Yamaha GRIZZLY 125 YFM125GZ Owner'S Manual Download Page 106 | Manualshive

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Rear brake lever

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 the intervals specified in the periodic mainte-

nance and lubrication chart.
Lubricate the pivoting points using a grease gun.

Left side

Recommended lubricant:

Lithium-soap-based grease

1. Grease nipple

1

1

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Summary of Contents for GRIZZLY 125 YFM125GZ

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 2009 03 0 1x1 E F S ...

Page 3: ...This A 1C5 28199 66 E0 YFM125GZ OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 4: ... of 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 ANSI SVIA 1 2007 Title and or number and date of issue of standards and or specifications General Manager RV Engineering Division RV Operations Signature Date of Issue Shinya Shimada ...

Page 5: ...d basic understanding 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 R...

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: ...rface paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFM125GZ OWNER S MANUAL 2009 by Yamaha Motor Co Ltd 1st edition February 2009 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: ...g brake 4 5 Drive select lever 4 6 Fuel tank cap 4 6 Fuel 4 6 Fuel cock 4 8 Starter choke 4 9 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 5 Instruments lights and switches 5 6 Battery 5 6 OPERATION 6 1 Starting a cold engine 6 1 Startin...

Page 9: ... the spark arrester 8 21 V belt case drain plug 8 23 Adjusting the carburetor 8 23 Adjusting the engine idling speed 8 23 Adjusting the throttle cable free play 8 24 Valve clearance 8 25 Brakes 8 26 Checking the front and rear brake shoes 8 26 Adjusting the front brake lever free play 8 27 Adjusting the rear brake lever free play 8 31 Drive chain slack 8 32 Lubricating the drive chain 8 35 Checkin...

Page 10: ...Troubleshooting 8 47 Troubleshooting chart 8 49 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 ...

Page 11: ...BU29692 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 8 9 1 3 4 2 7 6 5 ...

Page 12: ...1 2 1 2 3 4 5 6 7 8 9 10 11 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 5 ...

Page 13: ... 3 4 5 6 7 8 9 10 11 6 7 8 43P 2816R 00 4D3 2816L 20 5PG 2817L 10 YEAROFCONSTRUCTION 2009 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN MODEL YFM125A MAX POWER 6 5 kw MASS IN RUNNING ORDER 152 kg 1C5 2156A 10 9 ...

Page 14: ...r children under age 16 NEVER permit children under age 10 to operate this ATV Operation of this ATV by children under the age of 10 increases the risk of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 12 to operate this ATV Operation of this ATV by children under the age of 12 increases the risk of severe injury or death Adult supervisi...

Page 15: ...ol can result in severe injury or death Turning the ATV in 4WD LOCK DIFF LOCK takes more effort Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control 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 gea...

Page 16: ... trailer and all cargo in the trailer Overloading can cause loss of control Loss of control can result in severe injury or death This pictogram shows trailer Hitch Tongue weight limit Weight on the trailer tongue Overloading can cause loss of control Loss of control can result in severe injury or death ...

Page 17: ...rate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and paved streets Never operate an ATV on any paved street paved road or motorway Watch carefully for other vehicles wh...

Page 18: ...empting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going down...

Page 19: ... 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 tires specified in this manual Always maintain proper tire pressure as de scribed in this m...

Page 20: ...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 run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors WARNING EWB02591 When transporting the ATV in another vehicle be s...

Page 21: ...1 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 Spark arrester 7 Footboard 1 2 3 4 5 6 7 1 Seat 2 Drive select lever 3 Headlight 1 2 3 ...

Page 22: ...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 23: ...The key cannot be re moved OFF All electrical systems are off The key can be re moved EBU17792 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 24: ...or to starting the engine EBU18152 Light switch OFF Set this switch to to turn on the low beams and the taillight Set the switch to to turn on the high beams and the taillight Set the switch to OFF to turn off all the lights NOTICE ECB00041 Do not use the headlights with the engine turned off for an extended period of time oth erwise the battery may discharge to the point that the starter motor wi...

