READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFS200S This ATV should not be ridden by anyone under 16 years of age. LIT-11626-17-07 5VM-28199-11...
EBU01200 INTRODUCTION Congratulations on your purchase of the Yamaha YFS200. It represents the result of many years of 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.
EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERI- OUS INJURY 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 or death to the machine operator, a bystander or a person inspecting or...
EBU00014 Indicates a potential hazard that could result in serious injury or death. CONTENTS LOCATION OF THE WARNING AND Oil level warning light checking SPECIFICATION LABELS .......1-1 method ..........4-2 Handlebar switches ......4-3 SAFETY INFORMATION ......2-1 Throttle lever ........4-4 Throttle OverRide System ....4-5 DESCRIPTION AND MACHINE Speed limiter ........4-6 IDENTIFICATION........3-1...
Seat ............4-12 OPERATION ..........6-1 Front shock absorber Starting a cold engine......6-1 adjustment ........4-14 Starting a warm engine ......6-3 Rear shock absorber Warming up ..........6-3 adjustment ........4-15 Shifting ..........6-4 To start out and accelerate....6-5 PRE-OPERATION CHECKS ....5-1 To decelerate ........6-6 Front and rear brakes ......5-2 Engine break-in ........6-7 Fuel ............5-4 Parking ..........6-8...
Crossing through shallow water ..7-34 Brake pedal height adjustment ...8-27 Riding over rough terrain ....7-36 Parking brake adjustment....8-28 Sliding and skidding ......7-38 Adjusting the rear brake light switch...8-30 What to do if........7-40 Clutch adjustment.......8-31 What to do.........7-40 Autolube pump adjustment....8-31 Drive chain slack check ......8-32 PERIODIC MAINTENANCE AND Drive chain slack adjustment....8-32...
CLEANING AND STORAGE....9-1 A. Cleaning ...........9-1 B. Storage ..........9-3 SPECIFICATIONS .........10-1 NOISE REGULATION......11-1 MAINTENANCE RECORD ....12-1 ATV LIMITED WARRANTY ....13-1 YAMAHA EXTENDED SERVICE (Y.E.S.)...........14-1...
EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
Never remove any labels from your ATV. If a label Passengers can cause becomes difficult to read or comes off, a replace- a loss of control, ment label is available from your Yamaha dealer. resulting in SEVERE INJURY or DEATH. 5FE-2151H-01...
q WARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion. 8 Read owner’s manual for instructions. 8 Do not incinerate, puncture or open. 4AA-22259-80 5FE-21568-01...
EBU13380 SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper pre- cautions.
8 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. 8 Never operate an ATV on any public street, road or highway, even a dirt or gravel one. 8 Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.
8 Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. 8 Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds.
8 Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, fol- low the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill.
8 Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.
q WARNING When transporting the ATV in another vehicle, be sure it is kept upright and that POTENTIAL HAZARD the fuel cock is in the “OFF” position. Improper handling of gasoline. Otherwise, fuel may leak out of the carbu- WHAT CAN HAPPEN retor or fuel tank.
q WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation.
This tion in the spaces provided for assistance when number can be used for ordering a new key. ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: 2.
The model label is affixed to the location in the into the frame. illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Vehicle identification number NOTE: 1.
EBU00039 EBU00043 CONTROL FUNCTIONS Indicator lights EBU01274 Oil level warning light “ ” Indicates a potential hazard that could result This light comes on when the oil level is low. in serious injury or death. The light circuit can be checked by the following procedure.
(see NOTE). Wait a few seconds. The oil level warning light The oil level warning goes off. light stays on. Ask a Yamaha dealer to Engine oil level and Supply engine oil. inspect the electrical circuit. electrical circuit are OK. NOTE:...
EBU00053 EBU01286 Handlebar switches Light switch “LIGHTS” Set the switch to the “LO” position to switch on EBU01158 Engine stop switch “ENG. STOP” the low beam and the taillight. Make sure that the engine stop switch is in the Set the switch to the “HI” position to switch on “RUN”...
Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. 1. Throttle lever Consult a Yamaha dealer if you can’t find or solve the problem yourself.
Riding with a malfunction increases the chance for an accident and injury. HOW TO AVOID THE HAZARD Make sure that the cause of the malfunc- tion is corrected before restarting the engine. You should have the ATV inspect- ed by a Yamaha dealer.
EBU01159 q WARNING Speed limiter The speed limiter keeps the throttle from fully POTENTIAL HAZARD opening, even when the throttle lever is pushed Improper adjustment of the speed limiter to the maximum. Turning in the adjusting screw and throttle. limits the maximum engine power available and WHAT CAN HAPPEN decreases the maximum speed of the ATV.
EBU00068 EBU00988 Clutch lever Brake lever The clutch lever is located on the left handlebar. The brake lever is located on the right handle- Pull the clutch lever to the handlebar to disen- bar. Pull it toward the handlebar to apply the gage the clutch, and release the lever to engage front brake.
EBU00989 EBU00080 Brake pedal Parking brake The brake pedal is located on the right side of Use the parking brake when you have to start the machine. Push down on the pedal to apply the engine or park the machine, especially on a the rear brake.
q WARNING POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. 1. Button 2.
EBU00082 EBU00089 Shift pedal Kick starter This machine is equipped with a constant-mesh Rotate the kick starter away from the engine. 6-speed transmission. The shift pedal is located Push the starter down lightly with your foot until on the left side of the engine and is used in com- the gears engage, then kick smoothly and force- bination with the clutch when shifting.
EBU00092 Fuel tank cap OFF: With the lever in this position fuel will not Remove the fuel tank cap by turning it counter- flow. Always turn the lever to this position clockwise. when the engine is not running. With the lever in this position, fuel flows to the carburetor.
EBU00094 EBU00567 Starter (choke) Seat Starting a cold engine requires a richer air-fuel To remove the seat, pull the seat lock lever mixture. A separate starter circuit supplies this upward and pull up the seat at the rear. mixture. Move in direction a to turn on the starter (choke).
To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted. 1. Projection (×2) 2. Holder (×2) 4-13...
EBU01104 Front shock absorber adjustment NOTE: The spring preload can be adjusted to suit the A special wrench can be obtained at a Yamaha rider’s weight and riding conditions. dealer to make this adjustment. Adjust the spring preload as follows.
EBU01287 Rear shock absorber adjustment Never attempt to turn the adjusting nut The spring preload can be adjusted to suit the beyond the maximum or minimum setting. rider’s weight and riding conditions. Adjust the spring preload as follows. 3. The length of the spring changes 1 mm 1.
8 Do not subject the shock absorber to an open flame or other high heat. 8 Do not deform or damage the cylinder in any way. 8 Do not dispose of a damaged or worn out shock absorber yourself. Take the unit to a Yamaha dealer. 4-16...
EBU00112 Indicates a potential hazard that could result in serious injury or death. 4-17...
PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE 9 Check operation, free play, fluid level and fluid leakage. Brakes 5-2–5-3, 8-22–8-27 9 Fill with DOT4 brake fluid if necessary. 9 Check operation, condition and lever free play. Clutch 8-31 9 Check operation, condition and free play.
Brake lever and brake pedal POTENTIAL HAZARD 8 Check that there is no free play in the brake Failure to inspect the ATV before operat- lever. If there is free play, have a Yamaha ing. dealer adjust it. Failure to properly maintain the ATV.
If a problem mance, inspect the brake pads for wear. (See cannot be corrected by the adjustment page 8-24–8-25.) procedures provided in this manual, have a Yamaha dealer check for the cause.
Total: 9 L (1.98 Imp gal, 2.38 US gal) damage or vehicle performance problems. Reserve: 2.0 L (0.44 Imp gal, 0.53 US gal) Your Yamaha engine has been designed to use premium unleaded gasoline with a pump octane number ([R+M]/2) of 90 or higher, or research octane number of 95 or higher.
q WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank.
