Yamaha RAPTOR 90 2020 Owner's Manual
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Yamaha RAPTOR 90 2020 Owner's Manual

Yamaha RAPTOR 90 2020 Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM09RYXM
WARNING
This ATV should not be ridden by anyone under 10 years of age.
LIT-11626-34-05
BD3-F8199-15

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Summary of Contents for Yamaha RAPTOR 90 2020

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM09RYXM WARNING This ATV should not be ridden by anyone under 10 years of age. LIT-11626-34-05 BD3-F8199-15...
  • Page 2 EBU37021 Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well-ventilated area and wear gloves or wash your...
  • 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 ATV safely. Your ATV was delivered with an adjustable speed limiter. Yamaha recommends that all beginners start off to limit the amount of speed available while they learn. The adjusting screw may be gradually turned out as the beginner becomes more familiar with operating the ATV.
  • Page 5 EBU17331 IMPORTANT MANUAL INFORMATION EBU17344 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. EBU34380 YFM09RYXM OWNER’S MANUAL ©2021 by Yamaha Motor Corporation, U.S.A. 1st edition, December 2019 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

  • Page 7: Table Of Contents

    Handlebar switches ........5-2 EWB00012 WARNING Throttle lever..........5-3 Speed limiter..........5-3 Indicates a hazardous situation which, if not Front brake lever......... 5-5 avoided, could result in death or serious injury. Rear brake lever ......... 5-6 Parking brake ..........5-6 Drive select lever ........
  • Page 8 OPERATION ...........7-1 PERIODIC MAINTENANCE AND Starting a cold engine .........7-1 ADJUSTMENT ..........9-1 Starting a warm engine .......7-3 Owner’s Manual and tool kit....... 9-2 Operating the drive select lever and Periodic maintenance chart: Emission driving in reverse........7-3 control system .......... 9-3 Engine break-in ...........7-4 Periodic maintenance chart: General Parking ............7-5...
  • Page 9 Storage............10-2 SPECIFICATIONS ........11-1 CONSUMER INFORMATION ....... 12-1 Vehicle Emission Control Information label............12-1 Noise regulation ........12-2 Maintenance record ........12-3 YAMAHA MOTOR CORPORATION, U.S.A. 2020 AND LATER MODEL ATV LIMITED WARRANTY ......12-4 YAMAHA EXTENDED SERVICE (Y.E.S.) ... 12-6...

  • Page 10: Vehicle Identification

    EBU38860 VEHICLE IDENTIFICATION EBU26016 EBU26032 Vehicle identification number Identification numbers The vehicle identification number is stamped into Record the vehicle identification number, model the frame. This 17-digit number is used to identify label information and key identification number in your individual ATV. the spaces provided below.
  • Page 11 EBU34610 Key identification number The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key. 1. Model label Your specific model can be identified by checking the model type code found on the model label.

  • 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 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 14 2017 BD3-F817J-60 BD3-F816M-20 BD3-F151H-00...

  • Page 15: Safety Information

    EBU17432 SAFETY INFORMATION SAFETY INFORMATION  Never allow a child under 16 years old to oper- EBU34315 ate an ATV without adult supervision. AN ATV IS NOT A TOY AND CAN BE HAZARD-  Do not allow continued use of the ATV by a child OUS TO OPERATE.
  • Page 16  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 17  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 18 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 19 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 20  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 21 FOR MORE INFORMATION ABOUT ATV SAFE- TY, call the Consumer Products Safety Commis- sion at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.

  • 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. Reflector 3. Air filter 3. Tool kit 4. Fuse 4. Front shock absorber 5. Battery 5. Spark plug 6.

  • Page 23: Controls And Instruments

    EBU17715 Controls and instruments 1. Rear brake lever 2. Handlebar switches 3. Parking brake lock plate 4. Starter (choke) lever 5. Main switch 6. Throttle lever 7. Front brake lever 8. Drive select lever...

