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Yamaha BLASTER YFS200W Owner'S Manual Download Page 94

 

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8. Remove the float chamber by removing the

screws.

 

1.  Mixing chamber cap
2. Throttle valve
3.  Throttle cable holder
4. Screw
5. Throttle cable

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1. Float chamber
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Summary of Contents for BLASTER YFS200W

Page 1: ...This A MANUAL DEL PROPIETARIO 5VM 28199 64 YFS200W MANUEL DU PROPRIÉTAIRE OWNER S MANUAL ...

Page 2: ...PRINTED IN JAPAN 2006 06 0 7x2 E F S YAMAHA MOTOR CO LTD ...

Page 3: ...This A 5VM 28199 64 E0 YFS200W OWNER S MANUAL ...

Page 4: ......

Page 5: ...des important safety information It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDER STAND AL...

Page 6: ...ifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the ATV operator a bystander or a person inspecting or repairing the ATV A CAUTION indicates special precautions that must be taken to avoid damage to the ATV A NOTE provides key information to ...

Page 7: ...this ATV on any paved surface paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFS200W OWNER S MANUAL 2006 by Yamaha Motor Co Ltd 1st edition June 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 8: ...al 4 5 Parking brake 4 6 Shift pedal 4 7 Kickstarter 4 7 Fuel tank cap 4 8 Fuel 4 8 Fuel cock 4 9 Starter choke 4 11 Seat 4 11 Adjusting the front shock absorber assemblies 4 12 Adjusting the rear shock absorber assembly 4 13 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 4 2 stroke engine oil 5 4 Transmission oil 5 4 Front and rear brakes 5 4 Throttle lever 5 5 Drive chain 5 5 Tires...

Page 9: ...eaning the spark arrester 8 14 Changing the carburetor settings 8 16 Adjusting the engine idling speed 8 21 Adjusting the throttle cable free play 8 22 Checking the front and rear brake pads 8 23 Checking the brake fluid level 8 24 Changing the brake fluid 8 25 Checking the front brake lever free play 8 25 Checking the brake pedal position 8 26 Adjusting the parking brake free play 8 27 Brake ligh...

Page 10: ...e tail brake light bulb 8 41 Removing a wheel 8 42 Installing a wheel 8 43 Troubleshooting 8 43 Troubleshooting chart 8 45 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 ...

Page 11: ...child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and paved streets Never operate an ATV on any paved street paved road or motorway Watch carefu...

Page 12: ...ur abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur 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 spe...

Page 13: ...ommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always use the size and type of tires specified in this manual Always maintain proper tire pressure as de scribed in this manual Never modify an ATV through improper installa tion or use of accessories Neve...

Page 14: ...vapor or get some gasoline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and wa ter If gasoline spills on your clothing change your clothes WARNING EWB00070 Always operate your ATV in an area with ade quate ventilation Never start or run the engine in a closed area Exhaust fumes are poisonous and may cause loss of consciousness and death within a short t...

Page 15: ...2 1 1 2 3 4 5 6 7 8 9 10 11 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 5 4 6 1 2 3 ...

Page 16: ...erstand all of the labels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer ...

Page 17: ...IREPRESSUREOROVERLOADINGCAN CAUSELOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURYORDEATH OPERATINGTIREPRESSURE Set with tires cold 9Recommended FRONT 30 kPa 0 30 kgf cm 2 4 4 psi REAR 25 kPa 0 25 kgf cm 2 3 6 psi 9Minimum FRONT 27 kPa 0 27 kgf cm 2 3 9 psi REAR 22 kPa 0 22 kgf cm 2 3 2 psi 9Never set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING 9M...

Page 18: ...11 2 5FK 2151H 00 WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 5FE 2151H 01 For Europe For Oceania 3 YAMAHA MOTOR CO LTD SHIZUOKA JAPAN p 4GB 2155A 00 For Europe 2 ...

Page 19: ...ARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate 9 without proper training or instruction 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 ...

Page 20: ...0 11 5 16 5FK 21697 00 5 WARNING UNDER 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 5FE 21697 01 For Oceania For Europe 6 ...

