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Yamaha YFZ05YYXN Owner'S Manual Download Page 104

9-31

9

EBU36392

Lubricating the front arm pivots

The front arm pivots must be lubricated at the in-
tervals specified in the periodic maintenance
chart.

TIP

For parts 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

UBW421E0.book  Page 31  Monday, June 7, 2021  1:23 PM

Summary of Contents for YFZ05YYXN

Page 1: ...DIC183 YFZ05YYXN OWNER S MANUAL BW4 F8199 21 READ THIS MANUAL CAREFULLY It contains important safety information This ATV should not be ridden by anyone under 6 years of age WARNING ...

Page 2: ...EBU28981 Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if it is sold UBW421E0 book Page 1 Monday June 7 2021 1 23 PM ...

Page 3: ...ions 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 labels on the ATV This ATV should not be operated by a child under 6 years of age AN IMPORTANT NOTE TO PARENTS This ATV is not a toy Before you...

Page 4: ...as their youngster s riding skills improve Once the ATV rider can operate with skill at the top speed permitted by adjusting the vehicle speed limiter alone the engine speed limiter plate can be removed Since removal of this limiter will result in a significant increase in power turn the vehicle speed limiter adjusting screw completely back in again adjust it out in stages as done previously If yo...

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: ...d road or motorway Please check your local riding laws and regulations before operating this ATV EBU33790 YFZ05YYXN OWNER S MANUAL 2022 by Yamaha Motor Co Ltd 1st edition May 2021 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Taiwan UBW421E0 book Page 1 Monday June 7 2021 1 23 PM ...

Page 7: ... 5 3 Speed limiter 5 3 Front brake lever 5 5 Rear brake lever 5 6 Parking brake 5 6 Kickstarter 5 7 Fuel tank cap 5 8 Fuel 5 9 Fuel cock 5 10 Starter choke 5 12 Seat 5 13 Rear shock absorber 5 13 PRE OPERATION CHECKS 6 1 Fuel 6 3 Engine oil 6 3 Transmission oil 6 3 Front and rear brakes 6 3 Throttle lever 6 3 Drive chain 6 3 Tires 6 3 Chassis fasteners 6 6 Instruments and switches 6 6 OPERATION 7 ...

Page 8: ...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 front brake lever free play 9 24 Adjusting the rear brake lever free play 9 26 Drive chain slack 9 2...

Page 9: ...Troubleshooting 9 37 Troubleshooting chart 9 38 CLEANING AND STORAGE 10 1 Cleaning 10 1 Storage 10 2 SPECIFICATIONS 11 1 INDEX 12 1 UBW421E0 book Page 3 Monday June 7 2021 1 23 PM ...

Page 10: ...w VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION 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 UBW421E0 book Page 1 Monday June 7 2021 1 23 PM ...

Page 11: ...r specific model can be identified by checking the model type code found on the model label 1 Model label 1 Model type code 2 Production code 3 Color code 1 1 3 2 UBW421E0 book Page 2 Monday June 7 2021 1 23 PM ...

Page 12: ...2 1 2 EBU17661 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 3 6 5 4 2 UBW421E0 book Page 1 Monday June 7 2021 1 23 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 UBW421E0 book Page 2 Monday June 7 2021 1 23 PM ...

Page 14: ... balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and it turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS BD3 F1568 60 WARNING UNDER 6 Operation of this ATV by children under the age of 6 increases the ris...

Page 15: ... BD3 F151H 00 2 2 15 2 2 15 1 7 12 1 7 12 90 41 BW4 F816M 70 3 4 2017 BD3 F817J 70 6 5 WARNING RISK of ROLLOVER even on flat terrain ROLLOVERS could result in DEATH or SERIOUS INJURY AVOID sudden sharp turns AVOID steep inclines AVOID riding across slopes BD3 F156D 00 UBW421E0 book Page 4 Monday June 7 2021 1 23 PM ...

Page 16: ...gine 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 child if he or she does not have the abilities to operate it safe...

Page 17: ...edures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds and never turn at excessive speeds Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully befo...

Page 18: ...ch as ice go slowly and be very cautious in order to reduce 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 an...

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: ...d 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 Re evaluate your child s readiness before every use a child who is too tired or distracted should not be al lowed to operate the ATV Be sure your child is properly trained Your child should...

