Yamaha YFM09RYXG Owner'S Manual Download

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8-26

To adjust the drive chain slack

1. Loosen the bolts and nuts.

2. Loosen the rear brake lever free play adjust-

ing nut.

3. Loosen the locknut.

1. Bolt

1. Nut

1. Rear brake lever free play adjusting nut

UBD360E0.book Page 26 Wednesday, February 25, 2015 2:41 PM

Summary of Contents for YFM09RYXG

Page 1: ... DEL PROPIETARIO BD3 F8199 60 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad ...

Page 2: ...DIC183 Original instructions Notice originale Manual original PRINTED IN TAIWAN 2015 03 ...

Page 3: ...AL CAREFULLY It contains important safety information WARNING OWNER S MANUAL YFM09RYXG This ATV should not be ridden by anyone under 10 years of age BD3 F8199 60 E0 UBD360E0 book Page 1 Tuesday March 24 2015 4 07 PM ...

Page 4: ...olhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Akihiro Tsuzuki Date of Issue If applicable and to the other relevant Directives of EEC to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards...

Page 5: ... regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE Read this manual completely before operating your ATV Make sure you understand all instructions Pay close attention to the warning and notice labels on the ATV This ATV should not be operated by a child under 10 years of age AN IMPORTANT NOTE TO PARENTS This ATV is not a toy Before you le...

Page 6: ...heir youngster s riding skills improve Once the ATV rider can operate with skill at the top speed permitted by adjusting the vehicle speed limiter alone the engine speed limiter plate can be removed Since removal of this limiter will result in a significant increase in power turn the vehicle speed limiter adjusting screw completely back in again adjust it out in stages as done previously If your c...

Page 7: ...fety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key informa...

Page 8: ... or motorway Please check your local riding laws and regulations before operating this ATV EBU33790 YFM09RYXG OWNER S MANUAL 2015 by Yamaha Motor Co Ltd 1st edition January 2015 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Taiwan UBD360E0 book Page 1 Wednesday February 25 2015 2 41 PM ...

Page 9: ... select lever 4 6 Kickstarter 4 7 Fuel tank cap 4 8 Fuel 4 8 Fuel cock 4 10 Starter choke 4 11 Seat 4 12 Adjusting the front shock absorber assemblies 4 13 Adjusting the rear shock absorber assembly 4 14 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Transmission oil 5 3 Front and rear brakes 5 3 Throttle lever 5 3 Drive chain 5 3 Tires 5 3 Chassis fasteners 5 6 Instruments and switches 5 6 OPER...

Page 10: ...ng the spark plug 8 9 Engine oil 8 11 Transmission oil 8 14 Cleaning the air filter element 8 15 Cleaning the spark arrester 8 18 Adjusting the carburetor 8 19 Adjusting the engine idling speed 8 19 Adjusting the throttle lever free play 8 20 Valve clearance 8 21 Brakes 8 21 Checking the front and rear brake shoes 8 21 Adjusting the front brake lever free play 8 22 Adjusting the rear brake lever f...

Page 11: ...eshooting 8 35 Troubleshooting chart 8 36 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 INDEX 12 1 UBD360E0 book Page 3 Wednesday February 25 2015 2 41 PM ...

Page 12: ...ls 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 re placement label from your Yamaha dealer For Europe 1 4 5 6 7 2 3 UBD360E0 book Page 1 Wednesday February 25 2015 2 41 PM ...

Page 13: ...1 2 1 BD3 F816R 20 BD3 F811R 50 1 3 2 UBD360E0 book Page 2 Wednesday February 25 2015 2 41 PM ...

Page 14: ... cm 3 5 psi 24 0 kPa 0 24 kgf cm 3 5 psi BD3 F816M M0 BD3 F816P 50 BD3 F156A 10 YFM90R 4 5 kW 126 kg BD3 F817L 10 YAMAHAMOTORCO LTD 2500SHINGAI IWATA JAPAN 2015 6 7 5 4 UBD360E0 book Page 3 Wednesday February 25 2015 2 41 PM ...

