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Yamaha Raptor YFM7RZ Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM7RZ
YFM7RSEZ
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-23-09
1AS-28199-10

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Summary of Contents for Yamaha Raptor YFM7RZ

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM7RZ YFM7RSEZ WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-23-09 1AS-28199-10...
  • Page 2 EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold.
  • Page 3 Yamaha experience in the production of fine sporting, touring, and pacesetting racing ma- chines. 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 EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 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: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 5 Please check your local riding laws and regulations before operating this ATV. EBU17382 YFM7RZ/YFM7RSEZ OWNER’S MANUAL ©2009 by Yamaha Motor Corporation, U.S.A. 1st edition, February 2009 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

  • Page 6: Table Of Contents

    EWB00011 Speed limiter ..........4-7 WARNING Clutch lever ..........4-7 Indicates a hazardous situation which, if not Brake lever ..........4-8 avoided, could result in death or serious injury. Brake pedal ..........4-8 Parking brake lever ........4-9 Shift pedal ..........4-10 Reverse knob “REV” .........4-10 EBU17420 Fuel tank cap ..........4-11 TABLE OF CONTENTS...
  • Page 7 OPERATION ..........6-1 PERIODIC MAINTENANCE AND Starting the engine ........6-1 ADJUSTMENT..........8-1 Operating the reverse knob and driving in Owner’s manual and tool kit .......8-1 reverse ............. 6-2 Periodic maintenance chart for the Shifting ............6-3 emission control system ......8-3 Engine break-in ..........
  • Page 8 Checking and lubricating the brake Noise regulation ........11-4 pedal ............8-39 Maintenance record ........11-5 Checking the wheel hub bearings .... 8-39 YAMAHA MOTOR CORPORATION, Lubricating the swingarm pivots ....8-39 U.S.A. ATV LIMITED WARRANTY ..11-6 Lubricating the rear suspension relay arm YAMAHA EXTENDED SERVICE and connecting arm pivoting points ..

  • Page 9: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 10 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 11 Certification of Compliance This ATV complies with applicable provisions of ANSI/SVIA 1-2007 and is subject to an approved ATV action plan submitted by YAMAHA and is on file with the U.S. Consumer Product safety Commission. YAMAHA MOTOR CORPORATION U.S.A. 6555 Katella Avenue, Cypress, California 90630-5101, U.S.A.
  • Page 12 WARNING WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury of NEVER ride as a death. OPERATING TIRE PRESSURE : Set with tires cold passenger. • Recommended : Front : 4.0 psi ( 27.5 kPa ) : Rear : 4.0 psi ( 27.5 kPa ) •...

  • Page 13: Safety Information

    EBU17431 SAFETY INFORMATION Always follow the age recommendation: EBU26663 – A child under 16 years old should never oper- AN ATV IS NOT A TOY AND CAN BE HAZARD- ate an ATV with engine size greater than 90 cc. OUS TO OPERATE. Never allow a child under age 16 to operate an An ATV handles differently from other vehicles, in- ATV without adult supervision, and never allow...
  • Page 14 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 15 Always use proper procedures if you stall or roll reduced stopping ability. Test your brakes after backwards when climbing a hill. To avoid stall- leaving water. If necessary, apply them several ing, use the proper gear and maintain a steady times to let friction dry out the linings.
  • Page 16 EWB00071 Do not run engine outdoors where engine WARNING exhaust can be drawn into a building Avoid Carbon Monoxide Poisoning through openings such as windows and All engine exhaust contains carbon monoxide, doors. a deadly gas. Breathing carbon monoxide can FOR MORE INFORMATION ABOUT ATV SAFE- cause headaches, dizziness, drowsiness, nau- TY, call the Consumer Products Safety Commis-...

  • Page 17: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Engine oil tank 1. Spark arrester 2. Coolant reservoir 2. Seat 3. Idle adjusting screw 3. Headlight 4. Tail/brake light 4. Brake pedal 5. Shift pedal...

