Yamaha YFM90RA Owner'S Manual Download

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This A

43D-F8199-12

OWNER’S MANUAL

LIT-11626-24-16

This ATV should not be ridden by anyone under 12 years of age.

WARNING

READ THIS MANUAL CAREFULLY!

It contains important safety information.

YFM90RA

Summary of Contents for YFM90RA

Page 1: ...This A 43D F8199 12 OWNER S MANUAL LIT 11626 24 16 This ATV should not be ridden by anyone under 12 years of age WARNING READ THIS MANUAL CAREFULLY It contains important safety information YFM90RA ...

Page 2: ...Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if it is sold ...

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Page 5: ...n 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 together with tips for the ATV rider carefully and completely before operating your ATV Make sure you understand all instructions Pay close attention to the warning and notice labels on the ATV Never operate an ATV without proper tra...

Page 6: ... beginner becomes more familiar with operating the ATV Parents 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 vehicle speed limiter alone the engine speed limiter plate can be removed Since removal of this limiter will result in a significant increase in power turn ...

Page 7: ...ocedures easier or clearer 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 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN JURY OR DEATH Particularly important information is distinguished in this manual by the follo...

Page 8: ...and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV YFM90RA OWNER S MANUAL 2010 by Yamaha Motor Corporation U S A 1st edition July 2010 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Taiwan...

Page 9: ...ont brake lever 4 6 Rear brake lever 4 6 Parking brake lever 4 7 Fuel tank cap 4 8 Fuel 4 8 Fuel cock 4 10 Tire information 5 6 Aftermarket tires and rims 5 7 Choke 4 11 Seat 4 11 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 3 Engine oil 5 3 Final transmission oil 5 3 Front and rear brakes 5 3 Throttle lever 5 4 Drive chain 5 4 Tires 5 4 Tire pressure 5 4 Tire wear limit 5 6 Chassi...

Page 10: ...brake levers 8 30 Checking the wheel hub bearings 8 31 Battery 8 31 RIDING YOUR ATV 7 1 GETTING TO KNOW YOUR ATV 7 2 RIDE WITH CARE AND GOOD JUDGEMENT 7 2 BE CAREFUL WHERE YOU RIDE 7 11 TURNING YOUR ATV 7 15 CLIMBING UPHILL 7 17 RIDING DOWNHILL 7 20 CROSSING A SLOPE 7 21 CROSSING THROUGH SHALLOW WATER 7 22 RIDING OVER ROUGH TERRAIN 7 24 SLIDING AND SKIDDING 7 25 WHAT TO DO IF 7 26 WHAT TO DO 7 26 ...

Page 11: ...WARRANTY 11 5 YAMAHA EXTENDED SERVICE Y E S 11 7 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 Replacing the fuse 8 33 Removing a wheel 8 34 Installing a wheel 8 34 Troubleshooting 8 35 Troubleshooting chart 8 36 ...

Page 12: ...stand 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 1 1 1 ...

Page 13: ...1 2 1 2 1 l l l l ll ll l l l l ll ll I I I I l I l l I l l I l l l I I I ...

Page 14: ...1 1 3 4 3 l l I I l 5 ...

Page 15: ...courses nearest you Always follow the age recommendation A child under 12 years old should never oper ate an ATV with engine size greater than 70 cc A child under 16 years old should never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the ...

Page 16: ... 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 Shift your...

Page 17: ...th terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to re duce the chance of skidding or sliding out of 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 frict...

Page 18: ... carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself Also deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas If you experience 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...

Page 19: ...3 1 3 DESCRIPTION Left view Right view 1 Fuel cock 2 Rear wheel 3 Footrest 4 Front wheel 1 Spark arrester 2 Seat 3 Footrest 1 2 3 1 4 3 2 ...

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

Page 21: ... result in death or serious injury Main switch The positions of the main switch are as follows ON All electrical 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 1 Main switch OFF O I I T I N G N 1 ON OFF 4 ...

Page 22: ...nd stops the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run when this switch is set to Start switch Push this switch to crank the engine with the start er See the starting instructions on page 6 1 prior to starting the engine 1 2 1 Engine stop switch 2 Start switch ...

