Yamaha YFZ 50 Owner'S Manual Download Page 109 | Manualshive

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9-32

9

TIP

For parts equipped with a grease nipple, use a
grease gun.

EBU25096

Lubricating the steering shaft

The steering shaft must be lubricated by a
Yamaha dealer at the intervals specified in the pe-
riodic maintenance chart.

TIP

For parts equipped with a grease nipple, use a
grease gun.

EBU36401

Battery

This model is equipped with a 12-volt VRLA
(valve-regulated lead-acid) battery. There is no
need to check the electrolyte or to add distilled
water. However, the battery lead connections
need to be checked and tightened, and the bat-
tery terminals cleaned if corroded. If the battery
seems to have discharged, recharge it as soon as
possible.

1. Grease nipple

Recommended lubricant:

Lithium-soap-based grease

1

UBW415E0.book Page 32 Monday, June 7, 2021 1:01 PM

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Summary of Contents for YFZ 50

Page 1: ...DIC183 BW4 F8199 15 LIT 11626 35 35 This ATV should not be ridden by anyone under 6 years of age WARNING YFZ05YYXN OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 2: ...er reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if...

Page 3: ...formation about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE Read this manual together with TIPS FOR THE ATV RIDER carefully and completely before operating your ATV Make sure you understand...

Page 4: ...ount of speed available while they learn The adjusting 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 ca...

Page 5: ... the figures shown in this manual This is the safety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehi...

Page 6: ...aws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU34380 YFZ05YYXN OWNER S MANUAL 2022 by Yamaha Motor Corporation U S A 1st edition May 2021 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 P N LIT 1...

Page 7: ...NS 5 1 Main switch 5 1 Handlebar switches 5 2 Engine stop switch with lanyard 5 2 Throttle lever 5 3 Speed limiter 5 4 Front brake lever 5 6 Rear brake lever 5 6 Parking brake 5 6 Kickstarter 5 7 Fuel tank cap 5 9 Fuel 5 10 Fuel cock 5 11 Starter choke 5 12 Seat 5 13 Rear shock absorber 5 14 PRE OPERATION CHECKS 6 1 Fuel 6 3 Engine oil 6 3 Transmission oil 6 3 Front and rear brakes 6 3 Throttle le...

Page 8: ...9 5 Removing and installing the panel 9 9 Checking the spark plug 9 9 Engine oil 9 11 Why Yamalube 9 14 Transmission oil 9 15 Cleaning the air filter element 9 16 Cleaning the spark arrester 9 19 Adjusting the carburetor 9 20 Adjusting the engine idling speed 9 20 Adjusting the throttle lever free play 9 22 Valve clearance 9 22 Brakes 9 22 Checking the front and rear brake shoes 9 23 Adjusting the...

Page 9: ...8 CLEANING AND STORAGE 10 1 Cleaning 10 1 Storage 10 2 SPECIFICATIONS 11 1 CONSUMER INFORMATION 12 1 Vehicle Emission Control Information label 12 1 Noise regulation 12 2 Maintenance record 12 3 YAMAHA MOTOR CORPORATION U S A 2020 AND LATER MODEL ATV LIMITED WARRANTY 12 4 YAMAHA EXTENDED SERVICE Y E S 12 6 INDEX 13 1 UBW415E0 book Page 3 Monday June 7 2021 1 01 PM ...

Page 10: ...w VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION KEY IDENTIFICATION NUMBER EBU26032 Vehicle identification number The vehicle identification number is stamped into the frame This 17 digit number is used to identify your individual ATV EBU26053 Model label The model label is affixed at the location shown 1 Vehicle identification number 1 UBW415E0 book Page 1 Monday June 7 2021 1 01 PM ...

Page 11: ... 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 1 Model label 1 Model type code 2 Production code 3 Color code 1 1 3 2 1 Key identification number 1 UBW415E0 book Page 2 Monday June 7 2021 1 01 PM ...

Page 12: ...2 1 2 EBU17661 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 4 5 2 3 UBW415E0 book Page 1 Monday June 7 2021 1 01 PM ...

Page 13: ...TV 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 re placement label from your Yamaha dealer UBW415E0 book Page 2 Monday June 7 2021 1 01 PM ...

Page 14: ...NG UNDER 6 Operation of this ATV by children under the age of 6 increases the risk of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 6 to operate this ATV BW4 F816L 00 1 2 UBW415E0 book Page 3 Monday June 7 2021 1 01 PM ...

