Yamaha BANSHEE YFZ350S Owner'S Manual Download | Manualshive

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EBU00833

Adjusting the rear brake light switch

The rear brake light switch, which is activated
by the brake pedal and brake lever, is properly
adjusted when the brake light comes on just
before braking takes effect. If necessary,
adjust the brake light switch as follows.

1. Rear brake light switch
2. Adjusting nut

Turn the adjusting nut while holding the rear
brake light switch in place. To make the brake
light come on earlier, turn the adjusting nut in
direction

a

. To make the brake light come on

later, turn the adjusting nut in direction

b

.

EBU00539

Clutch adjustment

The clutch lever free play should be 5–10 mm
(0.20–0.39 in). If the free play is incorrect,
adjust as follows.

1. Loosen the locknut.
2. Turn the adjusting bolt so that clutch lever

free play is 5–10 mm (0.20–0.39 in).

3. Tighten the locknut.

8-36

1

2

a

b

q

w

a

1. Locknut

2. Adjusting bolt

a. Free play

5FK-9-16-03 3/13/03 8:39 AM Page 37

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Summary of Contents for BANSHEE YFZ350S

Page 1: ...This ATV should not be ridden by anyone under 16 years of age OWNER S MANUAL 5FK 28199 16 YFZ350S READ THIS MANUAL CAREFULLY It contains important safety information LIT 11626 17 04 w ...

Page 2: ...5FK 9 16 hyoshi 3 13 03 8 38 AM Page 2 ...

Page 3: ...udes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE 8 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS 8 PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV...

Page 4: ...ety 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 procedures easier or clearer...

Page 5: ... and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine AFFIX DEALER LABEL HERE EBU13330 YFZ350S OWNER S MANUAL 2003 by Yamaha Motor Corporation U S A 1st edition 2003 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed ...

Page 6: ...l 3 3 CONTROL FUNCTIONS 4 1 Main switch 4 1 Handlebar switches 4 2 Throttle lever 4 3 Throttle OverRide System 4 4 Speed limiter 4 4 Clutch lever 4 6 Front brake lever 4 6 Brake pedal 4 7 Parking brake 4 7 Shift pedal 4 9 Kick starter 4 9 Fuel tank cap 4 10 Fuel cock 4 10 Starter choke 4 11 EBU00014 w Indicates a potential hazard that could result in serious injury or death CONTENTS 1 2 3 4 5FK 9 ...

Page 7: ...tire pressure 5 10 Tire wear limit 5 11 OPERATION 6 1 Starting a cold engine 6 1 Starting a warm engine 6 3 Warming up 6 3 Shifting 6 4 To start out and accelerate 6 5 To decelerate 6 6 Engine break in 6 7 Parking 6 8 Parking on a slope 6 9 Accessories and loading 6 10 Riding Your ATV 7 1 Getting to know your ATV 7 3 Ride with care and good judgement 7 4 Be careful where you ride 7 16 Turning your...

Page 8: ...rear brake pad inspection 8 29 Brake fluid level check 8 30 Brake fluid replacement 8 31 Front brake lever free play 8 32 Brake pedal height adjustment 8 33 Parking brake adjustment 8 34 Adjusting the rear brake light switch 8 36 Clutch adjustment 8 36 Drive chain slack check 8 37 Drive chain slack adjustment 8 37 Lubricating the drive chain 8 38 Cable inspection and lubrication 8 39 Brake and shi...

Page 9: ...hooting 8 46 Troubleshooting chart 8 47 No spark 8 50 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 9 10 11 12 13 5FK 9 16 01 3 13 03 11 13 AM Page 7 ...

Page 10: ... 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 replacement label is available from your Yamaha dealer 1 1 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS q e t w r y 5FK 9 16 01 3 13 03 11 13 AM Page 8 ...

Page 11: ...q w 1 e 5FE 21568 01 qWARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 5FE 2151H 40 5FE 2151H 01 5FK 21696 01 5FK 9 16 01 3 13 03 11 13 AM Page 9 ...

Page 12: ...1 3 r t y 5FE 21697 01 5FK 9 16 01 3 13 03 11 13 AM Page 10 ...

Page 13: ... 8 Never operate an ATV without proper training or instruction Take a Training Course Beginners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you 8 Always follow these age recommendation A child under 16 years old should never operate an ATV with engine size greater than 90cc 8 Never allow ...

Page 14: ...ate at speeds too fast for your skills or the conditions Always go at a speed that is proper 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 described in this manual...

Page 15: ...faces 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 back ward Never go down a hill at high speed Avoid going down a hill at an a...

Page 16: ...s described in this manual 8 Always be careful when skidding or sliding Learn to safely control skidding or sliding by prac ticing 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 con trol 8 Never operate an ATV in fast flowing water or in water deeper than that recommende...

Page 17: ...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 2 5 5FK 9 16 01 3 13 03 11 13 AM Page 15 ...

Page 18: ...of ignition such as the pilot lights of water heaters and clothes dryers qWARNING When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF posi tion Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of ...

Page 19: ... 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 qWARNING 5FK 9 16 01 3 13 03 11 13 AM Page 17 ...

