Yamaha YFM90RY Owner'S Manual Download | Manualshive

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LOCATION OF THE WARNING AND SPECIFICATION LABELS

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.

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Summary of Contents for YFM90RY

Page 1: ... PROPRIÉTAIRE OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL II comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad ...

Page 2: ...PRINTED IN TAIWAN 2008 07 E F S YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ IMPRESO EN PAPEL RECICLADO DIC183 ...

Page 3: ...YFM90RY 43D F8199 60 E0 OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 4: ...336 EEC or 2004 108 EC Title and or number and date of issue of the other Directives of EEC If applicable To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted EN292 ANSI SVIA 1 2007 Title and or number and date of issue of standards and or specifications Manufacturer E TO...

Page 5: ...pecial tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND NOTICE LABE...

Page 6: ...djusting screw may be gradually turned out 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 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 wil...

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: ...ten permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Taiwan Welcome to the Yamaha world of motor sports This ATV is designed and manufactured for use on UNPAVED surfaces only It is unsafe to operate this ATV on any paved surface paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV ...

Page 9: ...l tank cap 4 8 Fuel 4 8 Fuel cock 4 10 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 Tires 5 4 Measuring the tire pressure 5 5 Tire wear limit 5 6 Chassis fasteners 5 7 Instruments and switches 5 7 OPERATION 6 1 Starting a cold engine 6 1 Starting a warm engine 6 3 Engine br...

Page 10: ...se 8 30 Removing a wheel 8 32 Installing a wheel 8 33 Troubleshooting 8 34 Troubleshooting chart 8 35 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 W...

Page 11: ...SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 ...

Page 12: ...hould 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 ing lots and streets Neve...

Page 13: ... 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 14: ...e 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 maintain ...

Page 15: ...ld 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 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 los...

Page 16: ...derstand 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 2 2 3 4 5 1 6 ...

Page 17: ...2 2 2 For Europe 5 1 3 2 4 I I I I I I I I I I I I I I I I I I I I I I I I I I I 6 l l l l ll ll I ...

Page 18: ...For Oceania 2 3 2 For Oceania 1 3 2 4 I I I I I ...

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 4 3 2 1 2 3 ...

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

Page 21: ...e 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 ...

Page 22: ...ps 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 OFF Start switch START 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 ENG STOP 2 Start switch START ...

Page 23: ...ur ATV was delivered with two speed limiter devices A vehicle speed limiter adjusting screw and a removable engine speed limiter plate Yamaha recommends that all beginning riders 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 1 WARNING Malfunction of the t...

Page 24: ...e 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 the vehicle speed limiter adjusting screw completely back in again adjust it out in stages as done previously Vehicle speed limiter 1 Loosen the locknut 2 To increase the maximum engine power available and the maximum speed of the ATV turn the adjust...

Page 25: ...r plate TIP Store the speed limiter plate with the owner s manual so that it is readily available whenever you want to reduce 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 Loose...

Page 26: ...e 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 4 6 1 Rear brake lever 4 1 1 ...

Page 27: ... button 4 1 WARNING Always set the parking brake before starting the engine The ATV could start moving 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 whic...

Page 28: ...hat there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Fuel tank cap 1 Fuel level 2 Filler tube 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 4 1 1 2 ...

Page 29: ...ill the fuel tank Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from 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 ...

Page 30: ... RES 5 1 Lever positioned over RES 1 Lever positioned over ON 4 10 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 t...

Page 31: ...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 ON 2 Half open warming up position 3 Closed OFF 4 Choke 1 2 3 a b 4 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: ... 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 installed or if the battery leads are disconnected ...

Page 33: ... Refer to the Periodic maintenance and lubrication charts on page 8 3 to determine which service should be performed by a Yamaha dealer 5 WARNING Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual Failure to inspect increases the possibility of an accident ...

Page 34: ...4 8 21 5 PAGE ROUTINE M E T IT 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...

Page 35: ... for correct free play in the brake levers If the free play is incorrect adjust it See pages 8 23 and 8 26 Check operation of the levers They should move smoothly and there should be a firm feel ATV checked by a Yamaha dealer 6 Brake fluid level Check the brake fluid level Add fluid if necessary See page 8 25 1 5 WARNING Do not overfill the fuel tank Fuel expands when it heats up If the fuel tank ...

