Yamaha RAPTOR 90 2022 Owner'S Manual Download

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DIC183

YFM09RYXN

OWNER’S MANUAL

BD3-F8199-21

READ THIS MANUAL CAREFULLY!

It contains important safety information.

This ATV should not be ridden by anyone under 10 years of age.

WARNING

Summary of Contents for RAPTOR 90 2022

Page 1: ...DIC183 YFM09RYXN OWNER S MANUAL BD3 F8199 21 READ THIS MANUAL CAREFULLY It contains important safety information This ATV should not be ridden by anyone under 10 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 UBD321E0 book Page 1 Wednesday June 2 2021 9 53 AM ...

Page 3: ...ns 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 10 years of age AN IMPORTANT NOTE TO PARENTS This ATV is not a toy Before you ...

Page 4: ... 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 your...

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 vehic...

Page 6: ... road or motorway Please check your local riding laws and regulations before operating this ATV EBU33790 YFM09RYXN 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 UBD321E0 book Page 1 Wednesday June 2 2021 9 53 AM ...

Page 7: ... Speed limiter 5 3 Front brake lever 5 5 Rear brake lever 5 5 Parking brake 5 5 Drive select lever 5 6 Kickstarter 5 7 Fuel tank cap 5 8 Fuel 5 9 Fuel cock 5 10 Starter choke 5 12 Seat 5 13 Front shock absorbers 5 13 Rear shock absorber 5 15 PRE OPERATION CHECKS 6 1 Fuel 6 3 Engine oil 6 3 Transmission 6 3 Front and rear brakes 6 3 Throttle lever 6 3 Drive chain 6 3 Tires 6 3 Chassis fasteners 6 6...

Page 8: ...and lubrication 9 5 Checking the spark plug 9 9 Engine oil 9 10 Why Yamalube 9 13 Transmission oil 9 14 Cleaning the air filter element 9 15 Cleaning the spark arrester 9 18 Adjusting the carburetor 9 19 Adjusting the engine idling speed 9 19 Adjusting the throttle lever free play 9 20 Valve clearance 9 21 Brakes 9 21 Checking the front and rear brake shoes 9 21 Adjusting the front brake lever fre...

Page 9: ...emoving a wheel 9 34 Installing a wheel 9 35 Troubleshooting 9 36 Troubleshooting chart 9 37 CLEANING AND STORAGE 10 1 Cleaning 10 1 Storage 10 2 SPECIFICATIONS 11 1 INDEX 12 1 UBD321E0 book Page 3 Wednesday June 2 2021 9 53 AM ...

Page 10: ... 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 UBD321E0 book Page 1 Wednesday June 2 2021 9 53 AM ...

Page 11: ... 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 UBD321E0 book Page 2 Wednesday June 2 2021 9 53 AM ...

Page 12: ... the labels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a re placement label from your Yamaha dealer 1 5 6 2 3 4 UBD321E0 book Page 1 Wednesday June 2 2021 9 53 AM ...

Page 13: ...lance 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 10 Operation of this ATV by children under the age of 10 increases the risk...

Page 14: ...om the rim LOADING Maximum weight capacity 82 kg 181 lbs Includes weight of operator cargo and accessories Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death 3 6 psi 3 6 psi 3 2 psi 3 2 psi BD3 F816M 70 2017 BD3 F817J 70 5 6 4 3 WARNING RISK of ROLLOVER even on ﬂat terrain ROLLOVERS could result in DEATH or SERIOUS INJURY AVOID sudd...

Page 15: ...w a child under 10 years old to oper ate this ATV Never allow a child under 16 years old to oper ate an ATV without adult supervision Do not allow continued use of the ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV This vehicle is intended for off road use only Do not operate on any paved surfaces such as sidewalks driveways parking l...

Page 16: ... 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 f...

Page 17: ...s 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 be sure there are n...

Page 18: ...sary If you can physically operate your vehicle inspect your vehicle If the vehicle is in safe operating con dition and you can safely operate it restart it 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 you...

