Yamaha RAPTOR 125 2012 Owner's Manual
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Yamaha RAPTOR 125 2012 Owner's Manual

Yamaha RAPTOR 125 2012 Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM125RD
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-26-11
2PA-28199-12

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Summary of Contents for Yamaha RAPTOR 125 2012

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM125RD WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-26-11 2PA-28199-12...
  • Page 2 EBU17092 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 EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 5 Please check your local riding laws and regulations before operating this ATV. EBU17382 YFM125RD OWNER’S MANUAL ©2012 by Yamaha Motor Corporation, U.S.A. 1st edition, March 2012 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

  • Page 6: Table Of Contents

    Clutch lever ..........4-4 EWB00011 WARNING Brake lever ..........4-5 Indicates a hazardous situation which, if not Brake pedal ..........4-5 avoided, could result in death or serious injury. Parking brake lever ........4-6 Shift pedal ...........4-7 Fuel tank cap ..........4-7 Fuel .............4-8 EBU17420 Fuel cock ..........4-10 TABLE OF CONTENTS Starter (choke) ..........4-11...
  • Page 7 Starting a warm engine ......6-3 Periodic maintenance chart for the Shifting ............6-3 emission control system ......8-3 Engine break-in .......... 6-5 General maintenance and lubrication Parking ............6-5 chart ............8-5 Parking on a slope ........6-6 Removing and installing the panel ....8-9 Accessories and loading ......
  • Page 8 Checking the shift pedal ......8-37 Maintenance record ........11-5 Checking and lubricating the brake YAMAHA MOTOR CORPORATION, pedal ............8-37 U.S.A. ATV LIMITED WARRANTY ..11-6 Checking the wheel hub bearings .... 8-37 YAMAHA EXTENDED SERVICE Lubricating the swingarm pivots ....8-38 (Y.E.S.) ...........11-8...

  • Page 9: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 10 Improper AT V use can result in SEVERE ANSI / SVIA 1 - 2010 and is subject to an approved INJURY or DEATH. ATV action plan submitted by YAMAHA and on file with the U.S. Consumer Product Safety Commission. YAMAHA MOTOR CORPORATION U.S.A.
  • Page 11 WARNING WARNING lmproper tire pressure or overloading can cause This unit contains high pressure nitrogen gas. loss of control. Mishandling can cause explosion. Loss of control can result in severe injury or death. Read owner's manual for instructions. Do not incinerate, puncture or open. OPERATING TIRE PRESSURE : Set with tires cold Recommended : Front : 3.6 psi 25.0 kPa...

  • Page 12: Safety Information

    EBU17431 SAFETY INFORMATION ● EBU17578 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 13 ● 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 14 speed when climbing a hill. If you stall or roll ● Always use the size and type of tires specified in backwards, follow the special procedure for this manual. braking described in this manual. Dismount on ● Always maintain proper tire pressure as de- the uphill side or to a side if pointed straight up- scribed in this manual.
  • Page 15 should move to a position off the trail. If you curs at twilight or night, leave the main switch have sustained head, neck, or back injuries, on so that your lights may warn other riders of or cannot feel your limbs, you should not your stopped vehicle.
  • Page 16 While you may find aftermarket products similar in of the operator and may limit control ability, design and quality to genuine Yamaha accesso- therefore, such accessories are not recom- ries, recognize that some aftermarket accessories mended.
  • Page 17 and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in en- closed or poorly ventilated areas. If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT.

  • Page 18: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 2 3 4 1. Headlight 1. Spark arrester 2. Fuel cock 2. Fuse 3. Starter (choke) 3. Fuel tank cap 4. Throttle stop screw 4. Front shock absorber assembly spring preload adjusting ring 5.

  • Page 19: Controls And Instruments

    EBU17712 Controls and instruments 1 2 3 1. Clutch lever 2. Parking brake lever 3. Handlebar switches 4. Main switch 5. Throttle lever 6. Brake lever The ATV you have purchased may differ slightly from the figures shown in this manual.

  • Page 20: Instrument And Control Functions

    EBU17726 INSTRUMENT AND CONTROL FUNCTIONS EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU30070 Main switch The positions of the main switch are as follows: “ ” (on) All electrical systems are supplied with power. The headlight and taillight come on when the light 1.

