Yamaha RAPTOR YFM660RP Owner'S Manual Download Page 178 | Manualshive

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PRINTED IN JAPAN
2001 . 7 - 6.0

×

1 CR

(E)

PRINTED ON RECYCLED PAPER

WARNING

ALWAYS

:

• use proper riding techniques to avoid
vehicle overturns on hills and rough terrain
and in turns.
• avoid paved surfaces-pavement may
seriously affect handling and control.

Improper ATV use can result in SEVERE INJURY or DEATH.

NEVER USE

WITH DRUGS
OR ALCOHOL

ALWAYS USE

AN APPROVED

HELMET AND

PROTECTIVE 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 replacement manual, call 1-800-532-1558)

YAMAHA MOTOR CO., LTD.

EBU00438

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Summary of Contents for RAPTOR YFM660RP

Page 1: ...YFM660RP OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information 5LP 28199 11 LIT 11626 15 31 This ATV should not be ridden by anyone under 16 years of age WARNING ...

Page 2: ...EBU00776 ...

Page 3: ... machine It also includes basic maintenance and inspec tion procedures If you have any questions regarding the operation or maintenance of your ma chine 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 MACHINE MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AN...

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

Page 5: ...k arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine EBU00981 AFFIX DEALER LABEL HERE YFM660RP OWNER S MANUAL 2001 by Yamaha Motor Corporation U S A 1st edition July 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressl...

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

Page 7: ...knob operation and reverse driving 6 5 Shifting 6 6 To start out and accelerate 6 7 To decelerate 6 8 Engine break in 6 9 Parking 6 10 Parking on a slope 6 11 Accessories and loading 6 12 RIDING YOUR ATV 7 1 Getting to know your ATV 7 3 Ride with care and good judgement 7 4 Be careful where you ride 7 16 Turning your ATV 7 23 Climbing uphill 7 25 Riding downhill 7 30 Crossing a slope 7 32 Crossing...

Page 8: ...ecting the brake fluid level 8 24 Brake fluid replacement 8 26 Front brake adjustment 8 27 Rear brake adjustment 8 28 Parking brake adjustment 8 29 Adjusting the rear brake light switch 8 31 Clutch lever free play adjustment 8 31 Drive chain slack check 8 33 Drive chain slack adjustment 8 33 Lubricating the drive chain 8 35 Cable inspection and lubrication 8 36 Brake and shift pedal brake and clut...

Page 9: ...roubleshooting charts 8 50 CLEANING AND STORAGE 9 1 A Cleaning 9 1 B Storage 9 3 SPECIFICATIONS 10 1 NOISE REGULATION 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE Y E S 14 1 9 10 11 12 13 14 ...

Page 10: ...1 1 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS ...

Page 11: ...er operation of your ATV Never remove any labels from your ATV If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 UNDER WARNING 5FE 21697 01 NEVER operate this ATV if you are under age 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death ...

Page 12: ...1 3 3 4 5 ...

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

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

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

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

Page 17: ...ies Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Products Safety Com mission at 1 800 638 2772 or the ATV Distributor s Safety Hotline at 1 800 852 5344 ...

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

Page 19: ...ng or running the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation ...

Page 20: ...l 6 Headlight 7 Fuel cock 8 Throttle stop screw 9 Coolant reservoir 10 Tail brake light 11 Shift pedal 12 Clutch lever 13 Handlebar switches 14 Parking brake 15 Main switch 16 Reverse knob 17 Throttle lever 18 Brake lever NOTE The machine you have purchased may differ slightly from those shown in the figures of this manual ...

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

Page 22: ...ication number NOTE The vehicle identification number is used to identify your machine EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label ...

Page 23: ...ult in serious injury or death EBU00942 Main switch Functions of the respective switch positions are as follows ON The engine can be started only at this position and the headlights and taillight come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position ...

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

Page 25: ...ht does not come on Coolant temperature warning light comes on Coolant temperature warning light does not come on Coolant temperature and electrical circuit are OK Go ahead with riding Push the start switch with the transmission in the neutral position Ask a Yamaha dealer to inspect the electrical circuit Coolant temperature warning light comes on momentarily ...

Page 26: ... and the taillight CAUTION _ Do not use the headlights with the engine turned off for more than thirty minutes The battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it _ EBU00849 Engine stop switch Make sure that the engine stop switch is in the position The engine stop switch controls ignition and can be used ...

