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Yamaha Raptor 660, Owner'S Manual

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Yamaha Raptor 660 Owner'S Manual Download Page 132

8-21

EBU00780 

Spark arrester cleaning

Be sure the exhaust pipe and muffler are cool
before cleaning the spark arrester.

1. Remove the bolt.

1. Bolt

2. Remove the tailpipe by pulling it out of

the muffler.

3. Tap the tailpipe lightly, then use a wire

brush to remove any carbon deposits
from the spark arrester portion of the
tailpipe.

1. Tailpipe

2. Spark arrester

4. Insert the tailpipe into the muffler and

align the bolt holes.

5. Install the bolt and tighten it.

U5LP13.book  Page 21  Wednesday, March 5, 2003  4:16 PM

Summary of Contents for Raptor 660

Page 1: ......

Page 2: ......

Page 3: ...formation It provides information about special techniques and skills necessary to ride your ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV ...

Page 4: ...ol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe in jury or death to the machine operator a bystander or a person in specting or repairing the machine CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures easier or clearer ...

Page 5: ...icable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine EBU00981 AFFIX DEALER LABEL HERE YFM660RS OWNER S MANUAL 2003 by Yamaha Motor Corporation U S A 1st edition February 2003 All rights reserved Any reprinting or unauthorized use U5LP13 book Page 2 Wednesday March 5...

Page 6: ...Key identification number 3 2 Vehicle identification number 3 3 1 2 3 CONTROL FUNCTIONS 4 1 Main switch 4 1 Indicator and warning lights 4 2 Handlebar switches 4 4 Throttle lever 4 6 Speed limiter 4 7 Clutch lever 4 8 Brake lever 4 8 Brake pedal 4 9 Parking brake 4 10 Shift pedal 4 11 Reverse knob 4 12 Fuel tank cap 4 12 Fuel cock 4 13 Starter choke 4 14 Seat 4 14 Front shock absorber adjustment 4...

Page 7: ... warm engine 6 4 Warming up 6 4 Engine break in 6 9 Parking 6 10 Parking on a slope 6 11 Accessories and loading 6 12 RIDING YOUR ATV 7 1 Getting to know your ATV 7 3 Ride with care and good judgement 7 4 Be careful where you ride 7 16 Turning your ATV 7 23 Climbing uphill 7 25 Riding downhill 7 30 Crossing a slope 7 32 Crossing through shallow water 7 34 Riding over rough terrain 7 36 Sliding and...

Page 8: ...tle lever adjustment 8 24 Front and rear brake pad inspection 8 25 Adjusting the rear brake light switch 8 32 Clutch lever free play adjustment 8 32 Drive chain slack check 8 34 Drive chain slack adjustment 8 35 Lubricating the drive chain 8 36 Cable inspection and lubrication 8 37 Brake and shift pedal brake and clutch lever lubrication 8 38 Front upper and lower arm pivot lubrication 8 39 Rear a...

Page 9: ...1 A Cleaning 9 1 B Storage 9 3 SPECIFICATIONS 10 1 NOISE REGULATION 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE Y E S 14 1 9 10 11 12 13 14 U5LP13 book Page 4 Wednesday March 5 2003 4 16 PM ...

Page 10: ...EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5LP13 book Page 1 Wednesday March 5 2003 4 16 PM ...

Page 11: ...TV Never remove any labels from your ATV If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 UNDER WARNING NEVER operate this ATV if you are under age 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death U5LP13 book Page 2 Wednesday March 5 2003 4 16 PM ...

Page 12: ...3 4 5 U5LP13 book Page 3 Wednesday March 5 2003 4 16 PM ...

Page 13: ...e operating procedures described Never operate an ATV without proper training or instruction Take a Training Course Beginners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you Always follow the age recommendation A child under 16 years old should never operate an ATV with engine size greate...

Page 14: ...Always go at a speed that is proper for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe operating condition Al ways follow the inspection and maintenance procedures and schedules described in this man ual Always keep both hands on the handlebars and both feet on ...

Page 15: ...of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight back ward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow ...

Page 16: ...operating over obstacles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by prac ticing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of con trol Never operate an ATV in fast flowing water or in water deepe...

Page 17: ...d load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Products Safety Com mission at 1 800 638 2772 or the ATV Distributor s Safety Hotline at 1 800 852 5344 U5LP13 book Page 5 Wednesda...

Page 18: ...f ignition such as the pi lot lights of water heaters and clothes dryers When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF posi tion Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline ...

Page 19: ... a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation U5LP13 book Page 7 Wednesday March 5 2003 4 16 PM ...

Page 20: ...ne oil tank 5 Brake pedal 6 Headlights 7 Fuel cock 8 Throttle stop screw 9 Coolant reservoir 10 Tail brake light 11 Shift pedal 12 Clutch lever 13 Handlebar switches 14 Parking brake 15 Main switch 16 Reverse knob 17 Throttle lever 18 Brake lever U5LP13 book Page 1 Wednesday March 5 2003 4 16 PM ...

Page 21: ... spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION EBU00035 Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key 1 Key identification number U5LP13 book Page 2 Wednesday Mar...

Page 22: ...icle identification number is used to identify your machine EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label U5LP13 book Page 3 Wednesday March 5 2003 4 16 PM ...

