Yamaha GRIZZLY 125 Owner's Manual
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Yamaha GRIZZLY 125 Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM125GX
This A
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-21-05
1C5-28199-14

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  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM125GX This A WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-21-05 1C5-28199-14...
  • Page 2 EBU17091...
  • Page 3 Yamaha experience in the production of fine sporting, touring, and pace-setting 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 EBU17341 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: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury WARNING...
  • Page 5 EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

  • Page 6: Table Of Contents

    EWB00010 Front brake lever ........4-5 WARNING Rear brake lever ........4-5 Parking brake ..........4-6 Indicates a potential hazard that could result in Drive select lever ........4-7 serious injury or death. Fuel tank cap ..........4-7 Fuel ............4-8 Fuel cock ...........
  • Page 7 Starting a warm engine ......6-3 General maintenance and lubrication chart ............8-5 Operating the drive select lever and driving in reverse ..........6-3 Checking the spark plug ......8-8 Engine break-in ......... 6-5 Engine oil ..........8-10 Parking ............6-5 Transmission oil ........
  • Page 8 Cleaning ............ 9-1 Storage ............9-2 SPECIFICATIONS ........10-1 CONSUMER INFORMATION ...... 11-1 Identification numbers ......11-1 Noise regulation ........11-3 Maintenance record ........ 11-4 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY ..11-5 YAMAHA EXTENDED SERVICE (Y.E.S.) ..........11-7...

  • Page 9: Safety Information

    EBU17430 SAFETY INFORMATION SAFETY INFORMATION EBU17442 – A child under 16 years old should never oper- ate an ATV with engine size greater than 90 cc. AN ATV IS NOT A TOY AND CAN BE HAZARD- Never allow a child under age 16 to operate an OUS TO OPERATE.
  • Page 10 that is proper for the terrain, visibility, operating before attempting larger hills. conditions, and your experience. Always follow proper procedures for climbing Never attempt wheelies, jumps, or other stunts. hills as described in this manual. Check the ter- Always inspect your ATV each time you use it to rain carefully before you start up any hill.
  • Page 11 ing, use the proper gear and maintain a steady Always be sure there are no obstacles or people speed when climbing a hill. If you stall or roll behind you when you operate in reverse. When backwards, follow the special procedure for it is safe to proceed in reverse, go slowly.
  • Page 12 EWB00021 HOW TO AVOID THE HAZARD WARNING If you should swallow some gasoline or in- POTENTIAL HAZARD hale a lot of gasoline vapor, or get some gas- Improper handling of gasoline. oline in your eyes, seek medical help WHAT CAN HAPPEN immediately.
  • Page 13 WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death with- in a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad- equate ventilation.

  • Page 14: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 15 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 replace- ment label from your Yamaha dealer. WARNING WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL.
  • Page 16 WARNING DRIVE SELECT LEVER Improper ATV use can result in SEVERE 8 Read owner’s manual carefully INJURY or DEATH. before operating. 8 When shifting the drive select lever, always be sure to stop the ATV and apply the rear brake. ALWAYS USE NEVER USE NEVER CARRY NEVER USE 5YT-2151E-30...

  • Page 17: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 4 5 6 1. Seat 1. Front carrier 2. Drive select lever 2. Starter (choke) 3. Headlight 3. Fuel cock 4. Tail/brake light 5. Rear carrier 6. Spark arrester 7. Footboard...

  • Page 18: Controls And Instruments

    EBU17712 from the figures shown in this manual. Controls and instruments 1. Rear brake lever 2. Parking brake 3. Reverse indicator light 4. Neutral indicator light 5. Front brake lever 6. Throttle lever 7. Main switch 8. Fuel tank cap 9.

  • Page 19: Instrument And Control Functions

    EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17740 Main switch 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.

  • Page 20: Indicator Lights

    EBU17791 EBU18061 Indicator lights Handlebar switches 1. Reverse indicator light “R” 1. Engine stop switch “ENG. STOP” 2. Neutral indicator light “N” 2. Start switch “START” 3. Light switch “LIGHTS” EBU17830 Reverse indicator light “ ” EBU18070 Engine stop switch “ENG. STOP” This indicator light comes on when the transmis- Set this switch to “RUN”...

  • Page 21: Throttle Lever

    EBU18090 tle lever will increase the engine speed. Start switch “START” Regulate the speed of the ATV by varying the Push this switch to crank the engine with the start- throttle position. Because the throttle is spring- loaded, the ATV will decelerate, and the engine will ECB00050 return to an idle any time the hand is removed from CAUTION:...