Page 27: ...4 5 EBU00607 Start switch The starter motor cranks the engine when this switch is pushed CAUTION See starting instructions prior to starting the engine See page 6 1 for details ...

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

Page 29: ...ATV 1 Locknut 2 Adjuster a 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an acci dent or be injured HOW TO AVOID THE HAZARD Do not turn the speed adjuster out more than 12 mm 0 47 in Always make sure the throttle lever free play is...

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

Page 31: ...4 9 EBU00989 Brake pedal The brake pedal is located on the right side of the machine Push down on the pedal to apply the rear brake 1 Brake pedal ...

Page 32: ...the button then push in the lock plate to apply the parking brake Squeeze the clutch lever to release the parking brake NOTE When the parking brake is used engine speed is limited to 2 300 r min Be sure the parking brake is released before moving the throttle lever Otherwise the engine will mis fire preventing normal operation 1 Button 2 Lock plate 1 Locked position ...

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

Page 34: ... shift into reverse gear Refer to the Reverse knob operation and re verse driving section page 6 5 before oper ating this machine in reverse gear 1 Reverse knob REV EBU00092 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap ...

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

Page 36: ...tion a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See page 6 1 1 Starter choke EBU01010 Seat To remove the seat insert your hand between the rear of the seat and the rear fender pull the seat lock lever upward and pull up the seat at the rear 1 Seat lock lever ...

Page 37: ... install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE _ Make sure that the seat is securely fitted _ 1 Projection 2 2 Seat holder 2 ...

Page 38: ...ring preload turn the ad justing ring in direction b 1 Adjusting ring NOTE _ A special wrench can be obtained at a Yamaha dealer _ Standard position C A Minimum Soft E Maximum Hard WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock...

Page 39: ...cial wrench NOTE _ A special wrench can be obtained at a Yamaha dealer _ WARNING POTENTIAL HAZARD This shock absorber contains highly pressurized nitrogen gas WHAT CAN HAPPEN The shock absorber could explode causing injury or property damage Cylinder damage could also result in poor handling which could cause an accident HOW TO AVOID THE HAZARD Do not tamper with or attempt to open the cylinder as...

Page 40: ...th 4 Tighten the locknut to the specified torque CAUTION _ Always tighten the locknut against the spring adjusting nut and tighten it to the specified torque _ Measurement A Installed length Minimum hard 232 mm 9 1 in Standard 240 mm 9 4 in Maximum soft 247 mm 9 7 in Tightening torque 42 Nm 4 2 m kgf 30 ft lb ...

Page 41: ...ession damping force as fol lows Turn the compression damping force adjust ing screw in direction a to increase the com pression damping force and in direction b to decrease the compression damping force 1 Compression damping force adjusting screw From the fully turned in position Minimum soft 20 clicks out Standard 10 clicks out Maximum hard 3 clicks out From the fully turned out position Minimum...

Page 42: ... a precise adjustment it would be advisable to check the number of clicks of each damping force adjusting mech anism and to modify the specifications as nec essary _ EBU00112 WARNING Indicates a potential hazard that could result in serious injury or death WARNING POTENTIAL HAZARD Suspension components become hot during operation WHAT CAN HAPPEN You could be burned HOW TO AVOID THE HAZARD Never to...

Page 43: ... play 8 31 8 32 Parking brake Check operation condition and cable free play 8 29 8 30 Fuel Check fuel level Fill with fuel if necessary 5 4 5 5 Engine oil Check oil level Fill with oil if necessary 5 6 8 6 8 10 Coolant reservoir Check coolant level Fill with coolant if necessary 5 7 8 11 8 14 Drive chain Check chain slack and condition Adjust if necessary 5 8 8 33 8 34 Throttle Check for proper th...

Page 44: ... ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op erating condition Always follow the inspection and main tenance procedures and schedules de scribed in the Owner s Manual ...

Page 45: ...ied If not have the machine in spected by a Yamaha dealer Brake fluid level Check the brake fluid level Add fluid if nec essary See pages 8 24 8 26 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or master cylinders Apply the brakes firmly for one minute If there is any leaking have the machine inspected by a Yamaha dealer Brake operation Test the brakes at sl...