Page 21: ... Left view EBU17700 Right view 1 Front shock absorber assembly 2 Fuel cock 3 Starter choke 4 Rear shock absorber assembly 5 Tail brake light 6 Footrest 1 2 3 4 5 6 1 Seat 2 Fuel tank cap 3 Headlight 4 Brake pedal 5 Brake light switch 6 Kickstarter 1 2 3 4 5 6 ...

Page 22: ...ontrols and instruments NOTE The ATV you have purchased may differ slightly from the figures shown in this manual 1 Clutch lever 2 Parking brake lock plate 3 Main switch 4 Front brake lever 5 Throttle lever 6 Handlebar switches 1 2 6 3 4 5 ...

Page 23: ... positions of the main switch are as follows ON All electrical systems are supplied with power The headlight and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch ON OFF 1 ...

Page 24: ...alube 2 or equivalent 2 stroke en gine oil The warning light should go off after the oil tank has been refilled The electrical circuit of the warning light can be checked by starting the engine See page 6 1 If the warning light does not come on for a few sec onds then go off have a Yamaha dealer check the electrical circuit CAUTION ECB00020 Always make sure there is enough engine oil before starti...

Page 25: ...s running EBU18280 Throttle lever Once the engine is running movement of the throt tle lever will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decelerate and the engine will return to an idle any time the hand is removed from the throttle lever Before starting the engine check the throttle to be sure it ...

Page 26: ...BU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum 1 Loosen the locknut 2 To increase the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction a To de crease the maximum engine power available and the maximum spee...

Page 27: ...the clutch pull the clutch lever toward the handlebar grip To engage the clutch release the clutch lever The clutch lever should be pulled rapidly and released slowly for smooth clutch oper ation EBU18411 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the brake lever toward the handlebar grip EBU18432 Brake pedal The brake pedal is located on the r...

Page 28: ...he 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 2300 r min Be sure the parking brake is released before moving the throttle lever Other wise the engine will misfire preventing normal op eration 1 Brake pedal 1 1 Button 2 Parking brake lock plate 1 2 ...

Page 29: ...e ATV without re leasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely EBU18530 Shift pedal This ATV is equipped with a constant mesh 6 speed transmission The shift pedal is located on the left side of the engine and is used in combina tion with the clutch when shifting EBU18650 Kickstarter Fold out the kickstarter...

Page 30: ... if the clutch is dis engaged However shifting the transmission into the neutral position before starting is recommend ed EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise EBU18770 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Kickstarter 1 1 Fuel tank cap 1 ...

Page 31: ...or the sun Be careful not to spill fuel especially on the engine or exhaust pipe which can cause a fire and severe injury Wipe up any spilled fuel immediately Do not refuel right after the engine has been running and is still very hot Be sure the fuel tank cap is closed securely EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it 1 Fuel level 2 F...

Page 32: ...tion fuel will not flow Always turn the fuel cock lever to this position when the engine is not running ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding 1 Arrow mark positioned over OFF RES ON FUEL OFF 1 1 Arrow mark positioned over ON ON FUEL RES OFF ON 1 ...

Page 33: ...ON EBU18840 Starter choke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke Move the starter choke in direction b to turn off the starter choke See the Starting a cold engine section on page 6 1 for proper operation EBU18880 Seat To remove the seat Pull the seat lock lever upward and ...

Page 34: ...0 Adjusting the front shock absorber assemblies The spring preload can be adjusted to suit the rid er s weight and the riding conditions Adjust the spring preload as follows Turn the adjusting ring in direction a to increase the spring preload and thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension 1 Seat lock lever 1 1 Projection 2 Se...

Page 35: ... EBU28240 Adjusting the rear shock absorber assembly The spring preload can be adjusted to suit the rid er s weight and the riding conditions Adjust the spring preload as follows 1 Loosen the locknut 2 Turn the adjusting nut in direction a to in crease the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension 1 Spring ...

Page 36: ... spring preload the longer distance A is the lower the spring preload With each complete turn of the adjusting nut distance A is changed by 1 0 mm 0 04 in CAUTION ECB00090 Never turn an adjusting mechanism beyond the minimum and maximum settings 1 Spring preload adjusting nut 2 Locknut 1 2 b a 1 Distance A Spring preload setting Minimum hard Distance A 222 mm 8 7 in Standard Distance A 230 mm 9 1 ...

