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Yamaha GRIZZLY 125 YFM125GD, Owner'S Manual

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Yamaha GRIZZLY 125 YFM125GD Owner'S Manual Download Page 90

8-19

8

7. Squeeze the excess solvent out of the sponge

material and let it dry. 

NOTICE:

 Do not twist

the sponge material when squeezing it.

[ECB00441]

8. Check the sponge material and replace it if

damaged.

9. Apply Yamaha foam air filter oil or other qual-

ity foam air filter oil to the sponge material.

TIP

The sponge material should be wet but not drip-
ping.

10. Pull the sponge material over the air filter ele-

ment frame.

11. Apply all-purpose grease to the air filter ele-

ment seat.

12. Install the washer and screw. 

NOTICE:

 Be

sure to install the washer with its curved
side facing outward as shown.

 [ECB00453]

1. Air filter element seat

1

U1PY61E0.book  Page 19  Wednesday, March 14, 2012  5:22 PM

Summary of Contents for GRIZZLY 125 YFM125GD

Page 1: ...OPIETARIO 1PY 28199 61 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad DIC183 ...

Page 2: ...PRINTED IN JAPAN 2012 03 0 3 1 CR E F S DIC183 PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ IMPRESO EN PAPEL RECICLADO ...

Page 3: ...AL CAREFULLY It contains important safety information WARNING OWNER S MANUAL YFM125GD This ATV should not be ridden by anyone under 16 years of age 1PY 28199 61 E0 U1PY61E0 book Page 1 Wednesday March 14 2012 5 22 PM ...

Page 4: ...or number and date of issue of the other Directives of EEC If applicable YAMAHA MOTOR EUROPE N V Koolhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Eiji Kato Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Direct...

Page 5: ...he features and operation of this ATV This manual includes 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...

Page 6: ...afety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key inform...

Page 7: ...road or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFM125GD OWNER S MANUAL 2012 by Yamaha Motor Co Ltd 1st edition March 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U1PY61E0 book Page 1 Wednesday March 14 2012 5 22 PM ...

Page 8: ...brake 4 5 Drive select lever 4 6 Fuel tank cap 4 7 Fuel 4 7 Fuel cock 4 8 Starter choke 4 10 Seat 4 10 Front carrier 4 11 Rear carrier 4 11 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Transmission oil 5 3 Front and rear brakes 5 3 Throttle lever 5 3 Drive chain 5 3 Tires 5 3 Chassis fasteners 5 6 Instruments lights and switches 5 6 Battery 5 6 OPERATION 6 1 Starting a cold engine 6 1 Starting...

Page 9: ...ing the engine and V belt case air filter elements 8 17 Cleaning the spark arrester 8 23 V belt case drain screw 8 24 Adjusting the carburetor 8 25 Adjusting the engine idling speed 8 26 Adjusting the throttle lever free play 8 26 Valve clearance 8 27 Brakes 8 28 Checking the front and rear brake shoes 8 28 Adjusting the front brake lever free play 8 29 Adjusting the rear brake lever free play 8 3...

Page 10: ...7 Removing a wheel 8 48 Installing a wheel 8 48 Troubleshooting 8 49 Troubleshooting chart 8 51 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 U1PY61E0 book Page 3 Wednesday March 14 2012 5 22 PM ...

Page 11: ...e 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 1 3 4 2 7 8 5 6 U1PY61E0 book Page 1 Wednesday March 14 2012 5 22 PM ...

Page 12: ... 2 1 1 2 3 4 1C5 2817R 00 5 kg 11 Ibs 1C5 2817R 10 10 kg 22 Ibs 1C5 2816M M0 kPa kgf cm2 psi 20 0 0 20 2 9 kPa kgf cm2 psi 25 0 0 25 3 6 1AS 2816P 00 U1PY61E0 book Page 2 Wednesday March 14 2012 5 22 PM ...

Page 13: ...1 3 1 43P 2816R 01 YFM125A 6 5kW 152kg 1C5 2156A 20 8AC 2817L 00 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN 2012 1PD 2811R 00 5 6 7 8 U1PY61E0 book Page 3 Wednesday March 14 2012 5 22 PM ...

