Yamaha BADGER Owner'S Manual Download Page 19

Page: 19 / 141

3-1

1. Spark arrester

10. Rear brake lever

2. Seat

11. Parking brake

3. Front cover

12. Neutral indicator light

4. Rear brake pedal

13. Front brake lever

5. Fuel cock

14. Throttle lever

6. Rear wheel

15. Main switch

7. Footrest

16. Fuel tank cap

8. Shift pedal

17. Handlebar switch

9. Front wheel

NOTE:

The machine you have purchased may differ

slightly from those shown in the figures of this

manual.

EBU00032

DESCRIPTION AND MACHINE IDENTIFICATION

i u

Summary of Contents for BADGER

Page 1: ...w This ATV should not be ridden by anyone under 12 years of age OWNER S MANUAL 4EM 28199 1B YFM80N C READ THIS MANUAL CAREFULLY It contains important safety information LIT 11626 14 04 ...

Page 2: ...out spe cial techniques and skills necessary to ride your machine It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your machine please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE 8 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COM PLETELY BEFORE OPERATING YOUR MACHINE MAKE SURE YOU UNDERST...

Page 3: ...sical abilities and judgement Some children may not be able to operate an ATV safely Parents should supervise their child s use of the ATV at all times Parents should permit continued use only if they determine that the child has the ability to operate the ATV safely If your child is a beginner or is inexperienced he or she should take a training course See the previ ous page for information about...

Page 4: ...notations Q The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED w Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine cC A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedure...

Page 5: ...arrester laws and regula tions in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine AFFIX DEALER LABEL HERE EBU00012 YFM80N C OWNER S MANUAL 2000 by Yamaha Motor Corporation U S A 1st Edition February 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expre...

Page 6: ...1 Indicator lights 4 1 Handlebar switches 4 2 Throttle lever 4 3 Speed limiter 4 4 Front brake lever 4 5 Rear brake pedal and lever 4 5 Parking brake 4 6 Shift pedal 4 7 Fuel tank cap 4 8 Fuel cock 4 8 Choke lever 4 9 Seat 4 10 PRE OPERATION CHECKS 5 1 Front and rear brakes 5 2 Fuel 5 3 Engine oil 5 5 Final gear oil 5 5 Throttle lever 5 6 Fittings and fasteners 5 6 EBU00014 w Indicates a potential...

Page 7: ... Ride with care and good judgement 7 4 Be careful where you ride 7 16 Turning your ATV 7 23 Climbing uphill 7 25 Riding downhill 7 30 Crossing a slope 7 32 Crossing through shallow water 7 34 Riding over rough terrain 7 36 Sliding and skidding 7 38 What to do if 7 40 What to do 7 40 PERIODIC MAINTENANCE AND ADJUSTMENT 8 1 Owner s manual and tool kit 8 1 Periodic maintenance Lubrication 8 3 Engine ...

Page 8: ... and shift pedal brake lever lubrication 8 23 Knuckle shaft and steering shaft lubrication 8 24 Wheel removal 8 24 Wheel installation 8 24 Battery 8 25 Replenishing the battery fluid 8 27 Fuse replacement 8 28 Troubleshooting 8 29 Troubleshooting chart 8 30 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 1...

Page 9: ...ant information for safe and proper operation of your ATV Never remove any labels from your ATV If a label becomes difficult to read or comes off a replace ment label is available from your Yamaha dealer 1 1 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS q w t r e ...

Page 10: ...1 2 1 1 3 2 4EM 21697 31 4EM 21578 A0 5FE 21568 01 ...

Page 11: ...1 3 4 5 qWARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 5FE 2151H 01 4EM 21696 11 ...

Page 12: ...thout proper training or instruction Take a Training Course Beginners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 447 4700 to find out about the training courses nearest you 8 Always follow the age recommendation A child under 12 years old should never operate an ATV with engine size greater than 70cc A child under 16 years old should never op...

Page 13: ... ATV 8 Never operate at speeds too fast for your skills or the conditions Always go at a speed that is prop er for the terrain visibility and operating conditions and your experience 8 Never attempt wheelies jumps or other stunts 8 Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules descri...

Page 14: ...ippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed 8 Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going d...

Page 15: ...ng over obstacles as described in this manual 8 Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control 8 Never operate an ATV in fast flowing water or in water deeper tha...

Page 16: ...urely 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 ...

