Yamaha YFM90RY Owner's Manual

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Page 1 It contains important safety information. LIRE ATTENTIVEMENT CE MANUEL! II comprend d’importantes informations de s écurité . LEA ESTE MANUAL ATENTAMENTE! Contiene indicaciones importantes acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM90RY This A 43D-F8199-60...
Page 2 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN TAIWAN IMPRIMÉ SUR PAPIER RECYCLÉ 2008.07 IMPRESO EN PAPEL RECICLADO (E,F,S)
Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM90RY 43D-F8199-60-E0...
Page 4: Ec Declaration Of Conformity
EC Declaration of Conformity conforming to Directive 98/37/EC We, YAMAHA MOTOR CO.,LTD. 2500 Shingai, Iwata, Japan,declare in sole responsibility, that the product YFM90RY (RK1AB07W080000001~) (Make, model) to which this declaration applies, conforms to the essential health...
Page 5 INTRODUCTION Congratulations on your purchase of the Yamaha YFM90RY. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
Page 6 ATV safely. Your ATV was delivered with an adjustable speed limiter . Yamaha recommends that all beginners start off to limit the amount of speed available while they learn. The adjusting screw may be gradually turned out as the beginner becomes more familiar with operating the ATV.
Page 7 IMPORTANT MANUAL INFORMATION 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 personal injury hazards.
Page 8 IMPORTANT NOTICE 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. Please check your local riding laws and regulations before operating this ATV.
Page 9: Table Of Contents
Fuel ............4-8 TABLE OF CONTENTS Fuel cock ..........4-10 Choke ............. 4-11 SAFETY INFORMATION......1-1 Seat ............4-11 Kick starter ..........4-12 LOCATION OF THE WARNING AND SPECIFICATION LABELS......2-1 PRE-OPERATION CHECKS......5-1 Pre-operation check list......5-1 DESCRIPTION ..........3-1 Fuel ............5-3 Left view.............3-1 Engine oil ..........
Page 10 Cleaning the spark arrester ...... 8-19 RIDING YOUR ATV ........7-1 Adjusting the carburetor ......8-20 GETTING TO KNOW YOUR ATV....7-2 Adjusting the engine idling speed .... 8-20 RIDE WITH CARE AND GOOD Checking the throttle cable free play ..8-21 JUDGEMENT..........
Page 11 SPECIFICATIONS ........10-1 CONSUMER INFORMATION ..... 11-1 Identification numbers ......11-1...
Page 12: Safety Information
SAFETY INFORMATION Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
Page 13 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. 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 14 Avoid crossing the side of a steep hill if possible. reduced stopping ability. Test your brakes after 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.
Page 15 fire and you could be burned. When transporting the ATV in another vehi- WARNING cle, be sure it is kept upright and that the fuel Always operate your ATV in an area with ade- cock is in the “OFF” position. Otherwise, fuel quate ventilation.
Page 16: Location Of The Warning And Specification Labels
Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer.
Page 17 For Europe...
Page 18 For Oceania For Oceania...
Page 19: Description
DESCRIPTION Left view Right view 1. Fuel cock 1. Spark arrester 2. Rear wheel 2. Seat 3. Footrest 3. Footrest 4. Front wheel...
Page 20: Controls And Instruments
Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Parking brake 3. Front brake lever 4. Throttle lever 5. Main switch 6. Fuel tank cap 7. Handlebar switches 8.
Page 21: Instrument And Control Functions
INSTRUMENT AND CONTROL FUNCTIONS 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. All electrical systems are off. The key can be re- moved.
Page 22: Handlebar Switches
Handlebar switches Start switch “START” Push this switch to crank the engine with the start- See the starting instructions on page 6-1 prior to starting the engine. 1. Engine stop switch “ENG. STOP” 2. Start switch “START” Engine stop switch “ENG. STOP” Set this switch to “RUN”...
Page 23: Throttle Lever
Correct the problem be- the throttle lever. fore riding the ATV or consult a Yamaha dealer. Speed limiters Your ATV was delivered with two speed limiter devices.