  • Page 22: Speed Limiter

    If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can’t find or solve the problem yourself. 1. Adjusting screw 2. Locknut...

  • Page 23: Front Brake Lever

    WHAT CAN HAPPEN The throttle cable could be damaged. Im- proper throttle operation could result. You could lose control, have an accident or be in- jured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 1.0–3.0 mm (0.04–0.12 in).

  • Page 24: Parking Brake

    1. Parking brake lock plate 1. Rear brake lever 2. Parking brake lever (locked position) EBU18450 Parking brake EWB00170 WARNING Use the parking brake before starting the engine or parking the ATV, especially on a slope. Apply the POTENTIAL HAZARD rear brake lever and push down the lock plate to Improper use of the parking brake.

  • Page 25: Drive Select Lever

    WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before start- ing the engine. This could cause loss of con- trol or a collision. The brake could overheat if you ride the ATV without releasing the parking brake.

  • Page 26: Fuel

    1. Fuel level 1. Fuel tank cap 2. Fuel tank filler tube EBU18730 Fuel Recommended fuel: Make sure that there is sufficient fuel in the tank. UNLEADED GASOLINE ONLY Fill the fuel tank to the bottom of the filler tube as Fuel tank capacity: shown.

  • Page 27: Fuel Cock

    WHAT CAN HAPPEN Fuel can spill, which can cause a fire and se- Your Yamaha engine has been designed to use vere injury. regular unleaded gasoline with a pump octane Fuel expands when it heats up. If the fuel...
  • Page 28 FUEL FUEL 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.

  • Page 29: Starter (Choke)

    the 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. FUEL 1. Arrow mark positioned over “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

  • Page 30: Front Carrier

    1. Seat lock lever 1. Projection 2. Seat holder To install the seat Insert the projections on the front of the seat into EBU18960 Front carrier the seat holders and push down on the seat at the Do not exceed the load limit of 5.0 kg (11 lb) for rear.
  • Page 31 (231 lb) for the ATV. EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 4-13...

  • Page 32: Pre-Operation Checks

    Always follow the inspection and maintenance procedures and schedules described in the Own- er’s Manual. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 33 ITEM ROUTINE PAGE Check fuel level in fuel tank, and add recommended fuel if neces- Fuel sary. 4-8, 5-3 Check fuel line for leakage. Correct if necessary. Check oil level in engine, and add recommended oil to specified Engine oil level if necessary.

  • Page 34: Fuel

    If not, have the HOW TO AVOID THE HAZARD ATV checked by a Yamaha dealer. Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust Brake operation pipe.

  • Page 35: Throttle Lever

    EBU19761 Throttle lever Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary. EBU19770 Drive chain Check the condition of the drive chain and check the drive chain slack.

  • Page 36: Tires

    HOW TO AVOID THE HAZARD Rear: The tires listed below have been approved 25.0 kPa (3.6 psi) (0.25 kgf/cm by Yamaha Motor Co., Ltd. for this model. Check and adjust tire pressures when Other tire combinations are not recom- the tires are cold.

  • Page 37: Specifications

    dirt in the gauge could cause the first reading to be Tire pressure below the minimum speci- incorrect. fied could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure: Front: 17.0 kPa (2.5 psi) (0.17 kgf/cm Rear: 22.0 kPa (3.2 psi) (0.22 kgf/cm Use no more than the following pressures...

  • Page 38: Tire Wear Limit

    Recommended pressure: Front 20.0 kPa (2.9 psi) (0.20 kgf/cm Rear 25.0 kPa (3.6 psi) (0.25 kgf/cm Minimum: Front 17.0 kPa (2.5 psi) (0.17 kgf/cm Rear 22.0 kPa (3.2 psi) (0.22 kgf/cm 1. Tire wear limit Maximum: Front EBU19840 23.0 kPa (3.3 psi) (0.23 kgf/cm Chassis fasteners Rear Make sure that all nuts, bolts and screws are prop-...

  • Page 39: Operation

    See the “Engine break-in” section on page 6-5 a control or function you do not understand, prior to operating the engine for the first time. ask your Yamaha dealer. 1. Set the parking brake. 2. Turn the fuel cock to “ON”.
  • Page 40 If the indicator light does not come on, Ambient temp./starter (choke) position have a Yamaha dealer check the electrical cir- cuit. NOTE: The engine can be started only when the drive se- lect lever is in the neutral position.

