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Yamaha YFM50R Owner's Manual

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OWNER'S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFM50RW
This A
5YF-28199-63

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Summary of Contents for Yamaha YFM50R

  • Page 1 OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM50RW This A 5YF-28199-63...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN 2006.05-0.1x1 ! (E,F,S)
  • Page 3 OWNER’S MANUAL YFM50RW This A 5YF-28199-63-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 Your ATV was delivered with an adjustable speed limiter. Yamaha recommends that all beginners start off with the speed limiter screw turned in to limit the amount of speed available while they learn. The speed limiter screw may be gradually turned out to increase maximum speed as the beginner becomes more fa- miliar with operating the ATV.
  • Page 7 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 8 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 9: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Choke ............4-10 Seat ............4-11 LOCATION OF THE WARNING AND PRE-OPERATION CHECKS ......5-1 SPECIFICATION LABELS ......2-1 Pre-operation check list ......5-1 Fuel ............5-3 DESCRIPTION ..........3-1 Engine oil ........... 5-3 Left view .............
  • Page 10 RIDING YOUR ATV ........7-1 Valve clearance ........8-18 Checking the front and rear brake GETTING TO KNOW YOUR ATV....7-2 shoes .............8-19 RIDE WITH CARE AND GOOD Adjusting the front brake lever free JUDGEMENT ...........7-2 play ............8-20 BE CAREFUL WHERE YOU RIDE.... 7-8 Adjusting the rear brake lever free play ...

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION SAFETY INFORMATION EBU17651 ate an ATV with engine size greater than 90 cc. Never allow a child under age 16 to operate an AN ATV IS NOT A TOY AND CAN BE HAZARD- ATV without adult supervision, and never allow OUS TO OPERATE.
  • Page 12 Never consume alcohol or drugs before or while speeds before attempting to turn at faster operating this ATV. speeds and never turn at excessive speeds. Never operate at speeds too fast for your skills Never operate the ATV on hills too steep for the or the riding conditions.
  • Page 13 nique described in this manual on level ground. leaving water. If necessary, apply them several Avoid crossing the side of a steep hill if possible. times to let friction dry out the linings. Always use proper procedures if you stall or roll Always use the size and type of tires specified in backwards when climbing a hill.
  • Page 14 rides in terrain that is too difficult, he or she struct your child. Go through this Owner’s Manual may lose control of the ATV, causing an acci- page by page with your child and be sure he or she dent. understands how to operate the ATV properly.
  • Page 15 ENGINE STOP SWITCH CORD times during ATV operation. This model has an engine stop switch cord (lan- NOTE: yard) designed for use by an adult supervising the The ATV will not start without the clip in place. Be child operating the ATV. When using the engine sure to remove the cord and store it in a safe place stop switch cord, be sure the speed limiter on the to prevent operation of the ATV when you are not...
  • Page 16 seek medical help immediately. If gasoline death within a short time. spills on your skin, wash with soap and wa- ter. If gasoline spills on your clothing, change your clothes. EWB00070 WARNING Always operate your ATV in an area with ade- quate ventilation.

  • Page 17: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 18 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 19 For Oceania For Europe For Europe WARNING UNDER < 6 YAMAHA MOTOR CO., LTD. SHIZUOKA JAPAN Operating this ATV if you are under the age of 6 increases your chance 4GB-2155A-00 of severe injury or death. Adult supervision required for children under age 16.
  • Page 20 For Oceania For Europe WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. 0.20 kgf/cm 0.20 kgf/cm OPERATING TIRE PRESSURE: Set with tires cold 2.9 psi 2.9 psi 9Recommended : FRONT : 20 kPa, { 0.20 kgf/cm } 2.9 psi REAR : 20 kPa, { 0.20 kgf/cm...
  • Page 21 For Oceania For Europe 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 22: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Spark arrester 1. Fuel cock 2. Seat 2. Fuse 3. Footboard 3. Engine stop switch with cord (lanyard) 4. Footboard 5. Drive select lever...

  • Page 23: 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 24: Instrument And Control Functions

    EBU17730 INSTRUMENT AND CONTROL FUNCTIONS EBU17740 EBU17780 Main switch Indicator light 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. All electrical systems are off. The key can be re- moved.