EBU00448 Engine oil NOTE: Make sure the engine oil is at the specified level. Be sure to push the cap into the filler neck until it Add oil as necessary. See page 10-2. is properly seated. Recommended oil: EBU01289 Yamalube 2-cycle oil or Transmission oil 2-stroke engine oil Make sure the transmission oil is at the specified...
8 In order to prevent clutch slippage (since and fasteners before a ride. Take the machine the transmission oil also lubricates the to a Yamaha dealer or refer to the Service clutch), do not mix any chemical additives. Manual for correct tightening torque.
HOW TO AVOID THE HAZARD lodge from the rim under severe riding 1. The tires listed below have been conditions. approved by Yamaha Motor Co., Ltd. The following are minimums: for this model. Other tire combinations Front 27 kPa (0.27 kgf/cm , 3.9 psi)
Set pressure with tires cold. 4. Use no more than the following pres- Set tire pressures to the following specifications: sures when seating the tire beads. Front 330 kPa (3.3 kgf/cm , 47 psi) Recommended Minimum Maximum Rear 280 kPa (2.8 kgf/cm , 40 psi) pressure Higher pressures may cause the tire to...
3. Turn the main switch to “ON” and the engine stop switch to “RUN”. understand, ask your Yamaha dealer. 4. Shift the transmission into neutral. 5. Use the starter (choke) in reference to the...
Position 1: Cold engine start- 6. Completely close the throttle lever and start ambient temperature below 5°C the engine by kicking the kick starter. (40°F). 7. If the engine is started with the starter Position 2: Cold engine start- (choke) in position 1, the starter (choke) ambient temperature at 0°C should be returned to position 2 to warm up (30°F)–30°C (90°F) and warming...
EBU00180 EBU00182 Starting a warm engine Warming up To start a warm engine, refer to the “Starting a To get maximum engine life, always warm up cold engine” section. The starter (choke) should the engine before starting off. Never accelerate not be used.
EBU01981 Shifting This model has a 6-speed forward transmission. 8 Do not coast for long periods with the The transmission allows you to control the engine off, and do not tow the machine a amount of power you have available at a given long distance.
EBU00203 7. Open the throttle part way and gradually To start out and accelerate: release the clutch lever. 1. Release the throttle lever. 8. Follow the same procedure when shifting to the next higher gear. Always close the throttle while shifting q WARNING gears.
EBU00207 q WARNING To decelerate: When slowing down or stopping, release the POTENTIAL HAZARD throttle and apply the brakes smoothly and Engaging a lower gear when the engine evenly. As you slow down, shift to a lower gear. speed is too high. Be sure that the engine has sufficiently slowed WHAT CAN HAPPEN before engaging a lower gear.
EBU02091 If any abnormality is noticed during this period, Engine break-in consult a Yamaha dealer. There is never a more important period in the 0–10 hours: life of your machine than the period between 8 Avoid continuous operation above half zero and 20 hours.
EBU01174 Parking on a slope q WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increas- ing the chance of an accident. HOW TO AVOID THE HAZARD 1. Bring the machine to a stop by applying the Avoid parking on hills or other inclines.
8 Use extra caution when riding an ATV with However, it is not possible for Yamaha to test all non-Yamaha accessories, nor have any accessories. The ATV may handle differently control over the quality or suitability of them.
EBU00584 8 Tie down cargo securely to the carriers. Make Loading As originally equipped, this ATV is not designed sure cargo in the trailer cannot move around. to carry cargo or tow a trailer. If you choose to A shifting load can cause an accident. 8 Make sure the load does not interfere with add accessories so that you can carry cargo or tow a trailer, you must use common sense and...
q WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow- ing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
EBU13550 Indicates a potential hazard that could result in serious injury or death. 6-13...
Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV controls. Pay particular attention to the safety This ATV is intended for recreational use by information on pages 2-1–2-7. Please also read experienced operators only. all caution and warning labels on your ATV.