Page 23: ...ers start off with the vehicle speed limiter adjusting screw fully turned in and the engine speed limiter plate installed to limit the amount of speed available while they learn 1 Throttle lever The vehicle speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum The adjusting screw may be gradually turned out as the beginner becomes more familiar w...

Page 24: ...w in direction b Do not turn the adjusting screw out more than 11mm 0 4 in or the throttle cable could be damaged Always make sure the throttle lever free play is adjusted to 1 0 3 0 mm 0 04 0 12 in See page 8 22 b a 1 2 3 Tighten the locknut 2 Adjusting screw 1 Locknut 3 No more than 11 mm 0 4 in 3 WARNING Improper adjustment of the speed limiter and throttle could cause throttle cable damage or ...

Page 25: ...educe the top engine speed With this plate installed the engine speed is limited to 4800 r min With this plate removed top engine speed 8000 r min is available Remove the plate as follows 1 Remove the seat See page 4 11 3 Pull the plate out of its case 4 Tighten the screw 2 Loosen the screws 5 Install the seat 1 Speed limiter plate 2 Screws 2 1 ...

Page 26: ... handle bar To apply the front brake pull the brake lever toward the handlebar grip 1 Front brake lever Rear brake lever The rear brake lever is located on the left handle bar To apply the rear brake pull the brake lever to ward the handlebar grip 1 Rear brake lever 1 1 ...

Page 27: ...e you begin to ride The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely 1 WARNING 1 Parking brake lever unlocked position 1 Use the parking brake before starting the engine or parking the ATV especially on a slope To apply the parking brake move the parking b...

Page 28: ...fore refueling turn off the engine and be sure that the rider is off the vehicle Never refuel while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reaches the bott...

Page 29: ...4 Be sure the fuel tank cap is closed securely by turning it clockwise NOTICE Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 4 8 L 1 27 US gal 1 06 Imp gal Fuel reserve amount 1 0 L 0 26 US gal 0 22 Imp gal wash wit...

Page 30: ...ing ON RES 1 Lever positioned over RES 1 Lever positioned over 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 This indicates reserve With the fuel cock lever in this position the fuel reserve is made available Turn the fuel cock lever to this position if you run out of fuel while riding When th...

Page 31: ...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 1 Fully open 2 Half open warming up position 3 Closed 4 Choke 1 2 3 a b 4 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear 1 1 Seat lock lever ...

Page 32: ...re that the seat is securely fitted 1 Projection 2 Seat holder 2 1 1 Kickstarter 1 NOTICE A kickstarter lever is located under the seat to use if the battery is discharged 1 Install the kickstarter lever 2 Move the kickstarter lever down lightly with your foot until the gears engage and then push it down smoothly but forcefully Kickstarter Do not use the kickstarter if there is no battery installe...

Page 33: ...cedures and schedules described in the Owner s Manual Before using this vehicle check the following points Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage Do not operate the vehicle if you find any problem If a problem cannot be corrected by the procedures provided in this manual have the vehicle inspected by a Yamaha dealer WARNING ...

Page 34: ...E T IT M Fuel Check fuel line for leakage Correct if necessary 4 8 5 3 Check ATV for oil leakage Correct if necessary 5 3 8 11 Final transmission oil 5 3 8 14 Check ATV for oil leakage Correct if necessary Front brake Check operation and correct if necessary Lubricate cable if necessary Check lever free play and adjust if necessary 5 3 8 22 8 23 Engine oil Check fuel level in fuel tank and add rec...

Page 35: ...age Check to see if any brake fluid is leaking out of the pipe joint or brake fluid reservoir Apply the brake firmly for one minute If there is any leakage have a Yamaha dealer check the brake system Brake levers Check for correct free play in the brake levers If the free play is incorrect adjust it See pages 8 23 and 8 27 Check operation of the levers They should move smoothly and there should be...

Page 36: ...the drive chain and check the drive chain slack Lubricate and adjust the drive chain as necessary See pages 8 28 and 8 29 Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage Tire pressure Use the tire pressure gauge to check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides WARNING Operation of...

Page 37: ...nd reading Dust or dirt in the gauge could cause the first reading to be incorrect 1 1 Low pressure tire gauge Set tire pressures to the following specifications Recommended pressure Front 25 kPa 3 6 psi 0 25 kgf cm2 Rear 25 kPa 3 6 psi 0 25 kgf cm2 Minimum Front 22 kPa 3 2 psi 0 22 kgf cm2 Rear 22 kPa 3 2 psi 0 22 kgf cm2 ...