Page 14: ...rom 12 years old Operation of this ATV by children under the age of 12 increases the risk of severe injury or death Adult supervision required for children under age 16 Use from 16 years old Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER use on paved roads NEVER carry passengers NEVER use with drugs or alcohol NEVER store fuel or flammable l...

Page 15: ...oss of control Adjust the tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death This pictogram shows the loading limits and or maximum load capacity for this ATV Follow all load limits and other loading guidelines in this manual Load may include the driver passenger human protective gear accessories goods luggage and all other load rela...

Page 16: ...1 6 1 kW kg 1 2 3 YAMAHAMOTORCO LTD 2500SHINGAI IWATA JAPAN 1 1 2 3 Model Name Max Power Mass In Running Order 1 Year of construction U1PY61E0 book Page 6 Wednesday March 14 2012 5 22 PM ...

Page 17: ...6 years old should never oper ate an ATV with engine size greater than 90 cc Never allow a 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 This vehicle is intended for off road use only Do not operate on any paved surfaces such as sidewal...

Page 18: ...ve speeds Never operate the ATV on hills too steep for the ATV or for your 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...

Page 19: ...er or in water deeper than that recommended 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 be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tire...

Page 20: ...d ride gently back to camp or other known location where you can receive medical atten tion If necessary contact your riding party or local authorities to let them know where you are and what has happened In the event of a breakdown 1 If your vehicle will not restart or is not in safe operating condition turn off the main switch and engine stop switch If the breakdown oc curs at twilight or night ...

Page 21: ... others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following guide lines in mind as well as those provided under Loading when mounting accessories Never install accessories that would impair the performance of your ATV Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground cl...

Page 22: ...areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or par tially enclosed areas such as barns garages or carports Do not...

Page 23: ... choke 3 Fuel cock 4 Throttle stop screw 5 Tail brake light 6 Rear carrier 7 Spark arrester 8 Footboard 1 2 3 5 6 7 8 4 1 Owner s tool kit 2 Battery 3 Drive select lever 4 Spark plug 5 Headlight 6 Engine oil filler cap 7 Fuse 2 3 5 6 7 1 4 U1PY61E0 book Page 1 Wednesday March 14 2012 5 22 PM ...

Page 24: ...rom the figures shown in this manual 1 Rear brake lever 2 Parking brake lock plate 3 Reverse indicator light 4 Neutral indicator light 5 Front brake lever 6 Throttle lever 7 Main switch 8 Fuel tank cap 9 Handlebar switches 1 2 3 4 5 9 8 7 6 U1PY61E0 book Page 2 Wednesday March 14 2012 5 22 PM ...

Page 25: ...ollows ON All electrical systems are supplied with power The headlights 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 OFF ON 1 U1PY61E0 book Page 1 Wednesday March 14 2012 5 22 PM ...

Page 26: ...switches EBU18080 Engine stop switch Set this switch to before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run when this switch is set to 1 Reverse indicator light R 2 Neutral indicator light N 1 2 1 Horn switch 2 Light switch OFF 3 Engine stop swit...

Page 27: ...e starter motor will not operate properly If this should happen remove the battery and recharge it See page 8 41 EBU18170 Horn switch Press the switch to sound the horn EBU18282 Throttle lever Once the engine is running pushing the throttle le ver 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 deceler...

Page 28: ... the adjusting screw out more than 12 mm 0 47 in or the throttle cable could be dam aged Always make sure the throttle lever free play is adjusted to 1 0 3 0 mm 0 04 0 12 in See page 8 26 WARNING Improper ad justment of the speed limiter and throttle could cause throttle cable damage or im proper throttle operation You could lose control resulting in an accident EWB00241 3 Tighten the locknut EBU1...

Page 29: ...ip EBU18461 Parking brake Use the parking brake before starting the engine or after parking the ATV especially on a slope Apply the rear brake lever and push down the lock plate to apply the parking brake Squeeze the rear brake lever to release the parking brake 1 Front brake lever 1 1 Rear brake lever 1 U1PY61E0 book Page 5 Wednesday March 14 2012 5 22 PM ...

Page 30: ... 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 EBU18581 Drive select lever The drive select lever is used to shift your ATV into the forward neutral and reverse positions See the Operating the drive select lever and driving in re verse section on page 6 3 for the drive select lever operation ...