Page 23: ...th EBU00942 Main switch Functions of the respective switch positions are as follows ON The engine can be started only at this position and the headlights and taillight come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position U5LP13 book Page 1 Wednesday March 5 2003 4 16 PM ...

Page 24: ...warn that the coolant temperature is too hot If the light comes on during operation stop the en gine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes The coolant temperature warning light circuit can be checked according to the procedure on page 4 3 CAUTION The engine may overheat if the ATV is overloaded If this happens reduce the load to specification Restart...

Page 25: ... temperature warning light comes on Coolant temperature warning light does not come on Coolant temperature and electrical circuit are OK Go ahead with riding Push the start switch with the transmission in the neutral position Ask a Yamaha dealer to inspect the electrical circuit Coolant temperature warning light comes on momentarily U5LP13 book Page 3 Wednesday March 5 2003 4 16 PM ...

Page 26: ...may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it _ EBU01205 Engine stop switch Make sure that the engine stop switch is set to before starting the engine The engine stop switch controls ignition and can be used at all times to stop the engine especially in an emergency The engine will not start or run when the engi...

Page 27: ...tart switch The starter motor cranks the engine when this switch is pushed CAUTION See starting instructions prior to starting the engine See page 6 1 for details U5LP13 book Page 5 Wednesday March 5 2003 4 16 PM ...

Page 28: ...gine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the le ver is released WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever befo...

Page 29: ...rew a 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an acci dent or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjust ed to 3 5 mm...

Page 30: ... clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch operation Refer to Starting a cold engine for a de scription of the ignition circuit cut off system EBU00988 Brake lever The brake lever is located on the right handle bar Pull it toward the handlebar to apply the front brake 1 Brake lever U5LP13 book Page 8 Wednesday March 5...

Page 31: ...EBU00989 Brake pedal The brake pedal is located on the right side of the machine Push down on the pedal to apply the rear brake 1 Brake pedal U5LP13 book Page 9 Wednesday March 5 2003 4 16 PM ...

Page 32: ...h in the lock plate to apply the parking brake Squeeze the clutch lever to release the parking brake NOTE When the parking brake is used engine speed is limited to 2 300 r min Be sure the parking brake is released before moving the throttle lever Otherwise the engine will mis fire preventing normal operation 1 Button 2 Lock plate U5LP13 book Page 10 Wednesday March 5 2003 4 16 PM ...

Page 33: ...ake WHAT CAN HAPPEN The ATV could start moving unexpect edly if the parking brake is not applied before starting the engine This could cause loss of control or a collision The brake disc could overheat if you ride the ATV without releasing the park ing brake You could lose braking per formance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Alwa...

Page 34: ...er to the Reverse knob operation and re verse driving section page 6 5 before oper ating this machine in reverse gear 1 Reverse knob REV EBU00092 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap U5LP13 book Page 12 Wednesday March 5 2003 4 16 PM ...

Page 35: ...ion when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling return the fuel cock lever to the ON position U5LP13 book Page 13 Wednesday March 5 20...

Page 36: ...e starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See page 6 1 EBU01010 Seat To remove the seat insert your hand between the rear of the seat and the rear fender pull the seat lock lever upward and pull up the seat at the rear 1 Seat lock lever U5LP13 book Page 14 Wednesday March 5 2003 4 16 PM ...

Page 37: ... projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE _ Make sure that the seat is securely fitted _ 1 Projection 2 2 Seat holder 2 U5LP13 book Page 15 Wednesday March 5 2003 4 16 PM ...

Page 38: ...spring preload as follows To increase the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Standard position C A Minimum soft E Maximum hard U5LP13 book Page 16 Wednesday March 5 2003 4 16 PM ...

Page 39: ...T CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set ting U5LP13 book Page 17 Wednesday March 5 2003 4 16 PM ...

Page 40: ...pring preload 1 Spring preload adjusting nut 2 Locknut 3 Special wrench NOTE _ A special wrench can be obtained at a WARNING POTENTIAL HAZARD This shock absorber contains highly pressurized nitrogen gas WHAT CAN HAPPEN The shock absorber could explode causing injury or property damage Cylinder damage could also result in poor handling which could cause an accident HOW TO AVOID THE HAZARD Do not ta...

Page 41: ...ecified torque CAUTION _ Always tighten the locknut against the ad justing nut and tighten it to the specified torque _ Measurement A Installed length Minimum hard 232 mm 9 1 in Standard 240 mm 9 4 in Maximum soft 247 mm 9 7 in Tightening torque 42 Nm 4 2 m kgf 30 ft lbf U5LP13 book Page 19 Wednesday March 5 2003 4 16 PM ...

Page 42: ...adjusting screw Adjust the compression damping force as fol lows Turn the compression damping force adjust ing screw in direction a to increase the com pression damping force and in direction b to decrease the compression damping force 1 Compression damping force adjusting screw From the fully turned in position Minimum soft 20 clicks out From the fully turned out position U5LP13 book Page 20 Wedn...

Page 43: ...nge To obtain a precise adjustment it would be advisable to check the number of clicks of each damping force adjusting mech anism and to modify the specifications as nec essary _ EBU00112 WARNING POTENTIAL HAZARD Suspension components become hot during operation WHAT CAN HAPPEN You could be burned HOW TO AVOID THE HAZARD Never touch the compression damping adjuster rebound damping adjuster or oil ...