Page 25: ... limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum 1 Loosen the locknut 2 To increase the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction a To de crease the maximum engine power available and the maximum speed of the ATV turn the adjusting screw in direction b Do not turn the ...

Page 26: ...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 lever to ward the handlebar grip 1 Adjusting screw 2 Locknut 3 No more than 12 mm 0 47 in 3 1 2 a b 1 Front brake lever 1 ...

Page 27: ...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 28: ...e 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 EBU28941 Fuel Make sure there is sufficient gasoline in the tank WARNING EWB02521 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling fol low these instructions 1 Neutral N 2 F...

Page 29: ...NOTICE Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfaces or plastic parts ECB00981 4 Turn the fuel tank cap fully clockwise to make sure it is securely closed WARNING EWB02531 Gasoline is poisonous and can cause injury or death Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gaso...

Page 30: ...ent brand Use of unleaded fuel will extend spark plug life and reduce maintenance costs EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations OFF With the fuel cock lever in this position fuel will not flow Always turn the fuel cock lever to this position when th...

Page 31: ...is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18840 Starter choke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on 1 Arrow mark positioned over ON ON FUEL...

Page 32: ...r proper operation EBU18881 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear To install the seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear Make sure that the seat is securely fitted 1 Fully open 2 Half open 3 Closed 4 Starter choke b a 4 1 2 3 1 Seat lock lever 1 ...

Page 33: ... 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 Projection 2 Seat holder 1 2 ...

Page 34: ...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 6 5 3 Engine oil Check oil level in engine and add recommended oil to specified level if necessary Check ATV for oil leakage Correct if necessary 5 3 8 9 Transmission oil Check oil level in transmission case and add r...

Page 35: ...f necessary 5 3 8 32 8 35 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 36 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 5 5 Instruments lights and swi...

Page 36: ...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 brakes for wear See page 8 26 EBU19761 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dea...

Page 37: ...e 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 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire Recommended tire pressure Front 20 0 kPa 0 200 kgf cm2 2 9 psi Rear 25 0 kPa 0 250 kgf cm2 3 6 psi Minimum tire pressu...

Page 38: ...maha Motor Co Ltd Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling braking and comfort Other tires rims sizes and combinations may not be appropriate EBU19840 Chassis fasteners Make sure that all nuts bolts and screws are prop 1 Tire wear limit Front Manufacturer model DUNLOP KT...

Page 39: ...ned 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 39 ...

Page 40: ...gine for the first time 1 Set the parking brake 2 Turn the fuel cock to ON 3 Turn the key to ON 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 only when the drive se lect lever is in the neutral ...

Page 41: ...rter choke in position 1 the starter choke should be returned to position 2 to warm up the engine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly then return the starter choke to position 3 before riding TIP The engine is warm when it responds normally to the throttl...

Page 42: ...ng 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 into reverse make sure there are no people or ob stacles behind you When...

Page 43: ... 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 on it for the...

Page 44: ...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 45: ...rket 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 s design...

Page 46: ...essories 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 weight in the maximum ATV load limit Load cargo on the carriers...

Page 47: ... 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 ...

Page 48: ...7 1 1 2 3 4 5 6 7 8 9 10 11 EBU21141 RIDING YOUR ATV ...

Page 49: ...artic ular attention to the safety information on pages 2 1 2 4 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 does not know how to operate the ATV properly in ...

Page 50: ...h 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 WARNING Never carry a passenger Carrying a passenger on...

Page 51: ...ty of injuries in an accident WARNING 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...

Page 52: ...cident EWB01421 Pre operation checks Always inspect your ATV each 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 o...

Page 53: ...ng can increase the risk of loss of control an overturn or other ac cident To reduce the risk of an accident Do not exceed the maximum loading limits for the vehicle see box in this section or ve hicle 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 c...

Page 54: ...ING Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident EWB01471 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an ...

Page 55: ...ark 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 and remain h...