  • Page 25: Handlebar Switches

    EBU18060 EBU18090 Handlebar switches 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. EBU18260 Engine stop switch with lanyard The clip must be attached to the engine stop switch for the engine to run.
  • Page 26 1. Engine stop switch 1. Lanyard 2. Clip 3. Lanyard Should the ATV be separated from the parent by a distance longer than the lanyard length, the lan- The lanyard should be held by putting your fingers yard will pull out the clip and stop the engine. in the loop as shown.

  • Page 27: Throttle Lever

    EBU18280 Throttle lever Once the engine is running, movement of the throt- tle lever will increase the engine speed. Regulate the speed of the ATV by varying the throttle position. Because the throttle is spring- loaded, the ATV will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.

  • Page 28: Speed Limiter

    If the throttle does not work smoothly, check for the cause. Correct the problem be- fore riding the ATV or consult a Yamaha dealer. EBU18361 Speed limiter Your ATV was delivered with an adjustable speed limiter.

  • Page 29: Front Brake Lever

    mm (0.47 in) or the throttle cable could be dam- aged. 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. 1. Rear brake lever EBU18460 Parking brake Use the parking brake before starting the engine or...

  • Page 30: Drive Select Lever

    prematurely. EBU18630 Drive select lever The drive select lever is located on the left side of the engine. Use the drive select lever to shift the transmission into drive or neutral. 1. Parking brake lock plate EWB00220 WARNING Always set the parking brake before starting the engine.

  • Page 31: Fuel

    1. Fuel level 1. Fuel tank cap 2. Filler tube EBU18750 Fuel Recommended fuel: Make sure that there is sufficient fuel in the tank. UNLEADED GASOLINE ONLY Fill the fuel tank to the bottom of the filler tube as For Europe: Regular unleaded gasoline only shown.

  • Page 32: Fuel Cock

    of gasoline or higher octane grade. The fuel cock lever positions are explained as fol- lows and shown in the illustrations. ECB00070 CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.

  • Page 33: 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 34: 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 35 1. Projection 2. Seat holder 4-12...

  • Page 36: 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 37 ITEM ROUTINE PAGE Check wheel condition, and replace if damaged. Wheels and tires Check tire condition and tread depth. Replace if necessary. 5-4, 5-5, 5-6 Check air pressure. Correct if necessary. Make sure that operation is smooth. Lubricate lever pivoting points Brake levers 8-24 if necessary.

  • Page 38: Fuel

    EBU19590 Final gear oil ment procedures provided in this manual, have the ATV checked by a Yamaha dealer. Make sure that the final gear oil is at the specified level. Add oil as necessary. (See page 8-11.)

  • Page 39: Throttle Lever

    Throttle lever Manufacturer/model: Check the operation of the throttle lever. It must DUNLOP/KT145 open smoothly and spring back to the idle position Size: when released. Have a Yamaha dealer correct if AT16 x 8-7 necessary. Type: Tubeless EBU19791 The tires should be set to the recommended...

  • Page 40: Measuring The Tire Pressure

    Use no more than the following pressures when seating the tire beads. Maximum tire seating pressure: Front: 250 kPa (36 psi) (2.5 kgf/cm 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.

  • Page 41: Tire Wear Limit

    Recommended pressure: Front 20.0 kPa (2.9 psi) (0.200 kgf/cm Rear 20.0 kPa (2.9 psi) (0.200 kgf/cm Minimum: Front 17.0 kPa (2.5 psi) (0.170 kgf/cm Rear 17.0 kPa (2.5 psi) (0.170 kgf/cm 1. Tire wear limit Maximum: Front EBU19840 23.0 kPa (3.3 psi) (0.230 kgf/cm Chassis fasteners Rear Make sure that all nuts, bolts and screws are prop-...

  • Page 42: Operation

    If there is a control or func- indicator light should come on. If the indicator tion you do not understand, ask your Yamaha light does not come on, have a Yamaha deal- dealer. er check the electrical circuit.
  • Page 43 Position (1): Ambient temp./choke position Cold engine start with ambient temperature be- low 30 °C (90 °F). °C 0° 10° 20° 30° Position (2): °F 30° 50° 70° 90° Warming up position. Position (3): Cold engine start with ambient temperature above 25 °C (80 °F).