Page 44: ...nd lever free play 8 32 8 33 Parking brake Check operation condition and cable length 8 30 8 31 Fuel Check fuel level Fill with fuel if necessary 5 4 5 5 Engine oil Check oil level Fill with oil if necessary 5 6 8 6 8 11 Coolant reservoir Check coolant level in reservoir Fill with coolant if necessary 5 7 8 11 8 15 Drive chain Check chain slack and condition Adjust if necessary 5 8 8 34 8 37 Throt...

Page 45: ...N 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 op erating condition Always follow the inspection and main tenance procedures and schedules de scribed in the Owner s Manual U5LP13 book Page 2 Wednesday March 5 2003 4 16 PM ...

Page 46: ... a Yamaha dealer inspect the brake system Brake fluid level Check the brake fluid level Add fluid if neces sary See pages 8 26 8 27 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs Apply the brakes firmly for one minute If there is any leakage have a Yamaha dealer inspect the brake system Brake operation Test the brakes at slow speed a...

Page 47: ...OTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any problem with the brakes If a problem cannot be corrected by the ad justment procedures provided in this manual have a Yamaha dealer check for the cause Re...

Page 48: ...HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe 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 th...

Page 49: ...In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ Recommended oil Recommended engine oil classification API Service SE SF SG type or higher 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 Oil quantity Periodic oil change 1 9 L 1 67 Imp qt 2 01 US qt W...

Page 50: ...years See pages 8 11 8 15 for details CAUTION _ Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water _ Coolant reservoir capacity WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the...

Page 51: ...tion when released Have a Yamaha dealer repair as necessary for proper operation EBU01162 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the machine EBU01003 Lights Check the headlights and tail brake light to make sure they are in working condition Re pair as necessary for proper operation EBU01170 Switches Check the operation of all switche...

Page 52: ...td for this model Other tire combina tions are not recommended 2 The tires should be set to the rec ommended pressure Recommended tire pressure Front 27 5 kPa 0 275 kgf cm2 4 0 psi Rear 27 5 kPa 0 275 kgf cm2 4 0 psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pressure below the minimum specified could cause the tire to dislodge from th...

Page 53: ...ssures when seating the tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst Recommended pressure Minimum Maximum Front 27 5 kPa 0 275 kgf cm2 4 0 psi 24 5 kPa 0 245 kgf cm2 3 5 psi 30 5 kPa 0 305 kgf cm2 4 4 psi Rear 27 5 kPa 0 275 kgf cm2 4 ...

Page 54: ...EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit U5LP13 book Page 11 Wednesday March 5 2003 4 16 PM ...

Page 55: ...iar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or colli sion HOW...

Page 56: ... transmission in any position However it is recommended to shift into neutral be fore starting the engine 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold engine start Position 3 Cold engine start ambient temperature above 25 C 80 F and warm engine start position 1 Fully open 2 Half open 3 Closed 6 Completely close t...

Page 57: ... with the starter choke in position 1 the starter choke should be returned to position 2 to warm up the engine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter choke to position 3 before riding CAUTION See the Engine break in section prior to op...

Page 58: ...imum engine life always warm up the engine before starting off Never acceler ate hard with a cold engine To see whether or not the engine is warm check if it responds to the throttle normally with the starter choke turned off NOTE When the parking brake is used engine speed is limited to 2 300 r min Be sure the parking brake is released before moving the U5LP13 book Page 4 Wednesday March 5 2003 4...

Page 59: ...first gear 2 While applying the brake pedal turn the reverse knob clockwise with your right hand 3 Apply the clutch lever and shift the trans mission into reverse by pressing down on the shift pedal 1 Reverse knob REV 2 Shift pedal NOTE _ When in reverse the reverse indicator light should be on If the light does not come on ask a Yamaha dealer to inspect the machine _ 4 Check behind you for people...

Page 60: ...ition apply the clutch and repeatedly depress the shift pedal until it stops When it stops it will be in first gear Raise the pedal slightly to neutral WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person be hind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behi...

Page 61: ... by shifting without the clutch _ EBU00203 To start out and accelerate 1 Release the throttle lever CAUTION Always close the throttle while shifting gears Otherwise damage to the engine and drive train may result 2 Pull the clutch lever to disengage the clutch 3 Shift into first gear 4 Open the throttle gradually and at the same time release the clutch lever slow ly 5 Once the machine has attained...

Page 62: ... the possibility of an accident WARNING POTENTIAL HAZARD Opening the throttle abruptly or releas ing the clutch lever too quickly WHAT CAN HAPPEN The machine could wheelie This would increase the chance of an accident in cluding overturn HOW TO AVOID THE HAZARD Open the throttle gradually Release the clutch lever gradually WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too...

Page 63: ... momentary 2 3 seconds maxi mum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest pe riod for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this peri od consult a Yamaha dealer 1 0 10 hours Avoid continuous operati...

Page 64: ...11 Parking When parking stop the engine and shift into neutral Turn the fuel cock to OFF and apply the parking brake 1 Button 2 Lock plate 1 Locked position U5LP13 book Page 10 Wednesday March 5 2003 4 16 PM ...

