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Yamaha GRIZZLY 125 YFM125GY, Owner'S Manual

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Yamaha GRIZZLY 125 YFM125GY Owner'S Manual Download Page 65

 

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NOTICE

 

ECB00800 

 

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 and the V-belt
case drain plug. Wash the ATV in fresh water if
it has been operated in salt water or muddy

 

conditions.

 

1. Air filter case check hose

1.  V-belt case drain plug

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Summary of Contents for GRIZZLY 125 YFM125GY

Page 1: ...U PROPRIÉTAIRE OWNER S MANUAL 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 ...

Page 2: ...PRINTED IN JAPAN 2008 03 0 8x2 E F S ...

Page 3: ...This A 1C5 28199 65 E0 YFM125GY OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 4: ...EEC If applicable If applicable To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted EN292 ANSI SVIA 1 2007 Title and or number and date of issue of standards and or specifications General Manager RV Engineering Division RV Company Signature Date of Issue Shinya Shimada 2...

Page 5: ...anding of the 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...

Page 6: ...ithout notice This is the safety 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 propert...

Page 7: ...his ATV on any paved surface paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFM125GY OWNER S MANUAL 2008 by Yamaha Motor Co Ltd 1st edition March 2008 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: ...ve select lever 4 6 Fuel tank cap 4 6 Fuel 4 6 Fuel cock 4 7 Starter choke 4 9 Seat 4 9 Front carrier 4 10 Rear carrier 4 10 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 3 Engine oil 5 3 Transmission oil 5 3 Front and rear brakes 5 3 Throttle lever 5 4 Drive chain 5 4 Tires 5 4 Measuring the tire pressure 5 5 Tire wear limit 5 6 Chassis fasteners 5 6 Instruments lights and switches...

Page 9: ...g the engine and V belt case air filter elements 8 15 V belt case drain plug 8 21 Adjusting the carburetor 8 22 Adjusting the engine idling speed 8 22 Adjusting the throttle cable free play 8 23 Valve clearance 8 24 Checking the front and rear brake shoes 8 24 Adjusting the front brake lever free play 8 25 Adjusting the rear brake lever free play 8 30 Drive chain slack 8 32 Lubricating the drive c...

Page 10: ...Installing a wheel 8 46 Troubleshooting 8 47 Troubleshooting chart 8 48 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 ...

Page 11: ...han 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 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 ...

Page 12: ...e 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 or make sudden gear chang...

Page 13: ...ter 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 tir...

Page 14: ...ne is poisonous If you should swal low some gasoline or inhale a lot of gasoline 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 f...

Page 15: ...670 Read and understand all of the labels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer 1 3 5 4 1 2 8 9 11 10 6 7 ...

Page 16: ... For Oceania sit here NEVER 3MX 24875 A0 5kg 11lbs 3LD 24877 A0 10kg 22lbs 1C5 24877 A0 1 2 3 4 4 WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 5FE 2151H 01 For Europe and Oceania For Europe and Oceania ...

Page 17: ...eania 5 5 For Oceania For Europe For Europe 7 8 6 WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death OPERATING TIRE PRESSURE Set with tires cold Recommended Front 20 0 kPa 2 9 psi Rear 25 0 kPa 3 6 psi Minimum Front 17 0 kPa 2 5 psi Rear 22 0 kPa 3 2 psi Never set tire pressure below minimum It could cause the tire to dislod...

Page 18: ...10 11 4D3 2816L 00 16 5FK 21697 00 For Europe For Oceania YAMAHA MOTOR CO LTD SHIZUOKA JAPAN p 4GB 2155A 00 For Europe 9 9 10 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death ...

Page 19: ... este vehículo lea el Manual del Propietario Lire le manuel du propriétaire avant d utiliser ce véhicule Prima di usare il veicolo leggete il manuale di istruzioni Voor het gebruik van dit voertuig de handleiding met aandacht lezen Antes de utilizar este veículo leia o manual do proprietário Innan du kör detta fordon läs handboken 5FK 21568 00 5FE 21568 11 For Europe For Oceania 11 11 ...

Page 20: ... 8 9 10 11 EBU17680 DESCRIPTION EBU17690 Left view EBU17700 Right view 1 Front carrier 2 Starter choke 3 Fuel cock 4 Tail brake light 5 Rear carrier 6 Footboard 1 2 3 4 5 6 1 Seat 2 Drive select lever 3 Headlight 1 2 3 ...

Page 21: ...TV you have purchased may differ slightly from the figures shown in this manual 1 Rear brake lever 2 Parking brake 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 ...