  • Page 21: Indicator Light

    EBU17783 EBU18061 Indicator light Handlebar switches 1. Neutral indicator light “N” 1. Light switch “ /OFF” 2. Engine stop switch “ ” EBU17860 3. Start switch “ ” Neutral indicator light “ ” This indicator light comes on when the transmis- EBU18080 Engine stop switch “...

  • Page 22: Throttle Lever

    Regulate the speed of the ATV by varying the EBU18101 Start switch “ ” throttle position. Because the throttle is spring- Push this switch to crank the engine with the start- loaded, the ATV will decelerate, and the engine will er.

  • Page 23: Speed Limiter

    EBU18323 Speed limiter Your ATV is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power avail- able and the maximum speed of the ATV, turn the adjusting screw in direction (a).

  • Page 24: Brake Lever

    1. Clutch lever 1. Brake lever EBU18411 EBU18432 Brake lever Brake pedal The brake lever is located at the right handlebar The brake pedal is located on the right side of the grip. To apply the front brake, pull the brake lever ATV.

  • Page 25: Parking Brake Lever

    1. Brake pedal 1. Parking brake lever (locked position) EBU18520 Parking brake lever Use the parking brake before starting the engine or parking the ATV, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a).

  • Page 26: Shift Pedal

    EWB00220 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. ● Always be sure you have released the park- ing brake before you begin to ride.

  • Page 27: Fuel

    of sparks, open flames, or other sources of ig- nition such as the pilot lights of water heaters 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 28 Fuel reserve amount: rings, as well as to the exhaust system. 1.0 L (0.26 US gal, 0.22 Imp.gal) Your Yamaha engine has been designed to use 3. Wipe up any spilled fuel immediately. regular unleaded gasoline with a pump octane...

  • Page 29: Fuel Cock

    EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car- buretor 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 30: Starter (Choke)

    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. Arrow mark positioned over “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

  • Page 31: Adjusting The Front Shock Absorber Assemblies

    1. Seat lock lever 1. Projection 2. Seat holder To install the seat Insert the projections on the front of the seat into EBU18993 Adjusting the front shock absorber as- the seat holders and push down on the seat at the semblies rear.

  • Page 32: Adjusting The Rear Shock Absorber Assembly

    (a) to increase the spring preload and thereby harden the suspension, and in direc- tion (b) to decrease the spring preload and A special wrench can be obtained at a Yamaha thereby soften the suspension. dealer to make this adjustment.
  • Page 33 3. Distance A Tightening torque: Locknut: 42 Nm (4.2 m·kgf, 30 ft·lbf) ● A special wrench can be obtained at a Yamaha dealer to make this adjustment. ● The spring preload setting is determined by measuring distance A, shown in the illustration.
  • Page 34 Do not deform or damage the cylinder in any way. ● Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha deal- er for any service. EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 35: 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 36 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Rear brake 5-3, 8-25, 8-26, 8-29 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.

  • Page 37: Fuel

    Check that there is no free play in the brake le- do not provide proper braking performance, check ver. If there is free play, have a Yamaha dealer the brake pads for wear. (See page 8-25.) check the brake system.

  • Page 38: Drive Chain

    EBU19770 Recommended tire pressure: Drive chain Front Check the condition of the drive chain and check 25.0 kPa (0.250 kgf/cm², 3.6 psi) the drive chain slack. Lubricate and adjust the Rear drive chain as necessary. (See page 8-33.) 30.0 kPa (0.300 kgf/cm², 4.4 psi) Minimum tire pressure: EBU19794 Tires...
  • Page 39 EWB02551 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 40: Chassis Fasteners

    EBU19850 Front: Instruments, lights and switches Manufacturer/model: Check that all instruments, lights and switches are MAXXIS/M957Y working properly. Correct if necessary. Size: AT19 x 6-10 Type: Tubeless Rear: Manufacturer/model: MAXXIS/M940 Size: AT18 x 9-8 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,...

