neces- Fuel sary. 4-8, 5-3 Check fuel line for leakage. Correct if necessary. Check oil level in engine, and add recommended oil to specified Engine oil level if necessary.

  • Page 34: Fuel

    HOW TO AVOID THE HAZARD plied. If not, have the ATV checked by a Yamaha Do not overfill the fuel tank. Be careful not to dealer.

  • Page 35: Throttle Lever

    ATV checked by a Yamaha dealer. EBU19761 Throttle lever Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary.

  • Page 36: Tires

    HOW TO AVOID THE HAZARD Rear: The tires listed below have been approved 20.0 kPa (2.9 psi) (0.20 kgf/cm by Yamaha Motor Co., Ltd. for this model. Check and adjust tire pressures when Other tire combinations are not recom- the tires are cold.

  • Page 37: Specifications

    dirt in the gauge could cause the first reading to be Tire pressure below the minimum speci- incorrect. fied could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure: Front: 17.0 kPa (2.5 psi) (0.17 kgf/cm Rear: 17.0 kPa (2.5 psi) (0.17 kgf/cm Use no more than the following pressures...

  • Page 38: Tire Wear Limit

    Recommended pressure: Front 20.0 kPa (2.9 psi) (0.20 kgf/cm Rear 20.0 kPa (2.9 psi) (0.20 kgf/cm Minimum: Front 17.0 kPa (2.5 psi) (0.17 kgf/cm Rear 17.0 kPa (2.5 psi) (0.17 kgf/cm 1. Tire wear limit Maximum: Front EBU19840 23.0 kPa (3.3 psi) (0.23 kgf/cm Chassis fasteners Rear Make sure that all nuts, bolts and screws are prop-...

  • Page 39: Operation

    See the “Engine break-in” section on page 6-5 a control or function you do not understand, prior to operating the engine for the first time. ask your Yamaha dealer. 1. Set the parking brake. 2. Turn the fuel cock to “ON”.
  • Page 40 Yamaha deal- Ambient temp./choke position er check the electrical circuit. °C 0° 10° 20° 30° NOTE: This model is equipped with an ignition circuit cut- °F 30° 50° 70° 90° off system. The engine can be started under the following conditions.

  • Page 41: Starting A Warm Engine

    crank the engine more than 10 seconds on each EBU20550 Shifting attempt. This ATV has a 3-speed forward transmission with 7. If the engine is started with the choke in posi- a centrifugal, automatic clutch. The transmission tion (1), the choke should be returned to posi- allows you to control the amount of power you tion (2) to warm up the engine.
  • Page 42 ECB00200 EBU20640 To decelerate CAUTION: When slowing down or stopping, release the throt- Always close the throttle before shifting gears, tle and apply the brakes smoothly and evenly. As otherwise damage to the engine and drive train you slow down, shift to a lower gear. Be sure that may result.

  • Page 43: Engine Break-In

    There is never a more important period in the life of Yamaha dealer check the ATV. your engine than the first 320 km (200 mi) or 20 hours of riding. For this reason, you should read EBU20721 the following material carefully.

  • Page 44: Parking On A Slope

    EBU20830 Parking on a slope EWB00790 WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the ATV trans- 1.

  • Page 45: Accessories And Loading

    However, dling of an ATV can be changed. When adding ac- it is not possible for Yamaha to test all non- cessories, keep the following points in mind: Yamaha accessories, nor control over their qual-...
  • Page 46 loaded ATV can be unstable. takes longer to stop. Avoid making sharp turns unless at very slow MAXIMUM LOADING LIMIT speeds. ATV loading limit (total weight of rider, cargo, Avoid hills and rough terrain. Choose terrain accessories, and tongue): carefully. Added weight affects the stability and 95.0 kg (209 lb) handling of the ATV.

  • Page 47: Riding Your Atv

    EBU21131 RIDING YOUR ATV...