Page 20: ...ake light switch 18 Parking brake 8 Front wheel 19 Main switch 9 Front shock absorber 20 Front brake lever 10 Radiator 21 Throttle lever 11 Fuel cock 22 Handlebar switch 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 t y q u i o 0 1 2 3 4 5 6 7 8 9 0 1 2 5FK 9 16 01 3 13 03 11 13 AM Page 1...

Page 21: ...rom 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 5FK 9 16 01 3 13 03 11 13 AM Page ...

Page 22: ... used to identify your machine 1 Vehicle identification number EBU00787 Model label The model label is affixed to the location in the 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 Model label 3 3 q q 5FK 9 16 01 3 13 03 11 13 AM Page 20 ...

Page 23: ...witch Functions of the respective switch positions are as follows ON The engine can be started only at this position and the headlights and taillight come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position 4 1 OFF ON 4 5FK 9 16 01 3 13 03 11 13 AM Page 21 ...

Page 24: ...ine espe cially in an emergency The engine will not start or run when the engine stop switch is turned to OFF EBU13740 Light switch LIGHTS Set the switch to the LO position to switch on the low beam and the taillight Set the switch to the HI position to switch on the high beam and the taillight Set the switch to the OFF position to switch off all the lights NOTE The headlights and the taillight ca...

Page 25: ...erating 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 making 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 start the engine If it does not work sm...

Page 26: ... the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV 1 Locknut 2 Adjusting screw a No more than 12 mm 0 47 in 4 4 POTENTIAL HAZARD Continuing to ride the ATV after the Throttle OverRide System T O R S has stopped the engine WHAT CAN HAPPEN Riding with a malfunction increases the chance for an accident and injury HOW TO AVOID THE HAZARD Make sure...

Page 27: ...aged Improper throttle operation could result You could lose control have an accident or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjusted to 4 6 mm 0 16 0 24 in See page 8 28 qWARNING 5FK 9 16 01 3 13 03 11 13 AM Page 25 ...

Page 28: ...d release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch operation 1 Clutch lever EBU00070 Front brake lever The front brake lever is located on the right handlebar Pull it toward the handlebar to apply the front brake 1 Front brake lever 4 6 q q 5FK 9 16 01 3 13 03 11 13 AM Page 26 ...

Page 29: ...hine especially on a slope Squeeze the clutch lever while push ing the button then push in the lock plate to apply the parking brake Squeeze the clutch lever to release the parking brake NOTE When the parking brake is used engine speed is limited to 2 300 r min Be sure the parking brake is released before moving the throttle lever Otherwise the engine will mis fire preventing normal operation 4 7 ...

Page 30: ...oss of control or a collision The brake disc could overheat if you ride the ATV without releasing the park ing brake You could lose braking per formance which could cause an acci dent You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine Always be sure you have released the parking brake before you begin to ride qWARNING q w ...

Page 31: ...0089 Kick starter Rotate the kick starter away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and forcefully to start the engine This model has a primary coupled kick starter so the engine can be started in any gear if the clutch is disengaged However shifting to neutral before starting is recommended 1 Kick starter 4 9 6 5 4 1 2 3 q N q 5FK ...

Page 32: ...l will not flow Always turn the lever to this position when the engine is not run ning 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 cock lever to the ...

Page 33: ...eparate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper operation See page 6 1 1 Starter choke 4 11 q a b RES ON OFF 5FK 9 16 01 3 13 03 11 13 AM Page 31 ...

Page 34: ...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 NOTE Make sure that the seat is securely fitted 1 Projection 2 Holder 4 12 q w 5FK 9 16 01 3 13 03 11 13 AM Page 32 ...

Page 35: ...cial wrench can be obtained at a Yamaha dealer to make this adjustment 4 13 A B C D E a b 1 2 POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor han dling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set ting qWARNING Standard position C A Mini...

Page 36: ...ing nut 4 14 POTENTIAL HAZARD This shock absorber contains highly pressurized nitrogen gas WHAT CAN HAPPEN The shock absorber could explode causing injury or property damage Cylinder damage could also result in poor handling which could cause an accident HOW TO AVOID THE HAZARD 8 Do not tamper with or attempt to open the cylinder assembly 8 Do not subject the shock absorber to an open flame or oth...

Page 37: ...ighten the locknut to the specified torque cC Always tighten the locknut against the adjusting nut and tighten it to the specified torque A Tightening torque 54 Nm 5 4 m0kgf 39 ft0lbf Installed length Measurement A Minimum hard 213 5 mm 8 4 in Standard 220 5 mm 8 7 in Maximum soft 228 5 mm 9 0 in A Spring length 4 15 5FK 9 16 01 3 13 03 11 13 AM Page 35 ...

Page 38: ...n damping force adjust ing screw in direction a to increase the com pression damping force and in direction b to decrease the compression damping force q b a From the fully turned in position Minimum soft 20 clicks out Standard 12 clicks out Maximum hard 3 clicks out 1 Compression damping adjuster 1 Rebound damping adjuster q b a From the fully turned out position Minimum soft 1 click in Standard ...