  • Page 41: Operation

    4. Shift the transmission into neutral. The neutral EBU19901 indicator light should come on. If the indicator light does not come on, have a Yamaha deal- Read the Owner’s Manual carefully before riding er check the electrical circuit. the ATV. If there is a control or function you do not understand, ask your Yamaha dealer.
  • Page 42 Position (2): Cold engine start with ambient temperature If the engine fails to start, release the start switch, between 0 °C (30 °F) and 30 °C (90 °F). then push it again. Pause a few seconds before Position (3): the next attempt. Each cranking should be as short Cold engine start with ambient temperature as possible to preserve battery energy.

  • Page 43: Starting A Warm Engine

    EBU20291 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. EBU20522 Shifting This ATV has a 5-speed forward transmission.
  • Page 44 4. Open the throttle gradually and at the same EWB00710 WARNING time, release clutch lever slowly. WARNING! Opening the throttle abruptly Make sure the engine has sufficiently slowed or releasing the clutch lever too quickly before shifting to a lower gear. Engaging a low- could make the ATV wheelie, which would er gear when the engine speed is too high increase the chance of an accident, includ-...

  • Page 45: Engine Break-In

    There is never a more important period in the life of engine break-in period, immediately have a your engine than the first 320 km (200 mi) or 20 Yamaha dealer check the ATV. hours of riding. For this reason, you should read the following material carefully.

  • Page 46: 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 front brake, shift into first gear, and then stop the engine. 2. With the front and rear brakes applied, apply the parking brake.

  • Page 47: Accessories And Loading

    An accessory which can shift position sories or offer other modifications for Yamaha or come off while you are riding could affect your vehicles. Yamaha is not in a position to test the ability to control the ATV. products that these aftermarket companies pro- ●...
  • Page 48 ● If you are carrying cargo and towing a trailer, in- EBU20941 Loading clude the tongue weight in the maximum ATV EWB00820 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 49 EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 50: Riding Your Atv

    EBU21132 RIDING YOUR ATV...

  • Page 51: Getting To Know Your Atv

    Before you begin to ride, be sure you complete the certified training course offered by have read this Owner’s Manual completely and un- Yamaha. They should then regularly practice the derstand the operation of the controls. Pay partic- skills learned in the course and the operating tech-...
  • Page 52 niques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics.
  • Page 53 proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. [EWB01411] Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury. Eye protection, such as a face shield or goggles, may reduce the risk of foreign material getting in your eyes and help prevent loss of vision.
  • Page 54 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance Do not operate after or while consuming alco- procedures and schedules described in the Own- hol or drugs.
  • Page 55 opening, even when the throttle lever is pushed to ● Do not exceed the maximum loading limits the maximum. Turning in the adjusting screw limits for the vehicle (see “MAXIMUM LOADING the maximum engine power available and de- LIMIT” below or vehicle labeling). ●...
  • Page 56 All parts and accessories added to this ATV should be genuine Yamaha or equivalent components de- signed for use on this ATV and should be installed and used according to instructions. If you have...
  • Page 57 questions, consult an authorized ATV dealer. other hot parts. Check under the vehicle after op- WARNING! Operating this ATV with improper erating in areas where combustible materials may modifications may cause changes in handling have collected. Do not idle or park the vehicle in which in some situations could lead to an acci- long dry grass or other dry ground cover.

  • Page 58: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE ATVs on public streets, roads and highways. This ATV is designed for off-road use only. WARNING! Never operate this ATV on any pub- WARNING! Paved surfaces may seriously af- lic street, road or highway, even a dirt or gravel fect handling and control of the ATV, and may one.
  • Page 59 ful when operating on unfamiliar terrain. Al- ways be alert to changing terrain conditions when operating the ATV. [EWB01531] 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 60 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 control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain.

  • Page 61: Turning Your Atv

    trol. NOTICE: Do not shift gears without To achieve maximum traction while riding off-road, [EWB02631] releasing the throttle. Damage to the engine or the two rear wheels turn together at the same drive train may occur. speed. Therefore, unless the wheel on the inside [ECB01071] Use this same procedure as you move into the of the turn is allowed to slip or lose some traction,...

