Yamaha Grizzly 80 YFM80GW Owner's Manual
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Yamaha Grizzly 80 YFM80GW Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM80GW
This A
WARNING
This ATV should not be ridden by anyone under 12 years of age.
LIT-11626-20-06
2D3-28199-13

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Isaac
March 9, 2025

Where is the oil filter ? Does it have one ?

0
1 comments:
Mr. Anderson
May 14, 2025

The provided context does not mention the presence or location of an oil filter on the Yamaha YFM80GW. Therefore, it cannot be determined from the given information whether the vehicle has an oil filter or where it is located.

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Summary of Contents for Yamaha Grizzly 80 YFM80GW

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM80GW This A WARNING This ATV should not be ridden by anyone under 12 years of age. LIT-11626-20-06 2D3-28199-13...
  • Page 2 EBU17091...
  • Page 3 Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 4 ATV safely. Your ATV was delivered with an adjustable speed limiter and also with an air intake restrictor plate. Yamaha recommends that all beginners start off with the speed limiter screw turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn.

  • Page 5: Important Manual Information

    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 or death to the ATV operator, a bystander, or a person inspecting or...

  • Page 6: Important Notice

    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 7: Table Of Contents

    EWB00010 Speed limiter and air intake restrictor WARNING plate ............4-4 Front brake lever ........4-5 Indicates a potential hazard that could result Brake pedal and rear brake lever ....4-5 in serious injury or death. Parking brake ..........4-6 Shift pedal ..........4-7 Fuel tank cap ..........
  • Page 8 Starting a warm engine ......6-3 General maintenance and lubrication chart ............8-5 Shifting ............6-3 Checking the spark plug ......8-8 Engine break-in ......... 6-5 Engine oil ..........8-10 Parking ............6-6 Final gear oil ..........8-13 Parking on a slope ........6-6 Cleaning the air filter element ....
  • Page 9 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 10: Safety Information

    EBU17430 SAFETY INFORMATION EBU17601 ate an ATV with engine size greater than 70 cc. – A child under 16 years old should never oper- AN ATV IS NOT A TOY AND CAN BE HAZARD- ate an ATV with engine size greater than 90 cc. OUS TO OPERATE.
  • Page 11 or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills. ● conditions, and your experience. Always follow proper procedures for climbing ●...
  • Page 12 backwards when climbing a hill. To avoid stall- times to let friction dry out the linings. ● ing, use the proper gear and maintain a steady Always use the size and type of tires specified in speed when climbing a hill. If you stall or roll this manual.
  • Page 13 HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or ex- haust pipe/muffler when refueling. Never refuel while smoking, or in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heat-...

  • 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 ATV use can result in SEVERE INJURY or DEATH.
  • Page 16 WARNING WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN NEVER ride as a CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE passenger. INJURY OR DEATH. OPERATING TIRE PRESSURE: Set with tires cold Passengers can cause Recommended : FRONT : 20 kPa, { 0.20 kgf/cm } 2.9 psi a loss of control, REAR : 20 kPa, { 0.20 kgf/cm...

  • Page 17: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Spark arrester 1. Fuel cock 2. Seat 2. Rear carrier 3. Panel 3. Rear wheel 4. Brake pedal 4. Footboard 5. Footboard 5. Shift pedal 6. Choke 7. Front wheel...

  • Page 18: Controls And Instruments

    EBU17712 from the figures shown in this manual. Controls and instruments 1. Rear brake lever 2. Parking brake 3. Neutral indicator light 4. Front brake lever 5. Throttle lever 6. Main switch 7. Fuel tank cap 8. Handlebar switches NOTE: The ATV you have purchased may differ slightly...

  • 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 Light

    EBU17780 EBU18060 Indicator light Handlebar switches 1. Neutral indicator light “N” 1. Engine stop switch “ENG. STOP” 2. Start switch “START” EBU17860 Neutral 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 Start switch “START” Push this switch to crank the engine with the start- ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. EBU18270 Throttle lever Once the engine is running, movement of the throt- 1.

  • Page 22: Speed Limiter And Air Intake Restrictor Plate

    ATV. Consult a 1. Loosen the locknut. Yamaha dealer if you can’t find or solve the 2. To increase the maximum engine power avail- problem yourself. able and the maximum speed of the ATV, turn the adjusting screw in direction (a).

