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Yamaha YFM50RY Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
LIRE ATTENTIVEMENT CE MANUEL!
Il comprend d'importantes informations de sécurité.
¡LEA ESTE MANUAL ATENTAMENTE!
Contiene indicaciones importantes acerca de la seguridad.
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
This A
OWNER'S MANUAL
YFM50RY
5YF-28199-65

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Summary of Contents for Yamaha YFM50RY

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. LIRE ATTENTIVEMENT CE MANUEL! Il comprend d’importantes informations de sécurité. ¡LEA ESTE MANUAL ATENTAMENTE! Contiene indicaciones importantes acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM50RY This A 5YF-28199-65...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN 2008.05-0.2x2 ! (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM50RY This A 5YF-28199-65-E0...
  • Page 4 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. 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 YFM50 ( YFM50R )
  • Page 5 INTRODUCTION EBU17200 Congratulations on your purchase of the Yamaha YFM50RY. 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 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 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 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 Adjusting the engine idling speed .... 8-18 Checking the throttle cable free play ..8-19 GETTING TO KNOW YOUR ATV....7-2 Valve clearance ........8-19 RIDE WITH CARE AND GOOD JUDGEMENT ...........7-2 Checking the front and rear brake shoes .............8-20 BE CAREFUL WHERE YOU RIDE....

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION SAFETY INFORMATION – A child under 16 years old should never oper- EBU17652 ate an ATV with engine size greater than 90 cc. AN ATV IS NOT A TOY AND CAN BE HAZARD- Never allow a child under age 16 to operate an OUS TO OPERATE.
  • Page 12 jacket, and long pants. described in this manual. Practice turning at low 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 any hill until you have mastered the turning tech- reduced stopping ability. Test your brakes after 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.
  • Page 14 If the child rides beyond his or her abilities, or proper riding techniques before continuing to in- 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.
  • Page 15 walk behind the vehicle. er, you must still closely supervise your child at all times during ATV operation. ENGINE STOP SWITCH CORD This model has an engine stop switch cord (lan- The ATV will not start without the clip in place. Be yard) designed for use by an adult supervising the sure to remove the cord and store it in a safe place child operating the ATV.
  • Page 16 vapor, or get some gasoline in your eyes, death within a short time. seek medical help immediately. If gasoline 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...
  • 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 0.20 kgf/cm 0.20 kgf/cm death. OPERATING TIRE PRESSURE: Set with tires cold 2.9 psi 2.9 psi 9Recommended : Front : 20 kPa, 2.9 psi Rear : 20 kPa, 2.9 psi Set with tires cold.
  • Page 21 For Europe For Oceania WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE Before you operate this vehicle, GEAR read the owner’s manual.

  • Page 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 The ATV you have purchased may differ slightly...

  • Page 24: Instrument And Control Functions

    EBU17732 INSTRUMENT AND CONTROL FUNCTIONS EBU17740 EBU17781 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

    EBU18061 EBU18090 Handlebar switches Start switch “START” Push this switch to crank the engine with the start- ECB00050 NOTICE 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 EBU18752 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 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.

  • 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

    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 charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 37 ITEM ROUTINE PAGE Check operation, and correct if necessary. Rear brake Lubricate cable if necessary. 5-3, 8-20, 8-23 Check lever free play, and adjust if necessary. Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary. 5-4, 8-19 Check cable free play, and adjust 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 8-12.)

  • 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 EBU19792 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 (2.5 kgf/cm , 36 psi) Rear: 250 kPa (2.5 kgf/cm , 36 psi) Higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully.

  • Page 41: Tire Wear Limit

    EBU19830 EBU19860 Tire wear limit Battery Replace the tire when the tire groove decreases to Check the fluid level in the battery. Fill with distilled 3 mm (0.12 in). water if necessary. (See page 8-26.) 1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened.

  • 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 5. Use the choke in reference to the figure: Ambient temp./choke position Position (1): °C 0° 10° 20° 30° Cold engine start with ambient temperature be- low 30 °C (90 °F). °F 30° 50° 70° 90° Position (2): 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

    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 47: Parking On A Slope

    EBU20800 Parking on a slope EWB00880 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, shift the shift lever to the drive posi- tion, stop the engine, apply the parking brake,...

  • Page 48: 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 49 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 EWB00820 ATV loading limit (total weight of rider, cargo, WARNING...

  • Page 50: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 51: Getting To Know Your Atv