  • Page 18: Controls And Instruments

    EBU17712 Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Clutch lever 2. Parking brake lever 3. Main switch 4. Brake lever 5. Throttle lever 6. Reverse knob 7. Fuel tank cap 8.

  • Page 19: Instrument And Control Functions

    EBU17725 INSTRUMENT AND CONTROL FUNCTIONS EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light 1.

  • Page 20: Indicator Lights And Warning Lights

    If the warning light does not come on initially when the key is turned to “ON”, or if the warning light re- mains on, have a Yamaha dealer check the electri- cal circuit. 1. Neutral indicator light “N”...

  • Page 21: Multi-Function Display

    “ON”, or if the warning light re- This warning light comes on when the fuel level mains on, have a Yamaha dealer check the electri- drops below approximately 2.6 L (0.69 US gal, cal circuit.
  • Page 22 two tripmeters (which show the distance trav- Clock mode eled since they were last set to zero) Push and hold “SELECT” button for at least three a clock seconds to switch the display between the clock an hour meter (which shows the total time the mode “CLOCK”...

  • Page 23: Handlebar Switches

    If the multi-function display indicates an error code, Set this switch to “ ” before starting the engine. note the code number, and then have a Yamaha The engine stop switch controls the ignition and dealer check the vehicle. stops the engine when it is running. Use this switch ECB00811 to stop the engine in an emergency situation.

  • Page 24: Throttle Lever

    EBU18101 Regulate the speed of the ATV by varying the Start switch “ ” throttle position. Because the throttle is spring- Push this switch to crank the engine with the start- loaded, the ATV will decelerate, and the engine will er.

  • Page 25: Speed Limiter

    EBU18322 Speed limiter Your ATV was delivered with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power avail- able and the maximum speed of the ATV, turn the adjusting screw in direction (a).

  • Page 26: Brake Lever

    leased slowly for smooth clutch operation. (See page 6-1 for a description of the ignition circuit cut- off system.) 1. Brake lever 2. Locknut 3. Brake lever position adjusting bolt 4. Distance between brake lever and handlebar grip 1. Clutch lever EBU18432 EBU18421 Brake pedal...

  • Page 27: Parking Brake Lever

    1. Parking brake lever (locked position) 1. Brake pedal EBU18520 Parking brake lever Use the parking brake before starting the engine or parking the ATV, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a).

  • Page 28: Shift Pedal

    EWB00220 WARNING Always set the parking brake before starting the engine. The ATV could start moving un- expectedly if the parking brake is not ap- plied. This could cause loss of control or a collision. Always be sure you have released the park- ing brake before you begin to ride.

  • Page 29: Fuel Tank Cap

    1. Reverse knob “REV” 1. Fuel tank cap EBU18720 EBU18731 Fuel tank cap Fuel Remove the fuel tank cap by turning it counter- Make sure there is sufficient gasoline in the tank. clockwise. EWB02521 WARNING Gasoline and gasoline vapors are extremely flammable.
  • Page 30 of sparks, open flames, or other sources of ig- Recommended fuel: nition such as the pilot lights of water heaters UNLEADED GASOLINE ONLY and clothes dryers. Fuel tank capacity: 2. Do not overfill the fuel tank. When refueling, 11.0 L (2.91 US gal, 2.42 Imp.gal) be sure to insert the pump nozzle into the fuel Fuel reserve amount: tank filler hole.

  • Page 31: Seat

    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.