Page 15: ...2 increases the risk of severe injury or death Adult supervision required for children under age 16 Use from 16 years old Operating this ATV if you are under the age of 16 increases your chance of severe injury or death Use from 10 years old Operating this ATV if you are under the age of 10 increases your chance of severe injury or death Adult supervision required for children under age 16 NEVER u...

Page 16: ...sure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death This pictogram shows the loading limits and or maximum load capacity for this ATV Follow all load limits and other loading guidelines in this manual Load may include the driver passenger human protective gear accessories goods luggage and all other load related items Make sure you do not exce...

Page 17: ...it Combined weight of the trailer and all cargo in the trailer Overloading can cause loss of control Loss of control can result in severe injury or death This pictogram shows trailer Hitch Tongue weight limit Weight on the trailer tongue Overloading can cause loss of control Loss of control can result in severe injury or death UBD360E0 book Page 6 Wednesday February 25 2015 2 41 PM ...

Page 18: ...1 7 1 For Oceania 2 1 3 4 UBD360E0 book Page 7 Wednesday February 25 2015 2 41 PM ...

Page 19: ...nce and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and it turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS BD3 F1568 60 WARNING UNDER 10 Operation of this ATV by children under the age of 10 increases the risk o...

Page 20: ...Maximum weight capacity 82 kg 181 lbs Includes weight of operator cargo and accessories Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death 3 5 psi 3 5 psi 3 0 psi 3 0 psi BD3 F816M 60 WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH BD3 F151H 00 3 4 UBD360E0 book Page 9 Wed...

Page 21: ...a child under 10 years old to oper ate this ATV Never allow a child under 16 years old to oper ate an ATV without adult supervision Do not allow continued use of the ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV This vehicle is intended for off road use only Do not operate on any paved surfaces such as sidewalks driveways parking lot...

Page 22: ...aster 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 surfaces Shift your weight for...

Page 23: ... cautious in order to reduce the chance of skidding or sliding out of control 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 of tires specified in th...

Page 24: ... ride gently back to camp or other known location where you can receive medical at tention If necessary contact your riding party or local authorities to let them know where you are and what has happened In the event of a breakdown 1 If your vehicle will not restart or is not in safe operating condition turn off the main switch and engine stop switch If the breakdown oc curs at twilight or night l...

Page 25: ...hers at greater risk of serious injury or death You are responsible for injuries re lated to changes in the vehicle Keep the following guidelines in mind as well as those provided un der Loading when mounting accessories Never install accessories that would impair the performance of your ATV Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clea...

Page 26: ...eas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or par tially enclosed areas such as barns garages or carports Do not r...

Page 27: ...ear shock absorber assembly spring preload adjusting ring 7 Kickstarter lever cap 1 2 3 4 5 7 6 1 Spark arrester 2 Owner s tool kit 3 Front shock absorber assembly spring preload adjusting ring 4 Spark plug 5 Engine oil filler cap 6 Transmission oil filler cap 1 2 3 6 5 4 UBD360E0 book Page 1 Wednesday February 25 2015 2 41 PM ...

Page 28: ...ffer slightly from the figures shown in this manual 1 Rear brake lever 2 Handlebar switches 3 Parking brake lock plate 4 Starter choke 5 Main switch 6 Throttle lever 7 Front brake lever 8 Drive select lever 1 2 3 5 6 7 4 8 UBD360E0 book Page 2 Wednesday February 25 2015 2 41 PM ...

Page 29: ...All electrical systems are off The key can be re moved EBU17794 Indicator lights EBU17861 Neutral indicator light This indicator light comes on when the transmis sion is in the neutral position EBU17831 Reverse indicator light This indicator light comes on when the transmis sion is in the reverse position ON OFF 1 Reverse indicator light R 2 Neutral indicator light N 1 2 UBD360E0 book Page 1 Wedne...