Page 24: Vehicle Speed Limiter
The vehicle speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. The adjusting screw may be gradually turned out as the beginner becomes more familiar with operating the ATV. Parents should decide when to adjust the ATV for more power as their youngster’s riding skills improve.
Page 25: Engine Speed Limiter Plate
WARNING 4. Tighten the screw. 5. Install the seat. Improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation. You could lose control, have an accident or be injured. Do not turn the adjusting screw out more than 5 mm (0.2 in).
Page 26: Front Brake Lever
Front brake lever Rear brake lever The rear brake lever is located on the left handle- The front brake lever is located on the right handle- bar. To apply the rear brake, pull the brake lever to- bar. To apply the front brake, pull the brake lever ward the handlebar grip.
Page 27: Parking Brake
Parking brake WARNING Use the parking brake before starting the engine or Always set the parking brake before starting parking the ATV, especially on a slope. Apply the the engine. The ATV could start moving un- front bake lever and push down the lock button to expectedly if the parking brake is not ap- apply the parking brake.
Page 28: Fuel Tank Cap
Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. 1. Fuel level 2. Filler tube Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 4.8 L (1.27 US gal) (1.06 Imp.gal) 1. Fuel tank cap Fuel reserve amount: 1.0 L (0.26 US gal) (0.22 Imp.gal) Fuel Make sure that there is sufficient fuel in the tank.
Page 29 NOTICE 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. WARNING Do not overfill the fuel tank. Fuel expands when it heats up.
Page 30: Fuel Cock
With the fuel cock lever in this position, fuel flows Fuel cock to the carburetor. Turn the fuel cock lever to this The fuel cock supplies fuel from the tank to the car- position when starting the engine and riding. buretor while also filtering it.
Page 31: Choke
Choke Seat The choke is used to start a cold engine. To remove the seat Move the choke in direction (a) to turn on the Pull the seat lock lever upward and pull up the seat choke. at the rear. Move the choke in direction (b) to turn off the choke.
Page 32: Kickstarter
To install the seat 2. Move the kickstarter lever down lightly with your Insert the projection on the front of the seat into the foot until the gears engage, and then push it seat holder and push down on the seat at the rear. down smoothly but forcefully.
Page 33: Pre-Operation Checks
Manual. Failure to inspect increases the possibility of an accident or equipment damage. The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the "Periodic maintenance and lubrication charts" on page 8-3 to determine which service should be performed by a...
Page 34 Front brake Lubricate cable if necessary. 5-3, 8-22, 8-23 Check lever free play, and adjust if necessary. Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear, and replace if necessary. Rear brake...
Page 35: Fuel
Wipe up any spilled ing when the brakes are applied. If not, have the fuel immediately. ATV checked by a Yamaha dealer. Do not refuel right after the engine has been Brake fluid level running and is still very hot.
Page 36: Throttle Lever
Do not ride the ATV if you find any prob- The tires listed below have been approved lem with the brakes or you could lose braking by Yamaha Motor Co., Ltd. for this model. ability, which could lead to an accident. If a Other tire combinations are not recommend-...
Page 37: Measuring The Tire Pressure
Size: Maximum tire seating pressure: AT18 x 9-8 Front: Type: 250 kPa (36 psi) (2.5 kgf/cm Tubeless Rear: The tires should be set to the recommend- 250 kPa (36 psi) (2.5 kgf/cm ed pressure: Higher pressures and fast inflation may Recommended tire pressure: cause a tire to burst.
Page 38: Tire Wear Limit
Recommended pressure: Front 25 kPa (3.6 psi) (0.25 kgf/cm Rear 25 kPa (3.6 psi) (0.25 kgf/cm Minimum: Front 22 kPa (3.2 psi) (0.22 kgf/cm Rear 22 kPa (3.2 psi) (0.22 kgf/cm 1. Low-pressure tire gauge Set the tire pressure when the tires are cold. Set Tire wear limit the tire pressures to the following specifications: Replace the tire when the tire groove decreases to...
