Yamaha YFM7RD Owner'S Manual Download

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5-3

Brake and clutch levers

• Make sure that operation is smooth. Lubricate lever pivoting points if

necessary.

8-42

Chassis fasteners

• Make sure that all nuts, bolts and screws are properly tightened.

5-7

Instruments, lights and
switches

• Check operation, and correct if necessary.

5-7

ITEM

ROUTINE

PAGE

U1PE60E0.book Page 3 Friday, March 2, 2012 1:22 PM

Summary of Contents for YFM7RD

Page 1: ...MANUAL DEL PROPIETARIO 1PE 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 DIC183 ...

Page 2: ...PRINTED IN USA 2012 03 0 4 1 CR E F S DIC183 ...

Page 3: ... It contains important safety information WARNING OWNER S MANUAL YFM7RD YFM7RSED YFM700RD YFM700RSED This ATV should not be ridden by anyone under 16 years of age 1PE F8199 60 E0 U1PE60E0 book Page 1 Friday March 2 2012 1 22 PM ...

Page 4: ...pplicable YAMAHA MOTOR EUROPE N V Koolhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Eiji Kato Date of Issue 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 and or technical specificat...

Page 5: ... includes important safety information It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE Read this manual completely before operating your ATV Make sure you understa...

Page 6: ... 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 property A TIP provides key info...

Page 7: ...way Please check your local riding laws and regulations before operating this ATV EBU17410 YFM7RD YFM7RSED YFM700RD YFM700RSED OWNER S MANUAL 2012 by Yamaha Motor Co Ltd 1st edition February 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A U1PE60E0 book Page 1 Friday March 2 2012 1 22 PM ...

Page 8: ...6 Brake lever YFM7RSED YFM700RSED 4 7 Brake pedal 4 7 Parking brake lever 4 8 Shift pedal 4 9 Reverse knob REV 4 9 Fuel tank cap 4 10 Fuel 4 10 Seat 4 12 Adjusting the front shock absorber assemblies YFM7RD YFM700RD 4 13 Adjusting the front shock absorber assemblies YFM7RSED YFM700RSED 4 15 Adjusting the rear shock absorber assembly YFM7RD YFM700RD 4 19 Adjusting the rear shock absorber assembly Y...

Page 9: ... AND ADJUSTMENT 8 1 Owner s manual and tool kit 8 2 Periodic maintenance chart for the emission control system 8 3 General maintenance and lubrication chart 8 5 Removing and installing the panel 8 10 Checking the spark plug 8 10 Engine oil and oil filter element 8 13 Coolant 8 17 Cleaning the air filter element 8 21 Cleaning the spark arrester 8 25 Adjusting the engine idling speed 8 27 Adjusting ...

Page 10: ...vots 8 43 Lubricating the rear suspension relay arm and connecting arm pivoting points 8 43 Lubricating the upper and lower arm pivots 8 44 Lubricating the steering shaft 8 45 Battery 8 46 Replacing a fuse 8 48 Replacing a headlight bulb 8 50 Adjusting a headlight beam 8 52 Tail brake light 8 52 Removing a wheel 8 52 Installing a wheel 8 53 Troubleshooting 8 54 Troubleshooting charts 8 55 CLEANING...

Page 11: ...abels 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 For Europe 1 1 4 3 5 2 6 7 U1PE60E0 book Page 1 Friday March 2 2012 1 22 PM ...

Page 12: ...1 2 1 1HP F2259 21 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM700R 35 0 kW 192 kg 2012 1PE F155A 00 YAMAHA 1HP F811R 00 1 2 4 3 U1PE60E0 book Page 2 Friday March 2 2012 1 22 PM ...

Page 13: ...1 3 1 3C2 F816P 00 YAMAHA 27 5 kPa 0 275 kgf cm 4 0 psi 27 5 kPa 0 275 kgf cm 4 0 psi 1PE F816M M0 1P0 F816R 00 YAMAHA 7 6 5 U1PE60E0 book Page 3 Friday March 2 2012 1 22 PM ...

Page 14: ... from 12 years old Operation of this ATV by children under the age of 12 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 NEVER use on paved roads NEVER carry passengers NEVER use with drugs or alcohol NEVER store fuel or flammable...

Page 15: ... loss of control Adjust the tire pressure 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 re...

Page 16: ...1 6 1 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN kW kg 1 2 3 4 1 2 3 4 Year of construction Model Name Max Power Mass In Running Order U1PE60E0 book Page 6 Friday March 2 2012 1 22 PM ...

Page 17: ...1 7 1 For Oceania 4 5 2 3 1 1 U1PE60E0 book Page 7 Friday March 2 2012 1 22 PM ...

Page 18: ... UNDER 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 1P0 F816L 00 YAMAHA 2 1 U1PE60E0 book Page 8 Friday March 2 2012 1 22 PM ...

Page 19: ...H 3C2 F151H 00 YAMAHA WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate ALWAYS 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 passen...

Page 20: ... 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 This vehicle is intended for off road use only Do not operate on any paved surfaces such as sidew...

Page 21: ...ver operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly or make sud...

Page 22: ...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 be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of t...

Page 23: ...and ride gently back to camp or other known location where you can receive medical atten tion 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 nigh...

