Yamaha Raptor 90 2017 Owner'S Manual Download Page 99

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8-24

6. Tighten the upper locknut.

TIP

After adjusting the brake lever free play, check the
front brake shoes for wear.

EBU33782

Adjusting the rear brake lever free play

The rear brake lever free play must be checked
and, if necessary, adjusted at the intervals speci-
fied in the periodic maintenance and lubrication
chart.

The brake lever free play should measure 30.0–
40.0 mm (1.18–1.57 in) as shown. If the free play is
incorrect, adjust it as follows.

Turn the adjusting nut in direction (a) to increase
the brake lever free play, and in direction (b) to de-
crease it.

1. Cable joint

a´

a=a´

1. Rear brake lever free play

UBD372E0.book Page 24 Wednesday, February 1, 2017 10:29 AM

Summary of Contents for Raptor 90 2017

Page 1: ...DIC183 This ATV should not be ridden by anyone under 10 years of age WARNING BD3 F8199 72 YF09RJ OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 2: ...EBU28981 Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if it is sold UBD372E0 book Page 1 Wednesday February 1 2017 10 29 AM ...

Page 3: ... 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 Make sure you understand all instructions Pay close attention to the warning and notice labels on the ATV This ATV should not be operated by a child under 10 years of age AN IMPORTANT NOTE TO PARENTS This ATV is...

Page 4: ...heir youngster s riding skills improve Once the ATV rider can operate with skill at the top speed permitted by adjusting the vehicle speed limiter alone the engine speed limiter plate can be removed Since removal of this limiter will result in a significant increase in power turn the vehicle speed limiter adjusting screw completely back in again adjust it out in stages as done previously If your c...

Page 5: ...fety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key informa...

Page 6: ...spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU33790 YF09RJ OWNER S MANUAL 2017 by Yamaha Motor Co Ltd 1st edition January 2017 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Taiwan UBD372E0 book ...

Page 7: ...Throttle lever 4 3 Speed limiter 4 3 Front brake lever 4 5 Rear brake lever 4 5 Parking brake 4 6 Drive select lever 4 7 Kickstarter 4 7 Fuel tank cap 4 8 Fuel 4 9 Fuel cock 4 11 Starter choke 4 12 Seat 4 13 Adjusting the front shock absorber assemblies 4 13 Adjusting the rear shock absorber 4 15 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Transmission oil 5 3 Front and rear brakes 5 3 Thrott...

Page 8: ...ol system 8 3 General maintenance and lubrication chart 8 5 Checking the spark plug 8 9 Engine oil 8 11 Transmission oil 8 14 Cleaning the air filter element 8 15 Cleaning the spark arrester 8 18 Adjusting the carburetor 8 19 Adjusting the engine idling speed 8 19 Adjusting the throttle lever free play 8 20 Valve clearance 8 21 Brakes 8 21 Checking the front and rear brake shoes 8 21 Adjusting the...

Page 9: ...shooting 8 36 Troubleshooting chart 8 37 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 YAMAHA MOTOR CANADA LTD ATV WARRANTY GUIDE 11 4 INDEX 12 1 UBD372E0 book Page 3 Wednesday February 1 2017 10 29 AM ...

Page 10: ...1 1 1 EBU17661 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 9 10 2 4 5 7 3 6 8 12 11 UBD372E0 book Page 1 Wednesday February 1 2017 10 29 AM ...

Page 11: ...hese labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a re placement label from your Yamaha dealer UBD372E0 book Page 2 Wednesday February 1 2017 10 29 AM ...

Page 12: ...ER 10 Operation of this ATV by children under the age of 10 increases the risk of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 10 to operate this ATV BD3 F816L 00 1 2 UBD372E0 book Page 3 Wednesday February 1 2017 10 29 AM ...

Page 13: ... I I I I I I I I I I I I I I I I I II I I I I I II I I I I I I I I I I I I I I I I I I I I I BD3 F816L 10 10 10 10 I I I II I I I BD3 F817J 50 BD3 F817J 40 3 5 4 6 UBD372E0 book Page 4 Wednesday February 1 2017 10 29 AM ...