Page 46: ...rand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost 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 problem with the brakes...

Page 47: ...el level WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled ...

Page 48: ... will cause clutch and or starter clutch slippage resulting in re duced component life and poor engine performance _ Recommended oil Recommended engine oil classification API Service SE SF SG type or higher 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 Oil quantity Periodic oil change 1 9 L 1 67 Imp qt 2 01 US qt With oil f...

Page 49: ...ls CAUTION Hard water or salt water is harmful to the engine You may use distilled water if you can t get soft water Reservoir tank capacity 0 29 L 0 26 Imp qt 0 31 US qt From LOW to FULL level 0 17 L 0 15 Imp qt 0 17 US qt WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressu...

Page 50: ...d Repair as necessary for proper operation EBU00152 Fittings and Fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque EBU00991 Lights Check the headlights and tail brake light to make sure they are in working condition Re pair as necessary for proper operation EBU00912 S...

Page 51: ...odel Other tire combina tions are not recommended Manufacturer Size Type Front DUNLOP AT21 7 10 KT331 Rear DUNLOP AT20 10 9 KT335 2 The tires should be set to the rec ommended pressure Recommended tire pressure Front 27 5 kPa 0 275 kgf cm2 4 0 psi Rear 27 5 kPa 0 275 kgf cm2 4 0 psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pressure b...

Page 52: ...ng specifica tions 1 Low pressure tire gauge 4 Use no more than the following pressures when seating the tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst Recommended pressure Minimum Maximum Front 27 5 kPa 0 275 kgf cm2 4 0 psi 24 5 kPa 0 ...

Page 53: ...5 11 EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a 3 mm 0 12 in ...

Page 54: ... being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or co...

Page 55: ...ith the transmission in any position However it is recommended to shift into neutral be fore starting the engine 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold engine start ambient temperature at 0 C 30 F 30 C 90 F and warming up position Position 3 Cold engine start ambient temperature above 25 C 80 F and warm eng...

Page 56: ... 7 If the engine is started with the starter choke in position 1 the starter choke should be returned to position 2 to warm up the engine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter choke to position 3 before riding CAUTION See the Engine b...

Page 57: ...life always warm up the engine before starting off Never acceler ate hard with a cold engine To see whether or not the engine is warm check if it responds to the throttle normally with the starter choke turned off NOTE When the parking brake is used engine speed is limited to 2 300 r min Be sure the parking brake is released before moving the throttle lever Otherwise the engine will mis fire preve...

Page 58: ...ransmission into first gear 2 While applying the rear brake pedal turn the reverse knob clockwise with your right hand 3 Shift the transmission into reverse by pressing down on the shift pedal 1 Reverse knob REV 2 Shift pedal NOTE When in reverse the reverse indicator light should be on If the light does not come on ask a Yamaha dealer to inspect the machine 4 Check behind you for people or obsta ...

Page 59: ...nal position apply the clutch and repeatedly depress the shift pedal until it stops When it stops it will be in first gear Raise the pedal slightly to neutral 1 Shift pedal N Neutral position R Reverse WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person be hind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into rever...

Page 60: ...fting without the clutch _ EBU00203 To start out and accelerate 1 Release the throttle lever CAUTION Always close the throttle while shifting gears Otherwise damage to the engine and drive train may result 2 Pull the clutch lever to disengage the clutch 3 Shift into first gear 4 Open the throttle gradually and at the same time release the clutch lever slow ly 5 Once the machine has attained adequa...

Page 61: ...accident WARNING POTENTIAL HAZARD Opening the throttle abruptly or releas ing the clutch lever too quickly WHAT CAN HAPPEN The machine could wheelie This would increase the chance of an accident in cluding overturn HOW TO AVOID THE HAZARD Open the throttle gradually Release the clutch lever gradually WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN T...

Page 62: ...onds maxi mum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest pe riod for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this peri od consult a Yamaha dealer 1 0 10 hours Avoid continuous operation above half thro...

Page 63: ...6 10 EBU00211 Parking When parking stop the engine and shift into neutral Turn the fuel cock to OFF and apply the parking brake 1 Button 2 Lock plate 1 Locked position ...

Page 64: ...WARNING POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control in creasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline put the machine in low gear apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that...

Page 65: ...suitability of them Choose a genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a...