  • Page 24: Instrument And Control Functions

    EBU1772C 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 EBU18068 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

    See the starting instructions on page 7-1 prior vices. A vehicle speed limiter adjusting screw and to starting the engine. a removable engine speed limiter plate. Yamaha recommends that all beginning riders start off with EBU18286 the vehicle speed limiter adjusting screw fully...
  • Page 27 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

    EBU18393 Front brake lever 1. Screw 2. Engine speed limiter plate 1. Front brake lever 3. Tighten the screws. The front brake lever is located on the right han- 4. Install the seat. dlebar. To apply the front brake, pull the brake le- ver toward the handlebar grip.

  • Page 29: Rear Brake Lever

    EBU18403 Rear brake lever 1. Parking brake lock plate 1. 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. EBU18462 Parking brake Use the parking brake before starting the engine or after parking the ATV, especially on a slope.

  • Page 30: Drive Select Lever

    EWB00221 EBU18583 Drive select lever WARNING  Always set the parking brake before starting the engine. The ATV could start moving un- expectedly if the parking brake is not ap- plied. This could cause loss of control or a collision. ...
  • Page 31 4. Move the kickstarter lever down lightly with your foot until the gears engage, and then push it down smoothly but forcefully. 1. Kickstarter lever 2. Remove the kickstarter lever cap. 1. Fold out. 2. Push down. 5. When the engine has started, remove the kickstarter lever and store it under the seat.

  • Page 32: Fuel Tank Cap

    of sparks, open flames, or other sources of EBU37980 Fuel tank cap 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: Fuel

    3. Wipe up any spilled fuel immediately. Recommended fuel: NOTICE: Immediately wipe off spilled fuel Regular unleaded gasoline (Gasohol [E10] with a clean, dry, soft cloth, since fuel may acceptable) deteriorate painted surfaces or plastic Fuel tank capacity: parts. [ECB00982] 6.6 L (1.7 US gal, 1.5 Imp.gal) 4.

  • Page 34: Fuel Cock

    ECB00071 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. EBU18821 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while also filtering it.

  • Page 35: 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 36: Seat

    EBU34551 Seat To remove the seat 1. Starter (choke) lever To use the starter (choke) and enrich the air-fuel ratio, move the starter (choke) lever in direction (a). To decrease the starter (choke) or turn it off, move 1. Seat the starter (choke) lever in direction (b).

  • Page 37: Front Shock Absorbers

    To install the seat EWB00401 WARNING Always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident. ECB01091 NOTICE Never turn the adjusting mechanism beyond the minimum and maximum settings.

  • Page 38: Rear Shock Absorber

    1. Spring preload adjusting ring 1. Special wrench 2. Position indicator Spring preload setting: Minimum (soft): A special wrench can be obtained at a Yamaha dealer to make this adjustment. Standard: Maximum (hard): EBU19027 Rear shock absorber The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions.
  • Page 39 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. Turn the spring preload adjusting ring in direction...
  • Page 40 EWB00012 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 5-17...

  • Page 41: 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 42 ITEM ROUTINE PAGE • Make sure that operation is smooth. Lubricate cable and lever Throttle lever housing if necessary. 6-3, 9-21 • Check lever free play, and adjust if necessary. Control cables • Make sure that operation is smooth. Lubricate if necessary. 9-28 •...

  • Page 43: Fuel

    Make sure that the engine oil is at the specified Check the operation of the throttle lever. It must level. Add oil as necessary. (See page 9-11.) open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if EBU38541 necessary. Transmission...
  • Page 44 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 45 After extensive tests, only the tires list- braking, and comfort. Other tires, rims, sizes, and ed below are approved for this model by Yamaha. combinations may not be appropriate. EWB02552...

  • Page 46: Chassis Fasteners

    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. Correct if necessary.

  • Page 47: 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 48  If the engine fails to start using the start switch, Ambient temp./starter (choke) position try using the kickstarter. (See page 5-7.) 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 49: 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 50: Engine Break-In

    If the indicator light does not come on, hours of operation. For this reason, you should fol- have a Yamaha dealer check the electrical circuit. low the engine break-in instructions carefully. Since the engine is brand new, do not put an ex- cessive load on it for the first 320 km (200 mi) or 20 hours.