Page 37: ...could explode causing injury or property damage Shock ab sorber cylinder damage could also result in poor handling which could cause an accident Do not tamper with or attempt to open the cylinder assembly Do not subject the shock absorber assembly to an open flame or other high heat Do not deform or damage the cylinder in any way Do not dispose of a damaged or worn out shock absorber assembly your...

Page 38: ...heck fuel line for leakage Correct if necessary 4 8 5 4 2 stroke engine oil Check oil level in oil tank and add recommended oil to specified level if necessary Check ATV for oil leakage Correct if necessary 5 4 Transmission oil Check oil level in transmission case and add recommended oil to specified level if necessary Check ATV for oil leakage Correct if necessary 5 4 8 8 Front brake Check operat...

Page 39: ...nd adjust if necessary 5 5 8 22 Control cables Make sure that operation is smooth Lubricate if necessary 8 33 Drive chain Check chain slack and adjust if necessary Check chain condition Lubricate if necessary 5 5 8 30 8 32 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 6 5 7 5 8 Brake...

Page 40: ...t 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 the Owner s Manual Failure to inspect increases the possibility of an accident or equipment damage ...

Page 41: ... the engine has been running and is still very hot Be sure the fuel tank cap is closed securely EBU19572 2 stroke engine oil Make sure that there is sufficient 2 stroke engine oil in the oil tank Add oil as necessary See page 10 1 EBU19580 Transmission oil Make sure that the transmission oil is at the speci fied level Add oil as necessary See page 8 8 EBU19710 Front and rear brakes Brake lever and...

Page 42: ...re they are working properly If the brakes do not provide proper braking performance check the brake pads for wear See page 8 23 WARNING EWB00580 Always check the brakes at the start of every ride Do not ride the ATV if you find any prob lem with the brakes or you could lose braking ability which could lead to an accident If a problem cannot be corrected by the adjust ment procedures provided in t...

Page 43: ...acturer model DUNLOP KT895A CHENG SHIN C 874N Size AT21 x 10 8 Type Tubeless The tires should be set to the recommended pressure Recommended tire pressure Front 30 0 kPa 4 4 psi 0 300 kgf cm2 Rear 25 0 kPa 3 6 psi 0 250 kgf cm2 Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides Tire pressure below the minimum speci fied could cause the tire to dislod...

Page 44: ...he tire pressure Use the low pressure tire gauge NOTE The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Set the tire pressure when the tires are cold Set the tire pressures to the following specifications 1 Low pressure tire gauge 1 ...

Page 45: ...ned EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary Recommended pressure Front 30 0 kPa 4 4 psi 0 300 kgf cm2 Rear 25 0 kPa 3 6 psi 0 250 kgf cm2 Minimum Front 27 0 kPa 3 9 psi 0 270 kgf cm2 Rear 22 0 kPa 3 2 psi 0 220 kgf cm2 Maximum Front 33 0 kPa 4 8 psi 0 330 kgf cm2 Rear 28 0 kPa 4 1 psi 0 280 kgf cm2 1 Tire wea...

Page 46: ...cold weather If the control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead to an acci dent or collision CAUTION ECB00150 See the Engine break in section on page 6 4 prior to operating the engine for the first time 1 Set the parking brake 2 Turn the fuel cock to ON 3 Turn the main switch to ON and the engine stop switch to RUN 4 Shift the transmiss...

Page 47: ...rming up the engine until it idles smoothly then return the starter choke to position 3 before riding NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the starter choke is not required when the engine is warm Instead start the engine wit...

Page 48: ...lly and at the same time release the clutch lever slowly 5 Once the ATV has attained adequate speed release the throttle and at the same time quickly pull in the clutch lever 6 Shift the transmission into second gear Make sure not to shift the transmission into neutral 7 Open the throttle part way and gradually re lease the clutch lever 8 Follow the same procedure when shifting to the next higher ...

Page 49: ...ion may damage the transmission Always use the clutch when changing gears The engine transmission and drive train are not designed to withstand the shock of forced shifting and can be damaged by shift ing without using the clutch EBU20672 Engine break in NOTE For ATVs equipped with an odometer or an hour meter follow the figures given in km mi or the figures given in hours For ATVs not equipped wi...

