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Yamaha YFZ05YYXH 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
OWNER'S MANUAL
YFZ05YYXH
BW4-F8199-60

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Summary of Contents for Yamaha YFZ05YYXH

  • 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 YFZ05YYXH BW4-F8199-60...
  • Page 2 Original instructions Notice originale Manual original PRINTED IN TAIWAN 2016.04...
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFZ05YYXH WARNING This ATV should not be ridden by anyone under 6 years of age. BW4-F8199-60-E0...

  • Page 4: Ec Declaration Of Conformity

    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 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product RF3 AA04W 0G0 000201 YFZ50 (YFZ05YYX) (RF3AA04W0G0000201–)
  • 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 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. Parents should decide when to adjust the ATV for more power as their youngster’s riding skills improve.
  • Page 7 EBU17331 IMPORTANT MANUAL INFORMATION EBU17343 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 Please check your local riding laws and regulations before operating this ATV. EBU33790 YFZ05YYXH OWNER’S MANUAL ©2016 by Yamaha Motor Co., Ltd. 1st edition, March 2016 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 9: Table Of Contents

    EBU17421 TABLE OF CONTENTS LOCATION OF THE WARNING AND Starter (choke) ......... 4-11 SPECIFICATION LABELS ......1-1 Seat ............4-12 Adjusting the rear shock absorber SAFETY INFORMATION ........ 2-1 assembly ..........4-13 DESCRIPTION..........3-1 PRE-OPERATION CHECKS ......5-1 Left view............3-1 Fuel .............
  • Page 10 RIDING YOUR ATV ........7-1 Cleaning the air filter element ....8-16 GETTING TO KNOW YOUR ATV ....7-2 Cleaning the spark arrester ...... 8-19 RIDE WITH CARE AND GOOD Adjusting the carburetor ......8-20 JUDGMENT ..........7-2 Adjusting the engine idling speed .... 8-20 BE CAREFUL WHERE YOU RIDE....7-9 Adjusting the throttle lever free play..
  • Page 11 CLEANING AND STORAGE ......9-1 Cleaning ............9-1 Storage............9-2 SPECIFICATIONS ........10-1 CONSUMER INFORMATION ....... 11-1 Identification numbers ......11-1 INDEX............12-1...

  • Page 12: 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 re- placement label from your Yamaha dealer.
  • Page 13 For Europe...
  • Page 14 BW4-F816L-50 BD3-F816R-20...
  • Page 15 BD3-F816P-50 13.8 kPa 13.8 kPa 0.14 kgf/cm² 0.14 kgf/cm² 2.0 psi 2.0 psi BW4-F816M-M0 YFZ50 2016 2.0 kW 100 kg YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN BW4-F156A-10 BD3-F817L-20...
  • Page 16 Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. For ATV Type 1 category Y12, use from 12 years old. Operation of this ATV by children under the age of 12 increases the risk of severe injury or death.
  • Page 17 NEVER use with drugs or alcohol. Measure the tire pressure when the tires are cold. NEVER store fuel or flammable liquids. Adjust the tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or death.
  • Page 18 Loss of control can result in severe injury or 1 Year of construction **** death. YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN This pictogram shows trailer Hitch Tow weight limit. (Combined weight of the trailer and all cargo in the trailer.) Overloading can cause loss of control.
  • Page 19 For Mexico...
  • Page 20 BW4-F816L-50 BD3-F816R-20...
  • Page 21 BD3-F816P-50 13.8 kPa 13.8 kPa 0.14 kgf/cm² 0.14 kgf/cm² 2.0 psi 2.0 psi BW4-F816M-M0 1-10...
  • Page 22 For Oceania 1-11...
  • Page 23 WARNING WARNING Improper ATV use can result in SEVERE INJURY or DEATH. UNDER ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR Operation of this ATV by children NEVER operate : under the age of 6 increases the without proper training or instruction.
  • Page 24 WARNING NEVER ride as a passenger. Passengers can cause 13.8 13.8 a loss of control, 12.4 resulting in SEVERE 12.4 INJURY or DEATH. BD3-F151H-00 BW4-F816M-60 1-13...