Page 17: ...r other sources of ignition such as the pilot lights of water heaters and clothes dryers qWARNING When transporting the machine in another vehicle be sure it is kept upright and that the fuel cock is in the OFF position Otherwise fuel may leak out of the carbu retor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline...

Page 18: ...ing 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 machine in an area with adequate ventilation qWARNING ...

Page 19: ...t brake lever 5 Fuel cock 14 Throttle lever 6 Rear wheel 15 Main switch 7 Footrest 16 Fuel tank cap 8 Shift pedal 17 Handlebar switch 9 Front wheel NOTE The machine you have purchased may differ slightly from those shown in the figures of this manual EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION w e r q u o i u y t 0 1 2 3 4 5 6 7 ...

Page 20: ...ring spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION EBU00035 Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key 1 Key identification number 3 2 1 6 q 3 ...

Page 21: ...dentification number NOTE The vehicle identification number is used to identify your machine EBU00038 Model label The model label is affixed to the frame Record the information on this label in the space provid ed This information will be needed to order spare parts from your Yamaha dealer 1 Model label 3 3 q q ...

Page 22: ...e switch positions are as follows ON The engine can be started only at this position OFF All electrical circuits are switched off The key can be removed in this position EBU00043 Indicator lights EBU00045 Neutral indicator light NEUTRAL This indicator light comes on when the transmis sion is in neutral 1 Neutral indicator light NEUTRAL 4 1 q 4 OFF ON ...

Page 23: ...gency The engine will not start or run when the engine stop switch is turned to OFF EBU00056 Start switch START The starter motor cranks the engine when this switch is pushed cC See starting instructions prior to starting engine see page 6 1 for details NOTE If the starter switch is pushed with the main switch ON and the engine stop switch OFF the starter motor will be activated but the engine wil...

Page 24: ...ck the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released 4 3 q POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate mak ing it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you sta...

Page 25: ...e and decreases the maximum speed of the ATV 1 Locknut 2 Adjuster a 15 mm 0 6 in 4 4 POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an accident or be injured HOW TO AVOID THE HAZARD Do not turn the speed adjuster out more than 15 mm 0 6 in qWARNING a q w ...

Page 26: ... apply the front brake 1 Front brake lever EBU00073 Rear brake pedal and lever The brake pedal is located on the right side of the machine and the brake lever is located on the left handlebar Push down on the pedal or pull the lever toward the handlebar to apply the rear brake 1 Rear brake pedal 1 Rear brake lever q q q ...

Page 27: ...brake when you have to start the engine or park the machine especially on a slope Apply the rear brake lever and push down the lock plate to apply the parking brake Squeeze the rear brake lever to release the parking brake 1 Lock plate 4 6 q ...

Page 28: ...oving unexpectedly if the parking brake is not applied before starting the engine This could cause loss of control or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before start ing the eng...

Page 29: ...n this position fuel will not flow Always turn the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling return the fuel ...

Page 30: ...96 Choke lever The choke is used to start a cold engine Refer to Starting a cold engine for proper operation See page 6 1 a Choke lever 1 Fully open ON 2 Half open Warming up position 3 Closed OFF 4 9 a q w e ...

Page 31: ...lock lever upward and pull up the seat at the rear 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 1 Seat lock lever NOTE Make sure that the seat is securely fitted 4 10 q ...

Page 32: ...4 11 EBU00112 w Indicates a potential hazard that could result in serious injury or death ...

Page 33: ...with fuel if necessary 5 3 5 4 Engine oil 9 Check oil level 9 Fill with oil if necessary 5 5 8 5 8 6 Final gear oil 9 Check for leakage 5 5 8 7 8 8 Throttle 9 Check for proper throttle cable operation 5 6 Wheels and tires 9 Check tire pressure wear and damage 5 7 5 9 8 24 Fittings and fasteners 9 Check all fittings and fasteners 5 6 Battery 9 Check fluid level 5 6 8 25 8 27 9 Fill with distilled w...

Page 34: ...ner s Manual qWARNING 5 EBU00476 Front and rear brakes 1 Brake levers and brake pedal Check for correct free play in the brake levers and brake pedal If the free play is incorrect adjust it See pages 8 17 8 21 Check operation of the levers and pedal They should move smoothly and there should be a firm feeling when the brake is applied If not have the machine inspected by a Yamaha dealer 2 Brake op...