Page 15: ...2 4 2 2017 BD3 F817J 60 BD3 F151H 00 l l I I l 2 2 15 2 2 15 1 7 12 1 7 12 90 41 BW4 F816M 20 3 4 5 UBW415E0 book Page 4 Monday June 7 2021 1 01 PM ...

Page 16: ...on A child under 6 years old should never operate an ATV with engine size greater than 50 cc 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 c...

Page 17: ...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 surfaces Shift your weight...

Page 18: ... the chance of skidding or sliding out of control 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 pr...

Page 19: ... and ride gently back to camp or other known location where you can receive medical at tention If necessary contact your riding party or local authorities to let them know where you are and what has happened In the event of a breakdown 1 If your vehicle will not restart or is not in safe operating condition turn off the main switch and engine stop switch If the breakdown oc curs at twilight or nig...

Page 20: ...h You are responsible for injuries re lated to changes in the vehicle Keep the following guidelines in mind as well as those found in the Loading section page 7 6 when mounting acces sories Never install accessories that would impair the performance of your ATV Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance limit suspension travel s...

Page 21: ...pment as well as an appropriately sized ATV and an appropriate rid ing area Be sure your child is ready to learn how to ride As a parent your first step is to decide when your child has the strength skills and judgment to learn how to operate an ATV safely To help you make that decision the ATV Safety Institute pub lishes a readiness checklist It is printed in the Par ents Youngsters and ATVs book...

Page 22: ... guidelines This ATV is fitted with an engine stop switch cord lanyard device that will let you stop the engine remotely as you walk behind the vehicle ENGINE STOP SWITCH CORD This model has an engine stop switch cord lan yard designed for use by an adult supervising the child operating the ATV When using the engine stop switch cord be sure the speed limiter on the handlebar is adjusted and the en...

Page 23: ...on 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 en closed or poorly ventilated areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust wi...

Page 24: ...3 9 3 UBW415E0 book Page 9 Monday June 7 2021 1 01 PM ...

Page 25: ...lter 5 Engine stop switch with cord lanyard 6 Rear shock absorber 7 Kickstarter lever cap 8 Throttle stop screw 2 3 5 6 1 4 7 8 1 Spark arrester 2 Reflector 3 Tool kit 4 Fuse 5 Battery 6 Spark plug 7 Engine oil filler cap 8 Transmission oil filler cap 1 2 3 4 5 6 7 8 UBW415E0 book Page 1 Monday June 7 2021 1 01 PM ...

Page 26: ...ols and instruments 1 Rear brake lever 2 Handlebar switches 3 Parking brake lock plate 4 Front brake lever 5 Throttle lever 6 Main switch 7 Starter choke lever 1 2 3 7 6 5 4 UBW415E0 book Page 2 Monday June 7 2021 1 01 PM ...

Page 27: ... result in death or serious injury EBU33850 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 ON OFF UBW415E0 book Page 1 Monday June 7 2021 1 01 PM ...

Page 28: ...hen this switch is set to EBU18102 Start switch Push this switch to crank the engine with the start er See the starting instructions on page 7 1 prior to starting the engine EBU36341 Engine stop switch with lanyard The cap must be attached to the engine stop switch for the engine to run The lanyard should be held by putting your fingers in the loop as shown 1 Engine stop switch 2 Start switch 2 1 ...

Page 29: ... cap re moved When your child has developed sufficient skill to no longer need you to follow with the lanyard securely tie up the lanyard However you must still closely supervise your child at all times dur ing ATV operation EBU18286 Throttle lever Push the throttle lever to increase engine speed Spring tension returns the lever to the rest position when released Always check that the throttle le ...

Page 30: ...ing the vehicle speed limiter alone the engine speed limiter plate can be removed Since removal of this plate will result in a significant increase in power turn the vehicle speed limiter adjusting screw completely back in again and adjust it out in stages as done previous ly Vehicle speed limiter 1 Loosen the locknut 2 To increase the maximum engine power available and the maximum speed of the AT...

Page 31: ...ollows 1 Remove panel A See page 9 9 2 Loosen the screws and then remove the plate as shown 3 Tighten the screws 4 Install the panel TIP Store the engine speed limiter plate with the own er s manual so that it is readily available whenever you want to reduce top engine speed 1 Locknut 2 Adjusting screw 3 No more than 14 5 mm 0 57 in 1 2 b a 3 1 Screw 2 Engine speed limiter plate 2 1 UBW415E0 book ...