  • Page 62: Climbing Uphill

    Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside.
  • Page 63 ● Never open the throttle suddenly or make sudden gear changes. 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 64 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footrests and leaning forward over the handlebars. Whenever possible, ride straight up hills.
  • Page 65 If you start to roll backwards, DO NOT apply the rear brake, and apply the front brake gradually. The ATV could easily tip over backwards. When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount the ATV im- mediately on the uphill side or to a side if pointed straight uphill.

  • Page 66: 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- EWB01131 WARNING sible. Move back on the seat and sit with your arms Going down a hill improperly could cause straight.

  • Page 67: Crossing A Slope

    ● Avoid crossing the side of a steep hill. ● Shift your weight to the uphill side of the ATV. ● 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.

  • Page 68: Crossing Through Shallow Water

    than the depth specified in your Owner’s Man- ual, as tires may float, increasing the risk of an overturn. The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth.
  • Page 69 Test your brakes after leaving the water. If neces- After riding your ATV in water, be sure to drain the sary, apply them several times to let friction dry out trapped water by removing the check hose at the the linings. Do not continue to ride your ATV with- bottom of the air filter case.

  • Page 70: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN ● Learn to safely control skidding or sliding by practicing at low speeds and on level, EWB01651 WARNING smooth terrain. ● Riding improperly over obstacles could cause On extremely slippery surfaces, such as ice, loss of control or a collision. Before operating go slowly and be very cautious in order to re- in a new area, check for obstacles.

  • Page 71: What To Do If

    If the rear wheels of your ATV start to slide side- WHAT TO DO IF... ways, control can usually be regained (if there is This section is designed to be a reference guide room to do so) by steering in the direction of the only.
  • Page 72 THE REAR BRAKE – the ATV may tip over on top of you. Dismount the ATV on the uphill side. (See page 7-13.) ● 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.

  • Page 73: 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 74: Owner's Manual And Tool Kit

    Always carry the owner’s man- If you do not have the tools or experience required ual along with the low-pressure tire gauge and the for a particular job, have a Yamaha dealer perform owner’s tool kit under the seat. it for you.

  • Page 75: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. INITIAL...
  • Page 76 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 77: 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 be followed. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. INITIAL...
  • Page 78 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses • Replace. Every 4 years √...
  • Page 79 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Make sure that all nuts, bolts, and screws are √ √ √ √ √ 14 * Chassis fasteners properly tightened.
  • Page 80 EBU23071 ● Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. ● Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

  • Page 81: Removing And Installing The Panel

    EWB00011 EBU30180 Panel A WARNING Indicates a hazardous situation which, if not To remove the panel avoided, could result in death or serious injury. 1. Remove the quick fasteners. EBU23080 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter.
  • Page 82 To install the panel 1. Place the panel in its original position, and then install the socket (together with the bulb) by pushing it in. NOTICE: When installing the panel, be sure not to pinch the cables or wires. [ECB00381] 1.

  • Page 83: Checking The Spark Plug

    1. Socket 1. Spark plug cap 2. Install the quick fasteners. 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool EBU23213 kit. Checking the spark plug The spark plug is an important engine component, which is easy to check.
  • Page 84 0.6–0.7 mm (0.024–0.028 in) the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. To install the spark plug 1. Clean the surface of the spark plug gasket 2.

  • Page 85: Engine Oil

    2. Install the spark plug with the spark plug wrench, and then tighten it to the specified If the engine was started before checking the oil torque. level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- Tightening torque: tles for an accurate reading.
  • Page 86 4. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level. The engine oil should be between the minimum and maximum level marks. 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type to raise it to the correct level.
  • Page 87 Recommended oil: See page 10-1. Oil quantity: 1.25 L (1.32 US qt, 1.10 Imp.qt) Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down. ECB00300 NOTICE 1. Engine oil drain bolt ●...