  • Page 44: Starting A Warm Engine

    crank the engine more than 10 seconds on each EBU27880 Shifting attempt. This ATV has an automatic, centrifugal clutch. 7. If the engine is started with the choke in posi- To shift into the drive position, release the throttle tion (1), the choke should be returned to posi- lever and apply the parking brake.
  • Page 45 EWB00740 WARNING Always open the throttle gradually. Opening the throttle abruptly would increase the chance of an accident. It could make the ATV wheelie or overturn. EBU20660 To decelerate When slowing down or stopping, release the throt- tle and apply the brakes smoothly and evenly. Im- proper use of the brakes can cause the tires to lose 1.

  • Page 46: Engine Break-In

    20 hours of riding. For engine break-in period, immediately have a this reason, you should read the following material Yamaha dealer check the ATV. carefully. Since the engine is brand new, do not put an ex- EBU26770 cessive load on it for the first 20 hours.

  • Page 47: 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 brakes in the drive position. 2. Stop the engine. 3. With the rear brake lever applied, apply the parking brake and slowly release the brake le- ver.

  • Page 48: Accessories And Loading

    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 49 of the ATV as possible. Put cargo at the rear of cargo or pulling a trailer. Allow greater dis- the front carrier, at the front of the rear carrier, tance for braking. and center it. Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around.

  • Page 50: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 51: Getting To Know Your Atv

    EBU21522 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV Beginners should get training from a certified in- This ATV is for recreation use. This section, Riding structor. your ATV, provides general ATV riding instructions Become familiar with this ATV at slow speeds first, for recreational riding.
  • Page 52 Not recommended for children under 6 years of age. EWB01400 WARNING EWB01750 WARNING Never carry a passenger. The long seat is to al- A child under 6 should never operate an ATV low the operator to shift position as needed with engine size greater than 50 cc.
  • Page 53 fits properly. proved motorcycle helmet, eye protection and You should also wear: protective clothing. Operating without an ap- eye protection (goggles or face shield) proved motorcycle helmet increases your gloves chances of a severe head injury or death in the boots event of an accident.
  • Page 54 EWB01420 Use of improper tires on this ATV, or operation WARNING of this ATV with improper or uneven tire pres- sure, may cause loss of control, increasing Never consume alcohol or drugs before or your risk of an accident. while driving this ATV. Do not operate at speeds too fast for your Pre-operation checks skills or the conditions.
  • Page 55 Yamaha recommends that all beginning riders start off with the speed limiter turned in to limit the MAXIMUM LOADING LIMIT amount of speed available while they learn. The ATV loading limit (total weight of cargo, rider, limiter may be gradually adjusted to increase max-...
  • Page 56 All parts and you or cause an accident. accessories added to this ATV should be gen- Avoid wheelies and jumping. You may lose control uine Yamaha or equivalent components de-...

  • Page 57: Be Careful Where You Ride

    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. If you have questions, consult an au- thorized ATV dealer.
  • Page 58 paved road or motorway. You can collide with 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.
  • Page 59 ing terrain conditions when operating the ATV. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution EWB01540 WARNING flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the...
  • Page 60 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 EWB01550 control of the throttle, brakes, and turning tech- WARNING niques in this area before trying more difficult ter- Always mount a caution flag on the ATV to rain.

  • Page 61: Turning Your Atv

    With the engine idling, shift the transmission into EWB01570 WARNING the drive position and then release the parking brake. Apply the throttle slowly and smoothly. The Always follow proper procedures for turning centrifugal clutch will engage and you will start to as described in this Owner’s Manual.

  • Page 62: Climbing Uphill

    curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside.
  • Page 63 er hills before attempting large hills. It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars.
  • Page 64 if possible. to continue up the hill, dismount the ATV on the up- When crossing the side of a hill: hill side. Physically turn the ATV around and then Always follow proper procedures as de- descend the hill. scribed in the Owner’s Manual. If you start to roll backwards, DO NOT apply the Avoid hills with excessively slippery or loose rear brake to stop or try to put the ATV in gear.

  • Page 65: Riding Downhill

    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 66: Crossing A Slope

    slopes, be sure not to make sharp turns either up or down hill. If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you wish to travel.

  • Page 67: Crossing Through Shallow Water

    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 68: Riding Over Rough Terrain

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

  • Page 69: Sliding And Skidding

    you go over obstacles, always follow proper If the rear wheels of your ATV start to slide side- procedures as described in the Owner’s Manu- ways, control can usually be regained (if there is room to do so) by steering in the direction of the slide.

  • Page 70: What To Do If

    EWB01661 If your ATV starts to slide sideways: WARNING Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not Learn to safely control skidding or sliding by recommended until you have corrected the practicing at low speeds and on level, smooth slide.
  • Page 71 ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See page 7-18.) 7-22...