  • Page 23: Front Brake Lever

    HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 20 mm (0.8 in). EBU18391 Front brake lever The front brake lever is located on the right handle- bar. To apply the front brake, pull the brake lever toward the handlebar grip.

  • Page 24: Parking Brake

    handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip. 1. Rear brake lever EBU18450 Parking brake 1. Brake pedal Use the parking brake before starting the engine or parking the ATV, especially on a slope.

  • Page 25: Shift Pedal

    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 Tank Cap

    1. Shift pedal 1. Fuel tank cap 2. Neutral position EBU18730 Fuel EBU18720 Fuel tank cap Make sure that there is sufficient fuel in the tank. Remove the fuel tank cap by turning it counter- Fill the fuel tank to the bottom of the filler tube as clockwise.
  • Page 27 Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research oc- tane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premi- um unleaded fuel.

  • Page 28: Fuel Cock

    EWB00270 WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and se- vere injury. Fuel expands when it heats up. If the fuel FUEL tank is overfilled, fuel could spill out due to heat from the engine or the sun.

  • Page 29: Choke

    FUEL FUEL 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 30: Seat

    Move the choke in direction (b) to turn off the choke. See the “Starting a cold engine” section on page 6- 1 for proper operation. 1. Seat lock lever To install the seat Insert the projection on the front of the seat into the seat holder and push down on the seat at the rear.

  • Page 31: Carrier

    1. Projection 2. Seat holder EBU18950 Carrier ● Do not exceed the load limit of 5.0 kg (11 lb) for the carrier. ● Do not exceed the maximum load of 95.0 kg (209 lb) for the ATV. EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death.

  • Page 32: Pre-Operation Checks

    Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 33 ITEM ROUTINE PAGE Check wheel condition, and replace if damaged. ● Wheels and tires Check tire condition and tread depth. Replace if necessary. 5-5, 5-6, 5-7 ● Check air pressure. Correct if necessary. ● Make sure that operation is smooth. Lubricate pedal pivoting points ●...

  • Page 34: Fuel

    HOW TO AVOID THE HAZARD plied. If not, have the ATV checked by a Yamaha Do not overfill the fuel tank. Be careful not to dealer.

  • Page 35: Throttle Lever

    ATV checked by a Yamaha dealer. 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.

  • Page 36: Tires

    Rear: ● The tires listed below have been approved 20 kPa (2.9 psi) (0.20 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: Measuring The Tire Pressure

    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 kPa (2.5 psi) (0.17 kgf/cm Rear: 17 kPa (2.5 psi) (0.17 kgf/cm ●...

  • Page 38: Specifications

    the tire pressures to the following specifications: Recommended pressure: Front 20 kPa (2.9 psi) (0.20 kgf/cm Rear 20 kPa (2.9 psi) (0.20 kgf/cm Minimum: Front 17 kPa (2.5 psi) (0.17 kgf/cm Rear 17 kPa (2.5 psi) (0.17 kgf/cm 1. Tire wear limit Maximum: Front EBU19840...

  • 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 Yamaha deal- Ambient temp./choke position er check the electrical circuit. °C 0° 10° 20° 30° NOTE: This model is equipped with an ignition circuit cut- °F 30° 50° 70° 90° off system. The engine can be started under the following conditions.

  • Page 41: Starting A Warm Engine

    crank the engine more than 10 seconds on each EBU20550 Shifting attempt. This ATV has a 3-speed forward transmission with 7. If the engine is started with the choke in posi- a centrifugal, automatic clutch. The transmission tion (1), the choke should be returned to posi- allows you to control the amount of power you tion (2) to warm up the engine.
  • Page 42 EBU20600 HOW TO AVOID THE HAZARD To start out and accelerate Release the shift pedal before opening the 1. Release the throttle lever. throttle. Open the throttle gradually. ECB00200 CAUTION: EBU20640 Always close the throttle before shifting gears, To decelerate otherwise damage to the engine and drive train When slowing down or stopping, release the throt- may result.

