Yamaha RAPTOR 90 Owner'S Manual Download | Manualshive

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Changing the rear brake fluid

Checking the rear brake lever free play

The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever free play should

measure 0 –1.5 mm (0 –0.06 in) as shown. If
the free play is incorrect, have a Yamaha dealer
check the brake system.

Have a Yamaha dealer change the rear brake fluid
at the intervals specified in the TIP after the periodic
maintenance and lubrication chart. In addition,
have the oil seals of the master cylinders and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are damaged
or leaking.

Oil seals: Replace every two years.

Brake hoses: Replace every four years.

1

LOWER

1

8-26

8

Recommended brake fluid:

DOT4

1. Brake lever free play

1. Minimum level mark

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Summary of Contents for RAPTOR 90

Page 1: ...This A 43D F8199 10 OWNER S MANUAL LIT 11626 22 13 This ATV should not be ridden by anyone under 12 years of age WARNING READ THIS MANUAL CAREFULLY It contains important safety information YFM90RY ...

Page 2: ...Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if it is sold ...

Page 3: ... 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 COMPLETE LY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND NOTICE LABELS ON THE ATV NEVER OPERATE AN ATV WITHOUT PROPER TRA...

Page 4: ... beginner becomes more familiar with operating the ATV Parents should decide when to adjust the ATV for more power as their 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 ...

Page 5: ...ocedures easier or clearer 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 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN JURY OR DEATH Particularly important information is distinguished in this manual by the follo...

Page 6: ... 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 ATV YFM90RY OWNER S MANUAL 2008 by Yamaha Motor Corporation U S A 1st edition July 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohib...

Page 7: ... 11 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 3 Engine oil 5 3 Final transmission oil 5 3 Front and rear brakes 5 3 Throttle lever 5 4 Tires 5 4 Measuring the tire pressure 5 5 Tire wear limit 5 6 Chassis fasteners 5 7 Instruments and switches 5 7 OPERATION 6 1 Starting a cold engine 6 1 Starting a warm engine 6 3 Engine break in 6 4 Parking 6 4 Parking on a slope 6 5 Accessorie...

Page 8: ...se 8 30 Removing a wheel 8 32 Installing a wheel 8 33 Troubleshooting 8 34 Troubleshooting chart 8 35 RIDING YOUR ATV 7 1 GETTING TO KNOW YOUR ATV 7 2 RIDE WITH CARE AND GOOD JUDGEMENT 7 2 BE CAREFUL WHERE YOU RIDE 7 11 TURNING YOUR ATV 7 15 CLIMBING UPHILL 7 17 RIDING DOWNHILL 7 20 CROSSING A SLOPE 7 21 CROSSING THROUGH SHALLOW WATER 7 22 RIDING OVER ROUGH TERRAIN 7 24 SLIDING AND SKIDDING 7 25 W...

Page 9: ...FICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 Noise regulation 11 3 Maintenance record 11 4 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY 11 5 YAMAHA EXTENDED SERVICE Y E S 11 7 ...

Page 10: ...ining courses nearest you Always follow the age recommendation A child under 12 years old should never oper ate an ATV with engine size greater than 70 cc A child under 16 years old should never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not hav...

Page 11: ... turn at faster speeds and never turn at excessive speeds Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your...

Page 12: ...e go slowly and be very cautious in order to re duce the chance of skidding or sliding out of con trol Never operate an ATV in fast flowing water 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 use the size and type...

Page 13: ... the OFF position Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause inju ries HOW TO AVOID THE HAZARD If you should swallow some gasoline or in hale a lot of gasoline vapor or get some gas oline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change y...

Page 14: ...nderstand all of the labels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer 2 1 2 3 4 5 ...

Page 15: ...2 2 2 2 1 l l l l ll ll l l l l ll ll I I I I l I l l I l l I l l l I I I ...

Page 16: ...2 3 2 4 3 l l I I l 5 ...

Page 17: ...3 1 3 DESCRIPTION Left view Right view 1 Fuel cock 2 Rear wheel 3 Footrest 4 Front wheel 1 Spark arrester 2 Seat 3 Footrest 1 2 3 1 4 3 2 ...