  • Page 41: Starting A Warm Engine

    attempt. EBU20350 Operating the drive select lever and 7. If the engine is started with the starter (choke) driving in reverse in position (1), the starter (choke) should be ECB00170 returned to position (2) to warm up the engine. CAUTION: If the engine is started with the starter (choke) Before shifting, stop the ATV, otherwise the in position (2), keep the starter (choke) in this...
  • Page 42 If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 4. Check behind for people or obstacles, and then release the parking brake. 5. Open the throttle lever gradually and continue to watch to the rear while backing.

  • Page 43: 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 44: Parking On A Slope

    HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the ATV trans- versely across the incline, shift the drive se- lect lever to the forward position, stop the engine, apply the parking brake, and then block the front and rear wheels with rocks or other objects.

  • Page 45: Accessories And Loading

    However, dling of an ATV can be changed. When adding ac- it is not possible for Yamaha to test all non- cessories, keep the following points in mind: Yamaha accessories, nor control over their qual- Never exceed the weight limits shown.
  • Page 46 clude the tongue weight in the maximum ATV WHAT CAN HAPPEN load limit. Could cause changes in ATV handling which Load cargo on the carriers as close to the center could lead to an accident. of the ATV as possible. Put cargo at the rear of HOW TO AVOID THE HAZARD the front carrier, at the front of the rear carrier, Never exceed the stated load capacity for...

  • Page 47: Riding Your Atv

    EBU21131 RIDING YOUR ATV...

  • Page 48: Getting To Know Your Atv

    EWB00010 labels on your ATV. WARNING RIDE WITH CARE AND GOOD JUDGEMENT Indicates a potential hazard that could result in serious injury or death. Get training if you are inexperienced. Beginners should get training from a certified in- EBU21292 structor. Become familiar with this ATV at slow speeds first, GETTING TO KNOW YOUR ATV even if you are an experienced operator.
  • Page 49 A child under 16 should never operate an should complete the certified training course ATV with engine size greater than 90 cc. offered by Yamaha. They should then regu- larly practice the skills learned in the course and the operating techniques described in this Owner’s Manual.
  • Page 50 EWB00910 WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passen- ger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 51 Apparel HOW TO AVOID THE HAZARD EWB00920 Always wear an approved motorcycle helmet WARNING that fits properly. POTENTIAL HAZARD You should also wear: Operating this ATV without wearing an ap- eye protection (goggles or face shield) proved motorcycle helmet, eye protection gloves and protective clothing.
  • Page 52 Do not operate after consuming alcohol or HOW TO AVOID THE HAZARD drugs. Never consume alcohol or drugs before or The operator’s performance capability is reduced while driving this ATV. by the influence of alcohol or drugs. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety.
  • Page 53 EWB00950 WARNING EWB00960 WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or POTENTIAL HAZARD with improper or uneven tire pressure. Operating this ATV at speeds too fast for WHAT CAN HAPPEN your skills or the conditions. Use of improper tires on this ATV, or opera- WHAT CAN HAPPEN tion of this ATV with improper or uneven tire Increases your chances of losing control of...
  • Page 54 MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 105.0 kg (231 lb) Front carrier: 5.0 kg (11 lb) Rear carrier: 10.0 kg (22 lb) EWB00970 WARNING 1. Adjusting screw 2. Locknut POTENTIAL HAZARD Overloading this ATV or carrying or towing Loading and accessories cargo improperly.
  • Page 55 HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and se- curely attached. Reduce speed when carrying cargo or pull- ing a trailer. Allow greater distance for brak- ing. Always follow the instructions in your Own- er’s Manual for carrying cargo or pulling a trailer.
  • Page 56 EWB00980 WHAT CAN HAPPEN WARNING Increases the chance of an accident, includ- POTENTIAL HAZARD ing an overturn. Removing hands from handlebars or feet HOW TO AVOID THE HAZARD from footboards during operation. Never attempt stunts, such as wheelies or WHAT CAN HAPPEN jumps.
  • Page 57 Someone touching the exhaust system dur- accessories added to this ATV should be ing or after operation could be burned. genuine Yamaha or equivalent components HOW TO AVOID THE HAZARD designed for use on this ATV and should be Do not operate, idle, or park the ATV in dry installed and used according to instructions.