  • Page 25: Safety Information

    EBU17432 SAFETY INFORMATION SAFETY INFORMATION EBU36351 – A child under 12 years old should never oper- ate an ATV with engine size greater than 70 cc. AN ATV IS NOT A TOY AND CAN BE HAZARD- – A child under 16 years old should never oper- OUS TO OPERATE.
  • Page 26  Never consume alcohol or drugs before or while  Always follow proper procedures for turning as operating this ATV. described in this manual. Practice turning at low  Never operate at speeds too fast for your skills speeds before attempting to turn at faster or the riding conditions.
  • Page 27  Never operate an ATV in fast flowing water or in surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around water deeper than that recommended in this on any hill until you have mastered the turning manual.
  • Page 28 In the event of an accident tention. If necessary, contact your riding party 1. If serious injuries are incurred, you may be or local authorities to let them know where safer staying next to your vehicle; it may you are and what has happened. shield you from oncoming riders.
  • Page 29 This im- While you may find aftermarket products similar in proper position limits the freedom of movement design and quality to genuine Yamaha accesso- of the operator and may limit control ability, ries, recognize that some aftermarket accessories...
  • Page 30 TEACHING YOUR CHILD TO OPERATE THE Be sure your child is ready to learn how to ride As a parent, your first step is to decide when your child has the strength, skills, and judgment to EWB00081 WARNING learn how to operate an ATV safely. Re-evaluate Never let your child ride an ATV without close your child’s readiness before every use;...
  • Page 31 Choose an appropriate riding area 1. Install the cap on the end of the engine stop Select an area appropriate for your child to learn switch cord onto the engine shut-off switch to ride. (See page 7-9.) Follow the instructions in (white button).
  • Page 32  Do not run engine outdoors where engine EWB00073 WARNING exhaust can be drawn into a building through openings such as windows and doors. Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, EWB02592 a deadly gas. Breathing carbon monoxide can WARNING cause headaches, dizziness, drowsiness, nau- When transporting the ATV in another vehicle,...

  • Page 33: Description

    EBU17681 DESCRIPTION EBU17691 EBU17701 Left view Right view 1. Fuel tank cap 1. Spark arrester 2. Fuel cock 2. Owner’s tool kit 3. Air filter 3. Fuse 4. Engine stop switch with cord (lanyard) 4. Battery 5. Rear shock absorber assembly spring preload adjusting 5.

  • Page 34: Controls And Instruments

    EBU17714 Controls and instruments 1. Rear brake lever 2. Handlebar switches 3. Parking brake lock plate 4. Front brake lever 5. Throttle lever 6. Main switch 7. Starter (choke) The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 35: Instrument And Control Functions

    EBU17738 INSTRUMENT AND CONTROL FUNCTIONS EBU33850 EBU18066 Main switch Handlebar switches 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 36: Engine Stop Switch With Lanyard

    EBU18102 Start switch “ ” Push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine. EBU36341 Engine stop switch with lanyard The cap must be attached to the engine stop switch for the engine to run.

  • Page 37: Throttle Lever

    Speed limiter Your ATV was delivered with two speed limiter de- vices. A vehicle speed limiter adjusting screw and a removable engine speed limiter plate. Yamaha recommends that all beginning riders start off with the vehicle speed limiter adjusting screw fully...
  • Page 38 The vehicle speed limiter keeps the throttle from free play is adjusted to 2.0–3.2 mm (0.08– fully opening, even when the throttle lever is 0.13 in). (See page 8-21.) WARNING! Im- pushed to the maximum. The adjusting screw may proper adjustment of the speed limiter and be gradually turned out as the beginner becomes throttle could cause throttle cable damage more familiar with operating the ATV.

  • Page 39: Front Brake Lever

    Engine speed limiter plate When the engine speed limiter plate is installed, Store the engine speed limiter plate with the own- engine speed is limited to 5200 r/min. When this er’s manual so that it is readily available whenever plate is removed, top engine speed (7400 r/min) is you want to reduce top engine speed.

  • Page 40: Rear Brake Lever

    EBU18402 Rear brake lever The rear brake lever is located on the left handle- bar. To apply the rear brake, pull the brake lever toward the handlebar grip. 1. Parking brake lock plate EWB00221 WARNING  Always set the parking brake before starting the engine.