Get training if you are inexperienced. should complete the certified training Beginners should get training from a certified course offered by Yamaha. They should instructor. then regularly practice the skills learned in Become familiar with this ATV at slow speeds the course and the operating techniques first, even if you are an experienced operator.
Not recommended for children under 16 years of age. q WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not rec- ommended for their age can lead to severe injury or death of the child.
This ATV is designed to carry operator only - passengers prohibited. q 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 acci- dent, resulting in harm to you and/or your passenger.
Apparel Operating without protective clothing q WARNING increases your chances of severe injury in the event of an accident. POTENTIAL HAZARD HOW TO AVOID THE HAZARD Operating this ATV without wearing an Always wear an approved motorcycle hel- approved motorcycle helmet, eye protec- met that fits properly.
Do not operate after consuming alcohol or q WARNING drugs. POTENTIAL HAZARD Operator’s performance capability is reduced by the influence of alcohol or drugs. Operating this ATV after consuming alco- hol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly.
Pre-operation checks q WARNING Always perform the pre-operation checks listed POTENTIAL HAZARD on page 5-1 before riding for safety and proper care of the ATV. Operating this ATV with improper tires, or with improper or uneven tire pressure. q WARNING WHAT CAN HAPPEN POTENTIAL HAZARD Use of improper tires on this ATV, or oper-...
Speed limiter For riders inexperienced with this model, this Indicates a potential hazard that could result model is equipped with a speed limiter in the in serious injury or death. throttle lever housing. The speed limiter limits the power and top speed of the ATV. Turning the adjusting screw in decreases the top speed, Do not operate at speeds too fast for your and turning it out increases the top speed.
Loading and accessories q WARNING Use extra caution when riding the ATV with POTENTIAL HAZARD additional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Overloading this ATV or carrying or tow- Reduce your speed when adding additional ing cargo improperly.
During operation q WARNING Always keep your feet on the footboards during POTENTIAL HAZARD operation. Otherwise your feet may contact the rear wheels. Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.
Avoid wheelies and jumping. You may lose con- trol of the ATV or overturn. q WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps.
Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used accord- ing to instructions. If you have questions, consult an authorized ATV dealer.
Exhaust system HOW TO AVOID THE HAZARD The exhaust system on the ATV is very hot dur- Do not operate, idle, or park the ATV in dry ing and following operation. To prevent burns, grass or other dry ground cover. avoid touching the exhaust system.
BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of con- trol. q WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect han- dling and control of the ATV, and may cause the vehicle to go out of control.
Do not ride on any public road, street, or high- way. Riding on public roads can result in collisions with other vehicles. q WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or...
Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden haz- ards which may cause the ATV to upset. q WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
q WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. 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...
When riding in an area where you might not WHAT CAN HAPPEN easily be seen, such as desert terrain, mount a You could be in a collision. You could be caution flag on the ATV. DO NOT use the flag injured.
Select a large, flat area off-road to become With the engine idling, pull the clutch lever to familiar with your ATV. Make sure that this area disengage the clutch and shift into 1st gear, and is free of obstacles and other riders. You should then release the parking brake.
q WARNING evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed POTENTIAL HAZARD before engaging a lower gear. Improper use of Opening the throttle abruptly or releasing the brakes or shifting can cause the tires to lose the clutch lever to quickly.
TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off- Always follow proper procedures for turn- road, the two rear wheels are mounted solidly ing as described in this Owner’s on one axle and turn together at the same Manual.Practice turning at low speeds speed.
Once you have learned this technique you should be able to perform it at higher speeds or Lean towards Support your in tighter curves. inside of turn. weight on the outer footrest. Improper riding procedures such as abrupt throt- tle changes, excessive braking, incorrect body movements, or too much speed for the sharp- ness of the turn may cause the ATV to tip.