  • Page 88: Cleaning The Air Filter Element

    9. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary. 10. Install the engine guard by installing the bolts, and then tighten them to the specified torque. Tightening torque: Engine guard bolt: 7 Nm (0.7 m·kgf, 5.1 ft·lbf) EBU30221...
  • Page 89 1. Air filter case cover 1. Wing bolt 2. Air filter case cover holder 2. Air filter element 4. Loosen the wing bolt. 6. Remove the wing bolt and washers from the 5. Remove the air filter element together with the air filter element.
  • Page 90 2. Air filter element frame damaged. 8. Wash the sponge material gently but thor- 11. Apply Yamaha foam air filter oil or other qual- oughly in solvent. WARNING! Always use ity foam air filter oil to the sponge material. parts cleaning solvent to clean the sponge material.
  • Page 91 1. Air filter element seat 1. Wing bolt 2. Lock washer 14. Install the washers onto the wing bolt as 3. Plain washer shown. 4. Flange washer 15. Insert the wing bolt into the hole in the air filter element frame. NOTICE: Be sure to install the flange washer with its curved side fac- ing outward as shown.

  • Page 92: Cleaning The Spark Arrester

    18. Install the seat. The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar- eas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions.
  • Page 93 1. Tailpipe bolt 1. Tailpipe 2. Tailpipe 2. Spark arrester 2. Remove the tailpipe by pulling it out of the 4. Check the gasket for damage, and replace it if muffler, and then remove the gasket. necessary. 3. Tap the tailpipe lightly, and then use a wire 5.

  • Page 94: Adjusting The Carburetor

    Therefore, 1. Gasket most carburetor adjustments should be left to a 2. Tailpipe Yamaha dealer, who has the necessary profes- 3. Tailpipe bolt sional knowledge and experience. The adjustment 6. Install the bolts and tighten them to the speci- described in the following section, however, may fied torque.

  • Page 95: Adjusting The Engine Idling Speed

    3. Check the engine idling speed and, if neces- If the specified idling speed cannot be obtained as sary, adjust it to specification by turning the described above, have a Yamaha dealer make the throttle stop screw at the carburetor. To in- adjustment.

  • Page 96: Valve Clearance

    The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart.

  • Page 97: Brakes

    If a brake pad has worn to the point that a wear indicator groove almost appears, have that a wear indicator groove almost appears, have a Yamaha dealer replace the brake pads as a set. a Yamaha dealer replace the brake pads as a set. 8-25...

  • Page 98: Checking The Brake Fluid Level

    Front brake 1. Wear indicator 1. Minimum level mark EBU30201 Rear brake Checking the brake fluid level Before riding, check that the brake fluid is above the minimum level mark. Check the brake fluid lev- el with the top of the reservoir level. Replenish the brake fluid if necessary.
  • Page 99 To access the rear brake fluid reservoir for replen- ishing: 1. Remove the brake fluid reservoir cap cover by removing the bolt. 1. Brake fluid reservoir cap 3. Refill with brake fluid. 4. Install the brake fluid reservoir cap. 5. Install the brake fluid reservoir cap cover by in- 1.
  • Page 100 If the brake fluid level goes down suddenly, mance. have a Yamaha dealer check the cause before fur- ● Clean the filler cap before removing. Use ther riding.

  • Page 101: Changing The Brake Fluid

    EBU24291 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and cali- pers as well as the brake hoses replaced at the in- tervals listed below or whenever they are damaged or leaking.

  • Page 102: Adjusting The Parking Brake Free Play

    1. Brake pedal height 1. Adjusting bolt 2. Cable length “A” EBU24715 3. Locknut Adjusting the parking brake free play 1. Release the parking brake by moving the The parking brake free play must be checked and, parking brake lever to the right. if necessary, adjusted at the intervals specified in 2.

  • Page 103: Brake Light Switches

    If the cable length cannot be adjusted to specifica- ATV off the ground and spin the rear wheels. tion, consult a Yamaha dealer. Check to make sure there is no brake drag. If brake drag is noticed, perform the adjustment 6.

  • Page 104: Adjusting The Clutch Lever Free Play

    10.0 mm (0.20–0.39 in) as shown. If the free play should be adjusted by a Yamaha dealer. is incorrect, adjust it as follows. Turn the rear brake light switch adjusting nut while holding the brake light switch in place.

  • Page 105: Drive Chain Slack

    5. Slide the rubber cover back to its original po- sition. If the specified free play cannot be obtained as de- scribed above or if the clutch does not operate cor- rectly, have a Yamaha dealer check the internal clutch mechanism. EBU26864 Drive chain slack The drive chain slack should be checked before 1.
  • Page 106 1. Rear wheel axle pinch bolt 2. Rod 3. Drive chain tensioner 4. Hole A rod can be obtained at a Yamaha dealer to make this adjustment. Tightening torque: Rear axle pinch bolt: 4. Shift the transmission into neutral.