Page 56: ...lks 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 Watch carefully for other vehicles Make sure you know your country s laws and regulations before you ride on unpaved public streets or roads Do not ride on any paved public street road or motorway WARNING Ne...

Page 57: ...xtra 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 the skills nec essary to control the ATV on such terrain Always be especially cautious on these kinds of terrain WARNING Failure to use extra care when op erating on excessively roug...

Page 58: ... 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 ...

Page 59: ...f directional control Avoid higher speeds 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 t...

Page 60: ...oose 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 turn may cause the ATV to tip If the ATV begi...

Page 61: ...ght 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 level ground Be very careful when turning on a...

Page 62: ...p 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 If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front...

Page 63: ...n the hill where possi ble Improper braking can cause the wheels on the uphill side to come off the ground or cause loss of traction Gradually apply only the rear brake when going downhill When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as pos sible Move back on the seat and sit with your arms straight Engine compression will do most of the braking for...

Page 64: ...ersing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slip pery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to cor...

Page 65: ...an overturn The ATV can be used to cross slow moving shal low water of up to a maximum of 20 cm 8 in in depth Before entering the water choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or upset the ATV Drive slowly and care fully Test your brakes after leaving the water If neces sary apply them several times to let friction ...

Page 66: ...ose at the bottom of the air filter case Also remove the V belt case drain plug to drain any water that may have accumulated NOTICE Undrained water can cause damage or improper operation ECB00841 Wash the ATV in fresh water if it has been operat ed in salt water or muddy conditions 1 Air filter case check hose 1 V belt case drain plug 1 1 ...

Page 67: ...f 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 re gain traction unexpectedly which may cause the ATV to overturn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very c...

Page 68: ...t 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 12 If your ATV begins to tip while turning Lean more into the turn to regain balance If nec essary gradually let off the throttle and or steer to the outside of the turn See ...

Page 69: ... 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 17 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let wa ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until y...

Page 70: ...f 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 1 for more information about carbon monoxide The intervals given in ...

Page 71: ...he 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 tire gauge 3 Owner s tool kit 1 2 3 ...

Page 72: ...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 73: ...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 74: ...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 75: ... 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 for oil leakage and ...

Page 76: ...ary Lubricate throttle lever housing and cable 20 Front and rear brake switches Check operation and correct if necessary 21 Lights and switches Check operation and correct if necessary Adjust headlight beams 22 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 c...

Page 77: ...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 78: ...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 EBU23266 Engine oil The engine oil level should be checked before each ride In addition the ...

Page 79: ...er cap and then wipe the engine oil 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 NOTICE Be su...

Page 80: ...olt to drain the oil from the crankcase NOTICE When remov ing the engine oil drain bolt the compres sion spring oil strainer and O ring will fall out Take care not to lose these parts ECB00311 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 sp...

Page 81: ...tely 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 EBU27025 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 periodic maintenance and lubrication chart To check the transmission oil ...

Page 82: ...w hole 6 Install the transmission oil check screw and transmission oil filler bolt and then tighten them to the specified torques 1 Transmission oil check screw 2 Transmission oil level check hole 3 Correct oil level 1 3 2 1 Transmission oil filler bolt Tightening torque Transmission oil check screw 16 Nm 1 6 m kgf 11 6 ft lbf Transmission oil filler bolt 23 Nm 2 3 m kgf 16 6 ft lbf 1 ...

Page 83: ... Refill with the specified amount of the recom mended transmission oil and then install and tighten the oil filler bolt NOTICE Make sure that no foreign material enters the trans mission case ECB00791 NOTICE ECB01061 Make sure that no oil gets on the tires or wheels 7 Start the engine and then let it idle for several minutes while checking the transmission for 1 Transmission oil drain bolt 1 Tight...

Page 84: ... 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 Place the ATV on a level surface 2 Remove the seat See page 4 10 3 Remove the breather ...

Page 85: ...r by removing the screws 5 Pull the air filter element out of the air filter case 6 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 86: ...erial and let it dry NOTICE Do not twist the sponge material when squeezing it ECB00441 9 Check the sponge material and replace it if damaged 10 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 11 Pull the sponge material over the air filter ele ment frame 12 Install the washer and bolt NOTICE Be s...