Page 66: ...ers Make sure cargo in the trailer cannot move around A shifting load can cause an acci dent Make sure the load does not interfere with controls or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slow er you should go Although conditions vary it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or wh...

Page 67: ...HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking ...

Page 68: ...6 15 EBU00929 WARNING _ Indicates a potential hazard that could result in serious injury or death ...

Page 69: ...7 1 7 1 Riding Your ATV ...

Page 70: ...7 2 ...

Page 71: ...your time to fully learn techniques be fore attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual completely and understand the opera...

Page 72: ...techniques well before attempting more difficult maneu vers WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in creased if the operator does not know how to operate the ATV properly in dif ferent situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the cer...

Page 73: ...lure to follow the age recommenda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc ...

Page 74: ...his ATV 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 passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers ...

Page 75: ... in the event of an accident Operating without eye protection can re sult in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or...

Page 76: ...rugs WARNING POTENTIAL HAZARD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV ...

Page 77: ...e op erating condition Always follow the in spection and maintenance procedures and schedules described in the Owner s Manual WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of an ...

Page 78: ...peed limiter limits the power and top speed of the ATV Turning the screw in decreases top speed and turning it out increases top speed 1 Locknut 2 Adjusting screw WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing con trol of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always go at a ...

Page 79: ...0 kg 220 lbs WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance f...

Page 80: ...n WHAT CAN HAPPEN Removing even one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of ...

Page 81: ... the ATV or overturn WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off ...

Page 82: ...andling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an autho rized ATV deale...

Page 83: ...T CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en gine area could catch fire Someone touching the exhaust system during or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exhaust syst...

Page 84: ... POTENTIAL HAZARD Operating this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of con trol HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets ...

Page 85: ...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 high ways ...

Page 86: ...TIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when op erating on unfamiliar terrain Always be alert to changing terrain con ditions when operating the ATV ...

Page 87: ...uld cause loss of traction or vehicle control which could result in an acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain ...

Page 88: ...de in areas posted no trespassing Do not ride on private property without getting permission 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 injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch care fully for other vehicles ...

Page 89: ...ow skin or clothing to come in contact with these components With the engine idling pull the clutch lever to disengage the clutch and shift into 1st gear and then release the parking brake Open the throttle gradually and at the same time re lease the clutch lever slowly Once the ATV has attained adequate speed release the throttle lever and at the same time quickly pull in the clutch lever and shi...

Page 90: ...ility of an accident WARNING POTENTIAL HAZARD Opening the throttle abruptly or releas ing the clutch lever to quickly WHAT CAN HAPPEN The ATV could wheelie This would in crease the chance of an accident in cluding overturn HOW TO AVOID THE HAZARD Open the throttle gradually Release the clutch lever gradually WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN ...

Page 91: ...he desired direc tion As you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneu ver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPP...

Page 92: ...at Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the in side It may also be nece...

Page 93: ... 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 lean ing forward and on steeper inclines standing on the footboards and leaning forward over the handlebars WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than o...

Page 94: ...ed in this Own er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other ...

Page 95: ... Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as de scribed ...

Page 96: ...sily tip over backwards In stead dismount the ATV immediately on the uphill side WARNING POTENTIAL HAZARD Stalling rolling backwards or improper ly dismounting while climbing a hill WHAT CAN HAPPEN Could result in the ATV overturning HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the park...

Page 97: ...7 29 Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the pro cedure described in the Owner s Manual ...

Page 98: ...ownhill Avoid sharp angles which could al low the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for go ing down hills as described i...

Page 99: ...7 31 ...

Page 100: ...t 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 gradually steer again in the direction you wish to travel 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 A...

Page 101: ...7 33 Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV ...

Page 102: ... slowly and carefully WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that spec ified in your Owner s Manual Remember that wet brakes may have re duced stopping abilit...

Page 103: ...fying that you have regained proper braking ability CAUTION _ After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case Wash the ATV in fresh water if it has been operated in salt water or muddy con ditions _ 1 Check hose ...

Page 104: ...ing the ATV as loss of control and damage to the ATV may result WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a colli sion Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles a...

Page 105: ...7 37 ...

Page 106: ...the tendency for the front wheels to slide in loose or slippery conditions position ing your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways control can usually be regained if there is room to do so by steering in the direc tion of the slide Applying the brakes or accel erating is not recommended until you have corrected the slide ...