Page 38: ...tubeless tires with valves Front Manufacturer model MAXXIS M939 Size AT18 x 7 8 Type Tubeless Rear Manufacturer model MAXXIS M940 Size AT18 x 9 8 Type Tubeless Use of improper tires on this ATV may cause loss of control increasing your risk of an accident Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire 1 Tire wear limit ...

Page 39: ...t all instruments and switches are working properly Correct if necessary Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling braking and comfort Other tires rims sizes and combinations may not be appropriate ...

Page 40: ...ing a cold engine WARNING WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury NOTICE See the Engine break in section on page 6 4 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 TIP This model is equipped with an ignition circuit cut off sys...

Page 41: ...e the next attempt Each cranking should be as short as possible to preserve battery energy Do not 1 Fully open 2 Half open warming up position 3 Closed 4 Choke 0 30 10 20 30 50 70 90 F C 1 3 Position 1 Cold engine start with ambient temperature be low 30 C 90 F Position 2 Warming up position Position 3 Cold engine start with ambient temperature above 25 C 80 F 1 3 2 4 crank the engine more than 10...

Page 42: ...ned off 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 To start out and accelerate 1 Squeeze the front brake lever to release the parking brake 2 Gradually open the throttle while slowly re leasing the rear brake lever To decelerate Whe...

Page 43: ...i or 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine freely but do not use full throttle at any time If any engine trouble should immediately have a Yamaha dealer check the ATV Parking When parking the ATV stop the engine apply the parking brake and then turn the fuel cock to OFF 320 km 200 mi or 20 hours and beyond The ATV can now be operated normally 0 160 km 0 100 mi or ...

Page 44: ... could cause the ATV to roll out of control increasing the chance of an accident If you must park on an incline place the ATV transversely across the incline stop the engine apply the parking brake and then block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easily 1 Parking brake lock lever 1 Locked position ...

Page 45: ...ccessories or modifications are not suitable because of potential safety hazards to you or others Installing after market products or having other modifications per formed to your ATV that change any of the vehicle 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 follo...

Page 46: ... Choose terrain carefully Added weight affects the stability and handling of the ATV MAXIMUM LOADING LIMIT ATV loading limit total weight of rider cargo accessories and tongue 70 0 kg 154 lb WARNING Never exceed the stated load capacity for this ATV Overloading this ATV or carrying or towing cargo improperly could cause changes in ATV handling which could lead to an accident Cargo should be proper...

Page 47: ...7 1 7 RIDING YOUR ATV ...

Page 48: ... 1 2 4 Also read all warning and caution labels on your ATV WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an accident is greatly increased if the operator does not know how to...

Page 49: ...he time to learn the basic techniques well before attempting more difficult maneuvers Become familiar with this ATV at slow speeds first even if you are an exper ienced operator Not recommended for children under 12 years of age WARNING A child under 12 should never operate an ATV with engine size greater than 70 cc Use by chil dren of ATVs that are not recommended for their age can lead to severe...

Page 50: ...perator to shift po sition as needed during operation It is not for carrying passengers WARNING Never carry a passenger Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV You could have an accident resulting in severe injury or death to you and or your passenger ...

Page 51: ...pment can reduce the severity of injuries in an accident WARNING Operating without an ap proved motorcycle helmet increases your ch ances of a severe head injury or death in the event of an accident 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 ey...

Page 52: ...hol or drugs before or while dr iving this ATV You increase your chance of an accident Pre operation checks Always inspect your ATV 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 Owner s Manual WARNING Failure to inspect the ATV before...

Page 53: ...ff with the vehicle speed limiter turned in and the engine speed limiter plate installed to limit the amount of speed available while they learn The vehicle speed limiter may be gradually adjusted to increase maximum speed as the beginner becomes more familiar with operating the ATV Parents should decide when to adjust the ATV for more power as their youngster s riding skills improve Once the ATV ...