Page 24: ...nd others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following guide lines in mind as well as those provided under 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 ...

Page 25: ...so deadly levels of carbon monoxide can linger for hours or days in en closed or poorly ventilated areas 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 ru...

Page 26: ...6 Rear shock absorber assembly compression damping force adjusting bolt for fast compression damping YFM7RSED YFM700RSED 7 Rear shock absorber assembly compression damping force adjusting screw for slow compression damping YFM7RSED YFM700RSED 1 2 3 4 6 7 8 9 5 10 8 Rear shock absorber assembly spring preload adjusting nut 9 Shift pedal 10 Engine oil tank drain bolt U1PE60E0 book Page 1 Friday Marc...

Page 27: ... assembly compression damping force adjusting screw for slow compression damping YFM7RSED YFM700RSED 10 Front shock absorber assembly spring preload adjusting nut YFM7RSED YFM700RSED 1 2 4 3 5 6 7 8 9 10 14 13 15 11 12 11 Front shock absorber assembly spring preload adjusting ring YFM7RD YFM700RD 12 Front shock absorber assembly rebound damping force adjusting screw YFM7RSED YFM700RSED 13 Crankcas...

Page 28: ...er slightly from the figures shown in this manual 1 Clutch lever 2 Parking brake lever 3 Main switch 4 Front brake fluid reservoir 5 Brake lever 6 Throttle lever 7 Reverse knob 8 Fuel tank cap 9 Handlebar switches 1 2 3 4 5 6 7 8 9 U1PE60E0 book Page 3 Friday March 2 2012 1 22 PM ...

Page 29: ... follows on All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed off All electrical systems are off The key can be re moved 1 Main switch OFF ON 1 U1PE60E0 book Page 1 Friday March 2 2012 1 22 PM ...

Page 30: ...g light can be checked by turning the key to on The warn ing light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to on or if the warning light remains on have a Yamaha dealer check the elec trical circuit NOTICE ECB00010 The engine may overheat if the ATV is over loaded In this case reduce the load to spec ification Start th...

Page 31: ...the engine is not work ing correctly When this occurs have a Yamaha dealer check the self diagnosis system The electrical circuit of the warning light can be checked by turning the key to on The warn ing light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to on or if the warning light remains on have a Yamaha dealer check th...

Page 32: ...ht switch OFF Set this switch to to turn on the low beams and the taillight Set the switch to to turn on the high beams and the taillight Set the switch to OFF to turn off all the lights NOTICE ECB00043 Do not use the headlights with the engine turned off for an extended period of time oth erwise the battery may discharge to the point that the starter motor will not operate properly If this should...

Page 33: ...hed to the maximum 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 available and the maximum speed of the ATV turn the adjusting screw in direction b Do not turn the adjusting screw out more than 12 mm 0 47 in or the throttle cable could be dam aged Always make sure...

Page 34: ...elease the clutch lever The clutch lever should be pulled rapidly and re leased slowly for smooth clutch operation See page 6 1 for a description of the ignition circuit cut off system EBU18411 Brake lever YFM7RD YFM700RD The brake lever is located at the right handlebar grip To apply the front brake pull the brake lever toward the handlebar grip 1 Locknut 2 Adjusting screw 3 No more than 12 mm 0 ...

Page 35: ...he handlebar grip hold the brake lever away from the handlebar so it does not contact the adjusting bolt loosen the locknut turn the adjust ing bolt and then tighten the locknut EBU18432 Brake pedal The brake pedal is located on the right side of the ATV To apply the rear brake push down on the brake pedal 1 Brake lever 1 1 Brake lever 2 Locknut 3 Brake lever position adjusting bolt 4 Distance bet...

Page 36: ...pecially on a slope To apply the parking brake move the parking brake lever in direction a To release the parking brake move the parking brake lever in direction b 1 Brake pedal 1 1 Parking brake lever locked position 1 Parking brake lever unlocked position U1PE60E0 book Page 8 Friday March 2 2012 1 22 PM ...

Page 37: ... braking performance which could cause an accident You could also wear out the brakes prematurely EBU18540 Shift pedal This ATV is equipped with a constant mesh 5 speed forward and 1 speed reverse transmission The shift pedal is located on the left side of the en gine and is used in combination with the clutch when shifting EBU18641 Reverse knob REV The reverse knob is used to shift into reverse S...

Page 38: ...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 Reverse knob REV 1 1 Fuel tank cap 1 U1PE60E0 book Page 10 Friday March 2 2012 1 22 PM ...

Page 39: ...loth since fuel may deteriorate painted surfaces or plastic parts ECB00981 4 Turn the fuel tank cap fully clockwise to make sure it is securely closed WARNING EWB02531 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 1 Fuel tan...

Page 40: ...esearch octane number 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 EBU29890 Seat To remove the seat Push the seat lock lever backward and pull up the seat at the rear To install the seat Fit the slot in the seat onto the projection on the fuel tank insert the p...

Page 41: ...e poor handling and loss of stability which could lead to an ac cident 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 sho...

Page 42: ...tained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Position indicator a b 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 1 U1PE60E0 book Page 14 Friday March 2 2012 1 22 PM ...