Page 39: Chassis Fasteners
1. Tire wear limit Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. Instruments and switches Check that all instruments and switches are working properly. Correct if necessary.
Page 40: Operation
3. Turn the main switch to “ON” and the engine vent any loss of control, which could cause an stop switch to “RUN”. accident or injury. If there is a control or func- tion you do not understand, ask your Yamaha dealer. Starting a cold engine WARNING...
Page 41 Ambient temp./choke position This model is equipped with an ignition circuit cut- off system. The engine can be started only when 0° 10° 20° 30° °C the rear brake lever is applied. 90° °F 30° 50° 70° 4. Use the choke in reference to the figure: Position (1): Cold engine start with ambient temperature be- low 30 °C (90 °F).
Page 42: Starting A Warm Engine
crank the engine more than 10 seconds on each To start out and accelerate attempt. 1. Squeeze the front brake lever to release the 6. If the engine is started with the choke in posi- parking brake. tion (1), the choke should be returned to posi- 2.
Page 43: Engine Break-In
Since the engine is brand new, do not put an ex- Yamaha dealer check the ATV. cessive load on it for the first 320 km (200 mi) or 20 hours. The various parts in the engine wear and...
Page 44: Parking On A Slope
Parking on a slope WARNING Avoid parking on hills or other inclines. Park- ing on a hill or other incline could cause the ATV to roll out of control, increasing the chance of an accident. If you must park on an incline, place the ATV transversely across the incline, stop the engine, apply the parking 1.
Page 45: Accessories And Loading
Yamaha accessories. Other accessories judgment as the stability and handling of an ATV may also be available on the market. However, can be changed. When adding accessories, keep it is not possible for Yamaha to test all non-...
Page 46 the following points in mind: speeds. Never exceed the weight limits shown. An over- Avoid hills and rough terrain. Choose terrain loaded ATV can be unstable. carefully. Added weight affects the stability and handling of the ATV. MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, cargo, accessories, and tongue): WARNING...
Page 47: Riding Your Atv
RIDING YOUR ATV...
Page 48: Getting To Know Your Atv
RIDE WITH CARE AND GOOD JUDGEMENT GETTING TO KNOW YOUR ATV Get training if you are inexperienced. This ATV is for recreation use. This section, Riding Beginners should get training from a certified in- your ATV, provides general ATV riding instructions structor.
Page 49 Not recommended for children under 12 years WARNING of age. Never operate this ATV without proper instruc- tion. Beginning and inexperienced operators should regularly practice the skills and the op- WARNING erating techniques described in this Owner’s A child under 12 should never operate an ATV Manual.
Page 50 This ATV is designed to carry operator only – passengers prohibited. WARNING Never carry a passenger. The long seat is to al- low the operator to shift position as needed during operation. It is not for carrying passen- gers. Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV.
Page 51 Apparel Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants WARNING Never operate this ATV without wearing an ap- proved motorcycle helmet, eye protection and 1.
Page 52 Do not operate after consuming alcohol or Pre-operation checks drugs. Always perform the pre-operation checks listed on The operator’s performance capability is reduced page 5-1 before riding for proper care of the ATV by the influence of alcohol or drugs. and to ensure safety.
Page 53 This model also has an engine speed limiter plate to limit the amount of engine power available. Yamaha recommends that all beginning riders start Do not operate at speeds too fast for your off with the vehicle speed limiter turned in and the skills or the conditions.
Page 54 result in a significant increase in power, turn the vehicle Loading and accessories speed limiter adjusting screw back in again; adjust it Use extra caution when riding the ATV with addi- out in stages as you did before. For engine speed tional loads, such as accessories or cargo.
Page 55 During operation WARNING Always keep your feet on the footboards during op- eration, otherwise they may contact the rear Always keep both hands on the handlebars wheels. and both feet on the footboards of your ATV during operation. Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.
Page 56 Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be gen- uine Yamaha or equivalent components de- signed for use on this ATV and should be installed and used according to instructions.
