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Yamaha YFM50R, Owner'S Manual

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Yamaha YFM50R Owner'S Manual Download Page 91

 

8-20

 

1

2

3

4

5

6

7

8

9

10

11

Rear brake

 

EBU24330

 

Adjusting the front brake lever free 
play 

 

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

NOTE:

 

Before adjusting the brake lever free play, check

 

the front brake shoes for wear.

The brake lever free play should measure 10.0–

12.0 mm (0.39–0.47 in) as shown. If the free play
is incorrect, adjust it as follows.

1. Loosen the upper locknut and fully turn in the

upper adjusting bolt.

2. Loosen the lower locknut.
3. Turn the lower adjusting bolt in direction (a) to

increase the free play, and in direction (b) to
decrease it.

 

1.  Wear limit mark
2. Wear indicator

1

2

 

1.  Brake lever free play

1

Summary of Contents for YFM50R

Page 1: ...This A MANUAL DEL PROPIETARIO 5YF 28199 63 YFM50RW MANUEL DU PROPRIÉTAIRE OWNER S MANUAL ...

Page 2: ...PRINTED IN JAPAN 2006 05 0 1x1 E F S YAMAHA MOTOR CO LTD ...

Page 3: ...This A 5YF 28199 63 E0 YFM50RW OWNER S MANUAL ...

Page 4: ......

Page 5: ...ny questions 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 UNDER STAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV THIS ATV AND ANY OTHER ATV OVER 50 cc SHOULD NOT BE OPERATED BY A CHILD UNDER 6 YEARS OF AGE AN IMPORTANT NOTE TO P...

Page 6: ...speed limiter screw turned in to limit the amount of speed available while they learn The speed limiter screw may be gradually turned out to increase maximum speed as the beginner becomes more fa miliar with operating the ATV If your child is a beginner or is inexperienced he or she should take a training course ...

Page 7: ...ifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the ATV operator a bystander or a person inspecting or repairing the ATV A CAUTION indicates special precautions that must be taken to avoid damage to the ATV A NOTE provides key information to ...

Page 8: ...this ATV on any paved surface paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFM50RW OWNER S MANUAL 2006 by Yamaha Motor Co Ltd 1st edition April 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 9: ...4 6 Rear brake lever 4 6 Parking brake 4 6 Drive select lever 4 7 Fuel tank cap 4 7 Fuel 4 8 Fuel cock 4 9 Choke 4 10 Seat 4 11 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Front and rear brakes 5 3 Throttle lever 5 4 Tires 5 4 Measuring the tire pressure 5 5 Tire wear limit 5 6 Chassis fasteners 5 6 Instruments lights and switches 5 6 Battery 5 ...

Page 10: ...ng the spark arrester 8 15 Adjusting the carburetor 8 17 Adjusting the engine idling speed 8 17 Checking the throttle cable free play 8 18 Valve clearance 8 18 Checking the front and rear brake shoes 8 19 Adjusting the front brake lever free play 8 20 Adjusting the rear brake lever free play 8 22 Checking and lubricating the cables 8 23 Checking and lubricating the front and rear brake levers 8 24...

Page 11: ...should never oper ate an ATV with engine size greater than 70 cc A child under 16 years old should never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operat...

Page 12: ...manual Practice turning at low speeds before attempting to turn at faster speeds and never turn at excessive speeds Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hil...

Page 13: ...idding or sliding out of con trol Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always use the size and type of tires specified in this manual Always maintain proper tire pressu...

Page 14: ...ure you thoroughly understand proper riding techniques before continuing to in struct your child Go through this Owner s Manual page by page with your child and be sure he or she understands how to operate the ATV properly Be sure your child is wearing all the proper safety equipment Your child must always wear an approved motor cycle helmet that fits properly Your child should also wear the safet...

Page 15: ...eloped sufficient skill to no longer need you to follow with the cord the cord can be stowed under the seat of the ATV Howev er you must still closely supervise your child at all times during ATV operation NOTE The ATV will not start without the clip in place Be sure to remove the cord and store it in a safe place to prevent operation of the ATV when you are not around to supervise WARNING EWB0006...

