Yamaha Raptor 90 2017 Owner's Manual
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Yamaha Raptor 90 2017 Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YF09RJ
WARNING
This ATV should not be ridden by anyone under 10 years of age.
BD3-F8199-72

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Summary of Contents for Yamaha Raptor 90 2017

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YF09RJ WARNING This ATV should not be ridden by anyone under 10 years of age. BD3-F8199-72...
  • Page 2 EBU28981 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold.
  • Page 3 Yamaha experience in the production of fine sporting, touring, and pacesetting racing 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 4 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 5 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 6 Please check your local riding laws and regulations before operating this ATV. EBU33790 YF09RJ OWNER’S MANUAL ©2017 by Yamaha Motor Co., Ltd. 1st edition, January 2017 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 7: Table Of Contents

    Front brake lever......... 4-5 EWB00012 WARNING Rear brake lever ......... 4-5 Parking brake ..........4-6 Indicates a hazardous situation which, if not Drive select lever ........4-7 avoided, could result in death or serious injury. Kickstarter ..........4-7 Fuel tank cap ..........4-8 Fuel .............
  • Page 8 Starting a warm engine .......6-3 Periodic maintenance chart for the Operating the drive select lever and emission control system......8-3 driving in reverse........6-3 General maintenance and lubrication Engine break-in ...........6-4 chart............8-5 Parking ............6-5 Checking the spark plug......8-9 Parking on a slope ........6-5 Engine oil ..........
  • Page 9 Installing a wheel........8-35 Troubleshooting ........8-36 Troubleshooting chart .......8-37 CLEANING AND STORAGE ......9-1 Cleaning ............9-1 Storage............9-2 SPECIFICATIONS ........10-1 CONSUMER INFORMATION ....... 11-1 Identification numbers ......11-1 YAMAHA MOTOR CANADA LTD. ATV WARRANTY GUIDE ........ 11-4 INDEX............12-1...

  • Page 10: Location Of The Warning And Specification Labels

    EBU17661 LOCATION OF THE WARNING AND SPECIFICATION LABELS 9 10...
  • Page 11 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 12 WARNING UNDER Operation of this ATV by children under the age of 10 increases the risk of severe injury or death. Adult supervision required for children under age 16. NEVER permit children under age 10 to operate this ATV. BD3-F816L-00 BD3-F1568-00...
  • Page 13 BD3-F816L-10 BD3-F1568-10 BD3-F817J-40 BD3-F817J-50...
  • Page 14 CAN ICES-2 / NMB-2 3JK-82377-30 BD3-F416E-40 24.0 24.0 20.7 20.7 BD3-F151H-00 BD3-F816M-60...
  • Page 15 24.0 24.0 ô 20.7 20.7 ê BD3-F151H-10 BD3-F816M-10...

  • Page 16: Safety Information

    EBU17432 SAFETY INFORMATION SAFETY INFORMATION  Do not allow continued use of the ATV by a child EBU34414 if he or she does not have the abilities to operate AN ATV IS NOT A TOY AND CAN BE HAZARD- it safely. OUS TO OPERATE.
  • Page 17  Always inspect your ATV each time you use it to  Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 18  Always use proper procedures if you stall or roll reduced stopping ability. Test your brakes after backwards when climbing a hill. To avoid stall- leaving water. If necessary, apply them several ing, use the proper gear and maintain a steady times to let friction dry out the linings.
  • Page 19 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 20 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 21  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 22: Description

    EBU17681 DESCRIPTION EBU17691 EBU17701 Left view Right view 1 2 3 1. Fuel tank cap 1. Spark arrester 2. Fuel cock 2. Owner’s tool kit 3. Air filter 3. Front shock absorber spring preload adjuster 4. Fuse 4. Spark plug 5.

  • Page 23: Controls And Instruments

    EBU17714 Controls and instruments 1. Rear brake lever 2. Handlebar switches 3. Parking brake lock plate 4. Starter (choke) 5. Main switch 6. Throttle lever 7. Front brake lever 8. Drive select lever The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 24: Instrument And Control Functions

    EBU17729 INSTRUMENT AND CONTROL FUNCTIONS EWB00012 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU33850 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power, and the engine can be started.

  • Page 25: Indicator Lights

    EBU17794 EBU18066 Indicator lights Handlebar switches 1. Reverse indicator light “R” 1. Engine stop switch “ ” 2. Neutral indicator light “N” 2. Start switch “ ” EBU17861 EBU18081 Neutral indicator light “ ” Engine stop switch “ ” This indicator light comes on when the transmis- Set this switch to “...

