Yamaha YFZ05YYXL Owner's Manual
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Yamaha YFZ05YYXL Owner's Manual

Yamaha YFZ05YYXL Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFZ05YYXL
WARNING
This ATV should not be ridden by anyone under 6 years of age.
BW4-F8199-30

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Summary of Contents for Yamaha YFZ05YYXL

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFZ05YYXL WARNING This ATV should not be ridden by anyone under 6 years of age. BW4-F8199-30...
  • 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: Important Manual Information

    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: Important Notice

    Please check your local riding laws and regulations before operating this ATV. EBU33790 YFZ05YYXL OWNER’S MANUAL ©2020 by Yamaha Motor Co., Ltd. 1st edition, December 2018 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 7: Table Of Contents

    EBU17421 TABLE OF CONTENTS LOCATION OF THE WARNING AND Starter (choke) ......... 4-11 SPECIFICATION LABELS ......1-1 Seat ............4-12 Rear shock absorber ........ 4-13 SAFETY INFORMATION ........ 2-1 PRE-OPERATION CHECKS ......5-1 DESCRIPTION..........3-1 Fuel ............. 5-3 Left view............3-1 Engine oil ............
  • Page 8 RIDING YOUR ATV ........7-1 Transmission oil........8-15 GETTING TO KNOW YOUR ATV ....7-2 Cleaning the air filter element ....8-16 RIDE WITH CARE AND GOOD Cleaning the spark arrester ...... 8-19 JUDGMENT ..........7-2 Adjusting the carburetor ......8-20 BE CAREFUL WHERE YOU RIDE....7-9 Adjusting the engine idling speed ....
  • Page 9 Troubleshooting chart .......8-38 CLEANING AND STORAGE ......9-1 Cleaning ............9-1 Storage............9-2 SPECIFICATIONS ........10-1 CONSUMER INFORMATION ....... 11-1 Identification numbers ......11-1 INDEX............12-1...

  • Page 10: 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 11 For Oceania...
  • Page 12 WARNING WARNING Improper ATV use can result in SEVERE INJURY or DEATH. UNDER ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR Operation of this ATV by children NEVER operate : under the age of 6 increases the without proper training or instruction.
  • Page 13 WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. BD3-F151H-00 BW4-F816M-70...
  • Page 14 For Mexico...
  • Page 15 BW4-F816L-50 BD3-F816R-20...
  • Page 16 BD3-F816P-50 15 kPa 15 kPa 0.15 kgf/cm² 0.15 kgf/cm² 2.2 psi 2.2 psi BW4-F816M-N0...

  • Page 17: Safety Information

    EBU17432 SAFETY INFORMATION SAFETY INFORMATION EBU36352 – A child under 12 years old should never oper- ate an ATV with engine size greater than 70 cc. AN ATV IS NOT A TOY AND CAN BE HAZARD- – A child under 16 years old should never oper- OUS TO OPERATE.
  • Page 18  Never consume alcohol or drugs before or while  Always follow proper procedures for turning as operating this ATV. described in this manual. Practice turning at low  Never operate at speeds too fast for your skills speeds before attempting to turn at faster or the riding conditions.
  • Page 19  Never operate an ATV in fast flowing water or in surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around water deeper than that recommended in this on any hill until you have mastered the turning manual.
  • Page 20 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 21 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 22 TEACHING YOUR CHILD TO OPERATE THE Be sure your child is ready to learn how to ride As a parent, your first step is to decide when your child has the strength, skills, and judgment to EWB00081 WARNING learn how to operate an ATV safely. Re-evaluate Never let your child ride an ATV without close your child’s readiness before every use;...
  • Page 23 Choose an appropriate riding area 1. Install the cap on the end of the engine stop Select an area appropriate for your child to learn switch cord onto the engine shut-off switch to ride. (See page 7-9.) Follow the instructions in (white button).
  • Page 24  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 25: Description

    EBU17681 DESCRIPTION EBU17691 EBU17701 Left view Right view 1. Fuel tank cap 1. Spark arrester 2. Fuel cock 2. Reflector 3. Air filter 3. Tool kit 4. Engine stop switch with cord (lanyard) 4. Fuse 5. Rear shock absorber 5. Battery 6.

  • Page 26: Controls And Instruments

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

  • Page 27: Instrument And Control Functions

    EBU17739 INSTRUMENT AND CONTROL FUNCTIONS EBU33850 EBU18067 Main switch Handlebar switches The positions of the main switch are as follows: All electrical systems are supplied with power, and the engine can be started. The key cannot be re- moved. All electrical systems are off. The key can be re- moved.