Page 16: ...with soap and wa ter If gasoline spills on your clothing change your clothes WARNING EWB00070 Always operate your ATV in an area with ade quate ventilation Never start or run the engine in a closed area Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time ...

Page 17: ...2 1 1 2 3 4 5 6 7 8 9 10 11 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 5 4 3 2 ...

Page 18: ...erstand all of the labels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer ...

Page 19: ... age of 6 increases your chance of severe injury or death NEVER permit children under age 6 to operate this ATV Adult supervision required for children under age 16 WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 5YF 21697 00 5FE 2151H 01 For Oceania For Europe For Europe For Europe For Oceania 1 2 3 ...

Page 20: ...UREOROVERLOADINGCAN CAUSELOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURYORDEATH OPERATINGTIREPRESSURE Set with tires cold 9Recommended FRONT 20 kPa 0 20 kgf cm2 2 9 psi REAR 20 kPa 0 20 kgf cm2 2 9 psi 9Minimum FRONT 17 kPa 0 17 kgf cm2 2 5 psi REAR 17 kPa 0 17 kgf cm2 2 5 psi 9Never set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING 9Maximum Vehic...

Page 21: ...V use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate 9 without proper training or instruction 9 at speeds too fast for your skills or the conditions 9 on public roads a collision can occur with another vehicle 9 with a passenger passengers affect balance and steeri...

Page 22: ...6 7 8 9 10 11 EBU17680 DESCRIPTION EBU17690 Left view EBU17700 Right view 1 Fuel cock 2 Fuse 3 Engine stop switch with cord lanyard 4 Footboard 5 Drive select lever 1 3 4 5 2 1 Spark arrester 2 Seat 3 Footboard 1 2 3 ...

Page 23: ...ents NOTE The ATV you have purchased may differ slightly from the figures shown in this manual 1 Rear brake lever 2 Parking brake 3 Neutral indicator light 4 Front brake lever 5 Throttle lever 6 Main switch 7 Fuel tank cap 8 Handlebar switches 1 2 3 4 8 7 6 5 ...

Page 24: ...lectrical systems are supplied with power and the engine can be started The key cannot be re moved OFF All electrical systems are off The key can be re moved EBU17780 Indicator light EBU17860 Neutral indicator light This indicator light comes on when the transmis sion is in the neutral position 1 Main switch OFF ON 1 1 Neutral indicator light N 1 ...

Page 25: ... stop the engine in an emergency situation The engine will not start or run when this switch is set to OFF EBU18090 Start switch START Push this switch to crank the engine with the start er CAUTION ECB00050 See the starting instructions on page 6 1 prior to starting the engine EBU18260 Engine stop switch with lanyard The clip must be attached to the engine stop switch for the engine to run 1 Engin...

Page 26: ... held by putting your fingers in the loop as shown Should the ATV be separated from the parent by a distance longer than the lanyard length the lan yard will pull out the clip and stop the engine 1 Engine stop switch 2 Clip 3 Lanyard 3 1 2 1 Lanyard 1 ...

Page 27: ...still closely supervise your child at all times during ATV operation EBU18280 Throttle lever Once the engine is running movement of the throt tle lever 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 the hand is removed from the throttle lever B...

Page 28: ...e speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum The adjusting screw may be gradu ally turned out as the beginner becomes more fa miliar with operating the ATV 1 Loosen the locknut 2 To increase the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction a To de crease the maximum engine power...

Page 29: ...01 Rear brake lever The rear brake lever is located on the left handle bar To apply the rear brake pull the brake lever to ward the handlebar grip EBU18460 Parking brake Use the parking brake before starting the engine or parking the ATV especially on a slope Apply 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...

Page 30: ...d overheat if you 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 EBU18630 Drive select lever The drive select lever is located on the left side of the engine Use the drive select lever to shift the transmission into drive or neutral EBU18720 Fuel tank cap Remove the fuel tank cap by t...