  • Page 26: Throttle Lever

    Throttle lever vices. A vehicle speed limiter adjusting screw and Once the engine is running, pushing the throttle le- a removable engine speed limiter plate. Yamaha ver will increase the engine speed. recommends that all beginning riders start off with...
  • Page 27 speed limiter adjusting screw completely back in again and adjust it out in stages as done previous- Vehicle speed limiter 1. Loosen the locknut. 2. To increase the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (a). To decrease the maximum engine power avail- able and the maximum speed of the ATV, turn the adjusting screw in direction (b).

  • Page 28: Front Brake Lever

    1. Screw 1. Front brake lever 2. Engine speed limiter plate EBU18402 3. Tighten the screws. Rear brake lever 4. Install the seat. The rear brake lever is located on the left handle- bar. To apply the rear brake, pull the brake lever toward the handlebar grip.

  • Page 29: Parking Brake

    1. Rear brake lever 1. Parking brake lock plate EWB00221 EBU18462 WARNING Parking brake  Always set the parking brake before starting Use the parking brake before starting the engine the engine. The ATV could start moving un- or after parking the ATV, especially on a slope. Ap- expectedly if the parking brake is not ap- ply the rear brake lever and push down the lock plied.

  • Page 30: Drive Select Lever

    braking performance which could cause an EBU33893 Kickstarter accident. You could also wear out the brakes Use the kickstarter to start the engine when the prematurely. battery voltage is low. 1. Remove the seat (page 4-13), and then re- EBU18583 move the kickstarter lever.

  • Page 31: Fuel Tank Cap

    1. Kickstarter lever cap 1. Fold out. 2. Push down. 3. Install the kickstarter lever. 5. When the engine has started, remove the 4. Move the kickstarter lever down lightly with kickstarter lever and store it under the seat. your foot until the gears engage, and then 6.

  • Page 32: Fuel

    of sparks, open flames, or other sources of ignition such as the pilot lights of water heat- ers and clothes dryers. 2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole.
  • Page 33 Yamaha because it can cause damage to the fuel immediately. If gasoline spills on your skin, system or vehicle performance problems.

  • Page 34: Fuel Cock

    EBU18821 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while also filtering it. The fuel cock lever positions are explained as fol- lows and shown in the illustrations. 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel flows to the carburetor.

  • Page 35: Starter (Choke)

    1. Starter (choke) lever 1. Arrow mark positioned over “RES” To use the starter (choke) and enrich the air-fuel This indicates reserve. With the fuel cock lever in ratio, move the starter (choke) lever in direction (a). this position, the fuel reserve is made available. To decrease the starter (choke) or turn it off, move Turn the fuel cock lever to this position if you run the starter (choke) lever in direction (b).

  • Page 36: Seat

    To install the seat EBU34551 Seat To remove the seat 1. Projection 2. Seat holder Insert the projection on the front of the seat into 1. Seat the seat holder, and then push down on the seat 2. Seat lock lever at the rear to lock it in place.
  • Page 37 Adjust the spring preload as follows. Turn the spring preload adjusting ring in direction (a) to increase the spring preload and thereby A special wrench can be obtained at a Yamaha harden the suspension, and in direction (b) to de- dealer to make this adjustment.

  • Page 38: Adjusting The Rear Shock Absorber

    ECB01091 NOTICE Never turn the adjusting mechanism beyond the minimum and maximum settings. Adjust the spring preload as follows. Turn the spring preload adjusting ring in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to de- crease the spring preload and thereby soften the suspension.
  • Page 39 A special wrench can be obtained at a Yamaha dealer to make this adjustment. EWB00012 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 1. Special wrench Spring preload setting: Minimum (soft): Standard:...

  • Page 40: 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 41 ITEM ROUTINE PAGE • Make sure that operation is smooth. Lubricate cable and lever Throttle lever housing if necessary. 5-3, 8-20 • Check lever free play, and adjust if necessary. Control cables • Make sure that operation is smooth. Lubricate if necessary. 8-28 •...

  • Page 42: 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 43 Tire pressure Tire pressure gauge Use a tire pressure gauge to check and adjust tire air pressure when the tires are cold. The tire air pressure must equal both sides. WARNING! Operation of this vehicle with im- proper tire pressure may cause severe injury or death from loss of control or rollover.
  • Page 44 This ATV is equipped with tubeless tires and tire air valves. After extensive tests, only the tires list- Aftermarket tires and rims ed below are approved for this model by Yamaha. 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 45: Chassis Fasteners

    EWB02552 WARNING Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent. EBU19841 Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened. EBU33810 Instruments and switches Check that all instruments and switches are work- ing properly.