Page 22: ...The key cannot be re moved OFF All electrical systems are off The key can be re moved EBU17791 Indicator lights EBU17830 Reverse indicator light This indicator light comes on when the transmis sion is in the reverse position EBU17860 Neutral indicator light This indicator light comes on when the transmis sion is in the neutral position 1 Main switch OFF ON 1 1 Reverse indicator light R 2 Neutral i...

Page 23: ... er NOTICE ECB00050 See the starting instructions on page 6 1 prior to starting the engine EBU18140 Light switch LIGHTS Set this switch to LO to turn on the low beams and the taillight Set the switch to HI to turn on the high beams and the taillight Set the switch to OFF to turn off all the lights NOTICE ECB00040 Do not use the headlights with the engine turned off for an extended period of time o...

Page 24: ...ld make it diffi cult to speed up or slow down when you need to This could cause an accident Check the op eration of the throttle lever before you start the engine If the throttle does not work smoothly check for the cause Correct the problem be fore riding the ATV or consult a Yamaha dealer EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter The speed limiter keeps the ...

Page 25: ...able 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 23 EBU18391 Front brake lever The front brake lever is located on the right handle bar To apply the front brake pull the brake lever toward the handlebar grip EBU18401 Rear brake lever The rear brake lever is located on the left handle bar To apply the rear brake pull the brake le...

Page 26: ...B00220 Always set the parking brake before starting the engine The ATV could start moving un expectedly if the parking brake is not ap plied This could cause loss of control or a collision Always be sure you have released the park ing brake before you begin to ride The brake could overheat if you ride the ATV without re leasing the parking brake You could lose braking performance which could cause...

Page 27: ...ee the Operating the drive select lever and driving in re verse section on page 6 3 for the drive select lever operation EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise EBU18752 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 Neutral N 2 Forward F 3 Reverse R 4 Drive select lever 1 2 3 4 1 Fuel ...

Page 28: ... en gine 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 ...

Page 29: ...ion 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 30: ...hoke 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 pull up the seat at t...

Page 31: ...re that the seat is securely fitted EBU18961 Front 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 EBU18971 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 1 Seat lock lever 1 1 Projection 2 Seat holder 1 2 ...

Page 32: ...4 11 1 2 3 4 5 6 7 8 9 10 11 231 lb for the ATV ...

Page 33: ... Yamaha dealer Refer to the periodic maintenance charts on page 8 3 to determine which service should be performed by a Yamaha dealer 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 6 5 3 Engine oil Check oil level in engine and add recommended oil to specified level if necessary Check ATV for oil leakag...

Page 34: ...in slack and adjust if necessary Check chain condition Lubricate if necessary 5 4 8 32 8 34 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 4 5 5 5 6 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 36 Chassis fasteners Make sure that all n...

Page 35: ...ion oil is at the speci fied level Add oil as necessary See page 8 12 EBU19650 Front and rear brakes Brake levers Check for correct free play in the brake levers If the free play is incorrect adjust it See pages 8 25 and 8 30 Check operation of the levers They should move smoothly and there should be a firm feel ing when the brake is applied If not have the ATV checked by a Yamaha dealer Brake ope...

Page 36: ...er or uneven tire pres sure may cause loss of control increasing your risk of accident Pay attention to the following The tires listed below have been approved by Yamaha Motor Co Ltd for this model Other tire combinations are not recommend ed Front Manufacturer model DUNLOP KT536A Size AT20 x 7 8 Type Tubeless Rear Manufacturer model DUNLOP KT537A Size AT22 x 10 8 Type Tubeless The tires should be...

Page 37: ...r 250 kPa 2 5 kgf cm2 36 psi Higher pressures and fast inflation may cause a tire to burst Inflate the tires very slowly and carefully EBU19820 Measuring the tire pressure Use the low pressure tire gauge TIP 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 ...

Page 38: ...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 38 Recommended pressure Front 20 0 kPa 0 200 kgf cm2 2 9 psi Rear 25 0 kPa 0 250 kgf cm2 3 6 psi Minimum Front 17 0 kPa 0 170 kgf cm2 2 5 psi Rear 22 0 kPa 0 220 kgf cm2 3 2 p...

Page 39: ...n or do not work smoothly you could be unable to control the ATV which could lead to an acci dent or collision NOTICE 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 drive select lever into the neutral po sition The neut...

Page 40: ...ngine more than 10 seconds on each attempt 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 NOTICE ECB00160 For maximum engine life always warm the en gine up before starting off Never acc...