Page 31: ...ube as shown NOTE If knocking or pinging occurs use a different brand 1 Fuel tank cap 1 1 Fuel level 2 Filler tube Recommended fuel UNLEADED GASOLINE ONLY For Europe Regular unleaded gasoline only with a research octane number of 91 or high er Fuel tank capacity 6 8 L 1 80 US gal 1 50 Imp gal Fuel reserve amount 0 9 L 0 24 US gal 0 20 Imp gal ...

Page 32: ...o spill fuel especially on the engine or exhaust pipe which can cause a fire and severe injury Wipe up any spilled fuel immediately Do not refuel right after the engine has been running and is still very hot Be sure the fuel tank cap is closed securely EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explained...

Page 33: ... this position the fuel reserve is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18860 Choke The choke is used to start a cold engine Move the choke in direction a to turn on the choke 1 Arrow mark positioned over ON ON FUEL RES OFF ON 1 1 Arrow mark posi...

Page 34: ...Seat To remove the seat Pull the seat lock lever upward and 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 NOTE Make sure that the seat is securely fitted 1 Fully open ON 2 Half open warming up position 3 Closed OFF 4 Choke 4 1 2 3 b a 1 Seat lock lever 1 ...

Page 35: ...4 12 1 2 3 4 5 6 7 8 9 10 11 1 Projection 2 Seat holder 1 2 ...

Page 36: ... 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 8 Final gear oil Check ATV for oil leakage Correct if necessary 5 3 8 11 Front brake Check operation and correct if necessary Lubricate cable if necessary Check lever free play and adjust if necessary 5 3 8 19 8 20 Rear brake Check operation and c...

Page 37: ...heels 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 4 5 5 5 6 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 24 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 5 6 Instruments and switches Check operation and ...

Page 38: ...r oil is at the specified level Add oil as necessary See page 8 11 EBU19650 Front and rear brakes Brake levers Check for correct free play in the brake levers If the free play is incorrect adjust it See pages 8 20 and 8 22 Check operation of the levers They should move smoothly and there should be a firm feel ing when the brake is applied If not have the ATV checked by a Yamaha dealer Brake operat...

Page 39: ...maha Motor Co Ltd for this model Other tire combinations are not recommend ed Front Manufacturer model DUNLOP KT145 Size AT16 x 7 7 Type Tubeless Rear Manufacturer model DUNLOP KT145 Size AT16 x 8 7 Type Tubeless The tires should be set to the recommended pressure Recommended tire pressure Front 20 0 kPa 2 9 psi 0 200 kgf cm2 Rear 20 0 kPa 2 9 psi 0 200 kgf cm2 Check and adjust tire pressures when...

Page 40: ...t Inflate the tires very slowly and carefully EBU19820 Measuring the tire pressure Use the low pressure tire gauge NOTE 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 Set the tire pressure when the tires are cold Set the tire pressures to the...

Page 41: ...t all instruments lights and switches are working properly Correct if necessary EBU19860 Battery Check the fluid level in the battery Fill with distilled water if necessary See page 8 25 Recommended pressure Front 20 0 kPa 2 9 psi 0 200 kgf cm2 Rear 20 0 kPa 2 9 psi 0 200 kgf cm2 Minimum Front 17 0 kPa 2 5 psi 0 170 kgf cm2 Rear 17 0 kPa 2 5 psi 0 170 kgf cm2 Maximum Front 23 0 kPa 3 3 psi 0 230 k...

Page 42: ...V which could lead to an acci dent or collision CAUTION ECB00150 See the Engine break in section on page 6 5 prior to operating the engine for the first time 1 Set the parking brake 2 Turn the fuel cock to ON 3 Turn the main switch to ON and the engine stop switch to RUN 4 Shift the transmission into neutral The neutral indicator light should come on If the indicator light does not come on have a ...

Page 43: ...oke position 6 Completely close the throttle lever and start the engine by pushing the start switch NOTE If the engine fails to start release the start switch then push it again Pause a few seconds before the next attempt Each cranking should be as short as possible to preserve battery energy Do not 1 Fully open ON 2 Half open warming up position 3 Closed OFF 4 Choke ON O F F 0 30 10 20 30 50 70 9...