Page 18: ... Rear brake lever 2 Parking brake 3 Front brake lever 4 Throttle lever 5 Main switch 6 Fuel tank cap 7 Handlebar switches 8 Choke 1 2 3 8 7 6 5 4 TIP The ATV you have purchased may differ slightly from the figures shown in this manual ...

Page 19: ...d could result in death or serious injury 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 1 Main switch OFF O I I T I N G N 1 ON OFF ...

Page 20: ...ps the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run when this switch is set to OFF Start switch START Push this switch to crank the engine with the start er See the starting instructions on page 6 1 prior to starting the engine 1 2 1 Engine stop switch ENG STOP 2 Start switch START ...

Page 21: ...e speed limiter adjusting 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 installed to limit the amount of speed available while they learn 1 Throttle lever WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be har...

Page 22: ...e 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 Vehicle speed limiter 1 Loosen the locknut 2 To increase the maximum engine power available and the maximum speed of the ATV turn the adjust...

Page 23: ... Im proper throttle operation could result The child could lose control have an accident or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 5 mm 0 2 in With this plate installed the engine speed is limited to 4800 r min With this plate removed top engine speed 8000 r min is available Remove the plate as follows 1 Remove the seat See page 4 11 3 Pull the plate out o...

Page 24: ...e bar To apply the front brake pull the brake lever toward the handlebar grip 1 Front brake lever Rear brake lever The rear brake lever is located on the left handle bar To apply the rear brake pull the brake lever to ward the handlebar grip 4 6 1 Rear brake lever 4 1 1 ...

Page 25: ...tedly if the parking brake is not applied before start ing the engine This could cause loss of con trol or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine Always b...

Page 26: ...hat there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Fuel tank cap 1 Fuel level 2 Filler tube Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 4 8 L 1 27 US gal 1 06 Imp gal Fuel reserve amount 1 0 L 0 26 US gal 0 22 Imp gal 4 1 1 2 ...

Page 27: ...leaded gasoline will cause severe damage to internal engine parts such as the valves and piston 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 oc tane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premi um unleaded fuel Unleaded fuel will give you long er spark plug life...

Page 28: ... RES 5 1 Lever positioned over RES 1 Lever positioned over ON 4 10 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 This indicates reserve With the fuel cock lever in this position the fuel reserve is made available Turn the fuel cock lever to this position if you run out of fuel while riding When t...

Page 29: ...the choke in direction b to turn off the choke See the Starting a cold engine section on page 6 1 for proper operation 1 Fully open ON 2 Half open warming up position 3 Closed OFF 4 Choke 1 2 3 a b 4 4 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear 1 1 Seat lock lever ...

Page 30: ...ituation which if not avoided could result in death or serious injury 2 1 1 Kickstarter 1 NOTICE A kickstarter lever is located under the seat to use if the battery is discharged 1 Install the kickstarter lever 2 Move the kickstarter lever down lightly with your foot until the gears engage and then push it down smoothly but forcefully Kickstarter Do not use the kickstarter if there is no battery i...

Page 31: ... page 8 3 to determine which service should be performed by a Yamaha dealer 5 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspe...

Page 32: ... 4 8 21 5 PAGE T ITEM Fuel Check fuel line for leakage Correct if necessary 4 8 5 3 Check ATV for oil leakage Correct if necessary 5 3 8 11 Final transmission oil 5 3 8 14 Check ATV for oil leakage Correct if necessary Front brake Check operation and correct if necessary Lubricate cable if necessary Check lever free play and adjust if necessary 5 3 8 22 8 23 Engine oil Check fuel level in fuel tan...

Page 33: ...fuel right after the engine has been running and is still very hot 3 6 1 5 Final transmission oil Make sure that the final transmission oil is at the specified level Add oil as necessary See page 8 14 Front and rear brakes Recommended brake fluid DOT4 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joint or brake fluid reservoir Apply the brake firmly for one minute ...

Page 34: ...throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary WARNING POTENTIAL 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 prob lem with t...

Page 35: ... 3 6 psi 0 25 kgf cm2 Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides Tire pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 22 kPa 3 2 psi 0 22 kgf cm2 Rear 22 kPa 3 2 psi 0 22 kgf cm2 Use no more than the following pressures when seating the tire beads M...