Page 14: ...40 3 5 24 0 3 5 24 0 3 0 20 7 3 0 20 7 181 82 BD3 F816M 60 BD3 F151H 00 I I I I C M V S S CANADA N S V A C T RANSPOR T 506 3JK 82377 30 CAN ICES 2 NMB 2 7 9 8 10 UBD372E0 book Page 5 Wednesday February 1 2017 10 29 AM ...

Page 15: ...1 6 1 BD3 F816M 10 181 82 3 5 24 0 3 5 24 0 3 0 20 7 3 0 20 7 BD3 F151H 10 I I I I I ô ê 11 12 UBD372E0 book Page 6 Wednesday February 1 2017 10 29 AM ...

Page 16: ... to oper ate this ATV Never allow a child under 16 years old to oper ate an ATV without adult supervision Do not allow continued use of the ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and streets Never operate an ATV on any public street...

Page 17: ...ing larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going down hill...

Page 18: ...r or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires...

Page 19: ... ride gently back to camp or other known location where you can receive medical at tention If necessary contact your riding party or local authorities to let them know where you are and what has happened In the event of a breakdown 1 If your vehicle will not restart or is not in safe operating condition turn off the main switch and engine stop switch If the breakdown oc curs at twilight or night l...

Page 20: ...u are responsible for injuries re lated to changes in the vehicle Keep the following guidelines in mind as well as those found in the Loading section page 6 7 when mounting acces sories Never install accessories that would impair the performance of your ATV Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance limit suspension travel steer...

Page 21: ...eas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or par tially enclosed areas such as barns garages or carports Do not r...

Page 22: ...e 5 Battery 6 Rear shock absorber spring preload adjuster 7 Kickstarter lever cap 1 2 3 4 5 7 6 1 Spark arrester 2 Owner s tool kit 3 Front shock absorber spring preload adjuster 4 Spark plug 5 Engine oil filler cap 6 Transmission oil filler cap 1 2 3 6 5 4 UBD372E0 book Page 1 Wednesday February 1 2017 10 29 AM ...

Page 23: ...ffer slightly from the figures shown in this manual 1 Rear brake lever 2 Handlebar switches 3 Parking brake lock plate 4 Starter choke 5 Main switch 6 Throttle lever 7 Front brake lever 8 Drive select lever 1 2 3 5 6 7 4 8 UBD372E0 book Page 2 Wednesday February 1 2017 10 29 AM ...

Page 24: ...ult in death or serious injury EBU33850 Main switch The positions of the main switch are as follows ON All electrical systems are supplied with power and the engine can be started The key cannot be re moved OFF All electrical systems are off The key can be re moved ON OFF UBD372E0 book Page 1 Wednesday February 1 2017 10 29 AM ...

Page 25: ...U18066 Handlebar switches EBU18081 Engine stop switch Set this switch to before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situa tion The engine will not start or run when this switch is set to 1 Reverse indicator light R 2 Neutral indicator light N 1 2 1 Engine stop switch 2 Start swit...

Page 26: ...usting screw and a removable engine speed limiter plate Yamaha recommends that all beginning riders start off with the vehicle speed limiter adjusting screw fully turned in and the engine speed limiter plate in stalled to limit the amount of speed available while they learn The vehicle speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum The adj...

Page 27: ...e the throttle lever free play is adjusted to 1 5 4 0 mm 0 06 0 16 in See page 8 20 WARNING Im proper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation You could lose control resulting in an accident EWB00242 3 Tighten the locknut Engine speed limiter plate When the engine speed limiter plate is installed engine speed is limited to 4900 r...

Page 28: ...ke lever The front brake lever is located on the right han dlebar To apply the front brake pull the brake le ver toward the handlebar grip EBU18402 Rear brake lever The rear brake lever is located on the left handle bar To apply the rear brake pull the brake lever toward the handlebar grip 1 Screw 2 Engine speed limiter plate 1 2 1 Front brake lever 1 UBD372E0 book Page 5 Wednesday February 1 2017...

Page 29: ...NG EWB00221 Always set the parking brake before starting the engine The ATV could start moving un expectedly if the parking brake is not ap plied This could cause loss of control or a collision Always be sure you have released the park ing brake before you begin to ride The brake could overheat if you ride the ATV without re leasing the parking brake You could lose 1 Rear brake lever 1 1 Parking b...