  • Page 28: Engine Stop Switch With Lanyard

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

  • Page 29: Throttle Lever

    However, you must vices. A vehicle speed limiter adjusting screw and still closely supervise your child at all times dur- a removable engine speed limiter plate. Yamaha ing ATV operation. recommends that all beginning riders start off with...
  • Page 30 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 31: 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 panel. dlebar. To apply the front brake, pull the brake le- ver toward the handlebar grip.

  • Page 32: Rear Brake Lever

    EBU18403 Rear brake lever 1. Parking brake lock plate EWB00221 1. Rear brake lever WARNING The rear brake lever is located on the left handle-  Always set the parking brake before starting bar. To apply the rear brake, pull the brake lever the engine.

  • Page 33: Kickstarter

    braking performance which could cause an accident. You could also wear out the brakes prematurely. EBU33893 Kickstarter Use the kickstarter to start the engine when the battery voltage is low. 1. Remove the seat (page 4-12), and then re- move the kickstarter lever. 1.

  • Page 34: Fuel Tank Cap

    EBU37980 Fuel tank cap 1. Fold out. 2. Push down. 1. Fuel tank cap 5. When the engine has started, remove the Remove the fuel tank cap by turning it counter- kickstarter lever and store it under the seat. clockwise. 6.

  • Page 35: Fuel

    of sparks, open flames, or other sources of 3. Wipe up any spilled fuel immediately. NOTICE: Immediately wipe off spilled fuel ignition such as the pilot lights of water heat- ers and clothes dryers. with a clean, dry, soft cloth, since fuel may 2.

  • Page 36: Fuel Cock

    EBU18821 Recommended fuel: Fuel cock Regular unleaded gasoline only The fuel cock supplies fuel from the tank to the Fuel tank capacity: carburetor while also filtering it. 5.6 L (1.5 US gal, 1.2 Imp.gal) The fuel cock lever positions are explained as fol- Fuel reserve amount: lows and shown in the illustrations.

  • Page 37: 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 38: Seat

    EBU36431 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 39: Rear Shock Absorber

    To install the seat 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 40 A special wrench can be obtained at a Yamaha dealer to make this adjustment. 1. Special wrench Spring preload setting: Minimum (soft): Standard: Maximum (hard): 4-14...

  • 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. 5-3, 8-22 • Check lever free play, and adjust if necessary. Control cables • Make sure that operation is smooth. Lubricate if necessary. 8-29 •...

  • 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 8-11.) open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if EBU34490 necessary. Transmission oil...
  • 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 4. Position the starter (choke) lever according to the ATV. If there is a control or function you do not the ambient temperature. understand, ask your Yamaha dealer. Position (1): EWB00632 Cold engine start with ambient temperature WARNING below 5 °C (40 °F).
  • Page 48  If the engine fails to start using the start switch, Ambient temp./starter (choke) position try using the kickstarter. (See page 4-7.) 6. If the engine is started with the starter (choke) lever in position (1), move the lever to position (2) to warm up the engine.

  • Page 49: Starting A Warm Engine

    240 km (150 mi) or 20 engine break-in period, immediately have a hours of operation. For this reason, you should fol- Yamaha dealer check the ATV. low the engine break-in instructions carefully. Since the engine is brand new, do not put an ex-...

  • Page 50: Parking On A Slope

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

  • Page 51: Accessories And Loading

    An accessory which can shift position and accessories or offer other modifications for or come off while you are riding could affect Yamaha vehicles. Yamaha is not in a position to your ability to control the ATV. test the products that these aftermarket compa- ...
  • Page 52  If you are carrying cargo and towing a trailer, in- EBU33880 Loading clude the tongue weight in the maximum ATV EWB00821 load limit. WARNING  Load cargo on the carriers as close to the center Never exceed the stated load capacity for this of the ATV as possible.

  • Page 53: Riding Your Atv

    EBU21142 RIDING YOUR ATV...