Page 32: ... handle bar To apply the rear brake pull the brake lever toward the handlebar grip EBU18462 Parking brake Use the parking brake before starting the engine or after parking the ATV especially on a slope Ap ply the rear brake lever and push down the lock plate to apply the parking brake Squeeze the rear brake lever to release the parking brake 1 Front brake lever 1 1 Rear brake lever 1 UBW415E0 book...

Page 33: ...e brake could overheat if you ride the ATV without re leasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely EBU33893 Kickstarter Use the kickstarter to start the engine when the battery voltage is low 1 Remove the seat page 5 13 and then re move the kickstarter lever 2 Remove the kickstarter lever cap 1 Parking bra...

Page 34: ...fully 5 When the engine has started remove the kickstarter lever and store it under the seat 6 Install the kickstarter lever cap and the seat NOTICE ECB02300 Do not use the kickstarter if the battery is not installed or if the battery leads are not connect ed 1 Kickstarter lever cap 1 1 Fold out 2 Push down 1 2 UBW415E0 book Page 8 Monday June 7 2021 1 01 PM ...

Page 35: ...uel while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heat ers 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 bottom of the filler tube Because fuel expands when it heats up heat from the engine or the s...

Page 36: ...mmediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes About the recommended fuel This model s engine has been designed to use regular unleaded gasoline The pump octane number R M 2 should be 86 or higher or RON 91 octane or higher If knocking or pinging occurs try a gasoline of a different brand or higher octane TIP Gasoline con...

Page 37: ...el cock The fuel cock supplies fuel from the tank to the carburetor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations OFF With the fuel cock lever in this position fuel will not flow Always turn the fuel cock lever to this posi tion when the engine is not running 1 Arrow mark positioned over OFF 1 UBW415E0 book Page 11 Monday June 7 2021...

Page 38: ... is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18852 Starter choke Starting a cold engine requires a richer air fuel mixture This mixture is controlled by the starter choke system 1 Arrow mark positioned over ON 1 1 Arrow mark positioned over RES 1 UBW...

Page 39: ...rter choke lever in direction b TIP See page 7 1 for engine starting instructions EBU36431 Seat To remove the seat Push down on the rear of the seat and pull the seat lock lever upward to release the seat lock Then pull up at the rear of the seat to remove it 1 Starter choke lever 1 a b 1 Seat 2 Seat lock lever 1 2 UBW415E0 book Page 13 Monday June 7 2021 1 01 PM ...

Page 40: ...e riding conditions NOTICE ECB01091 Never turn the adjusting mechanism beyond the minimum and maximum settings Adjust the spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension 1 Projection 2 Seat holder 2 1 1 Spring preload ...

Page 41: ...to make this adjustment WARNING EWB00012 Indicates a hazardous situation which if not avoided could result in death or serious injury 1 Special wrench Spring preload setting Minimum soft 1 Standard 1 Maximum hard 5 1 UBW415E0 book Page 15 Monday June 7 2021 1 01 PM ...

Page 42: ...ore using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 5 10 6 3 Engine oil Check oil level in engine and add recommended oil to specified level if necessary Check ATV for oil leakage Correct if necessary 6 3 9 11 Transmission oil Check ATV for oil leakage Correct ...

Page 43: ...ricate if necessary 6 3 9 26 9 29 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 6 3 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 9 30 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 6 6 Instruments and sw...

Page 44: ...feel ing when the brake is applied If not have the ATV checked by a Yamaha dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance check the brake shoes for wear See page 9 23 EBU19762 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the id...

Page 45: ...ipment with your vehicle See page 9 2 When using the tire pressure gauge make two measurements and use the second reading as grit in the gauge or tire valve could have caused the first reading to be incorrect Tire wear If the tire is damaged or the tire tread depth de creases to 3 mm 0 12 in or less replace the tire Recommended tire pressure Front 15 0 kPa 0 150 kgf cm 2 2 psi Rear 15 0 kPa 0 150 ...

Page 46: ...ed 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 WARNING EWB02552 Use of improper tires on this ATV may cause loss of control increasing your risk of an acci dent 1 Tire tread depth Front Manufacturer model DURO DI2040 Size AT16x6 5 7 Rear Manufacturer model DURO DI2041 Size A...

Page 47: ...rs Make sure that all nuts bolts and screws are properly tightened EBU33810 Instruments and switches Check that all instruments and switches are work ing properly Correct if necessary UBW415E0 book Page 6 Monday June 7 2021 1 01 PM ...