Page 39: ...would be advisable to check the number of clicks of each damping force adjusting mecha nism and to modify the specifications as nec essary EBU00112 w Indicates a potential hazard that could result in serious injury or death POTENTIAL HAZARD Suspension components become hot during operation WHAT CAN HAPPEN You could be burned HOW TO AVOID THE HAZARD Never touch the compression damping adjuster rebo...

Page 40: ...l 9 Fill with fuel if necessary 5 5 5 6 Transmission oil 9 Check oil level 9 Fill with oil if necessary 5 7 8 6 8 8 Coolant reservoir 9 Check coolant level 9 Fill with coolant if necessary 8 8 8 12 Drive chain 9 Check chain slack and condition 9 Adjust if necessary 5 7 8 37 8 40 Throttle 9 Check for proper throttle cable operation 5 8 8 28 Wheels and tires 9 Check tire pressure wear and damage 5 9...

Page 41: ...ses the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and main tenance procedures and schedules described in the Owner s Manual qWARNING 5 5FK 9 16 01 3 13 03 11 13 AM Page 39 ...

Page 42: ...aler inspect the brake system Brake fluid level Check the brake fluid level Add fluid if neces sary See pages 8 30 8 31 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs Apply the brakes firmly for one minute If there is any leakage the brake system should be inspected by a Yamaha dealer Brake operation Test the brakes at slow speed aft...

Page 43: ...d to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any problem with the brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have a Yamaha dealer check for the cause qWARNING 5FK 9 16 01 3 13 03 11 13 AM Page 41 ...

Page 44: ...ed mainte nance cost If unleaded gasoline is not avail able then leaded premium gasoline can be used Gasohol There are two types of gasohol gasohol con taining ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it may cause fuel system damage or vehicle performance probl...

Page 45: ...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 immediately Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and is still very hot qWARNING Recomm...

Page 46: ...addi tion do not use oils labeled ENERGY CONSERVING II or higher 8 Make sure that no foreign material enters the crankcase EBU00498 Chain Check the general condition of the chain and check the chain slack before every ride Lubricate and adjust the chain as necessary See pages 8 37 8 40 for details 5 7 Recommended oil Yamalube 4 10W30 or SAE 10W30 Recommended oil classification API Service SE SF SG...

Page 47: ...check 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 EBU10030 Lights Check the headlights and tail brake light to make sure they are in working condition Repair as necessary for proper operation EBU11700 Switches Check the operation of all switches Have a Yamaha dealer repair as necessar...

Page 48: ...51A Rear DUNLOP AT20 10 9 KT877 9 Recommended tire pressure Front 30 kPa 0 30 kgf cm2 4 4 psi Rear 30 kPa 0 30 kgf cm2 4 4 psi 9 Check and adjust tire pressures when the tires are cold 9 Tire pressures must be equal on both sides 3 Tire pressure below the minimum specified could cause the tire to dis lodge from the rim under severe rid ing conditions The following are minimums Front 27 kPa 0 27 kg...

Page 49: ...irt in the gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifica tions 1 Low pressure tire gauge q 30 kPa 0 30 kgf cm2 4 4 psi 27 kPa 0 27 kgf cm2 3 9 psi 33 kPa 0 33 kgf cm2 4 7 psi 30 kPa 0 30 kgf cm2 4 4 psi 27 kPa 0 27 kgf cm2 3 9 psi 33 kPa 0 33 kgf cm2 4 7 psi Front Rear Recommended pressure Minimum Maximum 5FK 9 16 01 ...

Page 50: ...EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire 5 11 a a Tire wear limit 5FK 9 16 01 3 13 03 11 13 AM Page 48 ...

Page 51: ...g familiar 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 ...

Page 52: ...rter choke in position 1 the starter choke should be returned to position 2 to warm up the engine If the engine is started with the 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 starter choke to position 3 before riding cC See the Engine break in section prior to operating engine for...

Page 53: ...e engine before starting off Never acceler ate hard with a cold engine To see whether or not the engine is warm check if it responds to the throttle normally with the starter choke turned off NOTE When the parking brake is used engine speed is limited to 2 300 r min Be sure the parking brake is released before moving the throttle lever Otherwise the engine will mis fire preventing normal operation...

Page 54: ...stops it will be in first gear Raise the pedal slightly to neutral cC 1 Do not coast for long periods with the engine off and do not tow the machine a long distance Even in neutral posi tion the transmission is only properly lubricated when the engine is running Inadequate lubrication may cause dam age 2 Always use the clutch when changing gears The engine transmission and drive train are not desi...

Page 55: ...hrottle and at the same time quickly pull in the clutch lever 6 Shift into second gear be careful not to shift into neutral 7 Open the throttle part way and gradually release the clutch lever 8 Follow the same procedure when shifting to the next higher gear 6 5 POTENTIAL HAZARD Opening the throttle abruptly or releas ing the clutch lever too quickly WHAT CAN HAPPEN The machine could wheelie This w...

Page 56: ... cause the tires to lose traction reducing con trol and increasing the possibility of an acci dent 6 6 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 HAZARD Make sure the engine has sufficiently slowed bef...

