Yamaha YFM50RY Owner'S Manual Download Page 8 | Manualshive

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EBU17350

IMPORTANT NOTICE

EBU17370

Welcome to the Yamaha world of motor sports!
This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate 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

YFM50RY

OWNER’S MANUAL

©2008 by Yamaha Motor Co., Ltd.

1st edition, April 2008

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

Printed in Japan.

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Summary of Contents for YFM50RY

Page 1: ... PROPRIÉTAIRE OWNER S MANUAL 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: ...PRINTED IN JAPAN 2008 05 0 2x2 E F S YAMAHA MOTOR CO LTD ...

Page 3: ...This A 5YF 28199 65 E0 YFM50RY OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 4: ... EEC If applicable If applicable To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted EN292 ANSI SVIA 1 2007 Title and or number and date of issue of standards and or specifications General Manager RV Engineering Division RV Company Signature Date of Issue Shinya Shimada ...

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: ...ithout notice This is the safety 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 propert...

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 YFM50RY OWNER S MANUAL 2008 by Yamaha Motor Co Ltd 1st edition April 2008 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: ...filter element 8 13 Cleaning the spark arrester 8 17 Adjusting the carburetor 8 18 Adjusting the engine idling speed 8 18 Checking the throttle cable free play 8 19 Valve clearance 8 19 Checking the front and rear brake shoes 8 20 Adjusting the front brake lever free play 8 21 Adjusting the rear brake lever free play 8 23 Checking and lubricating the cables 8 24 Checking and lubricating the front ...

Page 11: ...12 years old should never oper ate an ATV with engine size greater than 70 cc A child under 16 years old should never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always...

Page 12: ...es for turning as described in this 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 y...

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

Page 14: ... as the instructor so you should be sure 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 ...

Page 15: ...countered When your child has developed 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 TIP 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 aro...

Page 16: ...s on your skin wash 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: ...vere 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 2816L 00 5FE 2151H 01 For Oceania For Europe For Europe For Europe For Oceania 1 2 3 1 3 SHIZUOKA JAPAN YAMAHA MOTOR CO LTD ...

Page 20: ...0 20 kgf cm2 2 9 psi WARNING OPERATINGTIREPRESSURE Set with tires cold 9Recommended Front 20 kPa 2 9 psi Rear 20 kPa 2 9 psi 9Minimum Front 17 kPa 2 5 psi Rear 17 kPa 2 5 psi 9Never set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING 9Maximum weight capacity 40 kg 88 lbs Includes weight of operator cargo and accessories 5YF 2169M 00 5YF 21696 M0 Improper tire p...

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 TIP 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 EBU17781 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: ...o 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 NOTICE 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: ...till 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 Be...

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 TIP 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 TIP 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: ...some items in the table has to be performed by a Yamaha dealer Refer to the periodic maintenance charts on page 8 3 to determine which service should be performed by a Yamaha dealer 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 speci...

Page 37: ... is smooth Lubricate if necessary 8 24 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 4 5 5 5 6 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 25 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 5 6 Instr...

Page 38: ...r oil is at the specified level Add oil as necessary See page 8 12 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 21 and 8 23 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: ...y Yamaha 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 kPa 0 200 kgf cm2 2 9 psi Rear 20 kPa 0 200 kgf cm2 2 9 psi Check and adjust tire pressures when...

Page 40: ...Use the low pressure tire gauge TIP 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 following specifications 1 Low pressure tire gauge Recommended pressure Front 20 kP...

Page 41: ...is fasteners Make sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that 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 26 1 Tire wear limit ...

Page 42: ...able to control the ATV which could lead to an acci dent or collision NOTICE 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 doe...

Page 43: ...C 80 F Ambient temp choke position 6 Completely close the throttle lever and start the engine by pushing the start switch TIP 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 ...

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 NOTICE ECB00190 Even with the transmission in the neutral posi tion do not coast for long ...

Page 46: ...perating clear ances During this period prolonged full throttle operation or any condition that might result in en gine overheating must be avoided 0 160 km 0 100 mi or 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 160 320 km 100 200 mi or 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the en...

Page 47: ...ross 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 apply the parkin...

Page 48: ...unted An accessory which can shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the s...

Page 49: ...e where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV WARNING EWB00820 Never exceed the stated load capac...

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: ...an lead to severe injury or 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 resul...

Page 53: ...out an ap proved motorcycle 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 o...

Page 54: ...ases the possibility of an accident or equipment damage WARNING EWB01440 Always use the size and type tires specified in the Owner s Manual for this ATV on page 5 4 Always maintain proper tire pressure as de scribed in the Owner 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...