  • Page 48: Getting To Know Your Atv

    EWB00010 RIDE WITH CARE AND GOOD JUDGEMENT WARNING Get training if you are inexperienced. Indicates a potential hazard that could result in Beginners should get training from a certified in- serious injury or death. structor. Become familiar with this ATV at slow speeds first, EBU21562 even if you are an experienced operator.
  • Page 49 A child under 12 should never operate an should complete the certified training course ATV with engine size greater than 70 cc. offered by Yamaha. They should then regu- larly practice the skills learned in the course and the operating techniques described in this Owner’s Manual.
  • Page 50 EWB00910 WARNING 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 passen- ger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 51 Apparel HOW TO AVOID THE HAZARD EWB00920 Always wear an approved motorcycle helmet WARNING that fits properly. POTENTIAL HAZARD You should also wear: Operating this ATV without wearing an ap- eye protection (goggles or face shield) proved motorcycle helmet, eye protection gloves and protective clothing.
  • Page 52 Do not operate after consuming alcohol or HOW TO AVOID THE HAZARD drugs. Never consume alcohol or drugs before or The operator’s performance capability is reduced while driving this ATV. by the influence of alcohol or drugs. 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.
  • Page 53 EWB00950 WARNING EWB00960 WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or POTENTIAL HAZARD with improper or uneven tire pressure. Operating this ATV at speeds too fast for WHAT CAN HAPPEN your skills or the conditions. Use of improper tires on this ATV, or opera- WHAT CAN HAPPEN tion of this ATV with improper or uneven tire Increases your chances of losing control of...
  • Page 54 Yamaha recommends that all beginning riders start off with the speed limiter turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn. The limiter may be gradually adjusted to increase maximum speed as the beginner becomes more familiar with oper- ating the ATV.
  • Page 55 EWB00970 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.
  • Page 56 EWB00980 WHAT CAN HAPPEN WARNING Increases the chance of an accident, includ- POTENTIAL HAZARD ing an overturn. Removing hands from handlebars or feet HOW TO AVOID THE HAZARD from footboards during operation. Never attempt stunts, such as wheelies or WHAT CAN HAPPEN jumps.
  • Page 57 Do not operate, idle, or park the ATV in dry accessories added to this ATV should be grass or other dry ground cover. genuine Yamaha or equivalent components Keep the engine area free of dry grass, designed for use on this ATV and should be brush, or other combustible material.

  • Page 58: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. EWB01020 WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect han- dling and control of the ATV, and may cause the ATV to go out of control.
  • Page 59 EWB01040 HOW TO AVOID THE HAZARD WARNING Never operate this ATV on any public street, POTENTIAL HAZARD road or highway, even a dirt or gravel one. In Failure to use extra care when operating this many states it is illegal to operate ATVs on ATV on unfamiliar terrain.
  • Page 60 HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especial- ly cautious on these kinds of terrain. EWB01050 WARNING POTENTIAL HAZARD...
  • Page 61 Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. EWB01060 Select a large, flat area off-road to become familiar WARNING with your ATV. Make sure that this area is free of POTENTIAL HAZARD obstacles and other riders.

  • Page 62: Turning Your Atv

    the shift pedal. Remember that the engine and ex- When slowing down or stopping, release the throt- haust pipe will be hot when riding and afterwards; tle and apply the brakes smoothly and evenly. As do not allow skin or clothing to come in contact with you slow down, shift to a lower gear.
  • Page 63 lowed to slip or lose some traction, the ATV will of the turn slip slightly, allowing the ATV to make resist turning. A special turning technique must be the turn properly. used to allow the ATV to make turns quickly and easily.

  • Page 64: Climbing Uphill

    Once you have learned this technique, you should WHAT CAN HAPPEN be able to perform it at higher speeds or in tighter The ATV can overturn more easily on ex- curves. tremely steep hills than on level surfaces or Improper riding procedures such as abrupt throttle small hills.
  • Page 65 HOW TO AVOID THE HAZARD Always follow proper procedures for climb- ing 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 or make sudden gear changes.
  • Page 66 EWB01190 WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground.

  • Page 67: Riding Downhill

    EWB01231 WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dis- mounting while climbing a hill. WHAT CAN HAPPEN Could result in the ATV overturning. HOW TO AVOID THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.

  • Page 68: Crossing A Slope

    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. EWB01130 WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.

  • Page 69: Crossing Through Shallow Water

    the front wheels slightly uphill. When riding on When crossing the side of a hill: slopes, be sure not to make sharp turns either up Always follow proper procedures as de- or down hill. scribed in the Owner’s Manual. If your ATV does begin to tip over, gradually steer Avoid hills with excessively slippery or loose in the downhill direction if there are no obstacles in surfaces.
  • Page 70 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 care- fully. EWB01150 WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an acci-...