Page 30: ...s switch to crank the engine with the start er See the starting instructions on page 6 1 prior to starting the engine EBU18283 Throttle lever Once the engine is running pushing the throttle le ver will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decelerate and the engine will return to an idle any time ...

Page 31: ...ce 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 plate will result in a significant increase in power turn the vehicle speed limiter adjusting screw completely back in again and adjust it out in stages as done previous ly Vehicle speed limiter 1 Loosen the locknut 2 To...

Page 32: ...te as shown 3 Tighten the screws 4 Install the seat TIP Store the engine speed limiter plate with the own er s manual so that it is readily available whenever you want to reduce top engine speed EBU18392 Front brake lever The front brake lever is located on the right han dlebar To apply the front brake pull the brake le ver toward the handlebar grip 1 Locknut 2 Adjusting screw 3 No more than 10 mm...

Page 33: ...EBU18462 Parking brake Use the parking brake before starting the engine or after parking the ATV especially on a slope Ap ply the rear brake lever and push down the lock plate to apply the parking brake Squeeze the rear brake lever to release the parking brake 1 Front brake lever 1 1 Rear brake lever 1 UBD360E0 book Page 5 Wednesday February 25 2015 2 41 PM ...

Page 34: ...ride the ATV without re leasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely EBU18582 Drive select lever The drive select lever is used to shift your ATV into the forward neutral and reverse positions See the Operating the drive select lever and driving in re verse section on page 6 3 for the drive select le ver o...

Page 35: ...e if the battery is discharged 1 Remove the kickstarter lever cap 2 Install the kickstarter lever 3 Move the kickstarter lever down lightly with your foot until the gears engage and then push it down smoothly but forcefully 1 Kickstarter lever 1 1 Kickstarter lever cap 1 UBD360E0 book Page 7 Wednesday February 25 2015 2 41 PM ...

Page 36: ...ficient gasoline in the tank WARNING EWB02522 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling fol low these instructions 1 Before refueling turn off the engine and be sure that no one is sitting on the vehicle Nev er refuel while smoking or while in the vicinity 1 Kickstarter lever 1 1 Fuel tank cap 1 UBD360E0 book ...

Page 37: ...fuel may deteriorate painted surfaces or plastic parts ECB00982 4 Turn the fuel tank cap fully clockwise to make sure it is securely closed WARNING EWB02532 Gasoline is poisonous and can cause injury or death Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor 1 Maximum fuel...

Page 38: ...umber of 91 or higher 95 or higher for Europe If knocking or pinging occurs use a gasoline of a different brand Use of unleaded fuel will extend spark plug life and reduce maintenance costs EBU18821 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations OFF With the fuel co...

Page 39: ...uel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18851 Starter choke Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke 1 Arrow mark positioned over ON 1 1 Arrow mark pos...

Page 40: ...ile pushing the rear of the seat down pull the seat lock lever upward and then pull up the seat at the rear To install the seat Insert the projection on the front of the seat into the seat holder and push down on the seat at the rear Make sure that the seat is securely fitted 1 Starter choke 1 a b 1 Seat 2 Seat lock lever 1 2 UBD360E0 book Page 12 Wednesday February 25 2015 2 41 PM ...

Page 41: ...Never turn the adjusting mechanism beyond the minimum and maximum settings Adjust the spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension Align the appropriate notch in the adjusting ring with the position indicator on the...

Page 42: ...r turn the adjusting mechanism beyond the minimum and maximum settings Adjust the spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension 1 Special wrench Spring preload setting Minimum soft 1 Standard 3 Maximum hard 5 1 UBD36...

Page 43: ... Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Position indicator 1 2 3 4 5 2 1 a b 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 1 UBD360E0 book Page 15 Wednesday February 25 2015 2 41 PM ...

Page 44: ... using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 8 5 3 Engine oil Check oil level in engine and add recommended oil to specified level if necessary Check ATV for oil leakage Correct if necessary 5 3 8 11 Transmission oil Check ATV for oil leakage Correct if n...