Page 107: ...ces such as ice since all control may be lost WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or slid ing by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go ...

Page 108: ...rn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See pages 7 23 7 24 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide See pages 7 38 7 39 If your ATV can t make it up a hill you are trying to climb Turn the AT...

Page 109: ...TV is going to tip over dis mount on the uphill side See pages 7 32 7 33 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV un til you have regained adequate braking ability See pages 7 34 7 3...

Page 110: ... put this owner s manual and low pressure tire gauge in the vi nyl bag and always carry them along with the owner s tool kit under the seat 1 Owner s manual 2 Owner s tool kit 3 Low pressure tire gauge WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can sta...

Page 111: ...r machine to a Yamaha dealer to check the torque settings and adjust them as neces sary WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installa...

Page 112: ...st engine idling speed and synchronization Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Tighten if necessary Replace gasket if necessary Spark arrester Clean Fuel line Check fuel hose for cracks or damage Replace if necessary Engine oil Replace Warm engine before draining Engine oil filter cartridge Replace if necessary Dr...

Page 113: ...hoses every four years or if cracked or damaged WARNING Indicates a potential hazard that could result in serious injury or death Wheels Check balance damage runout Replace if necessary Wheel bearings Check bearing assembly for looseness damage Replace if damaged Steering system Check operation Repair if damaged Check toe in Adjust if necessary Upper and lower arm piv ot and steering shaft Lubrica...

Page 114: ...perform some of the maintenance described in this chapter Refer to this section each time the panel has to be removed or installed EBU01013 Panel A 1 Panel A 2 Bolt 2 To remove Remove the bolts and then take the panel off To install Place the panel in the original position and then install the bolts ...

Page 115: ...n seconds and then turn the en gine off NOTE _ To achieve the proper engine oil temperature for an accurate oil level reading the engine must have first completely cooled down and then warmed up again for several minutes to normal operating temperature _ 3 Wait a few minutes until the oil settles re move the engine oil tank filler cap wipe the dipstick clean with a clean rag insert it back into th...

Page 116: ... _ 5 Insert the dipstick into the oil filler hole and then tighten the oil filler cap CAUTION _ Make sure that the oil filler cap is securely tightened otherwise oil may seep out when the engine is running _ To change the engine oil with or without oil filter cartridge replacement 1 Engine guard 2 Bolt 6 1 Remove the engine guard by removing the bolts 2 Start the engine warm it up for several minu...

Page 117: ...crankcase engine oil drain bolt 1 Crankcase engine oil drain bolt 1 Engine oil tank drain bolt 5 Remove the engine oil tank filler cap and the oil tank drain bolt 6 Check the washers for damage and re place if necessary ...

Page 118: ...ench NOTE _ An oil filter wrench is available at a nearby Yamaha dealer _ 1 O ring 8 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge NOTE _ Make sure that the O ring is properly seated _ 9 Install a new oil filter cartridge and tighten it to the specified torque with a torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lb ...

Page 119: ... with the oil or use oils of a grade CD or higher In addition do not use oils labeled ENERGY CON SERVING II or higher Make sure that no foreign material en ters the crankcase _ 12 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 13 Turn the engine off and then check the oil level an...

Page 120: ...cap and then add coolant or dis tilled water to raise it to the specified level CAUTION _ Hard water or salt water is harmful to the engine You may use soft water if you can t get distilled water _ NOTE _ If water is added have a Yamaha dealer check the antifreeze content of the cool ant as soon as possible The radiator fan operation is completely automatic It is switched on or off accord ing to t...

Page 121: ...nt drain bolt 1 Coolant drain bolt WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before re moving the radiator cap Always use a thick rag over the cap Allow any re maining pressure to escape before completely removi...

Page 122: ...olant res ervoir side and then drain the coolant from the coolant reservoir 1 Coolant reservoir cap 2 Hose 7 After draining the coolant thoroughly flush the cooling system with clean tap water 8 Replace the coolant drain bolt washer if it is damaged and then tighten the coolant drain bolt to the specified torque ...