Page 65: ...n a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control in creasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline put the machine in low gear apply the parking brake and 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 u...

Page 66: ...a accesso ries nor have any control over the quality or suitability of them Choose a genuine Yamaha accessory or one that is equiva lent in design and quality Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object attached to the han dlebars which could make steering difficult an accessory that limits ...

Page 67: ...iers Make sure cargo in the trailer cannot move around A shifting load can cause an acci dent Make sure the load does not interfere with controls or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slow er you should go Although conditions vary it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or w...

Page 68: ...n vehicle han dling 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 securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking U5LP13 book Page 14 Wednesday March 5 2003 4 16 PM ...

Page 69: ...U5LP13 book Page 15 Wednesday March 5 2003 4 16 PM ...

Page 70: ...EBU13551 WARNING _ Indicates a potential hazard that could result in serious injury or death U5LP13 book Page 16 Wednesday March 5 2003 4 16 PM ...

Page 71: ...7 1 Riding Your ATV U5LP13 book Page 1 Wednesday March 5 2003 4 16 PM ...

Page 72: ...U5LP13 book Page 2 Wednesday March 5 2003 4 16 PM ...

Page 73: ...l skills acquired through prac tice Take your time to fully learn techniques before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you tion to the safety information on pages 2 1 2 7 Ple...

Page 74: ...time Take the time to learn the basic techniques well before attempting more difficult maneu vers WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regularly practice the skills lea...

Page 75: ...mmenda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc U5LP13 book Page 5 Wednesday March 5 2003 4 16 PM ...

Page 76: ...atly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers U5LP13 book Page 6 Wednesday March 5 2003 4 16 PM ...

Page 77: ...ccident Operating without eye protection can re sult in an accident and increases your chances of a severe injury in the event Operating without protective clothing increases your chances of severe injury in the event of an accident 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 sleev...

Page 78: ...RD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV U5LP13 book Page 8 Wednesday March 5 2003 4 16 PM ...

Page 79: ...fe op erating condition Always follow the in spection and maintenance procedures WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of an acci dent HOW TO AVOID THE HAZARD Always use ...

Page 80: ...p speed of the ATV Turning the adjusting screw in decreases the top speed and turning it out increases the top speed See page 4 7 for details 1 Locknut 2 Adjusting screw WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing con trol of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always g...

Page 81: ... LOADING LIMIT Vehicle loading limit total weight of rider cargo and accessories 100 kg 220 lb WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling 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 securely attac...

Page 82: ...ven one hand or foot can re duce 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 HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operation U5...

Page 83: ... POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off U5LP13 book Page 13 Wednesday March 5 2003 4 16 PM ...

Page 84: ...ause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed U5LP13 book Page 14 Wednesday March 5 2003 4 16 PM ...

Page 85: ...NING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en gine area could catch fire Someone touching the exhaust system during 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 U5LP13 book Page 15 Wedne...

Page 86: ...this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of con trol HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets U5LP13 book Page 16 Wednesday March 5 2003 4 16 PM ...

Page 87: ...rating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and high ways U5LP13 book Page 17 Wednesday March 5 2003 4 16 PM ...

Page 88: ... to upset WARNING 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 op U5LP13 book Page 18 Wednesday March 5 2003 4 16 PM ...

Page 89: ...r vehicle control which could result in an acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain U5LP13 book Page 19 Wednesday March 5 2003 4 16 PM ...

Page 90: ...er hitch Do not ride in areas posted no trespassing Do not ride on private property without getting permission WARNING WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch care fully for other vehicles U5LP13 book Page 20 Wednesday March 5 2003 4 16 PM ...

Page 91: ...g and afterwards do not allow With the engine idling pull the clutch lever to disengage the clutch and shift into 1st gear and then release the parking brake Open the throttle gradually and at the same time re lease the clutch lever slowly Once the ATV has attained adequate speed release the throttle lever and at the same time quickly pull in the clutch lever and shift into 2nd gear Open the throt...

Page 92: ...in creasing the possibility of an accident WARNING POTENTIAL HAZARD Opening the throttle abruptly or releas ing the clutch lever too quickly WHAT CAN HAPPEN The ATV could wheelie This would in crease the chance of an accident in cluding overturn HOW TO AVOID THE HAZARD Open the throttle gradually Release the clutch lever gradually WARNING POTENTIAL HAZARD Engaging a lower gear when the engine spee...

Page 93: ...s you do so put your weight on the footboard to the outside of the 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 maneu ver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN The ATV could go out of contr...

Page 94: ...proper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the in side It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember Av...

Page 95: ...tant when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by lean ing forward and on steeper inclines standing on the footboards and leaning forward over the handlebars WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small h...

Page 96: ...hills as described in this Own er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes An obstacle a sharp drop or another vehicle or person could be on the other side of the hill E 7 fm Page 26 Thursday March 6 2003 1 44 PM ...

Page 97: ...r 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 technique as described in the When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your w...

Page 98: ...ATV could easily tip over backwards In stead apply the front brake gradually or dis mount the ATV immediately on the uphill side WARNING POTENTIAL HAZARD Stalling rolling backwards or improper ly dismounting while climbing a hill WHAT CAN HAPPEN Could result in the ATV overturning HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill If you lose all forward speed K...