Page 50: ...ely but do not use full throttle at any time 320 km 200 mi or 20 hours and beyond The ATV can now be operated normally CAUTION ECB00220 If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the ATV EBU20721 Parking When parking the ATV stop the engine shift into first gear apply the parking brake and then turn the fuel cock to OFF 1 Button 2 Pa...

Page 51: ...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 walk up them easily 1 Bring the ATV to a stop by applying the brakes in first gear 2 Stop the engine and release the clutch lever 3 With the rear brake applied apply the parking brake and slowly release the brake pedal EBU20910 Accessories and loading EBU20920 Accessories...

Page 52: ...ssories The ATV may handle differently than it does without accessories EBU20940 Loading As originally equipped this ATV is not designed to carry cargo or tow a trailer If you choose to add ac cessories so that you can carry cargo or tow a trail er you must use common sense and good judgment as the stability and handling of an ATV can be changed When adding accessories keep the following points in...

Page 53: ...p turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV WARNING EWB00820 Never exceed the stated load capacity for this ATV Overloading this ATV or carrying or tow ing cargo improperly could cause changes in ATV handling which could lead to an accident Cargo should be properly distributed and se curely att...

Page 54: ...7 1 1 2 3 4 5 6 7 8 9 10 11 EBU21141 RIDING YOUR ATV ...

Page 55: ...s on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified in structor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until you are totally familiar with the ATV s handling and performance characteristics WARNING EWB01380 Never oper...

Page 56: ...ssenger The long seat is to al low the operator to shift position as needed during operation It is not for carrying passen gers Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV It could cause an accident resulting in harm to you and or your passenger Apparel Always wear an approved motorcycle helmet that fits properly You should also wear eye protection...

Page 57: ...n accident and in creases your chances of a severe injury in the event of an accident Operating without protec tive clothing increases your chances of severe injury in the event of an accident Do not operate after consuming alcohol or drugs The operator s performance capability is reduced by the influence of alcohol or drugs WARNING EWB01420 Never consume alcohol or drugs before or while driving t...

Page 58: ...his ATV with improper or uneven tire pres sure may cause loss of control increasing your risk of an accident Do not operate at speeds too fast for your skills or the conditions WARNING EWB01450 Always go at a speed that is proper for the ter rain visibility and operating conditions and your experience Operating this ATV at speeds too fast for your skills or the conditions in creases your chances o...

Page 59: ... your speed when adding additional loads WARNING EWB01460 Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own er s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the...

Page 60: ... of the ATV If you remove a foot from a footboard your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident Avoid wheelies and jumping You may lose control of the ATV or overturn WARNING EWB01480 Never attempt stunts such as wheelies or jumps Don t try to show off Modifications WARNING EWB01490 Never modify this ATV through improper in stallation or u...

Page 61: ...ly to touch it Also avoid parking in or around dry grass brush or other combustible materials to pre vent causing a fire hazard WARNING EWB01500 Do not touch the hot exhaust system Do not park the ATV during or after operation in a place where others might be likely to touch it Do not operate idle or park the ATV in dry grass dry ground cover or combustible ma terials BE CAREFUL WHERE YOU RIDE Thi...

Page 62: ...t road or motorway WARNING EWB01520 Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle In many areas it is illegal to operate ATVs on public streets roads and highways Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden hazards which may cause the ATV to upset WAR...

Page 63: ... the ATV on such terrain Failure to use extra care when operating on excessively rough slippery or loose terrain could cause loss of traction or ATV control which could result in an accident including an overturn When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch ...

Page 64: ... You should practice control of the throttle brakes shifting procedures and turning techniques in this area before trying more difficult terrain Always avoid riding on paved surfaces the ATV is designed for use on unpaved surfaces only and handling maneuvers are more difficult to perform on pavement Set the parking brake and follow the instruction on page 6 1 to start the engine Once it has warmed...

Page 65: ...G EWB01720 Always open the throttle gradually and release the clutch lever slowly Otherwise the ATV could wheelie which would increase the chance of an accident CAUTION ECB00230 Do not shift gears without releasing the throt tle Damage to the engine or drive train may oc cur When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly As you slow down shift to a low...

Page 66: ...ean 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 This procedure should be practiced at slow speed many times in a large unpaved area with no obsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn...

Page 67: ... or loose surfaces or obstacles that might cause you to lose control WARNING EWB01580 Never operate the ATV on hills too steep for the ATV or for your abilities The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills Practice on small er hills before attempting large hills It is important when climbing a hill to make sure that your weight is transferred forw...