Page 36: ...e tire pressures to the following specifications Tire wear limit Replace the tire when the tire groove decreases to 3 mm 0 12 in 1 Low pressure tire gauge Recommended pressure Front 25 kPa 3 6 psi 0 25 kgf cm2 Rear 25 kPa 3 6 psi 0 25 kgf cm2 Minimum Front 22 kPa 3 2 psi 0 22 kgf cm2 Rear 22 kPa 3 2 psi 0 22 kgf cm2 5 1 ...

Page 37: ...assis fasteners Make sure that all nuts bolts and screws are prop erly tightened Instruments and switches Check that all instruments and switches are working properly Correct if necessary 1 Tire wear limit 5 ...

Page 38: ... 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 Frozen control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables w...

Page 39: ...reserve battery energy Do not 1 Fully open ON 2 Half open warming up position 3 Closed OFF 4 Choke 0 30 10 20 30 50 70 90 F C 1 3 TIP This model is equipped with an ignition circuit cut off system The engine can be started only when the rear brake lever is applied 4 Use the choke in reference to the figure Position 1 Cold engine start with ambient temperature be low 30 C 90 F Position 2 Warming up...

Page 40: ...ure as for starting a cold engine with the exception that the choke is not re quired when the engine is warm Instead start the engine with the throttle slightly open To start out and accelerate 1 Squeeze the front brake lever to release the parking brake 2 Gradually open the throttle while slowly re leasing the rear brake lever WARNING POTENTIAL HAZARD The ATV could wheelie This would increase the...

Page 41: ...ve 3 4 throttle Rev the engine freely but do not use full throttle at any time NOTICE If any engine trouble should occur during the engine break in period immediately have a Parking When parking the ATV stop the engine shift the drive select lever into the drive position apply the parking brake and then turn the fuel cock to OFF Yamaha dealer check the ATV 320 km 200 mi or 20 hours and beyond The ...

Page 42: ... ATV could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the ATV trans versely across the incline stop the engine apply the parking brake and then block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them...

Page 43: ... which can shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that li...

Page 44: ...y the slower you should go Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in ATV handling which c...

Page 45: ...7 1 RIDING YOUR ATV 7 ...

Page 46: ...n of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 1 1 1 4 Please also read all notice and warning labels on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners...

Page 47: ...n HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regu larly practice the skills learned in the course and the operating techniques described in this Owner s Manual For more information about the training course contact an autho rized ATV dealer or call 1 800 887 2887 WARNING POTENTIAL HAZARD Failure to ...

Page 48: ...V WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passen ger 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 pas sengers 7 7 4 ...

Page 49: ...erating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing in creases 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 ...

Page 50: ...ment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE H...

Page 51: ...ich can result in an accident HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain visibility and operating conditions and your experience Speed limiters For riders less experienced with this model the throttle lever housing is equipped with a vehicle speed limiter This speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum ...

Page 52: ...in power turn the vehicle speed limiter adjusting screw back in again adjust it out in stages as you did before For engine speed limiter plate removal instructions see page 4 4 Loading and accessories Use extra caution when riding the ATV with addi tional loads such as accessories or cargo The ATV s handling may be adversely affected Re duce your speed when adding additional loads 2 Adjusting scre...

Page 53: ...g 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 handlebars and both feet on the footboards of your ATV during operation 7 During operation Always keep your feet on the footboards during op eration otherwise they may contact the rear wheels Cargo should be properly distributed and se curely attached Reduc...

Page 54: ... which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV dealer 7 WARNING PO...

Page 55: ... operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces WHAT CAN HAPPEN ATVs are desi...

Page 56: ...luding side walks driveways parking lots and streets WARNING POTENTIAL HAZARD Operating 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 highways 7 ...

Page 57: ...n hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operat ing on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery or loose terrain WHAT ...

Page 58: ...e terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especial ly cautious on these kinds of terrain WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be in jured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you ...

Page 59: ...h these compo nents Apply the throttle slowly and smoothly You will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds until you are thoroughly familiar with the operation of your ATV When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly Im proper ...

Page 60: ...nue to go straight If the ATV doesn t turn come to a stop and then practice the proce dure again If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN The...