  • Page 58: Be Careful Where You Ride

    HOW TO AVOID THE HAZARD Always avoid paved surfaces, including side- walks, driveways, parking lots and streets. BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. EWB01020 WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces.
  • Page 59 EWB01030 unfamiliar areas. Stay alert for holes, rocks, or WARNING roots in the terrain, and other hidden hazards which may cause the ATV to upset. POTENTIAL HAZARD Operating this ATV on public streets, roads EWB01040 WARNING or highways. WHAT CAN HAPPEN POTENTIAL HAZARD You can collide with another vehicle.
  • Page 60 HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especial- ly cautious on these kinds of terrain. EWB01050 WARNING POTENTIAL HAZARD...
  • Page 61 Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. EWB01060 Select a large, flat area off-road to become familiar WARNING with your ATV. Make sure that this area is free of POTENTIAL HAZARD obstacles and other riders.

  • Page 62: Turning Your Atv

    hot when riding and afterwards; do not allow skin easily. It is essential that this skill be learned first at or clothing to come in contact with these compo- low speed. nents. EWB01080 WARNING With the engine idling, return the starter knob to the closed position and shift the drive select lever into POTENTIAL HAZARD the forward position.

  • Page 63: Climbing Uphill

    curves. 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 64 EWB01090 HOW TO AVOID THE HAZARD WARNING Always follow proper procedures for climb- POTENTIAL HAZARD ing hills as described in this Owner’s Manual. Operating on excessively steep hills. Always check the terrain carefully before you WHAT CAN HAPPEN start up any hill. The ATV can overturn more easily on ex- Never climb hills with excessively slippery or tremely steep hills than on level surfaces or...
  • Page 65 EWB01190 WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD 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 66 EWB01341 WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dis- mounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.

  • Page 67: Riding Downhill

    stacles which may appear. EWB01130 WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owner’s Man- ual.

  • Page 68: Crossing A Slope

    the front wheels slightly uphill. When riding on slopes, be sure not to make sharp turns either up or down hill. If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path.

  • Page 69: Crossing Through Shallow Water

    carefully. Enter where there is no sharp drop off, When crossing the side of a hill: and avoid rocks or other obstacles which may be Always follow proper procedures as de- slippery or upset the ATV. Drive slowly and care- scribed in the Owner’s Manual.
  • Page 70 ECB00800 Test your brakes after leaving the water. Do not CAUTION: continue to ride your ATV without verifying that you After riding your ATV in water, be sure to drain have regained proper braking ability. the trapped water by removing the check hose at the bottom of the air filter case and the V-belt case drain plug.

  • Page 71: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident. Be sure to keep your feet firmly mounted on the footboards at all times.
  • Page 72 pected and uncorrected, sliding could lead to an accident. 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.

  • Page 73: What To Do If

    Lean more into the turn to regain balance. If nec- WHAT CAN HAPPEN essary, gradually let off the throttle and/or steer You may lose control of this ATV. You may to the outside of the turn. (See page 7-16.) also regain traction unexpectedly, which If your ATV starts to slide sideways: may cause the ATV to overturn.
  • Page 74 Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let wa- ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability.

  • Page 75: Periodic Maintenance And Minor Repair

    Safety is an obligation of the owner. Periodic in- nance unless otherwise specified. Have a spection, adjustment and lubrication will keep your Yamaha dealer perform the service if you are ATV in the safest and best operating condition not familiar with maintenance work.
  • Page 76 If you have questions, consult an authorized additional tools such as a torque wrench may be Yamaha ATV dealer. necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform...

  • Page 77: 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.
  • Page 78 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 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 79: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Engine and V-belt Every 20–40 hours (more often in wet or case air filter ele- Clean and replace if necessary.
  • Page 80 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check for wear, cracks or other damage, and √ √ V-belt replace if necessary. Make sure that all nuts, bolts, and screws are √...
  • Page 81 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check operation and correct if necessary. √ √ √ √ √ 19 * Lights and switches Adjust headlight beams. Check electrolyte level and specific gravity, and correct if necessary.

  • Page 82: Checking The Spark Plug

    EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU23211 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 accor- dance with the periodic maintenance and lubrica- 1.
  • Page 83 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 and excessive carbon or other deposits, and 2.