Page 87: ...over by installing the screws 15 Install the breather hose and then tighten the clamp screw 16 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 a...

Page 88: ...8 19 1 2 3 4 5 6 7 8 9 10 11 3 Remove the panel shown by removing the quick fasteners 4 Disconnect the coupler shown 1 Bolt 2 Front carrier 2 1 1 1 1 Panel 2 Quick fastener 1 2 2 1 ...

Page 89: ...8 20 1 2 3 4 5 6 7 8 9 10 11 5 Remove the air filter case cover by removing the screw 6 Remove the air filter element 1 Panel 2 Coupler 1 2 1 Air filter case cover 2 Screw 1 2 ...

Page 90: ... it if damaged 9 Install the air filter element into the air filter case 10 Install the air filter case cover by installing 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 EBU27630 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be 1 Air filter element 1 1 Air filter elemen...

Page 91: ...of the tailpipe and inside of the tailpipe housing 4 Insert the tailpipe into the muffler and align the screw holes 5 Install the screws and tighten them WARNING EWB02340 Do not start the engine when cleaning the spark arrester otherwise it could cause injury to the eyes burns carbon monoxide poison ing possibly leading to death and start a fire Always let the exhaust system cool prior to 1 Screw ...

Page 92: ...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 tested at the Y...

Page 93: ...cification 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 EBU24045 Adjusting the throttle cable free play The throttle cable free play should be check...

Page 94: ...To increase the throttle cable free play turn the throttle cable free play adjusting bolt in di rection a To decrease the throttle cable 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 ...

Page 95: ...e front 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...

Page 96: ...cified 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 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 ...

Page 97: ...8 28 1 2 3 4 5 6 7 8 9 10 11 2 Remove the panel shown by removing the quick fasteners then disconnect the coupler shown 1 Front carrier 2 Bolt 1 2 2 2 1 Panel 2 Quick fastener 1 2 2 1 ...

Page 98: ... 9 10 11 3 Remove the V belt air filter element cover by removing the screw 4 Loosen the locknut and fully turn in the adjust ing bolt at the brake lever 1 Panel 2 Coupler 1 2 1 V belt air filter element cover 2 Screw 1 2 ...

Page 99: ... 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 Locknut 2 Brake lever free play adjusting bolt 1 2 1 Brake equalizer 2 Cable joint a a a a 1 2 ...

Page 100: ...ter element cover by in stalling 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 EBU24492 Adjusting the rear brake lever free play The brake lever free play must be checked and if necessary adjusted at the intervals specified in 1 Locknut 2 Adjusting nut 1 2 2 1 1 Locknut 2 Brake lever free play adj...

Page 101: ...ar wheel hub in direction a to increase the free play and in direction b to decrease it If the correct free play cannot be obtained have a Yamaha dealer adjust it EBU24873 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 TIP When checking and adjusting the drive chain slack there s...

Page 102: ... stopper bolt 3 Loosen the axle holding bolts 4 Loosen the chain adjusting bolt locknut To tighten the drive chain turn the adjusting 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 the engine as well as other vital parts of the ATV and can lead to drive chain slippage or break Dri...

Page 103: ...cified torques NOTICE ECB00550 If measurement A of the drive chain adjust ing 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 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 lower 60 Nm 6 0 m kgf 43 4 ft lbf ...

Page 104: ...in dusty or wet areas Service the drive chain as follows NOTICE ECB00560 The drive chain must be lubricated after wash ing the ATV or riding in the rain 1 Clean the drive chain with kerosene and a small soft brush NOTICE To prevent 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 ...

Page 105: ...Corrosion can result when the cable sheaths become damaged and cables can also become frayed or kinked which could restrict the operation of controls and lead to an accident or injury Always make sure all control cables 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 de...

Page 106: ...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 the intervals specified in the periodic mainte nance and lubrication chart Lubricate the pivoting points using a grease gun Left side Recommended lubricant Lithium soap based gre...