Page 19: ...ange 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 guidelines in mind as well as those found in the Loading section page 7 7 when mounting acces sories Never install accessories that would impair the performance of your ATV Carefully in...

Page 20: ...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 with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or par...

Page 21: ...3 7 3 UBD321E0 book Page 7 Wednesday June 2 2021 9 53 AM ...

Page 22: ... Air filter 4 Fuse 5 Battery 6 Rear shock absorber 7 Kickstarter lever cap 8 Reflector 1 2 3 4 5 7 6 8 1 Spark arrester 2 Reflector 3 Tool kit 4 Front shock absorber 5 Spark plug 6 Engine oil filler cap 7 Transmission oil filler cap 1 2 3 4 7 6 5 UBD321E0 book Page 1 Wednesday June 2 2021 9 53 AM ...

Page 23: ...uments 1 Rear brake lever 2 Handlebar switches 3 Parking brake lock plate 4 Starter choke lever 5 Main switch 6 Throttle lever 7 Front brake lever 8 Drive select lever 1 2 3 5 6 7 4 8 UBD321E0 book Page 2 Wednesday June 2 2021 9 53 AM ...

Page 24: ...FF All electrical systems are off The key can be re moved EBU17794 Indicator lights EBU17861 Neutral indicator light This indicator light comes on when the transmis sion is in the neutral position EBU17831 Reverse indicator light This indicator light comes on when the transmis sion is in the reverse position ON OFF 1 Reverse indicator light R 2 Neutral indicator light N 1 2 UBD321E0 book Page 1 We...

Page 25: ... 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 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 ver returns normally before starting the engine 1 Engine st...

Page 26: ...ng 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 ATV...

Page 27: ...lows 1 Remove the seat See page 5 13 2 Loosen the screws and then remove the plate as shown 3 Tighten the screws 4 Install the seat 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 3 2 b a 1 Screw 2 Engine speed limiter plate 1 2 UBD321E0 book P...

Page 28: ...andle 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 UBD321E0 book P...

Page 29: ...ide The brake could overheat if you ride the ATV without re leasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely EBU18583 Drive select lever The drive select lever is used to shift the transmis sion into the forward neutral and reverse posi tions See page 7 3 for drive select lever operation 1 Parking brake lock p...

Page 30: ...nd 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 UBD321E0 book Page 7 Wednesday June 2 2021 9 53 AM ...

Page 31: ...ank 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 32: ...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 EBU38530 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 s...

Page 33: ...e 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 illustrations Recommende...

Page 34: ...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 UBD321E0 book Page 11 Wednesday June 2 2021 9 53 AM ...

Page 35: ...BU18852 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 ove...

Page 36: ... Insert the projection on the front of the seat into the seat holder and then push down on the seat at the rear to lock it in place Make sure that the seat is securely fitted EBU18997 Front shock absorbers 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 1 2 UBD321E0 book Page 13 Wednesday June 2 2021 9...

Page 37: ...reload 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 Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber TIP A special wrench can be obtained at a Yamaha dealer to make this adjustmen...

Page 38: ...ing 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 Special wrench Spring preload setting Minimum soft 1 Standard 3 Maximum hard 5 1 1 Spring preload adjusting ring 2 Position indicator 1 2 3 4 5 2 1 a b UBD321E0 book Page ...

Page 39: ... A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 1 UBD321E0 book Page 16 Wednesday June 2 2021 9 53 AM ...

Page 40: ...ler Before 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 10 Transmission Check transmission case for leak...

Page 41: ...cate if necessary 6 3 9 25 9 27 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 28 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 6 6 Instruments and swit...

Page 42: ...e 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 21 EBU19762 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when relea...

Page 43: ...pment 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 25 0 kPa 0 250 kgf cm 3 6 psi Rear 25 0 kPa 0 250 k...