Page 31: ...tting on the vehicle Nev er refuel while smoking or while in the vicinity of sparks open flames or other sources of ig nition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reach es the bottom of the filler tube Because fuel expands when it heats ...

Page 32: ...aded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane number of 95 or higher If knocking or pinging oc curs use a gasoline of a different brand Use of un leaded fuel will extend spark plug life and red...

Page 33: ...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 U1PY61E0 book Page 9 Wednesday March 14 2012 5 22 PM ...

Page 34: ...ich 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 EBU18892 Seat To remove the seat Insert your hand under the rear fender near the rear of the seat pull the seat lock lever and pull up the seat at the rear ...

Page 35: ... carrier Do not exceed the load limit of 5 0 kg 11 lb for the front carrier Do not exceed the maximum load of 105 0 kg 231 lb for the ATV EBU18972 Rear carrier Do not exceed the load limit of 10 0 kg 22 lb for the rear carrier Do not exceed the maximum load of 105 0 kg 231 lb for the ATV 1 Seat lock lever 1 1 Projection 2 Seat holder 1 2 U1PY61E0 book Page 11 Wednesday March 14 2012 5 22 PM ...

Page 36: ...by a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 7 5 3 Engine oil Check oil level in engine and add recommended oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary 5 3 8 11 Transmission oil Check oil le...

Page 37: ...Check chain condition Lubricate if necessary 5 3 8 34 8 37 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 3 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 38 Chassis fasteners Make sure that all nuts bolts and screws are properly tighten...

Page 38: ...e is applied If not have the ATV checked by a Yamaha dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance check the brake shoes for wear See page 8 28 EBU19761 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when relea...

Page 39: ...ions EWB02541 Set tire pressures to the following specifications 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 Recommended tire pressure Front 20 0 kPa 0 200 kgf cm 2 9 psi Rear 25 0 kPa 0 250 kgf cm 3 6 psi Minimum tire pressure Front 17 0 ...

Page 40: ...beless tires with valves WARNING EWB02551 Use of improper tires on this ATV may cause loss of control increasing your risk of an acci dent After extensive tests only the tires listed below have been approved for this model by Yamaha Motor Co Ltd 1 Low pressure tire gauge 1 1 Tire wear limit U1PY61E0 book Page 5 Wednesday March 14 2012 5 22 PM ...

Page 41: ...ke sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary EBU19860 Battery Check the fluid level in the battery Fill with distilled water if necessary See page 8 41 Front Manufacturer model DURO DI K635A Size AT20 x 7 8 Type Tubeless Rear Manufacturer model DURO DI...

Page 42: ...and the engine stop switch to 4 Shift the drive select lever into the neutral po sition The neutral indicator light should come on If the indicator light does not come on have a Yamaha dealer check the electrical cir cuit TIP The engine can be started under the following con ditions The drive select lever is in the neutral position The rear brake lever is applied with the drive se lect lever in an...

Page 43: ...tarter to start the engine 7 If the engine is started with the starter 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 then return the starter choke to position 3 before ridi...

Page 44: ... a complete stop 2 Shift from neutral to forward and vice versa by moving the drive select lever along the shift guide TIP Make sure that the drive select lever is completely shifted into position 3 Open the throttle lever gradually Shifting Reverse WARNING EWB00720 Improper operation in reverse could make you hit an obstacle or even a person behind you resulting in serious injury When you shift i...

Page 45: ...with an odometer or hour meter follow the figures given in hours There is never a more important period in the life of your engine than the first 320 km 200 mi or 20 hours of riding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the first 320 km 200 mi or 20 hours The various parts in the engine wear and polish...

Page 46: ...oll out of control increasing the chance of an accident If you must park on an incline place the ATV transversely across the incline shift the drive select lever to the for ward position stop the engine apply the park ing brake and then block the front and rear wheels with rocks or other objects Never park the ATV on hills that are too steep to walk up easily 1 With the transmission in the forward...

Page 47: ...r Aftermarket parts accessories and modifica tions While you may find aftermarket products similar in design and quality to genuine Yamaha Accesso ries recognize that some aftermarket accessories or modifications are not suitable because of poten tial safety hazards to you or others Installing after market products or having other modifications performed to your ATV that change any of the ve hicle...