    EBU21523 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 This ATV is designed to carry operator only – of age. passengers prohibited. EWB01750 EWB01400 WARNING WARNING A child under 6 should never operate an ATV Never carry a passenger. The long seat is to al- with engine size greater than 50 cc.
  • Page 53 Apparel EWB01410 WARNING Always wear an approved motorcycle helmet that fits properly. Never operate this ATV without wearing an ap- You should also wear: proved motorcycle helmet, eye protection and eye protection (goggles or face shield) protective clothing. Operating without an ap- gloves proved motorcycle helmet increases your boots...
  • Page 54 in the Owner’s Manual. Failure to inspect the ATV before operating or failure to properly maintain the ATV increases the possibility of an accident or equipment damage. EWB01440 WARNING Always use the size and type tires specified in the Owner’s Manual for this ATV on page 5-4. Always maintain proper tire pressure as de- scribed in the Owner’s Manual on page 5-5.
  • Page 55 ATV. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (See page 4-5.) Yamaha recommends that all beginning riders start off with the speed limiter turned in to limit the 1. Adjusting screw amount of speed available while they learn.
  • Page 56 EWB01460 WARNING Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and se- curely attached. Reduce speed when carrying cargo or pull- ing a trailer. Allow greater distance for brak- ing. Always follow the instructions in your Own- er’s Manual for carrying cargo or pulling a trailer.
  • Page 57 Avoid wheelies and jumping. You may lose control uine Yamaha or equivalent components de- of the ATV or overturn. signed for use on this ATV and should be EWB01480 installed and used according to instructions. WARNING Improper installation of accessories or modifi-...

  • Page 58: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE This ATV is designed for use on unpaved surfaces only. Riding on paved surfaces can cause loss of control. EWB01510 While riding on unpaved public streets or roads WARNING may be legal in your area, such operation can in- Always avoid paved surfaces, including side- crease the risk of collision with other vehicles.
  • Page 59 paved road or motorway. You can collide with ing terrain conditions when operating the ATV. another vehicle. In many areas, it is illegal to operate ATVs on public streets, roads and highways. EWB01540 WARNING Do not operate on excessively rough, slippery Know the terrain where you ride.
  • Page 60 EWB01550 When riding in an area where you might not easily WARNING be seen, such as desert terrain, mount a caution Always mount a caution flag on the ATV to flag on the ATV. DO NOT use the flag pole bracket make you more visible when operating in areas as a trailer hitch.

  • Page 61: Turning Your Atv

    With the engine idling, shift the transmission into the drive position and then release the parking brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is applied too abruptly, the front wheels may lift off the ground, resulting in a loss of directional control.
  • Page 62 EWB01570 WARNING Always follow proper procedures for turning as described in this Owner’s Manual. Practice turning at low speeds before attempting to turn at faster speeds. 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

    curves. er hills before attempting large hills. Improper riding procedures such as abrupt throttle It is important when climbing a hill to make sure changes, excessive braking, incorrect body move- that your weight is transferred forward on the ATV. ments, or too much speed for the sharpness of the This can be accomplished by leaning forward and, turn may cause the ATV to tip.
  • Page 64 if possible. When crossing the side of a hill: Always follow proper procedures as de- scribed in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room...

  • Page 65: Riding Downhill

    to continue up the hill, dismount the ATV on the up- hill side. Physically turn the ATV around and then descend the hill. If you start to roll backwards, DO NOT apply the rear brake to stop or try to put the ATV in gear. The ATV could easily tip over backwards.

  • Page 66: Crossing A Slope

    hill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- stacles which may appear. EWB01620 WARNING Always follow proper procedures for going down hills as described in this Owner’s Manu- Note: a special technique is required when braking as you go down a hill.

  • Page 67: 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 68 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 69: Riding Over Rough Terrain

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

  • Page 70: What To Do If

    If the rear wheels of your ATV start to slide side- EWB01661 WARNING ways, control can usually be regained (if there is room to do so) by steering in the direction of the Learn to safely control skidding or sliding by slide.
  • Page 71 If your ATV starts to slide sideways: ter drain from the ATV and CHECK YOUR Steer in the direction of the slide if you have the BRAKES FOR PROPER OPERATION when room. Applying the brakes or accelerating is not you come out of the water. Do not continue to recommended until you have corrected the ride your ATV until you have regained adequate slide.

  • 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 If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING...

  • Page 74: 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 75 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 76: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check chain tension. √ √ √ √ Timing chain Adjust if necessary. Every 20–40 hours (more often in wet or Air filter element Clean and replace if necessary.
  • Page 77 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Shock absorber Check operation and correct if necessary. √ √ √ assemblies Check for oil leakage and replace if necessary. Front knuckle piv- √...
  • Page 78 EBU23060 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 79: 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 80: 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 81 To check the engine oil level screwing it in), and then remove it again to 1. Place the ATV on a level surface. check the oil level. 2. Check the engine oil level on a cold engine. If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading.
  • Page 82 To change the engine oil 1. Place the ATV on a level surface. Tightening torque: 2. Start the engine, warm it up for several min- Engine oil drain bolt: utes, and then turn it off. 20 Nm (2.0 m·kgf, 14.5 ft·lbf) 3.

  • Page 83: 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 84: Cleaning The Air Filter Element

    To change the final gear oil 5. Refill with the specified amount of the recom- 1. Place the ATV on a level surface. mended final gear oil, and then check the oil 2. Place an oil pan under the final gear case to level.
  • Page 85 case. If dust or water collects in this hose, empty the hose and clean the air filter element and air fil- ter case. 1. Panel 2. Bolt 1. Air filter case check hose 1. Place the ATV on a level surface. 2.
  • Page 86 1. Air filter case cover 1. Air filter element holder 2. Air filter case cover holder 2. Sponge material 3. Remove the air filter case cover by unhooking 4. Unhook the holder holding the air filter ele- the holders. ment, and then pull out the sponge material from the air filter element.
  • Page 87 plode. ping. 6. Squeeze the excess solvent out of the sponge 9. Install the sponge material into the air filter el- material and let it dry. ement. ECB00440 10. Place the air filter element in the original posi- NOTICE tion, and then hook the holder. Do not twist the sponge material when squeez- 11.

