Yamaha YFM80RX Owner'S Manual Download Page 15 | Manualshive

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fire and you could be burned.

●

When transporting the ATV in another vehi-
cle, be sure it is kept upright and that the fuel
cock is in the “OFF” position. Otherwise, fuel
may leak out of the carburetor or fuel tank.

●

Gasoline is poisonous. If you should swal-
low some gasoline or inhale a lot of gasoline
vapor, or get some gasoline in your eyes,
seek medical help immediately. If gasoline
spills 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.

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Summary of Contents for YFM80RX

Page 1: ...This A MANUAL DEL PROPIETARIO 5TH 28199 66 YFM80RX MANUEL DU PROPRIÉTAIRE OWNER S MANUAL ...

Page 2: ...PRINTED IN JAPAN 2007 05 0 3x1 E F S YAMAHA MOTOR CO LTD ...

Page 3: ...This A 5TH 28199 66 E0 YFM80RX OWNER S MANUAL ...

Page 4: ......

Page 5: ...y 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 70 cc SHOULD NOT BE OPERATED BY A CHILD UNDER 12 YEARS OF AGE AN IMPORTANT NOTE TO P...

Page 6: ...he beginner becomes more familiar with operating the ATV Par ents should decide when to adjust the ATV for more power as their youngster s riding skills improve Once the ATV rider can operate with skill at the top speed permitted by adjusting the speed limiter alone the air intake restrictor plate can be removed Since removal of this plate will result in a significant increase in pow er turn the s...

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

Page 8: ... this ATV on any paved surface paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFM80RX OWNER S MANUAL 2007 by Yamaha Motor Co Ltd 1st edition May 2007 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: ...ake pedal and rear brake lever 4 5 Parking brake 4 6 Shift pedal 4 6 Fuel tank cap 4 7 Fuel 4 7 Fuel cock 4 8 Choke 4 10 Seat 4 10 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...

Page 10: ...restrictor plate 8 17 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 Timing chain 8 20 Valve clearance 8 20 Checking the front and rear brake shoes 8 20 Adjusting the front brake lever free play 8 21 Adjusting the rear brake lever and brake pedal free play 8 23 Adjusting the clutch free play 8 26 Chec...

Page 11: ...Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 ...

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

Page 13: ...tempting to turn at faster speeds and never turn at excessive speeds Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces...

Page 14: ... 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 in this manual Always ma...

Page 15: ...u should swal low some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes seek medical help immediately If gasoline spills 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 an...

Page 16: ...LS EBU27150 Read and understand 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 1 2 3 4 5 ...

Page 17: ...uzioni Voor het gebruik van dit voertuig de handleiding met aandacht lezen Antes de utilizar este veículo leia o manual do proprietário Innan du kör detta fordon läs handboken 5FK 21568 00 5 GB D E F I NL P S Set with tires cold Bei kalten Reifen Ajuste con los neum ticos en fr o Pneus froid Impostare a pneumatici freddi Wanneer de banden koud zijn Regular com pneus frios St ll in med kalla d ck 2...

Page 18: ...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 steering and increase risk of losing control ALWAYS 9 use proper riding techniques to avoid vehicle overturns on hills and rough terrain and it turns 9 a...

Page 19: ... 6 7 8 9 10 11 EBU17680 DESCRIPTION EBU17690 Left view EBU17700 Right view 1 Choke 2 Fuel cock 3 Rear wheel 4 Footrest 5 Shift pedal 6 Front wheel 2 6 5 4 3 1 1 Spark arrester 2 Seat 3 Brake pedal 4 Footrest 2 1 4 3 ...

Page 20: ...ents NOTE The ATV you have purchased may differ slightly from the figures shown in this manual 1 Rear brake lever 2 Parking brake 3 Neutral indicator light 4 Front brake lever 5 Throttle lever 6 Main switch 7 Fuel tank cap 8 Handlebar switches 1 2 3 4 5 6 7 8 ...

Page 21: ...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 22: ...EBU18090 Start switch START Push this switch to crank the engine with the start er CAUTION ECB00050 See the starting instructions on page 6 1 prior to starting the engine 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 d...