  • Page 72: Periodic Maintenance And Minor Repair

    1. Owner’s manual can cause shocks or start fires. Turn off the en- 2. Low-pressure tire gauge gine when performing maintenance unless 3. Owner’s tool kit otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with...
  • Page 73 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 74: 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 75 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours Check operation and correct if necessary. √ √ √ √ √ Check brake lever free play and adjust if neces- Rear brake sary.
  • Page 76 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1200 2400 2400 4800 first (mi) (200) (750) (1500) (1500) (3000) hours Crankcase breather Check breather hose for cracks or other damage, √ √ √ 18 * system and replace if necessary. Change.
  • Page 77 EBU23060 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 78: 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 79: Engine 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 80 To check the engine 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 before checking.
  • Page 81 utes, and then turn it off. 3. Place an oil pan under the engine to collect Tightening torque: the used oil. Engine oil drain bolt: 4. Remove the engine oil filler cap, and then re- 20 Nm (2.0 m·kgf, 14.5 ft·lbf) move the engine oil drain bolt to drain the oil from the crankcase.

  • Page 82: 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 83: Cleaning The Air Filter Element

    To change the final gear oil 5. Add the specified amount of the recommend- 1. Place the ATV on a level surface. ed final gear oil, and then check the oil level. 2. Place an oil pan under the final gear case to Recommended final gear oil: collect the used oil.
  • Page 84 the hose and clean the air filter element and air fil- ter case. 1. Panel 2. Bolt 1. Air filter case check hose 1. Remove the panel shown by removing the bolts. 8-13...
  • Page 85 1. Air filter case cover 1. Air filter element holder 2. Air filter case holder 2. Sponge material 2. Remove the air filter case cover by unhooking 3. Unhook the holder holding the air filter ele- the holders. ment, and then pull out the sponge material from the air filter element.

  • Page 86: Cleaning The Spark Arrester

    plode. often if the ATV is operated in extremely dusty ar- eas. Each time the air filter element maintenance 5. Squeeze the excess solvent out of the sponge is performed, check the air inlet of the air filter case material and let it dry. for obstructions.
  • Page 87 1. Screw 1. Tailpipe 2. Spark arrester 3. Screw 2. Remove the tailpipe by pulling it out of the muffler. 4. Insert the tailpipe into the muffler and align the 3. Tap the tailpipe lightly, and then use a wire screw holes.

  • Page 88: Adjusting The Carburetor

    1. Start the engine and warm it up. requires very sophisticated adjustment. Therefore, NOTE: most carburetor adjustments should be left to a Yamaha dealer, who has the necessary profes- The engine is warm when it quickly responds to the sional knowledge and experience. The adjustment throttle.

  • Page 89: Checking The Throttle Cable Free Play

    To prevent this from occurring, the valve clearance EBU27071 must be adjusted by a Yamaha dealer at the inter- Checking the throttle cable free play vals specified in the periodic maintenance and lu- The throttle cable free play should be checked at brication chart.

  • Page 90: Checking The Front And Rear Brake Shoes

    If a brake shoe has worn to the point that the wear indicator reaches the wear limit line or mark, have a Yamaha dealer replace the 1. Wear limit line brake shoes as a set.

  • Page 91: 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 EBU24330 1. Loosen the upper locknut and fully turn in the Adjusting the front brake lever free upper adjusting bolt.
  • Page 92 1. Upper locknut 1. Cable joint 2. Upper adjusting bolt 3. Lower locknut 6. Tighten the upper locknut. 4. Lower adjusting bolt EWB02080 WARNING 4. Tighten the lower locknut. Operating with improperly serviced or adjust- 5. While applying the front brake, turn out the up- ed brakes could cause loss of braking ability, per adjusting bolt until the upper and lower ca- which could lead to an accident.

  • Page 93: Adjusting The Rear Brake Lever Free Play

    Yamaha dealer. EBU24451 Adjusting the rear brake lever free play The brake lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. NOTE: Before adjusting the brake lever free play, check the rear brake shoes for wear.

  • Page 94: Checking And Lubricating The Cables

    7. Tighten the locknut at the brake lever. essary. If a cable is damaged or does not move NOTE: smoothly, have a Yamaha dealer check or replace If the specified free play cannot be obtained as de- scribed above or if the rear brake does not operate...