Page 99: ...ismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the pro cedure described in the Owner s Manu al U5LP13 book Page 29 Wednesday March 5 2003 4 16 PM ...

Page 100: ...n Whenever possible ride your ATV straight downhill Avoid sharp angles which could al low the ATV to tip or roll over Carefully choose your path and ride no faster than you WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for go ing down hills as described in this O...

Page 101: ...U5LP13 book Page 31 Wednesday March 5 2003 4 16 PM ...

Page 102: ...y up hill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no 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 unt...

Page 103: ...Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV U5LP13 book Page 33 Wednesday March 5 2003 4 16 PM ...

Page 104: ...ry or up set the ATV Drive slowly and carefully WARNING POTENTIAL HAZARD Operating 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 accident HOW TO AVOID THE HAZARD Remember that wet brakes may have re duced stopping ability Test your brakes after leaving water If necessary apply them several times to le...

Page 105: ...gained proper braking ability CAUTION _ After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case Wash the ATV in fresh water if it has been operated in salt water or muddy con ditions _ U5LP13 book Page 35 Wednesday March 5 2003 4 16 PM ...

Page 106: ...ol and damage to the ATV may result WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a colli sion Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always fol low proper procedu...

Page 107: ...U5LP13 book Page 37 Wednesday March 5 2003 4 16 PM ...

Page 108: ...heels to slide in loose or slippery conditions position ing your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways control can usually be regained if there is room to do so by steering in the direc tion of the slide Applying the brakes or accel erating is not recommended until you have corrected the slide U5LP13 book Page 38 Wednesday March 5 2...

Page 109: ...ntrol may be lost WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or slid ing by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious ...

Page 110: ...f necessary gradually let off the throttle and or steer to the outside of the turn See pag If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide See pages 7 38 7 39 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have for war...

Page 111: ...over that the ATV is going to tip over dis mount on the uphill side See pages 7 32 7 33 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water 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 un til you have regained adequate braking ability See...

Page 112: ...221 Owner s manual and tool kit You are recommended to put this owner s manual and low pressure tire gauge in the vi nyl bag and always carry them along with the owner s tool kit under the seat WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires...

Page 113: ...our machine to a Yamaha dealer to check the torque settings and adjust them as neces sary _ WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er inst...

Page 114: ...re often in wet or dusty areas Carburetor Check starter choke operation Adjust engine idling speed Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Tighten if necessary Replace gasket if necessary Spark arrester Clean Fuel line Check fuel hose for cracks or damage Replace if necessary Engine oil Replace Warm engine before drai...

Page 115: ...l bearings Check bearing assemblies for looseness damage Replace if damaged Steering system Check operation Repair if damaged Check toe in Adjust if necessary Front and rear suspension Check operation Correct if necessary Upper and lower arm pivot and steering shaft Lubricate every 6 months Rear arm pivot Lubricate every 6 months Fittings and fasteners Check all chassis fittings and fasteners Corr...

Page 116: ...ance described in this chapter Refer to this section each time the panel has to be removed or installed EBU01013 Panel A 1 Panel A 2 Bolt 2 To remove Remove the bolts and then take the panel off To install Place the panel in the original position and then install the bolts U5LP13 book Page 5 Wednesday March 5 2003 4 16 PM ...

Page 117: ... C 141 F let it continue to idle for twenty to thirty seconds During this period rev the engine two or three times to approximately 3 000 r min and then turn the engine off NOTE _ To achieve the proper engine oil temperature 3 Wait a few minutes until the oil settles re move the engine oil tank filler cap wipe the dipstick clean with a clean rag insert it back into the filler hole without screw in...

Page 118: ...pstick into the oil filler hole and then tighten the oil filler cap CAUTION _ Make sure that the oil filler cap is securely tightened otherwise oil may seep out when the engine is running _ To change the engine oil with or without oil filter cartridge replacement 1 Engine guard 2 Bolt 6 1 Remove the engine guard by removing the bolts 2 Start the engine warm it up for several minutes and then turn ...

Page 119: ...bolt 1 Crankcase engine oil drain bolt 1 Engine oil tank drain bolt 5 Remove the engine oil tank filler cap and the oil tank drain bolt 6 Check the washers for damage and re place if necessary U5LP13 book Page 8 Wednesday March 5 2003 4 16 PM ...

Page 120: ...ch NOTE _ An oil filter wrench is available at a nearby 1 O ring 8 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge NOTE _ Make sure that the O ring is properly seated _ 9 Install a new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench U5LP13 book Page 9 Wednesday March 5 2003 4 16 PM ...

Page 121: ...n order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY Tightening torques Crankcase engine oil drain bolt 30 Nm 3 0 m kgf 22 ft lbf Engine oil tank drain bolt 25 Nm 2 5 m kgf 18 ft lbf Recommended engi...

Page 122: ...f and then check the oil level and correct it if necessary 17 Install the engine guard by installing the bolts EBU10151 Cooling system 1 Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine tem perature NOTE _ The coolant should be between the minimum and maximum level marks _ U5LP13 book Page 11 Wednesday March 5 2003 4 16 PM ...