Page 44: ... the throttle with the choke turned off EBU20301 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the choke is not re quired when the engine is warm Instead start the engine with the throttle slightly open EBU27880 Shifting This ATV has an automatic centrifugal clutch To shift into the drive position release the throttle lever and apply the par...

Page 45: ... chance of an accident It could make the ATV wheelie or overturn EBU20660 To decelerate When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly Im proper use of the brakes can cause the tires to lose traction reducing control and increasing the possi bility of an accident CAUTION ECB00190 Even with the transmission in the neutral posi tion do not coast for long...

Page 46: ...esult in engine overheating must be avoided 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine freely but do not use full throttle at any time 20 hours and beyond The ATV can now be operated normally CAUTION ECB00220 If any engine trouble s...

Page 47: ...ransversely across the incline shift the shift lever to the drive posi tion stop the engine apply the parking brake and then block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easily 1 Bring the ATV to a stop by applying the brakes in the drive position 2 Stop the engine 3 With the rear brake lever applied ap...

Page 48: ...our ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when riding an ATV with ac cessories The ATV may handle differently than it does without accessories EBU20960 Loading As original...

Page 49: ...re weight you carry the slower you should go Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV WARNING EWB00820 Never exceed the stated load capacity for this ATV Overloading this ATV or carrying or tow ing cargo improper...

Page 50: ...7 1 1 2 3 4 5 6 7 8 9 10 11 EBU21141 RIDING YOUR ATV ...

Page 51: ...c ular attention to the safety information on pages 1 1 1 6 Please also read all caution and warning labels on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified in structor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until yo...

Page 52: ... death of the child This ATV is designed to carry operator only passengers prohibited WARNING EWB01400 Never carry a passenger The long seat is to al low the operator to shift position as needed during operation It is not for carrying passen gers Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV It could cause an accident resulting in harm to you and or ...

Page 53: ...helmet increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and in creases your chances of a severe injury in the event of an accident Operating without protec tive clothing increases your chances of severe injury in the event of an accident Do not operate after consuming alcohol or drugs The operator s perfo...

Page 54: ...ner s Manual on page 5 5 Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pres sure may cause loss of control increasing your risk of an accident Do not operate at speeds too fast for your skills or the conditions WARNING EWB01450 Always go at a speed that is proper for the ter rain visibility and operating conditions and your experience Operating this ATV at...

Page 55: ... may be adversely affected Re duce your speed when adding additional loads WARNING EWB01460 Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own er s Manual for carrying cargo or pulling a trailer During oper...

Page 56: ...emove a foot from a footboard your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident Avoid wheelies and jumping You may lose control of the ATV or overturn WARNING EWB01480 Never attempt stunts such as wheelies or jumps Don t try to show off Modifications WARNING EWB01490 Never modify this ATV through improper in stallation or use of accessories Al...

Page 57: ...avoid parking in or around dry grass brush or other combustible materials to pre vent causing a fire hazard WARNING EWB01500 Do not touch the hot exhaust system Do not park the ATV during or after operation in a place where others might be likely to touch it Do not operate idle or park the ATV in dry grass dry ground cover or combustible ma terials BE CAREFUL WHERE YOU RIDE This ATV is designed fo...

Page 58: ... any paved public street road or motorway WARNING EWB01520 Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle In many areas it is illegal to operate ATVs on public streets roads and highways Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden hazards which may cau...

Page 59: ...ls necessary to control the ATV on such terrain Failure to use extra care when operating on excessively rough slippery or loose terrain could cause loss of traction or ATV control which could result in an accident including an overturn 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...

Page 60: ... free of obstacles and other riders You should practice control of the throttle brakes and turning tech niques in this area before trying more difficult ter rain Always avoid riding on paved surfaces the ATV is designed for use on unpaved surfaces only and handling maneuvers are more difficult to per form on pavement Set the parking brake and follow the instruction on page 6 1 to start the engine ...

Page 61: ...dly on one axle and turn together at the same speed There fore unless the wheel on the inside of the turn is al lowed to slip or lose some traction the ATV will resist turning A special turning technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed WARNING EWB01570 Always follow proper procedures for turning as describ...

Page 62: ...de while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the out side of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL Use proper riding techniques to avoid ATV over turns on hills Be sure that you can maneuver your ATV well on flat gr...