Page 30: ... into the forward neutral and reverse posi tions See page 6 3 for drive select lever operation EBU33893 Kickstarter Use the kickstarter to start the engine when the battery voltage is low 1 Remove the seat page 4 13 and then re move the kickstarter lever 2 Remove the kickstarter lever cap 1 Drive select lever 1 1 Kickstarter lever 1 UBD372E0 book Page 7 Wednesday February 1 2017 10 29 AM ...

Page 31: ...he kickstarter lever and store it under the seat 6 Install the kickstarter lever cap and the seat NOTICE ECB02300 Do not use the kickstarter if the battery is not installed or if the battery leads are not connect ed EBU18721 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise 1 Kickstarter lever cap 1 1 Fold out 2 Push down 1 2 UBD372E0 book Page 8 Wednesday February 1 2017 10 2...

Page 32: ...oking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heat ers and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun can cause...

Page 33: ...ge to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand Use of unleaded fuel will extend spark plug life and reduce maintenance cos...

Page 34: ... fuel cock lever in this position fuel will not flow Always turn the fuel cock lever to this posi tion when the engine is not running ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding 1 Arrow mark positioned over OFF 1 1 Arrow mark positioned over ON 1 UBD372E0 book Page 11 Wednesday February 1 20...

Page 35: ...8852 Starter choke Starting a cold engine requires a richer air fuel mixture This mixture is controlled by the starter choke system To use the starter choke and enrich the air fuel ratio move the starter choke lever in direction a To decrease the starter choke or turn it off move the starter choke lever in direction b TIP See page 6 1 for engine starting instructions 1 Arrow mark positioned over R...

Page 36: ...jection on the front of the seat into the seat holder and then push down on the seat at the rear to lock it in place Make sure that the seat is securely fitted EBU18995 Adjusting the front shock absorber as semblies The spring preload can be adjusted to suit the rid er s weight and the riding conditions 1 Seat 2 Seat lock lever 1 2 1 Projection 2 Seat holder 1 2 UBD372E0 book Page 13 Wednesday Feb...

Page 37: ...oad as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment 1...

Page 38: ... spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension 1 Special wrench Spring preload setting Minimum soft 1 Standard 3 Maximum hard 5 1 1 Spring preload adjusting ring 2 Position indicator 1 2 3 4 5 2 1 a b UBD372E0 book P...

Page 39: ...ake this adjustment WARNING EWB00012 Indicates a hazardous situation which if not avoided could result in death or serious injury 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 1 UBD372E0 book Page 16 Wednesday February 1 2017 10 29 AM ...

Page 40: ... using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 9 5 3 Engine oil Check oil level in engine and add recommended oil to specified level if necessary Check ATV for oil leakage Correct if necessary 5 3 8 11 Transmission oil Check ATV for oil leakage Correct if n...

Page 41: ...te if necessary 5 3 8 25 8 27 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 3 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 29 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 5 6 Instruments and switch...

Page 42: ...is applied If not have the ATV checked by a Yamaha dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance check the brake shoes for wear See page 8 21 EBU19762 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when release...

Page 43: ...nt with your vehicle See page 8 2 When using the tire pressure gauge make two measurements and use the second reading as grit in the gauge or tire valve could have caused the first reading to be incorrect Tire wear If the tire is damaged or the tire tread depth de creases to 3 mm 0 12 in or less replace the tire Recommended tire pressure Front 24 0 kPa 0 240 kgf cm 3 5 psi Rear 24 0 kPa 0 240 kgf ...

Page 44: ...ms that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling braking and comfort Other tires rims sizes and combinations may not be appropriate 1 Tire tread depth Front Manufacturer model DURO DI2017 Size AT18 x 7 8 Type Tubeless Rear Manufacturer model DURO DI2016 Size AT18 x 9 8 Type Tubeless UBD372E0 book Page 5 Wednesday Februar...

Page 45: ...ng your risk of an acci dent EBU19841 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened EBU33810 Instruments and switches Check that all instruments and switches are work ing properly Correct if necessary UBD372E0 book Page 6 Wednesday February 1 2017 10 29 AM ...

Page 46: ...ngine break in section on page 6 4 prior to operating the engine for the first time 1 Set the parking brake The engine can be started only when the rear brake lever is ap plied 2 Turn the fuel cock to ON 3 Turn the key to ON and set the engine stop switch to 4 Shift the drive select lever into the neutral po sition The neutral indicator light should come on 5 Position the starter choke lever accor...