  • Page 32: Adjusting The Front Shock Absorber Assemblies

    EWB02601 WARNING Suspension components become hot during operation. Never touch the compression damping force adjusting screw, the rebound damping force adjusting screw or the oil res- ervoir with your bare hand or skin until sus- pension components have cooled. Always adjust the shock absorber assem- blies on the left and right side to the same setting.
  • Page 33 Distance A = 251.0 mm (9.88 in) 1. Spring preload adjusting nut 2. Locknut 3. Special wrench A special wrench can be obtained at a Yamaha dealer to make this adjustment. The spring preload setting is determined by measuring distance A, shown in the illustration.
  • Page 34 Tightening torque: Rebound damping setting: Locknut: Minimum (soft): 42 Nm (4.2 m·kgf, 30 ft·lbf) 20 click(s) in direction (b)* Standard: 12 click(s) in direction (b)* Rebound damping force Maximum (hard): Turn the rebound damping force adjusting screw in 3 click(s) in direction (b)* direction (a) to increase the rebound damping * With the adjusting screw fully turned in direc- force and thereby harden the damping, and in di-...
  • Page 35 Make sure that the position indicator marks are aligned when the shock absorber assembly is set to the standard setting. Compression damping force (for slow compres- sion damping) To increase the compression damping force and thereby harden the compression damping, turn the compression damping force adjusting screw in di- rection (a).
  • Page 36 Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always rep- resents the entire adjusting range. To obtain a pre- cise adjustment, it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as...

  • Page 37: Adjusting The Rear Shock Absorber Assembly

    Do not dispose of a damaged or worn out ECB00090 NOTICE shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha deal- Never turn an adjusting mechanism beyond er for any service. the minimum and maximum settings. EBU27963...
  • Page 38 A special wrench can be obtained at a Yamaha dealer to make this adjustment. The spring preload setting is determined by measuring distance A, shown in the illustration. The shorter distance A is, the higher the spring preload; the longer distance A is, the lower the spring preload.
  • Page 39 Rebound damping force Rebound damping setting: Turn the rebound damping force adjusting screw in Minimum (soft): direction (a) to increase the rebound damping 20 click(s) in direction (b)* force and thereby harden the damping, and in di- Standard: rection (b) to decrease the rebound damping force 13 click(s) in direction (b)* and thereby soften the damping.
  • Page 40 Make sure that the position indicator marks are aligned when the shock absorber assembly is set to the standard setting. Compression damping force (for slow compres- sion damping) To increase the compression damping force and thereby harden the compression damping, turn the 1.
  • Page 41 Take the resents the entire adjusting range. To obtain a pre- shock absorber assembly to a Yamaha deal- cise adjustment, it would be advisable to check the er for any service.

  • Page 42: Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 43 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Rear brake 5-3, 8-28, 8-29, 8-32 • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.

  • Page 44: Fuel

    Check that there is no free play in the brake le- Test the brakes at slow speed after starting out to ver. If there is free play, have a Yamaha dealer make sure they are working properly. If the brakes check the brake system.

  • Page 45: Throttle Lever

    [EWB02541] Check the operation of the throttle lever. It must pressures to the following specifications: open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if Recommended tire pressure: necessary. Front 27.5 kPa (0.275 kgf/cm², 4.0 psi)
  • Page 46 EWB02551 WARNING Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.

  • Page 47: Chassis Fasteners

    EBU19850 Front: Instruments, lights and switches Manufacturer/model: Check that all instruments, lights and switches are DUNLOP/KT341 Radial working properly. Correct if necessary. Size: AT21 x 7R10 Type: Tubeless Rear: Manufacturer/model: DUNLOP/KT345 Radial Size: AT20 x 10R9 Type: Tubeless Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling,...

  • Page 48: Operation

    3. Shift the transmission into neutral. The neutral indicator light should come on, if it does not come on, have a Yamaha dealer check the EBU29483 Starting the engine electrical circuit.

  • Page 49: Operating The Reverse Knob And Driving In Reverse

    The clutch is disengaged with the transmission reverse, make sure there are no people or ob- in gear. However, it is recommended to shift into stacles behind you. When it is safe to proceed, neutral before starting the engine. go slowly. 4.

  • Page 50: Shifting

    When in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 4. Check behind you for people or obstacles, and then release the brake pedal.
  • Page 51 EBU20571 8. Follow the same procedure when shifting to To start out and accelerate the next higher gear. 1. Release the throttle lever. ECB00200 EBU20650 NOTICE To decelerate When slowing down or stopping, release the throt- Always close the throttle before shifting gears, tle and apply the brakes smoothly and evenly.

