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Yamaha GRIZZLY 125, Owner'S Manual

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Yamaha GRIZZLY 125 Owner'S Manual Download Page 99

 

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EBU24043

 

Adjusting the throttle 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.

NOTE:

 

The engine idling speed must be checked, and ad-
justed if necessary, before adjusting the throttle ca-

 

ble free play.

1. Loosen the locknut.
2. To increase the throttle cable free play, turn

the adjusting bolt in direction (a). To decrease
the throttle cable free play, turn the adjusting
bolt in direction (b).

3. Tighten the locknut.

 

EBU24060

 

Valve clearance 

 

The valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.

 

1. Locknut
2.  Throttle cable free play adjusting bolt
3.  Throttle cable free play

3

1

2

(a)

(b)

Summary of Contents for GRIZZLY 125

Page 1: ...hould not be ridden by anyone under 16 years of age OWNER S MANUAL 1C5 28199 14 YFM125GX READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 2: ......

Page 3: ...f this ATV y information It provides information about special tech ATV It also includes basic maintenance and inspection proce g the operation or maintenance of your ATV please consult a H TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS RNING AND CAUTION LABELS ON THE ATV PROPER TRAINING OR INSTRUCTION FREE TRAINING IS A NEW ATV CALL 1 800 887 2887 FOR MORE...

Page 4: ...s change without notice Alert Symbol means ATTENTION BECOME ALERT YOUR NVOLVED ollow WARNING instructions could result in severe injury the ATV operator a bystander or a person inspecting or e ATV indicates special precautions that must be taken to avoid he ATV vides key information to make procedures easier or clearer ...

Page 5: ...laws and regulations in gulations before operating this ATV YFM125GX OWNER S MANUAL 2007 by Yamaha Motor Corporation U S A 1st edition March 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 21 05 ...

Page 6: ... choke 4 11 Seat 4 11 Front carrier 4 12 Rear carrier 4 12 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 5 Measuring the tire pressure 5 6 Tire wear limit 5 7 Chassis fasteners 5 7 Instruments lights and switches 5 7 Battery 5 7 OPERATION 6 1 Starting a cold engine 6 1 ...

Page 7: ...sting the engine idling speed 8 24 Adjusting the throttle cable free play 8 25 Valve clearance 8 25 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 32 Drive chain slack 8 33 Lubricating the drive chain 8 36 Checking and lubricating the cables 8 37 Checking and lubricating the front and rear brake levers 8 37 Che...

Page 8: ... 8 43 8 44 8 46 8 46 8 47 8 48 8 49 8 50 9 1 9 1 9 2 10 1 11 1 11 1 11 3 11 4 11 5 11 7 ...

Page 9: ...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 streets Never operate an ATV on any public street road or highway even a dirt or gravel one Never operate an ATV without wearing an ap proved motorcycle helmet that fits properly You should also wear eye protection goggles or face shie...

Page 10: ... for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ve hicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Av...

Page 11: ...e of tires specified in this manual Always maintain proper tire pressure as de scribed in this manual Never modify an ATV through improper installa tion or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow in structions in this manual for carrying cargo or pulling a trailer Allow greater distance f...

Page 12: ... should swallow some gasoline or in hale a lot of gasoline vapor or get some gas oline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes WARNING POTENTIAL HAZARD Starting or running the engine in a closed ar ea ...

Page 13: ...1 5 1 2 3 4 5 6 7 8 9 10 11 d may h with ith ad ...

Page 14: ...2 1 RNING AND SPECIFICATION LABELS 6 8 2 3 7 8 5 ...

Page 15: ...Set with tires cold Recommended FRONT 20 kPa 0 20 kgf cm 2 2 9 psi REAR 25 kPa 0 25 kgf cm 2 3 6 psi Minimum FRONT 17 kPa 0 17 kgf cm 2 2 5 psi REAR 22 kPa 0 22 kgf cm 2 3 2 psi Never set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING Maximum Vehicle Load 105 kg 231 lbs Includes weight of operator cargo and accessories WARNING NEVER ride as a passenger Passeng...