Page 45: ...te if necessary 5 3 8 25 8 27 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 3 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 29 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 5 6 Instruments and switch...

Page 46: ...is applied If not have the ATV checked by a Yamaha dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance check the brake shoes for wear See page 8 21 EBU19762 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when release...

Page 47: ...ons EWB02542 Set tire pressures to the following specifications The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Recommended tire pressure Front 24 0 kPa 0 240 kgf cm 3 5 psi Rear 24 0 kPa 0 240 kgf cm 3 5 psi Minimum tire pressure Front 20 7 k...

Page 48: ...eless tires with valves WARNING EWB02552 Use of improper tires on this ATV may cause loss of control increasing your risk of an acci dent After extensive tests only the tires listed below have been approved for this model by Yamaha Motor Co Ltd 1 Low pressure tire gauge 1 1 Tire wear limit UBD360E0 book Page 5 Wednesday February 25 2015 2 41 PM ...

Page 49: ... not be appropriate EBU19841 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened EBU33810 Instruments and switches Check that all instruments and switches are work ing properly Correct if necessary Front Manufacturer model MAXXIS M939 DURO DI2017 Size AT18 x 7 8 Type Tubeless Rear Manufacturer model MAXXIS M940 DURO DI2016 Size AT18 x 9 8 Type Tubeless UBD360E0 book P...

Page 50: ...perating the engine for the first time 1 Set the parking brake The engine can be started only when the rear brake lever is ap plied 2 Turn the fuel cock to ON 3 Turn the key to ON and set the engine stop switch to 4 Shift the drive select lever into the neutral po sition The neutral indicator light should come on 5 Use the starter choke in reference to the fig ure Position 1 Cold engine start with...

Page 51: ... is started with the starter choke in position 1 the starter choke should be returned to position 2 to warm up the en gine 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 then return the starter choke to position 3 before riding TIP The engine is warm when it respond...

Page 52: ...Apply the rear brake lever 3 Shift from neutral to forward and vice versa by moving the drive select lever along the shift guide TIP Make sure that the drive select lever is completely shifted into position 4 Open the throttle lever gradually Shifting Reverse WARNING EWB00721 Improper operation in reverse could make you hit an obstacle or even a person behind you resulting in serious injury When y...

Page 53: ... figures given in km mi or the figures given in hours For ATVs not equipped with an odometer or hour meter follow the figures given in hours There is never a more important period in the life of your engine than the first 320 km 200 mi or 20 hours of riding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the fir...

Page 54: ...EBU30021 Parking When parking the ATV apply the rear brake lever shift the drive select lever into the forward posi tion stop the engine apply the parking brake and then turn the fuel cock to OFF EBU20765 Parking on a slope WARNING EWB00832 Avoid parking on hills or other inclines Parking on a hill or other incline could cause the ATV to roll out of control increasing the chance of an accident If ...

Page 55: ... on your ATV Many companies with no connection to Yamaha manufacture parts and accessories or offer other modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket compa nies produce Therefore Yamaha can neither en dorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha even if sold and in...

Page 56: ...s your view Use extra caution when riding an ATV with ac cessories The ATV may handle differently than it does without accessories EBU33880 Loading WARNING EWB00821 Never exceed the stated load capacity for this ATV Overloading this ATV or carrying or tow ing cargo improperly could cause changes in ATV handling which could lead to an accident Cargo should be properly distributed and se curely atta...

Page 57: ...iler cannot move around A shifting load can cause an accident Make sure the load does not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain...

Page 58: ...7 1 7 EBU21142 RIDING YOUR ATV UBD360E0 book Page 1 Wednesday February 25 2015 2 41 PM ...

Page 59: ...otice and warning labels on the vehicle RIDE WITH CARE AND GOOD JUDGMENT Beginning riders should get training from a certified instructor WARNING EWB01382 Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of te...

Page 60: ... lead to severe injury or death of the child This ATV is designed to carry the operator only passengers prohibited The long seat is to allow the operator to shift posi tion as needed during operation It is not for carry ing passengers WARNING Never carry a passenger Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV You could have an accident resulting in...