Page 57: ...throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest peri od 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 peri od consult a Yamaha dealer 1 0 10 hours Avoid continuous operation above half throttle Allow a coolin...

Page 58: ...EBU00212 Parking When parking stop the engine and shift into low gear Turn the fuel cock to OFF and apply the parking brake 1 Locked position 6 8 q 5FK 9 16 01 3 13 03 11 14 AM Page 56 ...

Page 59: ...rking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control increasing 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 could not ...

Page 60: ...e a genuine Yamaha accesso ry or one that is equivalent in design and quality 8 Accessories should be rigidly and securely mounted An accessory which can shift position 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 heavy or bulky object...

Page 61: ...he trailer cannot move around A shifting load can cause an acci dent 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 whenever you are carrying heavier loads or when towing a trailer 8...

Page 62: ...dent 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 EBU13551 w Indicates a potential hazard that could result in serious injury or death 6 12 5FK 9 16 01 3 13 03 11 14 AM Page 60 ...

Page 63: ...1 7 1 Riding Your ATV OK OK OK OK 7 1 7 5FK 9 16 02 3 11 03 1 08 PM Page 1 ...

Page 64: ...7 2 5FK 9 16 02 3 11 03 1 08 PM Page 2 ...

Page 65: ...TV 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 necessary 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 attention to the safety information on pages 2 1 2 7 Please a...

Page 66: ...before attempting more difficult maneu vers POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in dif ferent situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course off...

Page 67: ...ommenda tions 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 16 should never operate an ATV with engine size greater than 90cc qWARNING 5FK 9 16 02 3 11 03 1 08 PM Page 5 ...

Page 68: ...eatly reduces your ability to balance and control this ATV Could cause an accident 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 carrying passengers qWARNING 5FK 9 16 02 3 11 03 1 08 PM Page 6 ...

Page 69: ...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 helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jack...

Page 70: ...ZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV qWARNING 5FK 9 16 02 3 11 03 1 08 PM Page 8 ...

Page 71: ...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 pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pressure may cause loss of control increasing your risk of an acci dent HOW TO AVOID TH...

Page 72: ...op speed of the ATV Turning the adjusting screw in decreases the top speed and turning it out increases the top speed See page 4 4 for details 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 con trol of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always go at a speed that is proper fo...

Page 73: ...LOADING LIMIT Vehicle loading limit total weight of rider cargo and accessories 100 kg 220 lb POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling 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 Reduc...

Page 74: ... 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 accident HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operation q...

Page 75: ...13 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 5FK 9 16 02 3 11 03 1 08 PM Page 13 ...

Page 76: ... ations 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 according to instructions If you have questions consult an autho rized ATV dealer qWARNING 5FK 9 16 02 3 11 ...

Page 77: ...rush or other combustible material accumulated around the engine area could catch fire Someone touching the exhaust system during or after oper ation could be burned qWARNING HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exhaust system Do not park the...

Page 78: ...g this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of con trol HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets qWARNING 5FK 9 16 02 3 11 03 1 08 PM Page 16 ...

Page 79: ...erating 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 high ways qWARNING 5FK 9 16 02 3 11 03 1 08 PM Page 17 ...

Page 80: ... 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 operating on unfamiliar terrain Always be alert to changing terrain con ditions when operating the ATV qWARNING 5FK 9 16 02 3 11 03...

Page 81: ...or vehicle control which could result in an acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain qWARNING 5FK 9 16 02 3 11 03 1 08 PM Page 19 ...

Page 82: ... no trespassing Do not ride on private property without getting permission 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 ATV to make you more visible Watch careful ly for other vehicles 5FK 9 16 02 3 11 03 1 08 PM Page 20 ...

Page 83: ... come in contact with these components With the engine idling pull the clutch lever to disengage the clutch and shift into 1st gear and then release the parking brake Open the throttle gradually and at the same time release the clutch lever slowly Once the ATV has attained adequate speed release the throttle lever and at the same time quickly pull in the clutch lever and shift into 2nd gear Open t...

Page 84: ...TENTIAL HAZARD Opening the throttle abruptly or releas ing the clutch lever too quickly WHAT CAN HAPPEN The ATV could wheelie This would increase the chance of an accident including overturn HOW TO AVOID THE HAZARD Open the throttle gradually Release the clutch lever gradually qWARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop ro...

Page 85: ...n 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 maneu ver 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 could go out of c...

Page 86: ... able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer t...

Page 87: ... is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by leaning forward and on steeper inclines standing on the footboards and leaning forward over the handlebars POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small h...

Page 88: ...lways check the terrain carefully before you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV could flip over backwards qWARNING OK Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill ...

Page 89: ...l 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 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 in the Owner s Manu...

Page 90: ...d easily tip over back wards Instead apply the front brake gradual ly or dismount the ATV immediately on the uphill side POTENTIAL HAZARD Stalling rolling backwards or improper ly 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 uphil...

Page 91: ...ar brake as well and then lock the park ing brake Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the pro cedure described in the Owner s Manual 5FK 9 16 02 3 11 03 1 08 PM Page 29 ...