  • Page 107: Lubricating The Drive Chain

    EBU24882 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. ECB00561 NOTICE The drive chain must be lubricated after wash-...

  • Page 108: Checking And Lubricating The Brake And Clutch Levers

    If a cable is damaged or does not move EBU24922 Checking and lubricating the brake and smoothly, have a Yamaha dealer check or replace clutch levers The operation of the brake and clutch levers Recommended lubricant: should be checked before each ride, and the lever Yamaha Chain and Cable Lube or engine oil pivots should be lubricated if necessary.

  • Page 109: Checking The Shift Pedal

    If there is play in a wheel hub or if a wheel does not turn smoothly, pedal have a Yamaha dealer check the wheel hub bear- The operation of the brake pedal should be ings. checked before each ride, and the pedal pivot should be lubricated if necessary.

  • Page 110: Lubricating The Swingarm Pivots

    Lubricating the upper and lower arm The swingarm pivots must be lubricated by a pivots Yamaha dealer at the intervals specified in the pe- The upper and lower arm pivots must be lubricated riodic maintenance and lubrication chart. at the intervals specified in the periodic mainte- nance and lubrication chart.

  • Page 111: Lubricating The Steering Shaft

    2. Lower grease nipple 2. Lower grease nipple EBU25092 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. For parts equipped with a grease nipple, use a grease gun.

  • Page 112: Battery

    EWB02160 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 113 2. Positive battery lead (red) 4. Pull the battery out of its compartment. To charge the battery 1. Band Have a Yamaha dealer charge the battery as soon 2. Battery holding plate as possible if it seems to have discharged. Keep in 3. Bolt...
  • Page 114 2. Connect the positive battery lead first, then ECB00931 NOTICE connect the negative battery lead by installing their bolt. NOTICE: When installing the bat- To charge a VRLA (Valve Regulated Lead Acid) battery, a special (constant-voltage) battery tery, the main switch must be off, and the charger is required.

  • Page 115: Replacing The Fuse

    EBU30590 Replacing the fuse The fuse holder is located beside the battery and can be accessed as follows: 1. Remove the seat. (See page 4-11.) 2. Unhook the band securing the owner’s tool kit, and then remove the battery holding plate by removing the bolts.

  • Page 116: Replacing The Headlight Bulb

    ” (on) and turn on the elec- trical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 1. Screw 5. Install the battery holding plate by installing the bolts, and then hook the band to secure the owner’s tool kit.
  • Page 117 1. Screw 1. Headlight bulb holder cover 2. Headlight unit 3. Tilt the headlight unit slightly forward, and then remove the headlight bulb holder cover. 4. Remove the headlight bulb holder by pushing it in and turning it counterclockwise, and then remove the burnt-out bulb.
  • Page 118 5. Place a new headlight bulb into position. NOTICE: Do not touch the glass part of the headlight bulb to keep it free from oil, oth- erwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected.

  • Page 119: Adjusting A Headlight Beam

    10. Adjust the headlight beam if necessary. 4. Rubber damper EBU25551 Adjusting a headlight beam ECB00690 NOTICE It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). 8-47...

  • Page 120: Replacing The Tail/Brake Light Bulb

    To lower a headlight beam, turn the adjusting screw in direction (b). 1. Nut 3. Remove the tail/brake light bulb holder (to- 1. Headlight beam adjusting screw gether with the bulb) by turning it counter- clockwise. EBU30211 Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as follows.

  • Page 121: Removing A Wheel

    1. Tail/brake light bulb holder 1. Tail/brake light bulb 2. Tail/brake light assembly 2. Tail/brake light bulb holder 4. Remove the burnt-out bulb by pushing it in 6. Install the bulb holder (together with the bulb) and turning it counterclockwise. by turning it clockwise.

  • Page 122: Installing A Wheel

    Rear wheel nut: 45 Nm (4.5 m·kgf, 33 ft·lbf) EBU25720 Troubleshooting Although Yamaha ATVs receive a thorough in- spection before shipment from the factory, trouble may occur during operation. Any problem in the fu- el, compression, or ignition systems, for example, can cause poor starting and loss of power.
  • Page 123 However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.