  • Page 84: Engine Oil

    and its mating surface, and then wipe off any 2. Check the engine oil level on a cold engine. grime from the spark plug threads. NOTE: 3. Install the spark plug with the spark plug If the engine was started before checking the oil wrench, and then tighten it to the specified level, be sure to warm up the engine sufficiently, torque.
  • Page 85 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. 1.

  • Page 86: Transmission Oil

    fall out. Take care not to lose these parts. ECB00330 CAUTION: 5. Clean the oil strainer with solvent. Do not use oils with a diesel specification of 6. Check the O-ring for damage and replace it if “CD” or oils of a higher quality than speci- necessary.
  • Page 87 utes, and then turn it off. 3. Wait a few minutes until the oil settles, and then remove the screw located at the right side of the crankcase. 1. Transmission oil filler bolt NOTE: The transmission oil should be at the brim of the 1.
  • Page 88 Tightening torque: Screw: 16 Nm (1.6 m·kgf, 11.6 ft·lbf) Oil filler bolt: 23 Nm (2.3 m·kgf, 16.6 ft·lbf) To change the transmission oil 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min- utes, and then turn it off.

  • Page 89: Cleaning The Engine And V-Belt Case Air Filter Elements

    EBU23831 Cleaning the engine and V-belt case air Recommended transmission oil: filter elements See page 10-1. Both air filter elements should be cleaned at the Oil quantity: specified intervals in the periodic maintenance 0.6 L (0.63 US qt) (0.53 Imp.qt) chart.
  • Page 90 1. Remove the seat. (See page 4-11.) 2. Remove the breather hose, and then loosen the clamp screw. 1. Air filter case cover 2. Screw 4. Pull the air filter element out of the air filter 1. Breather hose 2. Clamp screw case.
  • Page 91 8. Check the sponge material and replace it if clean the sponge material. damaged. WHAT CAN HAPPEN 9. Apply Yamaha foam air filter oil or other qual- Low-flash-point solvents or gasoline can ity foam air filter oil to the sponge material. catch fire or explode.
  • Page 92 13. Install the air filter case cover by installing the NOTE: screws. The sponge material should be wet but not drip- 14. Install the breather hose and then tighten the ping. clamp screw. 10. Pull the sponge material over the air filter ele- 15.
  • Page 93 will affect carburetor jetting with subsequent poor performance and possible engine over- heating. V-belt case air filter element 1. Remove the front carrier by removing the bolts. 1. Panel 2. Quick fastener 3. Disconnect the coupler shown. 1. Bolt 2. Front carrier 2.
  • Page 94 1. Panel 1. Air filter case cover 2. Coupler 2. Screw 4. Remove the air filter case cover by removing 5. Remove the air filter element. the screw. 8-20...

  • Page 95: Cleaning The Spark Arrester

    1. Air filter element 1. Air filter element 7. Check the air filter element and replace it if 6. Tap the air filter element lightly to remove damaged. most of the dust and dirt. Blow out the remain- 8. Install the air filter element into the air filter ing dirt with compressed air as shown.
  • Page 96 fore cleaning the spark arrester. 1. Remove the screws. 1. Screw 2. Gasket 3. Tailpipe 1. Screw 4. Spark arrester 2. Remove the tailpipe by pulling it out of the 4. Insert the tailpipe into the muffler and align the muffler.

  • Page 97: V-Belt Case Drain Plug

    If water drains from the V-belt case after removing most carburetor adjustments should be left to a the plug, have a Yamaha dealer check the ATV as Yamaha dealer, who has the necessary profes- the water may affect other engine parts.

  • Page 98: Adjusting The Engine Idling Speed

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

  • Page 99: Adjusting The Throttle Cable Free Play

    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 100: Checking The Front And Rear Brake Shoes

    If a brake shoe has worn to the point that the wear indicator reaches the wear limit line or mark, have a Yamaha dealer replace the 1. Wear limit line brake shoes as a set.