Page 63: ...se surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 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 stil...

Page 64: ...ll If you start to roll backwards DO NOT apply the rear brake to stop or try to put the ATV in gear The ATV could easily tip over backwards Instead ap ply the front brake gradually or dismount the ATV immediately on the uphill side WARNING EWB01761 Maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking brake after you are sto...

Page 65: ...ause a loss of traction 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 WARNING EWB01620 Always follow proper procedures for going down hills as described in this Owner s Manu al Note a special technique is required when bra...

Page 66: ...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 gradually steer again in the direction you wish to travel WARNING EWB01631 Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as desc...

Page 67: ...ever operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the lin ings If the ATV is operated through deep or fast flowing water the tires may float causing loss of traction and loss of control ...

Page 68: ...IN Riding over rough terrain should be done with cau tion Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult WARNING EWB01650 Before operating in a new area check for ob stacles Never attempt to ride over l...

Page 69: ...front wheels will sometimes help If the rear wheels of your ATV start to slide side ways control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide With practice over a period of time skill at con trolled sliding can be developed The terrain should be chosen carefully ...

Page 70: ...See page 7 12 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 page 7 20 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the A...

Page 71: ... 4 5 6 7 8 9 10 11 ter 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 until you have regained adequate braking ability See page 7 18 ...

Page 72: ...GRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01840 Never service an engine while it is running Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or start fires Turn off the en gine when performing maintenance unless otherwise specified Have a Yamaha dealer perform the service if you are...

Page 73: ... you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you WARNING EWB01850 Never modify this ATV through improper in stallation or use of accessories as it may cause changes in handling which in some sit uations could lead to an accident All parts and accessories added to this ATV should be gen uine Yamaha or equivalent components de signed for ...

Page 74: ...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 1200 750 2400 1500 2400 1500 4800 3000 hours 20 75 150 150 300 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust if necessary 4 Tim...

Page 75: ...grease 12 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 13 Shock absorber assemblies Check operation and correct if necessary Check for oil leakage and replace if necessary 14 Knuckle shafts Lubricate with lithium soap based grease 15 Steering shaft Lubricate with lithium soap based grease 16 Steering system Check operation and repair or replace if damaged Check...

Page 76: ...free play and adjust if neces sary Lubricate throttle lever housing and cable 23 Exhaust system Check for leakage and replace gasket s if neces sary Check for looseness and tighten all screw clamps and joints if necessary 24 Spark arrester Clean 25 Front and rear brake switches Check operation and correct if necessary 26 Battery Check electrolyte level and specific gravity and correct if necessary...

Page 77: ...8 6 1 2 3 4 5 6 7 8 9 10 11 EBU23060 NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas ...

Page 78: ...ion 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 normally NOTE If the spark plug shows a distinctly different col...

Page 79: ...rench and then tighten it to the specified torque NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 4 Install the spark plug cap EBU23251 Engine oil The engine oil level should be checked before each ride In addition the ...

Page 80: ...out screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the minimum and maximum level marks 6 If the engine oil is at or below the minimum level mark add sufficient oil of the recom mended type to raise it to the correct level 7 Insert the dipstick into the oil filler hole and then tighten the engine oil filler cap To change the engine oil 1 Place t...

Page 81: ... and then install and tighten the engine oil filler cap CAUTION ECB00300 In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher Make sure that no foreign material enters the cr...

Page 82: ...nance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface NOTE The final gear oil level must be checked on a cold engine 2 Remove the final gear oil filler cap wipe the dipstick off with a clean rag insert it back into the oil filler hole without screwing it in and then remove it again to check the oil level NOTE The final gear oil should be between the minim...

Page 83: ...the final gear case 6 Install and tighten the oil filler cap 7 Check the final gear case for oil leakage If oil is leaking check for the cause EBU23801 Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean the air filter element more frequently if you are riding in unusually wet or dusty areas NO...

Page 84: ...8 13 1 2 3 4 5 6 7 8 9 10 11 the hose and clean the air filter element and air fil ter case 1 Remove the panel shown by removing the bolts 1 Air filter case check hose 1 1 Panel 2 Bolt 1 2 2 ...