  • Page 52: Engine Break-In

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

  • Page 53: Parking On A Slope

    Do not park the ATV at all on hills that are so steep you could not walk up them easily. 1. Bring the ATV to a stop by applying the front brake. 2. With the front and rear brake applied, pull the clutch lever, shift into the neutral position, re- lease the clutch lever, and then apply the parking brake.

  • Page 54: Accessories And Loading

    Yamaha ability to control the ATV. vehicles. Yamaha is not in a position to test the Do not mount an accessory where it could inter- products that these aftermarket companies pro- fere with your ability to control the ATV.
  • Page 55 bulky object attached to the handlebars which judgment as the stability and handling of an ATV could make steering difficult, an accessory that can be changed. When adding accessories, keep limits your ability to move around on the seat, or the following points in mind: one that limits your view.
  • Page 56 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. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully.

  • Page 57: Riding Your Atv

    EBU21132 RIDING YOUR ATV...

  • Page 58: Getting To Know Your Atv

    Before you begin to ride, be sure you complete the certified training course offered by have read this Owner’s Manual completely and un- Yamaha. They should then regularly practice the derstand the operation of the controls. Pay partic- skills learned in the course and the operating tech-...
  • Page 59 niques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics.
  • Page 60 proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. [EWB01411] Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury. Eye protection, such as a face shield or goggles, may reduce the risk of foreign material getting in your eyes and help prevent loss of vision.
  • Page 61 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance Do not operate after or while consuming alco- procedures and schedules described in the Own- hol or drugs.
  • Page 62 opening, even when the throttle lever is pushed to Use extra caution when riding the ATV with addi- the maximum. Turning in the adjusting screw limits tional loads, such as accessories or cargo. The the maximum engine power available and de- ATV’s handling may be adversely affected.
  • Page 63 All parts and accessories added to this ATV should be genuine Yamaha or equivalent components de- signed for use on this ATV and should be installed and used according to instructions. If you have...
  • Page 64 WARNING! Operating this ATV with improper erating in areas where combustible materials may modifications may cause changes in handling have collected. Do not idle or park the vehicle in which in some situations could lead to an acci- long dry grass or other dry ground cover. dent.

  • Page 65: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE Do not ride on any public road, street, or highway. This ATV is designed for off-road use only. Riding on public roads can result in collisions with WARNING! Paved surfaces may seriously af- other vehicles. In many states it is illegal to operate fect handling and control of the ATV, and may ATVs on public streets, roads and highways.
  • Page 66 Know the terrain where you ride. Ride cautiously in Do not operate on rough, slippery, or loose terrain unfamiliar areas. Stay alert for holes, rocks, or until you have learned and practiced the skills nec- roots in the terrain, and other hidden hazards essary to control the ATV on such terrain.
  • Page 67 When riding in an area where you might not easily Do not ride in areas posted “no trespassing”. be seen, such as desert terrain, mount a caution Do not ride on private property without getting per- flag on the ATV. DO NOT use the flag pole bracket mission.

  • Page 68: Turning Your Atv

    Set the parking brake and follow the instruction on When slowing down or stopping, release the throt- page 6-1 to start the engine. Once it has warmed tle and apply the brakes smoothly and evenly. As up you are ready to begin riding your ATV. As you you slow down, shift to a lower gear.
  • Page 69 As you approach a curve, slow down and begin to This procedure should be practiced at slow speed turn the handlebars in the desired direction. As you many times in a large off-road area with no obsta- do so, put your weight on the footboard to the out- cles.

  • Page 70: Climbing Uphill

    CLIMBING UPHILL Avoid crossing the side of a steep hill if pos- EWB01591 sible. When crossing the side of a hill, shift WARNING your weight to the uphill side of the ATV. Climbing hills improperly can cause overturns or loss of control. Use proper riding tech- niques described in this Owner’s Manual.
  • Page 71 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. Whenev- er possible, ride straight up hills.