Page 92: ...gles 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 Owner s Manual Note a spe...

Page 93: ...7 31 OK 5FK 9 16 02 3 11 03 1 08 PM Page 31 ...

Page 94: ...ns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance 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 attem...

Page 95: ...7 33 Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV OK 5FK 9 16 02 3 11 03 1 08 PM Page 33 ...

Page 96: ...ly 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 qWARNING 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 your brakes ...

Page 97: ...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 con ditions 1 Check hose q 5FK 9 16 02 3 11 03 1 08 PM Page 35 ...

Page 98: ... 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 colli sion 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 obsta cles such as large rocks or fallen trees When you go over obstacles always fol low proper proced...

Page 99: ...7 37 5FK 9 16 02 3 11 03 1 08 PM Page 37 ...

Page 100: ...the front wheels to slide in loose or slippery conditions position ing your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways 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 5FK 9 16 02 3 11 03 1 08 PM Pa...

Page 101: ...ce 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 slid ing by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious...

Page 102: ...f necessary gradually let off the throttle and or steer to the outside of the turn See pages 7 23 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 recommended 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 trying to climb Turn the ATV around if you stil...

Page 103: ... over dis mount on the uphill side See pages 7 32 7 33 8 If your ATV encounters shallow water Ride slowly and carefully through slow moving 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 continue to ride your ATV until you have regained adequate braking ability See pages 7 34 7 35 w Indicates a p...

Page 104: ... 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 Owner s tool kit 8 1 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 qWARNING HOW T...

Page 105: ...the torque settings and adjust them as necessary 8 2 POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and acc...

Page 106: ...ck idle speed starter 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 s 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 necessary Throttle operation 9 Inspect and ad...

Page 107: ...chain guard and rollers 9 Check wear and replace if necessary 2 2 2 Steering system 9 Inspect free play clean and lubricate 2 2 2 2 2 Front and rear 9 Inspect and lubricate 2 2 2 2 2 suspension Tires 9 Inspect air pressure wheel runout and tire wear 2 2 2 2 2 Wheels 9 Inspect bearings 2 2 2 2 2 9 Replace bearings if necessary Throttle control cable 9 Check routing and connection 2 2 2 2 2 9 Lubric...

Page 108: ...id Normally check the brake fluid level and add the fluid as required 9 On the inner parts of the master cylinder and caliper cylinder replace the oil seals every two years 9 Replace the brake hoses every four years or if cracked or damaged w Indicates a potential hazard that could result in serious injury or death 5FK 9 16 03 3 13 03 8 39 AM Page 6 ...

Page 109: ...it a few minutes until the oil level settles before checking 4 Remove the dipstick and inspect the oil level 5 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 6 Install the oil filler cap Transmission oil replacement 1 Place the machine on a level surface 2 Warm up the engine for several minutes and then stop it 3 Place a c...

Page 110: ...addi tives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CON SERVING II or higher 8 Make sure that no foreign material enters the crankcase q Tightening torque Drain bolt 20 Nm 2 0 m0kgf 14 ft0lbf Recommended oil See page 10 2 Oil quantity Total amount 1 7 L 1 5 Imp qt 1 8 US qt Periodic oil change 1 5 L 1 3 ...

Page 111: ...1080 Cooling system 1 Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temper ature The coolant level should be between the maximum and minimum marks 1 Maximum level mark 2 Minimum level mark 2 If the level is low remove the seat See page 4 12 for seat removal and installa tion procedures q w 5FK 9 16 03 3 13 03 8 39 AM Page 9 ...

Page 112: ...cap 6 Close the coolant reservoir cover 7 Install the seat cC Hard water or salt water is harmful to the engine You may use soft water if you can t get distilled water NOTE 8 If water is added have a Yamaha dealer check the antifreeze content of the coolant as soon as possible 8 If your ATV overheats see page 8 48 for details w q Coolant reservoir capacity 0 28 L 0 25 Imp qt 0 30 US qt 8 9 5FK 9 1...

Page 113: ...n bolts 1 Drain bolt 2 q q q w w POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap qW...

Page 114: ...and drain the coolant from the coolant reservoir 1 Coolant reservoir hose 2 Coolant reservoir 7 After draining the coolant thoroughly flush the cooling system with clean tap water 8 Replace the coolant drain bolt washers if they are damaged and then tighten the coolant drain bolts to the specified torque 8 11 q q q w 5FK 9 16 03 3 13 03 8 39 AM Page 12 ...

Page 115: ...Fill the coolant reservoir with coolant up to the maximum level 14 Install the coolant reservoir cap and check for coolant leakage NOTE If any leakage is found ask a Yamaha dealer to inspect the cooling system 15 Install the radiator cover by installing the bolts 8 12 Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Antifreeze and ...

Page 116: ...ent color there could be something wrong with the engine Do not attempt to diagnose such problems your self Instead take the machine to a Yamaha deal er You should periodically remove and inspect the spark plugs because heat and deposits will cause any spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace t...