Page 57: Be Careful Where You Ride
WARNING Do not touch the hot exhaust system. Do not park the ATV during or after operation in a place where others might be likely to touch it. Do not operate, idle, or park the ATV in dry grass, dry ground cover, or combustible ma- terials.
Page 58 WARNING Never operate this ATV on any paved street, 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- crease the risk of collision with other vehicles.
Page 59 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. WARNING Go slowly and be extra careful when operating on a paved paved road or motorway.
Page 60 When riding in an area where you might not easily WARNING be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket Always mount a caution flag on the ATV to as a trailer hitch.
Page 61: Turning Your Atv
Do not ride in areas posted “no trespassing”. member that the engine and exhaust pipe will be Do not ride on private property without getting per- hot when riding and afterwards; do not allow skin mission. or clothing to come in contact with these compo- nents.
Page 62 low speed. WARNING Always follow proper procedures for turning as described in this Owner’s Manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions. As you approach a curve, slow down and begin to turn the handlebars in the desired direction.
Page 63: Climbing Uphill
level surfaces or small hills. Practice on small- curves. er hills before attempting large hills. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the It is important when climbing a hill to make sure turn may cause the ATV to tip.
Page 64 If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill.
Page 65 WARNING 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. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.
Page 66: Riding Downhill
WARNING Maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Lock the parking brake after you are stopped. If you begin rolling backwards: Keep weight uphill. Never apply the rear brake while rolling backwards.
Page 67: Crossing A Slope
hill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- stacles which may appear. 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 68: Crossing Through Shallow Water
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 69 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. WARNING Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual.
Page 70: Riding Over Rough Terrain
1. Air ﬁlter case check hose RIDING OVER ROUGH TERRAIN NOTICE 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 71: Sliding And Skidding
WARNING Before operating in a new area, check for ob- stacles. Never attempt to ride over large obsta- cles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manu- SLIDING AND SKIDDING Care should be used when riding on loose or slip- pery surfaces since the ATV may slide.
Page 72: What To Do If
terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of control. WHAT TO DO IF... This section is designed to be a reference guide only.
Page 73 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 7-15.) water, watching for obstacles.
Page 74: Periodic Maintenance And Minor Repair
PERIODIC MAINTENANCE AND MINOR REPAIR otherwise specified. Have a Yamaha dealer Safety is an obligation of the owner. Periodic in- perform the service if you are not familiar with spection, adjustment and lubrication will keep your maintenance work. ATV in the safest and best operating condition possible.
Page 75 If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. WARNING Never modify this ATV through improper in- stallation or use of accessories, as it may cause changes in handling, which in some sit- uations could lead to an accident.
Page 76: 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 77 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 78: General Maintenance And Lubrication Chart
General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 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 79 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 ﬁrst (mi) (200) (800) (1600) (1600) (3200) hours Check for looseness or damage, and replace if √ √ √ √ Wheel hub bearings necessary. Make sure that all nuts, bolts, and screws are √...
Page 80 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Drive select lever • Check operation and adjust or replace if neces- √ √ √ safety system cable sary.
Page 81 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
Page 82: Checking The Spark Plug
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- tion chart.
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...
Page 84: Engine Oil
2. Clean the surface of the spark plug gasket To check the engine oil level and its mating surface, and then wipe off any 1. Place the ATV on a level surface. grime from the spark plug threads. 2. Check the engine oil level on a cold engine. 3.
Page 85 4. Insert the dipstick into the filler hole (without To change the engine oil screwing it in), and then remove it again to 1. Place the ATV on a level surface. check the oil level. 2. Start the engine, warm it up for several min- utes, and then turn it off.
Page 86 minutes while checking it for oil leakage. If oil Tightening torque: is leaking, immediately turn the engine off and Engine oil drain bolt: check for the cause. 8 Nm (0.8m·kgf, 5.8 ft·lbf) 9. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if 7.
Page 87: Final Transmission Oil
The final transmission case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the final transmission oil must be changed at the intervals specified in the periodic maintenance and lubrication chart.