Page 41: ...ssion may be damaged Shifting Forward 1 Bring the ATV to 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 1 Bring the ATV to a complete stop 2 Apply the parking brake 3 Shift from neutral to reverse a...

Page 42: ... meter follow the figures given in km mi or the figures given in hours For ATVs not equipped 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 ...

Page 43: ...void parking on hills or other inclines Park ing on a hill or other incline could cause the ATV to roll 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 Do ...

Page 44: ...ch can shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits...

Page 45: ...oad The more weight you carry the slower you 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 WARNING EWB00820 Never exceed the stated load capacity for this ATV Overloading this ATV or carrying or tow ing carg...

Page 46: ...7 1 1 2 3 4 5 6 7 8 9 10 11 EBU21141 RIDING YOUR ATV ...

Page 47: ... partic ular attention to the safety information on pages 1 1 1 4 Please also read all caution and warning labels 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 un...

Page 48: ...ead to severe injury or death of the child This ATV is designed to carry operator and cargo only passengers prohibited WARNING EWB01400 Never carry a passenger 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...

Page 49: ...rel Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants 1 Protective clothing 2 Goggles 3 Gloves 4 Boots 5 Helmet ...

Page 50: ...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 this ATV Pre operation checks Always perform the pre operation checks listed on page 5 1 before riding fo...

Page 51: ...ur 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 of losing control of the ATV which can result in an accident Speed limiter For riders less experienced with this model the throttle lever housing is e...

Page 52: ...ying 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 footboards during op eration otherwise they may contact the rear wheels WARNING EWB01470 Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation...

Page 53: ...f accessories All parts and accessories added to this ATV should be gen uine Yamaha or equivalent components de signed for use on this ATV and should be installed and used according to instructions Improper installation of accessories or modifi cation of this ATV may cause changes in han dling which in some situations could lead to an accident If you have questions consult an au thorized ATV deale...

Page 54: ...ground cover or combustible ma terials BE CAREFUL WHERE YOU RIDE This ATV is designed for use on unpaved surfaces only Riding on paved surfaces can cause loss of control WARNING EWB01510 Always avoid paved surfaces including side walks driveways parking lots and streets ATVs are designed for use on unpaved surfac es only Paved surfaces may seriously affect handling and control of the ATV and may c...

Page 55: ...et 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 WA...

Page 56: ... 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 57: ...obstacles and other riders 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...

Page 58: ...ear wheels are mounted solidly on one axle and turn together at the same speed There fore unless the wheel on the inside of the turn is al lowed to slip or lose some traction the ATV will resist turning A special turning technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed WARNING EWB01570 Always follow proper proced...

Page 59: ...de while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the out side of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL Use proper riding techniques to avoid ATV over turns on hills Be sure that you can maneuver your ATV well on flat gr...

Page 60: ...xcessively 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 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...

Page 61: ...nd and then descend the hill If you start to roll backwards DO NOT apply the rear brake to stop or try to put the ATV in gear The ATV could easily tip over backwards Instead ap ply the front brake gradually or dismount the ATV immediately on the uphill side WARNING EWB01761 Maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parki...

Page 62: ... 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 WARNING EWB01620 Always follow proper procedures for going down hills as described in this Owner s Manu al Note a special technique is required when braking as you go down a hill Alway...

Page 63: ...l 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 WARNING EWB01631 Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as de...

Page 64: ...Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s 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 lin ings If the ATV is operated through deep or fast flowing water the tires may float causing loss of traction and loss of control...

Page 65: ...r be sure to drain the trapped water by removing the check hose at the bottom of the air filter case and the V belt case drain plug Wash the ATV in fresh water if it has been operated in salt water or muddy conditions 1 Air filter case check hose 1 V belt case drain plug 1 1 ...

Page 66: ...ocks 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 conditions positioning your weight ov...

Page 67: ...O 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 Position your weight over the front wheels for better control See page 7 13...

Page 68: ...eight 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 18 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let ...

Page 69: ...GRAPHICAL 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 service if you are...

Page 70: ...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 u...

Page 71: ...rmed by 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 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 Valv...

Page 72: ...ket s if neces sary Check for looseness 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 ...

Page 73: ...correct if necessary Check brake lever free play and adjust if neces sary Replace brake shoes Whenever worn to the limit 3 Rear brake Check operation and correct if necessary Check brake lever free play and adjust if neces sary Replace brake shoes Whenever worn to the limit 4 Wheels Check runout and for damage and replace if nec essary 5 Tires Check tread depth and for damage and replace if necess...