Page 48: ...U36361 Starting a cold engine NOTICE ECB00151 See the Engine break in section on page 7 3 prior to operating the engine for the first time 1 Set the parking brake The engine can be started only when the rear brake lever is ap plied 2 Turn the fuel cock to ON 3 Turn the key to ON and set the engine stop switch to 4 Position the starter choke lever according to the ambient temperature Position 1 Col...

Page 49: ... the starter choke lever in position 1 move the lever to position 2 to warm up the engine If the engine is started with the starter choke lever in posi tion 2 keep the lever in this position to warm up the engine 7 Continue warming up the engine until it idles smoothly then return the starter choke lever to position 3 before riding TIP The engine is warm when it responds quickly to the throttle wi...

Page 50: ...elves to the cor rect operating clearances Avoid prolonged full throttle operation or any condition that might re sult in engine overheating 0 120 km 0 75 mi or 0 8 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not oper ate it at one set throttle position 120 240 km 75 150 mi or 8 15 hours Avoid prolonged operation above 3 4 throttle Rev the engine freel...

Page 51: ...cross the incline stop the engine apply the parking brake and then block the front and rear wheels with rocks or other objects Never park the ATV on hills that are too steep to walk up easily 1 Bring the ATV to a stop by applying the brakes 2 Stop the engine 3 With the rear brake lever applied apply the parking brake and then slowly release the rear brake lever 4 Turn the fuel cock to OFF 1 Parkin...

Page 52: ... are not suitable because of po tential safety hazards to you or others Installing aftermarket products or having other modifica tions performed 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 re lated to changes in the vehicle Keep the following in mind when consider...

Page 53: ... carrying cargo and towing a trailer in clude the tongue weight in the maximum ATV load limit Load cargo on the carriers as close to the center of the ATV as possible Put cargo at the rear of the front carrier at the front of the rear carrier and center it Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the l...

Page 54: ...7 7 7 WARNING EWB00012 Indicates a hazardous situation which if not avoided could result in death or serious injury UBW415E0 book Page 7 Monday June 7 2021 1 01 PM ...

Page 55: ...8 1 8 EBU21133 RIDING YOUR ATV UBW415E0 book Page 1 Monday June 7 2021 1 01 PM ...

Page 56: ...e read this manual completely and understand how to operate all of the ATV s con trols Pay particular attention to the safety infor mation on pages 3 1 to 3 9 and all notice and warning labels on the vehicle RIDE WITH CARE AND GOOD JUDGMENT Beginning riders should get training from a certified instructor WARNING EWB01382 Do not operate this ATV or allow anyone else to operate it without proper ins...

Page 57: ... are familiar with this ATV s handling and performance charac teristics Take the time to learn the basic tech niques well before attempting more difficult maneuvers Not recommended for children under 6 years of age WARNING EWB01751 A child under 6 should never operate an ATV with engine size greater than 50 cc Use by children of ATVs that are not recommended for their age can lead to severe injury...

Page 58: ...or protective eyewear Over the ankle boots gloves long sleeved shirt or jacket and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident WARNING Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01412 Wear eye protection when operating your ATV to...

Page 59: ... use to make sure that it is safe operating condition Perform the pre operation checks listed on page 6 1 Follow the maintenance schedules and procedures as de scribed in the Periodic Maintenance and Adjust ment section of this manual WARNING Failure to inspect the ATV before riding it or failure to maintain it properly increases the possibility of an accident and equipment damage EWB01433 Speed l...

Page 60: ...imum speed as the beginner becomes more familiar with operating the ATV Parents should decide when to adjust the ATV for more power as their young ster 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 en gine speed limiter plate can be removed Since re moval of this plate will result in a significant incre...

Page 61: ...g the ATV with addi tional loads such as accessories or cargo The ATV s handling may be adversely affected Re duce your speed when adding additional loads 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 fa...

Page 62: ...ause changes in handling which in some situations could lead to an acci dent EWB01492 Exhaust system WARNING EWB01502 Dry grass or brush or other combustible ma terial accumulated around the engine area could catch fire Do not operate idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust ...

Page 63: ... pedestrians or children are not likely to touch it BE CAREFUL WHERE YOU RIDE This ATV is designed for off road use only WARNING Paved surfaces may seriously af fect 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 EWB01512 Do not ride on any public road street or highway Riding on public r...