  • Page 95: Checking And Lubricating The Front And Rear Brake Levers

    EWB02130 have a Yamaha dealer check the wheel bearings. WARNING EBU25070 Inspect cables frequently and replace if dam- Lubricating the knuckle shafts aged. Corrosion can result when the cable The knuckle shafts must be lubricated at the inter- sheaths become damaged, and cables can...

  • Page 96: Lubricating The Steering Shaft

    EBU25090 connections and breather hose routing should be Lubricating the steering shaft checked before each ride and at the intervals The steering shaft must be lubricated at the inter- specified in the periodic maintenance and lubrica- vals specified in the periodic maintenance and lu- tion chart.
  • Page 97 Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call a physician immediately. EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes or other sources of ig- nition away.
  • Page 98 To install the battery NOTE: Be sure the battery is fully charged. 1. Install the battery. 2. Connect the positive lead first, and then con- nect the negative lead. 3. Make sure that the breather hose is properly routed, in good condition, and not obstructed. 1.

  • Page 99: Replacing The Fuse

    The fuse holder is located under the seat. (See 4. If the fuse immediately blows again, have a page 4-11.) Yamaha dealer check the electrical system. If the fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off all electrical...

  • Page 100: Installing A Wheel

    Front Rear 1. Wheel nut 1. Wheel nut 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. EBU27480 Installing a wheel 1. Install the wheel and the nuts. NOTE: When installing the wheel, make sure its arrow mark...
  • Page 101 wheel. Rear Front 1. Arrow mark 1. Arrow mark 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified torques. Tightening torques: Front wheel nut: 28 Nm (2.8 m·kgf, 20 ft·lbf) Rear wheel nut: 28 Nm (2.8 m·kgf, 20 ft·lbf) 8-30...

  • Page 102: 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 103: 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 104: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25880 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 105: Storage

    linings. ing the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank. EBU25932 Storage 4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel from deteriorat- Short-term ing.
  • Page 106 the spark plug cap. 6. Lubricate all control cables and the pivoting points of all levers and pedals. 7. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that all of its wheels are off the ground. Alternative- ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.

  • Page 107: Specifications

    EBU25960 SPECIFICATIONS EBU25975 Compression ratio: Dimensions: 10.30 :1 Overall length: Starting system: 1537 mm (60.5 in) Electric starter Overall width: Lubrication system: 825 mm (32.5 in) Wet sump Overall height: Engine oil: 915 mm (36.0 in) Type: Seat height: SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 618 mm (24.3 in) or SAE20W40 or SAE20W50 Wheelbase:...
  • Page 108 Engine oil quantity: Clutch: Periodic oil change: Clutch type: 0.80 L (0.85 US qt) (0.70 Imp.qt) Wet, multiple-disc automatic Final gear oil: Transmission: Type: Primary reduction system: SAE80 API GL-4 Hypoid gear oil Spur gear Quantity: Primary reduction ratio: 0.12 L (0.13 US qt) (0.11 Imp.qt) 65/20 (3.250) Air filter: Secondary reduction system:...
  • Page 109 Manufacturer/model: Front wheel: DUNLOP/KT145 Wheel type: Rear tire: Panel wheel Type: Rim size: Tubeless 7x5.5AT Size: Rear wheel: AT16 x 8-7 Wheel type: Manufacturer/model: Panel wheel DUNLOP/KT145 Rim size: Loading: 7x6.5AT Maximum loading limit: Front brake: 40.0 kg (88 lb) Type: (Total weight of rider, cargo, accessories, and tongue) Drum brake...
  • Page 110 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 111: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 112 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 113 INDEX Engine stop switch ............4-2 Engine stop switch with lanyard ........4-2 Accessories and loading ..........6-7 Air filter element, cleaning..........8-12 Final gear oil............5-3 8-11 Fuel .................4-8 Battery..............5-6 8-25 Fuel cock................ 4-9 Brake lever free play, adjusting the front...... 8-20 Fuel tank cap..............
  • Page 114 Parking ................6-5 Wheel bearings, checking ..........8-24 Parking brake ..............4-6 Wheel, installing ............8-29 Parking on a slope ............6-6 Wheel, removing ............8-28 Part locations ..............3-1 Periodic maintenance and lubrication chart ....8-3 Pre-operation check list..........5-1 Riding your ATV .............
  • Page 116 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2006.05-0.1x1 !

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