  • Page 72: Riding Downhill

    If you start to roll backwards, DO NOT apply the rear brake, and apply the front brake gradually. The ATV could easily tip over backwards. When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount the ATV im- mediately on the uphill side or to a side if pointed straight uphill.
  • Page 73 Never operate the ATV on hills too steep for Whenever possible, ride your ATV straight down- the ATV or for your abilities. The ATV can hill. Avoid sharp angles which could allow the ATV overturn more easily on extremely steep hills to tip or roll over.

  • Page 74: Crossing A Slope

    CROSSING A SLOPE As you travel across a slope, lean your body in the EWB01632 uphill direction. It may be necessary to correct the WARNING steering when riding on loose surfaces by pointing Improperly crossing hills or turning on hills the front wheels slightly uphill.

  • Page 75: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER EWB01641 WARNING Operating this vehicle through deep or fast- flowing water can lead to loss of control or an overturn. To reduce your risk of drowning or other injuries, use care when crossing through water. Never operate this ATV water deeper than the depth specified in your Owner’s Man- ual, as tires may float, increasing the risk of an overturn.

  • Page 76: Riding Over Rough Terrain

    1. Air filter case check hose RIDING OVER ROUGH TERRAIN EWB01651 After riding your ATV in water, be sure to drain the WARNING trapped water by removing the check hose at the Riding improperly over obstacles could cause bottom of the air filter case. NOTICE: Undrained loss of control or a collision.

  • Page 77: Sliding And Skidding

    cident. 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 re- sult. SLIDING AND SKIDDING EWB01662 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.

  • Page 78: What To Do If

    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.
  • Page 79 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards 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.

  • Page 80: Periodic Maintenance And Adjustment

    If you are not fa- EBU27111 miliar with vehicle service, have a Yamaha Owner’s manual and tool kit dealer perform the service. Be sure to put this owner’s manual in the plastic bag and to always carry it as well as the owner’s...
  • Page 81 However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

  • Page 82: 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 83 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours √ √ √ Spark arrester • Clean.

  • Page 84: 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 Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) √...
  • Page 85 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for looseness or damage, and replace if √ √ √ √ Wheel hub bearings necessary. • Check operation and for excessive play, and re- √...
  • Page 86 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Engine oil filter ele- √ √ √ • Replace. ment • Check coolant level and ATV for coolant leakage, √...
  • Page 87 • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.

  • Page 88: Removing And Installing The Panel

    EWB00011 EBU23101 Panel A WARNING Indicates a hazardous situation which, if not To remove the panel avoided, could result in death or serious injury. Remove the bolts, and then take the panel off. EBU23080 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter.
  • Page 89 If the spark plug shows a distinctly different color, spark plug wrench included in the owner’s tool the engine could be operating improperly. Do not kit. attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-10...
  • Page 90 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/CR8E To install the spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.

  • Page 91: Engine Oil And Oil Filter Element

    If a torque wrench is not available when installing To achieve the proper engine oil temperature for a spark plug, a good estimate of the correct torque an accurate oil level reading, the engine must have is 1/4–1/2 turn past finger tight. However, the spark first completely cooled down, and then warmed up plug should be tightened to the specified torque as again for several minutes to normal operating tem-...
  • Page 92 Be sure the engine oil is at the correct lev- el, otherwise engine damage may result. [ECB00851] When adding oil, be careful not to overfill the en- gine oil tank; the oil level rises faster starting from the half-level-portion on the dipstick. 6.
  • Page 93 5. Remove the engine oil tank filler cap and the engine oil tank drain bolt. 1. Crankcase engine oil filler cap 1. Engine oil tank drain bolt 6. Check the washers for damage, and replace if necessary. Skip steps 7–10 if the oil filter element is not being replaced.
  • Page 94 1. Oil filter element cover 1. Oil filter element 2. Bolt 2. O-ring 8. Check the O-rings for damage, and replace 9. Install a new oil filter element and the O-rings. them if necessary. Make sure that the O-rings are properly seated. 10.
  • Page 95 11. Install the crankcase engine oil drain bolt and 15. Remove the engine oil tank filler cap, and then the engine oil tank drain bolt, and then tighten gradually fill the oil tank with the remaining oil them to the specified torques. quantity while regularly checking the oil level on the dipstick.