Page 55: ...t out increases top speed See page 4 5 Yamaha recommends that all beginning riders start off with the speed limiter turned in to limit the amount of speed available while they learn The limiter may be gradually adjusted to increase max imum speed as the beginner becomes more famil iar with operating the ATV Loading and accessories Use extra caution when riding the ATV with addi tional loads such a...

Page 56: ...ng a trailer During operation Always keep your feet on the footboards during op eration otherwise they may contact the rear wheels WARNING EWB01470 Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remov...

Page 57: ...on of this ATV may cause changes in han dling which in some situations could lead to an accident If you have questions consult an au thorized ATV dealer Exhaust system The exhaust system on the ATV is very hot during and following operation To prevent burns avoid touching the exhaust system Park the ATV in a place where pedestrians or children are not likely to touch it Also avoid parking in or ar...

Page 58: ... Paved surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control While riding on unpaved public streets or roads may be legal in your area such operation can in crease the risk of collision with other vehicles Watch carefully for other vehicles Make sure you know your country s laws and regulations before you ride on unpaved public streets or roads Do...

Page 59: ...the ATV to upset WARNING EWB01530 Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to chang ing terrain conditions when operating the ATV WARNING EWB01540 Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Failure to use extra care when operating on excessively...

Page 60: ...V DO NOT use the flag pole bracket as a trailer hitch WARNING EWB01550 Always mount a caution flag on the ATV to make you more visible when operating in areas where you might not be seen by other vehicles Watch carefully for other vehicles Do not ride in areas posted no trespassing Do not ride on private property without getting per mission ...

Page 61: ...on and then release the parking brake Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds un til you are thoroughly familiar with the operation of your ATV When slowing down or stopping release the thr...

Page 62: ...aintain an even speed through the turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly This procedure should be practiced at slow speed many times in a large unpaved area with no obsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the proce dure...

Page 63: ...es with slip pery or loose surfaces or obstacles that might cause you to lose control WARNING EWB01580 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 Practice on small er hills before attempting large hills It is important when climbing a hill to make sure that your weight is...

Page 64: ...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 possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV If your ATV has stalled or stopped and y...

Page 65: ...e rear brake while rolling backwards Apply the front brake When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and re mount following the procedure described in the Owner s Manual RIDING DOWNHILL When riding your ATV downhill shift your weight as far to the rear and uphill side of the AT...

Page 66: ... down a hill at high speed Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where possi ble CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surfa...

Page 67: ...hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving shal low water of up to a maximum of 20 cm 8 in in depth Before en...

Page 68: ...ter the tires may float causing loss of traction and loss of control which could lead to an accident Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability NOTICE ECB00240 After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case Wash the ATV in...

Page 69: ...re operating in a new area check for ob stacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manu al SLIDING AND SKIDDING Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To r...

Page 70: ...earn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to re duce the chance of skidding or sliding out of control WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each section on riding tech niques completely WHAT TO DO If your ATV doesn...

Page 71: ... the front brake or dis mount the ATV on the uphill side See page 7 14 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that the ATV is going to tip over dismount on the uphill side...

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 u...

Page 74: ...erformed by a Yamaha dealer as they require 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 ...

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

Page 76: ...tion and correct if necessary Check brake lever free play and adjust if neces sary Replace brake shoes Whenever worn to the limit 4 Rear brake Check operation and correct if necessary Check brake lever free play and adjust if neces sary Replace brake shoes Whenever worn to the limit 5 Wheels Check runout and for damage and replace if nec essary 6 Tires Check tread depth and for damage and replace ...

Page 77: ...al gear oil Change Check ATV for oil leakage and correct if neces sary 15 Moving parts and cables Lubricate 16 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 17 Front and rear brake switches Check operation and correct if necessary 18 Battery Check electrolyte level and sp...

Page 78: ...8 7 1 2 3 4 5 6 7 8 9 10 11 EBU23060 TIP The air filter needs more frequent service if you are riding in unusually wet or dusty areas ...

Page 79: ...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 TIP If the spark plug shows a distinctly different colo...

Page 80: ...rench and then tighten it to the specified torque TIP 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 EBU23254 Engine oil The engine oil level should be checked before each ride In addition the o...

Page 81: ...ller cap and then wipe the dipstick off with a clean rag 4 Insert the dipstick into the filler hole without screwing it in and then remove it again to check the oil level TIP The engine oil should be between the minimum and maximum level marks 5 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 6 Insert the dipstick...

Page 82: ... with the specified amount of the recom mended engine oil and then install and tight en the engine oil filler cap NOTICE 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 o...