Page 54: ...n or other accident To reduce the risk of an accident Do not exceed the Maximum Loading Limits for the vehicle see box in this section or ve hicle labeling Make sure the load does not interfere with your control or ability to see where you are going Loading and accessories As originally equipped this ATV is not designed to carry cargo or tow a trailer If you choose to add accessories to carry carg...

Page 55: ... off During operation Always keep your feet on the footboards during operation otherwise they may contact the rear wheels WARNING 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 footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an...

Page 56: ...over Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust system during or after operation could be burned Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it Modifications and Accessories Never modify this ATV through improper installation or use of accessories or other modification All part...

Page 57: ...eriously affect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets To prevent burns avoid touching the exhaust system Park the ATV in a place where pedestrians or children are not likely to touch it ...

Page 58: ...blic roads can result in collisions with other vehicles In many states it is illegal to operate ATVs on public streets roads and highways WARNING Never operate this ATV on any public street road or highway even a dirt or gravel one You could collide with another vehicle ...

Page 59: ...e terrain and other hidden hazards which may cause the ATV to upset WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV ...

Page 60: ...nt a caution flag on the ATV to make you more visible Watch carefully for other vehicles Do not operate on rough slippery or loose terrain until you have learned and practiced the skills nece ssary to control the ATV on such terrain Always be especially cautious on these kinds of terrain WARNING Failure to use extra care when oper ating on excessively rough slippery or loose terrain could cause lo...

Page 61: ...rwards do not allow skin or clothing to come in contact with these compo nents Apply the throttle slowly and smoothly You will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds until you are thoroughly familiar with the operation of your ATV When slowing down or stopping release the th...

Page 62: ...go straight If the ATV doesn t turn come to a stop and then practice the proce dure again If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter 1 Lean towards inside of turn 2 Support your weight on the outer footb...

Page 63: ...rt up any hill Never climb hills with ex cessively slippery or loose surfaces Do not attempt to climb hills until you have mast ered basic maneuvers on flat ground Always ch eck the terrain carefully before attempting any hill In all cases avoid inclines with slippery or loose surfaces or obstacles that might cause you to lose control To climb a hill you need traction momentum and steady throttle ...

Page 64: ...make sure that your weight is transferred forward on the ATV This can be accomplished by leaning forward and on steeper inclines standing on the footboards and leaning forward over the handlebars Whenever 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 Us...

Page 65: ...ont brake When fully stopped apply the rear brake as well and then lock the parking brake The ATV could easily tip over backwards Apply both the front and rear brakes gradually When fully stopped lock the parking brake or dismount the ATV immediately on the uphill side Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described ...

Page 66: ...oing down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where po ssible Improper braking can cause the wheels on the uphill side to come off the ground or cause loss of traction Gradually apply only the rear brake when going downhill When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as pos sible Move ba...

Page 67: ...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 WARNING Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to over turn Always follow proper procedures as described in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Avoid crossing the s...

Page 68: ...nting the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING Operating this vehicle through deep or fast flowing water can lead to los...

Page 69: ...ration Wash the ATV in fresh water if it has been operated in salt water or muddy conditions Test your brakes after leaving the water If necess ary apply them several times to let friction dry out the linings Do not continue to ride your ATV with out verifying that you have regained proper braking ability WARNING Wet brakes may have red uced stopping ability which could cause loss of control ...

Page 70: ...footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may result WARNING Riding improperly over obstacles could cause loss of control or a collision Before operating in a new area check for obstacles Never att empt to ride over large obstacles such as large rocks or fallen trees When you go over ob stacles always follow proper procedures as described in the Owner s...

Page 71: ...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 WARNING Skidding or sliding improperly may cause you to lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn Learn to safely control skidding or sliding by prac...

Page 72: ...mpletely WHAT TO DO If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight over the front wheels for better control See page 7 15 If your ATV begins to tip while turning Lean more into the turn to regain balance If nec essary gradually let off ...

Page 73: ... side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that the ATV is going to tip over dismount on the uphill side See page 7 21 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 ...

Page 74: ...miliar with vehicle service have a YAMAHA dealer perform the service WARNING Turn off the engine when performing mainten ance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide The intervals given in the perio...