Page 16: ...fully before operating 8 When shifting the drive select lever always be sure to stop the ATV and apply the rear brake 5kg 11lbs 3LD 24877 A0 10kg 22lbs 1C5 24877 A0 sit here NEVER 3MX 24875 A0 EVERE R USE DRUGS LCOHOL on ur lance errain y ol AL NINGS 1558 5 6 7 8 ...

Page 17: ...3 1 1 2 3 4 5 6 7 8 9 10 11 DESCRIPTION EBU17700 Right view 5 6 1 Seat 2 Drive select lever 3 Headlight 1 2 3 ...

Page 18: ...3 2 slightly from the figures shown in this manual ...

Page 19: ...4 1 1 2 3 4 5 6 7 8 9 10 11 AND CONTROL FUNCTIONS esult in lows wer and ot be re n be re 1 Main switch OFF ON 1 ...

Page 20: ...re starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run when this switch is set to OFF 1 Engine stop switch ENG STOP 2 Start switch START 3 Light switch LIGHTS 3 1 2 ...

Page 21: ...ed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decelerate and the engine will return to an idle any time the hand is removed from the throttle lever Before starting the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released 1 Throttle lever 1 ...

Page 22: ...nd the maximum speed of the ATV turn the adjusting screw in direction b 3 Tighten the locknut EWB00190 aking when ent er be work ct the sult a ve the 1 Adjusting screw 2 Locknut 3 No more than 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle 3 1 2 a b ...

Page 23: ...handle ke lever 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 d Im t You r be in more ure the 1 0 3 0 1 Front brake lever 1 ...

Page 24: ...4 6 ngine or pply the plate to r brake EWB00170 1 Parking brake lock plate 2 Parking brake lever locked position WARNING POTENTIAL HAZARD Improper use of the parking brake 2 1 ...

Page 25: ... See the ng in re ect lever EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise edly if e start of con he ATV e You could ear out tarting e park 1 Neutral N 2 Forward F 3 Reverse R 4 Drive select lever 1 2 3 4 ...

Page 26: ... leaded gasoline will cause severe damage to internal engine parts such as the valves and piston 1 Fuel level 2 Fuel tank filler tube Recommended fuel UNLEADED GASOLINE ONLY 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 ...

Page 27: ...wn in the illustrations WHAT CAN HAPPEN Fuel can spill which can cause a fire and se vere injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank...

Page 28: ... position 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 ON ON FUEL RES OFF ON 1 ...

Page 29: ...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 the rear 1 Fully open 2 Half open 3 Closed 4 Starter choke b a 4 1 2 3 ...

Page 30: ...d 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 EBU18970 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 Projection 2 Seat holder 1 2 ...

Page 31: ...4 13 1 2 3 4 5 6 7 8 9 10 11 esult in ...

Page 32: ... has to be performed by a Yamaha dealer Refer to the periodic ine which service should be performed by a Yamaha dealer WARNING ating t or equipment damage u use it to make sure it is in safe operating condition tenance procedures and schedules described in the Own ...

Page 33: ...8 27 and correct if necessary necessary lay and adjust if necessary 5 3 8 26 8 32 eration is smooth Lubricate cable and lever hous play and adjust if necessary 5 4 8 25 eration is smooth Lubricate if necessary 8 37 and adjust if necessary tion Lubricate if necessary 5 4 8 33 8 36 ition and replace if damaged n and tread depth Replace if necessary e Correct if necessary 5 5 5 6 5 7 eration is smoot...

Page 34: ... 8 32 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 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 EWB00530 nd se e fuel due to ...

Page 35: ...5 4 1 2 3 4 5 6 7 8 9 10 11 It must position orrect if d check just the could f every y prob not be es pro hecked ...

Page 36: ...37A Size AT22 x 10 8 Type Tubeless The tires should be set to the recommend ed pressure Recommended tire pressure Front 20 0 kPa 2 9 psi 0 20 kgf cm2 Rear 25 0 kPa 3 6 psi 0 25 kgf cm2 Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides ...