  • Page 46: Operation

    Read the Owner’s Manual carefully before riding sition. (The neutral indicator light should the ATV. If there is a control or function you do not come on.) understand, ask your Yamaha dealer. 5. Position the starter (choke) lever according to EWB00632 the ambient temperature.
  • Page 47  If the engine fails to start using the start switch, Ambient temp./starter (choke) position try using the kickstarter. (See page 4-7.) 7. If the engine is started with the starter (choke) lever in position (1), move the lever to position (2) to warm up the engine.

  • Page 48: Starting A Warm Engine

    EBU20292 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. EBU33831 Operating the drive select lever and driving in reverse ECB00171...

  • Page 49: Engine Break-In

    If the indicator light does not come on, meter, follow the figures given in km (mi) or the have a Yamaha dealer check the electrical circuit. figures given in hours.  For ATVs not equipped with an odometer or hour meter, follow the figures given in hours.

  • Page 50: Parking

    If any engine trouble should occur during the EWB00832 engine break-in period, immediately have a WARNING Yamaha dealer check the ATV. Avoid parking on hills or other inclines. Parking on a hill or other incline could cause the ATV to EBU30021...

  • Page 51: Accessories And Loading

    Yamaha manufacture parts 4. Turn the fuel cock to “OFF”. and accessories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket compa- nies produce. Therefore, Yamaha can neither en-...
  • Page 52 aftermarket products or having other modifica- EBU33880 Loading tions performed to your ATV that change any of EWB00821 the vehicle’s design or operation characteristics WARNING can put you and others at greater risk of serious Never exceed the stated load capacity for this injury or death.
  • Page 53  If you are carrying cargo and towing a trailer, in- EWB00012 WARNING clude the tongue weight in the maximum ATV load limit. Indicates a hazardous situation which, if not  Load cargo on the carriers as close to the center avoided, could result in death or serious injury.

  • Page 54: Riding Your Atv

    EBU21133 RIDING YOUR ATV...

  • Page 55: Getting To Know Your Atv

    RIDE WITH CARE AND GOOD JUDGMENT EWB00012 WARNING Beginning riders should get training from a Indicates a hazardous situation which, if not certified instructor. avoided, could result in death or serious injury. EWB01382 WARNING EBU34422  Do not operate this ATV or allow anyone else to operate it without proper instruction.
  • Page 56 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 10 years ing passengers.
  • Page 57 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 58 (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 59  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 4-4. going.
  • Page 60 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 61 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 62: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE ate ATVs on public streets, roads and highways. This ATV is designed for off-road use only. WARNING! Never operate this ATV on any pu- WARNING! Paved surfaces may seriously af- blic street, road or highway, even a dirt or grav- fect handling and control of the ATV, and may el one.
  • Page 63 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. DO NOT use the flag pole bracket Do not operate on rough, slippery, or loose terrain as a trailer hitch.
  • Page 64 Select a large, flat area off-road to become familiar 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 65: Turning Your Atv

    abruptly, the vehicle may lurch forward or the front ing technique must be used to allow the ATV to wheels may lift off the ground, resulting in a loss of make turns quickly and easily. It is essential that directional control. Avoid higher speeds until you this skill be learned first at low speed.

  • Page 66: 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 67  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 68 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 69: Riding Downhill

    ATV on the uphill side or to the left-hand side RIDING DOWNHILL when the ATV is pointed straight uphill. If possible, EWB01132 WARNING get help to turn the ATV around and then remount it when safe and ride downhill carefully as ex- Going down a hill improperly could cause over- plained in the following section.

  • Page 70: 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. Engine compression will do most of the braking for you. Use caution while descending a hill with loose or slippery surfaces.

  • Page 71: 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 72 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 20 cm (8 in) in reduced stopping ability, which could cause depth. Before entering the water, choose your loss of control.

  • Page 73: 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 74: 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 75: 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 76: 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 77: 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 78: 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 79 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (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 80: 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 81 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (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 82 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check operation and repair or replace if dam- √ √ √ √ √ Steering system aged. •...
  • Page 83 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 84: Checking The Spark Plug

    EWB00012 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU23214 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 ac- cordance with the periodic maintenance and lubri- 1.
  • Page 85 If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not 1. Spark plug gap attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) 8-10...