  • Page 101: Adjusting The Front Brake Lever Free Play

    Rear brake mm (0.20–0.31 in) as shown. If the free play is in- correct, adjust it as follows. 1. Wear limit line 2. Wear indicator 1. Brake lever free play EBU24360 1. Remove the front carrier by removing the Adjusting the front brake lever free bolts.
  • Page 102 1. Front carrier 1. Panel 2. Bolt 2. Quick fastener 2. Remove the panel shown by removing the quick fasteners, then disconnect the coupler shown. 8-28...
  • Page 103 1. Panel 1. V-belt air filter element cover 2. Coupler 2. Screw 3. Remove the V-belt air filter element cover by 4. Loosen the locknut and fully turn in the adjust- removing the screw. ing bolt at the brake lever. 8-29...
  • Page 104 a=a' 1. Locknut 1. Brake equalizer 2. Brake lever free play adjusting bolt 2. Cable joint 5. Make sure the brake cable joint in the equaliz- er is straight when the brake is applied. If the cable joint isn’t straight, loosen the locknuts, and then turn the adjusting nuts on the front brake cables until the cable joint becomes straight.
  • Page 105 1. Locknut 1. Locknut 2. Adjusting nut 2. Brake lever free play adjusting bolt 3. Brake lever free play 6. Tighten the locknut on each brake cable. 8. Tighten the locknut at the brake lever. 7. Turn the adjusting bolt in direction (a) to in- 9.

  • Page 106: Adjusting The Rear Brake Lever Free Play

    Replacement of brake components requires professional knowledge. These procedures 1. Brake lever free play should be performed by a Yamaha dealer. Turn the brake lever free play adjusting nut on the EBU24481 rear wheel hub in direction (a) to increase the free Adjusting the rear brake lever free play play, and in direction (b) to decrease it.

  • Page 107: Drive Chain Slack

    Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24871 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary.
  • Page 108 Drive chain slack: 30.0 mm (1.18 in) 1. Hub stopper bolt 2. Locknut 3. Axle holding bolt (lower) 4. Axle holding bolt (upper) 1. Drive chain slack 3. Loosen the chain adjusting bolt locknut. To tighten the drive chain, turn the adjusting bolt 3.
  • Page 109 If measurement “A” of the drive chain adjust- 2. Drive chain slack adjusting bolt ing bolt is less than 27 mm (1.06 in), have a Yamaha dealer replace the drive chain. ECB00541 CAUTION: Improper drive chain slack will overload the en- gine as well as other vital parts of the ATV and can lead to drive chain slippage or breakage.

  • Page 110: Lubricating The Drive Chain

    1. Measurement A 1. O-ring 5. Tighten the hub stopper bolt, and then its lock- ECB00560 CAUTION: nut. The drive chain must be lubricated after wash- EBU24880 ing the ATV or riding in the rain. Lubricating the drive chain 1. Clean the drive chain with kerosene and a The drive chain must be cleaned and lubricated at small soft brush.

  • Page 111: Checking And Lubricating The Cables

    If a cable is damaged or does not move The operation of the front and rear brake levers smoothly, have a Yamaha dealer check or replace should be checked before each ride, and the lever pivots should be lubricated if necessary.

  • Page 112: 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 bear- ings. EBU25030 Lubricating the upper and lower arm...

  • Page 113: Lubricating The Front Knuckle Pivots

    Left side Right side 1. Grease nipple 1. Grease nipple EBU28820 Lubricating the front knuckle pivots The front knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Lubricate the front knuckle pivots using a grease gun.

  • Page 114: Lubricating The Steering Shaft

    connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrica- tion chart. To check the electrolyte level 1. Place the ATV on a level surface. 2. Check the electrolyte level in the battery. 1.
  • Page 115 3. If the electrolyte is at or below the minimum EWB02140 WARNING level mark, add distilled water to raise it to the maximum level mark. POTENTIAL HAZARD Failure to handle batteries or battery electro- lyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severe- ly burned by the sulfuric acid in battery elec- trolyte.
  • Page 116 hose routing. ECB00600 CAUTION: To store the battery Do not leave or store the battery on its side. If the ATV will not be used for more than one 3. If the battery will be stored for more than two month, the battery will need to be removed and months, check the specific gravity of the elec- stored as follows.

  • Page 117: Replacing The Fuse

    EBU25252 Replacing the fuse 1. Battery 2. Negative lead 3. Positive lead 1. Fuse ECB00610 2. Spare fuse CAUTION: If the breather hose is positioned in such a way The fuse holder is located on the right side of the that the frame is exposed to electrolyte or gas ATV.

  • Page 118: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU25350 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
  • Page 119 EWB02190 WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and im- mediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the headlight bulb to cool before touching or removing it.

  • Page 120: Adjusting A Headlight Beam

    9. Adjust the headlight beam if necessary. EBU25550 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make this adjustment. 1. Headlight beam adjusting screw To raise a headlight beam, turn the adjusting screw in direction (a).