Page 22: ... adjusted and the engine speed limiter plate is installed to limit the ATV to a walking speed See page 5 3 1 Install the cap on the end of the engine stop switch cord onto the engine shut off switch white button 2 Put your fingers in the loop at the other end of the cord 3 As your child is riding walk behind the ATV closely watching his or her actions as well as the path ahead 4 If there is a pote...

Page 23: ...d areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or par tially enclosed areas such as barns garages or carports Do n...

Page 24: ...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 UBW421E0 book Page 1 Monday June 7 2021 1 23 PM ...

Page 25: ...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 UBW421E0 book Page 2 Monday June 7 2021 1 23 PM ...

Page 26: ... systems are off The key can be re moved EBU18068 Handlebar switches EBU18081 Engine stop switch Set this switch to before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situa tion The engine will not start or run when this switch is set to ON OFF 1 Engine stop switch 2 Start switch 2 1 UBW...

Page 27: ...be held by putting your fingers in the loop as shown Should the ATV be separated from the parent by a distance longer than the lanyard length the lan yard will pull out the cap and stop the engine For further explanation of this switch and the lan yard see TEACHING YOUR CHILD TO OPER ATE THE ATV in the SAFETY INFORMATION section TIP The engine cannot be started with the cap re moved 1 Engine stop ...

Page 28: ... adjusting screw fully turned in and the engine speed limiter plate in stalled to limit the amount of speed available while they learn The vehicle speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum The adjusting screw may be gradually turned out as the beginner becomes more familiar with operating the ATV Parents should decide when to adjust t...

Page 29: ...2 0 3 2 mm 0 08 0 13 in See page 9 22 WARNING Im proper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation You could lose control resulting in an accident EWB00242 3 Tighten the locknut Engine speed limiter plate When the engine speed limiter plate is installed engine speed is limited to 5200 r min When this plate is removed top engine spe...

Page 30: ...eadily available whenever you want to reduce top engine speed EBU18393 Front brake lever The front brake lever is located on the right han dlebar To apply the front brake pull the brake le ver toward the handlebar grip 1 Screw 2 Engine speed limiter plate 2 1 1 Front brake lever 1 UBW421E0 book Page 5 Monday June 7 2021 1 23 PM ...

Page 31: ...he parking brake Squeeze the rear brake lever to release the parking brake WARNING EWB00221 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 with...

Page 32: ...ttery voltage is low 1 Remove the seat page 5 13 and then re move the kickstarter lever 2 Remove the kickstarter lever cap 3 Install the kickstarter lever 4 Move the kickstarter lever down lightly with your foot until the gears engage and then push it down smoothly but forcefully 1 Kickstarter lever 1 1 Kickstarter lever cap 1 UBW421E0 book Page 7 Monday June 7 2021 1 23 PM ...

Page 33: ...tank cap Remove the fuel tank cap by turning it counter clockwise WARNING EWB02522 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling fol low these instructions 1 Before refueling turn off the engine and be sure that no one is sitting on the vehicle Nev er refuel while smoking or while in the vicinity 1 Fold out 2 Push...

Page 34: ... since fuel may deteriorate painted surfaces or plastic parts ECB00982 4 Turn the fuel tank cap fully clockwise to make sure it is securely closed EBU2793A Fuel Make sure there is sufficient gasoline in the tank before starting off Refuel if necessary WARNING EWB02532 Gasoline is poisonous and can cause injury or death Handle gasoline with care Never siphon gasoline by mouth If you should swallow ...

Page 35: ... or vehicle performance problems NOTICE ECB00071 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system EBU18821 Fuel 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 il...

Page 36: ...s posi tion when the engine is not running ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding 1 Arrow mark positioned over OFF 1 1 Arrow mark positioned over ON 1 UBW421E0 book Page 11 Monday June 7 2021 1 23 PM ...

Page 37: ...EBU18852 Starter choke Starting a cold engine requires a richer air fuel mixture This mixture is controlled by the starter choke system To use the starter choke and enrich the air fuel ratio move the starter choke lever in direction a To decrease the starter choke or turn it off move the starter choke lever in direction b TIP See page 7 1 for engine starting instructions 1 Arrow mark positioned ov...