Page 47: ...s started with the starter choke lever in position 1 move the lever to position 2 to warm up the engine If the engine is started with the starter choke lever in posi tion 2 keep the lever in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly then return the starter choke lever to position 3 before riding TIP The engine is warm when it responds quickly to t...

Page 48: ... stop 2 Apply the rear brake lever 3 Shift from neutral to forward by moving the drive select lever along the shift guide TIP Make sure that the drive select lever is completely shifted into position 4 Open the throttle lever gradually Shifting Reverse WARNING EWB00721 Improper operation in reverse could make you hit an obstacle or even a person behind you resulting in serious injury When you shif...

Page 49: ...s given in km mi or the figures given in hours For ATVs not equipped with an odometer or hour meter follow the figures given in hours There is never a more important period in the life of your engine than the first 320 km 200 mi or 20 hours of riding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the first 320 ...

Page 50: ...EBU30021 Parking When parking the ATV apply the rear brake lever shift the drive select lever into the forward posi tion stop the engine apply the parking brake and then turn the fuel cock to OFF EBU20765 Parking on a slope WARNING EWB00832 Avoid parking on hills or other inclines Parking on a hill or other incline could cause the ATV to roll out of control increasing the chance of an accident If ...

Page 51: ... on your ATV Many companies with no connection to Yamaha manufacture parts and accessories or offer other modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket compa nies produce Therefore Yamaha can neither en dorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha even if sold and in...

Page 52: ...s your view Use extra caution when riding an ATV with ac cessories The ATV may handle differently than it does without accessories EBU33880 Loading WARNING EWB00821 Never exceed the stated load capacity for this ATV Overloading this ATV or carrying or tow ing cargo improperly could cause changes in ATV handling which could lead to an accident Cargo should be properly distributed and se curely atta...

Page 53: ...cident Make sure the load does not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stab...

Page 54: ...7 1 7 EBU21133 RIDING YOUR ATV UBD372E0 book Page 1 Wednesday February 1 2017 10 29 AM ...

Page 55: ...o the safety infor mation on pages 2 1 to 2 6 and all notice and warning labels on the vehicle RIDE WITH CARE AND GOOD JUDGMENT Beginning riders should get training from a certified instructor WARNING EWB01382 Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an accident is greatly increased if the operator does not know how to operate the ATV proper...

Page 56: ... lead to severe injury or death of the child This ATV is designed to carry the operator only passengers prohibited The long seat is to allow the operator to shift posi tion as needed during operation It is not for carry ing passengers WARNING Never carry a passenger Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV You could have an accident resulting in...

Page 57: ...injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident EWB02612 Do not operate after or while consuming alco hol or drugs The operator s performance capability is red...

Page 58: ...d decreases the maximum speed of the ATV Turning in the adjusting screw decreases top speed and turning it out increases top speed See page 4 3 This model also has an engine speed limiter plate to limit the amount of engine power available Yamaha recommends that all beginning riders start off with the engine speed limiter plate in stalled and the vehicle speed limiter adjusting screw turned in to ...

Page 59: ...more room to stop A heavier vehicle takes longer to stop Avoid hills and rough terrain Choose terrain carefully Use extreme caution when towing or carrying a load on inclines Turn gradually and go slowly As originally equipped this ATV is not designed to carry cargo or tow a trailer If you choose to add accessories to carry cargo you must use com mon sense and good judgment Use extra caution when ...

Page 60: ...WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off EWB01482 Modifications and accessories Never modify this ATV through improper installa tion or use of accessories or other modification All parts and accessories added to this ATV should be genuine Yamaha or equivalent c...

Page 61: ... in a place where others might be likely to touch it The muffler and other engine parts become ex tremely hot during operation and remain hot after the engine has stopped To reduce the risk of fire during operation or after leaving the ATV do not let brush grass and other materials collect under the vehicle near the muffler or exhaust pipe or next to other hot parts Check under the vehicle after o...

Page 62: ...les In many states it is illegal to oper ate ATVs on public streets roads and highways WARNING Never operate this ATV on any pu blic street road or highway even a dirt or grav el one You could collide with another vehicle EWB01032 Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden hazards which may cause the ATV t...