Page 64: ...to react to hidden rocks bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Al ways be alert to changing terrain conditions when operating the ATV EWB01532 Do not operate on rough slippery or loose terrain until you have learned and practiced the skills nec essary to control the ATV on such terrain Always be especially cautious on these kinds of terrain WARNING Fai...

Page 65: ...itch WARNING You could collide with another vehicle if operating in off road ar eas where you cannot easily be seen Mount a caution flag on the ATV to make you more vis ible Watch carefully for other vehicles EWB01062 Do not ride in areas posted no trespassing Do not ride on private property without getting permission UBW415E0 book Page 11 Monday June 7 2021 1 01 PM ...

Page 66: ...y 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 throttle and apply the brakes smoothly and evenly Improper use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident TURNING YOUR ATV WARNING EWB017...

Page 67: ...turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly This procedure should be practiced at slow speed many times in a large off road area with no obsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the proce dure again If the riding surface is s...

Page 68: ...scribed in this Owner s Manual Never operate the ATV on hills too steep for the ATV or for your abilities The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills Always check the terrain carefully before you start up any hill Never climb hills with exces sively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV coul...

Page 69: ...les that might cause you to lose control To climb a hill you need traction momentum and steady throttle Travel fast enough to maintain mo mentum but not so fast that you cannot react to changes in the terrain as you climb 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 OK OK UBW415E0 book Page 15 M...

Page 70: ...e sure you do not lift the front wheels which could cause you to lose control If you are unable to continue up the hill dismount the ATV on the uphill side Physically turn the ATV around and then descend the hill If you start to roll backwards DO NOT apply the brakes abruptly Apply only the front brake When fully stopped apply the rear brake as well and then lock the parking brake The ATV could ea...

Page 71: ... 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 back on the seat and sit with your arms straight Engine compression will do most of the braking for you Use caution while descending a...

Page 72: ...equires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slip pery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loose...

Page 73: ...e risk of an overturn The ATV can be used to cross slow moving shal low water of up to a maximum of 11 cm 4 in in depth Before entering the water choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or upset the ATV Drive slowly and carefully Test your brakes after leaving the water If neces sary apply them several times to let ...

Page 74: ...r or muddy conditions RIDING OVER ROUGH TERRAIN WARNING EWB01652 Riding improperly over obstacles could cause loss of control or a collision Before operating in a new area check for obstacles Never at tempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual Riding over rough terrain should b...

Page 75: ...o slowly and be very cautious in order to re duce the chance of skidding or sliding out of control Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes hel...

Page 76: ... of the turn Position your weight over the front wheels for better control See page 8 12 If your ATV begins to tip while turning Lean more into the turn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See page 8 12 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating i...

Page 77: ...nt on the uphill side See page 8 18 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let wa ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability See page 8 19 WARNING EWB00012 Indicates a hazardous si...

Page 78: ... Turn off the engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 3 8 for more information about carbon monoxide WARNING EWB0269...

Page 79: ...kit are intended to assist you in the performance of preventive maintenance and minor repairs However additional tools are necessary to perform certain maintenance work correctly TIP There is a tire pressure gauge in the tool kit If you do not have the tools or experience re quired for a particular job have a Yamaha deal er perform it for you 1 Tool kit 2 Owner s Manual 2 1 UBW415E0 book Page 2 Mo...

Page 80: ...cal skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 1300 800 2500 1600 2500 1600 5000 3200 hours 15 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 s...

Page 81: ...rrester Clean 8 Air induction sys tem Check the air cut off valve reed valve and hose for damage Check condition and clean or replace if neces sary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 1300 800 2500 1600 2500 1600 5000 3200 hours 15 80 160 160 320 UBW415E0 book Page 4 Monday June 7 2021 1 01 PM ...

Page 82: ... skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 1300 800 2500 1600 2500 1600 5000 3200 hours 15 80 160 160 320 1 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Air filter check hose Clean 3 Front brake Check operation and correct if necessary Check brake lever free play and adjust i...

Page 83: ...y Clean and lubricate 10 V belt Check for wear cracks or other damage and re place if necessary 11 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 12 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 13 Front knuckle piv ots Lubricate with lithium soap based grease 14 Steering shaft Lubricate with li...

Page 84: ... sary 19 Moving parts and cables Lubricate 20 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 21 Brake switch Check operation and correct if necessary 22 Switches Check operation and correct if necessary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 1300 800 2500 1600 250...