Page 117: ...k hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case 1 Remove the seat 2 Remove the air filter case cover 1 Check hose 1 Air filter case cover 3 Remove the air filter element and sepa rate it from the guide 8 14 q 1 Tightening torque Spark plug 20 Nm 2 0 m0kgf 14 ft0lbf 5FK 9 16 03 3 13 03 8 39 AM Pag...

Page 118: ...ter element when squeezing it 6 Inspect the element If damaged replace it q w q w POTENTIAL HAZARD Using low flash point solvents or gaso line 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 5FK 9 16 03 3 13 03 8 39 AM Page 16 ...

Page 119: ...tremely dusty areas Each time filter ele ment maintenance is performed check the air inlet to the filter case for obstructions Check the air cleaner rubber joint to the carburetor and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possi bility of unfiltered air entering the engine cC Never operate the engine with the air filter element removed This will allow unf...

Page 120: ...he muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe 4 Make sure the gasket is properly posi tioned then insert the tailpipe into the muffler and align the screw holes 5 Install the screws and tighten them 1 Screw 3 q 1 Tailpipe 2 Spark arrester 3 Gasket w q e 5FK 9 16 03 3 13 03 8 39 AM Page 18 ...

Page 121: ...cause burns Could cause carbon monoxide poison ing 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 5FK 9 16 03 3 13 03 8 39 AM Page 19 ...

Page 122: ...ire hazard HOW TO AVOID THE HAZARD Carburetor adjustments should only be performed by a Yamaha dealer Do not qWARNING attempt to perform these procedures unless you have mechanical knowledge and the necessary tools Do not perform these procedures while the engine is hot Place a rag under each carburetor to catch any fuel Wipe up any spilled fuel completely After servicing the carburetors always ch...

Page 123: ...0 ft Temperature Main jet Jet needle Pilot air screw Main jet Jet needle Pilot air screw Above 0 C 200 3rd groove 2 0 turns out 190 3rd groove 2 1 2 turns out 32 F 5 C 15 C 220 3rd groove 1 1 2 turns out 200 3rd groove 2 0 turns out 41 F 5 F 10 C 30 C 240 4th groove 1 1 2 turns out 220 3rd groove 1 1 2 turns out 14 F 22 F 5FK 9 16 03 3 13 03 8 39 AM Page 21 ...

Page 124: ...e drain screw of each carbure tor and drain the fuel 3 Remove the seat 4 Remove the radiator cover and side cover 5 Disconnect the fuel hoses 6 Remove the fuel tank 7 Remove the air filter case cover 1 Air filter case cover 2 1 1 1 Radiator cover 2 Side cover 8 21 5FK 9 16 03 3 13 03 8 39 AM Page 22 ...

Page 125: ...r cap securing plate 9 Loosen the joint screws of each carbure tor 10 Remove each carburetor cap 11 Remove the throttle cables from the throt tle valves and then remove the holder 1 Throttle cable 2 Throttle valve 3 Holder 1 1 2 3 5FK 9 16 03 3 13 03 8 39 AM Page 23 ...

Page 126: ...s 1 Float chamber 13 Remove the floats and needle valves 1 Float 2 Needle valve 3 Main jet 14 Change the main jets and the jet needle clip positions See page 8 20 NOTE Optional main jets can be obtained at a Yamaha dealer 1 q w e 5FK 9 16 03 3 13 03 8 39 AM Page 24 ...

Page 127: ...on the carburetor cap with one of the indents on the securing plate 1 Securing plate 2 Projection 3 Slot cC If the securing plate does not match a pro jection tighten the carburetor cap until they align Do not loosen 6 Tighten the securing plate screw to the specified torque 7 Tighten the joint screws of each carbure tor 1 2 3 Carburetor cap tightening torque 4 Nm 0 4 m0kgf 2 9 ft0lbf Tightening t...

Page 128: ... each carbu retor to see if the punch mark on the throt tle valve is at the specified position a Specified position 4 If not loosen the locknuts and turn the adjusters until proper position is obtained 1 Locknut 2 2 Adjuster 2 5 Move the throttle lever a few times and recheck the position 6 Install the fuel tank side cover radiator cover and air filter case cover 7 Reconnect the fuel hoses 8 Insta...

Page 129: ...re adjusting the idle speed 1 Adjust the pilot air screws 8 Turn in both pilot air screws until they lightly seat 8 Turn out both pilot air screws to specifi cation Refer to the Carburetor set tings section 1 Pilot air screw 2 Remove the seat 3 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min 8 26 q 5FK 9 16 03 3 13 03 8 39 AM Page 27 ...

Page 130: ...ew 2 cC 8 Idle speed adjust screws were preset at the factory When adjusting idle speed turn the right and left idle speed adjust screws the same amount or carburetor synchronization will be incorrect 8 The pilot air screws and idle speed adjust screws are separate adjust ments but they must be adjusted at the same time to achieve optimum engine performance 8 27 1 b a a b Specified idle speed 1 45...

Page 131: ... speed before adjust ing the throttle lever free play 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle lever free play is 4 6 mm 0 16 0 24 in 3 Tighten the locknut 1 Adjusting bolt 2 Locknut a Free play 8 28 q w a 5FK 9 16 03 3 13 03 8 39 AM Page 29 ...