Page 36: ...ide the ATV if you find any prob lem with the brakes or you could lose braking ability which could lead to an accident If a problem cannot be corrected by the adjust ment procedures provided in this manual have a Yamaha dealer check for the cause WARNING 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 ...

Page 37: ...cm2 Rear 25 kPa 3 6 psi 0 25 kgf cm2 Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 2 2 Tire pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 22 kPa 3 2 psi 0 22 kgf cm Rear 22 kPa 3 2 psi 0 22 kgf cm Use no more than the following pressures when seating...

Page 38: ...g specifications Tire wear limit Replace the tire when the tire groove decreases to 3 mm 0 12 in 1 Low pressure tire gauge 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 22 kPa 3 2 psi 0 22 kgf cm2 Rear 5 1 ...

Page 39: ...assis fasteners Make sure that all nuts bolts and screws are prop erly tightened Instruments and switches Check that all instruments and switches are working properly Correct if necessary 1 Tire wear limit 5 ...

Page 40: ...ad the Owner s Manual carefully to become familiar with all controls in order to help pre vent any loss of control which could cause an accident or injury If there is a control or func tion you do not understand ask your Yamaha dealer Starting a cold engine WARNING Always make sure all control cables work smoothly before you begin riding in cold weather If the control cables are frozen or do not w...

Page 41: ...reserve battery energy Do not 1 Fully open ON 2 Half open warming up position 3 Closed OFF 4 Choke 0 30 10 20 30 50 70 90 F C 1 3 TIP This model is equipped with an ignition circuit cut off system The engine can be started only when the rear brake lever is applied 4 Use the choke in reference to the figure Position 1 Cold engine start with ambient temperature be low 30 C 90 F Position 2 Warming up...

Page 42: ...ke turned 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 decelera...

Page 43: ...ve 3 4 throttle Rev the engine freely but do not use full throttle at any time NOTICE If any engine trouble should occur during the engine break in period immediately have a Parking When parking the ATV stop the engine shift the drive select lever into the drive position apply the parking brake and then turn the fuel cock to OFF Yamaha dealer check the ATV 320 km 200 mi or 20 hours and beyond The ...

Page 44: ...n hills or other inclines Park ing on a hill or other incline 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...

Page 45: ... 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 seat or one that li...

Page 46: ...ou are going Ride more slowly than you would without a load The more weight you carry the slower you should go Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV 6 MAXIMUM LOADING LIMIT ATV loading limit total weight of ri...

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

Page 48: ... is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 1 1 1 4 Please also read all notice and warning labels on your ATV RIDE WITH CARE AND GOOD JU...

Page 49: ...ng and inexperienced operators should regularly practice the skills and the op erating techniques described in this Owner s Manual The risk of an accident is greatly in creased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain WARNING A child under 12 should never operate an ATV with engine size greater than 70 cc Use by chil dr...

Page 50: ...assenger 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 your passenger ...

Page 51: ...ad 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 Apparel Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles...

Page 52: ...e ATV and to ensure safety 7 WARNING Never consume alcohol or drugs before or while driving this ATV WARNING Always inspect your ATV each time you use it to make sure the ATV is in safe operating con dition Always follow the inspection and main tenance procedures and schedules described in the Owner s Manual Failure to inspect the ATV before operating or failure to properly maintain the ATV increa...

Page 53: ... 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 WARNING Always go at a speed that is proper for the ter rain visibility and operating conditions and your experience Operating this ATV at speeds too fast for your skills or the conditions in creases your chances of losing control of the ATV which can result in...

Page 54: ...ATV s handling may be adversely affected Re duce your speed when adding additional loads 2 Adjusting screw MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and tongue 70 0 kg 154 lb 7 1 Locknut 1 2 WARNING Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trail...

Page 55: ...ls WARNING 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 footboard your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident ...

Page 56: ...ps Don t try to show off WARNING Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be gen uine Yamaha or equivalent components de signed for use on this ATV and should be installed and used according to instructions Improper installation of accessories or modifi cation of this ATV may cause changes in han dling which in so...

Page 57: ...ration in a place where others might be likely to touch it Do not operate idle or park the ATV in dry grass dry ground cover or combustible ma terials 10 11 WARNING Always avoid paved surfaces including side walks driveways parking lots and streets ATVs are designed for use on unpaved surfac es only Paved surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out...