Page 61: ...first on gentle slopes Try more difficult climbs only after you have devel oped your skill In all cases avoid inclines with slip pery or loose surfaces or obstacles that might cause you to lose control It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by leaning forward and on steeper inclines standing on the footboards an...

Page 62: ...AZARD Always follow proper procedures for climb ing hills as described in this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another veh...

Page 63: ... brake gradually or dismount the ATV immediately on the uphill side WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful w...

Page 64: ...r ATV straight down WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dis mounting while climbing a hill WHAT CAN HAPPEN Could result in the ATV overturning HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking brake after you are stopped If you begin rolling backwards Keep weight uphi...

Page 65: ... your body in the uphill direction It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on 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 going down hills as described in this Owner ...

Page 66: ...se your path WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a st...

Page 67: ... 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 acci dent HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember that wet brakes may have re duced stopping ability Test your brakes af...

Page 68: ...d in salt water or muddy conditions RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau tion Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult 1 Air filter case check hose 7 1 ...

Page 69: ...trol can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check ...

Page 70: ... it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight over the front wheels for better control See page 7 15 If your ATV begins to tip while turning WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain tractio...

Page 71: ...ly the front brake or dis mount the ATV on the uphill side See page 7 17 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that the ATV is going to tip over dismount on the uphill si...

Page 72: ...ICAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED Owner s manual and tool kit Be sure to put this owner s manual in the plastic bag and to always carry it as well as the owner s tool kit and the low pressure tire gauge in their re spective compartments under the seat WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can...

Page 73: ...nd used according to instructions If you have questions consult an authorized Yamaha ATV dealer The service information included in this manual and the tools provided in the owner s tool kit are in tended to assist you in the performance of preven tive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP I...

Page 74: ...NITIAL 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 if necessary 4 Carburetor Check choke operation and correct if necessary Check...

Page 75: ...s sary Check for looseness and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 8 ...

Page 76: ...and correct if necessary Check brake lever free play and adjust if neces sary Replace brake shoes Whenever worn to the limit 7 Wheels Check runout and for damage and replace if nec essary 8 Tires Check tread depth and for damage and replace if necessary Check air pressure and balance and correct if necessary 8 5 Rear brake Check operation and correct if necessary Check fluid level and ATV for flui...

Page 77: ... Engine oil Change Check ATV for oil leakage and correct if neces sary Change 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 17 Check ATV for oil leakage and correct if neces sary 18 Moving parts and cables Lubricate 8 9 Wheel hub bearings Check for looseness or damage and replace i...

Page 78: ...place if neces sary 20 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 21 Front and rear brake switches Check operation and correct if necessary 22 Lights and switches Check operation and correct if necessary Adjust headlight beams 23 V belt Check operation Check for wear c...

Page 79: ...et or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged ...

Page 80: ...heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accor dance with the periodic maintenance and lubrica tion 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 ki...

Page 81: ...ating improperly 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 To install the spark plug 1 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification 1 Spark plug wrench Specified spark plug NGK...

Page 82: ...ark plug cap 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 be sure to warm up the engine suffic...

Page 83: ...en 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 min utes 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 remove the engine oil drain bolt to drain the oil from the crankcase 5 Check the washer for damage and replace it if necessary 6 Instal...

Page 84: ...tives 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 the crankcase 8 Start the engine and then let it idle for several Make sure that no foreign material enters minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 9 Turn the...

Page 85: ... ride If any leakage is found have a Yamaha dealer check and repair the ATV In addition the final transmission oil must be changed at the intervals specified in the periodic maintenance and lubrication chart 1 Place the ATV on a level surface 2 Place an oil pan under the final transmission 3 Remove the final transmission oil filler cap and the drain bolt to drain the oil from the final transmissio...

Page 86: ...ing check for the cause Recommended final transmission oil See page 10 1 Oil quantity 0 30 L 0 32 US qt 0 27 Imp qt Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean the air filter element more frequently if you are riding in unusually wet or dusty areas TIP There are check hoses at the botto...

Page 87: ...8 16 8 1 2 2 2 1 Remove the air filter case cover by remov ing the bolts 1 Air filter case cover left 2 Bolts 1 Air filter case check hose right 1 1 Air filter case cover right 2 Bolts 2 2 2 1 ...