Page 44: ... 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 DI2017 Size AT18 x 7 8 Rear Manufacturer model DURO DI2016 Size AT1...

Page 45: ...s 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 UBD321E0 book Page 6 Wednesday June 2 2021 9 53 AM ...

Page 46: ...g 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 Shift the drive select lever into the neutral po sition The neutral indicator light should come on 5 Position the starter choke lever according to the ambient temperature Position 1 Cold engi...

Page 47: ...e is started with 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 8 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 t...

Page 48: ...te stop 2 Apply the rear brake lever 3 Shift from neutral to forward by moving the drive select lever along the shift guide TIP Make sure that the drive select lever is completely shifted into position 4 Open the throttle lever gradually Shifting Reverse WARNING EWB00721 Improper operation in reverse could make you hit an obstacle or even a person behind you resulting in serious injury When you sh...

Page 49: ...or this reason you should fol low the engine break in instructions carefully Since the engine is brand new do not put an ex cessive load on it for the first 240 km 150 mi or 15 hours During this period the various parts in the engine wear and polish themselves to the cor rect operating clearances Avoid prolonged full throttle operation or any condition that might re sult in engine overheating 0 12...

Page 50: ...er incline could cause the ATV to roll out of control increasing the chance of an accident If you must park on an incline place the ATV transversely across the incline shift the drive select lever to the forward position 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 Wit...

Page 51: ...er Aftermarket parts accessories and modifica tions While you may find aftermarket products similar in design and quality to genuine Yamaha Accesso ries recognize that some aftermarket accessories or modifications 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...

Page 52: ... a trailer If you choose to add accessories so that you can carry cargo or tow a trailer you must use common sense and good judgment as the stability and handling of an ATV can be changed When adding accessories keep the following points in mind Never exceed the weight limits shown An over loaded ATV can be unstable If you are carrying cargo and towing a trailer in clude the tongue weight in the m...

Page 53: ...r ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV UBD321E0 book Page 8 Wednesday June 2 2021 9 53 AM ...

Page 54: ...8 1 8 EBU21142 RIDING YOUR ATV UBD321E0 book Page 1 Wednesday June 2 2021 9 53 AM ...

Page 55: ...l 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 of...

Page 56: ...an 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 resulting ...

Page 57: ...r 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 r...

Page 58: ...and 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 t...

Page 59: ...w 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 whe...

Page 60: ...g 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 equivalent...

Page 61: ...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 afte...

Page 62: ... 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 fo...

Page 63: ...a 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 oper...

Page 64: ...fore 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 65: ...ould 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 skil...

Page 66: ...TV 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 control...

Page 67: ...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 UBD321E0 book Page 14 Wednesday June 2 202...

Page 68: ...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 hill I...

Page 69: ... proper procedures for going down hills 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 ...

Page 70: ...e 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 proce...

Page 71: ...ect 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 WA...

Page 72: ...imes 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 dam...

Page 73: ...ards 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 slippe...

Page 74: ...ecommended 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 se...

Page 75: ...rward 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 t...

Page 76: ...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 6 for more information about carbon monoxide WARNING EWB02691...

Page 77: ...it 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 1 2 UBD321E0 book Page 2 Wed...

Page 78: ...l 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 sta...

Page 79: ...ess and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 1300 800 2500 1600 2500 1600 5000 3200 hours 15 80 160 160 320 UBD321E0 book Page 4 Wednesday June 2 2021 9 53 AM ...

Page 80: ...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 if...

Page 81: ...lean and lubricate 10 Drive chain rollers Check for wear and replace if necessary 11 V belt Check for wear cracks or other damage and re place if necessary 12 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 13 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 14 Front knuckle piv ots Lubricate with l...

Page 82: ...leakage and correct if neces sary 20 Moving parts and cables Lubricate 21 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 22 Brake switch Check operation and correct if necessary 23 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 24...

Page 83: ...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 UBD321E0 book Page 8 Wednesday June 2 2021 9 53 AM ...