  • Page 41: Kickstarter

    braking performance which could cause an accident. You could also wear out the brakes prematurely. EBU33892 Kickstarter Use the kickstarter to start the engine when the battery voltage is low. The kickstarter lever is lo- cated under the seat. (See page 4-12.) 1.

  • Page 42: Fuel Tank Cap

    1. Kickstarter lever 1. Fuel tank cap 4. When the engine has started, remove the EBU18757 Fuel kickstarter lever and store it under the seat. 5. Install the kickstarter lever cap. Make sure there is sufficient gasoline in the tank. ECB02300 EWB02522 NOTICE...
  • Page 43 of sparks, open flames, or other sources of Recommended fuel: ignition such as the pilot lights of water heat- Regular unleaded gasoline only ers and clothes dryers. For Europe: Regular unleaded gasoline only 2. Do not overfill the fuel tank. When refueling, with a research octane number of 95 or be sure to insert the pump nozzle into the fuel higher...

  • Page 44: Fuel Cock

    Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane 1. Arrow mark positioned over “OFF”...

  • Page 45: Starter (Choke)

    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 46: Seat

    Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Seat 2. Seat lock lever To install the seat Insert the projections on the front of the seat into 1.

  • Page 47: Adjusting The Rear Shock Absorber Assembly

    2. Position indicator er’s weight and the riding conditions. ECB01091 NOTICE A special wrench can be obtained at a Yamaha Never turn the adjusting mechanism beyond dealer to make this adjustment. the minimum and maximum settings. Adjust the spring preload as follows.
  • Page 48 1. Special wrench Spring preload setting: Minimum (soft): Standard: Maximum (hard): 4-14...

  • Page 49: Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 50 ITEM ROUTINE PAGE • Make sure that operation is smooth. Lubricate cable and lever Throttle lever housing if necessary. 5-3, 8-21 • Check lever free play, and adjust if necessary. Control cables • Make sure that operation is smooth. Lubricate if necessary. 8-29 •...

  • Page 51: Fuel

    Check the operation of the throttle lever. It must open smoothly and spring back to the idle position EBU34490 when released. Have a Yamaha dealer correct if Transmission oil necessary. Make sure that the transmission oil is at the spec- ified level.
  • Page 52 Tire pressure Recommended tire pressure: Use the low-pressure tire gauge to check and ad- Front just tire pressures when the tires are cold. Tire 13.8 kPa (0.14 kgf/cm², 2.0 psi) pressures must be equal on both sides. Rear WARNING! Operation of this vehicle with im- 13.8 kPa (0.14 kgf/cm², 2.0 psi) proper tire pressure may cause severe injury or Minimum tire pressure:...
  • Page 53 EWB02552 WARNING Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.

  • Page 54: Chassis Fasteners

    EBU33810 Front: Instruments and switches Manufacturer/model: Check that all instruments and switches are work- DURO/DI2040 ing properly. Correct if necessary. Size: AT16 x 6.5-7 Type: Tubeless Rear: Manufacturer/model: DURO/DI2041 Size: AT16 x 7-7 Type: Tubeless Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort.

  • Page 55: Operation

    Read the Owner’s Manual carefully before riding 4. Use the starter (choke) in reference to the fi- the ATV. If there is a control or function you do not gure: understand, ask your Yamaha dealer. Position (1): EWB00632 Cold engine start with ambient temperature WARNING below 5 °C (40 °F).
  • Page 56  If the engine fails to start using the start switch, Ambient temp./starter (choke) position try using the kickstarter. (See page 4-7.) 6. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the en- gine.

  • Page 57: Starting A Warm Engine

    Yamaha dealer check the ATV. There is never a more important period in the life of your engine than the first 240 km (150 mi) or 20 hours of riding.

  • Page 58: Parking On A Slope

    Never park the ATV on hills that are too steep to walk up easily. 1. Bring the ATV to a stop by applying the brakes. 2. Stop the engine. 3. With the rear brake lever applied, apply the parking brake, and then slowly release the rear brake lever.