Page 85: ...9 8 9 EBU23062 TIP Some maintenance items need more frequent service if you are riding in unusually wet dusty sandy or muddy areas or at full throttle UBW415E0 book Page 8 Monday June 7 2021 1 01 PM ...

Page 86: ...ion each time the panel needs to be removed and installed EBU23102 Panel A To remove the panel Remove the bolts and then take the panel off To install the panel Place the panel in the original position and install the bolts EBU23216 Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the 1 ...

Page 87: ...ench included in the tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally TIP If the spark plug shows a distinctly different color the engine could be operating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the A...

Page 88: ...o the specified torque TIP If a torque wrench is not available when installing the spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible 3 Install the spark plug cap EBU37001 Engine oil The engine oil level should be checked before each ride In addition the oil must be changed at th...

Page 89: ... remove it again to check the oil level 5 If the engine oil is at or below the minimum level mark add sufficient quantity of the rec ommended engine oil NOTICE Be sure the engine oil is at the correct level otherwise engine damage may result ECB00852 6 Check the O ring for damage and then insert the dipstick and tighten the engine oil filler cap To change the engine oil 1 Park the ATV on a level s...

Page 90: ...t O ring and then apply a thin coat of clean engine oil to the new O ring 7 Install the oil strainer the compression spring the new O ring and the engine oil drain bolt Tighten the engine oil drain bolt to the specified torque NOTICE Before in stalling the engine oil drain bolt be sure to install the O ring compression spring and oil strainer ECB00322 8 Refill with the specified amount of the reco...

Page 91: ...tes and then check the oil level and correct it if necessary EBU38620 Why Yamalube YAMALUBE oil is a Genuine YAMAHA Part born of the engineers passion and belief that engine oil is an important liquid engine component We form teams of specialists in the fields of mechanical en gineering chemistry electronics and track test ing and have them develop the engine together with the oil it will use Yama...

Page 92: ...ed in the periodic mainte nance chart To change the transmission oil 1 Place the ATV on a level surface 2 Place an oil pan under the transmission case to collect the used oil 3 Remove the transmission oil filler cap and its O ring from the transmission case 4 Remove the transmission oil drain bolt and its gasket to drain the oil from the transmission case 1 Transmission oil filler cap 2 O ring 1 2...

Page 93: ... Cleaning the air filter element The air filter element should be serviced at the in tervals specified in the periodic maintenance chart Clean or if necessary replace the air filter element more frequently if you are riding in unusu ally wet or dusty areas TIP There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter e...

Page 94: ...lement and clean it with solvent WARNING Always use parts cleaning solvent to clean the air filter ele ment Never use low flash point solvents or gasoline to clean the air filter element because the engine could catch fire or ex plode EWB03540 1 Air filter case check hose 1 1 Air filter case cover 2 Air filter case cover holder 1 2 UBW415E0 book Page 17 Monday June 7 2021 1 01 PM ...

Page 95: ... qual ity foam air filter oil to the element TIP The air filter element should be wet but not drip ping 8 Insert the air filter element into the air filter case 9 Install the air filter case cover by hooking the holders onto the air filter case NOTICE Make sure that the air filter element is properly seated in the air filter case Never operate the engine with the air filter ele 1 Air filter elemen...

Page 96: ... seat TIP The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty areas When servicing the air filter element be sure to check the air inlet of the air filter case for obstructions EBU28905 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Tailpi...

Page 97: ...uretor should be checked and if neces sary adjusted at the intervals specified in the pe riodic maintenance chart The carburetor is an important part of the engine and requires very so phisticated adjustment Therefore most carbure tor adjustments should be left to a Yamaha dealer who has the necessary professional knowledge and experience The adjustment described in the following section however m...

Page 98: ... if neces sary adjust it to specification by turning the throttle stop screw at the carburetor To in crease the engine idling speed turn the throt tle stop screw in direction a and to decrease it turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment 1 Throttle stop screw Engine idling speed 1600 1800 r min a b...

Page 99: ...en the locknut 5 Slide the rubber covers to their original posi tions EBU24062 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the inter vals specified in the periodic maintenance chart EBU29602 Brakes Replacement of brake components requires pro...

Page 100: ...cking the po sition of the brake lever free play adjusting bolts or nut Front brakes To check front brake shoe wear check the posi tion of the adjusting bolts If a bolt extends more than 12 mm 0 47 in from its locknut the brake shoes need to be replaced Rear brake To check rear brake shoe wear check the position of the adjusting nut If the nut is more than 18 mm 0 71 in from the end of the bolt th...