Page 37: ...he Dust or dirt in the gauge could cause the first reading to be incorrect Set the tire pressure when the tires are cold Set the tire pressures to the following specifications speci e from ns 2 2 ssures n may s very 1 Low pressure tire gauge 1 ...

Page 38: ...s are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary EBU19860 Battery Check the fluid level in the battery Fill with distilled water if necessary See page 8 40 1 Tire wear limit ...

Page 39: ...n switch to ON and the engine stop switch to RUN 4 Shift the drive select lever into the neutral po sition The neutral indicator light should come with all n acci here is stand WARNING POTENTIAL HAZARD Frozen control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always m...

Page 40: ...gine by pushing the start switch NOTE If the engine fails to start release the start switch then push it again Pause a few seconds before the next attempt Each cranking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each 1 Fully open 2 Half open 3 Closed 4 Starter choke 1 2 3 4 1 2 3 1 2 3 ...

Page 41: ... drive select lever and driving in reverse CAUTION ECB00170 Before shifting stop the ATV otherwise the transmission 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 NOTE Make sure that the drive select lever is completely shifted into position ...

Page 42: ...le backing NOTE If the drive select lever is shifted into reverse while the engine is running the engine will stop unless the rear brake lever or parking brake is applied EWB00670 WARNING POTENTIAL HAZARD Improper operation in reverse WHAT CAN HAPPEN You could hit an obstacle or even a person behind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there...

Page 43: ...e Rev the engine freely but do not use full throttle at any time 320 km 200 mi or 20 hours and beyond The ATV can now be operated normally CAUTION ECB00220 If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the ATV EBU20700 Parking When parking the ATV stop the engine shift the drive select lever into the forward position apply the parking b...

Page 44: ...AZARD Avoid parking on hills or other inclines If you must park on an incline place the ATV trans versely across the incline shift the drive se lect lever to the forward position stop the engine apply the parking brake and then block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easily ...

Page 45: ...U21070 Loading As originally equipped this ATV is not designed to tow a trailer If you choose to add accessories so that you can tow a trailer you must use common sense and good judgment as the stability and han dling of an ATV can be changed When adding ac cessories keep the following points in mind Never exceed the weight limits shown An over loaded ATV can be unstable If you are carrying cargo ...

Page 46: ...t could result in serious injury or death owing WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing ...

Page 47: ...7 1 1 2 3 4 5 6 7 8 9 10 11 DING YOUR ATV ...

Page 48: ...uctor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until you are totally familiar with the ATV s handling and performance characteristics EWB01280 WARNING POTENTIAL HAZARD Operating this ATV without proper instruc tion WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not...

Page 49: ...rs This ATV is designed to carry operator and cargo only passengers prohibited erators course n regu course bed in mation autho 7 ations ecom e inju HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc ...

Page 50: ...7 4 e and ident ssen t is to eeded g pas ...

Page 51: ...of dent ng in in the HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants 1 Protective clothing 2 Goggles 3 Gloves 4 Boots 5 Helmet ...

Page 52: ...fore or while driving this ATV WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and mainte nance procedures and sche...

Page 53: ...wer available and de creases the maximum speed of the ATV Turning in the adjusting screw decreases top speed and turning it out increases top speed See page 4 4 res or opera en tire creas ecified n page as de e 5 6 WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can result in ...

Page 54: ... weight of cargo rider accessories and tongue 105 0 kg 231 lb Front carrier 5 0 kg 11 lb Rear carrier 10 0 kg 22 lb WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident ...

Page 55: ...7 9 1 2 3 4 5 6 7 8 9 10 11 uring op he rear ity for nd se or pull r brak r Own lling a ...

Page 56: ... with ou or ebars r ATV other WHAT CAN HAPPEN Increases the chance of an accident includ ing an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off WARNING POTENTIAL HAZARD Operating this ATV with improper modifica tions ...