  • Page 43: Engine Break-In

    EBU20670 Engine break-in EWB00650 WARNING There is never a more important period in the life of your engine than the first 20 hours of riding. For POTENTIAL HAZARD this reason, you should read the following material Engaging a lower gear when the engine carefully.

  • Page 44: Parking

    ECB00220 CAUTION: If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV. EBU20721 Parking When parking the ATV, stop the engine, shift into first gear, apply the parking brake, and then turn 1.

  • Page 45: Accessories And Loading

    However, 2. Stop the engine. it is not possible for Yamaha to test all non- 3. With the rear brake lever and brake pedal ap- Yamaha accessories, nor control over their qual- plied, apply the parking brake and slowly re- ity or suitability.
  • Page 46 ● limits your ability to move around on the seat, or Load cargo on the carrier as close to the center one that limits your view. of the ATV as possible. Put cargo at the front of ● Use extra caution when riding an ATV with ac- the carrier and center it.
  • Page 47 handling of the ATV. EWB00750 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.

  • Page 48: Riding Your Atv

    EBU21131 RIDING YOUR ATV...

  • Page 49: Getting To Know Your Atv

    EWB00010 RIDE WITH CARE AND GOOD JUDGEMENT WARNING Get training if you are inexperienced. Indicates a potential hazard that could result in Beginners should get training from a certified in- serious injury or death. structor. Become familiar with this ATV at slow speeds first, EBU21562 even if you are an experienced operator.
  • Page 50 A child under 12 should never operate an should complete the certified training course ATV with engine size greater than 70 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 51 HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying pas- sengers. This ATV is designed to carry operator and cargo only – passengers prohibited. EWB00910 WARNING POTENTIAL HAZARD...
  • Page 52 Apparel EWB00920 WARNING POTENTIAL HAZARD Operating this ATV without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an acci- dent.
  • Page 53 Do not operate after consuming alcohol or HOW TO AVOID THE HAZARD drugs. Always wear an approved motorcycle helmet The operator’s performance capability is reduced that fits properly. by the influence of alcohol or drugs. You should also wear: ● eye protection (goggles or face shield) ●...
  • Page 54 EWB00930 HOW TO AVOID THE HAZARD WARNING Always inspect your ATV each time you use POTENTIAL HAZARD it to make sure the ATV is in safe operating Operating this ATV after consuming alcohol condition. or drugs. Always follow the inspection and mainte- WHAT CAN HAPPEN nance procedures and schedules described Could seriously affect your judgment.
  • Page 55 This model also has an air intake restrictor plate to Do not operate at speeds too fast for your limit the amount of engine power available. skills or the conditions. Yamaha recommends that all beginning riders EWB00960 start off with the speed limiter turned in and the air WARNING...
  • Page 56 see page 8-18. duce your speed when adding additional loads. MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 95.0 kg (209 lb) Carrier: 5.0 kg (11 lb) EWB00970 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly.
  • Page 57 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 58 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 59 Do not operate, idle, or park the ATV in dry accessories added to this ATV should be grass or other dry ground cover. genuine Yamaha or equivalent components Keep the engine area free of dry grass, designed for use on this ATV and should be brush, or other combustible material.

  • Page 60: Be Careful Where You Ride

    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. 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 ATV to go out of control.
  • Page 61 which may cause the ATV to upset. HOW TO AVOID THE HAZARD EWB01040 Never operate this ATV on any public street, WARNING road or highway, even a dirt or gravel one. In POTENTIAL HAZARD many states it is illegal to operate ATVs on Failure to use extra care when operating this public streets, roads and highways.
  • Page 62 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 63 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 64: Turning Your Atv

    the shift pedal. Remember that the engine and ex- When slowing down or stopping, release the throt- haust pipe will be hot when riding and afterwards; tle and apply the brakes smoothly and evenly. As do not allow skin or clothing to come in contact with you slow down, shift to a lower gear.
  • Page 65 lowed to slip or lose some traction, the ATV will of the turn slip slightly, allowing the ATV to make resist turning. A special turning technique must be the turn properly. used to allow the ATV to make turns quickly and easily.