  • Page 59: Accessories And Loading

    An accessory which can shift position and accessories or offer other modifications for or come off while you are riding could affect Yamaha vehicles. Yamaha is not in a position to your ability to control the ATV. test the products that these aftermarket compa- ...
  • Page 60  If you are carrying cargo and towing a trailer, in- EBU33880 Loading clude the tongue weight in the maximum ATV EWB00821 load limit. WARNING  Load cargo on the carriers as close to the center Never exceed the stated load capacity for this of the ATV as possible.

  • Page 61: Riding Your Atv

    EBU21142 RIDING YOUR ATV...

  • Page 62: Getting To Know Your Atv

    RIDE WITH CARE AND GOOD JUDGMENT EBU21525 Beginning riders should get training from a GETTING TO KNOW YOUR ATV certified instructor. This ATV is intended for recreational use by young EWB01382 operators under adult supervision. This section, WARNING “Riding your ATV”, provides general riding instruc- ...
  • Page 63 teristics. Take the time to learn the basic techni- This ATV is designed to carry the operator only ques well before attempting more difficult – passengers prohibited. maneuvers. The long seat is to allow the operator to shift posi- tion as needed during operation. It is not for carry- Not recommended for children under 6 years ing passengers.
  • Page 64 Apparel Always wear the following to reduce risk of injury in an accident:  Approved motorcycle helmet that fits properly  Eye protection (goggles, helmet face shield, or protective eyewear)  Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
  • Page 65 (See page 4-3.) This model also has an engine speed limiter plate to limit the amount of engine power available. Yamaha recommends that all beginning riders start off with the engine speed limiter plate in- Pre-operation checks stalled and the vehicle speed limiter adjusting...
  • Page 66  Make sure the load does not interfere with adjusting screw back in again and adjust it out in stages as you did before. For engine speed limiter your control or ability to see where you are plate removal instructions, see page 4-5. going.
  • Page 67 All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be in- stalled and used according to instructions. If you Avoid wheelies and jumping.
  • Page 68 modifications may cause changes in handling rials may have collected. Do not idle or park the which in some situations could lead to an acci- vehicle in long dry grass or other dry ground cov- dent. [EWB01492] To prevent burns, avoid touching the exhaust sys- Exhaust system tem.

  • Page 69: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE Watch carefully for other vehicles. Make sure you This ATV is designed for use on unpaved surfaces know your country’s laws and regulations before only. WARNING! Paved surfaces may seriously you ride on unpaved public streets or roads. Do affect handling and control of the ATV, and not ride on any paved public street, road or motor- may cause the ATV to go out of control.
  • Page 70 bumps, or holes. Go slowly and be extra care- ful when operating on unfamiliar terrain. Al- ways be alert to changing terrain conditions when operating the ATV. [EWB01532] When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.
  • Page 71 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 Do not ride in areas posted “no trespassing”. control of the throttle, brakes, and turning techni- Do not ride on private property without getting ques in this area before trying more difficult ter- permission.

  • Page 72: Turning Your Atv

    abruptly, the vehicle may lurch forward or the front nique must be used to allow the ATV to make wheels may lift off the ground, resulting in a loss of turns quickly and easily. It is essential that this skill directional control.

  • Page 73: Climbing Uphill

    Once you have learned this technique, you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throt- tle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip.
  • Page 74  Shift your weight forward.  Never open the throttle suddenly. The ATV could flip over backwards.  Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.
  • Page 75 on steeper inclines, standing on the footboards and leaning forward over the handlebars. When- ever possible, ride straight up hills. Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side – there could be another person, an obstacle, or a sharp drop-off.

  • Page 76: Riding Downhill

    mediately on the uphill side or to a side if pointed RIDING DOWNHILL straight uphill. Turn the ATV around and remount, EWB01132 WARNING following the procedure described in the Owner’s Manual. WARNING! Stalling, rolling backwards Going down a hill improperly could cause over- or improperly dismounting while climbing a hill turns or loss of control.

  • Page 77: Crossing A Slope

    When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as pos- sible. Move back on the seat and sit with your arms straight. Allow the engine compression to do most of the braking for you. Use caution while descending a hill with loose or slippery surfaces.

  • Page 78: Crossing Through Shallow Water

     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. Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance.
  • Page 79 The ATV can be used to cross slow moving, shal- braking ability. WARNING! Wet brakes may have low water of up to a maximum of 11 cm (4 in) in reduced stopping ability, which could cause depth. Before entering the water, choose your loss of control.