Page 123: ...n operation is completely automatic It is switched on or off accord EBU10161 Changing the coolant Coolant reservoir capacity up to the maximum level mark 0 29 L 0 26 Imp qt 0 31 US qt WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the ...

Page 124: ... A See page 8 5 for pan el removal and installation procedures 3 Place a container under the engine and then remove the coolant drain bolt 1 Coolant drain bolt 4 Remove the radiator cap 1 Radiator cap U5LP13 book Page 13 Wednesday March 5 2003 4 16 PM ...

Page 125: ...stall the coolant reservoir hose 10 Pour the recommended coolant into the radiator until it is full 11 Pour the recommended coolant into the coolant reservoir to the maximum level mark Tightening torque Coolant drain bolt 10 Nm 1 0 m kgf 7 ft lbf Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for alumi num engines Antifreeze and water mixing ratio 1 ...

Page 126: ...es Stop the engine and then check the coolant level in the radiator If it is low add more coolant until it reaches the top of the radiator 14 Check the coolant level in the reservoir If it is low add coolant to the maximum lev el mark 15 Start the engine and then check for cool ant leakage NOTE _ EBU00680 Spark plug inspection Removal 1 Remove the spark plug cap 1 Spark plug cap U5LP13 book Page 1...

Page 127: ...er electrode is a medium to light tan color for a ATV that is being ridden normally Do not attempt to diagnose such problems yourself Instead take the ATV to a Yamaha dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes ex cessive or if carbon and other deposits are excessive...

Page 128: ...ilable when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possible _ 4 Install the spark plug cap Spark plug gap 0 8 0 9 mm 0 03 0 04 in Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf U5LP13 book Page 17 Wednesday March 5 2003 4 16 PM ...

Page 129: ...empty the hose and clean the air filter element and air filter case _ 1 Check hose 1 Remove the seat See page 4 14 for 1 Air filter case cover 2 Holder 6 2 Remove the air filter case cover by un hooking the holders 3 Remove the air filter element 4 Remove the air filter element from its frame U5LP13 book Page 18 Wednesday March 5 2003 4 16 PM ...

Page 130: ...TION _ Do not twist the air filter element when squeezing it _ WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element U5LP13 book Page 19 Wednesday March 5 2003 4 16 PM ...

Page 131: ...ubri cated more often if the machine is operated in extremely dusty areas Each time air filter ele ment maintenance is performed check the air inlet to the air filter case for obstructions Check the air filter element rubber joint to the carburetor and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine _ CAUTION _ Nev...

Page 132: ...ve the bolt 1 Bolt 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and U5LP13 book Page 21 Wednesday March 5 2003 4 16 PM ...

Page 133: ...ests If the settings are disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poison ing possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the sp...

Page 134: ...4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Connect the tachometer to the spark plug lead and then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in direction a to increase the engine speed and in direc tion b to decrease the engine speed 1 Throttle stop screw Specified idle speed U5LP13 book Page 23 Wednesday M...

Page 135: ...regularly This adjust ment however should be left to a professional Yamaha service technician EBU00307 Throttle lever adjustment NOTE Adjust the engine idling speed before adjust ing the throttle lever free play 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle le ver free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut U5LP13 book Page 24 Wednesday March 5 2003 4 16 PM ...

Page 136: ... pad wear without disas sembling the brake Apply the brake and in spect the wear indicator grooves If a brake pad is worn to the point that the wear indicator grooves are almost in contact with the disc plate ask a Yamaha dealer to replace the brake pads as a set 1 Wear indicator groove Front Rear U5LP13 book Page 25 Wednesday March 5 2003 4 16 PM ...

Page 137: ...m level mark and replenish if necessary A low brake fluid level may indi cate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage 1 Minimum level mark NOTE _ To access the rear brake fluid reservoir re move the reservoir cover by removing the bolts _ Front Rear U5LP13 book Page 26 Wednesday March 5 20...

Page 138: ...nd lead to poor brake perfor mance Be careful that water does not enter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfac es or plastic parts Always clean up spilled fluid immediately Have a Yamaha dealer check the cause if the brake fluid level goes down EBU01186 Brake flui...

Page 139: ...with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident 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 Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re U5LP13 book Page 2...

Page 140: ...properly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the brake pedal position is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re U5LP13 book Pa...

Page 141: ...djusting bolt A Cable length 1 Fully loosen the locknut and the adjusting bolt at the clutch lever 3 Turn the adjusting bolt at the clutch lever in direction a to increase the cable length or in direction b to decrease the cable length 1 Locknut 2 Adjusting bolt NOTE _ If the cable cannot be adjusted to specifica tion consult a Yamaha dealer _ U5LP13 book Page 30 Wednesday March 5 2003 4 16 PM ...

Page 142: ...que Locknut 16 Nm 1 6 m kgf 12 ft lbf WARNING POTENTIAL HAZARD Operating with improperly adjusted brakes WHAT CAN HAPPEN The brakes could malfunction causing reduced braking performance This could increase the chance of a collision or accident HOW TO AVOID THE HAZARD After adjusting the parking brake block the rear of the machine off the ground and spin the rear wheels Check to make sure there is ...