Page 48: ... is not designed to tow a trailer If you choose to add accessories so that you can tow a trailer you must use common sense and good judgment as the stability and han dling of an ATV can be changed When adding ac cessories keep the following points in mind Never exceed the weight limits shown An over loaded ATV can be unstable If you are carrying cargo and towing a trailer in clude the tongue weigh...

Page 49: ...u should go Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV U1PY61E0 book Page 8 Wednesday March 14 2012 5 22 PM ...

Page 50: ...7 1 7 EBU21141 RIDING YOUR ATV U1PY61E0 book Page 1 Wednesday March 14 2012 5 22 PM ...

Page 51: ...nd un derstand the operation of the controls Pay partic ular attention to the safety information on pages 2 1 2 6 Also read all warning and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01381 Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an accident is greatly increased if the operator...

Page 52: ...0 A child under 16 should never operate an ATV with engine size greater than 90 cc Use by chil dren of ATVs that are not recommended for their age can lead to severe injury or death of the child This ATV is designed to carry the operator and cargo only passengers prohibited The long seat is to allow the operator to shift posi tion as needed during operation It is not for carry ing passengers WARNI...

Page 53: ... Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01411 Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating wit...

Page 54: ...ch time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 1 Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual WARNING Failure to inspect the ATV before operating it and to maintain it prop erly increases the possibility of an accident or equipment damage EWB01431 Speed limiter For ri...

Page 55: ...e risk of an accident Do not exceed the maximum loading limits for the vehicle see MAXIMUM LOADING LIMIT in this section or vehicle labeling Keep weight on racks centered side to side and as low as possible Be sure cargo is se cured a loose load could change handling unexpectedly Make sure the load does not interfere with your control or ability to see where you are going Tie down cargo in the tra...

Page 56: ...bility 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 EWB01471 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including an overturn Never attempt stunts ...

Page 57: ...e idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust system dur ing or after operation could be burned Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it The muffler and other engine parts become ex tremely hot during operation a...

Page 58: ... only WARNING Paved surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets EWB01511 While riding on unpaved public streets or roads may be legal in your area such operation can in crease the risk of collision with other vehicles U1PY61E0 book Page 9 Wednesday March 1...

Page 59: ...ther hidden hazards which may cause the ATV to upset WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Al ways be alert to changing terrain conditions when operating the ATV EWB01531 Do not operate on rough slippery or loose terrain until you have learned and practiced ...

Page 60: ... flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if operating in areas where you cannot easily be seen Mount a caution flag on the ATV to make you more visible Watch carefully for other vehicles EWB01551 Do not ride in areas posted no trespassing Do not ride on private property without getting per mission U1PY61E0 book Page 11 Wedn...

Page 61: ...eds until you are thoroughly familiar with the operation of your ATV When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly Im proper use of the brakes can cause the tires to lose traction reducing control and increasing the possi bility of an accident TURNING YOUR ATV WARNING EWB01771 Always follow proper procedures for turning as described in this Owner s Ma...

Page 62: ...ain If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body move ments or too much speed for the sharpness of the tur...

Page 63: ...y slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards 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 Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on lev...

Page 64: ...n the other side there could be another person an obstacle or a sharp drop off Use common sense and remember that some hills are too steep for you to climb or de scend If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill...

Page 65: ... as de scribed in this Owner s Manual Always check the terrain carefully before you start down any hill 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 Shift your weight backward and to the up side of the hill Never go down a hill at high speed Avoid going down a hill at an an...

Page 66: ... Gradual ly apply only the rear brake Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear CROSSING A SLOPE WARNING EWB01632 Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to overturn A...

Page 67: ... may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns 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 CRO...

Page 68: ... not continue to ride your ATV with out verifying that you have regained proper braking ability WARNING Wet brakes may have re duced stopping ability which could cause loss of control EWB02621 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 Also remove the V belt case drain screw to drain any water that may have accu...

Page 69: ... should be done with cau tion Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult SLIDING AND SKIDDING WARNING EWB01662 Skidding or sliding improperly may cause you to lose control of this ATV You may also r...

Page 70: ...ioning your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide side ways control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide With practice over a period of time skill at con trolled sliding can be developed The terrain...

Page 71: ... you are trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 14 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to...