Page 61: ...injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident EWB02612 Do not operate after or while consuming alco hol or drugs The operator s performance capability is red...

Page 62: ...eed of the ATV Turning in the adjusting screw decreases top speed and turning it out increases top speed See page 4 3 This model also has an engine speed limiter plate to limit the amount of engine power available Yamaha recommends that all beginning riders start off with the engine speed limiter plate in stalled and the vehicle speed limiter adjusting screw turned in to limit the amount of speed ...

Page 63: ...carrying a load on inclines Turn gradually and go slowly As originally equipped this ATV is not designed to carry cargo or tow a trailer If you choose to add accessories to carry cargo you must use com mon sense and good judgment Use extra caution when 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 addi...

Page 64: ...w off EWB01482 Modifications and accessories Never modify this ATV through improper installa tion or use of accessories or other modification All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be in stalled and used according to instructions If you have questions consult an authorized ATV dealer WARNING Operating th...

Page 65: ... The muffler and other engine parts become ex tremely hot during operation and remain hot after the engine has stopped To reduce the risk of fire during operation or after leaving the ATV do not let brush grass and other materials collect under the vehicle near the muffler or exhaust pipe or next to other hot parts Check under the vehicle after operating in areas where combustible mate rials may h...

Page 66: ...atch carefully for other vehicles Make sure you know your country s laws and regulations before you ride on unpaved public streets or roads Do not ride on any paved public street road or motor way WARNING Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle EWB01522 Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for ...

Page 67: ...are when op erating on excessively rough slippery or loose terrain could cause loss of traction or ATV con trol which could result in an accident includ ing an overturn EWB01542 When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if operati...

Page 68: ...e trying more difficult ter rain Set the parking brake and follow the instruction on page 6 1 to start the engine Once it has warmed up you are ready to begin riding your ATV Re member that the engine and exhaust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these compo nents With the engine idling release the parking brake Apply the throttle slo...

Page 69: ...ld go out of control causing a collision or overturn To achieve maximum traction on unpaved surfac es the two rear wheels turn together at the same speed Therefore unless the wheel on the inside of the turn is allowed to slip or lose some traction the ATV will resist turning A special turning tech nique must be used to allow the ATV to make turns quickly and easily It is essential that this skill ...

Page 70: ... be gins to tip over to the outside while negotiating a turn lean more to the inside It may also be nec essary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL WARNING EWB01672 Climbing hills improperly can cause overturns or loss of control U...

Page 71: ... on the other side of the hill Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if pos sible When crossing the side of a hill shift your weight to the uphill side of the ATV OK UBD360E0 book Page 14 Wednesday February 25 ...

Page 72: ...e other side there could be another person an obstacle or a sharp drop off Use common sense and remem ber that some hills are too steep for you to climb or descend If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill If ...

Page 73: ...oper procedures for going down hills as described in this Owner s Manual Always check the terrain carefully before you start down any hill Never operate the ATV on hills too steep for the ATV or for your abilities The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills Shift your weight backward and to the up side of the hill Never go down a hill at high spe...

Page 74: ...rear brake Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear CROSSING A SLOPE WARNING EWB01633 Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to overturn Always follow proper procedu...

Page 75: ... the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance grad ually steer again in the direction you wish to travel CROSSING THROUGH SHALLOW WATER...

Page 76: ...es to let friction dry out the linings Do not continue to ride your ATV without verifying that you have regained proper braking ability WARNING Wet brakes may have reduced stopping ability which could cause loss of control EWB02622 After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case NOTICE Undrained water can cause damag...

Page 77: ...s at all times Avoid jumping the ATV as loss of control and damage to the ATV may result SLIDING AND SKIDDING WARNING EWB01663 Skidding or sliding improperly may cause you to lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery ...

Page 78: ...mmended until you have corrected the slide With practice over a period of time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are reduced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost WHAT TO DO IF This secti...