Page 23: ...th the speed limiter adjusting screw fully turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn The 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 Parents should decide wh...

Page 24: ...ge 8 17 3 Tighten the locknut WARNING EWB00230 Improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation The child could lose control have an accident or be injured Do not turn the adjusting screw out more than 20 mm 0 8 in or the throttle cable could be dam aged EBU18391 Front brake lever The front brake lever is located on the right ha...

Page 25: ...e brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar To apply the rear brake push down on the brake pedal or pull the brake lever toward the handlebar grip 1 Front brake lever 1 1 Brake pedal 1 Rear brake lever 1 1 ...

Page 26: ...ving un expectedly if the parking brake is not ap plied This could cause loss of control or a collision Always be sure you have released the park ing brake before you begin to ride The brake could 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 EBU18550 Shift pedal This...

Page 27: ...ap Remove the fuel tank cap by turning it counter clockwise EBU18752 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Shift pedal 2 Neutral position 3 2 1 1 N 2 1 Fuel tank cap 1 ...

Page 28: ...om the en gine or the sun Be careful not to 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 1...

Page 29: ...ion fuel will not flow Always turn the fuel cock lever to this position when the engine is not running ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding 1 Arrow mark positioned over OFF RES ON FUEL OFF 1 1 Arrow mark positioned over ON ON FUEL RES OFF ON 1 ...

Page 30: ...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 Move the choke in direction b to turn off the choke See the Starting a cold engine section on page 6 1 for proper operation EBU18870 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear 1 Arrow mark positioned over RES OFF ON FUEL RES ...

Page 31: ...11 To install the seat Insert the projection on the front of the seat into the seat holder and push down on the seat at the rear NOTE Make sure that the seat is securely fitted 1 Seat lock lever 1 1 Projection 2 Seat holder 1 2 ...

Page 32: ...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 7 5 3 Engine oil Check oil level in engine and add recommended oil to speci...

Page 33: ... 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 and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 8 28 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 27 Chassis fasteners Make sure that...

Page 34: ...e specified level Add oil as necessary See page 8 12 EBU19670 Front and rear brakes Brake levers and brake pedal Check for correct free play in the brake levers and brake pedal If the free play is incorrect ad just it See pages 8 21 and 8 23 Check operation of the brake levers and brake pedal They should move smoothly and there should be a firm feeling when the brakes are ap plied If not have the ...

Page 35: ...es listed below have been approved by Yamaha Motor Co Ltd for this model Other tire combinations are not recommend ed Front Manufacturer model DUNLOP KT586 Size AT18 x 7 7 Type Tubeless Rear Manufacturer model DUNLOP KT587 Size AT18 x 8 7 Type Tubeless The tires should be set to the recommended pressure Recommended tire pressure Front 20 kPa 2 9 psi 0 20 kgf cm2 Rear 20 kPa 2 9 psi 0 20 kgf cm2 Ch...

Page 36: ...se a tire to burst Inflate the tires very slowly and carefully EBU19820 Measuring the tire pressure Use the low pressure tire gauge NOTE The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Set the tire pressure when the tires are cold Set the tire...

Page 37: ...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 29 Recommended pressure Front 20 kPa 2 9 psi 0 20 kgf cm2 Rear 20 kPa 2 9 psi 0 20 kgf cm2 Minimum Front 17 kPa 2 5 psi 0 17 kgf cm2 Rear 17 kPa 2 5 psi 0 17 kgf cm2 Maximum Front 23 kPa 3 3 psi 0 23 kgf cm2...

Page 38: ...l the ATV which could lead to an acci dent or collision CAUTION ECB00150 See the Engine break in section on page 6 5 prior to operating the engine for the first time 1 Set the parking brake 2 Turn the fuel cock to ON 3 Turn the main switch to ON and the engine stop switch to RUN 4 Shift the transmission into neutral The neutral indicator light should come on If the indicator light does not come on...

Page 39: ...oke position 6 Completely close the throttle lever and start the engine by pushing the start switch NOTE If the engine fails to start release the start switch then push it again Pause a few seconds before the next attempt Each cranking should be as short as possible to preserve battery energy Do not 1 Fully open ON 2 Half open warming up position 3 Closed OFF 4 Choke ON O F F 0 30 10 20 30 50 70 9...