Page 107: ...n chart Lubricate the front knuckle pivots using a grease gun EBU25090 Lubricating the steering shaft The steering shaft must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart Lubricate the steering shaft using a grease gun 1 Grease nipple Recommended lubricant Lithium soap based grease 1 1 1 Grease nipple Recommended lubricant Lithium soap based grease 1...

Page 108: ...ica tion chart To check the electrolyte level 1 Place the ATV on a level surface 2 Check the electrolyte level in the battery TIP The electrolyte should be between the minimum 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...

Page 109: ...al attention Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ig nition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN 4 Check and if 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 remo...

Page 110: ...er necessary 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 3 Make sure that the breather hose is properly routed in good condition and not obstructed NOTICE If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the bat tery the frame...

Page 111: ...TV If the fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits NOTICE ECB00640 To prevent accidental short circuiting turn off the main switch when checking or replacing a 1 Battery 2 Negative battery lead black 3 Positive battery lead red 1 2 3 1 Fuse 2 Spare fuse 1 2 ...

Page 112: ...ical 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 Remove the headlight...

Page 113: ...y of the bulb and the bulb life will be 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 ov...

Page 114: ... direction a To lower a headlight beam turn the adjusting screw in direction b EBU25611 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove the bulb holder together with the bulb by turning it counterclockwise 2 Remove the burnt out bulb by pushing it in and turning it counterclockwise 1 Headlight beam adjusting screw 1 a b 1 Tail brake light b...

Page 115: ...g a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 3 Elevate the ATV 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 ...

Page 116: ...mple can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself However should your ATV re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may...

Page 117: ...NG EWB02280 Do not smoke when checking the fuel system Fuel can ignite or explode causing severe inju ry or property damage Make sure there are no open flames or sparks in the area including pi lot lights from water heaters or furnaces ...

Page 118: ...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 119: ...eds to let friction dry out the lin ings EWB02311 NOTICE Excessive water pres sure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car washers ECB00711 4 Once most of the dirt has been hosed off wash all s...

Page 120: ... 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 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 hea...

Page 121: ... 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 more than 30 C 90 F For more in formation on storing the battery see page 8 39 TIP Make any necessary repairs before storing the ATV ...

Page 122: ...335 lb Noise and vibration level Noise level 77 311 EEC 75 1 dB A Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s2 Vibration on handlebar EN1032 ISO5008 Will not exceed 2 5 m s2 Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 124 cm3 Bore stroke 49 0 66 0 mm 1 93 2 60 in Compression ratio 9 00 1 Starting system Electric starte...

Page 123: ...rve 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 Transmission ...

Page 124: ...ssories 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 Panel wheel Rim size 8 x 8 0AT Front brake Type Drum brake Operation Right hand operation Rear bra...

Page 125: ...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 30 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 126: ...arts 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 EBU26041 Vehicle identification number The vehicle identification numbe...

Page 127: ...nti 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 0 0 8 2008 9 2009 A 2010 B 2011 I O Q U Z not used 1 2 ...

Page 128: ...11 3 1 2 3 4 5 6 7 8 9 10 11 1 Model label 1 ...

Page 129: ...Chassis fasteners 5 5 Cleaning 9 1 D Drive chain 5 3 Drive chain lubricating 8 35 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 23 Engine oil 5 3 8 9 Engine starting a warm 6 2 Engine stop switch 4 2 F Front knuckle pivots lubricating 8 38 Fuel 4 6 5 3 Fuel cock 4 8 Fuel tank cap 4 6 Fus...

Page 130: ...eaning 8 21 Spark plug checking 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 37 T Tail brake light bulb replacing 8 45 Throttle cable free play adjusting 8 24 Throttle lever 4 3 5 3 Tires 5 3 Transmission oil 5 3 8 12 Troubleshooting 8 47 Troubleshooting chart 8 49 V ...

Page 131: ......

Page 132: ...PRINTED IN JAPAN 2009 03 0 1x1 E YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER ...

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