Page 85: ...he air filter element 4 Wash the sponge material gently but thor oughly in solvent WARNING EWB01940 Always use parts cleaning solvent to clean the sponge material Never use low flash point solvents or gasoline to clean the sponge mate rial because the engine could catch fire or ex 1 Air filter case cover 2 Air filter case holder 2 2 1 1 Air filter element holder 2 Sponge material 1 2 ...

Page 86: ...he air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions CAUTION ECB00460 Make sure that the air filter element is prop erly seated in the air filter case Never operate the engine with ...

Page 87: ...ailpipe housing 4 Insert the tailpipe into the muffler and align the screw holes 5 Install the screws and tighten them WARNING EWB02340 Do not start the engine when cleaning the spark arrester otherwise it could cause injury to the eyes burns carbon monoxide poison ing possibly leading to death and start a fire Always let the exhaust system cool prior to touching exhaust components 1 Screw 1 1 Tai...

Page 88: ...ed at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor performance of or damage to the engine EBU24000 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica tion chart NOTE A diagnostic tachometer is needed to make this adj...

Page 89: ...ay should measure 1 0 3 0 mm 0 04 0 12 in at the throttle lever Period ically check the throttle cable free play and if nec essary have a Yamaha dealer adjust it EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the inter vals specified in...

Page 90: ...ke is provided with a wear indicator which allows you to check the brake shoe wear without having to dis assemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit line or mark have a Yamaha dealer replace the brake shoes as a set Front brake 1 Wear limit line...

Page 91: ... the brake lever free play check the front brake shoes for wear The brake lever free play should measure 10 0 12 0 mm 0 39 0 47 in as shown If the free play is incorrect adjust it as follows 1 Loosen the upper locknut and fully turn in the upper adjusting bolt 2 Loosen the lower locknut 3 Turn the lower adjusting bolt in direction a to increase the free play and in direction b to decrease it 1 Wea...

Page 92: ...ING EWB02080 Operating with improperly serviced or adjust ed brakes could cause loss of braking ability which could lead to an accident After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures 1 Upper locknut 2 Upper adjusting bolt 3 Lower locknut 4 Lower...

Page 93: ...own If the free play is incorrect adjust it as follows 1 Loosen the locknut at the brake lever 2 Turn the brake lever free play adjusting bolt at the brake lever in direction a to increase the free play and in direction b to decrease it 3 Tighten the locknut at the brake lever If the specified free play cannot be obtained proceed with the following steps 4 Loosen the locknut at the brake lever 5 F...

Page 94: ...of braking ability which could lead to an accident After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer EBU24900 Checking and lubricating the cables The operation and the condition of all control ca bles should b...

Page 95: ...s should be lubricated if necessary EBU24961 Checking the wheel bearings The front and rear wheel 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 smoothly have a Yamaha dealer check the wheel bearings EBU25070 Lubricating the knuckle shafts The knuckle shafts must be lubricated at the ...

Page 96: ... battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrica tion chart To check the electrolyte level 1 Place the ATV on a level surface 2 Check the electrolyte level in the battery NOTE The electrolyte should be between the minimum and maximum level marks 3 If the electrolyte is at or below the minim...

Page 97: ...agnesia 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 ig nition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN 4 Check and if necessary tighten the battery lead connections and correct the breat...

Page 98: ...e at least once a month and fully charge the battery whenever necessary To install the battery NOTE Be sure the battery is fully charged 1 Install the battery 2 Connect the positive lead first and then con nect the negative lead 3 Make sure that the breather hose is properly routed in good condition and not obstructed CAUTION ECB00610 If the breather hose is positioned in such a way 1 Battery 2 Ne...

Page 99: ...switch when checking or replacing a fuse 2 Remove the blown fuse and then install a new fuse of the specified amperage WARNING EWB02171 Always use a fuse of the specified rating and never use a substitute object in place of the proper fuse An improper fuse or a substitute object can cause damage to the electrical sys tem which could lead to a fire 3 Turn the key to ON and turn on the electrical ci...