Page 88: Cleaning The Air Filter Element
Tightening torque: Cleaning the air filter element Final transmission oil drain bolt: The air filter element should be cleaned at the in- 15 Nm (1.5 m·kgf, 10.8 ft·lbf) tervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more 5.
Page 89 1. Air filter case check hose (right) 1. Air filter case cover (right) 2. Bolts 1. Remove the air filter case cover by remov- ing the bolts. 1. Air filter case cover (left) 2. Bolts 8-16...
Page 90 2. Remove the air filter element by removing the rial because the engine could catch fire or ex- screw, and then pull off the sponge material plode. from the air filter element holder. 4. Squeeze the excess solvent out of the sponge material and let it dry.
Page 91 This will allow unfiltered air 6. Apply Yamaha foam air filter oil or other qual- to enter the engine, causing rapid engine ity foam air filter oil to the sponge material. wear and possible engine damage. Addition- ally, operation without the air filter element...
Page 92: Cleaning The Spark Arrester
Cleaning the spark arrester 2. Remove the spark arrester by pulling it out of the muffler. Be sure the exhaust pipe and muffler are cool be- 3. Tap the spark arrester lightly, and then use fore cleaning the spark arrester. a wire brush to remove any carbon deposits.
Page 93: Adjusting The Carburetor
Always let the exhaust system cool prior to most carburetor adjustments should be left to a touching exhaust components. Yamaha dealer, who has the necessary profes- sional knowledge and experience. The adjustment described in the following section, however, may be performed by the owner as part of routine main- tenance.
Page 94: Checking The Throttle Cable Free Play
(a), and to decrease it, turn the screw in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. Checking the throttle cable free play...
Page 95: Timing Chain
To essary, have a Yamaha dealer adjust it. prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart.
Page 96: Adjusting The Front Brake Lever Free Play
12mm (0.47in), the brake shoes should be replaced The brake lever free play should measure 4.0– 6.0 mm (0.16–0.24 in) as shown. If the free play as a set by Yamaha dealer. is incorrect, adjust it as follows. 1. Upper adjusting bolt 2.
Page 97 1. Cable joint 1. Upper locknut 2. Upper adjusting bolt 3. Lower locknut 6. Tighten the upper locknut. 4. Lower adjusting bolt WARNING 4. Tighten the lower locknut. 5. While applying the front brake, turn out the up- Operating with improperly serviced or adjust- per adjusting bolt until the upper and lower ca- ed brakes could cause loss of braking ability, ble lengths are equal.
Page 98: Checking The Rear Brake Pads
A low brake fluid level may indicate worn brake pads have a Yamaha dealer replace the brake pads as a and/or brake system leakage. If the brake fluid level set.
Page 99: Changing The Rear Brake Fluid
The brake lever free play should measure 0 – 1.5 mm (0 – 0.06 in) as shown. If the free play is incorrect, have a Yamaha dealer check the brake system. 1. Minimum level mark...
Page 100: Checking And Lubricating The Cables
The operation of the front and rear brake levers essary. If a cable is damaged or does not move should be checked before each ride, and the lever smoothly, have a Yamaha dealer check or replace pivots should be lubricated if necessary. 8-27...
Page 101: Checking The Wheel Hub Bearings
INTERNAL: Drink large quantities of water or in a wheel hub or if a wheel does not turn smoothly, milk. Follow with milk of magnesia, beaten egg have a Yamaha dealer check the wheel hub bearings. or vegetable oil. Call a physician immediately. 8-28...
Page 102 To install the battery To charge the battery Be sure the battery is fully charged. Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in 1. Place the battery in its compartment.
Page 103: Replacing The Fuse
If you fuse. do not have access to a constant-voltage 2. Remove the blown fuse, and then install a battery charger, have a Yamaha dealer charge new fuse of the specified amperage. your battery. Specified fuse:...
Page 104 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 8-31...