Page 63: ...essively rough slippery or loose terrain could cause loss of traction or ATV con trol which could result in an accident includ ing an overturn EWB01542 When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if operating in off road ar eas wher...

Page 64: ...e trying more difficult ter rain 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 your ATV Re member that the engine and exhaust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these compo nents With the engine idling release the parking brake Apply the throttle slo...

Page 65: ...d go out of control causing a collision or overturn To achieve maximum traction while riding off road the two rear wheels turn together at the same speed Therefore unless the wheel on the inside of the turn is allowed to slip or lose some traction the ATV will resist turning A special turn ing technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill ...

Page 66: ... be gins to tip over to the outside while negotiating a turn lean more to the inside It may also be nec essary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL WARNING EWB01672 Climbing hills improperly can cause overturns or loss of control U...

Page 67: ... on the other side of the hill Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if pos sible When crossing the side of a hill shift your weight to the uphill side of the ATV OK UBD372E0 book Page 14 Wednesday February 1 2...

Page 68: ...e other side there could be another person an obstacle or a sharp drop off Use common sense and remem ber that some hills are too steep for you to climb or descend If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill If ...

Page 69: ...oper procedures for going down hills as described in this Owner s Manual Always check the terrain carefully before you start down any hill Never operate the ATV on hills too steep for the ATV or for your abilities The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills Shift your weight backward and to the up side of the hill Never go down a hill at high spe...

Page 70: ...rear brake Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear CROSSING A SLOPE WARNING EWB01633 Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to overturn Always follow proper procedu...

Page 71: ... the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance grad ually steer again in the direction you wish to travel CROSSING THROUGH SHALLOW WATER...

Page 72: ...es to let friction dry out the linings Do not continue to ride your ATV without verifying that you have regained proper braking ability WARNING Wet brakes may have reduced stopping ability which could cause loss of control EWB02622 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 NOTICE Undrained water can cause damag...

Page 73: ...ds at all times Avoid jumping the ATV as loss of control and damage to the ATV may result SLIDING AND SKIDDING WARNING EWB01663 Skidding or sliding improperly may cause you to lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery...

Page 74: ...mmended until you have corrected the slide With practice over a period of time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are reduced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost WHAT TO DO IF This secti...

Page 75: ...e 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 13 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 maintain proper balance If the ATV starts to tip steer down the hill if there are no ...

Page 76: ...off the engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 6 for more information about carbon monoxide WARNING EWB02691 Brak...

Page 77: ...e intended to assist you in the performance of pre ventive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP There is a low pressure tire gauge located in the tool kit If you do not have the tools or experience re quired for a particular job have a Yamaha deal er perform it for you 1 Owner s tool kit 2 ...

Page 78: ...ire special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust ...

Page 79: ... and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 UBD372E0 book Page 4 Wednesday February 1 2017 10 29 AM ...

Page 80: ... data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Air filter check hose Clean 3 Front brake Check operation and correct if necessary Check brake lever fre...

Page 81: ...place if necessary 10 V belt Check for wear cracks or other damage and re place if necessary 11 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 12 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 13 Front knuckle piv ots Lubricate with lithium soap based grease 14 Steering shaft Lubricate with lithi...

Page 82: ...y 19 Moving parts and cables Lubricate 20 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 21 Brake switch Check operation and correct if necessary 22 Switches Check operation and correct if necessary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 16...

Page 83: ...8 8 EBU23062 TIP Some maintenance items need more frequent service if you are riding in unusually wet dusty sandy or muddy areas or at full throttle UBD372E0 book Page 8 Wednesday February 1 2017 10 29 AM ...

Page 84: ...ause any spark plug to slowly erode the spark plug should be removed and checked in ac cordance with the periodic maintenance and lubri cation chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit 1 Spark plug cap 1 UBD...

Page 85: ...ly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification 1 Spark plug wrench 1 Specified spark plug NGK CR6HSA 1 Spark plug gap Spark plug ga...

Page 86: ...k plug cap EBU37000 Engine oil The engine oil level should be checked before each ride In addition the oil must be changed at the intervals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the ATV on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level warm up the engine and then w...

Page 87: ...ipstick and tighten the engine oil filler cap To change the engine oil 1 Place the ATV on a level surface 2 Start the engine warm it up for several minu tes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase NOTICE When remov ing the engine oil drain bolt ...