  • Page 80: Riding Over Rough Terrain

    accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. SLIDING AND SKIDDING EWB01663 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.

  • Page 81: What To Do If

    To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help. With practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control If the rear wheels of your ATV start to slide side-...

  • Page 82: What To Do

     If your ATV is traversing a sloping surface: WHAT TO DO...  If your ATV doesn’t turn when you want it to: Be sure to ride with your weight positioned to- Bring the ATV to a stop and practice the turning wards the uphill side of the ATV to maintain maneuvers again.

  • Page 83: Periodic Maintenance And Adjustment

    The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.

  • Page 84: Owner's Manual And Tool Kit

     If you do not have the tools or experience re- kit on the bottom of the seat. quired for a particular job, have a Yamaha deal- er perform it for you. 1. Owner’s tool kit 2.

  • Page 85: 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 still be followed.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 86 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (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 87: General 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 still be followed.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 88 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours • Check runout and for damage, and replace if nec- √ √ √ √ Wheels essary. • Check tread depth and for damage, and replace if necessary.
  • Page 89 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours • Check operation and repair or replace if dam- √ √ √ √ √ Steering system aged. •...
  • Page 90 EBU23062 Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle.

  • Page 91: Removing And Installing The Panel

    EBU23081 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. 1. Panel A 2.
  • Page 92 (the ideal color when the ATV tool kit. is ridden normally). 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. 8-10...

  • Page 93: Engine Oil

    2. Check the spark plug for electrode erosion To install the spark plug and excessive carbon or other deposits, and 1. Clean the surface of the spark plug gasket replace it if necessary. and its mating surface, and then wipe off any grime from the spark plug threads.
  • Page 94 To check the engine oil level 4. Insert the dipstick into the filler hole, screw it 1. Place the ATV on a level surface. in, and then remove it again to check the oil 2. Check the engine oil level on a cold engine. level.
  • Page 95 NOTICE: Be sure the engine oil is at the correct level, otherwise engine damage may result. [ECB00852] 6. Check the O-ring for damage, and replace it if necessary. 7. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap. To change the engine oil 1.

  • Page 96: Transmission Oil

    Be sure to wipe off spilled oil on any parts after the leakage before each ride. If any leakage is found, engine and exhaust system have cooled down. have a Yamaha dealer check and repair the ATV. In addition, the transmission oil must be changed ECB00331...
  • Page 97 1. Transmission oil filler cap 1. Transmission oil drain bolt 2. O-ring 2. Gasket 4. Remove the transmission oil drain bolt and its 5. Install the transmission oil drain bolt and its gasket to drain the oil from the transmission new gasket, and then tighten the bolt to the case.

  • Page 98: Cleaning The Air Filter Element

    Recommended oil: See page 10-1. Oil quantity: 0.35 L (0.37 US qt, 0.31 Imp.qt) 7. Check the oil filler cap O-ring for damage, and replace it if necessary. 8. Install and tighten the oil filler cap. 9. Check the transmission case for oil leakage. If oil is leaking, check for the cause.
  • Page 99 1. Air filter case cover 1. Air filter element 2. Air filter case cover holder 5. Squeeze the excess solvent out of the air filter element and let it dry. NOTICE: Do not twist 4. Remove the air filter element, and clean it with solvent.
  • Page 100 [ECB00462] 6. Check the air filter element and replace it if damaged. 7. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the element. The air filter element should be wet but not drip- ping.

  • Page 101: Cleaning The Spark Arrester

    dusty areas. When servicing the air filter element, 3. Tap the tailpipe lightly, and then use a wire be sure to check the air inlet of the air filter case brush to remove any carbon deposits from for obstructions. the spark arrester portion of the tailpipe and inside of the tailpipe housing.

  • Page 102: Adjusting The Carburetor

    There- fore, most carburetor adjustments should be left The engine is warm when it quickly responds to to a Yamaha dealer, who has the necessary pro- the throttle. fessional knowledge and experience. The adjust- ment described in the following section, however, 2.