Page 75: ... If you do not have the tools or experience required for a particular job have a Yamaha dealer perform 5 T H 2 8 1 9 9 6 6 Y F M 9 0 R O W N E R S M A N U A L 1 6 2 6 2 1 3 8 Th is A TV sh ou ld no t be rid de n by an yo ne un de r ye ar s e g a f o W A R N IN G R EA D TH IS M A N U A L C A R EF U LL Y It co nt ai ns im po rt an t sa fe ty in fo rm at io n 1 2 3 Owner s manual and tool kit Be sure...

Page 76: ... INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust if necessary 4 Carburetor Check choke operation and correct if necessary Che...

Page 77: ...ces 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 78: ...st if neces sary Replace brake shoes Whenever worn to the limit 7 Wheels Check runout and for damage and replace if nec essary 8 Tires Check tread depth and for damage and replace if necessary Check air pressure and balance and correct if necessary 4 Rear brake Check operation and correct if necessary Check fluid level and ATV for fluid leakage and correct if necessary Replace brake pads Whenever ...

Page 79: ...ry Engine oil Change Check ATV for oil leakage and correct if neces sary Change 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 17 Check ATV for oil leakage and correct if neces sary 18 Moving parts and cables Lubricate 9 Wheel hub bearings Check for looseness or damage and replace i...

Page 80: ...nd lubricate Check for wear and replace if necessary 23 Drive chain 24 Drive chain rollers INSPECT OR MAINTAIN Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable Front and rear brake switches Check operation and correct if necessary Check operation and correct if necessary Che...

Page 81: ...wet dusty sandy or muddy areas or at full throttle Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the brake master cylinder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged ...

Page 82: ...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 can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit 1 S...

Page 83: ...perating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary To install the spark plug 1 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification 1 Spark plug wrench Specified spark plug ...

Page 84: ...spark plug cap Engine oil The engine oil level should be checked before each ride In addition the oil must be changed at the intervals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the ATV on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level be sure to warm up the engine suff...

Page 85: ...ghten the engine oil filler cap To change the engine oil 1 Place the ATV on a level surface 2 Start the engine warm it up for several min utes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and then remove the engine oil drain bolt to drain the oil from the crankcase 5 Check the washer for damage and replace it if necessary 6 Ins...

Page 86: ...iesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher the crankcase Make sure that no foreign material enters 9 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary 8 Start the engine check oil lubrication by oil check bolt and then let it idle for several min utes wh...

Page 87: ...h ride If any leakage is found have a Yamaha dealer check and repair the ATV In addition the final transmission oil must be changed at the intervals specified in the periodic maintenance and lubrication chart 1 Place the ATV on a level surface 2 Place an oil pan under the final transmission 3 Remove the final transmission oil filler cap and the drain bolt to drain the oil from the final transmissi...

Page 88: ... check for the cause Recommended final transmission oil See page 10 1 Oil quantity 0 30 L 0 32 US qt 0 27 Imp qt Cleaning the air filter elements The air filter elements should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean the air filter elements more frequently if you are riding in unusually wet or dusty areas TIP There is a check hose at the botto...

Page 89: ...8 8 16 8 1 2 2 2 1 Remove the air filter case covers by remov ing the bolts 1 Air filter case cover left 2 Bolts 1 Air filter case check hose right 1 1 Air filter case cover right 2 Bolts 2 2 2 1 ...

Page 90: ...solvent 4 screws and then pull off the sponge materials from the air filter element holders WARNING Always use parts cleaning solvent to clean the sponge materials Never use low flash point solvents or gasoline to clean the sponge materials be cause the engine could catch fire or explode Squeeze the excess solvent out of the sponge materials and let them dry NOTICE Do not them twist the sponge mat...

Page 91: ...V is operated in extremely dusty ar eas Each time the air filter elements maintenance is performed check the air inlet of the air filter cases for obstructions NOTICE Make sure that the air filter elements are prop erly seated in their air filter case Never operate the engine with the air filter el ements removed This will allow unfiltered air to enter the engine causing rapid engine wear and poss...

Page 92: ...the screw and nut 2 Remove the spark arrester by pulling it out of the muffler 3 Tap the spark arrester lightly and then use a wire brush to remove any carbon deposits 4 Insert the spark arrester into the muffler and align the screw holes 5 Install the screw and nut and then tighten the nut 1 Spark arrester 2 Screw 3 Nut 1 2 3 ...