Page 123: ...vel in the radiator If it is low add more coolant until it reaches the top of the radiator 14 Check the coolant level in the reservoir If it is low add coolant to the maximum lev el mark 15 Start the engine and then check for cool ant leakage NOTE _ If any leakage is found have a Yamaha deal er check the cooling system _ 16 Install the panel Tightening torque Coolant drain bolt 10 Nm 1 0 m kgf 7 f...

Page 124: ...olor on the white insulator around the center electrode is a medium to light tan color for a ATV that is being ridden normally Do not attempt to diagnose such problems yourself Instead take the ATV to a Yamaha dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes ex cessive or...

Page 125: ...l the spark plug and tighten it to the specified torque NOTE _ If a torque wrench is not available when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possible _ 4 Install the spark plug cap Spark plug gap 0 8 0 9 mm 0 03 0 04 in Tightening torque Spark plug 17 5 Nm 1 75 m k...

Page 126: ...is hose empty the hose and clean the air filter element and air filter case 1 Check hose 1 Remove the seat See page 4 14 for seat removal procedure 2 Remove the air filter case cover by un hooking the holders 1 Air filter case cover 2 Holder 6 3 Remove the air filter element and remove it from its frame 1 Unlock 2 Element retaining plate ...

Page 127: ... it dry CAUTION Do not twist the filter element when squeezing it 6 Inspect the element and replace it if dam aged WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element ...

Page 128: ...the machine is operated in extremely dusty areas Each time the filter el ement maintenance is performed check the air inlet to the filter case for obstructions Check the air cleaner rubber joint to the car buretor and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine CAUTION Never operate the engine with the air filt...

Page 129: ...ve the bolt 1 Bolt 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the bolt and tighten it ...

Page 130: ...Yamaha fac tory after many tests If the settings are disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poison ing possibly leading to death Could start a fire HOW TO AVOID THE...

Page 131: ...to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Connect the tachometer and set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in to increase engine speed and out to de crease engine speed 1 Throttle stop screw Specified idle speed 1 450 1 550 r min ...

Page 132: ... regularly This adjust ment however should be left to a professional Yamaha service technician EBU00307 Throttle lever adjustment NOTE Adjust the engine idling speed before adjust ing the throttle lever free play 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle le ver free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut 1 Locknut 2 Adjusting bolt a Throttle lever free play ...

Page 133: ...r grooves are al most in contact with the disc plate ask a Yamaha dealer to replace the pads 1 Wear indicator groove 1 Wear indicator groove EBU01017 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the lower level and re plenish when necessary NOTE _ To a...

Page 134: ...op of the brake fluid reservoir is level Use only the designated quality brake fluid Otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reac tion and lead to poor brake performance Front Recommended brake fluid DOT 4 Rear ...

Page 135: ... dealer replace the fol lowing components during periodic main tenance or when they are damaged or leaking Replace all rubber seals every two years Replace all hoses every four years WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brake...

Page 136: ...sted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is cor rect Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re quires professional knowledge These procedures sh...

Page 137: ...y serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the brake pedal po sition is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re quires professional ...

Page 138: ...t on the clutch lever 1 Locknut 2 Adjusting bolt 2 Loosen the adjusting bolt locknut and the adjusting bolt on the rear brake caliper 1 Locknut 2 Adjusting bolt a Cable length 3 Turn the adjusting bolt on the clutch lever so that cable length a is 64 68 mm 2 52 2 68 in NOTE _ If the cable cannot be adjusted to specifica tion consult a Yamaha dealer _ 4 Tighten the adjusting bolt locknut on the clu...

Page 139: ... with the locknut _ Tightening torque Locknut 16 Nm 1 6 m kgf 12 ft lb WARNING POTENTIAL HAZARD Operating with improperly adjusted brakes WHAT CAN HAPPEN The brakes could malfunction causing reduced braking performance This could increase the chance of a collision or accident HOW TO AVOID THE HAZARD After adjusting the parking brake block the rear of the machine off the ground and spin the rear wh...

Page 140: ... brake light come on later turn the adjusting nut in direction b 1 Rear brake light switch 2 Adjusting nut EBU00741 Clutch lever free play adjustment The clutch lever free play should be adjusted to 5 10 mm 0 20 0 39 in 1 Loosen the locknut at the clutch lever 2 Turn the adjusting bolt at the clutch lever in direction a to increase the free play or in direction b to decrease the free play 3 Tighte...