  • Page 51: Parking

    ATV to engine break-in period, immediately have a roll out of control, increasing the chance of an Yamaha dealer check the ATV. accident. If you must park on an incline, place the ATV transversely across the incline, shift...

  • Page 52: Accessories And Loading

    Yamaha manufacture parts or come off while you are riding could affect and accessories or offer other modifications for your ability to control the ATV. Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket compa-...
  • Page 53  Do not mount an accessory where it could inter- trailer, you must use common sense and good fere with your ability to control the ATV. Exam- judgment as the stability and handling of an ATV ples include (but are not limited to) a heavy or can be changed.
  • Page 54  Allow more braking distance. A heavier ATV takes longer to stop.  Avoid making sharp turns unless at very slow speeds.  Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV. EWB00012 WARNING Indicates a hazardous situation which, if not...

  • Page 55: Riding Your Atv

    EBU21133 RIDING YOUR ATV...

  • Page 56: 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 EBU34322  Do not operate this ATV or allow anyone else to operate it without proper instruction.
  • Page 57 Riding your ATV requires skills acquired through practice over a period of time. Become familiar with riding this ATV by riding at slow speeds first, even if you have experience rid- ing other ATVs. Do not attempt to operate it at UNDER higher performance levels until you are familiar with this ATV’s handling and performance charac-...
  • Page 58 This ATV is designed to carry the operator only Apparel – passengers prohibited. Always wear the following to reduce risk of injury The long seat is to allow the operator to shift posi- in an accident:  Approved motorcycle helmet that fits properly tion as needed during operation.
  • Page 59 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV before use to make sure 3. Gloves that it is safe operating condition. Perform the pre- 4. Boots 5. Helmet operation checks listed on page 6-1. Follow the maintenance schedules and procedures as de- Do not operate after or while consuming alco- scribed in the “Periodic Maintenance and Adjust- hol or drugs.
  • Page 60 (See page 5-3.) 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- stalled and the vehicle speed limiter adjusting screw turned in to limit the amount of speed avail- 1.
  • Page 61  Do not exceed the maximum loading limits During operation for the vehicle (see “MAXIMUM LOADING Always keep your feet on the footboards during LIMIT” below or vehicle labeling). operation; otherwise, they may contact the rear  Make sure the load does not interfere with wheels.
  • Page 62 ATV should the engine has stopped. To reduce the risk of fire be genuine Yamaha or equivalent components during operation or after leaving the ATV, do not designed for use on this ATV and should be in-...

  • Page 63: Be Careful Where You Ride

    the vehicle, near the muffler or exhaust pipe, or BE CAREFUL WHERE YOU RIDE next to other hot parts. Check under the vehicle This ATV is designed for off-road use only. after operating in areas where combustible mate- WARNING! Paved surfaces may seriously af- rials may have collected.
  • Page 64 ate ATVs on public streets, roads and highways. ful when operating on unfamiliar terrain. Al- WARNING! Never operate this ATV on any pub- ways be alert to changing terrain conditions lic street, road or highway, even a dirt or gravel when operating the ATV.
  • Page 65 Do not ride in areas posted “no trespassing”. When riding in an area where you might not easily Do not ride on private property without getting be seen, such as desert terrain, mount a caution permission. flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch.

  • Page 66: Turning Your Atv

    abruptly, the vehicle may lurch forward or the front wheels may lift off the ground, resulting in a loss of directional control. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly.
  • Page 67 ing technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the footboard to the outside of the turn (opposite your desired direc- tion) and lean your upper body into the turn.

  • Page 68: Climbing Uphill

     Shift your weight forward. Once you have learned this technique, you should  Never open the throttle suddenly. The ATV be able to perform it at higher speeds or in tighter curves. could flip over backwards.  Never go over the top of any hill at high Improper riding procedures such as abrupt throt- tle changes, excessive braking, incorrect body speed.
  • Page 69 Do not attempt to climb hills until you have mas- tered basic maneuvers on flat ground. Always check the terrain carefully before attempting any hill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.
  • Page 70 on steeper inclines, standing on the footboards ATV on the uphill side or to the left-hand side and leaning forward over the handlebars. When- when the ATV is pointed straight uphill. If possible, ever possible, ride straight up hills. get help to turn the ATV around and then remount Slow down when you reach the crest of the hill if it when safe and ride downhill carefully as ex- you cannot see clearly what is on the other side –...