  • Page 71: Riding Over Rough Terrain

    1. Air filter case check hose RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- ECB00240 tion. Look out for obstacles which could cause CAUTION: damage to the ATV or could lead to an upset or ac- After riding your ATV in water, be sure to drain cident.

  • Page 72: Sliding And Skidding

    EWB01160 WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for ob- stacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees.

  • Page 73: What To Do If

    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.
  • Page 74 Lean more into the turn to regain balance. If nec- If your ATV encounters shallow water: essary, gradually let off the throttle and/or steer Ride slowly and carefully through slow moving to the outside of the turn. (See page 7-16.) water, watching for obstacles.

  • Page 75: Periodic Maintenance And Minor Repair

    Safety is an obligation of the owner. Periodic in- nance unless otherwise specified. Have a spection, adjustment and lubrication will keep your Yamaha dealer perform the service if you are ATV in the safest and best operating condition not familiar with maintenance work.
  • Page 76 If you have questions, consult an authorized additional tools such as a torque wrench may be Yamaha ATV dealer. necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform...

  • Page 77: Periodic Maintenance Chart For The Emission Control System

    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 78 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 79: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check chain tension. √ √ √ √ Timing chain Adjust if necessary. Every 20–40 hours (more often in wet or Air filter element Clean and replace if necessary.
  • Page 80 √ √ √ √ 16 * Lubricate. cables Check operation and correct if necessary. Throttle lever hous- Check throttle cable free play and have a Yamaha √ √ √ √ √ 17 * ing and cable dealer adjust if necessary.
  • Page 81 EBU23060 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 82: Checking The Spark Plug

    EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU23211 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 accor- dance with the periodic maintenance and lubrica- 1.
  • Page 83 If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, 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 2.

  • Page 84: Engine Oil

    and its mating surface, and then wipe off any 2. Check the engine oil level on a cold engine. grime from the spark plug threads. NOTE: 3. Install the spark plug with the spark plug If the engine was started before checking the oil wrench, and then tighten it to the specified level, be sure to warm up the engine sufficiently, torque.
  • Page 85 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil. 4. Remove the engine oil filler cap, and then re- move the engine oil drain bolt to drain the oil from the crankcase.
  • Page 86 minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and Tightening torque: check for the cause. Engine oil drain bolt: 9. Turn the engine off, wait at least ten minutes, 20 Nm (2.0 m·kgf, 14.5 ft·lbf) and then check the oil level and correct it if necessary.

  • Page 87: Final Gear Oil

    The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 88: Cleaning The Air Filter Element

    Recommended final gear oil: See page 10-1. Oil quantity: 0.12 L (0.13 US qt) (0.11 Imp.qt) ECB00420 CAUTION: Be sure no foreign material enters the final gear case. 6. Install and tighten the oil filler cap. 1. Final gear oil drain bolt 7.
  • Page 89 ter case. 1. Quick fastener 1. Air filter case check hose 2. Remove the panel by sliding it forward and pulling it off as shown. 1. Remove the quick fasteners. 8-15...
  • Page 90 1. Air filter case cover 1. Panel 2. Air filter case holder 3. Remove the air filter case cover by unhooking 4. Unhook the holder holding the air filter ele- the holders. ment, and then pull out the sponge material from the air filter element.
  • Page 91 WHAT CAN HAPPEN 7. Check the sponge material and replace it if Low-flash-point solvents or gasoline can damaged. catch fire or explode. 8. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material. 8-17...

  • Page 92: Removing The Air Intake Restrictor Plate

    wear and possible engine damage. Addition- NOTE: ally, operation without the air filter element The sponge material should be wet but not drip- will affect carburetor jetting with subsequent ping. poor performance and possible engine over- 9. Install the sponge material into the air filter el- heating.

  • Page 93: Cleaning The Spark Arrester

    3. Tap the tailpipe lightly, and then use a wire NOTE: brush to remove any carbon deposits from the Store the air intake restrictor plate with the owner’s spark arrester portion of the tailpipe and inside manual so that it is readily available whenever you of the tailpipe housing.

  • Page 94: Adjusting The Carburetor

    EWB01910 Yamaha dealer, who has the necessary profes- WARNING sional knowledge and experience. The adjustment described in the following section, however, may POTENTIAL HAZARD be performed by the owner as part of routine main- Improper cleaning of the spark arrester.