Page 93: ...t and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor performance of or damage to the engine Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica tion chart WARNING Never run the engine in an enclose...

Page 94: ...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 TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment Checking the throttle cable free play The throttle cable free play should be checked at the intervals specified in the...

Page 95: ...curring the valve clearance must be adjusted by a Yamaha dealer at the inter vals specified in the periodic maintenance and lu brication chart 1 Throttle lever free play Brakes Replacement of brake components requires professional knowledge Brake service should be performed by a Yamaha dealer Checking the front brake shoes The front brake shoes must be checked for wear at the intervals specified i...

Page 96: ...osen the lower locknut 3 Turn the lower adjusting bolt in direction a to increase the free play and in direction b to decrease it 1 Brake lever free play TIP Before adjusting the brake lever free play check the front brake shoes for wear 3 3 No more than 12 mm 0 47 in 1 Upper adjusting bolt 2 Lower adjusting bolt 2 1 to check the brake shoe wear without having to disassemble the brake To check the...

Page 97: ...ut 2 Upper adjusting bolt 3 Lower locknut 4 Lower adjusting bolt 1 2 4 3 a b a b 1 1 Cable joint 6 Tighten the upper locknut Adjusting the parking brake free play The parking brake free play must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart Cable length A should measure 53 57 mm 2 09 2 24 in Adjust the parking brake free play as ...

Page 98: ...o increase the cable length and in direction b to decrease it 1 Locknut 2 Adjusting nut If the cable length cannot be adjusted to specifica tion consult a Yamaha dealer 5 Tighten the locknut on the brake cable 6 Turn in the adjusting bolt at the rear brake cal iper until it feels tight then turn it out 1 8 turn and tighten its locknut to the specified torque TIP When tightening the locknut hold th...

Page 99: ... and lubrication chart Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake If a brake pad has worn to the point that the wear indicator grooves have almost disappeared have a Yamaha dealer replace the brake pads as a set Checking the rear brake pads Insufficient brake fluid may allow air to enter the brake syste...

Page 100: ...amaha dealer check the brake system Have a Yamaha dealer change the rear brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart In addition have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Repl...

Page 101: ...locate the tightest portion of the drive chain and then measure the drive chain slack as shown Drive chain slack 10 0 25 0 mm 0 39 0 98 in 3 If the drive chain slack is incorrect adjust it as follows To adjust the drive chain slack 1 Drive chain slack TIP The drive chain slack is adjusted by the rotation of the rear axle hub 1 Loosen the rear axle pinch bolts 2 Loosen the locknut 3 To tighten the ...

Page 102: ...ive chain with a special chain lubricant TIP The chain should be cleaned and lubricated after every use of the vehicle The drive chain must be lubricated after wash ing the ATV or riding in the rain NOTICE Do not use engine oil or any other lubricants for the drive chain as they may contain sub stances that could damage the drive chain NOTICE 4 Tighten the locknut 5 Tighten the rear wheel axle pin...

Page 103: ... be lubricated if necessary Recommended lubricant Engine oil WARNING 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 re strict the operation of controls and lead to an accident or injury WARNING Always make sure all control cables work smo othly before you begin riding in cold weath...

Page 104: ... electrolyte or to add distilled water However the battery lead connections need to be checked and if necessary tightened NOTICE Never attempt to remove the battery cell seals as this would permanently damage the battery WARNING Battery electrolyte is poisonous and danger ous as it contains sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Always shield your eyes ...

Page 105: ...partment 2 Make sure to properly connect the battery leads to the battery terminals 1 Battery 2 Negative lead 3 Positive lead 1 2 3 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 To store the bat...

Page 106: ...ealer charge your battery Replacing the fuse 1 Turn the key to OFF and turn off all electrical circuits NOTICE To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 2 Remove the blown fuse and then install a new fuse of the specified amperage Specified fuse 10 A The fuse holder is located under the seat See page 4 11 If the fuse is blown replace it as fo...

Page 107: ...he nuts TIP When installing the wheel make sure its arrow mark points toward the rotating direction of the 1 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Wheel nuts Removing a wheel 1 Loosen the wheel nuts 1 1 ...

Page 108: ...art 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 replacement parts Im itation parts may look like YAMAHA parts but they are often inferior have a shorter service life...