Page 43: ...neven adjustment can cause poor handling and loss of stability which could lead to an accident NOTICE ECB00090 Never turn an adjusting mechanism beyond the minimum and maximum settings TIP Although the total number of clicks or turns of a damping force adjusting mechanism may not ex actly match the following specifications due to small differences in production the actual number of clicks or turns...

Page 44: ...ete turn of the adjusting nut distance A is changed by 1 5 mm 0 06 in 3 Tighten the locknut to the specified torque NOTICE Always tighten the locknut against the adjusting nut and then tighten it to the specified torque ECB00081 1 Spring preload adjusting nut 2 Locknut 3 Special wrench 2 1 3 a b Spring preload setting Minimum soft Distance A 263 0 mm 10 35 in Standard Distance A 260 0 mm 10 24 in ...

Page 45: ... and thereby harden the compression damping turn the compression damping force adjusting bolt in direc tion a To decrease the compression damping force and thereby soften the compression damp ing turn the adjusting bolt in direction b Tightening torque Locknut 42 Nm 4 2 m kgf 30 ft lbf 1 Rebound damping force adjusting screw 1 a b Rebound damping setting Minimum soft 20 click s in direction b Stan...

Page 46: ...ession damp ing turn the adjusting screw in direction b 1 Compression damping force adjusting bolt for fast compression damping Compression damping setting for fast com pression damping Minimum soft 4 turn s out from the fully turned in posi tion Standard 2 turn s out from the fully turned in posi tion Maximum hard Adjusting bolt fully turned in 1 a b 1 1 Compression damping force adjusting screw ...

Page 47: ... a Yamaha deal er for any service EBU19044 Adjusting the rear shock absorber as sembly YFM7RD YFM700RD The spring preload can be adjusted to suit the rid er s weight and the riding conditions NOTICE ECB01090 Never turn the adjusting mechanism beyond the minimum and maximum settings Adjust the spring preload as follows 1 Loosen the locknut 2 Turn the spring preload adjusting nut in direc tion a to ...

Page 48: ...lete turn of the adjusting nut distance A is changed by 1 5 mm 0 06 in 3 Tighten the locknut to the specified torque NOTICE Always tighten the locknut against the adjusting nut and then tighten it to the specified torque ECB00081 1 Spring preload adjusting nut 2 Locknut 3 Special wrench 1 b a 2 3 Spring preload setting Minimum soft Distance A 243 0 mm 9 57 in Standard Distance A 233 0 mm 9 17 in M...

Page 49: ...ice EBU30041 Adjusting the rear shock absorber as sembly YFM7RSED YFM700RSED This shock absorber assembly is equipped with a spring preload adjusting nut a rebound damping force adjusting screw with a compression damp ing force adjusting bolt for fast compression damping and a compression damping force ad justing screw for slow compression damping WARNING EWB02680 Suspension components become hot ...

Page 50: ...2 Turn the spring preload adjusting nut in direc tion a to increase the spring preload and thereby harden the suspension and in direc tion b to decrease the spring preload and thereby soften the suspension TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment The spring preload setting is determined by measuring distance A shown in the illustration The shorter distance A ...

Page 51: ...crease the rebound damping force and thereby harden the damping and in di rection b to decrease the rebound damping force and thereby soften the damping Spring preload setting Minimum soft Distance A 243 0 mm 9 57 in Standard Distance A 233 0 mm 9 17 in Maximum hard Distance A 228 0 mm 8 98 in 1 Distance A 1 Tightening torque Locknut 42 Nm 4 2 m kgf 30 ft lbf 1 Rebound damping force adjusting scre...

Page 52: ... direction b Rebound damping setting Minimum soft 20 click s in direction b Standard 13 click s in direction b Maximum hard 3 click s in direction b With the adjusting screw fully turned in di rection a 1 Compression damping force adjusting bolt for fast compression damping Compression damping setting for fast com pression damping Minimum soft 4 turn s out from the fully turned in posi tion Standa...

Page 53: ...e shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Do not subject the shock absorber assembly to an open flame or other high heat source This may cause the unit to explode due to ex cessive gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance 1 Compression damping force adjusting screw for slow compr...

Page 54: ...4 26 4 Do not dispose of a damaged or worn out shock absorber assembly yourself Take the shock absorber assembly to a Yamaha deal er for any service U1PE60E0 book Page 26 Friday March 2 2012 1 22 PM ...

Page 55: ...by the procedures provided in this manual have the vehicle inspected by a Yamaha dealer Before 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 10 5 4 Engine oil Check oil level in engine oil tank and add recommended oil to spec ified level if necessary Check ...

Page 56: ...tion and correct if necessary Lubricate cable if necessary Check lever free play and adjust if necessary 8 37 Throttle lever Make sure that operation is smooth Lubricate cable and lever hous ing if necessary Check lever free play and adjust if necessary 5 5 8 28 Control cables Make sure that operation is smooth Lubricate if necessary 8 41 Drive chain Check chain slack and adjust if necessary Check...

Page 57: ...ate lever pivoting points if necessary 8 42 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 5 7 Instruments lights and switches Check operation and correct if necessary 5 7 ITEM ROUTINE PAGE U1PE60E0 book Page 3 Friday March 2 2012 1 22 PM ...