Page 74: ...kage and replace if necessary 12 Front knuckle piv ots Lubricate with lithium soap based grease 13 Steering shaft Lubricate with lithium soap based grease 14 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 15 Engine oil Change Check ATV for oil leakage and correct if neces sary 16 Engine oil strainer Clean 17 Transmission oil Change Check ATV f...

Page 75: ...tle lever housing and cable 19 Front and rear brake switches Check operation and correct if necessary 20 Lights and switches Check operation and correct if necessary Adjust headlight beams 21 Battery Check electrolyte level and specific gravity and correct if necessary Make sure that the breather hose is properly routed NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 ...

Page 76: ...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 TIP If the spark plug shows a distinctly different colo...

Page 77: ...wrench and then tighten it to the specified torque TIP 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 EBU23265 Engine oil The engine oil level should be checked before each ride In addition the ...

Page 78: ...r cap and then wipe the dipstick off with a clean rag 4 Insert the dipstick into the filler hole without screwing it in and then remove it again to check the oil level TIP The engine oil should be between the minimum and maximum level marks 5 If the engine oil is at or below the minimum level mark add sufficient oil of the recom mended type to raise it to the correct level 6 Insert the dipstick in...

Page 79: ...all out Take care not to lose these parts 5 Clean the oil strainer with solvent 6 Check the O ring for damage and replace it if necessary 7 Install the O ring oil strainer compression spring and drain bolt Tighten the engine oil drain bolt to the specified torque NOTICE ECB00320 Before installing the engine oil drain bolt be sure to install the O ring compression spring and oil strainer 8 Refill w...

Page 80: ...l minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 10 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary EBU27023 Transmission oil The transmission oil level should be checked be fore each ride In addition the transmission oil must be changed at the intervals specified in the Reco...

Page 81: ...e screw located at the right side of the crankcase 4 Check the transmission oil level TIP The transmission oil should be at the brim of the hole 5 If the transmission oil level is below the brim of the hole remove the oil filler bolt add suffi cient oil of the recommended type to raise it to the correct level and then install and tighten the screw and the oil filler bolt 1 Screw 2 Transmission oil...

Page 82: ... amount of the recom mended transmission oil and then install and tighten the oil filler bolt NOTICE ECB00790 Make sure that no foreign material enters the transmission case Make sure that no oil gets on the tires or wheels 7 Start the engine and then let it idle for several Tightening torque Screw 16 Nm 1 6 m kgf 11 6 ft lbf Oil filler bolt 23 Nm 2 3 m kgf 16 6 ft lbf 1 Transmission oil drain bol...

Page 83: ...ng the engine and V belt case air filter elements Both air filter elements should be cleaned at the specified intervals in the periodic maintenance chart Engine air filter element TIP 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 clean the air filter element and air fil ter case 1 Remove the seat See page 4 9 2 Remove the breat...

Page 84: ...r by removing the screws 4 Pull the air filter element out of the air filter case 5 Remove the bolt and washer shown and then pull the sponge material off from the air filter element frame 1 Breather hose 2 Clamp screw 1 2 1 Air filter case cover 2 Screw 1 2 2 2 2 ...

Page 85: ...ine could catch fire or ex plode 7 Squeeze the excess solvent out of the sponge material and let it dry NOTICE ECB00440 Do not twist the sponge material when squeez ing it 8 Check the sponge material and replace it if damaged 9 Apply a quality 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 1 Bol...

Page 86: ...ter element maintenance is performed check the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air tight seal Tighten all fit tings securely to avoid the possibility of unfiltered air entering the engine NOTICE ECB00460 Make sure that the air filter element is prop erly seated in the a...

Page 87: ...V belt case air filter element 1 Remove the front carrier by removing the bolts 2 Remove the panel shown by removing the quick fasteners 3 Disconnect the coupler shown 1 Bolt 2 Front carrier 2 1 1 1 1 Panel 2 Quick fastener 1 2 2 1 ...

Page 88: ...8 20 1 2 3 4 5 6 7 8 9 10 11 4 Remove the air filter case cover by removing the screw 5 Remove the air filter element 1 Panel 2 Coupler 1 2 1 Air filter case cover 2 Screw 1 2 ...

Page 89: ...ce it if damaged 8 Install the air filter element into the air filter case 9 Install the air filter case cover by installing the screw 10 Connect the coupler and then install the pan el by installing the quick fasteners 11 Install the front carrier by installing the bolts EBU23930 V belt case drain plug After riding in water deep enough to allow it to en 1 Air filter element 1 1 Air filter element...