Page 68: ...round Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV If your ATV has stalled or stopped and you believe you can continue up the hill restart carefull...

Page 69: ... fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and re mount following the procedure described in the Owner s Manual RIDING DOWNHILL When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as pos sible Move back on the seat and sit with your arms str...

Page 70: ...eed Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where possi ble CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with sl...

Page 71: ...side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving shal low water of up to a maximum of 35 cm 14 in in depth Before entering the water choose...

Page 72: ...ter the tires may float causing loss of traction and loss of control which could lead to an accident Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability CAUTION ECB00240 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 i...

Page 73: ...large obsta cles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manu al SLIDING AND SKIDDING Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery condi...

Page 74: ...n order to re duce the chance of skidding or sliding out of control WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each section on riding tech niques completely WHAT TO DO If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn P...

Page 75: ...e sure to ride with your weight positioned to wards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that the ATV is going to tip over dismount on the uphill side See page 7 14 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for...

Page 76: ...EATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01840 Never service an engine while it is running Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or start fires Turn off the en gine when performing maintenance unless otherwise specified Have a Yamaha dealer perform the ...

Page 77: ... you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you WARNING EWB01850 Never modify this ATV through improper in stallation or use of accessories as it may cause changes in handling which in some sit uations could lead to an accident All parts and accessories added to this ATV should be gen uine Yamaha or equivalent components de signed for ...

Page 78: ... a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1200 750 2400 1500 2400 1500 4800 3000 hours 20 75 150 150 300 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Replace 3 Air filter element Clean and replace if necessary Every 20 ...

Page 79: ...lace if necessary Check air pressure and balance and correct if necessary 11 Wheel bearings Check for looseness or damage and replace if necessary 12 Upper and lower arm pivots Lubricate with lithium soap based grease 13 Drive chain Check chain slack and adjust if necessary Check rear wheel alignment and correct if necess sary Clean and lubricate 14 Drive chain rollers Check for wear and replace i...

Page 80: ...other damage and replace if necessary 21 Transmission oil Change Check ATV for oil leakage and correct if neces sary 22 Autolube pump Check operation and bleed if necessary 23 Moving parts and cables Lubricate 24 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 25 Exhaust sy...

Page 81: ... brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 26 Spark arrester Clean 27 Front and rear brake switches Check operation and correct if necessary 28 Lights and switches Check operation and correct if necessary Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 1...

Page 82: ...ion of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally NOTE If the spark plug shows a distinctly different col...

Page 83: ...hen tighten it to the specified torque NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 4 Install the spark plug cap EBU23350 Transmission oil The transmission oil level should be checked be fore each ride In addition th...

Page 84: ...smission oil should be between the mini mum and maximum level marks 4 If the oil is at or below the minimum level mark remove the oil filler cap add sufficient oil of the recommended type to raise it to the cor rect level and then install and tighten the oil filler cap To change the transmission oil 1 Place the ATV on a level surface 2 Start the engine warm it up for several min utes and then turn...

Page 85: ... chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In ad dition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase 7 Start the engine and then let it idle for several minutes while checking the transmission for oil leakage If oil is leaking immediately turn off the engine and c...

Page 86: ...nd experience to do so EBU23781 Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean the air filter element more frequently if you are riding in unusually wet or dusty areas NOTE There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and ...

Page 87: ...terial gently but thor oughly in solvent WARNING EWB01940 Always use parts cleaning solvent to clean the sponge material Never use low flash point solvents or gasoline to clean the sponge mate rial because the engine could catch fire or ex plode 7 Squeeze the excess solvent out of the sponge material and let it dry 1 Air filter case cover 2 Screw 1 2 2 1 Sponge material 2 Air filter element frame ...

Page 88: ...ty foam air filter oil to the sponge material NOTE The sponge material should be wet but not drip ping 10 Install the sponge material onto the air filter el ement frame 11 Install the air filter element into the air filter case 12 Install the washer and screw CAUTION ECB00451 Be sure to install the washer with the bent edge facing outward as shown 1 Sponge material 1 ...