  • Page 54: Getting To Know Your Atv

    RIDE WITH CARE AND GOOD JUDGMENT EBU21525 Beginning riders should get training from a GETTING TO KNOW YOUR ATV certified instructor. This ATV is intended for recreational use by young EWB01382 operators under adult supervision. This section, WARNING “Riding your ATV”, provides general riding instruc- ...
  • Page 55 teristics. Take the time to learn the basic tech- This ATV is designed to carry the operator only niques well before attempting more difficult – passengers prohibited. maneuvers. The long seat is to allow the operator to shift posi- tion as needed during operation. It is not for carry- Not recommended for children under 6 years ing passengers.
  • Page 56 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 57 (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 58  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 59 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 60 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 61: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE Watch carefully for other vehicles. Make sure you This ATV is designed for use on unpaved surfaces know your country’s laws and regulations before only. WARNING! Paved surfaces may seriously you ride on unpaved public streets or roads. Do affect handling and control of the ATV, and not ride on any paved public street, road or motor- may cause the ATV to go out of control.
  • Page 62 bumps, or holes. Go slowly and be extra care- ful when operating on unfamiliar terrain. Al- ways be alert to changing terrain conditions when operating the ATV. [EWB01532] When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.
  • Page 63 Select a large, flat, unpaved area to become famil- iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice Do not ride in areas posted “no trespassing”. control of the throttle, brakes, and turning tech- Do not ride on private property without getting niques in this area before trying more difficult ter- permission.

  • Page 64: Turning Your Atv

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

  • Page 65: 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 66  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 67 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 68: Riding Downhill

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

  • Page 69: Crossing A Slope

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

  • Page 70: 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 71 The ATV can be used to cross slow moving, shal- braking ability. WARNING! Wet brakes may have low water of up to a maximum of 11 cm (4 in) in reduced stopping ability, which could cause depth. Before entering the water, choose your loss of control.

  • Page 72: 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 73: 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 74: 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 75: 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 76: 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 77: 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 distance 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 78 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 79: 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 distance 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 80 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours • Check runout and for damage, and replace if nec- √ √ √ √ Wheels essary. • Check tread depth and for damage, and replace if necessary.
  • Page 81 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours • Check operation and repair or replace if dam- √ √ √ √ √ Steering system aged. •...
  • Page 82 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 83: Removing And Installing The Panel

    EBU23081 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. 1. Panel A 2.
  • Page 84 (the ideal color when the ATV is ridden normally). If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-10...

  • Page 85: Engine Oil

    2. Check the spark plug for electrode erosion To install the spark plug and excessive carbon or other deposits, and 1. Clean the surface of the spark plug gasket replace it if necessary. and its mating surface, and then wipe off any grime from the spark plug threads.
  • Page 86 To check the engine oil level 1. Park the ATV on a level surface. 2. Wait for the engine to cool. If the engine was started before checking the oil level, wait 10 minutes. This will allow oil to settle into the crankcase for an accurate reading.
  • Page 87 2. Start the engine, warm it up for several min- 5. Clean the oil strainer with solvent. utes, and then turn it off. 6. Discard the old engine oil drain bolt O-ring, 3. Place an oil pan under the engine to collect and then apply a thin coat of clean engine oil the used oil.

  • Page 88: Why Yamalube

    EBU38620 Why Yamalube Be sure to wipe off spilled oil on any parts after the YAMALUBE oil is a Genuine YAMAHA Part born of engine and exhaust system have cooled down. the engineers’ passion and belief that engine oil is an important liquid engine component.

  • Page 89: Transmission Oil

    The transmission case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. 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 4-12.) 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

    1. Remove the tailpipe bolts. to a Yamaha dealer, who has the necessary pro- 2. Remove the tailpipe by pulling it out of the fessional knowledge and experience. The adjust- muffler, and then remove the gasket.
  • Page 95 1600–1800 r/min tle stop screw in direction (a), and to decrease it, turn the screw in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 8-21...

  • Page 96: 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 4. Throttle lever free play vals specified in the periodic maintenance and lu- brication chart.

  • Page 97: Checking The Front And Rear Brake Shoes

    EWB02572 WARNING Operating with improperly serviced or adjust- ed brakes could lead to a loss in braking ability and an accident. EBU34511 Checking the front and rear brake shoes The front and rear brake shoes must be checked for wear at the intervals specified in the periodic 1.

  • Page 98: 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: 9.3–13.3 mm (0.37–0.52 in) Periodically check the front brake lever free play and adjust if necessary.
  • Page 99 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 100: 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. 7.6–12.9 mm (0.30–0.51 in) EBU34014 Periodically check the rear brake lever free play...
  • Page 101 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: 6.0–12.0 mm (0.24–0.47 in) 1.
  • Page 102 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 103: Cleaning And Lubricating The Drive Chain

     Inspect cables frequently and replace if damaged. Corrosion can result when the ca- For a thorough cleaning, have a Yamaha dealer re- ble sheaths become damaged, and cables move the drive chain and soak it in solvent.