Page 141: ...sen the locknut at the crankcase side 7 Turn the adjusting nut at the crankcase in direction a to increase the free play or in direction b to decrease the free play 8 Tighten the locknut at the crankcase and the clutch lever 1 Locknut 2 Adjusting nut ...

Page 142: ...chain slack a Drive chain slack EBU00917 Drive chain slack adjustment 1 Loosen the rear wheel hub upper and lower nuts 1 Upper wheel hub nut 2 Lower wheel hub nut 2 Loosen the adjusting bolt locknuts on each side of the swingarm To tighten the drive chain turn the adjusting bolts in di rection a To loosen the drive chain turn the adjusting bolts in direction b and push the wheels forward Turn each...

Page 143: ...el axle alignment 1 Locknut 2 2 Adjusting bolt 2 3 Alignment marks 3 After adjusting tighten the adjusting bolt locknuts and the wheel hub nuts to the specified torques Tightening torque Locknut 16 Nm 1 6 m kgf 12 ft lb Upper wheel hub nut 90 Nm 9 0 m kgf 65 ft lb Lower wheel hub nut 90 Nm 9 0 m kgf 65 ft lb ...

Page 144: ...e chain must be lubricated after washing the ATV or riding in the rain 1 Clean the drive chain with kerosene and a small soft brush CAUTION To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION Do not use engine o...

Page 145: ...edal WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables Recommended lubricant Yamaha chain and cable lube or SAE...

Page 146: ...8 37 EBU01018 Front upper and lower arm pivot lubrication Lubricate the upper and lower arm pivots 1 Upper 2 Lower 1 Upper 2 Lower Recommended lubricant Lithium soap based grease Left side Right side ...

Page 147: ...8 38 EBU01019 Rear arm pivot lubrication Lubricate the rear arm pivot Recommended lubricant Lithium soap based grease ...

Page 148: ...8 39 EBU00373 Wheel removal 1 Elevate the wheel by placing a suitable stand under the frame 2 Remove the nuts from the wheel 3 Remove the wheel assembly 1 Nut 4 1 Nut 4 Front Rear ...

Page 149: ...k on the tire must point toward the rotating direction of the wheel When installing a rear wheel the wording on the tire SIDE FACING OUTWARDS must be facing outwards 1 Arrow mark 1 SIDE FACING OUTWARDS Tighten the wheel nuts to the specified torque Front Wheel nut torque Front 45 Nm 4 5 m kgf 33 ft lb Rear 45 Nm 4 5 m kgf 33 ft lb Rear ...

Page 150: ...d be poisoned You could be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magne sia beaten egg or vegeta...

Page 151: ...for recharging a sealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine EBU00390 Fuse replacement 1 The fuse case is located under the seat 2 If the fuse is blown turn off the main switch and install a new fuse of the spec ified amperage Then turn on the switch es If the fuse ...

Page 152: ... Remove the headlight assembly by re moving the bolts 1 Headlight assembly 2 Bolt 2 WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rat ing Never use a material in place of the proper fuse ...

Page 153: ...8 44 2 Disconnect the headlight coupler 1 Headlight coupler 3 Remove the screw 1 Screw 4 Remove the headlight cover from the headlight assembly ...

Page 154: ... headlight unit out from its case 1 Screw 1 Headlight unit 2 Headlight case NOTE _ Pull outward on the rear of the headlight unit and then pull outward on the front _ 6 Remove the headlight bulb holder cover 1 Headlight bulb holder cover ...

Page 155: ... Headlight bulb holder WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flamma ble HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it ...

Page 156: ...rely fitted over the bulb holder and seated against the reflector _ 10 Align the projections with the holders in stall the headlight unit into the case and install the screw 11 Install the headlight cover in the original position and then install the screw 12 Connect the headlight coupler 13 Install the headlight assembly in the orig inal position and tighten the bolts 14 Have a Yamaha dealer adju...

Page 157: ...ns 1 Lens 2 Screw 2 2 Remove the defective bulb by pushing it inward and turning it counterclockwise 1 Bulb 3 Install a new bulb by pushing it inward and turning it clockwise 4 Install the lens and tighten the screws CAUTION _ Do not overtighten the screws as the lens may break _ ...