  • Page 95: Checking The Throttle Cable Free Play

    The engine is warm when it quickly responds to the If the specified idling speed cannot be obtained as throttle. described above, have a Yamaha dealer make the adjustment. 2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if neces-...

  • Page 96: Timing Chain

    Yamaha dealer replace the this from occurring, the timing chain tensioner brake shoes as a set. must be adjusted by a Yamaha dealer at the inter- Front brake vals specified in the periodic maintenance and lu- brication chart.

  • Page 97: Adjusting The Front Brake Lever Free Play

    Rear brake 12.0 mm (0.39–0.47 in) as shown. If the free play is incorrect, adjust it as follows. 1. Wear limit mark 2. Wear indicator 1. Brake lever free play EBU24320 1. Loosen the upper locknut and fully turn in the Adjusting the front brake lever free upper adjusting bolt.
  • Page 98 1. Upper locknut 1. Cable joint 2. Upper adjusting bolt 3. Lower locknut 6. Tighten the upper locknut. 4. Lower adjusting bolt EWB02020 WARNING 4. Tighten the lower locknut. POTENTIAL HAZARD 5. While applying the front brake, turn out the up- Operating with improperly serviced or ad- per adjusting bolt until the upper and lower ca- justed brakes.

  • Page 99: Adjusting The Rear Brake Lever And Brake Pedal Free Play

    Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24463 Adjusting the rear brake lever and brake pedal free play...
  • Page 100 (a) to scribed above or if the rear brake does not operate increase the free play, and in direction (b) to de- correctly, have a Yamaha dealer check the internal crease it. rear brake mechanism.

  • Page 101: Adjusting The Clutch Free Play

    Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24791 Adjusting the clutch free play The clutch free play must be adjusted periodically.
  • Page 102 1. Footboard 1. Rubber cap 2. Screw 2. Locknut 3. Bolt 3. Adjusting bolt 2. Remove the rubber cap. NOTE: 3. Loosen the locknut. Turning the adjusting bolt in decreases clutch free 4. Slowly turn the adjusting bolt clockwise until play and turning it out increases clutch free play.

  • Page 103: Checking And Lubricating The Cables

    If a cable is damaged or does not move Recommended lubricant: smoothly, have a Yamaha dealer check or replace Silicone grease Recommended lubricant: Engine oil...

  • Page 104: Checking And Lubricating The Brake And Shift Pedals

    If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bear- ings. EBU28820 Lubricating the front knuckle pivots...

  • Page 105: Lubricating The Steering Shaft

    lubrication chart. Lubricate the front knuckle pivots using a grease Recommended lubricant: gun. Lithium-soap-based grease Recommended lubricant: Lithium-soap-based grease EBU25111 Battery A poorly maintained battery will corrode and dis- charge quickly. The electrolyte level, battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrica- tion chart.

  • Page 106: Battery

    1. Battery 1. Maximum level mark 2. Battery breather hose 2. Minimum level mark NOTE: ECB00590 The electrolyte should be between the minimum CAUTION: and maximum level marks. Use only distilled water, as tap water contains 3. If the electrolyte is at or below the minimum minerals that are harmful to the battery.
  • Page 107 stored as follows. WHAT CAN HAPPEN 1. Disconnect the negative lead first and then the You could be poisoned. You could be severe- positive lead. ly burned by the sulfuric acid in battery elec- trolyte. Batteries produce explosive gases. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing.

  • Page 108: Replacing The Fuse

    the battery whenever necessary. ECB00610 CAUTION: To install the battery If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas NOTE: expelled from the battery, the frame could suf- Be sure the battery is fully charged. fer structural and external damages.

  • Page 109: Removing A Wheel

    1. Turn the key to “OFF” and turn off all electrical circuits to check if the devices operate. circuits. 4. If the fuse immediately blows again, have a ECB00640 Yamaha dealer check the electrical system. CAUTION: EBU25650 To prevent accidental short-circuiting, turn off Removing a wheel the main switch when checking or replacing a 1.

  • Page 110: Installing A Wheel

    However, should your ATV re- 3. Remove the nuts from the wheel. quire any repair, take it to a Yamaha dealer, whose 4. Remove the wheel. skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.
  • Page 111 EWB02260 WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe in- jury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys- tem.

  • Page 112: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.

  • Page 113: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25870 applications such as those available in coin- Cleaning operated car washers. Frequent, thorough cleaning of your ATV will not 4. Once most of the dirt has been hosed off, only enhance its appearance but will improve its wash all surfaces with warm water and mild, general performance and extend the useful life of detergent-type soap.