Page 90: ...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 tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor performance o...

Page 91: ...ottle cable free play The throttle cable free play should be checked and if necessary adjusted at the intervals speci fied in the periodic maintenance and lubrication chart The throttle cable free play should measure 1 0 3 0 mm 0 04 0 12 in at the throttle lever Period ically check the throttle cable free play and if nec essary adjust it as follows TIP The engine idling speed must be checked and a...

Page 92: ...ont and rear brake shoes must be checked for 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...

Page 93: ... must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and 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 1 Wear limit line 2 Wear indicator 1 2 1 Wear limit line 2 Wear indicator 1 2 ...

Page 94: ...own If the free play is in correct adjust it as follows 1 Remove the front carrier by removing the bolts 2 Remove the panel shown by removing the quick fasteners then disconnect the coupler shown 1 Brake lever free play 1 1 Front carrier 2 Bolt 1 2 2 2 ...

Page 95: ...8 27 1 2 3 4 5 6 7 8 9 10 11 3 Remove the V belt air filter element cover by removing the screw 1 Panel 2 Quick fastener 1 2 2 1 1 Panel 2 Coupler 1 2 ...

Page 96: ...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 ...

Page 97: ... 11 6 Tighten the locknut on each brake cable 7 Turn the adjusting bolt in direction a to in crease the free play and in direction b to de crease it 1 Brake equalizer 2 Cable joint a a a a 1 2 1 Locknut 2 Adjusting nut 1 2 2 1 ...

Page 98: ... and that the free play is correct Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer EBU24491 Adjusting the rear brake lever free play The brake lever free play must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart TIP Before adjust...

Page 99: ... dealer adjust it WARNING EWB02080 Operating with improperly serviced or adjust ed brakes could cause loss of braking ability which could lead to an accident After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures 1 Brake lever free play 1 1 Brake lever ...

Page 100: ...lack there should be no weight on the ATV and all tires must be touching the ground 2 Move the ATV back and forth to locate the tightest portion of the drive chain and then measure the drive chain slack as shown 3 If the drive chain slack is incorrect adjust it as follows To adjust the drive chain slack 1 Place the ATV on a level surface 2 Loosen the hub stopper bolt locknut and then the hub stopp...

Page 101: ...0541 Improper drive chain slack will overload the en gine as well as other vital parts of the ATV and can lead to drive chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 5 Tighten the locknut and the axle holding bolts to the specified torques 1 Hub stopper bolt 2 Locknut 3 Axle holding bolt lower 4 Axle holding bolt upper 1 2 3 4 1 Lo...

Page 102: ...rive 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 Tightening torques Chain adjusting bolt locknut 15 5 Nm 1 6 m kgf 11 2 ft lbf Axle holding bolt upper 85 Nm 8 5 m kgf 61 5 ft lbf Axle holding bolt lo...

Page 103: ...l or any 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 WAR...

Page 104: ...ver EBU24962 Checking the wheel hub bearings The front and rear wheel hub 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 hub bear ings EBU25032 Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at...

Page 105: ...e front knuckle pivots The front knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricate the front knuckle pivots using a grease gun Recommended lubricant Lithium soap based grease 1 Grease nipple 1 1 1 Grease nipple Recommended lubricant Lithium soap based grease all purpose grease 1 1 ...

Page 106: ...tained battery will corrode and dis charge quickly The electrolyte level battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrica tion chart To check the electrolyte level 1 Place the ATV on a level surface 2 Check the electrolyte level in the battery 1 Grease nipple Recommended lubricant Lithium so...

Page 107: ...ark NOTICE ECB00590 Use only distilled water as tap water contains minerals that are harmful to the battery 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 1 Battery 2 Battery breather hose 3 Guide 1 2 3 1 Maximum level mark 2 Minim...

Page 108: ...f necessary tighten the battery lead connections and correct the breather hose routing To store the battery If the ATV will not be used for more than one month the battery will need to be removed and stored as follows 1 Disconnect the negative lead first and then the positive lead 2 Remove the battery fully charge it and then place it in a cool dry place NOTICE ECB00600 Do not leave or store the b...

Page 109: ...operly routed in good condition and not obstructed NOTICE ECB00610 If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the battery the frame could suf fer structural and external damages EBU25262 Replacing the fuse The fuse holder is located on the right side of the ATV 1 Battery 2 Negative battery lead black 3 Positive battery lead red 1 ...