Page 132: ... pad wear without disassembling the brake Apply the brake and inspect the wear indica tors If they are ALMOST in contact with the disc plate ask a Yamaha dealer to replace the pads 1 Wear indicator a Wear limit 1 0 mm 0 039 in 8 29 a 1 q q a Front Rear 1 Wear indicator a Wear limit 1 0 mm 0 039 in 5FK 9 16 03 3 13 03 8 39 AM Page 30 ...

Page 133: ...stem leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions 8 When checking the brake fluid level make sure the top of the brake fluid reservoir is level 8 Use only the designated quality brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance 1 Minimum level mark LOWER ...

Page 134: ...ay deteriorate painted sur faces or plastic parts Always clean up spilled fluid immediately 8 Have a Yamaha dealer check the cause if the brake fluid level goes down EEBU11860 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking...

Page 135: ...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 8 Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by a Yama...

Page 136: ...PEN 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 brake pedal position is correct 8 Make sure the brakes do not drag 8 Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be ...

Page 137: ...ever 1 Locknut 2 Adjusting bolt 2 Loosen the locknut and the adjusting bolt at the rear brake caliper 3 Turn the adjusting bolt at the clutch lever in direction a to increase the cable length or in direction b to decrease the cable length NOTE If the cable cannot be adjusted to specification consult a Yamaha dealer 4 Tighten the locknut at the clutch lever 8 34 A a b 1 2 Tightening torque Locknut ...

Page 138: ...ether with the locknut 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 accident HOW TO AVOID THE HAZARD After adjusting the parking brake block the rear of the machine off the ground and spin the rear wheels Check to make sure there is no brake drag If brake ...

Page 139: ...ng the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EBU00539 Clutch adjustment The clutch lever free play should be 5 10 mm 0 20 0 39 in If the free play is incorrect adjust as follows 1 Loosen the locknut 2 Turn the adjusting bolt so that clutch lever free ...

Page 140: ... the slack exceeds 20 mm 0 79 in adjust it to specification EBU00351 Drive chain slack adjustment 1 Loosen the rear wheel hub bolts 1 Upper wheel hub bolt 2 2 Lower wheel hub bolt 2 2 Loosen the adjuster locknuts on each side To tighten the chain turn the chain adjuster clockwise To loosen the chain turn the adjuster counterclockwise and push the wheel forward Turn each adjuster exactly the same a...

Page 141: ... or wet areas Service the drive chain as follows cC The drive chain must be lubricated after washing the ATV or riding in the rain 1 Clean the drive chain with kerosene and a small soft brush cC To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents Upper wheel hub bolt 120 Nm 12 0 m0kgf 85 ft0lbf Lower wheel hub bolt 60 Nm ...

Page 142: ...ate the inner cables and the cable ends If the cables do not operate smoothly ask a Yamaha dealer to replace them q 8 39 POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering 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 HAZAR...

Page 143: ...BU01018 Front upper and lower arm pivot lubrica tion Lubricate the upper and lower arm pivots 8 40 Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Yamaha chain and cable lube or SAE 10W30 motor oil Recommended lubricant Lithium soap based grease 5FK 9 16 03 3 13 03 8 39 AM Page 41 ...

Page 144: ...8 41 EBU00987 Rear arm pivot lubrication Lubricate the rear arm pivots Recommended lubricant Lithium soap based grease 5FK 9 16 03 3 13 03 8 39 AM Page 42 ...

Page 145: ...emove the nuts from the wheel 4 Remove the wheel EBU00871 Wheel installation When installing the wheel reverse the removal procedure Tighten the wheel nuts to the specified torques Front Rear Tightening torque Wheel nut Front 45 Nm 4 5 m0kgf 32 ft0lbf Rear 45 Nm 4 5 m0kgf 32 ft0lbf 5FK 9 16 03 3 13 03 8 39 AM Page 43 ...

Page 146: ...b holder cover 3 Turn the bulb holder counterclockwise to remove the defective bulb q 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 Wait for the bulb to cool before touching or removing it qWARNING 5FK 9 16 03 3 13 03 8 39 AM Page 4...

Page 147: ...the reflector 6 Install the headlight unit assembly 7 Adjust the headlight beam if necessary EBU01089 Headlight beam adjustment cC It is advisable to have a Yamaha dealer make this adjustment To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b 1 Adjusting screw a b 1 e q w 1 Bulb holder cover 2 Bulb holder 3 Reflector 5FK 9 16 03 3 13...

Page 148: ...ockwise 1 Bulb holder 2 Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise 1 Bulb holder 2 Bulb 3 Install a new bulb in the bulb holder by pushing it inward and turning it clockwise 4 Install the bulb holder together with the bulb q q w 5FK 9 16 03 3 13 03 8 39 AM Page 46 ...

Page 149: ...experience and know how to properly service your machine Use only genuine 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 46 POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe ...

Page 150: ... Dry Attach plug cap and ground to chassis Kick the kick starter strongly Spark weak Spark good Ignition system normal No spark Ask a Yamaha dealer to inspect Adjust plug gap or replace plug s 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 pipe No fuel Fuel cock clogged Clean fuel cock Some fuel Turn the ...