Page 83: ...riodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface TIP 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 TIP The final gear oil should be betwee...

Page 84: ...e no foreign material enters 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 EBU23804 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 un...

Page 85: ...dust or water collects in this hose empty the hose and clean the air filter element and air fil ter case 1 Place the ATV on a level surface 2 Remove the panel shown by removing the bolts 1 Air filter case check hose 1 1 Panel 2 Bolt 1 2 2 ...

Page 86: ...air filter element 5 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 cover holder 2 2 1 1 Air filter element holder 2 Sponge material 1 2 ...

Page 87: ...ooking the holders onto the air filter case 12 Install the panel by installing the bolts TIP The 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 NOTICE ECB00460 Make sure that the...

Page 88: ...wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe 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 de...

Page 89: ...tensively tested 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 TIP A diagnostic tachometer is needed to ...

Page 90: ...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 91: ...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 92: ...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...

Page 93: ...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 94: ...wn 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 Fu...

Page 95: ...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 96: ...uld be lubricated if necessary EBU24962 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 smoothly have a Yamaha dealer check the wheel hub bear ings EBU28822 Lubricating the front knuckle pivots The front knuckle pivots must b...

Page 97: ...lectrolyte level 1 Place the ATV on a level surface 2 Check the electrolyte level in the battery TIP The electrolyte should be between the minimum and maximum level marks 3 If the electrolyte is at or below the minimum level mark add distilled water to raise it to the maximum level mark NOTICE ECB00590 Use only distilled water as tap water contains minerals that are harmful to the battery WARNING ...

Page 98: ... 4 Check and if necessary tighten the battery lead connections and correct the breather hose routing To store the battery If the ATV will not be used for more than one month the battery will need to be removed and stored as follows 1 Disconnect the negative lead first and then the positive lead 2 Remove the battery fully charge it and then place it in a cool dry place NOTICE ECB00600 Do not leave ...

Page 99: ...nd not obstructed NOTICE ECB00610 If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the battery the frame could suf fer structural and external damages EBU25242 Replacing the fuse The fuse holder is located under the seat See page 4 11 If the fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits 1...

Page 100: ...ng 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 circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU25651 Removing a wheel 1 Place the ATV on a le...

Page 101: ...rame 4 Remove the nuts from the wheel 5 Remove the wheel EBU27481 Installing a wheel 1 Place the ATV on a level surface 2 Install the wheel and the nuts TIP When installing the wheel make sure its arrow mark points toward the rotating direction of the wheel Front 1 Wheel nut 1 1 Arrow mark 1 ...

Page 102: ...d 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 checking the fuel syst...

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: ...se and vibration level Noise level 77 311 EEC 76 7 dB A EUR Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s2 EUR Vibration on handlebar EN1032 ISO5008 Will not exceed 2 5 m s2 EUR 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 st...

Page 108: ...gasoline only EUR Unleaded gasoline only AUS NZL 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 Carburetor Manufacturer MIKUNI Type 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 reducti...

Page 109: ...pe Tubeless Size AT16 x 8 7 Manufacturer model DUNLOP KT145 Loading Maximum loading limit 40 0 kg 88 lb Total weight of rider cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 20 kPa 0 200 kgf cm2 2 9 psi Rear 20 kPa 0 200 kgf cm2 2 9 psi Minimum Front 17 kPa 0 170 kgf cm2 2 5 psi Rear 17 kPa 0 170 kgf cm2 2 5 psi Front wheel Wheel type Panel wheel Rim size 7 ...

Page 110: ...pring oil damper Wheel travel 57 mm 2 3 in Rear suspension Type Swingarm Spring shock absorber type 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 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 EBU26040 Vehicle identification number The vehicle identification number...

Page 112: ...ation number is used to identi 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 Vehicle identification number 2 Year of manufacture ...

Page 113: ...11 3 1 2 3 4 5 6 7 8 9 10 11 1 Model label 1 ...

Page 114: ...1 D Drive select lever 4 7 E Engine break in 6 5 Engine cold start 6 1 Engine idling speed 8 18 Engine oil 5 3 8 9 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 12 Front knuckle pivots lubricating 8 25 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...

Page 115: ...8 17 Spark plug checking 8 8 Specifications 10 1 Speed limiter 4 5 Start switch 4 2 Steering shaft lubricating 8 26 Storage 9 2 T Throttle cable free play checking 8 19 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 19 Vehicle identification number 11 1 W Wheel hub bearings checking 8 25 Wheel ins...

Page 116: ...PRINTED IN JAPAN 2008 05 0 2x2 E YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER ...

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