  • Page 71: Riding Downhill

    RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as pos- EWB01132 WARNING sible. Move back on the seat and sit with your arms straight. Engine compression will do most of Going down a hill improperly could cause over- turns or loss of control.

  • Page 72: Crossing A Slope

     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 73: Crossing Through Shallow Water

    The ATV can be used to cross slow moving, shal- low water of up to a maximum of 20 cm (8 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV.

  • Page 74: Riding Over Rough Terrain

    braking ability. WARNING! Wet brakes may have reduced stopping ability, which could cause loss of control. [EWB02622] 1. Air filter case check hose RIDING OVER ROUGH TERRAIN EWB01652 WARNING After riding your ATV in water, be sure to drain the Riding improperly over obstacles could cause trapped water by removing the check hose at the loss of control or a collision.

  • Page 75: Sliding And Skidding

    accident. Be sure to keep your feet firmly mounted To reduce the tendency for the front wheels to on the footboards at all times. Avoid jumping the slide in loose or slippery conditions, positioning ATV as loss of control and damage to the ATV may your weight over the front wheels will sometimes result.

  • Page 76: What To Do If

    WHAT TO DO...  If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn.
  • Page 77  If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.

  • Page 78: 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 79: Owner's Manual And Tool Kit

     If you do not have the tools or experience re- EBU33902 Owner’s Manual and tool kit quired for a particular job, have a Yamaha deal- Place the Owner’s Manual in a plastic bag, and er perform it for you.

  • Page 80: Periodic Maintenance Chart: Emission Control System

     For odometer or hour meter-equipped vehicles, follow the month maintenance interval if the ATV isn’t ridden for the stated mileage or engine operating hours.  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 for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 82: Periodic Maintenance Chart: General Maintenance And Lubrication

     For odometer or hour meter-equipped vehicles, follow the month maintenance interval if the ATV isn’t ridden for the stated mileage or engine operating hours.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 83 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 84 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours √ √ √ Steering shaft • Lubricate with lithium-soap-based grease. • Check operation and repair or replace if dam- √...
  • Page 85 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 86: Checking The Spark Plug

    EWB00012 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU23216 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 chart.
  • Page 87 If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 1. Spark plug gap 2. Check the spark plug for electrode erosion...

  • Page 88: Engine Oil

    Tightening torque: Spark plug: If the engine was started before checking the oil 12 N·m (1.2 kgf·m, 8.9 lb·ft) level, wait 10 minutes. This will allow oil to settle into the crankcase for an accurate reading. 3. Remove the engine oil filler cap and wipe the If a torque wrench is not available when installing dipstick with a clean rag.
  • Page 89 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil. 4. Remove the engine oil filler cap, and then re- move the engine oil drain bolt to drain the oil from the crankcase.
  • Page 90 5. Clean the oil strainer with solvent. 6. Discard the old engine oil drain bolt O-ring, Be sure to wipe off spilled oil on any parts after the and then apply a thin coat of clean engine oil engine and exhaust system have cooled down. to the new O-ring.

  • Page 91: Why Yamalube

    EBU34473 Why Yamalube Transmission oil YAMALUBE oil is a Genuine YAMAHA Part born of The transmission case must be checked for oil the engineers’ passion and belief that engine oil is leakage before each ride. If any leakage is found, an important liquid engine component.
  • Page 92 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 93: Cleaning The Air Filter Element

    Recommended oil: See page 11-1. 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 94 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 95 [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 96: Cleaning The Spark Arrester

    The carburetor is an 2. Remove the spark arrester by pulling it out of important part of the engine and requires very so- the muffler. phisticated adjustment. Therefore, most carbure- tor adjustments should be left to a Yamaha dealer, 9-19...

  • Page 97: Adjusting The Engine Idling Speed

    (a), and to decrease The carburetor has been set and extensively it, turn the screw in direction (b). tested at the Yamaha factory. Changing these settings without sufficient technical knowl- edge may result in poor performance of or damage to the engine.