Page 57: ...combustible ma terial accumulated around the engine area could catch fire Someone touching the exhaust system dur ing or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exhaust system Do not park the ATV in a place where ...

Page 58: ... on any public road street or highway Riding on public roads can result in collisions with other vehicles only han cause HOW TO AVOID THE HAZARD Always avoid paved surfaces including side walks driveways parking lots and streets ...

Page 59: ...ING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operat ing on unfamiliar terrain Always be alert to changing terrain conditions when operating t...

Page 60: ...TV DO NOT use the flag pole bracket as a trailer hitch ng on rrain ontrol uding HOW TO AVOID THE HAZARD Do not operate on excessively rough slip pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especial ly cautious on these kinds of terrain ...

Page 61: ...trol 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 off road use only and handling maneuvers are more difficult to perform on pavement Set the parking brake and follow the instruction on page 6 1 to start the engine Once it has warmed up you are ready to begin riding y...

Page 62: ...e turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causing a colli sion or overturn HOW TO AVOID THE HAZARD A...

Page 63: ... 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 ground before attempting any in cline and then practice riding fi...

Page 64: ...er s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively 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 ...

Page 65: ...ever 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 any hill Avoid crossing the side of a steep hill if pos sible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shi...

Page 66: ... when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking brake after you are stopped If you begin rolling backwards Keep weight uphill Never apply the rear brake while rolling backwards Apply the front brake When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to a side if pointed straight uphill ...

Page 67: ... ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owner s Man ual Note a special technique is required when braking as you go down a hill Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ATV to lean ...

Page 68: ...th As you regain proper balance gradually steer again in the direction you wish to travel EWB01141 WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never 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...

Page 69: ...perating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an acci dent HOW TO AVOID THE HAZARD 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 re duced stopping ability Test your brakes af ter leaving water If neces...

Page 70: ...r 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 ...

Page 71: ...TV may re sult EWB01160 SLIDING AND SKIDDING Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for ob stacles Never attempt to ride over large...

Page 72: ...ding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are re duced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost EWB01170 WARNING POTENTIAL HAZARD Skidding or sliding improperly ...

Page 73: ...around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 17 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to m...

Page 74: ...7 28 moving let wa YOUR N when inue to equate esult in ...

Page 75: ... to put this owner s manual in the plastic bag and to always carry it as well as the owner s tool kit and the low pressure tire gauge in their re spective compartments under the seat arts of cks or HOW TO AVOID THE HAZARD Turn off the engine when performing mainte nance unless otherwise specified Have a Yamaha dealer perform the service if you are not familiar with maintenance work ...

Page 76: ...this ATV may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult...

Page 77: ... month maintenance e performed by a Yamaha dealer as they require special tools TENANCE 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 s for cracks or other damage and ary and clean regap or replace if rance and adjust if necessary hoke operation and correct if nec ing speed and adjust if neces hose for cracks or o...

Page 78: ...and replace gasket s if neces ess and tighten all screw clamps ssary TENANCE 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 79: ... hours more often in wet or dusty areas and correct if necessary er free play and adjust if neces hoes Whenever worn to the limit and correct if necessary er free play and adjust if neces hoes Whenever worn to the limit d for damage and replace if nec h and for damage and replace if re and balance and correct if ess or damage and replace if k and adjust if necessary l alignment and correct if nece...

Page 80: ...e and repair or replace if damaged adjust if necessary leakage and correct if neces leakage and correct if neces and correct if necessary ble free play and adjust if neces lever housing and cable and correct if necessary TENANCE 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 81: ...ly wet or dusty areas and correct if necessary beams e level and specific gravity and ary he breather hose is properly TENANCE 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 82: ...8 8 esult in ponent eposits e spark accor ubrica e spark 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit 1 Spark plug cap 1 ...

Page 83: ... replace it if necessary To install the spark plug 1 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification 2 Clean the surface of the spark plug gasket 1 Specified spark plug NGK CR7HSA Spark plug gap 0 6 0 7 mm 0 024 0 028 in 1 Spark plug gap ...