Page 72: ...n off the engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 6 for more information about carbon monoxide WARNING EWB02690 Br...

Page 73: ... the tools provided in the owner s tool kit are in tended to assist you in the performance of preven tive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Owner s manual 2 Low pressure tir...

Page 74: ...e 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 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust if...

Page 75: ...ss and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 U1PY61E0 book Page 4 Wednesday March 14 2012 5 22 PM ...

Page 76: ...s 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 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Engine and V belt case air filter ele ment Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Front brake Check operation and correct if necessary Check brake lever free pla...

Page 77: ...lean and lubricate 9 Drive chain roller Check for wear and replace if necessary 10 V belt Check for wear cracks or other damage and re place if necessary 11 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 12 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 13 Front knuckle piv ots Lubricate with lit...

Page 78: ...s sary 19 Moving parts and cables Lubricate 20 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 21 Front and rear brake switches Check operation and correct if necessary 22 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first m...

Page 79: ... 23 Battery Check electrolyte level and specific gravity and correct if necessary Make sure that the breather hose is properly rout ed NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 U1PY61E0 book Page 8 Wednesday March 14 2012 5 22 PM ...

Page 80: ...ition the condition of the spark plug can reveal the condition 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 norma...

Page 81: ...cessary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification To install the spark plug 1 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 2 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Specified spark plug NGK CR7HSA 1 Spark...

Page 82: ...check the engine oil level 1 Place the ATV on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil set tles for an accurate reading 3 Remove the engine oil filler cap and then wipe the engine oil dipstick off with a clean rag 4 Insert the ...

Page 83: ... engine oil filler cap To change the engine oil 1 Place the ATV on a level surface 2 Start the engine warm it up for several min utes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase NOTICE When remov ing the engine oil drain bolt the compres sion spring...

Page 84: ...and then install and tight en the engine oil filler cap TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down NOTICE ECB00330 Do not use oils with a diesel specification of CD or oils of a higher quality than speci fied In addition do not use oils labeled EN ERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase 1 Engine...

Page 85: ...st be changed at the intervals specified in the periodic maintenance and lubrication chart To check the transmission oil level 1 Place the ATV on a level surface 2 Start the engine warm it up for several min utes and then turn it off 3 Wait a few minutes until the oil settles and then loosen the transmission oil check screw located at the right side of the crankcase until oil flows out 4 If no oil...

Page 86: ...he transmission oil 1 Place the ATV on a level surface 2 Start the engine warm it up for several min utes and then turn it off 3 Place an oil pan under the transmission to col lect the used oil 4 Remove the transmission oil filler bolt the transmission oil drain bolt and their gasket to drain the oil from the transmission case 1 Transmission oil filler bolt 2 Gasket Tightening torque Transmission ...

Page 87: ...Make sure that no oil gets on the tires or wheels 9 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 check for the cause 10 Turn the engine off and then check the oil lev el and correct it if necessary 1 Transmission oil drain bolt 2 Gasket Tightening torque Transmission oil drain bolt 23...

Page 88: ... empty the hose and clean the air filter element and air fil ter case 1 Place the ATV on a level surface 2 Remove the seat See page 4 10 3 Remove the breather hose by pulling it out and then loosen the air filter joint screw 4 Remove the air filter case cover by removing its screws then disconnecting the air filter case cover from the air filter joint 1 Air filter case check hose 1 1 Breather hose...

Page 89: ...lways use parts cleaning solvent to clean the sponge material Never use low flash point sol vents or gasoline to clean the sponge ma terial because the engine could catch fire or explode EWB01941 1 Air filter case cover 2 Screw 1 2 2 2 2 1 Screw 2 Washer 3 Sponge material 4 Air filter element frame 5 Air filter case cover 3 4 2 1 5 U1PY61E0 book Page 18 Wednesday March 14 2012 5 22 PM ...

Page 90: ...ther qual ity foam air filter oil to the sponge material TIP The sponge material should be wet but not drip ping 10 Pull the sponge material over the air filter ele ment frame 11 Apply all purpose grease to the air filter ele ment seat 12 Install the washer and screw NOTICE Be sure to install the washer with its curved side facing outward as shown ECB00453 1 Air filter element seat 1 U1PY61E0 book...