CLIMBING UPHILL HOW TO AVOID THE HAZARD Use proper riding techniques to avoid vehicle Never operate the ATV on hills too steep overturns on hills. Be sure that you can maneu- for the ATV or for your abilities. ver your ATV well on flat ground before attempt- Practice on smaller hills before attempting ing any incline and then practice riding first on large hills.
q WARNING Never go over the top of any hill at high speed. POTENTIAL HAZARD An obstacle, a sharp drop, or another Climbing hills improperly. vehicle or person could be on the other WHAT CAN HAPPEN side of the hill. Could cause loss of control or cause the ATV to overturn.
If you are climbing a hill and you find that you When crossing the side of a hill: have not properly judged your ability to make it Always follow proper procedures as to the top, you should turn the ATV around while described in the Owner’s Manual.
If your ATV has stalled or stopped and you q WARNING believe you can continue up the hill, restart care- POTENTIAL HAZARD fully to make sure you do not lift the front wheels Stalling, rolling backwards or improperly which could cause you to lose control. If you are dismounting while climbing a hill.
When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the proce- dure described in the Owner’s Manual. 7-29...
RIDING DOWNHILL q WARNING When riding your ATV downhill, shift your weight POTENTIAL HAZARD as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with Going down a hill improperly. your arms straight.
CROSSING A SLOPE q WARNING Traversing a sloping surface on your ATV POTENTIAL HAZARD requires you to properly position your weight to maintain proper balance. Be sure that you have Improperly crossing hills or turning on learned the basic riding skills on flat ground hills.
Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. 7-33...
CROSSING THROUGH SHALLOW WATER HOW TO AVOID THE HAZARD The ATV can be used to cross slow moving, Never operate this ATV in fast flowing shallow water of up to a maximum of 35 cm water or in water deeper than that speci- (14 inches) in depth.
Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that After riding your ATV in water, be sure to you have regained proper braking ability. drain the trapped water by removing the check hose at the bottom of the air filter case.
RIDING OVER ROUGH TERRAIN q WARNING Riding over rough terrain should be done with POTENTIAL HAZARD caution. Look out for obstacles which could cause damage to the ATV or could lead to an Improperly operating over obstacles. upset or accident. Be sure to keep your feet WHAT CAN HAPPEN firmly mounted on the footboards at all times.
SLIDING AND SKIDDING If the rear wheels of your ATV start to slide side- Care should be used when riding on loose or ways, control can usually be regained (if there is slippery surfaces since the ATV may slide. If room to do so) by steering in the direction of the unexpected and uncorrected, sliding could lead slide.
With practice, over a period of time, skill at con- q WARNING trolled sliding can be developed. The terrain POTENTIAL HAZARD should be chosen carefully before attempting Skidding or sliding improperly. such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneu- WHAT CAN HAPPEN vers should always be avoided on extremely You may lose control of this ATV.
WHAT TO DO IF ... 8 If your ATV starts to slide sideways: This section is designed to be a reference guide Steer in the direction of the slide if you have only. Be sure to read each section on riding the room.
8 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.
MAINTENANCE AND Turn off the engine when performing maintenance unless otherwise specified. ADJUSTMENT Have a Yamaha dealer perform service if Periodic inspection, adjustment and lubrication you are not familiar with machine service. will keep your machine in the safest and most efficient condition possible.
HOW TO AVOID THE HAZARD during a service operation requiring one, take Never modify this ATV through improper your machine to a Yamaha dealer to check the installation or use of accessories. All parts torque settings and adjust them as necessary.
EBU00261 PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY ITEM ROUTINE month months months months year 9 Replace oil. Transmission 9 Check condition. 9 Adjust gap and clean. Spark plug 9 Replace if necessary. 9 Clean. Every 20–40 hours. Air filter element 9 Replace if necessary. (More often in wet or dusty areas) 9 Check idle speed / starter operation.
9 Check routing and connection. * Throttle, control 9 Lubricate. cable Outside nuts and bolts 9 Tighten if necessary. 9 Clean and inspect. Frame 9 Inspect. Lighting * It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease...