Page 79: ...ard speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 13 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to maintain proper balance If the...

Page 80: ...off the engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 6 for more information about carbon monoxide WARNING EWB02691 Brak...

Page 81: ...e intended to assist you in the performance of pre ventive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP There is a low pressure tire gauge located in the tool kit If you do not have the tools or experience re quired for a particular job have a Yamaha deal er perform it for you 1 Owner s tool kit 2 ...

Page 82: ...ire special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust ...

Page 83: ... 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 UBD360E0 book Page 4 Wednesday February 25 2015 2 41 PM ...

Page 84: ... data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Air filter check hose Clean 3 Front brake Check operation and correct if necessary Check brake lever fre...

Page 85: ...place if necessary 10 V belt Check for wear cracks or other damage and re place if necessary 11 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 12 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 13 Front knuckle piv ots Lubricate with lithium soap based grease 14 Steering shaft Lubricate with lithi...

Page 86: ...9 Moving parts and cables Lubricate 20 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 21 Front brake switch Check operation and correct if necessary 22 Switches Check operation and correct if necessary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500...

Page 87: ...8 8 EBU23062 TIP Some maintenance items need more frequent service if you are riding in unusually wet dusty sandy or muddy areas or at full throttle UBD360E0 book Page 8 Wednesday February 25 2015 2 41 PM ...

Page 88: ...ion the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normall...

Page 89: ...essary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification To install the spark plug 1 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 2 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Specified spark plug NGK CR6HSA 1 Spark ...

Page 90: ...n 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 sufficiently and then wait at least ten minutes until the oil set tles for an accurate reading 3 Remove the engine oil filler cap and then wipe the engine oil dipstick off with a clean rag 4 ...

Page 91: ...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 re move the engine oil drain bolt to drain the oil from the crankcase NOTICE When remov ing the engine oil drain bolt the compres sion spring oil strainer and O ring w...

Page 92: ...nstall and tight en the engine oil filler cap TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down NOTICE ECB00331 Do not use oils with a diesel specification of CD or oils of a higher quality than speci fied In addition do not use oils labeled EN ERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase 1 Engine oil drain...

Page 93: ...found have a Yamaha dealer check and repair the ATV In addition the transmission oil must be changed at the intervals specified in the periodic mainte nance and lubrication chart To change the transmission oil 1 Place the ATV on a level surface 2 Place an oil pan under the transmission case to collect the used oil 3 Remove the transmission oil filler cap and its O ring from the transmission case 4...

Page 94: ...er element The air filter element should be serviced at the in tervals specified in the periodic maintenance and lubrication chart Clean or if necessary replace the air filter element more frequently if you are rid ing in unusually wet or dusty areas TIP There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element...

Page 95: ...nt and clean it with solvent WARNING Always use parts cleaning solvent to clean the air filter ele ment Never use low flash point solvents or gasoline to clean the air filter element because the engine could catch fire or ex plode EWB03540 1 Air filter case check hose 1 1 Air filter case cover 2 Air filter case cover holder 1 2 UBD360E0 book Page 16 Wednesday February 25 2015 2 41 PM ...

Page 96: ...l ity foam air filter oil to the element TIP The air filter element should be wet but not drip ping 8 Insert the air filter element into the air filter case 9 Install the air filter case cover by hooking the holders onto the air filter case NOTICE Make sure that the air filter element is properly seated in the air filter case Never operate the engine with the air filter ele 1 Air filter element 1 ...

Page 97: ...leaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty areas When servicing the air filter element be sure to check the air inlet of the air filter case for obstructions EBU33941 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the tailpipe bolt and nut 2 Remove the spar...

Page 98: ... the engine and requires very sophisticated adjustment There fore most carburetor adjustments should be left to a Yamaha dealer who has the necessary pro fessional knowledge and experience The adjust ment described in the following section however may be performed by the owner as part of routine maintenance NOTICE ECB00481 The carburetor has been set and extensively tested at the Yamaha factory Ch...