Page 58: ...8 34 If the pedal height is incorrect have a Yamaha dealer adjust it Check the operation of the lever and pedal They should move smoothly and there should be a firm feeling when the brakes are applied If not have a Yamaha dealer check the brake system Brake fluid level Check the brake fluid level Add fluid if necessary See page 8 31 Brake fluid leakage Check to see if any brake fluid is leaking ou...

Page 59: ...ion of this vehicle with im proper tire pressure may cause severe injury or death from loss of control or rollover Tire pressure below the minimum specified could also cause the tire to dislodge from the rim un der severe riding conditions EWB02541 Set tire pressures to the following specifications The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pre...

Page 60: ... with valves WARNING EWB02551 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 Manufacturing Corporation of America 1 Low pressure tire gauge 1 Tire wear limit U1PE60E0 book Page 6 Friday March 2 2012 1 22 PM ...

Page 61: ...ay not be appropriate EBU19840 Chassis 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 Front Manufacturer model MAXXIS M971Y Bias Size AT21 x 7 10 Type Tubeless Rear Manufacturer model MAXXIS M976Y Bias Size AT20 x 10 9 Type Tubeless U1PE60E0 ...

Page 62: ...on for a few seconds then go off Coolant temperature warning light Fuel level warning light Engine trouble warning light NOTICE ECB00824 If a warning light does not go off see page 4 2 for the corresponding warning light circuit check To avoid possible damage do not oper ate the ATV if a warning light stays on 3 Shift the transmission into neutral The neutral indicator light should come on if it d...

Page 63: ...transmission The transmission allows you to control the amount of power you have available at a given speed or for starting accelerating climb ing hills etc To shift into neutral release the throttle lever ap ply the clutch and then repeatedly depress the shift pedal until it stops When it stops it will be in first gear Raise the pedal slightly to reach the neutral position and then re lease the c...

Page 64: ...hen shifting to the next higher gear EBU20650 To decelerate When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly As you slow down shift to a lower gear Be sure that the engine has sufficiently slowed before engaging a lower gear Improper use of the brakes or shifting can cause the tires to lose traction reducing con trol and increasing the possibility of an ...

Page 65: ...behind you resulting in serious injury When you shift into reverse make sure there are no people or ob stacles behind you When it is safe to proceed go slowly NOTICE ECB00170 Before shifting stop the ATV otherwise the transmission may be damaged 1 Bring the ATV to a complete stop apply the clutch lever and then shift the transmission into first gear 2 While applying the brake pedal turn the re ver...

Page 66: ... following material carefully Since the engine is brand new do not put an ex cessive load on it for the first 320 km 200 mi or 20 hours The various parts in the engine wear and polish themselves to the correct operating 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 pro...

Page 67: ... incline place the ATV transversely across the incline shift into first gear stop the engine ap ply the parking brake and then block the front and rear wheels with rocks or other objects Never park the ATV on hills that are too steep to walk up easily 1 Bring the ATV to a stop by applying the front brake shift into first gear and then stop the engine 2 With the front and rear brakes applied apply ...

Page 68: ...are not suitable because of poten tial safety hazards to you or others Installing after market products or having other modifications performed to your ATV that change any of the ve hicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following in mind when consideri...

Page 69: ... in the maximum ATV load limit Load cargo on the carriers as close to the center of the ATV as possible Put cargo at the rear of the front carrier at the front of the rear carrier and center it Tie down cargo securely to the carriers Make sure cargo in the trailer 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 wh...

Page 70: ...7 1 7 EBU21141 RIDING YOUR ATV U1PE60E0 book Page 1 Friday March 2 2012 1 22 PM ...

Page 71: ...anual completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 2 1 2 6 Also read all warning and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01381 Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an accident is greatly increas...

Page 72: ...EWB01390 A child under 16 should never operate an ATV with engine size greater than 90 cc Use by chil dren of ATVs that are not recommended for their age can 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 ...

Page 73: ...NG Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01411 Wear eye protection when operating your ATV to reduce the risk of a serious accident or 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 w...

Page 74: ...each time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 1 Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual WARNING Failure to inspect the ATV before operating it and to maintain it prop erly increases the possibility of an accident or equipment damage EWB01431 Speed limiter For ...

Page 75: ...r control or ability to see where you are going Reduce speed and allow more room to stop A heavier vehicle takes longer to stop Avoid hills and rough terrain Choose terrain carefully Use extreme caution when towing or 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 ac cessories to carry ca...

Page 76: ...d wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off EWB01481 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...

Page 77: ...ystem Do not park the ATV in a place where others might be likely to touch it 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 ...

Page 78: ...ion 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 not ride on any paved public street road or motorway WARNING Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle EWB01521 Know the terrain where you ride Ride cautiously in unfamili...

Page 79: ...ING Failure to use extra care when op erating on excessively rough slippery or loose terrain could cause loss of traction or ATV control which could result in an accident including an overturn EWB01541 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 an...

Page 80: ...e not to accidentally move the shift pedal With the engine idling pull the clutch lever to disengage the clutch and shift into 1st gear and then release the parking brake Open the throttle gradually and at the same time re lease the clutch lever slowly Once the ATV has at tained adequate speed release the throttle lever and at the same time quickly pull in the clutch le ver and shift into 2nd gear...