Page 84: ...efore checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil set tles for an accurate reading 3 Remove the engine oil filler cap and then wipe the 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 1 Dipstick 1 ...

Page 85: ...the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase CAUTION ECB00310 When removing the engine oil drain bolt the compression spring oil strainer and O ring will 1 Engine oil drain bolt 2 O ring 3 Spring 4 Oil strainer 1 4 3 2 1 ...

Page 86: ...inutes 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 EBU27021 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 periodi...

Page 87: ...t 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 Transmission oil filler bolt 1 ...

Page 88: ... then tighten it to the specified torque 6 Add the specified amount of the recommend ed transmission oil and then install and tight en the oil filler bolt 1 Transmission oil drain bolt Tightening torque Transmission oil drain bolt 23 Nm 2 3 m kgf 16 6 ft lbf 1 ...

Page 89: ...r filter elements Both air filter elements should be cleaned at the specified intervals in the periodic maintenance chart Engine air filter element NOTE There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air fil ter case 1 Check hose 1 ...

Page 90: ...moving 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 1 Air filter case cover 2 Screw 1 2 2 2 2 ...

Page 91: ...TION ECB00440 Do not twist the sponge material when squeez ing it 8 Check the sponge material and replace it if damaged 9 Apply Yamaha foam air filter oil or other qual ity foam air filter oil to the sponge material line to e can 2 1 HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material ...

Page 92: ...d 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 CAUTION ECB00460 Make sure that the air filter element is prop erly seated in the air filter case Never operate the e...

Page 93: ...8 19 1 2 3 4 5 6 7 8 9 10 11 sequent ne over ving the ving the 3 Disconnect the coupler shown 1 1 Panel 2 Quick fastener 1 2 2 1 ...

Page 94: ...8 20 moving 5 Remove the air filter element 1 Air filter case cover 2 Screw 1 2 ...

Page 95: ...t 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 EBU23891 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be 1 Air filter element 1 ...

Page 96: ...ert the tailpipe into the muffler and align the screw holes 5 Install the screws and tighten them EWB01910 1 Screw 2 Gasket 3 Tailpipe 4 Spark arrester WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system 3 4 2 1 ...

Page 97: ...nd lubrication chart The carburetor is an important part of the engine and requires very sophisticated adjustment Therefore most carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience The adjustment described in the following section however may be performed by the owner as part of routine main tenance oning rior to the ex 1 V belt cas...

Page 98: ...he 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 NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment 1 Throttle stop screw Engine idling speed 1650 1750 r min a b 1 ...

Page 99: ...e clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the inter vals specified in the periodic maintenance and lu brication chart 1 Locknut 2 Throttle cable free play adjusting bolt 3 Throttle cable free play 3 1 2 a b ...

Page 100: ...8 26 e hecked periodic brake is s you to to dis e shoe or while n to the ear limit ace the Front brake 1 Wear limit line 2 Wear indicator 1 2 ...

Page 101: ...4 5 6 7 8 9 10 11 ee d and if cified in hart y check 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 Brake lever free play 1 ...

Page 102: ...8 28 ing the coupler 2 1 Panel 2 Quick fastener 1 2 2 1 ...

Page 103: ...8 29 1 2 3 4 5 6 7 8 9 10 11 cover by 4 Loosen the locknut and fully turn in the adjust ing bolt at the brake lever 1 V belt air filter element cover 2 Screw 1 2 ...

Page 104: ...8 30 equaliz d If the cknuts he front ecomes 1 Brake equalizer 2 Cable joint a a a a 1 2 ...

Page 105: ...9 Install the V belt air filter 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 1 Locknut 2 Brake lever free play adjusting bolt 3 Brake lever free play 3 1 2 b a ...

Page 106: ...free play is in correct adjust it as follows Turn the brake lever free play adjusting nut on the rear 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 or ad could oothly quires dures ler 1 Brake lever free play 1 ...

Page 107: ...d 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 or ad could HOW TO AVOID THE HAZARD 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 profes...