  • Page 96: Coolant

    a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERV- The coolant level must be checked on a cold en- ING II” or higher. gine since the level varies with engine tempera- Make sure that no foreign material enters the ture.
  • Page 97 If water to escape before completely removing the cap. has been added to the coolant, have a Yamaha dealer check the antifreeze con- 1. Place the ATV on a level surface. tent of the coolant as soon as possible, 2.
  • Page 98 5. Remove the coolant reservoir cap. 6. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the cool- ant reservoir. 1. Coolant drain bolt 4. Remove the radiator cap. 1. Coolant reservoir cap 2. Hose 7.

  • Page 99: Cleaning The Air Filter Element

    Do not use hard water or salt water since they are If any leakage is found, have a Yamaha dealer harmful to the engine. [ECB00991] check the cooling system.
  • Page 100 1. Air filter case check hose 1. Air filter case cover 2. Air filter case cover holder 1. Place the ATV on a level surface. 2. Remove the seat. (See page 4-13.) 4. Loosen the wing bolt. 3. Remove the air filter case cover by unhooking 5.
  • Page 101 1. Wing bolt 1. Sponge material 2. Air filter element 2. Air filter element frame 6. Remove the wing bolt and washer from the air 8. Wash the sponge material gently but thor- filter element. oughly in solvent. WARNING! Always use 7.
  • Page 102 10. Check the sponge material and replace it if damaged. 14. Insert the air filter element into the air filter 11. Apply Yamaha foam air filter oil or other qual- case, and then tighten the wing bolt. NOTICE: ity foam air filter oil to the sponge material.

  • Page 103: Cleaning The Spark Arrester

    16. Install the seat. 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 ar- eas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions.
  • Page 104 1. Tailpipe 1. Purging bolt 2. Spark arrester 7. Start the engine and rev it up approximately 4. Insert the tailpipe into the muffler and align the twenty times while momentarily creating ex- bolt holes. haust system back pressure by blocking the 5.

  • Page 105: Adjusting The Engine Idling Speed

    EWB02380 3. Check the engine idling speed and, if neces- WARNING sary, adjust it to specification by turning the Never run the engine in an enclosed area when idle adjusting screw. To increase the engine purging the spark arrester, otherwise it could idling speed, turn the idle adjusting screw in cause injury to the eyes, burns, carbon monox- direction (a), and to decrease it, turn the screw...

  • Page 106: Adjusting The Throttle Cable Free Play

    3. To increase the throttle cable free play, turn must be adjusted by a Yamaha dealer at the inter- the throttle cable free play adjusting bolt in di- vals specified in the periodic maintenance and lu- rection (a).

  • Page 107: Brakes

    If a brake pad has worn to the point that the wear indicator grooves have al- most disappeared, have a Yamaha dealer replace the brake pads as a set. 1. Wear indicator groove...

  • Page 108: Checking The Brake Fluid Level

    EBU26822 Rear brake 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 109 1. Cowling 1. Quick fastener screw 2. Brake fluid reservoir cap 2. Bolt 3. Remove the brake fluid reservoir cap, and 2. Pull the cowling slightly outward as shown. then refill with brake fluid. 4. Install the brake fluid reservoir cap. 5.

  • Page 110: Changing The Brake Fluid

    Yamaha dealer check the cause. EBU24291 Changing the brake fluid Have a Yamaha dealer change the brake fluid at 1. No free play the intervals specified in the TIP after the periodic maintenance and lubrication chart. In addition,...

  • Page 111: Checking The Brake Pedal Position

    15.3 mm (0.60 in) below the top of the footrest as shown. If the brake pedal is not positioned as spec- ified, have a Yamaha dealer adjust it. 1. Cable length “A” 1. Release the parking brake by moving the parking brake lever to the right.