NOTE: 8 Recommended brake fluid: DOT 4 8 Brake fluid replacement: 9 When disassembling the master cylinders or caliper cylinders, replace the brake fluid. Normally check the brake fluid level and add fluid as required. 9 On the inner parts of the master cylinders and caliper cylinders, replace the oil seals every two years.
EBU12771 Transmission oil Transmission oil measurement 1. Place the machine on a level surface. 2. Warm up the engine for several minutes, and stop it. 3. Check the oil level through the level win- dow located at the right side crankcase cover.
4. Remove the oil filler cap and the drain bolt 5. Install the drain bolt and tighten it to the to drain the oil. specified torque. Tightening torque Drain bolt: 20 Nm (2.0 m0kgf, 14 ft0lbf) 6. Fill the engine with the recommended oil, and then install the oil filler cap.
EBU00680 Spark plug inspection Removal 8 In order to prevent clutch slippage (since 1. Remove the spark plug cap. the transmission oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD”...
Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug.
EBU12901 Installation Air filter cleaning 1. Measure the electrode gap with a wire NOTE thickness gauge and, if necessary, adjust There is a check hose at the bottom of the air fil- the gap to specification. ter case. If dust or water collects in this hose, empty the hose and clean the sponge material Spark plug gap: and air filter case.
4. Wash the sponge material gently but thor- oughly in solvent. q WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. 1.
7. Apply Yamaha foam air filter oil or other NOTE: quality foam air filter oil to the sponge The air filter element should be cleaned every material. If foam air filter oil is not avail- 20–40 hours. It should be cleaned and lubricat- able, engine oil may be used.
EBU13611 2. Remove the tailpipe by pulling it out of the Spark arrester cleaning muffler. Be sure the exhaust pipe and muffler are cool 3. Tap the tailpipe lightly, and then use a wire before cleaning the spark arrester. brush to remove any carbon deposits from 1.
q WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system. WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components.
Jet needle clip position 2nd groove would be a fire hazard. Pilot air screw 1-1/2 turns out HOW TO AVOID THE HAZARD Carburetor adjustments should only be performed by a Yamaha dealer. Do not attempt to perform these procedures 8-15...
Carburetor setting chart Temperature Main jet Jet needle Pilot air screw 0°C (32°F) above #230 2nd groove 1 1/2 turns out (Standard) +5°C –15°C #230 2nd groove 1 1/2 turns out – (41°F) (5°F) –10°C –30°C #240 3rd groove 1 1/2 turns out –...
3. Disconnect the fuel hose and the oil hose. 1. Clamp screw (×2) 2. Securing plate 3. Screw 4. Mixing chamber cap 1. Fuel hose 2. Oil hose 4. Loosen the clamp screws on each side of the carburetor, and then remove the carbu- retor.
7. Disconnect the throttle cable from the throttle valve by removing the holder screws and holder. 8. Remove the float chamber by removing the screws. 1. Mixing chamber cap 2. Throttle valve 3. Holder 4. Screw (×2) 5. Throttle cable 1.
4. Connect the throttle cable onto the throttle valve by installing the holder and the screws. 1. Float 2. Pin 3. Needle valve 4. Float arm 5. Main jet NOTE: An optional main jet can be obtained at a Yamaha dealer. 8-19...
5. Install the mixing chamber cap and tighten 7. Install the carburetor and tighten the clamp screws. 6. Install the securing plate by installing the 8. Connect the fuel hose and the oil hose. screw. 9. Tighten the carburetor float bowl drain screw.
EBU13020 Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 1. Throttle stop screw to 5,000 r/min.
EBU00307 EBU01185 Throttle lever adjustment Brake fluid level check Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to NOTE: become ineffective. Adjust the engine idling speed before adjusting Before riding, check that the brake fluid is above the throttle lever free play.
8 Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid 1. Minimum level mark immediately. 8 Have a Yamaha dealer check the cause if the Rear brake fluid level goes down. LOWER 1. Minimum level mark...