Page 151: ...akage Ask a Yamaha dealer to inspect and repair the cooling system Add coolant See NOTE Restart the engine If the engine overheats again ask a Yamaha dealer to inspect and or repair the cooling system NOTE If it is difficult to get recommended coolant tap water can be temporarily used provided that it is changed to the recommended coolant as soon as possible 5FK 9 16 03 3 13 03 8 39 AM Page 49 ...

Page 152: ... You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap qWARNING 5FK 9 16 03 3 13 03 8 39 AM Page 50 ...

Page 153: ...l not stop if the throttle does not close properly This could cause loss of control and an accident You could be burned if you touch the hot exhaust pipe while disconnecting the wire coupler qWARNING HOW TO AVOID THE HAZARD Have the system checked by a Yamaha dealer Before bypassing T O R S be sure the throttle closes properly when the throt tle lever is released If the machine must be ridden ride...

Page 154: ...8 51 5FK 9 16 03 3 13 03 8 39 AM Page 52 ...

Page 155: ... the dirt and degreaser off with a garden hose Use only enough pressure to do the job cC Excessive water pressure may cause water seepage and deterioration of wheel bear ings brakes transmission seals and elec trical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail able in coin operated car washers 4 Once the majority of the d...

Page 156: ...e paint or protective finish When finished start the engine and let it idle for several minutes 9 2 POTENTIAL HAZARD Operation with wet brakes after wash ing 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 brakes several times at slow speeds to let friction dry out the linings qWARNIN...

Page 157: ...e engine over sever al times to coat the cylinder walls with oil 3 Clean the drive chain thoroughly and lubricate it See page 8 38 for details Reinstall the chain or store it in a plastic bag tied to frame for safekeeping 4 Lubricate all control cables 5 Block up the frame to raise all wheels off the ground 6 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 7 If sto...

Page 158: ...in Minimum ground clearance 135 mm 5 31 in Minimum turning radius 3 600 mm 141 7 in Basic weight With oil and full fuel tank 187 kg 412 lb Engine Type Liquid cooled 2 stroke Cylinder arrangement Forward inclined parallel 2 cylinder Displacement 347 cm3 Bore Stroke 64 54 mm 2 52 2 13 in Compression ratio 6 5 1 Starting system Kick starter Lubrication system Premix 5FK 9 16 03 3 13 03 8 39 AM Page 5...

Page 159: ...nce the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENER GY CONSERVING II or higher Capacity Periodic oil change 1 5 L 1 3 Imp qt 1 6 US qt Total amount 1 7 L 1 5 Imp qt 1 8 US qt Radiator capacity Including all routes 1 5 L 1 3 Imp qt 1 6 US ...

Page 160: ...rer MIKUNI Spark plug Type manufacturer BR8ES NGK Spark plug gap 0 7 0 8 mm 0 028 0 031 in Clutch type Wet multiple disc Transmission Primary reduction system Helical gear Primary reduction ratio 66 23 2 869 Secondary reduction system Chain drive Secondary reduction ratio 41 14 2 929 Transmission type Constant mesh 6 speed Operation Left foot operation 5FK 9 16 03 3 13 03 8 39 AM Page 58 ...

Page 161: ...th 21 24 0 875 Chassis Frame type Steel tube frame Caster angle 9 Trail 40 mm 1 57 in Tire Type Tubeless Size front AT21 7 10 rear AT20 10 9 Brake Front brake type Dual disc brake operation Right hand operation Rear brake type Single disc brake operation Right foot operation 5FK 9 16 03 3 13 03 8 39 AM Page 59 ...

Page 162: ...ng Oil damper Rear shock absorber Coil spring Gas Oil damper Wheel travel Front wheel travel 230 mm 9 1 in Rear wheel travel 220 mm 8 7 in Electrical Ignition system C D I Generator system C D I magneto Headlight Type Krypton bulb Bulb voltage wattage quantity Headlight 12V 30W 30W 2 Tail brake light 12V 5W 21W 1 5FK 9 16 03 3 13 03 8 39 AM Page 60 ...

Page 163: ...e 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 etc Exhaust syst...

Page 164: ...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 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 SERVICING DEALER NAME AND ADDRESS REMARKS 5FK 9 16 03 3 13 03 8 39 AM Page 62 ...

Page 165: ...12 12 2 5FK 9 16 03 3 13 03 8 39 AM Page 63 ...

Page 166: ... specified in the appropriate owner s manual 2 Give notice to an authorized Yamaha ATV dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent pur chaser s it is imperative that the machi...

Page 167: ...le and upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Q Is the warranty transferable to second owners A Yes The reminder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain effective CUSTOMER SERVICE If you...

Page 168: ...EBU00436 w Indicates a potential hazard that could result in serious injury or death 5FK 9 16 03 3 13 03 8 39 AM Page 66 ...

Page 169: ...EBU00437 PROTECT YOUR INVESTMENT 5FK 9 16 03 3 13 03 8 39 AM Page 68 ...

Page 170: ...ds 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 EBU00438 LOCATE AND ...

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