  • Page 98: Adjusting The Throttle Lever Free Play

    1. Rubber cover prevent this from occurring, the valve clearance 2. Throttle lever free play adjusting nut must be adjusted by a Yamaha dealer at the inter- 3. Locknut vals specified in the periodic maintenance chart. 4. Throttle lever free play Throttle lever free play: 1.5–4.0 mm (0.06–0.16 in)

  • Page 99: Brakes

    EBU29602 Brakes Replacement of brake components requires pro- fessional knowledge. Brake service should be performed by a Yamaha dealer. EWB02572 WARNING Operating with improperly serviced or adjust- ed brakes could lead to a loss in braking ability and an accident.

  • Page 100: Adjusting The Front Brake Lever Free Play

    EBU24334 Adjusting the front brake lever free play 1. Rear brake lever free play adjusting nut 2. Bolt 3. No more than 18 mm (0.71 in) 1. Front brake lever free play Front brake lever free play: 20.0–25.0 mm (0.79–0.98 in) Periodically check the front brake lever free play and adjust if necessary.
  • Page 101 a=a´ a´ 1. Upper locknut 1. Cable joint 2. Upper adjusting bolt 6. Tighten the upper locknut. 3. Lower locknut 4. Lower adjusting bolt After adjusting the brake lever free play, check the 4. Tighten the lower locknut. front brake shoes for wear. 5.

  • Page 102: Adjusting The Rear Brake Lever Free Play

    EBU33784 Adjusting the rear brake lever free play 1. Rear brake lever free play adjusting nut 1. Rear brake lever free play After adjusting the brake lever free play, check the Rear brake lever free play: rear brake shoes for wear. 30.0–40.0 mm (1.18–1.57 in) EBU34014 Periodically check the rear brake lever free play...
  • Page 103 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 104 4. To tighten the drive chain, turn the drive chain slack adjusting nut in direction (a). To loosen the drive chain, turn the adjusting nut in direc- tion (b) and push the rear wheels forward. NOTICE: Improper drive chain slack will overload the engine as well as other vital parts of the ATV and can lead to drive chain slippage or breakage.

  • Page 105: Lubricating The Drive Chain

    Service the essary. If a cable is damaged or does not move drive chain as follows. smoothly, have a Yamaha dealer check or replace ECB00562 NOTICE The drive chain must be lubricated after wash- Recommended lubricant: ing the ATV or riding in the rain or wet areas.

  • Page 106: Checking And Lubricating The Front And Rear Brake Levers

    Front brake lever EWB02582 WARNING  Inspect cables frequently and replace if damaged. Corrosion can result when the ca- ble sheaths become damaged, and cables can also become frayed or kinked, which could restrict the operation of controls and lead to an accident or injury. ...

  • Page 107: Checking The Wheel Hub Bearings

    If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bearings. 1. Grease nipple For parts equipped with a grease nipple, use a grease gun.

  • Page 108: Lubricating The Steering Shaft

    Lubricating the steering shaft hands after handling.  It is recommended to have the battery serviced The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the pe- by a Yamaha dealer. riodic maintenance chart. Recommended lubricant:...
  • Page 109 EWB02161 WARNING Battery electrolyte is poisonous and danger- ous, as it contains sulfuric acid, which can cause severe burns. Avoid contact with skin, eyes or clothing. Always shield your eyes when working near batteries. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk.
  • Page 110 ECB00622 ECB00942 NOTICE NOTICE  Always keep the battery charged. Storing the Never attempt to open the battery or remove the battery cell seals, as this would permanent- battery in a discharged state for an extended ly damage the battery. period of time will cause permanent battery damage.

  • Page 111: Replacing The Fuse

    EBU25248 Replacing the fuse 1. Positive battery lead (red) 2. Negative battery lead (black) 1. Fuse 3. Hook the battery band. 2. Spare fuse 4. Install the seat. (See page 5-13.) If an electrical problem is suspected, check the fuse and replace it if necessary as follows. ...