Page 143: ...light come on later turn the adjusting nut in direction b EBU00741 Clutch lever free play adjustment The clutch lever free play should be adjusted to 5 10 mm 0 20 0 39 in 1 Loosen the locknut at the clutch lever 2 Turn the adjusting bolt at the clutch lever in direction a to increase the free play or in direction b to decrease the free play 3 Tighten the locknut at the clutch lever NOTE If the spe...

Page 144: ...e crankcase side 7 Turn the adjusting nut at the crankcase in direction a to increase the free play or in direction b to decrease the free play 8 Tighten the locknut at the crankcase and the clutch lever 1 Locknut 2 Adjusting nut U5LP13 book Page 33 Wednesday March 5 2003 4 16 PM ...

Page 145: ...ight est position _ To check the drive chain slack all tires must be touching the ground and there should be no weight on it Check the drive chain slack at the position shown in the illustration Normal slack is approximately 27 37 mm 1 1 1 5 in If the slack exceeds 37 mm 1 5 in adjust it to specification a Drive chain slack U5LP13 book Page 34 Wednesday March 5 2003 4 16 PM ...

Page 146: ...ve chain turn the adjusting bolts in direction a To loosen the drive chain turn the adjusting NOTE _ There are alignment marks on each side of the swingarm and on the hub Use them to check for proper wheel axle alignment _ 1 Locknut 2 2 Adjusting bolt 2 3 Alignment marks 3 After adjusting tighten the locknuts and the wheel hub nuts to the specified U5LP13 book Page 35 Wednesday March 5 2003 4 16 P...

Page 147: ...and lubrication chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows 1 O rings Tightening torques Locknut 16 Nm 1 6 m kgf 12 ft lbf Upper wheel hub nut 90 Nm 9 0 m kgf 65 ft lbf Lower wheel hub nut 90 Nm 9 0 m kgf 65 ft lbf U5LP13 book Page 36 Wednesday March 5 2003 4 16 PM ...

Page 148: ... or any other lubri cants for the drive chain as they may contain substances that could damage the O rings EBU00356 Cable inspection and lubrication WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accid...

Page 149: ... them EBU00737 Brake and shift pedal brake and clutch lever lubrication Lubricate the pivoting parts of each lever and pedal Recommended lubricant Yamaha chain and cable lube or SAE 10W30 motor oil Recommended lubricant Lithium soap based grease all purpose grease U5LP13 book Page 38 Wednesday March 5 2003 4 16 PM ...

Page 150: ... Lubricate the upper and lower arm pivots 1 Upper grease nipple 2 Lower grease nipple 2 1 Upper grease nipple 2 Lower grease nipple 2 Recommended lubricant Lithium soap based grease Left side Right side U5LP13 book Page 39 Wednesday March 5 2003 4 16 PM ...

Page 151: ...EBU00987 Rear arm pivot lubrication Lubricate the rear arm pivots 1 Grease nipple Recommended lubricant Lithium soap based grease U5LP13 book Page 40 Wednesday March 5 2003 4 16 PM ...

Page 152: ...oval 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut 4 1 Nut 4 Front Rear U5LP13 book Page 41 Wednesday March 5 2003 4 16 PM ...

Page 153: ...t toward the rotating direction of the wheel When installing a rear wheel the wording on the tire SIDE FACING OUTWARDS must be facing outwards 1 SIDE FACING OUTWARDS Tighten the wheel nuts to the specified torque Front Wheel nut torque Front 45 Nm 4 5 m kgf 33 ft lbf Rear 45 Nm 4 5 m kgf 33 ft lbf Rear U5LP13 book Page 42 Wednesday March 5 2003 4 16 PM ...

Page 154: ...te carefully WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magne sia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes and get prompt med...

Page 155: ...ealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine EBU00390 Fuse replacement 1 The fuse case is located under the seat 2 If the fuse is blown turn off the main switch and install a new fuse of the spec ified amperage Then turn on the switch es If the fuse immediately blows ...

Page 156: ...1 Remove the headlight assembly by re moving the bolts 1 Headlight assembly 2 Bolt 2 WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rat ing Never use a material in place of the proper fuse U5LP13 book Page 45 Wednesday March 5 2003 4 16 P...

Page 157: ...2 Disconnect the headlight coupler 1 Headlight coupler 3 Remove the screw 1 Screw 4 Remove the headlight cover from the headlight assembly U5LP13 book Page 46 Wednesday March 5 2003 4 16 PM ...

Page 158: ...unit out from its case 1 Screw NOTE _ Pull outward on the rear of the headlight unit and then pull outward on the front _ 6 Remove the headlight bulb holder cover 1 Headlight bulb holder cover U5LP13 book Page 47 Wednesday March 5 2003 4 16 PM ...

Page 159: ...NG POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flamma ble HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it U5LP13 book Page 48 Wednesday March 5 2003 4 16 PM ...

Page 160: ...e glass part of the bulb CAUTION _ Do not touch the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the luminos ity of the bulb and the bulb life will be ad versely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb U5LP13 book Page 49 Wednesday March 5 2003 4 16 PM ...

Page 161: ...dlight unit with the holders install the headlight unit into the case and then install the screw 1 Headlight unit 2 Headlight case 12 Connect the headlight coupler 13 Place the headlight assembly in the orig inal position and then install the bolts 14 Have a Yamaha dealer adjust the head light beam if necessary U5LP13 book Page 50 Wednesday March 5 2003 4 16 PM ...