Page 35: ...aded gasoline is not available then leaded regular gasoline can be used Recommended fuel UNLEADED FUEL Fuel tank capacity Total 6 8L 1 5 Imp gal 1 8 US gal Reserve 0 9L 0 2 Imp gal 0 2 US gal 5 3 POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of ever...

Page 36: ...el 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 Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediate...

Page 37: ... final gear oil is at the specified level Add oil as necessary See pages 8 7 8 8 for details If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used 5 5 Recommended oil Recommended engine oil classification API Service SE SF SG type or higher Recommended oil SAE 80 API GL 4 Hypoid gear oi...

Page 38: ...eck the tightness of chassis fittings and fasteners before a ride Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque EBU00154 Switches Check the operation of the start switch engine stop switch and any other switches Repair as necessary for proper operation EBU00499 Battery Check fluid level and fill if necessary Use only distilled water if refilling i...

Page 39: ... following are mini mums Front 17 kPa 0 17 kgf cm2 2 5 psi Rear 17 kPa 0 17 kgf cm2 2 5 psi Manufacturer Size Type Front DUNLOP AT18 7 7 KT586 Rear DUNLOP AT18 8 7 KT587 POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or oper ation of this ATV with improper or uneven tire pressure may cause loss of c...

Page 40: ...lowing specifications 1 Low pressure tire gauge 5 8 4 Use no more than the following pres sures when seating the tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst 20 kPa 0 20 kgf cm2 2 9 psi 17 kPa 0 17 kgf cm2 2 5 psi 23 kPa 0 23 kgf cm2 3...

Page 41: ...EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a 3 mm 0 12 in 5 9 a ...

Page 42: ...iliar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer qWARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or colli sion ...

Page 43: ...ar and the rear brake lever is applied However it is recommended to shift into neutral before starting the engine 5 Use the choke lever in reference to the fig ure Position 1 Cold engine start ambient temperature below 30 C 90 F Position 2 Warming up position Position 3 Cold engine start ambient temperature above 25 C 80 F and warm engine start posi tion a Choke lever 1 Fully open ON 2 Half open W...

Page 44: ... starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the choke lever to posi tion 3 before riding cC See the Engine break in section prior to operating engine for the first time EBU00181 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The choke lever s...

Page 45: ...til it stops 1 Shift pedal N Neutral cC Do not coast for long periods with the engine off and do not tow the machine a long dis tance Even with gears in neutral the trans mission is only properly lubricated when the engine is running Inadequate lubrication may damage the transmission EBU00205 To start out and accelerate 1 Release the throttle lever cC Always close the throttle while shifting gears...

Page 46: ...es to lose traction reducing control and increasing the possibility of an accident 6 5 POTENTIAL HAZARD Opening the throttle before releasing the shift pedal WHAT CAN HAPPEN The machine could wheelie This would increase the chance of an accident including overturn HOW TO AVOID THE HAZARD Release the shift pedal before opening the throttle Open the throttle gradually qWARNING POTENTIAL HAZARD Engag...

Page 47: ...conds maximum full throt tle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this period consult a Yamaha dealer 1 0 10 hours Avoid continuous operation above half throt...

Page 48: ...EBU00211 Parking When parking stop the engine and shift into neutral Turn the fuel cock to OFF and apply the parking brake 1 Lock plate 6 7 q ...

Page 49: ...AZARD 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 Avoid parking on hills or other inclines If you must park on an incline put the machine in low gear apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you c...

Page 50: ...ility of them Choose a genuine Yamaha accessory or one that is equivalent in design and quality 8 Accessories should be rigidly and securely mounted An accessory which can shift posi tion or come off while you are riding could affect your ability to control the ATV 8 Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a he...

Page 51: ...ake sure cargo in the trailer cannot move around A shifting load can cause an accident 8 Make sure the load does not interfere with controls or your ability to see where you are going 8 Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed 2nd gear when ever you are carrying heavier loads or when...

Page 52: ...ould 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 Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking qWARNING ...

Page 53: ...6 12 EBU00555 w Indicates a potential hazard that could result in serious injury or death ...

Page 54: ...Riding Your ATV 7 7 1 OK OK OK OK ...

Page 55: ...7 2 ...

Page 56: ...fore attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill neces sary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual completely and understand the operation of the controls Pay particular at...