  • Page 124: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.

  • Page 125: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE may cause water seepage and deteriora- EBU25902 Cleaning tion of wheel bearings, brakes, transmis- Frequent, thorough cleaning of your ATV will not sion seals and electrical devices. Many only enhance its appearance but will improve its expensive repair bills have resulted from general performance and extend the useful life of improper high-pressure detergent applica-...

  • Page 126: Storage

    EBU25933 Specified amount: Storage 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel) Short-term Always store your ATV in a cool, dry place and, if 5. Perform the following steps to protect the cyl- necessary, protect it against dust with a porous inder, piston rings, etc.
  • Page 127 ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month.

  • Page 128: Specifications

    EBU25961 SPECIFICATIONS Dimensions: Compression ratio: 10.00 : 1 Overall length: Starting system: 1610 mm (63.4 in) Electric starter Overall width: Lubrication system: 1018 mm (40.1 in) Wet sump Overall height: Engine oil: 1010 mm (39.8 in) Seat height: Recommended brand: 715 mm (28.1 in) YAMALUBE Wheelbase:...
  • Page 129 Engine oil quantity: Secondary reduction ratio: Periodic oil change: 48/14 (3.429) 1.25 L (1.32 US qt, 1.10 Imp.qt) Transmission type: Air filter: Constant mesh 5-speed Operation: Air filter element: Left foot operation Wet element Gear ratio: Fuel: 1st: Recommended fuel: 37/14 (2.643) Unleaded gasoline only 2nd:...
  • Page 130 Rear tire: Rim size: 8 x 7.0AT Type: Front brake: Tubeless Size: Type: AT18 x 9-8 Disc brake Manufacturer/model: Operation: MAXXIS/M940 Right hand operation Loading: Specified brake fluid: DOT 4 Maximum loading limit: Rear brake: 100.0 kg (220 lb) (Total weight of rider, cargo, accessories, and tongue) Type: Tire air pressure (measured on cold tires): Disc brake...
  • Page 131 Electrical system: Ignition system: DC CDI Charging system: AC magneto Battery: Model: YTZ7S Voltage, capacity: 12 V, 6.0 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage × quantity: Headlight: 12 V, 35.0/36.5 W × 1 Tail/brake light: 12 V, 5.0/21.0 W × 1 Neutral indicator light: 12 V, 1.7 W ×...

  • Page 132: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 133 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 deal- 11-2...
  • Page 134 1. Vehicle Emission Control Information label 11-3...

  • Page 135: Noise Regulation

    EBU26060 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 de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ul- timate 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 136: Maintenance Record

    EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.

  • Page 137: Yamaha Motor Corporation, U.s.a. Atv Limited Warranty

    (6) months from the date of purchase. appropriate owner’s manual; YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 2. Give notice to an authorized Yamaha ATV dealer OTHER WARRANTY OF ANY KIND, EXPRESSED OR of any and all apparent defects within ten (10) days DURING THE PERIOD OF WARRANTY any authorized IMPLIED.
  • Page 138 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 139: Yamaha Extended Service (Y.e.s.)

    Yamaha people who handle your warranty – and it 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 much more valuable! “moving par ts”...
  • Page 140 Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
  • Page 141 INDEX Accessories and loading ..........6-7 Engine break-in .............. 6-5 Air filter element, cleaning ..........8-16 Engine, cold start ............6-1 Engine idling speed ............. 8-23 Engine oil .............. 5-3, 8-13 Battery ................8-40 Engine, starting a warm ..........6-3 Brake and clutch levers, checking and lubricating ..
  • Page 142 Maintenance chart, emission control system ....8-3 Storage ................9-2 Maintenance record ............. 11-5 Suspension, lubricating the upper and lower arm Model label ..............11-2 pivots ................. 8-38 Swingarm pivots, lubricating ........8-38 Neutral indicator light ............. 4-2 Noise regulation ............11-4 Tail/brake light bulb, replacing ........
  • Page 143 EBU30390 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 144 EBU26142 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 ALWAYS operate: 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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