Page 89: ...ttings for an air tight seal Tighten all fit tings securely to avoid the possibility of unfiltered air entering the engine CAUTION ECB00460 Make sure that the air filter element is prop erly seated in the air filter case Never operate the engine with the air filter el ement removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Addition ally...

Page 90: ...sing 4 Make sure the gasket is properly positioned then insert the tailpipe into the muffler and align the screw holes 5 Install the screws and tighten them WARNING EWB02340 Do not start the engine when cleaning the spark arrester otherwise it could cause injury to the eyes burns carbon monoxide poison ing possibly leading to death and start a fire Always let the exhaust system cool prior to 1 Scr...

Page 91: ...ak fuel which would be a fire hazard Carburetor adjustments should only be per formed by a Yamaha dealer Do not attempt to perform these procedures unless you have mechanical knowledge and the neces sary tools Do not perform this procedure while the en gine is hot Place a rag under the carburetor to catch any fuel Wipe up any spilled fuel completely After servicing the carburetor always check the ...

Page 92: ...e carburetor float bowl drain screw and drain the fuel 3 Disconnect the fuel hose and the oil hose 1 Standard position Groove 2 Temperature Main jet Jet needle Pilot air screw Above 0 C 32 F standard 230 2nd groove 1 1 2 turns out 5 C 41 F 15 C 5 F 230 2nd groove 1 1 2 turns out 10 C 14 F 30 C 22 F 240 3rd groove 1 1 2 turns out 1 1 Carburetor float bowl drain screw 1 ...

Page 93: ...or 5 Remove the securing plate by removing the screw 6 Remove the mixing chamber cap by unscrew ing it 7 Disconnect the throttle cable from the throttle valve by removing the holder screws and holder 1 Fuel hose 2 Oil hose 1 2 1 Clamp screw 2 Mixing chamber cap securing plate 3 Screw 4 Mixing chamber cap 1 4 2 3 1 ...

Page 94: ... 1 2 3 4 5 6 7 8 9 10 11 8 Remove the float chamber by removing the screws 1 Mixing chamber cap 2 Throttle valve 3 Throttle cable holder 4 Screw 5 Throttle cable 2 5 4 3 1 4 1 Float chamber 2 Screw 2 2 1 2 ...

Page 95: ...o the float arm 2 Install the float by inserting the pin into the holder 3 Install the float chamber by installing the screws 4 Connect the throttle cable onto the throttle valve by installing the holder and the screws 5 Install the mixing chamber cap and tighten it 6 Install the securing plate by installing the screw NOTE When installing the securing plate align the slot in the securing plate wit...

Page 96: ...aintenance and lubrica tion chart NOTE A diagnostic tachometer is needed to make this adjustment 1 Start the engine and warm it up NOTE The engine is warm when it quickly responds to the throttle 2 Attach the tachometer to the spark plug lead 3 Check the engine idling speed and if neces sary adjust it to specification by turning the throttle stop screw at the carburetor To in crease the engine idl...

Page 97: ...The throttle cable free play should measure 4 0 6 0 mm 0 16 0 24 in at the throttle lever Period ically check the throttle cable free play and if nec essary adjust it as follows NOTE The engine idling speed must be checked and ad justed if necessary before adjusting the throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting bolt in direction a ...

Page 98: ... is less than 1 0 mm 0 04 in have a Yamaha dealer replace the brake pads as a set EBU24190 Rear brake pads Each brake pad is provided with a wear indicator which allows you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the position of the wear indicator while applying the brake If a brake pad has worn to the point that the wear indicator almo...

Page 99: ...e inef fective Before riding check that the brake fluid is above the minimum level mark and replenish if neces sary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Front brake 1 Wear indicator 1 1 1 Minimum level mark LOWER 1 ...

Page 100: ...painted surfaces or plastic parts Always clean up spilled fluid imme diately As the brake pads wear it is normal for the brake fluid level to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause EBU24290 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the peri odic maintenance an...

Page 101: ...play is correct Make sure the brakes do not drag 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 Yamaha dealer EBU24611 Checking the brake pedal position The brake pedal position must be checked and if necessary adjusted at the intervals specified in the periodic...

Page 102: ... brake system Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer EBU24670 Adjusting the parking brake free play The parking brake free play must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart Cable length A should measure 64 68 mm 2 52 2 68 in Adjust the parking b...