Page 57: ...basic techniques well before attempting more difficult maneuvers POTENTIAL HAZARD Operating this ATV without proper instruc tion WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to oper ate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certifi...

Page 58: ...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 HOW TO AVOID THE HAZARD A child under 12 should never operate an ATV with engine size greater than 70cc qWARNING ...

Page 59: ... 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 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 car rying passengers qWARNING ...

Page 60: ...ting without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle hel met that fits properly You should also wear eye protection goggles or face shield gloves boots long sle...

Page 61: ...rugs POTENTIAL HAZARD Operating this ATV after consuming alco hol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV qWARNING ...

Page 62: ...erating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual qWARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or oper ation of this ATV with improper or uneven tire pressure may cause loss of control increasing your risk of an acciden...

Page 63: ...ter limits the power and top speed of the machine Turning the screw in decreases top speed and turning it out increases top speed 1 Locknut 2 Adjuster 7 10 POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always go at a speed that is pr...

Page 64: ...s 95 kg 209 lb 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 Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for brak...

Page 65: ...N 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 If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an acci dent HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV ...

Page 66: ...the machine or overturn 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 Don t try to show off qWARNING ...

Page 67: ...which in some situa tions could lead to an accident HOW TO AVOID THE HAZARD 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 qWARNING...

Page 68: ...achine in a place where pedestrians or children are not likely to touch it 7 15 POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system during or after operation could be burned HOW TO AVOID THE HAZARD Do not touch the hot exhaust system Do not park the machine in a place where others might be likely to touch it qWARNING ...

Page 69: ...TIAL 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 HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets qWARNING ...

Page 70: ...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 gravel one In many states it is illegal to operate ATVs on public streets roads and highways qWARNING ...

Page 71: ...ZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when oper ating on unfamiliar terrain Always be alert to changing terrain condi tions when operating the ATV qWARNING...

Page 72: ...e 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 to control the ATV on such terrain Always be especially cautious on these kinds of terrain qWARNING ...

Page 73: ...de in areas posted no trespassing Do not ride on private property without getting per mission POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles qWARNING WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the machine to make you more visible Watch carefully for other vehicles ...

Page 74: ...wards do not allow skin or clothing to come in contact with these compo nents With the engine idling lift the shift pedal to the 1st gear position and then release the parking brake Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate Once the ATV has attained adequate speed release the throttle and lift the shift pedal to the 2nd gear position...

Page 75: ...gaging a lower gear Improper use of the brakes or shifting can cause the tires to lose traction reducing control and increasing the possibility of an accident POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating This could cause loss of control an accident and injury It could also cause engine or drive train damage HOW TO AVOID THE...

Page 76: ...e desired direction As you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN The ATV ...

Page 77: ...que you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throt tle changes excessive braking incorrect body movements or too much speed for the sharp ness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while nego tiating a turn lean more to the inside It may also be necessary to gradually let off on the ...

Page 78: ...to lose control It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by leaning for ward and on steeper inclines standing on the footboards and leaning forward over the handle bars POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level ...

Page 79: ...s 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 The ATV could flip over backwards qWARNING Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other sid...

Page 80: ...se 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 turn ing technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible qWARNING When crossing the side of a hill Always follow proper procedures as described i...

Page 81: ...try to put the ATV in gear The ATV could easily tip over backwards Instead dismount the ATV immediately on the uphill side POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN Could result in the ATV overturning HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphi...

Page 82: ...y stopped apply rear brake as well and then lock 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 ...

Page 83: ...downhill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear 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 Ow...

Page 84: ...7 31 OK OK ...

Page 85: ...p 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 As you regain proper bal ance gradually steer again in the direction you wish to travel 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...

Page 86: ...7 33 Shift your weight to the uphill side of the ATV OK OK ...

Page 87: ... slowly and carefully 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 accident HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that speci fied in your Owner s Manual Remember that wet brakes may have reduced stopping ability Test yo...

Page 88: ...erifying that you have regained proper braking ability cC After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case Wash the ATV in fresh water if it has been operated in salt water or muddy condi tions 1 Check hose q ...

Page 89: ...ping the ATV as loss of control and damage to the ATV may result 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 obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always fol...

Page 90: ...7 37 ...

Page 91: ... the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide side ways control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide ...