Yamaha service personnel. Have a brake pad thickness is less than 1 mm (0.04 in), Yamaha dealer replace the following compo- have a Yamaha dealer replace the pads as a nents during periodic maintenance or when they set.
This indicator allows checking of brake pad wear without disassembling the brake. Apply the brake and inspect the wear indicator. If the brake pads are worn to the wear limit, have a Yamaha dealer replace the pads. 1. Wear indicator 8-25...
The front brake lever should have a free play of POTENTIAL HAZARD zero mm (zero in) at the lever end. If not, have a Operating with improperly serviced or Yamaha dealer adjust it. adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.
The top of the brake pedal should be positioned POTENTIAL HAZARD 0–10 mm (0–0.4 in) below the top of the Operating with improperly serviced or footrest. If not, have a Yamaha dealer adjust it. adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.
EBU01193 Parking brake adjustment Parking brake adjustment may be required if the parking brake does not hold properly. The cable length “A” should be adjusted to 64–68 mm (2.52–2.68 in). 1. Locknut 2. Adjusting bolt 2. Loosen the locknut and the adjusting bolt at the rear brake caliper.
NOTE If the cable cannot be adjusted to specification, consult a Yamaha dealer. 4. Tighten the locknut at the clutch lever. 5. Screw in the adjusting bolt at the rear brake caliper by hand until it feels tight, then screw it out 1/8 turn. Tighten the lock- nut to the specified torque.
EBU00833 q WARNING Adjusting the rear brake light switch POTENTIAL HAZARD Operating with improperly adjusted brakes. WHAT CAN HAPPEN The brakes could malfunction, causing reduced braking performance. This could increase the chance of a collision or acci- dent. 1. Rear brake light switch 2.
(0.20–0.39 in). If the free play is incorrect, adjust and requires very sophisticated adjustment. as follows. Most adjusting should be left to a Yamaha deal- er who has the professional knowledge and 1. Loosen the locknut. experience to do so.
EBU01144 EBU00351 Drive chain slack check Drive chain slack adjustment 1. Loosen the rear wheel hub bolts. NOTE Move the ATV back and forth and find the tight- est position of the drive chain. Check and/or adjust the chain slack while it is in this tightest position.
EBU00805 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic mainte- nance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. The drive chain must be lubricated after 1.
Do not use engine oil or any other lubricants for the drive chain, as they may contain sub- stances that could damage the O-rings. 1. O-rings To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate sol- vents.
EBU01018 Yamaha dealer to replace them. Front upper and lower arm pivot lubrication Recommended lubricant: Lubricate the upper and lower arm pivots. Yamaha chain and cable lube or Recommended lubricant: SAE 10W30 motor oil Lithium-soap-based grease 8-35...
EBU12810 Steering shaft lubrication Left side Lubricate the pivot points with a grease gun. Recommended lubricant: Lithium-soap-based grease (all purpose grease) 1. Grease nipple (×3) Right side 1. Grease nipple 1. Grease nipple (×3) 8-36...
EBU01112 Rear Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Front EBU01300 Wheel installation 1. Install the wheel and the nuts. 2.
EBU01292 Replacing a headlight bulb If a headlight bulb burns out, replace the bulb as follows. 1. Remove the front panel by removing the screws. 1. Headlight beam adjusting screw 2. Washer 3. Spring 4. Nut 3. Disconnect the main switch leads. 1.
1. Headlight unit assembly 2. Screw (×2) 1. Headlight bulb holder cover 2. Headlight bulb holder 4. Remove the headlight unit assembly from the headlight body by removing the screws. 5. Remove the headlight bulb holder cover. 6. Turn the headlight bulb holder counter- clockwise, and then remove the defective bulb.
q WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately 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 a.
8. Install the headlight bulb holder cover. 10. Install the headlight beam adjusting screw, the washer, the spring and the nut. Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seat- ed properly. 9. Install the headlight unit assembly by installing the screws.