Page 91: ...lling the screws and then tighten the air filter joint screw 16 Install the breather hose 17 Install the seat TIP The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions Check the air...

Page 92: ...ing the quick fas teners and then pulling it upward as shown 4 Disconnect the coupler shown 1 Front carrier bolt 2 Front carrier 2 1 1 1 1 Panel 2 Quick fastener 1 Coupler 1 2 2 1 1 U1PY61E0 book Page 21 Wednesday March 14 2012 5 22 PM ...

Page 93: ...ove the air filter element 7 Tap the air filter element lightly to remove most of the dust and dirt Blow out the remain ing dirt with compressed air as shown 1 Air filter case cover 2 Screw 1 2 1 Air filter element 1 U1PY61E0 book Page 22 Wednesday March 14 2012 5 22 PM ...

Page 94: ...fied torque EBU27632 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the tailpipe screws and their gasket 2 Remove the tailpipe by pulling it out of the 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 and inside of the tailpipe housing 1 ...

Page 95: ...y leading to death and start a fire Always let the exhaust system cool prior to touching exhaust components EBU30061 V belt case drain screw After riding in water deep enough to allow it to en ter the V belt case remove this screw to drain the water from the case TIP If water drains from the V belt case after removing the screw have a Yamaha dealer check the ATV as the water may affect other engin...

Page 96: ...rburetor is an important part of the engine and requires very sophisticated adjustment Therefore most carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience The adjustment described in the following section however may be performed by the owner as part of routine main tenance NOTICE ECB00480 The carburetor has been set and extensively ...

Page 97: ... neces sary adjust it to specification by turning the throttle stop screw at the carburetor To in crease the engine idling speed turn the throt tle stop screw in direction a and to decrease it turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EBU24047 Adjusting the throttle lever free play The throttle lev...

Page 98: ...ing bolt in di rection a To decrease the throttle lever free play turn the adjusting bolt in direction b 4 Tighten the locknut 5 Slide the rubber cover to its original position EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the inter va...

Page 99: ...or wear at the intervals specified in the periodic maintenance and lubrication chart Each brake is provided with a wear indicator which allows you to check the brake shoe wear without having to dis assemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit lin...

Page 100: ... lubrication chart TIP Before adjusting the brake lever free play check the front brake shoes for wear The brake lever free play should measure 5 0 8 0 mm 0 20 0 31 in as shown If the free play is in correct adjust it as follows 1 Remove the front carrier by removing the bolts 1 Wear limit line 2 Wear indicator 1 2 1 Brake lever free play 1 U1PY61E0 book Page 29 Wednesday March 14 2012 5 22 PM ...

Page 101: ...ing the quick fas teners and then pulling it upward as shown 3 Disconnect the coupler shown 1 Front carrier 2 Front carrier bolt 1 2 2 2 1 Panel 2 Quick fastener 1 Coupler 1 2 2 1 1 U1PY61E0 book Page 30 Wednesday March 14 2012 5 22 PM ...

Page 102: ...re the brake cable joint in the equaliz er is straight when the brake is applied If the cable joint isn t straight loosen the locknuts and then turn the adjusting nuts on the front brake cables until the cable joint becomes straight 1 V belt air filter element cover 2 Screw 1 2 1 Locknut 2 Brake lever free play adjusting bolt 1 2 U1PY61E0 book Page 31 Wednesday March 14 2012 5 22 PM ...

Page 103: ...lter element cover by in stalling the screw 11 Connect the coupler and then install the pan el by installing the quick fasteners 12 Install the front carrier by installing the bolts and then tighten them to the specified torque 1 Brake equalizer 2 Cable joint 1 Locknut 2 Adjusting nut a a a a 1 2 2 1 1 2 1 Locknut 2 Brake lever free play adjusting bolt 3 Brake lever free play 3 1 2 b a U1PY61E0 bo...

Page 104: ... check the rear brake shoes for wear The brake lever free play should measure 5 0 8 0 mm 0 20 0 31 in as shown If the free play is in correct adjust it as follows 1 Loosen the locknut 2 Turn the brake lever free play adjusting bolt in direction a to increase the free play and in direction b to decrease it Tightening torque Front carrier bolt 7 Nm 0 7 m kgf 5 1 ft lbf 1 Brake lever free play 1 U1PY...