Page 38: ...t Insert the projections on the front of the seat into the seat holders and then push down on the seat at the rear to lock it in place Make sure that the seat is securely fitted EBU19027 Rear shock absorber The spring preload can be adjusted to suit the rid er s weight and the riding conditions 1 Seat 2 Seat lock lever 1 2 1 Projection 2 Seat holder 2 1 UBW421E0 book Page 13 Monday June 7 2021 1 2...

Page 39: ...g preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Position indicator 1 2 3 4 5 2 1 a b 1 Special wrench Spring preload setting Minimum soft 1 Standard 1 Maximum hard 5 1 UBW421E0 book Page 14 Monday June 7 2...

Page 40: ...fore 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 9 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 41: ...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 42: ...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 43: ...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 44: ...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 45: ...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 UBW421E0 book Page 6 Monday June 7 2021 1 23 PM ...

Page 46: ...ngine 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 Cold engine start with ambient temperature below 5 C 40 F ...

Page 47: ... 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 48: ...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 49: ...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 50: ... 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 51: ... 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 52: ...8 1 8 EBU21142 RIDING YOUR ATV UBW421E0 book Page 1 Monday June 7 2021 1 23 PM ...

Page 53: ...ll 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 instruction The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types o...

Page 54: ...age can lead to severe injury or death of the child This ATV is designed to carry the operator only passengers prohibited The long seat is to allow the operator to shift posi tion as needed during operation It is not for carry ing passengers WARNING Never carry a passenger Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV You could have an accident resul...

Page 55: ... or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident EWB02612 Do not operate after or while consuming alco hol or drugs The operator s performance capability is...

Page 56: ...decreases the maximum speed of the ATV Turning in the adjusting screw decreases top speed and turning it out increases top speed See page 5 3 This model also has an engine speed limiter plate to limit the amount of engine power available Yamaha recommends that all beginning riders start off with the engine speed limiter plate in stalled and the vehicle speed limiter adjusting screw turned in to li...

Page 57: ...low more room to stop A heavier vehicle takes longer to stop Avoid hills and rough terrain Choose terrain carefully Use extreme caution when towing or carrying a load on inclines Turn gradually and go slowly As originally equipped this ATV is not designed to carry cargo or tow a trailer If you choose to add accessories to carry cargo you must use com mon sense and good judgment Use extra caution w...

Page 58: ...ing WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off EWB01482 Modifications and accessories Never modify this ATV through improper installa tion or use of accessories or other modification All parts and accessories added to this ATV should be genuine Yamaha or equivale...

Page 59: ... ATV in a place where others might be likely to touch it The muffler and other engine parts become ex tremely hot during operation and remain hot after the engine has stopped To reduce the risk of fire during operation or after leaving the ATV do not let brush grass and other materials collect under the vehicle near the muffler or exhaust pipe or next to other hot parts Check under the vehicle aft...

Page 60: ...es Watch carefully for other vehicles Make sure you know your country s laws and regulations before you ride on unpaved public streets or roads Do not ride on any paved public street road or motor way WARNING Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle EWB01522 Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert ...

Page 61: ...ra care when op erating on excessively rough slippery or loose terrain could cause loss of traction or ATV con trol which could result in an accident includ ing an overturn EWB01542 When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if ope...

Page 62: ...efore trying more difficult ter rain Set the parking brake and follow the instruction on page 7 1 to start the engine Once it has warmed up you are ready to begin riding your ATV Re member that the engine and exhaust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these compo nents With the engine idling release the parking brake Apply the throttle...

Page 63: ... could go out of control causing a collision or overturn To achieve maximum traction on unpaved surfac es the two rear wheels turn together at the same speed Therefore unless the wheel on the inside of the turn is allowed to slip or lose some traction the ATV will resist turning A special turning tech nique must be used to allow the ATV to make turns quickly and easily It is essential that this sk...

Page 64: ... ATV be gins to tip over to the outside while negotiating a turn lean more to the inside It may also be nec essary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL WARNING EWB01672 Climbing hills improperly can cause overturns or loss of contr...

Page 65: ...d be on the other side of the hill Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if pos sible When crossing the side of a hill shift your weight to the uphill side of the ATV OK UBW421E0 book Page 14 Monday June 7 2021...