Page 81: ...ning at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions ATV could 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 resis...

Page 82: ...he ATV begins to tip over to the outside 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 WARNING EWB01591 Climbing hills improperly can cause overturns or loss of cont...

Page 83: ... or person could be 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 U1PE60E0 book Page 14 Friday...

Page 84: ...ever possible ride straight up hills Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side there could be another person an obstacle or a sharp drop off Use common sense and remember that some hills are too steep for you to climb or de scend If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you ...

Page 85: ...ng the procedure described in the Owner s Manual WARNING Stalling rolling backwards or improperly dismounting while climbing a hill could result in ATV overturning If you cannot control the ATV dismount immediately on the uphill side EWB01802 RIDING DOWNHILL WARNING EWB01131 Going down a hill improperly could cause overturns or loss of control Always follow proper procedures for going down hills a...

Page 86: ...hill When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as pos sible Move back on the seat and sit with your arms straight Choose a low gear which will allow the en gine compression to do most of the braking for you Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces ...

Page 87: ... 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 surface Avoid slopes with slip pery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loo...

Page 88: ...oving shal low water of up to a maximum of 35 cm 14 in in depth Before entering the water choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or upset the ATV Drive slowly and care fully Test your brakes after leaving the water If neces sary apply them several times to let friction dry out the linings Do not continue to ride yo...

Page 89: ...B01651 Riding improperly over obstacles could cause loss of control or a collision Before operating in a new area check for obstacles Never at tempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual Riding over rough terrain should be done with cau tion Look out for obstacles which could ca...

Page 90: ... slowly and be very cautious in order to re duce the chance of skidding or sliding out of control 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 reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help...

Page 91: ...of the turn Position your weight over the front wheels for better control See page 7 12 If your ATV begins to tip while turning Lean more into the turn to regain balance If nec essary gradually let off the throttle and or steer to the outside of the turn 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 i...

Page 92: ... you discover that the ATV is going to tip over dismount on the uphill side See page 7 18 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let wa 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 S...

Page 93: ...urn 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 EWB02690 ...

Page 94: ... the tools provided in the owner s tool kit are in tended to assist you in the performance of preven tive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Owner s manual 2 Owner s tool kit...

Page 95: ...ed 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 Valves...

Page 96: ...ness 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 U1PE60E0 book Page 4 Friday March 2 2012 1 22 PM ...

Page 97: ...ls 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 Clutch Check operation and adjust if necessary 3 Front brake Check operation and correct if necessary Check fluid level and ATV ...

Page 98: ...sary 10 Swingarm pivots Check operation and for excessive play and re place bearings if necessary Lubricate with lithium soap based grease 11 Upper and lower arm pivots Lubricate with lithium soap based grease 12 Drive chain Check chain slack and adjust if necessary Check rear wheel alignment and correct if neces sary Clean and lubricate 13 Drive chain roller Check for wear and replace if necessar...

Page 99: ...Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 19 Engine mount Check for cracks or other damage and replace if necessary 20 Engine oil Change Check ATV for oil leakage and correct if neces sary 21 Engine oil filter ele ment Replace 22 Cooling system Check coolant level and ATV for coolant leakage and correct if necessary Replace coolant Every ...

Page 100: ...djust or replace if neces sary 25 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 26 Front and rear brake switches Check operation and correct if necessary 27 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 ...

Page 101: ...rs replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U1PE60E0 book Page 9 Friday March 2 2012 1 22 PM ...

Page 102: ...the panel Place the panel in the original position and install the bolts EBU23213 Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accor dance with the periodic maintenance and lubrica tion chart In addition the condition of the spark plug ...

Page 103: ...ulator 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 color the engine could be operating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 1 Spark plug cap 1 1 Spark plug wrench 1 U1PE60E0 book Page 11 Friday March 2 201...

Page 104: ...k plug threads 2 Install the spark plug with the spark plug wrench and then tighten it to the specified torque TIP If a torque wrench is not available when installing the 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 3 Install the spark plug cap Specified spark plug NGK CR8E ...

Page 105: ...reading the engine must have first completely cooled down and then warmed up again for several minutes to normal operating tem perature 3 Remove the engine oil tank filler cap and then wipe the engine oil dipstick off with a clean rag 4 Insert the dipstick in 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 ...

Page 106: ...r cap is securely tightened other wise oil may seep out when the engine is running ECB00362 To change the engine oil with or without oil fil ter element replacement 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 crankcase engine oil filler cap and its O ring and then...

Page 107: ...et TIP Skip steps 6 9 if the oil filter element is not being replaced 6 Remove the oil filter element cover by remov ing the bolts 7 Remove the oil filter element and the O rings 1 Engine oil tank drain bolt 2 Gasket 1 2 1 Oil filter element cover 2 Bolt 2 1 U1PE60E0 book Page 15 Friday March 2 2012 1 22 PM ...

Page 108: ...oil filler cap to the specified torque 12 Pour only 1 3 L 1 37 US qt 1 14 Imp qt of the specified amount of the recommended en gine oil through the engine oil tank filler hole and then install and tighten the oil tank filler cap 13 Start the engine rev it several times and then turn it off 1 Oil filter element 2 O ring Tightening torque Oil filter element cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 2 ...