  • Page 121: Removing A Wheel

    1. Tail/brake light bulb holder 1. Tail/brake light bulb 2. Tail/brake light bulb holder 2. Remove the defective bulb by pushing it in 3. Insert a new bulb into the bulb holder, push it and turning it counterclockwise. in, and then turn it clockwise until it stops. 4.

  • Page 122: Installing A Wheel

    Front wards the wheel. 1. Wheel nut 1. Tapered nut 2. Elevate the ATV and place a suitable stand 2. Lower the ATV to the ground. under the frame. 3. Tighten the wheel nuts to the specified 3. Remove the nuts from the wheel. torques.

  • Page 123: Troubleshooting

    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 EBU25890 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.

  • Page 126: Storage

    EWB02300 nia) and areas where strong chemicals are WARNING stored. POTENTIAL HAZARD Operation with wet brakes after washing. Long-term WHAT CAN HAPPEN Before storing your ATV for several months: Wet brakes may have reduced stopping abil- 1. Follow all the instructions in the “Cleaning” ity, increasing the chance of an accident.
  • Page 127 plug, and then place the spark plug on the 8-40. cylinder head so that the electrodes are NOTE: grounded. (This will limit sparking during Make any necessary repairs before storing the the next step.) ATV. d. Turn the engine over several times with the starter.

  • Page 128: Specifications

    EBU25960 SPECIFICATIONS EBU25978 Compression ratio: Dimensions: 9.00 :1 Overall length: Starting system: 1700 mm (66.9 in) Electric starter Overall width: Lubrication system: 990 mm (39.0 in) Wet sump Overall height: Engine oil: 980 mm (38.6 in) Type: Seat height: YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 685 mm (27.0 in) Wheelbase: 0˚...
  • Page 129 Engine oil quantity: Transmission: Periodic oil change: Primary reduction system: 1.25 L (1.32 US qt) (1.10 Imp.qt) Helical gear/spur gear Transmission oil: Primary reduction ratio: 43/14 × 40/17 (7.226) Quantity: 0.6 L (0.63 US qt) (0.53 Imp.qt) Secondary reduction system: Air filter: Chain drive Secondary reduction ratio:...
  • Page 130 Rear tire: Rim size: 8 x 5.5AT Type: Rear wheel: Tubeless Size: Wheel type: AT22 x 10-8 Panel wheel Manufacturer/model: Rim size: DUNLOP/KT537A 8 x 8.0AT Loading: Front brake: Maximum loading limit: Type: 105.0 kg (231 lb) Drum brake (Total weight of rider, cargo, accessories, and tongue) Operation: Tire air pressure (measured on cold tires): Right hand operation...
  • Page 131 Electrical system: Ignition system: DC. CDI Charging system: AC magneto Battery: Model: 12N12C-4A-2 Voltage, capacity: 12 V, 12.0 Ah Headlight: Bulb type: Krypton bulb Bulb voltage, wattage x quantity: Headlight: 12 V, 30.0/30.0 W × 2 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 EBU26050 Model label 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: 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 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 135: 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 136: 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 137 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 138: 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 139 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 140 EBU26132 11-9...
  • Page 141 INDEX Accessories and loading ..........6-7 Engine break-in .............. 6-5 Air filter elements, engine and V-belt filter cleaning ..8-15 Engine, cold start ............6-1 Engine idling speed............8-24 Engine oil ............. 5-3 8-10 Battery..............5-7 8-40 Engine, starting a warm ..........6-3 Brake lever free play, adjusting the front......
  • Page 142 Suspension, lubricating the upper and lower arm pivots................8-38 Main switch ..............4-1 Maintenance and lubrication chart ......... 8-5 Maintenance chart, emission control system ....8-3 Tail/brake light bulb, replacing ........8-46 Maintenance record ............. 11-4 Throttle cable free play, adjusting ........ 8-25 Model label..............
  • Page 144 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2007.04-0.5x1 !
  • Page 145 8 TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA – ASK YOUR DEALER FOR DETAILS OR CALL 1-800-887-2887 If you have any questions about these points, or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership, please fill out the information below and mail this card to yamaha today.
  • Page 146 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES FIRST CLASS PERMIT NO. 4 CYPRESS, CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U.S.A. P.O. BOX 6555 CYPRESS, CALIFORNIA 90630-9989 ATTN: SALES ADMINISTRATION...

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