Page 105: ... direction b to decrease it 5 Use the adjusting bolt to obtain a precise ad justment if necessary and then tighten the locknut If the correct free play cannot be ob tained have a Yamaha dealer adjust it EBU24874 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 1 Locknut 2 Brake lev...

Page 106: ...surface 2 Loosen the hub stopper bolt locknut and then the hub stopper bolt 3 Loosen the axle holding bolts 4 Loosen the drive chain slack adjusting bolt locknut To tighten the drive chain turn the ad justing bolt in direction a To loosen the drive chain turn the adjusting bolt in direction b and then push the wheels forward NOTICE Improper drive chain slack will overload Drive chain slack 30 0 mm...

Page 107: ...ts to the spec ified torques NOTICE ECB00551 If measurement A of the drive chain slack ad justing bolt is less than 27 mm 1 06 in have a Yamaha dealer replace the drive chain 1 Locknut 2 Drive chain slack adjusting bolt 1 2 a b Tightening torques Drive chain slack adjusting bolt locknut 16 Nm 1 6 m kgf 12 ft lbf Axle holding bolt upper 85 Nm 8 5 m kgf 61 ft lbf Axle holding bolt lower 60 Nm 6 0 m ...

Page 108: ...vent dam aging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents ECB00571 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lubricants for the drive chain as they may contain substances that could damage the O rings ECB00581 EBU24902 Checking an...

Page 109: ...les work smoothly before you begin riding in 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 EBU28702 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if neces...

Page 110: ...wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bear ings EBU30380 Lubricating the lower arm pivots The lower arm pivots must be lubricated at the in tervals specified in the periodic maintenance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun Recommended lubricant Lithium soap based grease U1PY61E0 book Page 39 Wednesday M...

Page 111: ...lubricated at the intervals specified in the periodic maintenance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun 1 Grease nipple 1 Grease nipple 1 1 1 1 Recommended lubricant Lithium soap based grease 1 Grease nipple 1 U1PY61E0 book Page 40 Wednesday March 14 2012 5 22 PM ...

Page 112: ...ore each ride and at the intervals specified in the periodic maintenance and lubrica tion chart WARNING EWB02160 Battery electrolyte is poisonous and danger ous as it contains sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Foll...

Page 113: ...imum and maximum level marks 3 If the electrolyte is at or below the minimum level mark add distilled water to raise it to the maximum level mark NOTICE Use only dis tilled water as tap water contains minerals that are harmful to the battery ECB00591 4 Check and if necessary tighten the battery lead connections and correct the breather hose routing To remove the battery 1 Unhook the battery band 1...

Page 114: ... lyte at least once a month and fully charge the battery whenever necessary NOTICE ECB01100 Always keep the battery charged Storing a discharged battery can cause permanent battery damage Do not leave or store the battery on its side To install the battery TIP Be sure the battery is fully charged 1 Install the battery 2 Connect the positive lead first and then con nect the negative lead NOTICE Whe...

Page 115: ...d suffer structural and external damages ECB00611 4 Hook the battery band onto the holder EBU25263 Replacing the fuse The fuse holder is located on the right side of the ATV If the fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits 1 Battery 2 Negative battery lead black 3 Positive battery lead red 4 Battery band 1 2 4 3 1 Fuse 2 Spare fuse 1 2 U1PY61E0 ...

Page 116: ...age to the electrical system which could lead to a fire EWB02172 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU25481 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the cover at the rear of the headlight by pulling it off 2 Rem...

Page 117: ...e adversely affected Thoroughly clean off any dirt and finger prints on the headlight bulb using a cloth moistened with alcohol or thinner ECB00651 6 Install the bulb holder by pushing it in and turn ing it clockwise 7 Install the bulb holder cover and the cover at the rear of the headlight NOTICE Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly...

Page 118: ...ng the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove the tail brake light bulb holder to gether with the bulb by turning it counter clockwise 2 Remove the burnt out bulb by pushing it in and turning it counterclockwise 3 Insert a new bulb into the bulb holder push it in and then turn it clockwise until it stops 1 Headlight beam adjusting screw 1 a b 1 ...