Page 109: ...ING II or higher Make sure that no foreign material enters the crankcase 16 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 17 Turn the engine off and then check the oil lev el and correct it if necessary EBU23470 Coolant The coolant level should be checked before each ride In addi...

Page 110: ...ap NOTICE If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since they are harmful to the engine If water has been used instead of coolant replace it with coolant as soon as possible other wise the cooling system will not be pro tected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifr...

Page 111: ...could be burned by hot fluid and steam blown out under pressure Always place a thick rag over the cap when opening Allow any remaining pressure to escape before completely removing the cap 1 Place the ATV on a level surface 2 Remove panel A See page 8 10 3 Place a container under the engine and then remove the coolant drain bolt and its gasket 1 Coolant reservoir cap Coolant reservoir capacity up ...

Page 112: ...r draining the coolant thoroughly flush the cooling system with clean tap water 8 Install the coolant drain bolt and its new gas ket and then tighten the bolt to the specified torque 1 Coolant drain bolt 2 Gasket 1 Radiator cap 1 2 1 1 Coolant reservoir cap 2 Coolant reservoir hose Tightening torque Coolant drain bolt 11 Nm 1 1 m kgf 8 0 ft lbf 1 2 U1PE60E0 book Page 20 Friday March 2 2012 1 22 PM...

Page 113: ... check for coolant leakage TIP If any leakage is found have a Yamaha dealer check the cooling system 15 Install the panel EBU26806 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 or if necessary replace the air filter element more frequently if you are riding in unusually wet or dusty areas...

Page 114: ...air filter case cover by unhooking the holders 4 Fully loosen the wing bolt 5 Remove the air filter element together with the wing bolt and washer 1 Air filter case check hose 1 1 Air filter case cover 2 Air filter case cover holder 2 1 2 U1PE60E0 book Page 22 Friday March 2 2012 1 22 PM ...

Page 115: ...ean the sponge material Never use low flash point sol vents or gasoline to clean the sponge ma terial because the engine could catch fire or explode EWB01941 9 Squeeze the excess solvent out of the sponge material and let it dry NOTICE Do not twist the sponge material when squeezing it ECB00441 1 Air filter element 2 Washer 3 Wing bolt 3 2 1 1 Sponge material 2 Air filter element frame 2 1 U1PE60E...

Page 116: ...Pull the sponge material over the air filter ele ment frame 13 Apply all purpose grease to the air filter ele ment seat 14 Install the washer onto the air filter element frame and then insert the wing bolt into the hole in the air filter element frame NOTICE Be sure to install the washer with its curved side facing outward as shown ECB00453 1 Air filter element seat 1 U1PE60E0 book Page 24 Friday ...

Page 117: ...ders onto the air filter case 17 Install the seat 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 Check the air filter case rubber joint to the throttle body and the rubbe...

Page 118: ...the tailpipe and inside of the tailpipe housing 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the bolt and tighten it to the specified torque 6 Remove the purging bolt and the gasket 1 Tailpipe 2 Tailpipe bolt 2 1 1 Tailpipe 2 Spark arrester Tightening torque Tailpipe bolt 8 Nm 0 8 m kgf 5 8 ft lbf 1 2 U1PE60E0 book Page 26 Friday March 2 2012 1 22 PM ...

Page 119: ...rk arrester otherwise it could cause injury to the eyes burns carbon monox ide poisoning possibly leading to death and start a fire Always let the exhaust system cool prior to touching exhaust components Always wear eye protection and make sure no one is behind the ATV Make sure there are no combustible materi als in the area EBU26811 Adjusting the engine idling speed The engine idling speed must ...

Page 120: ...maha dealer make the adjustment EBU24047 Adjusting the throttle lever free play The throttle lever free 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 2 0 4 0 mm 0 08 0 16 in as shown Periodically check the throttle lever free play and if necessary adjust it as follows TIP The...

Page 121: ... and lu brication chart EBU24080 Adjusting the reverse lock release ca ble The reverse lock release cable stretches with use which can result in improper function Therefore the reverse lock release cable should be checked and adjusted at the intervals specified in the peri odic maintenance and lubrication chart EBU29601 Brakes Replacement of brake components requires pro fessional knowledge Brake ...

Page 122: ...o the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a set TIP The wheels need to be removed to check the brake pads See page 8 52 EBU29831 Rear brake pads Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wear...

Page 123: ...e brake fluid is above the minimum level mark Check the brake fluid lev el with the top of the reservoir level Replenish the brake fluid if necessary Front brake YFM7RD YFM700RD 1 Wear indicator groove 1 1 Minimum level mark 1 U1PE60E0 book Page 31 Friday March 2 2012 1 22 PM ...

Page 124: ...at See page 4 12 To access the rear brake fluid reservoir for replen ishing 1 Remove the bolt and quick fastener screw 2 Pull the cowling slightly outward as shown 1 Minimum level mark 1 Minimum level mark 1 1 1 Quick fastener screw 2 Bolt 1 2 U1PE60E0 book Page 32 Friday March 2 2012 1 22 PM ...

Page 125: ...th the same type of brake fluid Add ing a brake fluid other than DOT 4 may result in a harmful chemical reaction Be careful that water does not enter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock NOTICE ECB01160 Brake fluid may damage painted surfaces or plastic parts Always clean up spilled fluid im mediately As...