Page 105: Removing A Wheel
Removing a wheel 2. Elevate the ATV and place a suitable stand under the frame. 1. Loosen the wheel nuts. 3. Remove the nuts from the wheel. 4. Remove the wheel. 1. Wheel nuts 8-32...
Page 106: Installing A Wheel
Installing a wheel 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified 1. Install the wheel and the nuts. torques. Tightening torques: When installing the wheel, make sure its arrow Front wheel nut: mark points toward the rotating direction of the 45 Nm (4.5 m·kgf, 33 ft·lbf) wheel.
Page 107: 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 108: 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 109: Cleaning And Storage
CLEANING AND STORAGE 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 110: Storage
Long-term WARNING Before storing your ATV for several months: Wet brakes may have reduced stopping ability, 1. Follow all the instructions in the “Cleaning” section of this chapter. increasing the chance of an accident. Test the 2. Turn the fuel cock lever to “OFF”. brakes after washing.
Page 111 plug, and then place the spark plug on the cylinder head so that the electrodes are Make any necessary repairs before storing the grounded. (This will limit sparking during ATV. the next step.) d. Turn the engine over several times with the starter.
Page 112: Specifications
SPECIFICATIONS Compression ratio: Dimensions: 10.2 : 1 Overall length: Starting system: 1490 mm (58.7 in) Electric starter & kickstarter Overall width: Lubrication system: 885 mm (34.8 in) Wet sump Overall height: 910 mm (35.8 in) Seat height: Engine oil: 654 mm (25.7 in) Type: Wheelbase: SAE10W-40 or SAE20W-50...
Page 113 Transmission: Engine oil quantity: Periodic oil change: Primary reduction system: 0.8 L (0.84 US qt) (0.70 Imp.qt) V-belt Final transmission oil: Primary reduction ratio: 2.47-0.61:1 Type: Secondary reduction system: SAE80 API GL-4 Hypoid gear oil Spur Quantity: Secondary reduction ratio: 0.30 L (0.32 US qt) (0.27 Imp.qt) 41/15 ×...
Page 114 Rear tire: Rear wheel: Type: Wheel type: Tubeless Panel wheel Size: Rim size: AT18 x 9-8 8 x 7AT Front brake: Manufacturer/model: MAXXIS/M940 Type: Loading: Drum brake Maximum loading limit: Operation: 70.0 kg (154 lb) Right hand operation Rear brake: (Total weight of rider, cargo, accessories, and tongue) Tire air pressure (measured on cold tires): Type:...
Page 115 Rear suspension: Type: Swingarm Spring/shock absorber type: Coil spring/oil damper Wheel travel: 83 mm (3.3 in) Electrical system: Ignition system: Charging system: AC magneto Battery: Model: GTX5L-BS Voltage, capacity: 12 V,4 .0 Ah Fuses: Main fuse: 10 A Noise and vibration level: Noise level (77/311/EEC): 77.4 dB(A) (EUR) Vibration on seat (EN1032, ISO5008):...
Page 116: Consumer Information
Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
Page 117 ATV. 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 118 INDEX Engine oil............5-3, 8-11 Accessories and loading ..........6-6 Engine, starting a warm..........6-3 Air filter element, cleaning..........8-15 Engine stop switch............4-2 Engine speed limiter plate..........4-5 Battery................8-28 Brake lever, front.............4-6 Final transmission oil ........... 5-3, 8-14 Brake lever, rear............4-6 Brake lever free play, checking the rear......8-26 Fuel................4-8, 5-3 Brake lever free play, adjusting the front......8-23 Fuel cock..............4-10...
Page 119 Valve clearance............8-22 Owner’s manual and tool kit........... 8-1 Vehicle identification number ........11-1 Vehicle speed limiter ............4-4 Parking ................6-4 Parking brake ..............4-7 Parking on a slope ............6-5 Wheel hub bearings, checking ........8-28 Part locations ..............3-1 Wheel, installing ............
Page 120 YAMAHA MOTOR CO., LTD. PRINTED IN TAIWAN PRINTED ON RECYCLED PAPER 2008.07...

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