  • Page 66: Climbing Uphill

    Once you have learned this technique, you should WHAT CAN HAPPEN be able to perform it at higher speeds or in tighter The ATV can overturn more easily on ex- curves. tremely steep hills than on level surfaces or Improper riding procedures such as abrupt throttle small hills.
  • Page 67 HOW TO AVOID THE HAZARD Always follow proper procedures for climb- ing hills as described in this Owner’s Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes.
  • Page 68 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 69: Riding Downhill

    immediately on the uphill side. EWB01231 WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dis- mounting while climbing a hill. WHAT CAN HAPPEN Could result in the ATV overturning. HOW TO AVOID THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill.

  • Page 70: Crossing A Slope

    to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- 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.

  • Page 71: Crossing Through Shallow Water

    the front wheels slightly uphill. When riding on When crossing the side of a hill: slopes, be sure not to make sharp turns either up Always follow proper procedures as de- or down hill. scribed in the Owner’s Manual. If your ATV does begin to tip over, gradually steer Avoid hills with excessively slippery or loose in the downhill direction if there are no obstacles in surfaces.
  • Page 72 carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and care- fully. EWB01150 WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an acci-...

  • Page 73: Riding Over Rough Terrain

    1. Air filter case check hose RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- ECB00240 tion. Look out for obstacles which could cause CAUTION: damage to the ATV or could lead to an upset or ac- After riding your ATV in water, be sure to drain cident.

  • Page 74: Sliding And Skidding

    EWB01160 WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for ob- stacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees.

  • Page 75: What To Do If

    WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain.
  • Page 76 ● Lean more into the turn to regain balance. If nec- If your ATV encounters shallow water: essary, gradually let off the throttle and/or steer Ride slowly and carefully through slow moving to the outside of the turn. (See page 7-17.) water, watching for obstacles.

  • Page 77: 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 78 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 79: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. INITIAL...
  • Page 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 leakage and replace gasket(s) if neces- ● sary. √ √ √ Exhaust system Check for looseness and tighten all screw clamps ●...

  • Page 81: General Maintenance And Lubrication Chart

    EBU21862 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 Check chain tension. ● √ √ √ √ Timing chain Adjust if necessary. ●...
  • Page 82 √ √ 17 * Lubricate. ● cables Check operation and correct if necessary. ● Throttle lever hous- Check throttle cable free play and have a Yamaha ● √ √ √ √ √ 18 * ing and cable dealer adjust if necessary.
  • Page 83 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check electrolyte level and specific gravity, and ● correct if necessary. √ √ √ √ √ 20 * Battery Make sure that the breather hose is properly ●...

  • Page 84: Checking The Spark Plug

    EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU23210 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 85 If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to di- agnose such problems yourself. Instead, 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 86: Engine Oil

    and its mating surface, and then wipe off any 2. Start the engine, warm it up for several min- grime from the spark plug threads. utes, and then turn it off. 3. Install the spark plug with the spark plug 3.
  • Page 87 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil. 4. Remove the engine oil filler cap, and then re- move the engine oil drain bolt to drain the oil from the crankcase.
  • Page 88 en it to the specified torque. minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and Tightening torque: check for the cause. Engine oil drain bolt: 9. Turn the engine off, and then check the oil lev- 20 Nm (2.0 m·kgf, 14.5 ft·lbf) el and correct it if necessary.

  • Page 89: Final Gear Oil

    The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 90: Cleaning The Air Filter Element

    ed final gear oil, and then check the oil level. Recommended final gear oil: See page 10-1. Oil quantity: 0.12 L (0.13 US qt) (0.11 Imp.qt) ECB00420 CAUTION: Be sure no foreign material enters the final gear case. 6. Install and tighten the oil filler cap. 1.
  • Page 91 ter case. 1. Quick fastener 1. Air filter case check hose 2. Remove the panel by sliding it forward and pulling it off as shown. 1. Remove the quick fasteners. 8-15...
  • Page 92 1. Air filter case cover 1. Panel 2. Air filter case holder 3. Remove the air filter case cover by unhooking 4. Unhook the holder holding the air filter ele- the holders. ment, and then pull out the sponge material from the air filter element.
  • Page 93 7. Check the sponge material and replace it if damaged. 1. Unhook. 8. Apply Yamaha foam air filter oil or other qual- 2. Sponge material ity foam air filter oil to the sponge material. 5. Wash the sponge material gently but thor- NOTE: oughly in solvent.