Page 108: ...ocknut 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 1 Hub stopper bolt 2 Locknut 3 Axle holding bolt lower 4 Axle holding bolt upper 1 2 3 4 ...

Page 109: ...ement A of the drive chain adjust ing bolt is less than 27 mm 1 06 in have a Yamaha dealer replace the drive chain 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 110: ...ed after wash ing the ATV or riding in the rain 1 Clean the drive chain with kerosene and a small soft brush CAUTION ECB00570 To prevent damaging the O rings do not clean the drive chain with steam cleaners high pres sure washers or inappropriate solvents 2 Wipe the drive chain dry 1 O ring 1 ...

Page 111: ...levers should be checked before each ride and the lever pivots should be lubricated if necessary WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged and cables can also be come frayed or kinked which could restrict the operation of controls and lead to an acci dent or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Recommended lubricant Silico...

Page 112: ...is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bear ings EBU25030 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 Recommended lubricant Lithium soap based grease ...

Page 113: ...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 1 Grease nipple Recommended lubricant Lithium soap based grease 1 1 ...

Page 114: ... 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 NOTE The electrolyte should be between the minimum and maximum level marks 1 Battery 2 Battery breather hose 3 Guide 1 2 3 ...

Page 115: ...yte Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Al ways shield eyes when working near batter ies Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical at tention EYES Flush with water for 15 minutes and get pr...

Page 116: ...k the specific gravity of the elec trolyte at least once a month and fully charge the battery whenever necessary To install the battery NOTE 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 ...

Page 117: ...use holder is located on the right side of the ATV If the fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits CAUTION ECB00640 To prevent accidental short circuiting turn off the main switch when checking or replacing a 1 Fuse 2 Spare fuse 1 2 ...

Page 118: ...l a ectrical have a stem ollows 1 Remove the cover at the rear of the headlight by pulling it off 2 Remove the bulb holder cover by pulling it off to the a fire ating proper 1 Cover at the rear of the headlight 1 ...

Page 119: ...OTENTIAL HAZARD A headlight bulb is hot when it is on and im mediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flammable HOW TO AVOID THE HAZARD Wait for the headlight bulb to cool before touching or removing it 1 Headlight bulb 1 ...

Page 120: ...ing djusting EBU25610 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Headlight beam adjusting screw 1 a b ...

Page 121: ...lb 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 EBU25650 Removing a wheel 1 Loosen the wheel nuts 1 Tail brake light bulb 2 Tail brake light bulb holder 1 2 ...

Page 122: ...ide to wards the wheel 2 Lower the ATV to the ground 3 Tighten the wheel nuts to the specified torques 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 39 8 ft lbf Rear wheel nut 55 Nm 5 5 m kgf 39 8 ft lbf 1 ...

Page 123: ...ents a ese vital ATV re whose s expe properly arts Im but they life and ing or ere in HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys tem Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces ...

Page 124: ...dry cloth and correct the rk plug gap or replace the spark plug ve 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 ver ver The battery is good Check the electrolyte level recharge the battery and check the lead connections Open the throttle halfway and operate the electric starter ...

Page 125: ...d toothbrush or bot tle brush is handy for hard to reach places 5 Rinse the ATV off immediately with clean wa ter and dry all surfaces with a chamois clean towel or soft absorbing cloth 6 Dry the chain and lubricate it to prevent it from rusting 7 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 8 Automotive type wax may be applied to all painted and chrome plate...

Page 126: ...ent 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 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...

Page 127: ... g on the des are g during mes with der wall he spark lug and pivoting tire air so that ernative in order egraded c bag to it Store once a n exces 0 C 30 more in ee page 8 40 NOTE Make any necessary repairs before storing the ATV ...

Page 128: ...ion system Wet sump Engine oil Type YAMALUBE 4 SAE5W30 or SAE10W30 or SAE20W40 Recommended engine oil grade API service SE SF SG type or higher 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 YAMALUBE 4 CW 5W30 or SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 ...