Page 92: ...ces such as ice since all control may be lost POTENTIAL HAZARD Skidding or sliding improperly 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 On extremely slippery surfaces such as ice go slowly an...

Page 93: ...rn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See pages 7 23 7 24 8 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not rec ommended until you have corrected the slide See pages 7 38 7 39 8 If your ATV can t make it up a hill you are try ing to climb Turn ...

Page 94: ...e ATV is going to tip over dismount on the uphill side See pages 7 32 7 33 8 If your ATV encounters shallow water Ride slowly and carefully through slow mov ing water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not con tinue to ride your ATV until you have regained adequate braking ability See pages 7 3...

Page 95: ...o put this owner s man ual and low pressure tire gauge in the vinyl bag and always carry them along with the owner s tool kit under the seat 1 Owner s manual 2 Low pressure tire gauge 3 Tool kit q w e POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires ...

Page 96: ...maha dealer to check the torque settings and adjust them as necessary POTENTIAL HAZARD Operating this ATV with improper modifi cations WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situa tions could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories ...

Page 97: ...n in wet or dusty areas Carburetor 9 Check idle speed choke lever operation 2 2 2 2 9 Adjust if necessary Crankcase breather 9 Check breather hose for cracks or damage 2 2 2 system 9 Replace if necessary 9 Check for leakage Exhaust system 9 Retighten if necessary 2 2 2 9 Replace gasket if necessary Spark arrester 9 Clean 2 2 2 Fuel line 9 Check fuel hose for cracks or damage 2 2 2 9 Replace if nec...

Page 98: ...ance damage runout 2 2 2 2 9 Replace if necessary 9 Check brearing assemblies for looseness Wheel bearings damage 2 2 2 2 9 Replace if damaged 9 Check operation Steering system 9 Replace if damaged 2 2 2 2 2 9 Check toe in 9 Adjust if necessary Knuckle shafts 9 Lubricate every 6 months 2 2 2 Steering shaft Fittings and Fasteners 9 Check all chassis fittings and fasteners 2 2 2 2 2 9 Correct if nec...

Page 99: ...ove the dipstick and inspect the oil level e The oil level should be between the maxi mum and minimum marks If the level is low add oil to raise it to the proper level cC Be sure no foreign material enters the crankcase 1 Dipstick 2 Maximum level mark 3 Minimum level mark 2 Engine oil replacement a Place the machine on a level place b Warm up the engine for several minutes and stop it c Place a co...

Page 100: ...ankcase h Warm up the engine for several minutes at idle speed Check for oil leakage while warming up cC If oil leakage is found stop the engine imme diately and check for the cause q Tightening torque Drain plug 20 Nm 2 0 m kg 14 ft lb Recommended oil See page 10 2 Oil quantity Periodic oil change 0 8 L 0 70 Imp qt 0 85 US qt Total amount 0 95 L 0 84 Imp qt 1 00 US qt ...

Page 101: ... oil level d The oil level should be between the maxi mum and minimum marks If the level is low add oil to raise it to the proper level cC Be sure no foreign material enters the final gear case e Install the dipstick 1 Dipstick 2 Maximum level mark 3 Minimum level mark 2 Final gear oil replacement a Place the machine on a level place b Place a container under the final gear case c Remove the dipst...

Page 102: ...ith oil cC Be sure no foreign material enters the final gear case f Install the dipstick g Check for oil leakage If oil leakage is found check for the cause q Tightening torque Drain bolt 23 Nm 2 3 m kg 17 ft lb Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 12 L 0 11 lmp qt 0 13 US qt ...

Page 103: ...tempt to diagnose such problems yourself Instead take the machine 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 you should replace the spark plug with one of the proper type Before installing the spark plug measure the electrode gap with a feeler ...

Page 104: ... to the specified torque EBU00292 Air filter cleaning NOTE There is a check hose at the bottom of the air fil ter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case 1 Check hose 1 Remove the front cover 1 Front cover Tightening torque Spark plug 12 5 Nm 1 25 m kg 9 1 ft lb q q ...

Page 105: ...ess solvent out of the filter and let it dry cC Do not twist the filter element when squeez ing it w q POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element qWARNING ...

Page 106: ...ed in extremely dusty areas Each time filter element maintenance is performed check the air inlet to the filter case for obstructions Check the air cleaner rubber joint to the carburetor and mani fold fittings for an air tight seal Tighten all fit tings securely to avoid the possibility of unfil tered air entering the engine cC Never operate the engine with the air filter element removed This will...