Page 162: ...ove the defective bulb by pushing it inward and turning it counterclockwise 1 Bulb 3 Install a new bulb by pushing it inward and turning it clockwise 4 Install the lens by installing the screws CAUTION _ Do not overtighten the screws as the lens may break _ U5LP13 book Page 51 Wednesday March 5 2003 4 16 PM ...

Page 163: ...ience and know how to properly service your machine Use only genuine Yamaha parts on your machine Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to ex pensive repair bills WARNING POTENTIAL HAZARD Checking the fuel system while smok ing or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing se vere...

Page 164: ...lectric starter to see if there is compression There is compression Compression normal No compression Ask a Yamaha dealer to inspect 3 Ignition Remove the spark plug and check the electrodes Wet Wipe clean with dry cloth Dry Attach spark plug cap and ground to chassis Use the electric starter Spark is good Ignition system is normal Spark is weak Adjust the spark plug gap No spark Check the fuel fl...

Page 165: ...over the cap Allow any re maining pressure to escape before completely removing the cap Wait until the engine has cooled Check the coolant level in the reservoir tank and or radiator Level is OK Level is low check the cooling system for leakage No leakage Leakage Ask a Yamaha dealer to inspect and repair the cooling system Add coolant See NOTE Restart the engine If the engine overheats again ask a...

Page 166: ...k ets or wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure CAUTION Excessive water pressure may cause wa ter 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 wash ers 4 Once the...

Page 167: ... may mar the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the ...

Page 168: ...tor oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine over seve ral times to coat the cylinder wall with oil 3 Clean the drive chain thoroughly and lu bricate it See page 8 36 4 Lubricate all control cables 5 Block up the frame to raise all wheels off the ground 6 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering ...

Page 169: ...ry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the machine U5LP13 book Page 4 Wednesday March 5 2003 4 16 PM ...

Page 170: ...n 860 mm 33 9 in 1 245 mm 49 in 265 mm 10 4 in 3 300 mm 129 9 in Basic weight With oil and full fuel tank 193 kg 426 lb Engine Type Cylinder arrangement Displacement Bore stroke Compression ratio Starting system Lubrication system Liquid cooled 4 stroke SOHC Forward inclined single cylinder 660 cm3 100 84 mm 3 94 3 31 in 9 2 1 Electric starter Dry sump U5LP13 book Page 1 Wednesday March 5 2003 4 1...

Page 171: ...UBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 CAUTION In order to prevent clutch slippage since the en gine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher U5LP13 book Page 2 Wedne...

Page 172: ...ufacturer BSR33 2 MIKUNI Spark plug Type manufacturer Gap DPR8EA 9 NGK 0 8 0 9 mm 0 03 0 04 in Clutch Type Operation Wet multiple disc Left hand operation Transmission Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Transmission type Spur gear 71 34 2 088 Chain drive 40 13 3 076 Constant mesh 5 speed forward 1 speed reverse MODEL YFM660R U5LP13...

Page 173: ...Caster angle Trail Steel tube 8 47 mm 1 85 in Tire Type Size Front Size Rear Tubeless AT21 7 10 AT20 10 9 Brake Front brake type Operation Rear brake type Operation Dual disc brake Right hand operation Single disc brake Right foot operation Suspension Front Double wishbone MODEL YFM660R U5LP13 book Page 4 Wednesday March 5 2003 4 16 PM ...

Page 174: ... DC C D I A C magneto YTX14 BS 12 V 12 Ah Headlight type Krypton bulb Bulb voltage wattage quantity Headlight Tail brake light Indicator warning lights Neutral Reverse Coolant temperature 12V 30 W 30 W 2 12V 5 W 21 W 1 12V 1 7 W 1 12V 1 7 W 1 12V 1 7 W 1 Fuse 20 A MODEL YFM660R U5LP13 book Page 5 Wednesday March 5 2003 4 16 PM ...

Page 175: ...e of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Muffl...

Page 176: ...rdance with the warranty The chart below is printed only as a re minder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE SERVICING DEALER NAME AND ADDRESS REMARKS 1 Month 3 Months 6 Months 12 Months 18 Months 24 Months 30 Months 36 Months 42 Months 48 Months U5LP13 book Page 1 Wednesday March 5 2003 4 16 PM ...

Page 177: ...EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U5LP13 book Page 1 Wednesday March 5 2003 4 16 PM ...

Page 178: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U5LP13 book Page 2 Wednesday March 5 2003 4 16 PM ...

Page 179: ...EBU00435 YAMAHA EXTENDED SERVICE Y E S U5LP13 book Page 1 Wednesday March 5 2003 4 16 PM ...

Page 180: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U5LP13 book Page 2 Wednesday March 5 2003 4 16 PM ...

Page 181: ...EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death U5LP13 book Page 3 Wednesday March 5 2003 4 16 PM ...

Page 182: ...EBU00437 U5LP13 book Page 5 Wednesday March 5 2003 4 16 PM ...

Page 183: ...EBU00438 ...

Page 184: ...Card fm Page 1 Wednesday June 13 2001 9 35 AM ...

Page 185: ...Card fm Page 2 Wednesday June 13 2001 9 35 AM ...

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