Page 58: ...or other vehicles Make sure you know your country s laws and regulations before you ride on unpaved public streets or roads Do not ride on any paved public street road or motorway WARNING Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle In many areas it is illegal to operate ATVs on public streets roads and highways ...

Page 59: ...ay You can collide with another vehicle In many areas it is illegal to operate ATVs on public streets roads and highways WARNING 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 rough slippery or loose terrain could cause loss of traction...

Page 60: ...sert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch 7 WARNING 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 ...

Page 61: ...h 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 throt tle and apply the brakes smoothly and evenly Im proper ...

Page 62: ...with no obsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the proce dure 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 ...

Page 63: ...ith slip pery or loose surfaces or obstacles that might cause you to lose control It is important when climbing a hill to 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 7 WARNING Never operate the ATV on hills too steep for the ATV or for your abiliti...

Page 64: ...bing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill OK 7 ...

Page 65: ...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 OK 7 WARNING Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible...

Page 66: ...urfaces Improper braking may also cause a loss of traction Whenever possible ride your ATV straight down 7 WARNING Maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking brake after you are stopped If you begin rolling backwards Keep weight uphill Never apply the rear brake while rolling backwards Apply the front brake When f...

Page 67: ...h terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on OK 7 WARNING Always follow proper procedures for going down hills as described in this Owner s Manu al Note a special technique is required when braking as you ...

Page 68: ...w water of up to a maximum of 20 cm 8 in in depth Before entering the water choose your path OK 7 WARNING Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper ...

Page 69: ...ned proper braking ability 7 WARNING Never 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...

Page 70: ...d in salt water or muddy conditions RIDING OVER ROUGH TERRAIN 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 1 Air filter case check hose 7 1 ...

Page 71: ...els 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 7 WARNING Before operating in a new area check for ob stacles Never attempt to ride over large obsta cles such as large rocks or f...

Page 72: ...read each section on riding tech niques completely 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 7 WARNING Learn to safely contro...

Page 73: ...AR BRAKE the ATV may tip over on top of you Instead apply the front brake or dis mount the ATV on the uphill side See page 7 17 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that...

Page 74: ...E WEATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED Owner s manual and tool kit Be sure to put this owner s manual in the plastic bag and to always carry it as well as the owner s tool kit and the low pressure tire gauge in their re spective compartments under the seat 8 WARNING Never service an engine while it is running Moving parts can ...

Page 75: ...m 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 8 1 2 3 WARNING Never modify this ATV through improper in stallation or use of accessories as it may cause changes in handling which in some s...

Page 76: ...NITIAL 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 Check...

Page 77: ...s 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 8 ...

Page 78: ...and correct if necessary Check brake lever free play and adjust 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 8 5 Rear brake Check operation and correct if necessary Check fluid level and ATV for flui...

Page 79: ... 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 8 9 Wheel hub bearings Check for looseness or damage and replace i...

Page 80: ...place if neces sary 20 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 21 Front and rear brake switches Check operation and correct if necessary 22 Lights and switches Check operation and correct if necessary Adjust headlight beams 23 V belt Check operation Check for wear c...

Page 81: ...et or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of 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: ...ode 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 Spark plug cap 1 ...

Page 83: ...ating 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 NGK...

Page 84: ...ark 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 suffic...

Page 85: ...en the engine oil filler cap 1 Maximum level mark 2 Minimum level mark 1 2 8 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...

Page 86: ...tives 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 CONSERVING II or higher the crankcase 8 Start the engine and then let it idle for several Make sure that no foreign material enters minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 9 Turn the...

Page 87: ... 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 transmissio...

Page 88: ...ing 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 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 TIP There are check hoses at the botto...

Page 89: ...8 16 8 1 2 2 2 1 Remove the air filter case cover 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: ...ng the 3 Wash the sponge material gently but thor oughly in solvent 4 Squeeze the excess solvent out of the sponge material and let it dry screw and then pull off the sponge material from the air filter element holder WARNING 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 fir...

Page 91: ...urs It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions NOTICE Make sure that the air filter element is prop erly seated in the air filter case Never operate the engine with the air filter el ement removed This will allow unfiltered air t...

Page 92: ...e 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 8 1 2 3 ...

Page 93: ... owner as part of routine main tenance NOTICE The carburetor has been set 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 maint...