  • Page 112: Removing A Wheel

    3. Elevate the ATV and place a suitable stand 5. Install the seat. under the frame. 6. If the fuse immediately blows again, have a 4. Remove the bolts from the wheel. Yamaha dealer check the vehicle. 5. Remove the wheel. EBU34030 Removing a wheel EBU34042 Installing a wheel 1.

  • Page 113: Troubleshooting

    The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, ex- 1. Arrow mark perience, and know-how to service the ATV prop- 2.

  • Page 114: 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 115: 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 116: 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 117 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 118: Specifications

    EBU25964 SPECIFICATIONS Dimensions: Cooling system: Air cooled Overall length: Valve train: 1485 mm (58.5 in) SOHC Overall width: Number of cylinders: 1020 mm (40.2 in) Single cylinder Overall height: Displacement: 955 mm (37.6 in) 90 cm³ Seat height: Bore × stroke: 750 mm (29.5 in) 47.0 ×...
  • Page 119 Recommended engine oil grade: Minimum research octane: API service SG type or higher, JASO standard MA Fuel tank capacity: 130 ˚F 6.6 L (1.7 US gal, 1.5 Imp.gal) Fuel reserve amount: SAE 5W-30 0.9 L (0.24 US gal, 0.20 Imp.gal) Carburetor: SAE 10W-30 Type ×...
  • Page 120 Front tire: Front brake: Size: Type: AT18 x 7-8 Mechanical leading, trailing drum brake Manufacturer/model: Rear brake: DURO/DI2017 Type: Rear tire: Mechanical leading, trailing drum brake Front suspension: Size: AT18 x 9-8 Type: Manufacturer/model: Swing axle DURO/DI2016 Spring: Tire air pressure (measured on cold tires): Coil spring Vehicle load: Shock absorber:...
  • Page 121 Battery: Model: GTX5L-BS Voltage, capacity: 12 V, 4.0 Ah Lights: Neutral indicator light: 3.5 W Reverse indicator light: 3.5 W Fuses: Main fuse: 7.5 A 11-4...

  • Page 122: Consumer Information

    EBU25983 CONSUMER INFORMATION EBU29663 Vehicle Emission Control Information label The Vehicle Emission Control Information label is affixed at the location in the illustration. This label shows specifications related to exhaust emissions as required by federal law, state law and Environ- ment Canada.

  • Page 123: Noise Regulation

    EBU26061 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 124: Maintenance Record

    EBU26081 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work. MAINTENANCE INTERVAL DATE OF SERVICING DEALER...

  • Page 125: Yamaha Motor Corporation, U.s.a. 2020 And Later Model Atv Limited Warranty

    EBU30972 YAMAHA MOTOR CORPORATION, U.S.A. 2020 AND LATER MODEL ATV LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants THE CUSTOMER’S RESPONSIBILITY under this YAMAHA MOTOR CORPORATION, U.S.A. MAKES that new Yamaha ATVs purchased from warranty shall be to: OTHER WARRANTY...
  • Page 126 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

  • Page 127: Yamaha Extended Service (Y.e.s.)

    Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn’t limited to “moving par ts” or the “drive train” like many other plans.
  • Page 128 Yamaha. See your dealer today! YAMAHA EXTENDED SERVICE A special note: If visiting your dealer isn’t convenient, contact Yamaha with your VIN number (vehicle identification number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O. Box 6555...
  • Page 129 INDEX Engine stop switch ............5-2 Accessories and loading ..........7-6 Air filter element, cleaning ........... 9-16 Front and rear brake shoes, checking ......9-22 Front arm pivots, lubricating ........9-30 Front knuckle pivots, lubricating ......... 9-30 Battery ................. 9-31 Fuel ...............5-10, 6-3 Brake lever free play, adjusting the front .....
  • Page 130 Owner’s Manual and tool kit ..........9-2 Valve clearance ............9-21 Vehicle Emission Control Information label ....12-1 Vehicle identification number ......... 1-1 Parking ................7-5 Parking brake ..............5-6 Parking on a slope ............7-5 Warranty, extended ............12-6 Part locations ..............4-1 Warranty, limited ............12-4 Wheel hub bearings, checking ........
  • Page 131 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 132 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 GEAR NEVER operate: ALWAYS without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough...

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