Page 40: ...e is warm when it responds normally to 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 EBU20550 Shifting This ATV has a 3 speed forward transmission with a centrifugal automatic clutch The ...

Page 41: ... 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 accident WARNING EWB00710 Make sure the engine has sufficiently slowed before shifting to a lower gear Engaging a l...

Page 42: ...rrect 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 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...

Page 43: ...ely 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 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 first gear 2 Stop the engine 3 With the rear brake lever and brake pedal ap plied apply the parking brake...

Page 44: ...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 45: ... The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trail er 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 handl...

Page 46: ...7 1 1 2 3 4 5 6 7 8 9 10 11 EBU21141 RIDING YOUR ATV ...

Page 47: ...c ular attention to the safety information on pages 1 1 1 4 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 48: ...r death of the child This ATV is designed to carry operator only passengers prohibited WARNING EWB01400 Never carry a passenger The long seat is to al low the operator to shift position as needed during operation It is not for carrying passen gers Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV It could cause an accident resulting in harm to you and or...

Page 49: ...helmet increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and in creases your chances of a severe injury in the event of an accident Operating without protec tive clothing increases your chances of severe injury in the event of an accident Do not operate after consuming alcohol or drugs The operator s perfo...

Page 50: ...ner s Manual on page 5 5 Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pres sure may cause loss of control increasing your risk of an accident Do not operate at speeds too fast for your skills or the conditions WARNING EWB01450 Always go at a speed that is proper for the ter rain visibility and operating conditions and your experience Operating this ATV at...

Page 51: ...rmitted by adjust ing the speed limiter alone the air intake restrictor plate can be removed Since removal of this plate will result in a significant increase in power turn the speed limiter back in again adjust it out in stag es as you did before Adjusting for maximum throttle lever movement without removing the air intake restrictor plate will cause the engine to run roughly at higher speeds For...

Page 52: ...ation 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 remove a foot from a footboar...

Page 53: ... 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 around dry grass brush or ...

Page 54: ... 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 55: ...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 56: ...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 57: ...t pedal to the 1st gear position and then release the parking brake Apply the throttle slowly and smoothly The centrif ugal clutch will engage and you will start to accel erate Once the ATV has attained adequate speed release the throttle and lift the shift pedal to the 2nd gear position Release the shift pedal and apply the throttle smoothly Use this same proce dure as you move into the higher ge...

Page 58: ... or lose some traction the ATV will resist turning A special turning technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed WARNING EWB01570 Always follow proper procedures for turning as described in this Owner s Manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at speeds too...

Page 59: ...ide while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the out side of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL Use proper riding techniques to avoid ATV over turns on hills Be sure that you can maneuver your ATV well on flat g...

Page 60: ...ift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around ...

Page 61: ...If you start to roll backwards DO NOT apply the rear brake to stop or try to put the ATV in gear The ATV could easily tip over backwards Instead ap ply the front brake gradually or dismount the ATV immediately on the uphill side WARNING EWB01711 Use the proper gear and maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking br...

Page 62: ...proper braking may also cause a loss of traction Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear WARNING EWB01620 Always follow proper procedures for going down hills as described in this Owner s Manu al Note a special techn...

Page 63: ...When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING EWB01631 Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as desc...

Page 64: ...ever operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the lin ings If the ATV is operated through deep or fast flowing water the tires may float causing loss of traction and loss of control ...

Page 65: ...IN Riding over rough terrain should be done with cau tion Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult WARNING EWB01650 Before operating in a new area check for ob stacles Never attempt to ride over l...

Page 66: ...front wheels will sometimes help If the rear wheels of your ATV start to slide side ways control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide With practice over a period of time skill at con trolled sliding can be developed The terrain should be chosen carefully ...

Page 67: ...See page 7 13 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide See page 7 21 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the A...

Page 68: ... 4 5 6 7 8 9 10 11 ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability See page 7 19 ...

Page 69: ...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 70: ... you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you WARNING EWB01850 Never modify this ATV through improper in stallation or use of accessories as it may cause changes in handling which in some sit uations could lead to an accident All parts and accessories added to this ATV should be gen uine Yamaha or equivalent components de signed for ...