Page 94: ...g 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 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 ...

Page 95: ...ng in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the inter vals specified in the periodic maintenance and lu brication chart 1 Throttle lever free play 1 Brakes Replacement of brake components requires professional knowledge Brake service should be performed by a Yamaha dealer WARNING Operating with improp...

Page 96: ...2 Loosen the lower locknut 3 Turn the lower adjusting bolt in direction a to increase the free play and in direction b to decrease it 1 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...

Page 97: ...lengths are equal The cable joint will become vertical 1 Upper locknut 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 8 24 8 WARNING Operating with improperly serviced or adjust ed brakes could cause loss of braking ability which could lead to an accident ...

Page 98: ...may allow air to enter the brake system possibly causing it to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Checking the brake fluid level ...

Page 99: ...ealer check the brake system 1 LOWER 1 8 26 8 Recommended brake fluid DOT4 1 Brake lever free play 1 Minimum level mark 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 whe...

Page 100: ...ngine oil 8 WARNING 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 Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional kno...

Page 101: ...er the battery lead connections need to be checked and if necessary tightened Recommended lubricant Front brake lever Lithium soap based grease NOTICE Never attempt to remove the battery cell seals as this would permanently damage the battery 1 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 ...

Page 102: ...the battery will be stored for more than two months check it at least once a month and fully charge it if necessary To install the battery TIP Be sure the battery is fully charged 1 Place the battery in its compartment 2 Make sure to properly connect the battery leads to the battery terminals 8 1 Battery 2 Negative lead 3 Positive lead 1 2 3 EYES Flush with water for 15 minutes and get prompt medi...

Page 103: ...eep the battery charged Storing a discharged battery can cause permanent battery damage To charge a VRLA Valve Regulated Lead Acid battery a special constant voltage battery charger is required Using a conventional battery charger will damage the battery If you do not have access to a constant voltage battery charger have a Yamaha dealer charge your battery 1 2 Replacing the fuse WARNING Always us...

Page 104: ...8 31 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 8 ...

Page 105: ...8 32 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 8 1 1 ...

Page 106: ...es Tightening torques Front wheel nut 45 Nm 4 5 m kgf 33 ft lbf Rear wheel nut 45 Nm 4 5 m kgf 33 ft lbf wheel Front 1 Arrow mark Installing a wheel 1 Install the wheel and the nuts TIP When installing the wheel make sure its arrow mark points toward the rotating direction of the 8 1 ...

Page 107: ...ould your ATV re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills 8 WARNING Do not smoke when checking the fuel system F...

Page 108: ...emove 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 Ch...

Page 109: ...e 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 rea...

Page 110: ...buretor 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 piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engi...

Page 111: ...d 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 it ...

Page 112: ...10 2 1 Engine oil Type 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 SAE 10W 40 SAE 5W 30 20 10 0 10 20 30 40 50 C 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 clearance 100 mm 3 9 in Minimum t...

Page 113: ...l Carburetor Manufacturer 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 rati...

Page 114: ...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 wishbone Spring s...

Page 115: ... Ah Fuses Main fuse 10 A Noise and vibration level Noise level 77 311 EEC 77 4 dB A EUR Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s2 EUR Vibration on handlebar EN1032 ISO5008 Will not exceed 2 5 m s2 EUR Rear suspension Type Swingarm Spring shock absorber type Coil spring oil damper Wheel travel 83 mm 3 3 in ...

Page 116: ...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 117: ...r ATV 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 Model label 1 1 ...

Page 118: ...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 30 F K Key identification number 11 1 L Label locations 2 1 H Handlebar switches 4 2 I Identification numbers 11 1 Instruments and switches 5...

Page 119: ...g 8 9 Specifications 10 1 Start switch 4 2 Storage 9 2 T Throttle cable free play checking 8 21 Throttle lever 4 3 5 4 Timing chain 8 22 Tire pressure measuring 5 5 Tires 5 4 Tire wear limit 5 6 Troubleshooting 8 34 Troubleshooting chart 8 35 V Valve clearance 8 22 Vehicle identification number 11 1 W Wheel hub bearings checking 8 28 Wheel installing 8 33 Wheel removing 8 32 Seat 4 11 Vehicle spee...

Page 120: ...YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN TAIWAN 2008 07 E ...

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