Page 100: ...uitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel EBU27480 Installing a wheel 1 Install the wheel and the nuts NOTE When installing the wheel make sure its arrow mark points toward the rotating direction of the 1 Wheel nut 1 1 1 Wheel nut 1 ...

Page 101: ... wheel Front Rear 2 Lower the ATV to the ground 3 Tighten the wheel nuts to the specified torques 1 Arrow mark 1 1 Arrow mark Tightening torques Front wheel nut 28 Nm 2 8 m kgf 20 ft lbf Rear wheel nut 28 Nm 2 8 m kgf 20 ft lbf 1 ...

Page 102: ...lf However should your ATV re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02280 Do not smoke when checki...

Page 103: ...eck 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 Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The batte...

Page 104: ...cal de vices Many expensive repair bills have result ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach places 5 Rinse the ATV off immediately with clean wa ter and dry all sur...

Page 105: ...ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore ...

Page 106: ... a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it 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 in formation on sto...

Page 107: ...ith oil and fuel 115 0 kg 254 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 49 0 cm3 Bore stroke 39 0 41 4 mm 1 54 1 63 in Compression ratio 10 30 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 Recommended engine oil grade API servi...

Page 108: ...t 0 9 L 0 24 US gal 0 20 Imp gal Carburetor Manufacturer MIKUNI Type x quantity VM16SH x 1 Spark plug s Manufacturer model NGK CR7HSA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet multiple disc automatic Transmission Primary reduction system Spur gear Primary reduction ratio 65 20 3 250 Secondary reduction system Shaft drive Secondary reduction ratio 19 18 34 10 3 588 Transmissio...

Page 109: ...psi 0 200 kgf cm2 Minimum Front 17 0 kPa 2 5 psi 0 170 kgf cm2 Rear 17 0 kPa 2 5 psi 0 170 kgf cm2 Maximum Front 23 0 kPa 3 3 psi 0 230 kgf cm2 Rear 23 0 kPa 3 3 psi 0 230 kgf cm2 Front wheel Wheel type Panel wheel Rim size 7x5 5AT Rear wheel Wheel type Panel wheel Rim size 7x6 5AT Front brake Type Drum brake Operation Right hand operation Rear brake Type Drum brake Operation Left hand operation F...

Page 110: ... Coil spring oil damper Wheel travel 56 mm 2 2 in Electrical system Ignition system CDI Charging system AC magneto Battery Model 12N7D 3B Voltage capacity 12 V 7 0 Ah Bulb voltage wattage x quantity Neutral indicator light 12 V 1 7 W 1 Fuses Main fuse 5 0 A ...

Page 111: ...rts from a Yamaha dealer or for ref erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26030 Vehicle identification number The vehicle identification number...

Page 112: ... fy your ATV EBU26050 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha deal er 1 Vehicle identification number 1 1 Model label 1 ...

Page 113: ...s 5 6 Choke 4 10 Cleaning 9 1 D Drive select lever 4 7 E Engine break in 6 5 Engine cold start 6 1 Engine idling speed 8 17 Engine oil 5 3 8 8 Engine starting a warm 6 3 Engine stop switch 4 2 Engine stop switch with lanyard 4 2 F Final gear oil 5 3 8 11 Fuel 4 8 5 3 Fuel cock 4 9 Fuel tank cap 4 7 Fuse replacing 8 28 H Handlebar switches 4 2 I Identification numbers 11 1 Indicator light 4 1 Instr...

Page 114: ...cleaning 8 15 Spark plug checking 8 7 Specifications 10 1 Speed limiter 4 5 Start switch 4 2 Steering shaft lubricating 8 25 Storage 9 2 T Throttle cable free play checking 8 18 Throttle lever 4 4 5 4 Tire pressure measuring 5 5 Tires 5 4 Tire wear limit 5 6 Troubleshooting 8 31 Troubleshooting chart 8 32 V Valve clearance 8 18 Vehicle identification number 11 1 W Wheel bearings checking 8 24 Whee...

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Page 116: ...PRINTED IN JAPAN 2006 05 0 1x1 E YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER ...

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