Page 109: ...V 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 battery is good...

Page 110: ...age and deterioration of wheel bearings brakes transmission seals and electrical 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 r...

Page 111: ... instructions in the Cleaning section of this chapter 2 Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosen 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 ...

Page 112: ...and if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative ly turn the wheels 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 i...

Page 113: ...4 SAE5W 30 or SAE10W 40 or SAE20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W 40 or SAE 10W 40 SAE 5W 30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W 50 or SAE 20W 50 Dimensions Overall length 1490 mm 58 7 in Overall width 885 mm 34 8 in Overall height 910 mm 35 8 in Seat height 654 mm 25 7 in Wheelbase 1010 mm 39 8 in Ground ...

Page 114: ...nufacturer TK Type x quantity SVR 22 1G x 1 Spark plug s Manufacturer model NGK CR7HSA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Chassis Frame type Steel tube frame Caster angle 4 0 Trail 16 mm 0 63 in Front tire Type Tubeless Size AT18 x 7 8 Manufacturer model MAXXIS M939 Clutch Clutch type Dry centrifugal automatic Transmission Primary reduction system V belt Primary reduction ratio 2 47 0 61 1 S...

Page 115: ... kgf cm2 Rear 25 kPa 3 6 psi 0 25 kgf cm2 Minimum Front 22 kPa 3 2 psi 0 22 kgf cm2 Rear 22 kPa 3 2 psi 0 22 kgf cm2 Front wheel Wheel type Panel wheel Rim size 8 x 5 5AT Rear wheel Wheel type Panel wheel Rim size 8 x 7AT Front brake Type Drum brake Operation Right hand operation Rear brake Type Single disc brake Operation Left hand operation Recommended fluid DOT4 Front suspension Type Double wis...

Page 116: ...r suspension Type Swingarm Spring shock absorber type Coil spring oil damper Wheel travel 83 mm 3 3 in Electrical system Ignition system CDI Charging system AC magneto Battery Model GTX5L BS Voltage capacity 12 V 4 0 AH Fuses Main fuse 10 A ...

Page 117: ...Yamaha dealer or for ref erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION 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 Vehicle identification number The vehicle identification number is stamped into the frame 1 ...

Page 118: ...ering spare parts from a Yamaha deal er 1 Vehicle identification number 1 Model label 2 Vehicle emission control information label 3 Vehicle emission control information label Canada only 1 1 Vehicle emission control information label The vehicle emission control information label is affixed at the location in the illustration This label shows specifications related to exhaust emissions as require...

Page 119: ...w vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal ...

Page 120: ... reminder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 22500 14400 1440 60...

Page 121: ...l purchaser to any subsequent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Co...

Page 122: ...on at the time of sale and upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Q Is the warranty transferable to second owners A Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain effective CU...

Page 123: ...There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone call...

Page 124: ...ave money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 WARNING Indicates a hazardous situation which if not avoided could re...

Page 125: ...11 11 9 ...

Page 126: ...uretor adjusting 8 20 Chassis fasteners 5 7 Cleaning 9 1 E Engine break in 6 4 Engine cold start 6 1 Engine idling speed 8 20 Engine oil 5 3 8 11 Engine starting a warm 6 3 Engine stop switch 4 2 Fuel 4 8 5 3 Fuel cock 4 10 Fuel tank cap 4 8 Fuse replacing 8 33 F K Key identification number 11 1 L Label locations 1 1 H Handlebar switches 4 2 I Identification numbers 11 1 Instruments and switches 5...

Page 127: ...2 T Throttle cable free play checking 8 21 Throttle lever 4 3 5 4 Tire pressure measuring 5 4 Tires 5 4 Tire wear limit 5 6 Troubleshooting 8 35 Troubleshooting chart 8 36 V Valve clearance 8 22 Vehicle identification number 11 1 W Wheel hub bearings checking 8 31 Wheel installing 8 34 Wheel removing 8 34 Seat 4 11 Vehicle speed limiter 4 4 Speed limiters 4 3 Tire and rims aftermarket 5 7 Tire inf...

Page 128: ...urfaces pavement may seriously affect handling and control Improper ATV use can result in SEVERE INJURY or DEATH 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 ALWAYS USE AN APPROVED HELMET ...

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