  • Page 86: Engine Oil

    To install the spark plug To check the engine oil level 1. Clean the surface of the spark plug gasket 1. Place the ATV on a level surface. and its mating surface, and then wipe off any 2. Check the engine oil level on a cold engine. grime from the spark plug threads.
  • Page 87 NOTICE: Be sure the engine oil is at the 4. Insert the dipstick into the filler hole, screw it in, and then remove it again to check the oil correct level, otherwise engine damage level. may result. [ECB00852] 6. Check the O-ring for damage, and then insert the dipstick and tighten the engine oil filler cap.
  • Page 88 Tightening torque: Engine oil drain bolt: 15 N·m (1.5 kgf·m, 11 lb·ft) 8. Refill with the specified amount of the recom- mended engine oil. Recommended oil: See page 10-1. Oil quantity: 0.80 L (0.85 US qt, 0.70 Imp.qt) 1. Engine oil drain bolt 2.

  • Page 89: Transmission Oil

    4. Remove the transmission oil drain bolt and its leakage before each ride. If any leakage is found, gasket to drain the oil from the transmission have a Yamaha dealer check and repair the ATV. case. In addition, the transmission oil must be changed at the intervals specified in the periodic mainte- nance and lubrication chart.

  • Page 90: 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 91 1. Air filter case check hose 1. Air filter case cover 2. Air filter case cover holder 1. Park the ATV on a level surface. 4. Remove the air filter element, and clean it with 2. Remove the seat. (See page 4-13.) solvent.
  • Page 92 5. Squeeze the excess solvent out of the air filter element and let it dry. NOTICE: Do not twist 7. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the element. the air filter element when squeezing it.

  • Page 93: Cleaning The Spark Arrester

    ment removed. This will allow unfiltered air dusty areas. When servicing the air filter element, to enter the engine, causing rapid engine be sure to check the air inlet of the air filter case wear and possible engine damage. Addi- for obstructions.

  • Page 94: Adjusting The Carburetor

    3. Tap the spark arrester lightly, and then use a fore, most carburetor adjustments should be left wire brush to remove any carbon deposits. to a Yamaha dealer, who has the necessary pro- 4. Insert the spark arrester into the muffler and fessional knowledge and experience. The adjust- align the bolt hole.

  • Page 95: Adjusting The Throttle Lever Free Play

    The engine is warm when it quickly responds to If the specified idling speed cannot be obtained as the throttle. described above, have a Yamaha dealer make the adjustment. 2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if neces-...

  • Page 96: 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 97: 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 98 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 99: Adjusting The Rear Brake Lever Free Play

    The brake lever free play should measure 30.0– 40.0 mm (1.18–1.57 in) as shown. If the free play is a=a´ incorrect, 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 100: Drive Chain Slack

    To check the drive chain slack 1. Place the ATV on a level surface. 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. Drive chain slack: 24.0–32.0 mm (0.94–1.26 in) 1.
  • Page 101 1. Bolt 1. Rear brake lever free play adjusting nut 3. Loosen the locknut. 1. Nut 1. Drive chain slack adjusting nut 2. Loosen the rear brake lever free play adjust- 2. Locknut ing nut. 8-26...

  • Page 102: Lubricating The Drive Chain

    4. To tighten the drive chain, turn the drive chain EBU24883 Lubricating the drive chain slack adjusting nut in direction (a). To loosen The drive chain must be cleaned and lubricated at the drive chain, turn the adjusting nut in direc- the intervals specified in the periodic maintenance tion (b) and push the rear wheels forward.

  • Page 103: Checking And Lubricating The Cables

    If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Yamaha cable lubricant or other suitable cable lubricant EWB02582 WARNING  Inspect cables frequently and replace if damaged. Corrosion can result when the ca- 1.

  • Page 104: Checking And Lubricating The Front And Rear Brake Levers

    The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. 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. 8-29...

  • Page 105: Lubricating The Front Knuckle Pivots

    Recommended lubricant: EBU25095 Lubricating the steering shaft Lithium-soap-based grease The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the pe- riodic maintenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease 8-30...

  • Page 106: Battery

    Wash KEEP OUT OF REACH OF CHILDREN. hands after handling.  It is recommended to have the battery serviced by a Yamaha dealer. To remove the battery 1. Remove the seat. (See page 4-13.) 2. Unhook the battery band.
  • Page 107 ECB00622 NOTICE Never attempt to open the battery or remove the battery cell seals, as this would permanent- ly damage the battery. To charge the battery  Confirm the recommended charging rate as specified on the battery itself.  Select a suitable charger and follow the manu- facturer’s instructions.
  • Page 108 ECB00942 NOTICE  Always keep the battery charged. Storing the battery in a discharged state for an extended period of time will cause permanent battery damage.  Do not store the battery in an excessively cold or warm place [below freezing or above 30 °C (90 °F)].

  • Page 109: Replacing The Fuse

    7.5 A 4. Turn on the main switch and start the engine. 5. If the fuse immediately blows again, have a 1. Fuse Yamaha dealer check the vehicle. 2. Spare fuse If an electrical problem is suspected, check the EBU34030 fuse and replace it if necessary as follows.