  • Page 112: Brake Light Switches

    2. Brake lever free play adjusting nut adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. If the cable length cannot be adjusted to specifica- The brake light switch is properly adjusted when tion, consult a Yamaha dealer.

  • Page 113: Adjusting The Clutch Lever Free Play

    1. Locknut 2. Clutch lever free play adjusting bolt 3. Clutch lever free play 1. Brake light switch 1. Loosen the locknut at the clutch lever. 2. Brake light switch adjusting nut 2. To increase the clutch lever free play, turn the adjusting bolt at the clutch lever in direction EBU24820 Adjusting the clutch lever free play...

  • Page 114: Drive Chain Slack

    8. Tighten the locknut at the crankcase and the clutch lever. If the specified free play cannot be obtained as de- scribed above or if the clutch does not operate cor- rectly, have a Yamaha dealer check the internal clutch mechanism. EBU26864 Drive chain slack The drive chain slack should be checked before 1.
  • Page 115 3. If the drive chain slack is incorrect, adjust it as follows. A rod can be obtained at a Yamaha dealer to make this adjustment. To adjust the drive chain slack 1. Place the ATV on a level surface. 4. Shift the transmission into neutral.

  • Page 116: Lubricating The Drive Chain

    1. O-ring Tightening torque: ECB00560 Rear axle pinch bolt: NOTICE 21 Nm (2.1 m·kgf, 15 ft·lbf) The drive chain must be lubricated after wash- ing the ATV or riding in the rain. EBU24881 Lubricating the drive chain 1. Clean the drive chain with kerosene and a The drive chain must be cleaned and lubricated at small soft brush.

  • Page 117: Checking And Lubricating The Cables

    If a cable is damaged or does not move pivots should be lubricated if necessary. smoothly, have a Yamaha dealer check or replace Recommended lubricants: Brake lever: Recommended lubricant:...

  • Page 118: Checking And Lubricating The Brake Pedal

    If there is play points in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bear- The rear suspension relay arm and connecting ings. arm pivoting points must be lubricated at the inter-...

  • Page 119: Lubricating The Upper And Lower Arm Pivots

    1. Grease nipple 1. Grease nipple EBU25032 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 1.

  • Page 120: Battery

    Left side Right side 1. Upper grease nipple 1. Upper grease nipple 2. Lower grease nipple 2. Lower grease nipple EBU29184 Battery This model is equipped with a VRLA (Valve Regu- lated Lead Acid) battery. There is no need to check the electrolyte or to add distilled water.
  • Page 121 EWB02160 3. Disconnect the negative battery lead first, WARNING then the positive battery lead by removing Battery electrolyte is poisonous and danger- their bolt. NOTICE: When removing the bat- ous, as it contains sulfuric acid, which can tery, the main switch must be off, and the cause severe burns.
  • Page 122 To charge the battery ECB00940 NOTICE Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in Always keep the battery charged. Storing a dis- mind that the battery tends to discharge more...

  • Page 123: Replacing A Fuse

    1. Positive battery lead (red) 1. Main fuse 2. Negative battery lead (black) 2. Spare main fuse 3. Install the battery holding plate by installing the bolts. 4. Install the seat. (See page 4-13.) EBU25326 Replacing a fuse The main fuse and the fuse box are located under the seat.
  • Page 124 3. Turn the key to “ON” and turn on the electrical To prevent accidental short-circuiting, turn off circuits to check if the devices operate. the main switch when checking or replacing a 4. If the fuse immediately blows again, have a fuse. Yamaha dealer check the electrical system. 8-45...

  • Page 125: Replacing A Headlight Bulb

    EBU25442 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the bolt. 1. Headlight bulb holder cover 2. Headlight coupler 4. Remove the headlight bulb holder by pushing it in and turning it counterclockwise, and then remove the burnt-out bulb.

  • Page 126: Adjusting A Headlight Beam

    10. Adjust the headlight beam if necessary. off any dirt and fingerprints on the head- light bulb using a cloth moistened with al- EBU25560 Adjusting a headlight beam cohol or thinner. [ECB00651] ECB00690 NOTICE It is advisable to have a Yamaha dealer make this adjustment. 8-47...