Page 88: ...specified amount of the recom mended engine oil TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down NOTICE ECB00331 Do not use oils with a diesel specification of CD or oils of a higher quality than speci fied In addition do not use oils labeled EN ERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase 1 Engine oil dra...

Page 89: ...ed for oil leakage before each ride If any leakage is found have a Yamaha dealer check and repair the ATV In addition the transmission oil must be changed at the intervals specified in the periodic mainte nance and lubrication chart To change the transmission oil 1 Place the ATV on a level surface 2 Place an oil pan under the transmission case to collect the used oil 3 Remove the transmission oil ...

Page 90: ...e air filter element The air filter element should be serviced at the in tervals specified in the periodic maintenance and lubrication chart Clean or if necessary replace the air filter element more frequently if you are rid ing in unusually wet or dusty areas TIP There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filt...

Page 91: ...nt and clean it with solvent WARNING Always use parts cleaning solvent to clean the air filter ele ment Never use low flash point solvents or gasoline to clean the air filter element because the engine could catch fire or ex plode EWB03540 1 Air filter case check hose 1 1 Air filter case cover 2 Air filter case cover holder 1 2 UBD372E0 book Page 16 Wednesday February 1 2017 10 29 AM ...

Page 92: ...l ity foam air filter oil to the element TIP The air filter element should be wet but not drip ping 8 Insert the air filter element into the air filter case 9 Install the air filter case cover by hooking the holders onto the air filter case NOTICE Make sure that the air filter element is properly seated in the air filter case Never operate the engine with the air filter ele 1 Air filter element 1 ...

Page 93: ...leaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty areas When servicing the air filter element be sure to check the air inlet of the air filter case for obstructions EBU33941 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the tailpipe bolt and nut 2 Remove the spar...

Page 94: ... the engine and requires very sophisticated adjustment There fore most carburetor adjustments should be left to a Yamaha dealer who has the necessary pro fessional knowledge and experience The adjust ment described in the following section however may be performed by the owner as part of routine maintenance NOTICE ECB00481 The carburetor has been set and extensively tested at the Yamaha factory Ch...

Page 95: ... play should be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart The throttle lever free play should measure 1 5 4 0 mm 0 06 0 16 in as shown Periodically check the throttle lever free play and if necessary adjust it as follows TIP The engine idling speed must be checked and adjusted if necessary before adjusting the throttle lever free...

Page 96: ...ly serviced or adjust ed brakes could lead to a loss in braking ability and an accident EBU34511 Checking the front and rear brake shoes The front and rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart Without disas sembling the brake this can be performed by checking the position of the brake lever free play adjusting bolts or nu...

Page 97: ... must be checked and if necessary adjusted at the intervals speci fied in the periodic maintenance and lubrication chart The brake lever free play should measure 20 0 25 0 mm 0 79 0 98 in as shown If the free play is incorrect adjust it as follows 1 Upper adjusting bolt 2 Lower adjusting bolt 3 No more than 12 mm 0 47 in 3 2 1 1 Rear brake lever free play adjusting nut 2 Bolt 3 No more than 18 mm ...

Page 98: ...n direction b to decrease it 4 Tighten the lower locknut 5 While applying the front brake turn out the upper adjusting bolt until the upper and lower cable lengths are equal The cable joint will become vertical 1 Front brake lever free play 1 1 Upper locknut 2 Upper adjusting bolt 3 Lower locknut 4 Lower adjusting bolt 1 2 4 3 a b UBD372E0 book Page 23 Wednesday February 1 2017 10 29 AM ...

Page 99: ...djusted at the intervals speci fied in the periodic maintenance and lubrication chart The brake lever free play should measure 30 0 40 0 mm 1 18 1 57 in as shown If the free play is incorrect adjust it as follows Turn the adjusting nut in direction a to increase the brake lever free play and in direction b to de crease it 1 Cable joint 1 a a a a 1 Rear brake lever free play 1 UBD372E0 book Page 24...

Page 100: ... be touching the ground To check the drive chain slack 1 Place the ATV on a level surface 2 Move the ATV back and forth to locate the tightest portion of the drive chain and then measure the drive chain slack as shown 3 If the drive chain slack is incorrect adjust it as follows To adjust the drive chain slack 1 Loosen the bolts and nuts 1 Rear brake lever free play adjusting nut 1 a b Drive chain ...