Headlight beam adjustment Tail/brake light bulb replacement 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. It is advisable to have a Yamaha dealer make this adjustment. To raise the beam, turn the adjusting screw in direction a.
The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer. The skilled technicians at a Yamaha dealership have the tools, experience, and know-how to properly service your machine.
q WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe injury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys- tem.
2. Compression Kick the kick lever to There is compresson Compression normal see if there is compression No compression Ask a Yamaha dealer to inspect Wipe clean with 3. Ignition dry cloth Remove plug and Spark good Ignition system normal...
EBU00414 No spark HOW TO AVOID THE HAZARD Throttle OverRide System (T.O.R.S.) is incorpo- Have the system checked by a Yamaha rated in the ignition circuit, and if the system dealer. should fail, the spark plug will not spark. Before bypassing T.O.R.S., be sure the throttle closes properly when the throttle lever is released.
EBU00417 CLEANING AND STORAGE Excessive water pressure may cause water A. CLEANING seepage and deterioration of wheel bearings, Frequent, thorough cleaning of your machine brakes, transmission seals and electrical will not only enhance its appearance but will devices. Many expensive repair bills have improve its general performance and extend the resulted from improper high pressure deter- useful life of many components.
4. Once the majority of the dirt has been q WARNING hosed off, wash all surfaces with warm POTENTIAL HAZARD water and mild, detergent-type soap. An Operation with wet brakes after washing. old toothbrush or bottle brush is handy for hard-to-get-at places.
Use of fuel stabilizer and conditioner eliminates parts or the seat cover. the need to drain the fuel system. Consult a NOTE: Yamaha dealer if the fuel system needs to be drained instead. Make any necessary repairs before storing the machine.
Type Air cooled, 2-stroke Cylinder arrangement Single cylinder, Forward inclined Displacement 195 cm Bore × Stroke 66.0 × 57.0 mm (2.60 × 2.24 in) Compression ratio 6.6 : 1 Starting system Kick starter Lubrication system Separate lubrication (Yamaha Autolube) 10-1...
Model YFS200 Engine oil (2-cycle): Type Yamalube 2 or air cooled 2-stroke engine oil Quantity 1.3 L (1.14 Imp qt, 1.37 US qt) Transmission oil: Type Yamalube 4 (10W30) or SAE 10W30 type SE motor oil Recommended transmission oil API Service SE, SF, SG type or higher classification In order to prevent clutch slippage (since the transmission oil also lubricates the clutch),...
Model YFS200 Air filter: Wet type element Fuel: Type PREMIUM UNLEADED GASOLINE ONLY Tank capacity 9.0 L (1.98 Imp gal, 2.38 US gal) Reserve amount 2.0 L (0.44 Imp gal, 0.53 US gal) Carburetor: Type/manufacturer VM26SS/MIKUNI Spark plug: Type/manufacturer BR8ES (NGK) 0.7–0.8 mm (0.028–0.031 in) Clutch: Type...
Model YFS200 Gear ratio 34/11 (3.091) 31/14 (2.214) 25/15 (1.667) 20/16 (1.250) 19/18 (1.056) 19/21 (0.905) Chassis: Frame type Steel Tube Frame Caster angle 9.0° Trail 40 mm (1.57 in) Tire: Type Tubeless AT21 × 7 - 10 Size – Front AT21 ×...
Model YFS200 Suspension: Front Double wishbone Rear Swingarm (monocross) Shock Absorber: Front Coil spring, Oil damper Rear Coil spring, Gas-Oil damper Wheel travel: Front 180 mm (7.09 in) Rear 180 mm (7.09 in) Electrical: Ignition system C.D.I. Generator system C.D.I. Magneto Headlight Type: Bulb type Bulb voltage, wattage ×...
EBU13640 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inopera- tive by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
EBU13651 MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work. DATE MAINTENANCE SERVICING DEALER...
9 with a passenger - passengers affect balance and steering and increase risk of losing control. 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 2003.3–3.6x1 !