Page 71: ...performed 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 72: ...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 73: ...nt 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 Rear brake Check operation and correct if necessary Check brake lever and pedal free play and adjust if necessary Replace brake shoes Whenever worn to the limit 6 Wheels Check runout and for damage and replace if nec essary 7 Tires Check tread dept...

Page 74: ...l Change Check ATV for oil leakage and correct if neces sary 16 Moving parts and cables Lubricate 17 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and have a Yamaha dealer adjust if necessary Lubricate throttle lever housing and cable 18 Front and rear brake switches Check operation and correct if necessary 19 Battery Check electrolyte le...

Page 75: ...8 7 1 2 3 4 5 6 7 8 9 10 11 EBU23060 NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas ...

Page 76: ...ion of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally NOTE If the spark plug shows a distinctly different col...

Page 77: ...rench and then tighten it to the specified torque NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 4 Install the spark plug cap EBU23253 Engine oil The engine oil level should be checked before each ride In addition the ...

Page 78: ...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 NOTE 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 dipstic...

Page 79: ...d the specified amount of the recommend ed engine oil and then install and tighten the engine oil filler cap CAUTION ECB00300 In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or hi...

Page 80: ...iodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface NOTE The final gear oil level must be checked on a cold engine 2 Remove the final gear oil filler cap wipe the dipstick off with a clean rag insert it back into the oil filler hole without screwing it in and then remove it again to check the oil level NOTE The final gear oil should be betwe...

Page 81: ...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 EBU23802 Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean the air filter element more frequently if you are riding in unusually wet or dusty areas NO...

Page 82: ...0 11 the hose and clean the air filter element and air fil ter case 1 Remove the panel shown by removing the bolts 2 Remove the air filter case cover by unhooking the holders 1 Air filter case check hose 1 1 Panel 2 Bolt 1 2 2 ...

Page 83: ...hly 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 plode 5 Squeeze the excess solvent out of the sponge material and let it dry 1 Air filter case cover 2 Air filter case holder 2 2 1 1 Air filter element holder 2 Sponge material 2 1 ...

Page 84: ... by installing the bolts NOTE 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 CAUTION ECB00460 Make sure that the air filter element is prop erly seated in the air filter case...

Page 85: ...ner s manual so that it is readily available whenever you want to reduce the top speed 3 Install the air filter element EBU27630 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the screws 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits fro...

Page 86: ...buretor is an important part of the engine and requires very sophisticated adjustment Therefore most carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience The adjustment described in the following section however may be performed by the owner as part of routine main tenance CAUTION ECB00480 The carburetor has been set and extensively ...

Page 87: ... turning the throttle stop screw at the carburetor To in crease the engine idling speed turn the throt tle stop screw in direction a and to decrease it turn the screw in direction b NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EBU27071 Checking the throttle cable free play The throttle cable free play should be checked at the int...

Page 88: ... 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 the periodic maintenance and lu brication chart EBU24090 Checking the front and rear brake shoes The front and rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart Each brake is prov...

Page 89: ...y must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart NOTE Before adjusting the brake lever free play check the front brake shoes for wear The brake lever free play should measure 10 0 1 Wear limit line 2 Wear indicator 1 2 1 Wear limit mark 2 Wear indicator 1 2 ...

Page 90: ... Turn the lower adjusting bolt in direction a to increase the free play and in direction b to decrease it 4 Tighten the lower locknut 5 While applying the front brake turn out the up per adjusting bolt until the upper and lower ca ble lengths are equal The cable joint will become vertical 1 Brake lever free play 1 1 Upper locknut 2 Upper adjusting bolt 3 Lower locknut 4 Lower adjusting bolt 1 2 4 ...

Page 91: ... a Yamaha dealer EBU24473 Adjusting the rear brake lever and brake pedal free play The brake lever and brake pedal free play must be checked and if necessary adjusted at the inter vals specified in the periodic maintenance and lu brication chart NOTE Always perform this maintenance completely in the following order whenever adjusting the rear brake Before adjusting the brake lever and brake pedal ...