Page 101: ...rake lever free play adjust ing nut 3 Loosen the locknut 1 Bolt 1 Nut 1 1 1 Rear brake lever free play adjusting nut 1 Drive chain slack adjusting nut 2 Locknut 1 1 2 a b UBD372E0 book Page 26 Wednesday February 1 2017 10 29 AM ...

Page 102: ...4 EBU24883 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECB00562 The drive chain must be lubricated after wash ing the ATV or riding in the rain or wet areas 1 Clean the d...

Page 103: ...t move smoothly have a Yamaha dealer check or replace it WARNING EWB02582 Inspect cables frequently and replace if damaged Corrosion can result when the ca ble sheaths become damaged and cables can also become frayed or kinked which could restrict the operation of controls and lead to an accident or injury Always make sure all control cables work smoothly before you begin riding in cold weather If...

Page 104: ...ke lever Rear brake lever EBU24964 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smooth ly have a Yamaha dealer check the wheel hub bearings Recommended lubricant Lithium soap based grease UBD372E0 book Page 29 Wednesday Fe...

Page 105: ...quipped with a grease nipple use a grease gun EBU25095 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the pe riodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease 1 Grease nipple Recommended lubricant Lithium soap based grease 1 UBD372E0 book Page 30 Wednesday February 1 2017 10 29 AM ...

Page 106: ...Yamaha dealer WARNING EWB02161 Battery electrolyte is poisonous and danger ous as it contains sulfuric acid which can cau se severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately...

Page 107: ...specified on the battery itself Select a suitable charger and follow the manu facturer s instructions NOTICE ECB00933 To charge a VRLA valve regulated lead acid battery a special battery charger is required Using a conventional battery charger will dam age the battery To store the battery If the ATV will not be used for more than one month remove the battery fully charge it and then place it in a ...

Page 108: ... the positive battery lead first then connect the negative battery lead by installing their bolt NOTICE When installing the bat tery the main switch must be off and the positive lead must be connected before the negative lead ECB01111 3 Hook the battery band 4 Install the seat See page 4 13 TIP Make sure the positive and negative battery leads are installed as shown Fully charge the battery before...

Page 109: ...e of the specified amperage WARNING Always use a fuse of the spec ified rating and never use a substitute ob ject in place of the proper fuse An improper fuse or a substitute object can cause damage to the electrical system which could lead to a fire EWB02173 4 Turn on the main switch and start the engine 5 If the fuse immediately blows again have a Yamaha dealer check the vehicle EBU34030 Removin...

Page 110: ...in the forward rotating direction of the wheel and then install the wheel bolts 2 Lower the ATV to the ground 3 Tighten the wheel bolts to the specified torques 1 Wheel bolt 1 1 1 Arrow mark 2 Forward rotating direction 3 Wheel bolt Tightening torques Front wheel bolt 45 N m 4 5 kgf m 33 lb ft Rear wheel bolt 45 N m 4 5 kgf m 33 lb ft 3 1 2 UBD372E0 book Page 35 Wednesday February 1 2017 10 29 AM ...

Page 111: ...repair take it to a Yamaha dealer whose skilled technicians have the necessary tools ex perience and know how to service the ATV prop erly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02281 Do not smoke when checking the fuel system Fuel can ignite or e...

Page 112: ...ave a Yamaha dealer check the ATV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The battery is good Check the battery lead c...

Page 113: ... several times at slow speeds to let friction dry out the linings EWB02312 NOTICE Excessive wa ter pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure de tergent applications such as those avail able in coin operated car washers ECB00712 4 Once most of the dirt ha...

Page 114: ...uctions in the Cleaning sec tion of this chapter 3 Fill up the fuel tank and add fuel stabilizer Fu el Med Rx if available and then run the en gine for 5 minutes to distribute the treated fuel 4 Turn the fuel cock lever off and then drain the carburetor float chamber by loosening the drain bolt Pour the drained fuel into the fuel tank 5 Perform the following steps to protect the en gine from inter...

Page 115: ...e on stands or blocks to raise all wheels off the ground Alternatively turn the wheels each month to prevent the tires from degrading in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it See page 8 31 UBD372E0 book Page 3 Wednesday February 1 2017 10 29 AM ...