Page 99: ... play should be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart The throttle lever free play should measure 1 5 4 0 mm 0 06 0 16 in as shown Periodically check the throttle lever free play and if necessary adjust it as follows TIP The engine idling speed must be checked and adjusted if necessary before adjusting the throttle lever free...

Page 100: ...ly serviced or adjust ed brakes could lead to a loss in braking ability and an accident EBU34511 Checking the front and rear brake shoes The front and rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart Without disas sembling the brake this can be performed by checking the position of the brake lever free play adjusting bolts or nu...

Page 101: ... must be checked and if necessary adjusted at the intervals speci fied in the periodic maintenance and lubrication chart The brake lever free play should measure 20 0 25 0 mm 0 79 0 98 in as shown If the free play is incorrect adjust it as follows 1 Upper adjusting bolt 2 Lower adjusting bolt 3 No more than 12 mm 0 47 in 3 2 1 1 Rear brake lever free play adjusting nut 2 Bolt 3 No more than 18 mm ...

Page 102: ...n direction b to decrease it 4 Tighten the lower locknut 5 While applying the front brake turn out the upper adjusting bolt until the upper and lower cable lengths are equal The cable joint will become vertical 1 Front brake lever free play 1 1 Upper locknut 2 Upper adjusting bolt 3 Lower locknut 4 Lower adjusting bolt 1 2 4 3 a b UBD360E0 book Page 23 Wednesday February 25 2015 2 41 PM ...

Page 103: ... adjusted at the intervals speci fied in the periodic maintenance and lubrication chart The brake lever free play should measure 30 0 40 0 mm 1 18 1 57 in as shown If the free play is incorrect adjust it as follows Turn the adjusting nut in direction a to increase the brake lever free play and in direction b to de crease it 1 Cable joint 1 a a a a 1 Rear brake lever free play 1 UBD360E0 book Page ...

Page 104: ...king and adjusting the drive chain slack there should be no weight on the ATV and all tires must be touching the ground 2 Move the ATV back and forth to locate the tightest portion of the drive chain and then measure the drive chain slack as shown 3 If the drive chain slack is incorrect adjust it as follows 1 Rear brake lever free play adjusting nut 1 a b Drive chain slack 24 0 32 0 mm 0 94 1 26 i...

Page 105: ...in slack 1 Loosen the bolts and nuts 2 Loosen the rear brake lever free play adjust ing nut 3 Loosen the locknut 1 Bolt 1 Nut 1 1 1 Rear brake lever free play adjusting nut 1 UBD360E0 book Page 26 Wednesday February 25 2015 2 41 PM ...

Page 106: ......

Page 107: ... of all control 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 WARNING EWB02582 Inspect cables frequently and replace if damaged Corrosion can result when the ca ble sheaths become damaged and cables can also become frayed or kinked which could restr...

Page 108: ...er pivots should be lubricated if necessary Front brake lever Rear brake lever EBU24964 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smooth ly have a Yamaha dealer check the wheel hub bearings Recommended lubricant Lithium...

Page 109: ...e a grease gun EBU25094 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the pe riodic maintenance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun Recommended lubricant Lithium soap based grease 1 Grease nipple Recommended lubricant Lithium soap based grease 1 UBD360E0 book Page 30 Wednesday Feb...

Page 110: ...sh with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ignition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN ...

Page 111: ...d Using a conventional bat tery charger will damage the battery To store the battery If the ATV will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary NOTICE ECB00941 Always keep the battery charged Storing a discharged ba...

Page 112: ...he fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits NOTICE ECB00641 To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 1 Positive battery lead red 2 Negative battery lead black 2 1 1 Fuse 2 Spare fuse 2 1 UBD360E0 book Page 33 Wednesday February 25 2015 2 41 PM ...

Page 113: ...ces operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU34030 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel bolts 3 Elevate the ATV and place a suitable stand under the frame 4 Remove the bolts from the wheel 5 Remove the wheel EBU34040 Installing a wheel 1 Place the ATV on a level surface 2 Install the wheel and the bolts TIP ...