  • Page 114: Storage

    EWB02300 nia) and areas where strong chemicals are WARNING stored. POTENTIAL HAZARD Operation with wet brakes after washing. Long-term WHAT CAN HAPPEN Before storing your ATV for several months: Wet brakes may have reduced stopping abil- 1. Follow all the instructions in the “Cleaning” ity, increasing the chance of an accident.
  • Page 115 plug, and then place the spark plug on the 8-31. cylinder head so that the electrodes are NOTE: grounded. (This will limit sparking during Make any necessary repairs before storing the the next step.) ATV. d. Turn the engine over several times with the starter.

  • Page 116: Specifications

    EBU25960 SPECIFICATIONS Bore × stroke: EBU2597A 47.0 × 45.6 mm (1.85 × 1.80 in) Compression ratio: Dimensions: 9.60 :1 Overall length: Starting system: 1550 mm (61.0 in) Electric starter Overall width: Lubrication system: 855 mm (33.7 in) Wet sump Overall height: Engine oil: 930 mm (36.6 in) Type:...
  • Page 117 Engine oil quantity: Transmission: Periodic oil change: Primary reduction system: 0.80 L (0.85 US qt) (0.70 Imp.qt) Spur gear Final gear oil: Primary reduction ratio: Type: 65/20 (3.250) SAE80 API GL-4 Hypoid gear oil Secondary reduction system: Quantity: Shaft drive 0.12 L (0.13 US qt) (0.11 Imp.qt) Secondary reduction ratio: 19/18 ×...
  • Page 118 Manufacturer/model: Front wheel: DUNLOP/KT586 Wheel type: Rear tire: Panel wheel Type: Rim size: Tubeless 7 x 5.5AT Size: Rear wheel: AT18 x 8-7 Wheel type: Manufacturer/model: Panel wheel DUNLOP/KT587 Rim size: Loading: 7 x 6.5AT Maximum loading limit: Front brake: 95.0 kg (209 lb) Type: (Total weight of rider, cargo, accessories, and tongue)
  • Page 119 Spring/shock absorber type: Coil spring/oil damper Wheel travel: 56 mm (2.2 in) Electrical system: Ignition system: Charging system: AC magneto Battery: Model: 12N7D-3B Voltage, capacity: 12 V, 7.0 Ah Bulb voltage, wattage x quantity: Neutral indicator light: 12 V, 1.7 W × 1 Fuses: Main fuse: 5.0 A...

  • Page 120: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 121 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 122: Noise Regulation

    EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign 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.

  • Page 123: Maintenance Record

    EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.

  • Page 124: Yamaha Motor Corporation, U.s.a. Atv Limited Warranty

    (6) months from the date of purchase. appropriate owner’s manual; YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 2. Give notice to an authorized Yamaha ATV dealer OTHER WARRANTY OF ANY KIND, EXPRESSED OR of any and all apparent defects within ten (10) days DURING THE PERIOD OF WARRANTY any authorized IMPLIED.
  • Page 125 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

  • Page 126: Yamaha Extended Service (Y.e.s.)

    Yamaha people who handle your warranty – and it Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn’t limited to much more valuable! “moving par ts”...
  • Page 127 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.
  • Page 128 EBU26132 11-9...
  • Page 129 INDEX Engine idling speed............8-20 Engine oil ............. 5-3 8-10 Accessories and loading ..........6-7 Engine, starting a warm ..........6-3 Air filter element, cleaning..........8-14 Engine stop switch ............4-2 Air intake restrictor plate, removing......8-18 Final gear oil............5-3 8-13 Battery..............
  • Page 130 Model label..............11-2 Tires ................5-5 Tire wear limit..............5-7 Troubleshooting ............8-36 Neutral indicator light ............. 4-2 Troubleshooting chart ..........8-38 Noise regulation ............11-3 Valve clearance............8-22 Owner’s manual and tool kit........... 8-1 Vehicle identification number ........11-1 Parking ................
  • Page 132 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2007.4-0.6x1 !
  • Page 133 8 TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA – ASK YOUR DEALER FOR DETAILS OR CALL 1-800-887-2887 If you have any questions about these points, or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership, please fill out the information below and mail this card to yamaha today.
  • Page 134 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...

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