Page 119: ...V and place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel EBU25692 Installing a wheel 1 Place the ATV on a level surface 2 Elevate the ATV and place a suitable stand under the frame 3 Install the wheel and the nuts 1 Tail brake light bulb 2 Tail brake light bulb holder 1 2 1 Wheel nut 1 1 U1PY61E0 book Page 48 Wednesday March 14 2012 5 22 PM ...

Page 120: ...s 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 replacement parts Im itation parts may look like Yamaha parts but they are...

Page 121: ... 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 U1PY61E0 book Page 50 Wednesday March 14 2012 5 22 PM ...

Page 122: ...check the electrodes 3 Ignition 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 The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is good Check the electrolyte level...

Page 123: ... EWB02311 NOTICE Excessive water pressure may cause water seepage and deteriora tion of wheel bearings brakes transmis sion seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applica tions such as those available in coin oper ated car washers ECB00711 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild dete...

Page 124: ...er if available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sp...

Page 125: ...m entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation on storing the battery see page 8 41 TIP Make any necessary repairs before storing the ATV U1PY61E0 book Page 3 Wednesday March 14 2012 5 22 PM ...

Page 126: ...se and vibration level Noise level 77 311 EEC 78 0 dB A 3500 r min Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s Vibration on handlebar EN1032 ISO5008 Will not exceed 2 5 m s Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder Displacement 124 cm Bore stroke 49 0 66 0 mm 1 93 2 60 in Compression ratio 9 00 1 Starting system Electric starter Lubrication syste...

Page 127: ...uel reserve amount 1 3 L 0 34 US gal 0 29 Imp gal Carburetor Type quantity VM18SH x 1 Spark plug s Manufacturer model NGK CR7HSA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Dry centrifugal automatic Transmission Primary reduction system Helical gear spur gear Primary reduction ratio 43 14 40 17 7 226 Secondary reduction system Chain drive Secondary reduction ratio 32 12 2 666 Trans...

Page 128: ...argo accessories and tongue Tire air pressure measured on cold tires Recommended Front 20 0 kPa 0 200 kgf cm 2 9 psi Rear 25 0 kPa 0 250 kgf cm 3 6 psi Minimum Front 17 0 kPa 0 170 kgf cm 2 5 psi Rear 22 0 kPa 0 220 kgf cm 3 2 psi Front wheel Wheel type Panel wheel Rim size 8 x 5 5AT Rear wheel Wheel type Panel wheel Rim size 8 x 8 0AT Front brake Type Drum brake Operation Right hand operation Rea...

Page 129: ...or Europe only The figures quoted are emission levels and are not necessarily safe working levels Whilst there is a correlation between the emission and exposure levels this cannot be used reliably to determine whether or not further precautions are required Factors that influence the actual level of exposure of work force include the characteristics of the work room the other sources of noise etc...

Page 130: ...R MODEL LABEL INFORMATION EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame TIP The vehicle identification number is used to identify 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 ...

Page 131: ...11 2 11 1 Model label 1 U1PY61E0 book Page 2 Wednesday March 14 2012 5 22 PM ...

Page 132: ...cating 8 37 Drive chain slack 8 34 Drive select lever 4 6 Drive select lever and driving in reverse 6 3 E Engine break in 6 4 Engine cold start 6 1 Engine idling speed 8 26 Engine oil 5 3 8 11 Engine starting a warm 6 3 Engine stop switch 4 2 F Front knuckle pivots lubricating 8 40 Fuel 4 7 5 3 Fuel cock 4 8 Fuel tank cap 4 7 Fuse replacing 8 44 H Handlebar switches 4 2 Headlight beam adjusting 8 ...

Page 133: ...choke 4 10 Start switch 4 3 Steering shaft lubricating 8 41 Storage 9 2 Suspension lubricating the lower arm pivots 8 39 T Tail brake light bulb replacing 8 47 Throttle lever 4 3 5 3 Throttle lever free play adjusting 8 26 Tires 5 3 Transmission oil 5 3 8 14 Troubleshooting 8 49 Troubleshooting chart 8 51 V Valve clearance 8 27 V belt case drain screw 8 24 Vehicle identification number 11 1 W Whee...

Page 134: ... AND PROTECTIVE GEAR NEVER USE ON PAVED ROADS NEVER CARRY PASSENGERS NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS PRINTE...

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