Page 92: ... loosen the brake cable 6 To increase the brake lever free play turn the adjusting nut on the brake cable at the rear wheel hub in direction a and to decrease it turn the nut in direction b 7 Tighten the locknut at the crankcase and the brake lever NOTE If the specified free play cannot be obtained as de scribed above or if the rear brake does not operate correctly have a Yamaha dealer check the i...

Page 93: ...irection a to increase the free play and in direction b to de crease it WARNING 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 The...

Page 94: ...locknut to the specified torque NOTE When tightening the locknut hold the adjusting bolt with a screwdriver so that the adjusting bolt does not turn together with the locknut 5 Install the rubber cap securely EBU24900 Checking and lubricating the cables The operation and the condition of all control ca bles should be checked before each ride and the cables and cable ends should be lubricated if ne...

Page 95: ...rayed or kinked which could re strict the operation of controls and lead to an accident or injury EBU28700 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if necessary Front brake lever Rear brake lever Recommended lubricant Lithium soap based grease ...

Page 96: ... in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bear ings EBU28820 Lubricating the front knuckle pivots The front knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricate the front knuckle pivots using a grease gun EBU25100 Lubricating the steering shaft The steering shaft must be lubricat...

Page 97: ...ry NOTE 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 CAUTION ECB00590 Use only distilled water as tap water contains minerals that are harmful to the battery WARNING EWB02160 Battery electrolyte is poisonous and danger ous as it contains sulfuric acid which ...

Page 98: ... 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 CAUTION ECB00600 Do not leave or store the b...

Page 99: ...nd not obstructed CAUTION 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 10 If the fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits ...

Page 100: ...the specified rating and never use a substitute object in place of the proper fuse An improper fuse or a substitute object can cause damage to the electrical sys tem which could lead to a fire 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU25650 Removing a wheel 1 Loo...

Page 101: ...on or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself However should your ATV re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacem...

Page 102: ...NG EWB02280 Do not smoke when checking the fuel system Fuel can ignite or explode causing severe inju ry or property damage Make sure there are no open flames or sparks in the area including pi lot lights from water heaters or furnaces ...

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: ... With oil and fuel 116 0 kg 256 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 79 0 cm3 Bore stroke 47 0 45 6 mm Compression ratio 9 60 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 Recommended engine oil grade API service SG type o...

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

Page 109: ...0 kPa 2 9 psi 0 20 kgf cm2 Rear 20 kPa 2 9 psi 0 20 kgf cm2 Minimum Front 17 kPa 2 5 psi 0 17 kgf cm2 Rear 17 kPa 2 5 psi 0 17 kgf cm2 Maximum Front 23 kPa 3 3 psi 0 23 kgf cm2 Rear 23 kPa 3 3 psi 0 23 kgf cm2 Front wheel Wheel type Panel wheel Rim size 7 x 5 5AT Rear wheel Wheel type Panel wheel Rim size 7 x 6 5AT Front brake Type Drum brake Operation Right hand operation Rear brake Type Drum bra...

Page 110: ...m 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 x quantity Neutral indicator light 12 V 1 7 W 1 Fuses Main fuse 5 0 A ...

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

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

Page 113: ...g and lubricating 8 26 Carburetor adjusting 8 18 Chassis fasteners 5 6 Choke 4 10 Cleaning 9 1 Clutch free play adjusting 8 26 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 F Final gear oil 5 3 8 12 Front knuckle pivots lubricating 8 28 Fuel 4 7 5 3 Fuel cock 4 8 Fuel tank cap 4 7 Fuse replacing 8 31 H Hand...

Page 114: ...17 Spark plug checking 8 8 Specifications 10 1 Speed limiter and air intake restrictor plate 4 3 Start switch 4 2 Steering shaft lubricating 8 28 Storage 9 2 T Throttle cable free play checking 8 19 Throttle lever 4 2 5 4 Timing chain 8 20 Tire pressure measuring 5 5 Tires 5 4 Tire wear limit 5 6 Troubleshooting 8 33 Troubleshooting chart 8 35 V Valve clearance 8 20 Vehicle identification number 1...

Page 115: ......

Page 116: ...PRINTED IN JAPAN 2007 05 0 3x1 E YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER ...

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