  • Page 94: Removing The Air Intake Restrictor Plate

    2. Remove the air intake restrictor plate. NOTE: The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar- eas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions.
  • Page 95 1. Tailpipe 1. Screw 2. Spark arrester 3. Screw 2. Remove the tailpipe by pulling it out of the muffler. 4. Insert the tailpipe into the muffler and align the 3. Tap the tailpipe lightly, and then use a wire screw holes.

  • Page 96: Adjusting The Carburetor

    EWB01910 Yamaha dealer, who has the necessary profes- WARNING sional knowledge and experience. The adjustment described in the following section, however, may POTENTIAL HAZARD be performed by the owner as part of routine main- Improper cleaning of the spark arrester.

  • Page 97: Checking The Throttle Cable Free Play

    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 adjustment. 2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if neces-...

  • Page 98: Timing Chain

    Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart. EBU24090 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 maintenance and lubrication chart.

  • Page 99: Adjusting The Front Brake Lever Free Play

    Front brake Rear brake 1. Wear limit line 1. Wear limit mark 2. Wear indicator 2. Wear indicator EBU24320 Adjusting the front brake lever free play The brake lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 100 12.0 mm (0.39–0.47 in) as shown. If the free play is incorrect, adjust it as follows. 1. Upper locknut 2. Upper adjusting bolt 3. Lower locknut 1. Brake lever free play 4. Lower adjusting bolt 1. Loosen the upper locknut and fully turn in the 4.

  • Page 101: Adjusting The Rear Brake Lever And Brake Pedal Free Play

    ● Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24462 Adjusting the rear brake lever and brake pedal free play 1. Cable joint...
  • Page 102 mm (0.20–0.31 in) as shown. If the free play is in- cable at the rear wheel hub until the brake lever correct, adjust it as follows. free play measures 5.0–8.0 mm (0.20–0.31 in). 1. Locknut 1. Brake lever free play adjusting nut 2.
  • Page 103 1. Brake pedal free play 1. Brake pedal free play adjusting nut Turn the brake pedal free play adjusting nut on the brake rod at the rear wheel hub in direction (a) to increase the free play, and in direction (b) to de- crease it.

  • Page 104: Adjusting The Clutch Free Play

    Make sure the brakes do not drag. 2. Screw Replacement of brake components requires 3. Bolt professional knowledge. These procedures should be performed by a Yamaha dealer. 2. Remove the rubber cap. 3. Loosen the locknut. EBU24791 4. Slowly turn the adjusting bolt clockwise until...

  • Page 105: Checking And Lubricating The Cables

    If a cable is damaged or does not move Turning the adjusting bolt in decreases clutch free smoothly, have a Yamaha dealer check or replace play and turning it out increases clutch free play. 5. Tighten the locknut to the specified torque.

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

    EWB02120 Front brake lever WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged, and cables can also be- come frayed or kinked, which could restrict the operation of controls and lead to an acci- dent or injury.

  • Page 107: Checking And Lubricating The Brake And Shift Pedals

    If there is play in a wheel hub or if a wheel does not turn smoothly, 1. Grease nipple have a Yamaha dealer check the wheel bearings. EBU25090 Lubricating the steering shaft EBU25070...

  • Page 108: Battery

    Lubricate the steering shaft using a grease gun. To check the electrolyte level 1. Place the ATV on a level surface. Recommended lubricant: 2. Check the electrolyte level in the battery. Lithium-soap-based grease 1. Battery 2. Battery breather hose 1. Grease nipple NOTE: EBU25111 The electrolyte should be between the minimum...
  • Page 109 WHAT CAN HAPPEN You could be poisoned. You could be severe- ly burned by the sulfuric acid in battery elec- trolyte. Batteries produce explosive gases. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Al- ways shield eyes when working near batter- ies.
  • Page 110 stored as follows. the battery whenever necessary. 1. Disconnect the negative lead first and then the To install the battery positive lead. NOTE: Be sure the battery is fully charged. 1. Install the battery. 2. Connect the positive lead first, and then con- nect the negative lead.