  • Page 88: Cleaning The Spark Arrester

    poor performance and possible engine over- of the tailpipe housing. heating. EBU27630 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be- fore cleaning the spark arrester. 1. Remove the screws. 1. Tailpipe 2. Spark arrester 3.

  • Page 89: Adjusting The Carburetor

    Therefore, most carburetor adjustments should be left to a The engine is warm when it quickly responds to the Yamaha dealer, who has the necessary profes- throttle. sional knowledge and experience. The adjustment described in the following section, however, may 2.

  • Page 90: 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 91: 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 92: Adjusting The Front Brake Lever Free Play

    Rear brake The brake lever free play should measure 10.0– 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 Adjusting the front brake lever free 1.
  • Page 93 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 94: 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. Before adjusting the brake lever free play, check the rear brake shoes for wear.

  • Page 95: Checking And Lubricating The Cables

    7. Tighten the locknut at the brake lever. essary. If a cable is damaged or does not move 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 96: Checking And Lubricating The Front And Rear Brake Levers

    If there is play 1. Grease nipple in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bear- 8-25...

  • Page 97: Lubricating The Steering Shaft

    EBU25102 maximum level mark. Lubricating the steering shaft The steering shaft must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart. Recommended lubricant: Lithium-soap-based grease EBU25121 Battery A poorly maintained battery will corrode and dis- charge quickly.
  • Page 98 when working near batteries. 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.

  • Page 99: Replacing The Fuse

    To install the battery that the frame is exposed to electrolyte or gas expelled from the battery, the frame could suf- fer structural and external damages. Be sure the battery is fully charged. 1. Install the battery. EBU25242 Replacing the fuse 2.

  • Page 100: Removing A Wheel

    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. EBU25651 Removing a wheel 1. Place the ATV on a level surface.

  • Page 101: Installing A Wheel

    Rear mark points toward the rotating direction of the wheel. Front 1. Wheel nut 3. Elevate the ATV and place a suitable stand 1. Arrow mark under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. EBU27481 Installing a wheel 1.

  • 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 EBU2597B Engine: Engine type: Air cooled 4-stroke, SOHC Dimensions: Cylinder arrangement: Overall length: Forward-inclined single cylinder 1537 mm (60.5 in) Displacement: Overall width: 49.0 cm 825 mm (32.5 in) Bore × stroke: Overall height: 39.0 × 41.4 mm (1.54 × 1.63 in) 915 mm (36.0 in) Compression ratio: Seat height:...
  • Page 108 Air filter: 50 ˚C Air filter element: Wet element Fuel: SAE 5W-30 Recommended fuel: SAE 10W-30 Regular unleaded gasoline only (EUR) Unleaded gasoline only (AUS)(NZL) SAE 10W-40 Fuel tank capacity: SAE 15W-40 6.8 L (1.80 US gal, 1.50 Imp.gal) Fuel reserve amount: SAE 20W-40 0.9 L (0.24 US gal, 0.20 Imp.gal) Carburetor:...
  • Page 109 Secondary reduction ratio: Loading: 19/18 × 34/10 (3.588) Maximum loading limit: Transmission type: 40.0 kg (88 lb) Constant mesh 1-speed (Total weight of rider, cargo, accessories, and tongue) Operation: Tire air pressure (measured on cold tires): Left hand operation Recommended: 1st: Front: 38/14 (2.714)
  • Page 110 Bulb voltage, wattage × × × × quantity: Rear brake: Type: Neutral indicator light: 12 V, 1.7 W × 1 Drum brake Operation: Fuses: Left hand operation Main fuse: Front suspension: 5.0 A Type: Leading arm Spring/shock absorber type: Coil spring/oil damper Wheel travel: 57 mm (2.3 in) Rear suspension:...

  • 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 1. Model label 11-3...
  • Page 114 INDEX Engine stop switch ............4-2 Engine stop switch with lanyard ........4-2 Accessories and loading ..........6-7 Air filter element, cleaning..........8-13 Final gear oil............5-3 8-12 Front knuckle pivots, lubricating........8-25 Battery..............5-6 8-26 Fuel ................ 4-8 Brake lever free play, adjusting the front...... 8-21 Fuel cock................
  • Page 115 Owner’s manual and tool kit..........8-1 Valve clearance ............8-19 Vehicle identification number ........11-1 Parking................6-5 Parking brake..............4-6 Wheel hub bearings, checking........8-25 Parking on a slope ............6-6 Wheel, installing............8-30 Part locations ..............3-1 Wheel, removing ............8-29 Pre-operation check list ..........5-1 Riding your ATV..............7-1 Safety information ............1-1 Seat................4-11...
  • Page 116 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2008.05-0.2x2 !

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