Page 116: ... Cylinder arrangement Single cylinder Displacement 90 cm Bore stroke 47 0 51 8 mm 1 85 2 04 in Compression ratio 9 2 1 Starting system Electric starter and kickstarter Lubrication system Wet sump Engine oil Recommended brand YAMALUBE Type SAE 5W 30 10W 30 10W 40 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA 0 10 30 50 70 90 110 130 F 20 10 0 10...

Page 117: ...66D x 1 Spark plug s Manufacturer model NGK CR6HSA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Dry centrifugal automatic Transmission Secondary reduction system Chain drive Secondary reduction ratio 35 14 2 500 Transmission type V belt automatic Operation Centrifugal automatic type Chassis Frame type Steel tube frame Caster angle 3 40 Trail 19 8 mm 0 78 in Front tire Type Tubeless ...

Page 118: ...l wheel Rim size 8 x 5 5AT Front brake Type Mechanical leading trailing drum brake Operation Right hand operation Rear brake Type Mechanical leading trailing drum brake Operation Left hand operation Front suspension Type Swing axle Spring shock absorber type Coil spring oil damper Wheel travel 126 mm 5 0 in Rear suspension Type Swingarm Spring shock absorber type Coil spring oil damper Wheel trave...

Page 119: ...10 4 10 Bulb voltage wattage quantity Neutral indicator light 12 V 3 5 W 1 Reverse indicator light 12 V 3 5 W 1 Fuse Fuse 7 5 A UBD372E0 book Page 4 Wednesday February 1 2017 10 29 AM ...

Page 120: ... in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU34610 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EBU26031 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key ident...

Page 121: ... will be need ed when ordering spare parts from a Yamaha dealer EBU29663 Vehicle Emission Control Information label The Vehicle Emission Control Information label is affixed at the location in the illustration This label shows specifications related to exhaust emissions as required by federal law state law and Environ ment Canada 1 Vehicle identification number 1 1 Model label 1 UBD372E0 book Page...

Page 122: ...11 3 11 1 Vehicle Emission Control Information label 1 UBD372E0 book Page 3 Wednesday February 1 2017 10 29 AM ...

Page 123: ... 2 Commercial Use b The MANUFACTURER reserves the right to change the design of any model without obligation to modify any model previously manufactured The warranty set forth in Section A may be transferred to any subsequent owner provided that the period of warranty has not expired and that the CUSTOMER has complied with all terms and conditions of this warranty The subsequent owner has the resp...

Page 124: ...of any province of Canada Subject to any applicable sales or consumer legislation the above warranty is in lieu of any warranty or representation expressed or implied including any warranty of performance merchantability or fitness for a particular purpose on the part of YAMAHA and any other obligation or liability on behalf of YAMAHA and the above warranty constitutes your sole remedy and the ful...

Page 125: ...11 6 11 WARNING EWB00012 Indicates a hazardous situation which if not avoided could result in death or serious injury UBD372E0 book Page 6 Wednesday February 1 2017 10 29 AM ...

Page 126: ...driving in reverse 6 3 E Engine break in 6 4 Engine cold start 6 1 Engine idling speed 8 19 Engine oil 5 3 8 11 Engine starting a warm 6 3 Engine stop switch 4 2 F Front and rear brake shoes checking 8 21 Front knuckle pivots lubricating 8 30 Fuel 4 9 5 3 Fuel cock 4 11 Fuel tank cap 4 8 Fuse replacing 8 34 H Handlebar switches 4 2 I Identification numbers 11 1 Indicator lights 4 2 Instruments and...

Page 127: ...ifications 10 1 Speed limiter 4 3 Starter choke 4 12 Start switch 4 3 Steering shaft lubricating 8 30 Storage 9 2 T Throttle lever 4 3 5 3 Throttle lever free play adjusting 8 20 Tires 5 3 Transmission oil 5 3 8 14 Troubleshooting 8 36 Troubleshooting chart 8 37 V Valve clearance 8 21 Vehicle Emission Control Information label 11 2 Vehicle identification number 11 1 W Warranty 11 4 Wheel hub beari...

Page 128: ...UBD372E0 book Page 3 Wednesday February 1 2017 10 29 AM ...

Page 129: ...ight right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service manual...

Page 130: ...ROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For replace...

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