Page 107: ...e screw 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and align the screw holes 5 Install the screw and tighten it 1 Screw q w q ...

Page 108: ...ure 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 Do not start the engine when cleaning the exhaust system qWARNING ...

Page 109: ... turbed by someone without sufficient techni cal knowledge poor engine performance and damage may result EBU00301 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 to 5 000 r min The engine is warm when it quickly responds to the throttle 2...

Page 110: ...he cam chain becomes loose with use result ing in improper valve timing and engine noise To prevent this the cam chain tensioner must be adjusted regularly This adjustment should be left to a Yamaha service technician EBU00308 Front and rear brake shoe inspection A wear indicator is provided on each brake The indicators allows checking of brake shoe wear without disassembling the brake Apply the b...

Page 111: ...free play adjustment NOTE Before adjusting the brake inspect the front brake shoes The front brake lever free play should be adjust ed to 10 12 mm 0 4 0 5 in at the brake lever pivot If the free play is incorrect adjust as follows a Free play 10 12 mm 0 4 0 5 in 8 17 w q a Front w q Rear ...

Page 112: ...ned 1 Upper locknut 2 Upper adjusting bolt 3 Lower locknut 4 Lower adjusting bolt 4 Tighten the lower locknut 5 While applying the front brake turn out the upper adjusting bolt until the upper and lower cable lengths are equal The cable joint will become vertical 1 Cable joint 6 Tighten the upper locknut w q r e Specified free play 10 12 mm 0 4 0 5 in q a a a a ...

Page 113: ...cknut 2 Adjusting bolt 8 19 a q w POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing 8 Make sure the brakes operate smooth ly and that the free play is correct 8 Make sure the brakes do not drag Replacement of brake components requires professional knowledge Th...

Page 114: ...usting nut at the rear wheel hub until brake lever free play is 5 8 mm 0 20 0 31 in 1 Adjusting nut brake cable 2 Brake pedal free play adjustment a Turn the brake rod adjusting nut at the rear wheel hub until brake pedal free play is 20 30 mm 0 8 1 2 in a 20 30 mm 0 8 1 2 in q a ...

Page 115: ...lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing 8 Make sure the brakes operate smooth ly and that the free play is correct 8 Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer qWARNING ...

Page 116: ...elt Then turn it 1 8 counterclockwise 1 Rubber cap 2 Locknut 3 Adjusting bolt 4 Tighten the locknut to the specified torque NOTE Turn the adjusting bolt clockwise to decrease the clutch free play and turn it counterclockwise to increase the free play 5 Install the rubber cap securely 8 22 q w e Tightening torque 8 Nm 0 8 m kg 5 8 ft lb ...

Page 117: ...TENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer cov ering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables qWARNING Recommended lubricant Yamaha chain and cable lube or SAE 10W3...

Page 118: ...able stand under the frame 2 Remove the nuts from the wheel 3 Remove the wheel assembly EBU00375 Wheel installation When installing the wheels reverse the removal procedure Tighten the wheel nuts to the specified torque Recommended lubricant Lithium soap base grease Tightening torque Wheel nut Front 28 Nm 2 8 m kg 20 ft lb Rear 28 Nm 2 8 m kg 20 ft lb Front Rear ...

Page 119: ...w cC Do not leave or store the battery on its side When inspecting the battery be sure the breather hose is routed correctly If it touch es the frame or exists in such a way as to cause battery electrolyte or gas to exit onto the frame structural and cosmetic damage to the machine can occur 1 Battery 2 Battery breather hose 8 25 q w ...

Page 120: ...in eyes or clothing Always shield eyes when working near batteries Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention qWARNING EYES Flush with water for 15 minutes and get prompt medical attention Keep batter ies away from sparks flames cigarettes or ...

Page 121: ...mal tap water contains minerals which are harmful to a battery Therefore refill only with distilled water 4 When the machine is not to be used for a month or longer remove the battery and store it in a cool dark place Completely recharge the battery before reusing 5 If the battery is to be stored for a longer period than the above check the specific gravity at least once a month and recharge the b...

Page 122: ...sult a Yamaha dealer 1 Main fuse 2 Spare fuse cC To prevent accidental short circuiting turn off the main switch when checking or replac ing a fuse Specified fuse 5 A w q POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rating Never use a material ...