Page 110: ...stitute object in place of the proper fuse An improper fuse or a substitute object can cause damage to the electrical sys tem which could lead to a fire 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 EBU25480 Replacing a headlight bulb If a headlight bulb burns out repla...

Page 111: ...touch es something flammable 5 Insert a new headlight bulb into the bulb hold er by pushing it in NOTICE 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...

Page 112: ...Adjusting a headlight beam NOTICE ECB00690 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the headlight beam adjusting screw in direction a To lower a headlight beam turn the adjusting screw 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 ...

Page 113: ...b into the bulb 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 EBU25651 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 1 Tail brake light bulb holder 1 1 Tail brake light bulb 2 Tail brake light bulb holder 1 2 ...

Page 114: ...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 TIP Tapered nuts are used for both the front and rear wheels Install the nuts with their tapered side to wards the wheel 4 Lower the ATV to the ground 5 Tighten the wheel nuts to the specified torques 1 Wheel nut 1 1 1 Tapered nut 1 ...

Page 115: ...t 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 often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02280 Do not smoke when checking the fuel system Fuel can ignite or explode causing...

Page 116: ...eck the ATV Remove the spark plug and 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 batte...

Page 117: ...eel 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 to reach places 5 Rinse the ATV...

Page 118: ...he 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 deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc f...

Page 119: ...e 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 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 m...

Page 120: ...ise and vibration level Noise level 77 311 EEC 75 1 dB A EUR Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s2 EUR Vibration on handlebar EN1032 ISO5008 Will not exceed 2 5 m s2 EUR Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 124 0 cm3 Bore stroke 49 0 66 0 mm 1 93 2 60 in Compression ratio 9 00 1 Starting system Electric s...

Page 121: ...aded gasoline only AUS NZL Fuel tank capacity 7 0 L 1 85 US gal 1 54 Imp gal Fuel reserve amount 1 3 L 0 34 US gal 0 29 Imp gal Carburetor Manufacturer MIKUNI 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...

Page 122: ...odel DUNLOP KT537A Loading Maximum loading limit 105 0 kg 231 lb Total weight of rider cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 20 0 kPa 0 200 kgf cm2 2 9 psi Rear 25 0 kPa 0 250 kgf cm2 3 6 psi Minimum Front 17 0 kPa 0 170 kgf cm2 2 5 psi Rear 22 0 kPa 0 220 kgf cm2 3 2 psi Front wheel Wheel type Panel wheel Rim size 8 x 5 5AT Rear wheel Wheel type P...

Page 123: ...Coil spring oil damper Wheel travel 80 mm 3 1 in Electrical system Ignition system DC CDI Charging system AC magneto Battery Model 12N12C 4A 2 Voltage capacity 12 V 12 0 Ah Headlight Bulb type Krypton bulb Bulb voltage wattage quantity Headlight 12 V 30 0 30 0 W 2 Tail brake light 12 V 5 0 21 0 W 1 Neutral indicator light 12 V 1 7 W 1 Reverse indicator light 12 V 1 7 W 1 Fuses Main fuse 15 0 A ...

Page 124: ...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 EBU26040 Vehicle identification number The vehicle identification number...

Page 125: ...ation number is used to identi 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 Vehicle identification number 2 Year of manufacture ...

Page 126: ...11 3 1 2 3 4 5 6 7 8 9 10 11 1 Model label 1 ...

Page 127: ...0 Chassis fasteners 5 6 Cleaning 9 1 D Drive chain 5 4 Drive chain lubricating 8 34 Drive chain slack 8 32 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 22 Engine oil 5 3 8 9 Engine starting a warm 6 3 Engine stop switch 4 2 F Front knuckle pivots lubricating 8 37 Fuel 4 6 5 3 Fuel cock 4 7 Fuel tank cap 4 6 F...

Page 128: ...hecking 8 8 Specifications 10 1 Speed limiter 4 3 Starter choke 4 9 Start switch 4 2 Steering shaft lubricating 8 38 Storage 9 2 Suspension lubricating the upper and lower arm pivots 8 36 T Tail brake light bulb replacing 8 44 Throttle cable free play adjusting 8 23 Throttle lever 4 3 5 4 Tire pressure measuring 5 5 Tires 5 4 Tire wear limit 5 6 Transmission oil 5 3 8 12 Troubleshooting 8 47 Troub...

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Page 130: ...PRINTED IN JAPAN 2008 03 0 8x2 E YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER ...

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