  • Page 127: Tail/Brake Light

    1. Place the ATV on a level surface. If the tail/brake light does not come on, have a 2. Install the wheel and the nuts. Yamaha dealer check it. EBU25651 Removing a wheel 1. Place the ATV on a level surface.

  • Page 128: Troubleshooting

    However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.

  • Page 129: Troubleshooting Charts

    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 130 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible.

  • Page 131: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25901 ter pressure may cause water seepage and Cleaning deterioration of wheel bearings, brakes, Frequent, thorough cleaning of your ATV will not transmission seals and electrical devices. only enhance its appearance but will improve its Many expensive repair bills have resulted general performance and extend the useful life of from improper high-pressure detergent many components.

  • Page 132: Storage

    EBU27261 3. Perform the following steps to protect the cyl- Storage inder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark Short-term plug. Always store your ATV in a cool, dry place and, if b. Pour a teaspoonful of engine oil into the necessary, protect it against dust with a porous spark plug bore.
  • Page 133 6. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 7. 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 exces- sively cold or warm place [less than 0 °C (30 °F) or more than 30 °C (90 °F)].

  • Page 134: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Overall length: Starting system: 1845 mm (72.6 in) Electric starter Overall width: Lubrication system: 1170 mm (46.1 in) Dry sump Overall height: Engine oil: 1130 mm (44.5 in) Seat height: Recommended brand: 815 mm (32.1 in) YAMALUBE Wheelbase: Type:...
  • Page 135 Engine oil quantity: Clutch: Without oil filter element replacement: Clutch type: 1.75 L (1.85 US qt, 1.54 Imp.qt) Wet, multiple-disc With oil filter element replacement: Transmission: 1.85 L (1.96 US qt, 1.63 Imp.qt) Primary reduction system: Cooling system: Spur gear Coolant reservoir capacity (up to the maximum level mark): Primary reduction ratio: 0.25 L (0.26 US qt, 0.22 Imp.qt)
  • Page 136 Caster angle: Rear: 5.0 ° 24.5 kPa (0.245 kgf/cm², 3.6 psi) Trail: Front wheel: 21.0 mm (0.83 in) Wheel type: Front tire: Panel wheel Type: Rim size: Tubeless 10 x 5.5AT Rear wheel: Size: AT21 x 7R10 Wheel type: Manufacturer/model: Panel wheel DUNLOP/KT341 Radial Rim size:...
  • Page 137 Wheel travel: Fuel level warning light: 230 mm (9.1 in) Rear suspension: Reverse indicator light: Type: Coolant temperature warning light: Swingarm (link suspension) Spring/shock absorber type: Engine trouble warning light: Coil spring/gas-oil damper Wheel travel: Fuses: 256 mm (10.1 in) Electrical system: Main fuse: 20.0 A...

  • Page 138: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 139 Model label ment Canada. 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 140 1. Vehicle Emission Control Information label 11-3...

  • Page 141: 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 ul- timate 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 142: 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 143: 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 144 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 145: 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 146 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 147 EBU26132 11-10...
  • Page 148 INDEX Drive chain slack ............8-35 Accessories and loading ..........6-7 Air filter element, cleaning ..........8-20 Engine break-in .............. 6-5 Engine idling speed ............8-26 Engine oil ............... 5-3 Battery ................8-41 Engine oil and oil filter element ........8-12 Brake and clutch levers, checking and lubricating ..
  • Page 149 Spark arrester, cleaning ..........8-24 Spark plug, checking ............. 8-9 Main switch ..............4-1 Specifications ............... 10-1 Maintenance and lubrication chart ......... 8-5 Speed limiter ..............4-7 Maintenance chart, emission control system ....8-3 Start switch ..............4-6 Maintenance record ............. 11-5 Storage ................
  • Page 152 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2009.02-0.3×1 CR...

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