  • Page 103: Adjusting The Throttle Lever Free Play

    If the specified idling speed cannot be obtained as throttle stop screw at the carburetor. To in- described above, have a Yamaha dealer make the crease the engine idling speed, turn the throt- adjustment.

  • Page 104: Valve Clearance

    If a bolt extends more must be adjusted by a Yamaha dealer at the inter- than 12 mm (0.47 in) from its locknut, the brake vals specified in the periodic maintenance and lu- shoes need to be replaced.

  • Page 105: Adjusting The Front Brake Lever Free Play

    1. Upper adjusting bolt 1. Rear brake lever free play adjusting nut 2. Lower adjusting bolt 2. Bolt 3. No more than 12 mm (0.47 in) 3. No more than 18 mm (0.71 in) Rear brake EBU24332 Adjusting the front brake lever free To check rear brake shoe wear, check the position play of the adjusting nut.
  • Page 106 1. Front brake lever free play 1. Upper locknut 2. Upper adjusting bolt 1. Loosen the upper locknut and fully turn in the 3. Lower locknut upper adjusting bolt. 4. Lower adjusting bolt 2. Loosen the lower locknut. 4. Tighten the lower locknut. 3.

  • Page 107: Adjusting The Rear Brake Lever Free Play

    The brake lever free play should measure 7.6–12.9 mm (0.30–0.51 in) as shown. If the free play is in- a=a´ correct, adjust it as follows. a´ 1. Cable joint 6. Tighten the upper locknut. 1. Rear brake lever free play After adjusting the brake lever free play, check the Turn the adjusting nut in direction (a) to increase front brake shoes for wear.

  • Page 108: Drive Chain Slack

    When checking and adjusting the drive chain slack, there should be no weight on the ATV and all tires must be touching the ground. 2. Move the ATV back and forth to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown.
  • Page 109 To adjust the drive chain slack 2. Loosen the rear brake lever free play adjust- 1. Loosen the bolts and nuts. ing nut. 1. Bolt 1. Rear brake lever free play adjusting nut 3. Loosen the locknut. 1. Nut 8-27...

  • Page 110: Cleaning And Lubricating The Drive Chain

    Tightening torques: Locknut: 22 N·m (2.2 kgf·m, 16 lb·ft) Bolt: 45 N·m (4.5 kgf·m, 33 lb·ft) Nut: 54 N·m (5.4 kgf·m, 39 lb·ft) 6. Adjust the rear brake lever free play. (See page 8-25.) 1. Drive chain slack adjusting nut EBU36480 Cleaning and lubricating the drive 2.

  • Page 111: Checking And Lubricating The Cables

    For a thorough cleaning, have a Yamaha dealer re- lead to an accident or injury. move the drive chain and soak it in solvent.  Always make sure all control cables work smoothly before you begin riding in cold 2.

  • Page 112: Checking The Wheel Hub Bearings

    If there is play in a wheel hub or if a wheel does not turn smooth- ly, have a Yamaha dealer check the wheel hub bearings. Rear brake lever...

  • Page 113: Lubricating The Front Knuckle Pivots

    The front knuckle pivots must be lubricated at the The steering shaft must be lubricated by a intervals specified in the periodic maintenance Yamaha dealer at the intervals specified in the pe- and lubrication chart. riodic maintenance and lubrication chart.

  • Page 114: Battery

    This model is equipped with a VRLA (Valve Regu- lated Lead Acid) battery. There is no need to For parts equipped with a grease nipple, use a check the electrolyte or to add distilled water. grease gun. However, the battery lead connections need to be checked and, if necessary, tightened.
  • Page 115 To charge the battery To remove the battery Have a Yamaha dealer charge the battery as soon 1. Remove panel A. (See page 8-9.) as possible if it seems to have discharged. Keep 2.
  • Page 116 ECB00941 NOTICE Always keep the battery charged. Storing a discharged battery can cause permanent bat- tery damage. To install the battery Be sure the battery is fully charged. 1. Place the battery in its compartment. 1. Positive battery lead (red) 2.

  • Page 117: Replacing The Fuse

    1. Fuse 4. If the fuse immediately blows again, have a 2. Spare fuse Yamaha dealer check the electrical system. The fuse holder is located under panel A. (See page 8-9.) EBU34030 If the fuse is blown, replace it as follows.