Page 66: ... on the other side there could be another person an obstacle or a sharp drop off Use common sense and remem ber that some hills are too steep for you to climb or descend If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hi...

Page 67: ...ills as described in this Owner s Manual Always check the terrain carefully before you start down any hill 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 Shift your weight backward and to the up side of the hill Never go down a hill at high speed Avoid going down a hill at an...

Page 68: ...nly the rear brake Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear CROSSING A SLOPE WARNING EWB01633 Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to overturn Always follow proper...

Page 69: ...rect the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance grad ually steer again in the direction you wish to travel CROSSING THROUGH SHALLOW W...

Page 70: ... times to let friction dry out the linings Do not continue to ride your ATV without verifying that you have regained proper braking ability WARNING Wet brakes may have reduced stopping ability which could cause loss of control EWB02622 After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case NOTICE Undrained water can cause d...

Page 71: ...oards at all times Avoid jumping the ATV as loss of control and damage to the ATV may result SLIDING AND SKIDDING WARNING EWB01663 Skidding or sliding improperly may cause you to lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slipp...

Page 72: ...recommended until you have corrected the slide With practice over a period of time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are reduced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost WHAT TO DO IF This s...

Page 73: ...forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the uphill side See page 8 13 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...

Page 74: ... 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 75: ...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 UBW421E0 book Page 2 Mo...

Page 76: ...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 77: ...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 UBW421E0 book Page 4 Monday June 7 2021 1 23 PM ...

Page 78: ... 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 79: ...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 80: ... 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 81: ...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 UBW421E0 book Page 8 Monday June 7 2021 1 23 PM ...

Page 82: ... 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 spark plug should be removed and checked in ac cordance with the periodic maintenance chart In addition the condition of the spark plug can reve...

Page 83: ...or around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally TIP If the spark plug shows a distinctly different color the engine could be operating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 1 Spark plug cap 1 1 Spark plug wrench 1 UBW421E0 book Page 10 Monday June 7 2021 1 2...

Page 84: ...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 85: ... 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 86: ...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 87: ...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 88: ...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 89: ... 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 90: ...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 UBW421E0 book Page 17 Monday June 7 2021 1 23 PM ...

Page 91: ... 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 92: ... 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 93: ...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 94: ... 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 95: ...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 96: ...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 97: ...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 UBW421E0 book Page 24 Monday June 7 2021 1 23 PM ...

Page 98: ...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 UBW421E0 book Page 25 Monday June 7 2021 1 23 PM ...

Page 99: ...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 100: ...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 UBW421E0 book Page 27 Monday June 7 2021 1 23 PM ...

Page 101: ...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 102: ...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 103: ... 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 104: ...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 UBW421E0 book Page 31 Monday June 7 2021 1 23 PM ...

Page 105: ... 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 106: ... 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 107: ...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 108: ...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 UBW421E0 book Page 35 Monday June 7 20...

Page 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 114: ... 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 UBW421E0 book Page 3 Monday June 7 2021 1 23 PM ...

Page 115: ...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 UBW421E0 book...

Page 116: ...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 117: ...11 3 11 Battery Model GTX5L BS Voltage capacity 12 V 4 0 Ah UBW421E0 book Page 3 Monday June 7 2021 1 23 PM ...

Page 118: ...rt 7 1 Engine idling speed 9 20 Engine oil 6 3 9 11 Engine starting a warm 7 3 Engine stop switch 5 1 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 9 6 3 Fuel cock 5 10 Fuel tank cap 5 8 Fuse replacing 9 35 H Handlebar switches 5 1 I Identification numbers 1 1 Instruments and switches 6 ...

Page 119: ...tarter choke 5 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 identification number 1 1 W Wheel hub bearings checking 9 30 Wheel installing 9 36 Wheel removing 9 36 Y Yamalube 9 14 UBW421E0 book Page 2 ...

Page 120: ...B6 yoko_Blank fm Page 1 Thursday December 8 2011 2 26 PM ...

Page 121: ...B6 yoko_Blank fm Page 1 Thursday December 8 2011 2 26 PM ...

Page 122: ...GS OR ALCOHOL ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PAVED ROADS NEVER CARRY PASSENGERS NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control LOCATE AND READ OWNER S MANUAL ...

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