Page 129: ...econdary reduction system Chain drive Secondary reduction ratio 32 12 2 666 Transmission type V belt automatic Operation Centrifugal automatic type Reverse gear 49 14 49 15 40 17 26 902 Chassis Frame type Steel tube frame Caster angle 6 0 Trail 15 0 mm 0 59 in Front tire Type Tubeless Size AT20 x 7 8 Manufacturer model DUNLOP KT536A ...

Page 130: ...rake Operation Right hand operation Rear brake Type Drum brake Operation Left hand operation Front suspension Type Swing axle Spring shock absorber type Coil spring oil damper Wheel travel 70 mm 2 8 in Rear suspension Type Swingarm Spring shock absorber type Coil spring oil damper Wheel travel 80 mm 3 1 in ...

Page 131: ...10 4 1 2 3 4 5 6 7 8 9 10 11 ...

Page 132: ...n number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key identification number 1 ...

Page 133: ...11 2 1 2 3 4 5 6 7 8 9 10 11 o identi n the il label in e need ha deal 1 Model label 1 ...

Page 134: ... element of de the purpose of noise control prior to its sale or delivery to the 2 the use of the vehicle after such device or element of design by any person CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW wing systems i e modification removal etc haust system ffler haust pipe encer ke system cleaner case cleaner element ake duct ...

Page 135: ...9 10 11 arts you purchase and install will be required to document main anty The chart below is printed only as a reminder to you that the eptable proof of maintenance work MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS ...

Page 136: ... of manufacture and that it is defects in materials and workmanship uld cause it not to meet these standards within the period listed immediately below Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and or lack of proper maintenance are not covered by this warranty All Models Thirty 30 months from the original purchase date...

Page 137: ...TIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model V I N frame number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a s...

Page 138: ... are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period Y E S coverage is honored at any authorized Yamaha dealer nationwide Y E S coverage is transferable to a new owner if you sell or trade in your ATV That can make your Yamaha much more valuable This excellent Y E S pl...

Page 139: ...11 8 1 2 3 4 5 6 7 8 9 10 11 benefits of y knowing after your also save after you maha with We ll be d Indicates a potential hazard that could result in serious injury or death WARNING ...

Page 140: ...11 9 ...

Page 141: ...gine starting a warm 6 3 Engine stop switch 4 2 F Front knuckle pivots lubricating 8 39 Fuel 4 8 5 3 Fuel cock 4 9 Fuel tank cap 4 7 Fuse replacing 8 43 H Handlebar switches 4 2 Headlight beam adjusting 8 46 Headlight bulb replacing 8 44 I Identification numbers 11 1 Indicator lights 4 2 Instruments lights and switches 5 7 K Key identification number 11 1 L Label locations 2 1 Light switch 4 3 ...

Page 142: ...46 Throttle cable free play adjusting 8 25 Throttle lever 4 3 5 4 Tire pressure measuring 5 6 Tires 5 5 Tire wear limit 5 7 Transmission oil 5 3 8 12 Troubleshooting 8 49 Troubleshooting chart 8 50 V Valve clearance 8 25 V belt case drain plug 8 23 Vehicle identification number 11 1 W Warranty extended 11 7 Warranty limited 11 5 Wheel hub bearings checking 8 38 Wheel installing 8 48 Wheel removing...

Page 143: ......

Page 144: ...58 WARNING ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control n result in SEVERE INJURY or DEATH on the cur with ct risk USE LIC S NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL B E E R B E E R ...

Page 145: ...E AN ATV WITH ENGINE SIZE GREATER THAN 90CC 8 TAKE THE FREE HANDS ON TRAINING COURSE OFFERED BY YAMAHA ASK YOUR DEALER FOR DETAILS OR CALL 1 800 887 2887 If you have any questions about these points or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership please fill out the information below and mail this card...

Page 146: ...ED IN THE UNITED STATES FIRST CLASS PERMIT NO 4 CYPRESS CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U S A P O BOX 6555 CYPRESS CALIFORNIA 90630 9989 ATTN SALES ADMINISTRATION ATV card for US 4 2 03 9 06 AM Page 2 ...

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