  • Page 118: Installing A Wheel

    1. Wheel bolt 1. Arrow mark 3. Elevate the ATV and place a suitable stand 2. Lower the ATV to the ground. under the frame. 3. Tighten the wheel bolts to the specified 4. Remove the bolts from the wheel. torques.

  • Page 119: Troubleshooting

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

  • Page 120: Troubleshooting Chart

    Have a Yamaha dealer check the ATV. Check the compression. 4. Compression There is compression. The engine does not start. Have a Yamaha dealer check the ATV. Operate the electric starter. Have a Yamaha dealer check the ATV. There is no compression.

  • Page 121: Cleaning And Storage

    EBU25861 CLEANING AND STORAGE ter pressure may cause water seepage EBU25903 Cleaning and deterioration of wheel bearings, Frequent, thorough cleaning of your ATV will not brakes, transmission seals and electrical only enhance its appearance but will improve its devices. Many expensive repair bills have general performance and extend the useful life of resulted from improper high-pressure de- many components.

  • Page 122: Storage

    abrasives which may mar the paint or protec- 4. Fill up the fuel tank and add fuel stabilizer (if tive finish. When finished cleaning, start the available) to prevent the fuel from deteriorat- engine and let it idle for several minutes. ing.
  • Page 123 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. Alterna- tively, turn the wheels a little every month in order to prevent the tires from becoming de- graded in one spot.

  • Page 124: Specifications

    EBU25962 SPECIFICATIONS Dimensions: Vibration on handle (EN1032, ISO5008): 4.7 m/s² (EUR, FRA, GBR) Overall length: Uncertainty of measurement: 1250 mm (49.2 in) 0.4 m/s² (EUR, FRA, GBR) Overall width: Engine: 820 mm (32.3 in) Overall height: Engine type: 770 mm (30.3 in) Air cooled 4-stroke, SOHC Seat height: Cylinder arrangement:...
  • Page 125 Type: Fuel: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- Recommended fuel: Regular unleaded gasoline only Fuel tank capacity: 130 ˚F 5.6 L (1.48 US gal, 1.23 Imp.gal) Fuel reserve amount: SAE 5W-30 0.7 L (0.18 US gal, 0.15 Imp.gal) Carburetor: SAE 10W-30 Type ×...
  • Page 126 Caster angle: Rear: 1.10 ° 12.4 kPa (0.124 kgf/cm², 1.8 psi) Trail: Front wheel: 10.4 mm (0.41 in) Wheel type: Front tire: Panel wheel Type: Rim size: Tubeless 7 x 5.2AT Size: Rear wheel: AT16 x 6.5-7 Wheel type: Manufacturer/model: Panel wheel DURO/DI2040 Rim size:...
  • Page 127 Rear suspension: of work-force include the characteristics of the Type: work room, the other sources of noise, etc. i.e. the Swingarm number of machines and other adjacent process- Spring/shock absorber type: es, and the length of time for which an operator is Coil spring/oil damper exposed to the noise.

  • Page 128: Consumer Information

    Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number...
  • Page 129 1. Model label 11-2...

  • Page 130: Index

    INDEX Accessories and loading ..........6-5 Front and rear brake shoes, checking ......8-22 Air filter element, cleaning ..........8-16 Front arm pivots, lubricating ........8-30 Front knuckle pivots, lubricating ........8-31 Fuel ................ 4-8, 5-3 Battery ................8-32 Fuel cock ..............4-10 Brake lever free play, adjusting the front .....8-23 Fuel tank cap ..............
  • Page 131 Part locations ..............3-1 Riding your ATV ............. 7-1 Safety information ............2-1 Seat ................4-12 Shock absorber assembly, adjusting the rear ..... 4-13 Spark arrester, cleaning ..........8-19 Spark plug, checking ............. 8-9 Specifications .............. 10-1 Speed limiter ..............4-3 Starter (choke) .............
  • Page 132 EBU33961 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. NEVER USE ALWAYS USE NEVER USE NEVER CARRY AN APPROVED PASSENGERS WITH DRUGS ON PAVED HELMET AND OR ALCOHOL ROADS PROTECTIVE GEAR NEVER ALWAYS operate: • without proper training or instruction. •...

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