Page 126: ...s Replace every four years EBU24394 Checking the front brake lever free play The brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart The brake lever should have no free play as shown If there is free play have a Yamaha dealer check the brake system EBU24613 Checking the brake pedal height The brake pedal height must be checked and if n...

Page 127: ...lay as follows 1 Release the parking brake by moving the parking brake lever to the right 2 Fully loosen the locknut and the adjusting bolt at the rear brake caliper 3 Slide the rubber cover back at the brake ca ble 4 Loosen the locknut 5 Turn the parking brake free play adjusting nut in direction a to increase the cable length and in direction b to decrease it 1 Brake pedal height 1 1 Adjusting b...

Page 128: ...rviced or adjust ed brakes could cause the brakes to malfunc tion resulting in reduced braking performance This could increase the chance of a collision or accident After adjusting the parking brake free play block the rear of the ATV off the ground and spin the rear wheels Check to make sure there is no brake drag If brake drag is noticed perform the adjustment again EBU24743 Brake light switches...

Page 129: ...ls specified in the periodic maintenance and lubrication chart The clutch lever free play should measure 5 0 10 0 mm 0 20 0 39 in as shown If the free play is incorrect adjust it as follows 1 Slide the rubber cover back 2 Loosen the locknut at the clutch lever 3 To increase the clutch lever free play turn the adjusting bolt at the clutch lever in direction a and to decrease it turn the bolt in dir...

Page 130: ...ed as de scribed above or if the clutch does not operate cor rectly have a Yamaha dealer check the internal clutch mechanism EBU26864 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary To check the drive chain slack 1 Place the ATV on a level surface TIP When checking and adjusting the drive chain slack there should be no weight on the ATV and all ...

Page 131: ...TIP A rod can be obtained at a Yamaha dealer to make this adjustment 4 Shift the transmission into neutral 5 To tighten the drive chain push the ATV back ward To loosen the drive chain push the ATV forward NOTICE Improper drive chain slack will overload the engine as well as other vital parts of the ATV and can lead to drive chain slippage or breakage To pre 1 Drive chain slack 1 1 Rear wheel axle...

Page 132: ...hart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECB00561 The drive chain must be lubricated after wash ing the ATV or riding in the rain or wet areas 1 Clean the drive chain with kerosene and a small soft brush NOTICE To prevent dam aging the O rings do not clean the drive chain with steam cleaners high pressure washers...

Page 133: ... or does not move smoothly have a Yamaha dealer check or replace it WARNING EWB02581 Inspect cables frequently and replace if dam aged Corrosion can result when the cable sheaths become damaged and cables can also become frayed or kinked which could restrict the operation of controls and lead to an accident or injury Always make sure all control cables work smoothly before you begin riding in cold...

Page 134: ...rake pedal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricated if necessary EBU24963 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...

Page 135: ...nsion relay arm and connecting arm pivoting points The rear suspension relay arm and connecting arm pivoting points must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart TIP For parts equipped with a grease nipple use a grease gun Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease U1PE60E0 book Page 43 Friday ...

Page 136: ...ubricated at the intervals specified in the periodic mainte nance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun 1 Grease nipple 1 Grease nipple 1 1 1 Grease nipple Recommended lubricant Lithium soap based grease 1 U1PE60E0 book Page 44 Friday March 2 2012 1 22 PM ...

Page 137: ... the intervals specified in the periodic maintenance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun 1 Upper grease nipple 2 Lower grease nipple 1 2 1 Upper grease nipple 2 Lower grease nipple Recommended lubricant Lithium soap based grease 1 2 U1PE60E0 book Page 45 Friday March 2 2012 1 22 PM ...

Page 138: ...antities 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 ig nition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN NOTICE ECB00620 Never attempt to rem...

Page 139: ... a VRLA Valve Regulated Lead Acid battery a special constant voltage battery charger is required 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...

Page 140: ...3 Hook the battery holding plate onto the battery box 4 Install the battery holding plate with the bat tery cover by installing the bolts and the quick fastener screws 5 Install the seat See page 4 12 EBU25327 Replacing a fuse The main fuse and the fuse box are located under the seat See page 4 12 1 Positive battery lead red 2 Negative battery lead black 2 1 1 Battery holding plate 2 Battery box 2...

Page 141: ...00640 To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 1 Main fuse 2 Spare main fuse 1 2 1 Fuel injection system fuse 2 Radiator fan fuse 3 Ignition fuse 4 Signaling system fuse 5 Headlight fuse 6 Spare fuse 1 2 3 4 5 6 U1PE60E0 book Page 49 Friday March 2 2012 1 22 PM ...

Page 142: ... if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU30161 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the headlight unit by removing the bolt and then pulling the headlight unit out ward as shown 2 Remove the headlight bulb holder cover Specified fuses Main fuse 30 0 A Headlight fuse 10 0 A Ig...

Page 143: ...part of the headlight bulb to keep it free from oil oth erwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the head light bulb using a cloth moistened with al cohol or thinner ECB00651 1 Headlight bulb holder cover 1 1 Headlight bulb holder 1 U1PE60E0 book Page 51 Friday March 2 2012 1 22 PM...