Page 103: ...ult a Yamaha dealer 5 Tighten the locknut at the clutch lever 6 Turn in the adjusting bolt at the rear brake cal iper by hand until it feels tight then turn it out 1 8 turn and tighten its locknut to the specified torque CAUTION ECB00520 When tightening the locknut hold the adjust ing bolt with a wrench so that it does not turn together with the locknut 1 Locknut 2 Adjusting bolt 1 2 a b 1 Adjusti...

Page 104: ...ance and lu brication chart The brake light switch for the brake pedal can be adjusted as follows but the other brake light switches should be adjusted by a Yamaha dealer NOTE The brake light switch is properly adjusted when the brake light comes on just before braking takes effect Turn the adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the...

Page 105: ... a Yamaha dealer check the internal clutch mechanism EBU24851 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary To check the drive chain slack 1 Place the ATV on a level surface NOTE When checking and adjusting the drive chain slack there should be no weight on the ATV and all tires must be touching the ground 2 Move the ATV back and forth to loca...

Page 106: ...in turn the ad justing bolts in direction a To loosen the drive chain turn the adjusting bolts in direction b and push the wheels forward Turn each adjusting bolt exactly the same amount to maintain correct axle alignment NOTE There are alignment marks on each side of the swingarm and on the wheel hubs Use them to check for proper wheel axle alignment 1 Drive chain slack 1 1 Axle holding nut upper...

Page 107: ...he specified torques EBU24880 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows 1 Locknut 2 Drive chain slack adjusting bolt 3 Alignment marks 3 1 2 1 2 a b a b Tightening torques Loc...

Page 108: ...y other lubricants for the drive chain as they may contain sub stances that could damage the O rings EBU24900 Checking and lubricating the cables The operation and the condition of all control ca bles should be checked before each ride and the cables and cable ends should be lubricated if nec essary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EW...

Page 109: ...cessary EBU24961 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EBU24992 Lubricating the swingarm pivots The swingarm pivots must be lubricated at the in tervals specified in th...

Page 110: ...t Lubricate the pivoting points using a grease gun Left side Right side EBU25090 Lubricating the steering shaft The steering shaft must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart Lubricate the steering shaft using a grease gun Recommended lubricant Lithium soap based grease 1 Grease nipple 1 1 Grease nipple Recommended lubricant Lithium soap based ...

Page 111: ...e headlight bulb burns out replace it as follows 1 Remove the panel shown by removing the screws 2 Remove the headlight beam adjusting screw the washer the spring and the nut NOTE Be sure not to lose the washer the spring and the nut 1 Grease nipple 1 1 Panel 2 Screw 1 2 2 ...

Page 112: ...5 6 7 8 9 10 11 3 Disconnect the main switch leads 4 Remove the headlight unit from the headlight assembly by removing the screws 1 Headlight beam adjusting screw 2 Washer 3 Spring 4 Nut 1 2 3 4 1 Main switch lead 1 ...

Page 113: ... Remove the headlight bulb holder cover 6 Remove the headlight bulb holder by turning it counterclockwise and then remove the defec tive bulb 1 Headlight unit 2 Screw 1 2 1 2 1 Headlight bulb holder cover 2 Headlight bulb holder 1 2 ...

Page 114: ...n install the bulb holder by turning it clockwise CAUTION ECB00650 Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affect ed Thoroughly clean off any dirt and finger prints on the headlight bulb using a cloth moistened with alcohol or thinner 8 Install the headlight bul...

Page 115: ...tall the screws 10 Install the headlight beam adjusting screw the washer the spring and the nut 11 Connect the main switch leads 12 Install the panel by installing the screws 13 Adjust the headlight beam EBU25550 Adjusting a headlight beam CAUTION ECB00690 It is advisable to have a Yamaha dealer make this adjustment 1 Headlight unit 2 Screw 1 2 1 2 1 Headlight beam adjusting screw 2 Washer 3 Sprin...

Page 116: ...in direction b EBU25610 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove the bulb holder together with the bulb by turning it counterclockwise 2 Remove the defective bulb by pushing it in and turning it counterclockwise 1 Headlight beam adjusting screw 1 a b 1 Tail brake light bulb holder 1 ...