Page 101: ...e upper adjusting bolt 2 Loosen the lower locknut 3 Turn the lower adjusting bolt in direction a to increase the lever free play and in direction b to decrease it 1 Rear brake lever free play adjusting nut 2 Bolt 3 No more than 18 mm 0 71 in 1 2 3 1 Front brake lever free play Front brake lever free play 9 3 13 3 mm 0 37 0 52 in 1 UBW415E0 book Page 24 Monday June 7 2021 1 01 PM ...

Page 102: ...ble lengths are equal The cable joint will become vertical 6 Tighten the upper locknut TIP After adjusting the brake lever free play check the front brake shoes for wear 1 Upper locknut 2 Upper adjusting bolt 3 Lower locknut 4 Lower adjusting bolt 1 2 4 3 a b 1 Cable joint 1 a a a a UBW415E0 book Page 25 Monday June 7 2021 1 01 PM ...

Page 103: ...ever free play check the rear brake shoes for wear EBU34014 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary TIP When checking and adjusting the drive chain slack there should be no weight on the ATV and all tires must be touching the ground 1 Rear brake lever free play Rear brake lever free play 7 6 12 9 mm 0 30 0 51 in 1 1 Rear brake lever free...

Page 104: ...and then measure the drive chain slack as shown 3 If the drive chain slack is incorrect adjust it as follows To adjust the drive chain slack 1 Loosen the bolts and nuts 2 Loosen the rear brake lever free play adjust ing nut Drive chain slack 6 0 12 0 mm 0 24 0 47 in 1 Drive chain slack 1 1 Bolt 1 Nut 1 1 UBW415E0 book Page 27 Monday June 7 2021 1 01 PM ...

Page 105: ...d to drive chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits ECB00543 5 Tighten the locknut and then the bolts and nuts to their specified torques 6 Adjust the rear brake lever free play See page 9 26 1 Rear brake lever free play adjusting nut 1 Drive chain slack adjusting nut 2 Locknut 1 1 2 a b Tightening torques Locknut 22 N m 2 2 k...

Page 106: ...that all side plates and rollers have been sufficiently oiled EBU24905 Checking and lubricating the cables The operation and the condition of all control ca bles should be checked before each ride and the cables and cable ends should be lubricated if nec essary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWB02582 Inspect cables frequently and re...

Page 107: ... and the lever pivots should be lubricated if necessary Front brake lever Rear brake lever EBU24965 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bearings Recommended lubricant Lithium soap...

Page 108: ...ts equipped with a grease nipple use a grease gun EBU28826 Lubricating the front knuckle pivots The front knuckle pivots must be lubricated at the intervals specified in the periodic maintenance chart Recommended lubricant Lithium soap based grease 1 Grease nipple Recommended lubricant Lithium soap based grease 1 UBW415E0 book Page 31 Monday June 7 2021 1 01 PM ...

Page 109: ... grease gun EBU36401 Battery This model is equipped with a 12 volt VRLA valve regulated lead acid battery There is no need to check the electrolyte or to add distilled water However the battery lead connections need to be checked and tightened and the bat tery terminals cleaned if corroded If the battery seems to have discharged recharge it as soon as possible 1 Grease nipple Recommended lubricant...

Page 110: ... oil Call a physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ignition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN To remove the battery 1 Remove panel A See page 9 9 2 Unhook the battery band 3 Disconnect the negative battery lea...

Page 111: ...the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary NOTICE ECB00942 Always keep the battery charged Storing the battery in a discharged state for an extended period of time will cause permanent battery damage Do not store the battery in an excessively cold or warm pl...

Page 112: ...lectrical problem is suspected check the fuse and replace it if necessary as follows NOTICE ECB00641 To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 1 Turn off all electrical systems See page 5 1 2 Remove panel A See page 9 9 1 Positive battery lead red 2 Negative battery lead black 2 1 1 Fuse 2 Spare fuse 2 1 UBW415E0 book Page 35 Monday June 7 20...

Page 113: ...t the engine 5 Install the panel 6 If the fuse immediately blows again have a Yamaha dealer check the vehicle EBU34030 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel bolts 3 Elevate the ATV and place a suitable stand under the frame 4 Remove the bolts from the wheel 5 Remove the wheel EBU34042 Installing a wheel 1 Install the wheel with the arrow mark pointing in the forwar...