Page 123: ...p have the tools experience and know how to properly service your machine Use only gen uine Yamaha parts on your machine Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills 8 29 POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explo...

Page 124: ... a Yamaha dealer to inspect Adjust plug gap or replace plug There is compresson Compression normal Ask a Yamaha dealer to inspect No compression There is fuel Turn the fuel cock to OFF Remove the fuel hose from the fuel cock Water or dirt mixed in fuel Turn the fuel cock to ON No fuel Fuel cock clogged Some fuel Turn the fuel cock to RES Restart engine No fuel Supply fuel Clean filter element and ...

Page 125: ...vely greasy apply degreaser with a paint brush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a gar den hose Use only enough pressure to do the job cC Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure deter gent...

Page 126: ...ted surfaces Avoid combination cleaner waxes Many contain abrasives which may mar the paint or pro tective finish When finished start the engine and let it idle for several minutes POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the...

Page 127: ...and reinstall the spark plug Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe out let to prevent moisture from entering 6 If storing in a humid or salt air atmosphere coat all exposed metal surfaces with a light film of...

Page 128: ...30 mm 40 6 in Minimum ground clearance 100 mm 3 9 in Minimum turning radius 2 000 mm 78 7 in Basic weight With oil and full fuel tank 116 kg 256 lbs Engine Type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder Forward inclined Displacement 79 cm3 Bore Stroke 47 0 45 6 mm 1 85 1 80 in Compression ratio 9 6 1 Starting system Electric starter Lubrication system Wet sump 10 ...

Page 129: ...s often labeled Energy Conserving contain anti friction additives which will cause clutch and or starter clutch slippage resulting in reduced component life and poor engine performance Quantity Periodic oil change 0 80 L 0 70 lmp qt 0 85 US qt Total amount 0 95 L 0 84 lmp qt 1 00 US qt 10 0 30 50 70 90 110 SAE 5W30 20 10 0 10 20 30 40 YAMALUBE 4 20W40 or SAE20W40 YAMALUBE 4 10W30 or SAE10W30 130 F...

Page 130: ...p qt 0 13 US qt Air filter Wet type element Fuel Type UNLEADED FUEL Tank capacity 6 8 L 1 5 Imp gal 1 8 US gal Reserve amout 0 9 L 0 2 Imp gal 0 2 US gal Caburetor Type manufacturer VM16SH MIKUNI Spark plug Type manufacturer CR7HS NGK Gap 0 6 0 7 mm 0 024 0 028 in Clutch type Wet multiple disc automatic ...

Page 131: ...ion system Shaft drive Secondary reduction ratio 19 18 34 10 3 588 Transmission type Constant mesh 3 speed Operation Left foot operation Gear ratio 1st 39 11 3 545 2nd 35 17 2 059 3rd 31 22 1 409 Chassis Frame type Steel tube Caster angle 1 Trail 3 8 mm 0 15 in Tire Type Tubeless Size Front AT18 7 7 Size Rear AT18 8 7 ...

Page 132: ...operation Suspension Front Leading arm Rear Swingarm Shock Absorber Front Coil spring Oil damper Rear Coil spring Oil damper Wheel travel Front 57 mm 2 2 in Rear 56 mm 2 2 in Electrical Ignition system C D I Generator system C D I magneto Battery type voltage capacity 12N7D 3B 12V 7AH Indicator light voltage wattage quantity Neutral 12V 3 4W 1 ...

Page 133: ...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 AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal et...

Page 134: ...h 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 12 1 12 MAINTENACE INTERVAL 1 Month 3 Months 6 Months 12 Months 18 Months 24 Months 30 Months 36 Months 42 Months 48 Months 54 Months 60 Months DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS 11 ...

Page 135: ...13 1 EBU00432 ...

Page 136: ...13 2 13 ...

Page 137: ...EBU00435 14 1 ...

Page 138: ...14 2 14 ...

Page 139: ...EBU00436 w Indicates a potential hazard that could result in serious injury or death ...

Page 140: ...EBU00437 ...

Page 141: ...struction 9 at speeds too fast for your skills or the conditions 9 on public roads a collision can occur with another vehicle 9 with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS 9 use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns 9 avoid paved surfaces pavement may seriously affect handling and control L...

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Yamaha BADGER, Owner'S Manual

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