Page 117: ... holder push it in and then turn it clockwise until it stops 4 Install the bulb holder together with the bulb by turning it clockwise EBU25650 Removing a wheel 1 Loosen the wheel nuts Front 1 Tail brake light bulb holder 2 Tail brake light bulb 1 2 1 Wheel nut 1 1 ...

Page 118: ...ion or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself However should your ATV re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replace...

Page 119: ...NG EWB02280 Do not smoke when checking the fuel system Fuel can ignite or explode causing severe inju ry or property damage Make sure there are no open flames or sparks in the area including pi lot lights from water heaters or furnaces ...

Page 120: ...pression Check the ignition Have a Yamaha dealer check the ATV Remove the spark plug and check the electrodes 3 Ignition Wet Dry Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV Open the throttle halfway and operate the kickstarter Check the compression The engine does ...

Page 121: ... seepage and deterioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard...

Page 122: ...term Before storing your ATV for several months 1 Follow all the instructions in the Cleaning section of this chapter 2 Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosen ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteri...

Page 123: ...te all control cables and the pivoting points of all levers and pedals 7 Check and if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative ly turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it NOT...

Page 124: ...placement 195 0 cm3 Bore stroke 66 0 57 0 mm 2 60 2 24 in Compression ratio 6 60 1 Starting system Kickstarter Lubrication system Separate lubrication Yamaha autolube Type YAMALUBE 2 cycle oil or 2 stroke engine oil AUS NZL YAMALUBE 2 cycle oil or 2 stroke engine oil JASO FC grade EUR Engine oil quantity Quantity 1 3 L 1 37 US qt 1 14 Imp qt Transmission oil Type SAE10W30 type SE motor oil Quantit...

Page 125: ...ndary reduction system Chain drive Secondary reduction ratio 40 13 3 076 Transmission type Constant mesh 6 speed Operation Left foot operation 1st 34 11 3 091 2nd 31 14 2 214 3rd 25 15 1 667 4th 20 16 1 250 5th 19 18 1 056 6th 19 21 0 905 Chassis Frame type Steel tube frame Caster angle 9 0 Trail 40 0 mm 1 57 in Front tire Type Tubeless Size AT21 x 7 10 Manufacturer model DUNLOP KT851A Manufacture...

Page 126: ...3 0 kPa 4 8 psi 0 330 kgf cm2 Rear 28 0 kPa 4 1 psi 0 280 kgf cm2 Front wheel Wheel type Panel wheel Rim size 10 x 5 5AT Rear wheel Wheel type Panel wheel Rim size 8 x 8 0AT Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 Front suspension Type Double wishbone Spring shoc...

Page 127: ...ctrical system Ignition system CDI Charging system Flywheel magneto Headlight Bulb type Halogen bulb Bulb voltage wattage x quantity Headlight 12 V 35 0 36 5 W 1 Tail brake light 12 V 5 0 21 0 W 1 Oil level warning light 12 V 3 4 W 1 ...

Page 128: ...rts from a Yamaha dealer or for ref erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26030 Vehicle identification number The vehicle identification number...

Page 129: ... fy your ATV EBU26050 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha deal er 1 Vehicle identification number 1 1 Model label 1 ...

Page 130: ...5 4 C Cables checking and lubricating 8 33 Carburetor settings changing 8 16 Chassis fasteners 5 8 Cleaning 9 1 Clutch lever 4 5 Clutch lever free play adjusting 8 29 D Drive chain 5 5 Drive chain lubricating 8 32 Drive chain slack 8 30 E Engine break in 6 4 Engine cold start 6 1 Engine idling speed 8 21 Engine starting a warm 6 2 Engine stop switch 4 3 F Fuel 4 8 5 4 Fuel cock 4 9 Fuel tank cap 4...

Page 131: ...g 8 14 Spark plug checking 8 7 Specifications 10 1 Speed limiter 4 4 Starter choke 4 11 Steering shaft lubricating 8 35 Storage 9 2 Suspension lubricating the upper and lower arm pivots 8 35 Swingarm pivots lubricating 8 34 T Tail brake light bulb replacing 8 41 Throttle cable free play adjusting 8 22 Throttle lever 4 3 5 5 Throttle OverRide System 4 4 Tire pressure measuring 5 7 Tires 5 6 Tire we...

Page 132: ...PRINTED IN JAPAN 2006 06 0 7x2 E YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER ...

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