Page 88: ...ponge material 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 sponge material 1 2 8 8 17 2 Remove the air filter element by removing the 3 Wash the sponge material gently but thor oughly in solvent 4 Squeeze the excess solvent out of the sponge material and let it dry screw and then pull off the sponge ...

Page 89: ...urs It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions NOTICE Make sure that the air filter element is prop erly seated in the air filter case Never operate the engine with the air filter el ement removed This will allow unfiltered air t...

Page 90: ...e screw and nut 2 Remove the spark arrester by pulling it out of the muffler 3 Tap the spark arrester lightly and then use a wire brush to remove any carbon deposits 4 Insert the spark arrester into the muffler and align the screw holes 5 Install the screw and nut and then tighten the nut 1 Spark arrester 2 Screw 3 Nut 8 1 2 3 ...

Page 91: ... extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor performance of or damage to the engine Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica WARNING POTENTIAL HAZARD Improper cleaning of the spark ar...

Page 92: ...g the throttle stop screw at the carburetor To in crease the engine idling speed turn the throt tle stop screw in direction a and to decrease it turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment Checking the throttle cable free play The throttle cable free play should be checked at the intervals specified ...

Page 93: ...ng in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the inter vals specified in the periodic maintenance and lu brication chart 1 Throttle lever free play 1 Brakes Replacement of brake components requires professional knowledge Brake service should be performed by a Yamaha dealer WARNING Operating with improp...

Page 94: ...Loosen the lower locknut 3 Turn the lower adjusting bolt in direction a to increase the free play and in direction b to decrease it 1 Brake lever free play TIP Before adjusting the brake lever free play check the front brake shoes for wear 3 3 No more than 12 mm 0 47 in 1 Upper adjusting bolt 2 Lower adjusting bolt 2 1 to check the brake shoe wear without having to disassemble the brake To check t...

Page 95: ...ual The cable joint will become vertical 1 Upper locknut 2 Upper adjusting bolt 3 Lower locknut 4 Lower adjusting bolt 1 2 4 3 a b a b 1 WARNING POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident 1 Cable joint 6 Tighten the upper locknut 8 24 8 ...

Page 96: ...ake pad wear without having to disassemble the brake If a brake pad has worn to the point that the wear indicator grooves have almost disappeared have a Yamaha dealer replace the brake pads as a set Checking the rear brake pads Insufficient brake fluid may allow air to enter the brake system possibly causing it to become ineffective Before riding check that the brake fluid is above the minimum lev...

Page 97: ...ealer check the brake system Have a Yamaha dealer change the rear brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart In addition have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace eve...

Page 98: ...rol ca bles should be checked before each ride and the cables and cable ends should be lubricated if nec essary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if necessary Rec...

Page 99: ...eed to check the electrolyte or to add distilled water However the battery lead connections need to be checked and if necessary tightened Recommended lubricant Front brake lever Lithium soap based grease NOTICE Never attempt to remove the battery cell seals as this would permanently damage the battery 1 Rear brake lever Silicone grease WARNING Failure to handle batteries or battery electro lyte ca...

Page 100: ...maha dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electrical accessories To store the battery 1 If the ATV will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 2 If the battery will be stored for more than tw...

Page 101: ...e fuse holder is located under the seat An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD 8 See page 4 11 If the fuse is blown replace it as follows 1 Fuse 2 Spare fuse 1 2 NOTICE Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a VRLA Valve Regulated Lead Acid battery a special con...

Page 102: ...8 31 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 8 ...

Page 103: ...8 32 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Wheel nuts Removing a wheel 1 Loosen the wheel nuts 8 1 1 ...

Page 104: ...es Tightening torques Front wheel nut 45 Nm 4 5 m kgf 33 ft lbf Rear wheel nut 45 Nm 4 5 m kgf 33 ft lbf wheel Front 1 Arrow mark Installing a wheel 1 Install the wheel and the nuts TIP When installing the wheel make sure its arrow mark points toward the rotating direction of the 8 1 ...

Page 105: ...r whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ig...

Page 106: ...emove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is good Ch...