Page 114: ... Yamaha dealer whose skilled technicians have the necessary tools ex perience and know how to service the ATV prop erly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02281 Do not smoke when checking the fuel system Fuel can ignite or explode causing seve...

Page 115: ...ave a Yamaha dealer check the ATV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The battery is good Check the battery lead c...

Page 116: ... several times at slow speeds to let friction dry out the linings EWB02312 NOTICE Excessive wa ter pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure de tergent applications such as those avail able in coin operated car washers ECB00712 4 Once most of the dirt ha...

Page 117: ...is will prevent fuel depos its from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark ...

Page 118: ... 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 once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more infor mation on storing the battery see page 8 31 TIP Make any necessary repairs before storing the ATV UBD...

Page 119: ...UR FRA GBR Uncertainty of measurement 0 3 m s EUR FRA GBR Vibration on handle EN1032 ISO5008 6 3 m s EUR FRA GBR Uncertainty of measurement 1 3 m s EUR FRA GBR Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder Displacement 89 cm Bore stroke 47 0 51 8 mm 1 85 2 04 in Compression ratio 9 2 1 Starting system Electric starter and kickstarter Lubrication system Wet sump E...

Page 120: ... 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Dry centrifugal automatic Transmission Secondary reduction system Chain drive Secondary reduction ratio 35 14 2 500 Transmission type V belt automatic Operation Centrifugal automatic type Chassis Frame type Steel tube frame Caster angle 3 4 Trail 19 8 mm 0 78 in Front tire Type Tubeless Size AT18 x 7 8 Manufacturer model MAXXIS M939 Manufacturer model ...

Page 121: ...l wheel Rim size 8 x 5 5AT Front brake Type Mechanical leading trailing drum brake Operation Right hand operation Rear brake Type Mechanical leading trailing drum brake Operation Left hand operation Front suspension Type Swing axle Spring shock absorber type Coil spring oil damper Wheel travel 126 mm 5 0 in Rear suspension Type Swingarm Spring shock absorber type Coil spring oil damper Wheel trave...

Page 122: ...ine whether or not further precautions are required Factors that influence the actual level of exposure of work force include the characteristics of the work room the other sources of noise etc i e the number of machines and other adjacent process es and the length of time for which an operator is exposed to the noise Also the permissible expo sure level can vary from country This information howe...

Page 123: ...MODEL LABEL INFORMATION EBU26031 Vehicle identification number The vehicle identification number is stamped into the frame TIP The vehicle identification number is used to iden tify your ATV EBU26051 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...

Page 124: ...11 2 11 1 Model label 1 UBD360E0 book Page 2 Wednesday February 25 2015 2 41 PM ...

Page 125: ...ver and driving in reverse 6 3 E Engine break in 6 4 Engine cold start 6 1 Engine idling speed 8 19 Engine oil 5 3 8 11 Engine starting a warm 6 3 Engine stop switch 4 2 F Front and rear brake shoes checking 8 21 Front knuckle pivots lubricating 8 30 Fuel 4 8 5 3 Fuel cock 4 10 Fuel tank cap 4 8 Fuse replacing 8 33 H Handlebar switches 4 2 I Identification numbers 11 1 Indicator lights 4 1 Instrum...

Page 126: ... Spark plug checking 8 9 Specifications 10 1 Speed limiter 4 3 Starter choke 4 11 Start switch 4 2 Steering shaft lubricating 8 30 Storage 9 2 T Throttle lever 4 2 5 3 Throttle lever free play adjusting 8 20 Tires 5 3 Transmission oil 5 3 8 14 Troubleshooting 8 35 Troubleshooting chart 8 36 V Valve clearance 8 21 Vehicle identification number 11 1 W Wheel hub bearings checking 8 29 Wheel installin...

Page 127: ...UBD360E0 book Page 3 Wednesday February 25 2015 2 41 PM ...

Page 128: ...N APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PAVED 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 AN...

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