Page 114: ...e skilled technicians have the necessary tools ex perience and know how to service the ATV prop erly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02281 Do not smoke when checking the fuel system Fuel can ignite or explode causing severe inju ry or prope...

Page 115: ...eck the ATV Have a Yamaha dealer check the ATV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The battery is good Check the b...

Page 116: ...rakes several times at slow speeds to let friction dry out the linings EWB02312 NOTICE Excessive wa ter pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure de tergent applications such as those avail able in coin operated car washers ECB00712 4 Once most of the di...

Page 117: ...d perform all outstanding maintenance 2 Follow all the instructions in the Cleaning sec tion of this chapter 3 Fill up the fuel tank and add fuel stabilizer Fu el Med Rx if available and then run the en gine for 5 minutes to distribute the treated fuel 4 Turn the fuel cock lever off and then drain the carburetor float chamber by loosening the drain bolt Pour the drained fuel into the fuel tank 5 P...

Page 118: ... frame on stands or blocks to raise all wheels off the ground Alternatively turn the wheels each month to prevent the tires from degrading 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 See page 9 32 UBW415E0 book Page 3 Monday June 7 2021 1 01 PM ...

Page 119: ...Maximum load 41 0 kg 90 lb Total weight of rider cargo accessories and tongue Engine Combustion cycle 4 stroke Cooling system Air cooled Valve train SOHC Number of cylinders Single cylinder Displacement 49 cm Bore stroke 39 0 41 4 mm 1 54 1 63 in Starting system Electric starter and kickstarter Engine oil Recommended brand SAE viscosity grades 5W 30 10W 30 10W 40 15W 40 20W 40 20W 50 UBW415E0 book...

Page 120: ...rve amount 0 7 L 0 18 US gal 0 15 Imp gal Carburetor Type quantity VM12 1 Front tire Size AT16x6 5 7 Manufacturer model DURO DI2040 Rear tire Size AT16x7 7 Manufacturer model DURO DI2041 Front brake Type Mechanical leading trailing drum brake Rear brake Type Mechanical leading trailing drum brake Front suspension Type Swing axle Rear suspension Type Swingarm Electrical system System voltage 12 V 0...

Page 121: ...11 3 11 Battery Model GTX5L BS Voltage capacity 12 V 4 0 Ah UBW415E0 book Page 3 Monday June 7 2021 1 01 PM ...

Page 122: ...le Emission Control Information label is affixed at the location in the illustration This label shows specifications related to exhaust emissions as required by federal law state law and Environ ment Canada 1 Vehicle Emission Control Information label 1 UBW415E0 book Page 1 Monday June 7 2021 1 01 PM ...

Page 123: ...rpose 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 etc Exhaust system M...

Page 124: ...t 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 1 240 150 15 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 25000 16000 1600 UB...

Page 125: ...nd repairs at such dealer s place of business 2 EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each applicable model Yamaha ATV covered by this warranty that the vehicle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture a...

Page 126: ...d 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 CUSTOMER SERVICE If your ma...

Page 127: ...le 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 250 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lod...

Page 128: ...irst 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 VIN number vehicle identification 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 Indicates a hazardous situation which if not avoided could result in death or serious injury WARNING YA...

Page 129: ... Engine idling speed 9 20 Engine oil 6 3 9 11 Engine starting a warm 7 3 Engine stop switch 5 2 Engine stop switch with lanyard 5 2 F Front and rear brake shoes checking 9 23 Front arm pivots lubricating 9 31 Front knuckle pivots lubricating 9 31 Fuel 5 10 6 3 Fuel cock 5 11 Fuel tank cap 5 9 Fuse replacing 9 35 H Handlebar switches 5 2 I Identification numbers 1 1 Instruments and switches 6 6 K K...

Page 130: ... 12 Start switch 5 2 Steering shaft lubricating 9 32 Storage 10 2 T Throttle lever 5 3 6 3 Throttle lever free play adjusting 9 22 Tires 6 3 Transmission oil 6 3 9 15 Troubleshooting 9 37 Troubleshooting chart 9 38 V Valve clearance 9 22 Vehicle Emission Control Information label 12 1 Vehicle identification number 1 1 W Warranty extended 12 6 Warranty limited 12 4 Wheel hub bearings checking 9 30 ...

Page 131: ...rm right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service ma...

Page 132: ... 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 AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVE...

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