  • Page 110: Installing A Wheel

    1. Wheel bolt 1. Arrow mark 2. Forward rotating direction 3. Elevate the ATV and place a suitable stand 3. Wheel bolt under the frame. 2. Lower the ATV to the ground. 4. Remove the bolts from the wheel. 3. Tighten the wheel bolts to the specified 5.

  • Page 111: 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 112: 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 113: 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 114: Storage

    abrasives which may mar the paint or protec- 3. Fill up the fuel tank and add fuel stabilizer (Fu- tive finish. When finished cleaning, start the el Med Rx if available), and then run the en- engine and let it idle for several minutes. gine for 5 minutes to distribute the treated fuel.
  • Page 115 e. Install the spark plug and the spark plug cap. 6. Lubricate all control cables and the pivoting points of all levers. 7. Put the frame on stands or blocks to raise all wheels off the ground. (Alternatively, turn the wheels each month to prevent the tires from degrading in one spot.) 8.

  • Page 116: Specifications

    EBU25962 SPECIFICATIONS Dimensions: Compression ratio: 9.2 : 1 Overall length: Starting system: 1485 mm (58.5 in) Electric starter and kickstarter Overall width: Lubrication system: 1020 mm (40.2 in) Wet sump Overall height: Engine oil: 955 mm (37.6 in) Seat height: Recommended brand: 750 mm (29.5 in) YAMALUBE...
  • Page 117 Engine oil quantity: Transmission: Periodic oil change: Secondary reduction system: 0.80 L (0.85 US qt, 0.70 Imp.qt) Chain drive Transmission oil: Secondary reduction ratio: Type: 35/14 (2.500) SAE 80W-90 Transmission type: Quantity: V-belt automatic 0.35 L (0.37 US qt, 0.31 Imp.qt) Operation: Air filter: Centrifugal automatic type...
  • Page 118 Loading: Rear brake: Maximum loading limit: Type: 82.0 kg (181 lb) Mechanical leading, trailing drum brake (Total weight of rider, cargo, accessories, and tongue) Operation: Tire air pressure (measured on cold tires): Left hand operation Front suspension: Recommended: Front: Type: 24.0 kPa (0.240 kgf/cm², 3.5 psi) Swing axle Rear:...
  • Page 119 Bulb voltage, wattage × quantity: Neutral indicator light: 12 V, 3.5 W × 1 Reverse indicator light: 12 V, 3.5 W × 1 Fuse: Fuse: 7.5 A 10-4...

  • Page 120: Consumer Information

    Yamaha dealer or for reference in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 121 Model label ment Canada. The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha dealer. 11-2...
  • Page 122 1. Vehicle Emission Control Information label 11-3...

  • Page 123: Yamaha Motor Canada Ltd. Atv Warranty Guide

    CANADA LTD. (‘YAMAHA’), sold at retail by an authorized The subsequent owner has the responsibility for ensuring shown in the Owner’s Manual; Yamaha dealer (‘DEALER’). The term ‘CUSTOMER’ shall that a change of registration is sent to YAMAHA at the CUSTOMER provide record refer to the owner or lessee of record of the ATV time of such transfer of ownership.
  • Page 124 YAMAHA, and any other • Drive System batteries, generator brushes, sealed beams and obligation or liability on behalf of YAMAHA, and the above •...
  • Page 125 EWB00012 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 11-6...

  • Page 126: Index

    INDEX Engine stop switch ............4-2 Accessories and loading ..........6-6 Air filter element, cleaning ..........8-15 Front and rear brake shoes, checking ......8-21 Front knuckle pivots, lubricating ........8-30 Fuel ................ 4-9, 5-3 Battery ................8-31 Fuel cock ..............4-11 Brake lever free play, adjusting the front .....8-22 Fuel tank cap ..............
  • Page 127 Vehicle identification number ........11-1 Parking ................6-5 Parking brake ..............4-6 Warranty ..............11-4 Parking on a slope ............6-5 Wheel hub bearings, checking ........8-29 Part locations ..............3-1 Wheel, installing ............8-35 Wheel, removing ............8-34 Reverse indicator light ........... 4-2 Riding your ATV .............
  • Page 129 EBU30393 For your best ownership experience, think Genuine Yamaha! Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect.
  • Page 130 EBU34431 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. NEVER USE ALWAYS USE NEVER USE NEVER CARRY WITH DRUGS AN APPROVED ON PUBLIC PASSENGERS HELMET AND OR ALCOHOL ROADS PROTECTIVE GEAR NEVER ALWAYS operate: • without proper training or instruction. •...

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