  • Page 111: Replacing The Fuse

    If the fuse is blown, replace it as follows. ECB00610 1. Turn the key to “OFF” and turn off all electrical CAUTION: circuits. ECB00640 If the breather hose is positioned in such a way CAUTION: that the frame is exposed to electrolyte or gas expelled from the battery, the frame could suf- To prevent accidental short-circuiting, turn off fer structural and external damages.

  • Page 112: Removing A Wheel

    3. Turn the key to “ON” and turn on the electrical Rear circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU25650 Removing a wheel 1. Loosen the wheel nuts.

  • Page 113: 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 114: 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 115: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25870 applications such as those available in coin- Cleaning operated car washers. Frequent, thorough cleaning of your ATV will not 4. Once most of the dirt has been hosed off, only enhance its appearance but will improve its wash all surfaces with warm water and mild, general performance and extend the useful life of detergent-type soap.

  • Page 116: 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 117 plug, and then place the spark plug on the NOTE: cylinder head so that the electrodes are Make any necessary repairs before storing the grounded. (This will limit sparking during ATV. the next step.) d. Turn the engine over several times with the starter.

  • Page 118: Specifications

    EBU25960 SPECIFICATIONS EBU25974 Compression ratio: Dimensions: 9.60 :1 Overall length: Starting system: 1550 mm (61.0 in) Electric starter Overall width: Lubrication system: 855 mm (33.7 in) Wet sump Overall height: Engine oil: 930 mm (36.6 in) Type: Seat height: YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 665 mm (26.2 in) Wheelbase: 0˚...
  • Page 119 Engine oil quantity: Transmission: Periodic oil change: Primary reduction system: 0.80 L (0.85 US qt) (0.70 Imp.qt) Spur gear Final gear oil: Primary reduction ratio: Type: 65/20 (3.250) SAE80 API GL-4 Hypoid gear oil Secondary reduction system: Quantity: Shaft drive 0.12 L (0.13 US qt) (0.11 Imp.qt) Secondary reduction ratio: 19/18 ×...
  • Page 120 Manufacturer/model: Front wheel: DUNLOP/KT586 Wheel type: Rear tire: Panel wheel Type: Rim size: Tubeless 7x5.5AT Size: Rear wheel: AT18 x 8-7 Wheel type: Manufacturer/model: Panel wheel DUNLOP/KT587 Rim size: Loading: 7x6.5AT Maximum load: Front brake: 95.0 kg (209 lb) Type: (Total weight of rider, cargo, accessories, and tongue) Drum brake Tire air pressure (measured on cold tires):...
  • Page 121 Spring/shock absorber type: Coil spring/oil damper Wheel travel: 56.0 mm (2.20 in) Electrical system: Ignition system: Charging system: AC magneto Battery: Model: 12N7D-3B Voltage, capacity: 12 V, 7.0 Ah Bulb voltage, wattage x quantity: Neutral indicator light: 12 V, 1.7 W × 1 Fuses: Main fuse: 5.0 A...

  • Page 122: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. ●...
  • Page 123 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 124: 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 125: 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 126: 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 127 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 128: 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 129 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 130 EBU26132 11-9...
  • Page 131 INDEX Engine idling speed............8-20 Engine oil ..............5-3 8-10 Accessories and loading ..........6-7 Engine, starting a warm ..........6-3 Air filter element, cleaning..........8-14 Engine stop switch ............4-2 Air intake restrictor plate, removing......8-18 Final gear oil............5-3 8-13 Battery..............
  • Page 132 Model label..............11-2 Tires................5-5 Tire wear limit ..............5-7 Troubleshooting ............8-37 Neutral indicator light ............4-2 Troubleshooting chart ...........8-38 Noise regulation ............11-3 Valve clearance ............8-22 Owner’s manual and tool kit..........8-1 Vehicle identification number........11-1 Parking................6-6 Warranty, extended ............11-7 Parking brake..............4-6 Warranty, limited............11-5 Parking on a slope ............6-6 Wheel bearings, checking..........8-31 Part locations ..............3-1 Wheel, installing............8-36...
  • Page 133 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 2006.3-0.6x1 !
  • Page 134 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 135 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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