Page 158: ...er ship have the tools experience and know how to properly service your machine Use only genuine Yamaha parts on your machine Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to ex pensive repair bills WARNING POTENTIAL HAZARD Checking the fuel system while smok ing or near an open flame WHAT CAN HAPPEN Fuel can ignit...

Page 159: ...ssion Compression normal No compression Ask a Yamaha dealer to inspect 3 Ignition Remove the spark plug and check the electrodes Wet Wipe clean with dry cloth Dry Attach spark plug cap and ground to chassis Use the electric starter Spark is good Ignition system is normal Spark is weak Adjust the spark plug gap or replace the spark plug No spark Ask a Yamaha dealer to inspect 4 Battery Use the elec...

Page 160: ... HOW TO AVOID THE HAZARD Wait for the engine to cool before re moving the radiator cap Always use a thick rag over the cap Allow any re maining pressure to escape before completely removing the cap Wait until the engine has cooled Check the coolant level in the reservoir tank and or radiator Level is OK Level is low check the cooling system for leakage No leakage Leakage Ask a Yamaha dealer to ins...

Page 161: ... wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car wash ers 4 On...

Page 162: ...Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds ...

Page 163: ...spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine over sever al times to coat the cylinder wall with oil 3 Clean the drive chain thoroughly and lu bricate it See page 8 35 4 Lubricate all control cables 5 Block up the frame to raise all wheels off the ground 6 Tie a plastic bag ov...

Page 164: ...d charge it Store it in a dry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the machine ...

Page 165: ... mm 43 3 in 1 150 mm 45 3 in 860 mm 33 9 in 1 245 mm 49 in 265 mm 10 4 in 3 300 mm 129 9 in Basic weight With oil and full fuel tank 193 kg 426 lb Engine Type Cylinder arrangement Displacement Bore stroke Compression ratio Starting system Lubrication system Liquid cooled 4 stroke SOHC Forward inclined single cylinder 660 cm3 100 84 mm 3 94 3 31 in 9 2 1 Electric starter Dry sump ...

Page 166: ...qt 2 3 L 2 02 Imp qt 2 43 US qt MODEL YFM660R 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 CAUTION Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled ENERGY CONSERVING II contain anti friction additives which will cause clutch and or starter clutch slippage resultin...

Page 167: ...pe quantity Manufacturer BSR33 2 MIKUNI Spark plug Type manufacturer Gap DPR8EA 9 NGK 0 8 0 9 mm 0 03 0 04 in Clutch Type Operation Wet multiple disc Left hand operation Transmission Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Transmission type Operation Spur gear 71 34 2 088 Chain drive 40 13 3 076 Constant mesh 5 speed forward 1 speed rev...

Page 168: ...tube 8 47 mm 1 85 in Tire Type Size Front Size Rear Tubeless AT21 7 10 AT20 10 9 Brake Front brake type Operation Rear brake type Operation Dual disc brake Right hand operation Single disc brake Right foot operation Suspension Front Rear Double wishbone Swingarm link suspension Shock absorber Front Rear Coil spring oil damper Coil spring gas oil damper MODEL YFM660R ...

Page 169: ...em Battery type voltage capacity DC C D I A C magneto YTX14 BS 12V 12Ah Headlight type Krypton bulb Bulb voltage wattage quantity Headlight Tail brake light Indicator warning lights Neutral Reverse Coolant temperature 12V 30W 30W 2 12V 5W 21W 1 12V 1 7W 1 12V 1 7W 1 12V 1 7W 1 Fuse 20 A MODEL YFM660R ...

Page 170: ...y new vehicle 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 remo...

Page 171: ...in accordance with the warranty The chart below is printed only as a re minder to you that the maintenance work is required It is not acceptable proof of maintenance work ACL 02EACL 02E MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS 1 Month 3 Months 6 Months 12 Months 18 Months 24 Months 30 Months 36 Months 42 Months 48 Months 54 Months 60 Months ...

Page 172: ...13 1 EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY ...

Page 173: ...13 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ...

Page 174: ...14 1 EBU00435 YAMAHA EXTENDED SERVICE Y E S ...

Page 175: ...14 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ...

Page 176: ...14 3 EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death ...

Page 177: ...14 5 EBU00437 ...

Page 178: ... DRUGS OR ALCOHOL ALWAYS USE AN APPROVED HELMET AND PROTECTIVE 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 MA...

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