  • 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. 8-30...

  • Page 105: Lubricating The Front Arm Pivots

    1. Grease nipple EBU36391 Lubricating the front arm pivots The front arm pivots must be lubricated at the in- For parts equipped with a grease nipple, use a tervals specified in the periodic maintenance and grease gun. lubrication chart. Recommended lubricant: EBU28825 Lubricating the front knuckle pivots Lithium-soap-based grease...

  • Page 106: Lubricating The Steering Shaft

    (valve-regulated lead-acid) battery. There is no The steering shaft must be lubricated by a need to check the electrolyte or to add distilled Yamaha dealer at the intervals specified in the pe- water. However, the battery lead connections riodic maintenance and lubrication chart.
  • Page 107 1. Remove panel A. (See page 8-9.) hands after handling. 2. Unhook the battery band.  It is recommended to have the battery serviced by a Yamaha dealer. EWB02161 WARNING Battery electrolyte is poisonous and danger- ous, as it contains sulfuric acid, which can cause severe burns.
  • Page 108 4. Pull the battery out of its compartment. ECB00942 NOTICE ECB00622 NOTICE  Always keep the battery charged. Storing the Never attempt to open the battery or remove battery in a discharged state for an extended the battery cell seals, as this would permanent- period of time will cause permanent battery ly damage the battery.

  • Page 109: Replacing The Fuse

    EBU36415 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 panel. If an electrical problem is suspected, check the fuse and replace it if necessary as follows. ...

  • Page 110: Removing A Wheel

    3. Elevate the ATV and place a suitable stand 5. Install the panel. 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 111: 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 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

    EBU25963 SPECIFICATIONS Dimensions: Cooling system: Air cooled Overall length: Valve train: 1250 mm (49.2 in) SOHC Overall width: Number of cylinders: 820 mm (32.3 in) Single cylinder Overall height: Displacement: 770 mm (30.3 in) 49 cm³ Seat height: Bore × stroke: 585 mm (23.0 in) 39.0 ×...
  • Page 117 Recommended engine oil grade: Minimum research octane: API service SG type or higher, JASO standard MA Fuel tank capacity: 130 ˚F 5.6 L (1.5 US gal, 1.2 Imp.gal) Fuel reserve amount: SAE 5W-30 0.7 L (0.18 US gal, 0.15 Imp.gal) Carburetor: SAE 10W-30 Type ×...
  • Page 118 Front tire: Front brake: Size: Type: AT16x6.5-7 Mechanical leading, trailing drum brake Manufacturer/model: Rear brake: DURO/DI2040 Type: Rear tire: Mechanical leading, trailing drum brake Front suspension: Size: AT16x7-7 Type: Manufacturer/model: Swing axle DURO/DI2041 Spring: Tire air pressure (measured on cold tires): Coil spring Vehicle load: Shock absorber:...
  • Page 119 Battery: Model: GTX5L-BS Voltage, capacity: 12 V, 4.0 Ah Fuses: Main fuse: 7.5 A 10-4...

  • Page 120: Consumer Information

    Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number...
  • Page 121 1. Model label 11-2...

  • Page 122: Index

    INDEX Accessories and loading ..........6-5 Front and rear brake shoes, checking ......8-23 Air filter element, cleaning ..........8-16 Front arm pivots, lubricating ........8-31 Front knuckle pivots, lubricating ........8-31 Fuel ................ 4-9, 5-3 Battery ................8-32 Fuel cock ..............4-10 Brake lever free play, adjusting the front .....8-24 Fuel tank cap ..............
  • Page 123 Part locations ..............3-1 Riding your ATV ............. 7-1 Safety information ............2-1 Seat ................4-12 Shock absorber, rear ........... 4-13 Spark arrester, cleaning ..........8-19 Spark plug, checking ............. 8-9 Specifications .............. 10-1 Speed limiter ..............4-3 Starter (choke) ............. 4-11 Start switch ..............
  • Page 124 EBU33961 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. NEVER USE ALWAYS USE NEVER USE NEVER CARRY AN APPROVED PASSENGERS WITH DRUGS ON PAVED HELMET AND OR ALCOHOL ROADS PROTECTIVE GEAR NEVER ALWAYS operate: • without proper training or instruction. •...

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