Page 144: ...Yamaha dealer make this adjustment To raise a headlight beam turn the headlight beam adjusting bolt in direction a To lower a headlight beam turn the adjusting bolt in direction b EBU26920 Tail brake light This model is equipped with an LED type of tail brake light If the tail brake light does not come on have a Yamaha dealer check it EBU25651 Removing a wheel 1 Place the ATV on a level surface 1 ...

Page 145: ...urface 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 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torques 1 Wheel nut 1 Arrow mark Tightening torques Front wheel nut 45 Nm 4 5 m kgf 33 ft lbf Rear wheel nut 45 Nm 4 5 m kgf 33 ft lbf U1PE60E0 book Page 53 Friday March 2 2012 1 22 P...

Page 146: ...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 system Fuel can ignite o...

Page 147: ...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 battery Dry Wet Operate the electric starter The engine does not start Have a Yamaha dealer check the ATV Operate the electric starter 4 Battery The engine turns over quickly The e...

Page 148: ...r can be temporarily used instead provided that it is changed to the rec ommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See TIP Start the engine If the engine overheats...

Page 149: ...gs EWB02311 NOTICE Excessive water pressure may cause water seepage and deteriora tion of wheel bearings brakes transmis sion seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applica tions such as those available in coin oper ated car washers ECB00711 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild de...

Page 150: ... the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparking during the next step d Turn the engine over several times with the starter This will coat the cylinder wall with oil e Remove the spark plug cap...

Page 151: ...e 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 storing the battery see page 8 46 TIP Make any necessary repairs before storing the ATV U1PE60E0 book Page 3 Friday March 2 2012 1 22 PM ...

Page 152: ...in A weighted sound power level YFM7RD 97 0 dB A 3125 r min YFM7RSED 97 0 dB A 3125 r min Vibration on seat EN1032 ISO5008 YFM7RD Will not exceed 0 5 m s YFM7RSED Will not exceed 0 5 m s Vibration on handlebar EN1032 ISO5008 YFM7RD Will not exceed 2 5 m s YFM7RSED Will not exceed 2 5 m s Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Single cylinder Displacement 686 cm Bore st...

Page 153: ...Wet element Fuel Recommended fuel YFM700RD Unleaded gasoline only YFM700RSED Unleaded gasoline only YFM7RD Regular unleaded gasoline only YFM7RSED Regular unleaded gasoline only Fuel tank capacity 11 0 L 2 91 US gal 2 42 Imp gal Fuel reserve amount 2 9 L 0 77 US gal 0 64 Imp gal Fuel injection Throttle body ID mark 1S3H 10 Spark plug s Manufacturer model NGK CR8E Spark plug gap 0 7 0 8 mm 0 028 0 ...

Page 154: ...21 0 mm 0 83 in Front tire Type Tubeless Size AT21 x 7 10 Manufacturer model MAXXIS M971Y Bias Speed rating 130 km h 80 8 mph Rear tire Type Tubeless Size AT20 x 10 9 Manufacturer model MAXXIS M976Y Bias Speed rating 130 km h 80 8 mph Loading Maximum loading limit 100 0 kg 220 lb Total weight of rider cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 27 5 kPa ...

Page 155: ...type YFM700RD Coil spring oil damper YFM700RSED Coil spring gas oil damper YFM7RD Coil spring oil damper YFM7RSED Coil spring gas oil damper Wheel travel 230 mm 9 1 in Rear suspension Type Swingarm link suspension Spring shock absorber type Coil spring gas oil damper Wheel travel 256 mm 10 1 in Electrical system Ignition system TCI Charging system AC magneto Battery Model GT9B 4 Voltage capacity 1...

Page 156: ...Whilst there is a correlation between the emission and exposure levels this cannot be used reliably to determine 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 oper...

Page 157: ...BER MODEL LABEL INFORMATION EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame TIP The vehicle identification number is used to identify 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 fro...

Page 158: ...11 2 11 1 Model label 1 U1PE60E0 book Page 2 Friday March 2 2012 1 22 PM ...

Page 159: ...steners 5 7 Cleaning 9 1 Clutch lever 4 6 Clutch lever free play adjusting 8 37 Coolant 5 4 8 17 Coolant temperature warning light 4 2 D Drive chain 5 5 Drive chain lubricating 8 40 Drive chain slack 8 38 E Engine break in 6 5 Engine idling speed 8 27 Engine oil 5 4 Engine oil and oil filter element 8 13 Engine start 6 1 Engine stop switch 4 4 Engine trouble warning light 4 3 F Fuel 4 10 5 4 Fuel ...

Page 160: ...ck absorber assemblies adjusting the front YFM7RSED YFM700RSED 4 15 Shock absorber assembly adjusting the rear YFM7RD YFM700RD 4 19 Shock absorber assembly adjusting the rear YFM7RSED YFM700RSED 4 21 Spark arrester cleaning 8 25 Spark plug checking 8 10 Specifications 10 1 Speed limiter 4 5 Start switch 4 4 Steering shaft lubricating 8 45 Storage 9 2 Suspension lubricating the upper and lower arm ...

Page 161: ...U1PE60E0 book Page 3 Friday March 2 2012 1 22 PM ...

Page 162: ... 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 AND...

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