Page 107: ...e and deterioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to rea...

Page 108: ...t this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spa...

Page 109: ...d if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative ly turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it ...

Page 110: ...4 SAE5W 30 or SAE10W 40 or SAE20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W 40 or SAE 10W 40 SAE 5W 30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W 50 or SAE 20W 50 Dimensions Overall length 1490 mm 58 7 in Overall width 885 mm 34 8 in Overall height 910 mm 35 8 in Seat height 654 mm 25 7 in Wheelbase 1010 mm 39 8 in Ground ...

Page 111: ...r TK Type x quantity SVR 22 1G x 1 Spark plug s Manufacturer model NGK CR7HSA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Chassis Frame type Steel tube frame Caster angle 4 0 Trail 16 mm 0 63 in Front tire Type Tubeless Size AT18 x 7 8 Manufacturer model MAXXIS M939 Clutch Clutch type Dry centrifugal automatic Transmission Primary reduction system V belt Primary reduction ratio 2 47 0 61 1 Secondary ...

Page 112: ... kgf cm2 Rear 25 kPa 3 6 psi 0 25 kgf cm2 Minimum Front 22 kPa 3 2 psi 0 22 kgf cm2 Rear 22 kPa 3 2 psi 0 22 kgf cm2 Front wheel Wheel type Panel wheel Rim size 8 x 5 5AT Rear wheel Wheel type Panel wheel Rim size 8 x 7AT Front brake Type Drum brake Operation Right hand operation Rear brake Type Single disc brake Operation Left hand operation Recommended fluid DOT4 Front suspension Type Double wis...

Page 113: ...r suspension Type Swingarm Spring shock absorber type Coil spring oil damper Wheel travel 83 mm 3 3 in Electrical system Ignition system CDI Charging system AC magneto Battery Model GTX5L BS Voltage capacity 12 V 4 0 AH Fuses Main fuse 10 A ...

Page 114: ...Yamaha dealer or for ref erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key Vehicle identification number The vehicle identification number is stamped into the frame 1 ...

Page 115: ...r ATV Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha deal er 1 Vehicle identification number 1 Model label 1 1 ...

Page 116: ...ehicle for the purpose 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...

Page 117: ...minder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 22500 14400 1440 60 25...

Page 118: ...urchaser to any subsequent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corpo...

Page 119: ...at the time of sale and upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Q Is the warranty transferable to second owners A Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain effective CUSTO...

Page 120: ...re s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls e...

Page 121: ...oney Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 WARNING A WARNING indicates a hazardous situation which if not avoided cou...

Page 122: ...11 9 11 ...

Page 123: ...uretor adjusting 8 20 Chassis fasteners 5 7 Cleaning 9 1 E Engine break in 6 4 Engine cold start 6 1 Engine idling speed 8 20 Engine oil 5 3 8 11 Engine starting a warm 6 3 Engine stop switch 4 2 Fuel 4 8 5 3 Fuel cock 4 10 Fuel tank cap 4 8 Fuse replacing 8 30 F K Key identification number 11 1 L Label locations 2 1 H Handlebar switches 4 2 I Identification numbers 11 1 Instruments and switches 5...

Page 124: ...g 8 9 Specifications 10 1 Speed limiters 4 3 Start switch 4 2 Storage 9 2 T Throttle cable free play checking 8 21 Throttle lever 4 3 5 4 Timing chain 8 22 Tire pressure measuring 5 5 Tires 5 4 Tire wear limit 5 6 Troubleshooting 8 34 Troubleshooting chart 8 35 V Valve clearance 8 22 Vehicle identification number 11 1 W Wheel hub bearings checking 8 28 Wheel installing 8 33 Wheel removing 8 32 Sea...

Page 125: ...urfaces pavement may seriously affect handling and control Improper ATV use can result in SEVERE INJURY or DEATH 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 ALWAYS USE AN APPROVED HELMET ...

Page 126: ......

Page 127: ...E NECESSARY IF MAILED IN THE UNITED STATES FIRST CLASS PERMIT NO 4 CYPRESS CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U S A P O BOX 6555 CYPRESS CALIFORNIA 90630 9989 ATTN SALES ADMINISTRATION ...

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