Page 84: ...g 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench 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...

Page 85: ... 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 the...

Page 86: ...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 su...

Page 87: ...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 recom ...

Page 88: ...s 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 Yamalu...

Page 89: ... 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 U...

Page 90: ...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 el...

Page 91: ...ment 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 UBD321E0 book Page 16 Wednesday June 2 2021 9 53 AM ...

Page 92: ...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 element...

Page 93: ...e 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 EBU33942 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the tailpipe bolt and nut 2 Remove the s...

Page 94: ...ent 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 may be performed by the owner as part of routine maintenance NOTICE ECB00481 The carburetor has been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical kn...

Page 95: ... 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 EBU38470 Adjusting the throttle lever free play 1 Throttle stop screw Engine idling speed 1600 1800 r min a b 1 1 Rubber cover 2 Throttle lever free play adjusting nut 3 Locknut 4 Throttle lever free play Throttle lever free play 1 5 4 0 mm 0 0...

Page 96: ... be adjusted by a Yamaha dealer at the inter vals specified in the periodic maintenance chart EBU29602 Brakes Replacement of brake components requires pro fessional knowledge Brake service should be performed by a Yamaha dealer WARNING EWB02572 Operating with improperly serviced or adjust ed brakes could lead to a loss in braking ability and an accident EBU34512 Checking the front and rear brake s...

Page 97: ... more than 18 mm 0 71 in from the end of the bolt the brake shoes need to be replaced 1 Upper adjusting bolt 2 Lower adjusting bolt 3 No more than 12 mm 0 47 in 3 2 1 1 Rear brake lever free play adjusting nut 2 Bolt 3 No more than 18 mm 0 71 in 1 2 3 UBD321E0 book Page 22 Wednesday June 2 2021 9 53 AM ...

Page 98: ...a to increase the lever free play and in direction b to decrease it 4 Tighten the lower locknut 5 While applying the front brake turn out the upper adjusting bolt until the upper and lower cable lengths are equal The cable joint will become vertical 1 Front brake lever free play Front brake lever free play 20 0 25 0 mm 0 79 0 98 in 1 1 Upper locknut 2 Upper adjusting bolt 3 Lower locknut 4 Lower a...

Page 99: ...er free play Periodically check the rear brake lever free play and adjust if necessary Turn the adjusting nut in direction a to increase the brake lever free play and in direction b to de crease it 1 Cable joint 1 a a a a 1 Rear brake lever free play Rear brake lever free play 30 0 40 0 mm 1 18 1 57 in 1 UBD321E0 book Page 24 Wednesday June 2 2021 9 53 AM ...

Page 100: ...st be touching the ground To check the drive chain slack 1 Place the ATV on a level surface 2 Move the ATV back and forth to locate the tightest portion of the drive chain 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 1 Rear brake lever free play adjusting nut 1 a b Drive chai...

Page 101: ...r brake lever free play adjust ing nut 3 Loosen the locknut 1 Bolt 1 Nut 1 1 1 Rear brake lever free play adjusting nut 1 Drive chain slack adjusting nut 2 Locknut 1 1 2 a b UBD321E0 book Page 26 Wednesday June 2 2021 9 53 AM ...

Page 102: ...and then the bolts and nuts to their specified torques 6 Adjust the rear brake lever free play See page 9 24 EBU24886 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECB00562 The drive chain...

Page 103: ... smoothly have a Yamaha dealer check or replace it WARNING EWB02582 Inspect cables frequently and replace if damaged Corrosion can result when the ca ble sheaths become damaged and cables can also become frayed or kinked which could restrict the operation of controls and lead to an accident or injury Always make sure all control cables work smoothly before you begin riding in cold weather If the c...

Page 104: ... 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 EBU36392 Lubricating the front arm pivots The front arm pivots must be lubricated at the in tervals specified in the periodic maintenance chart Recommended lubricant Lithium soap based grease UBD321E0 book Page 29 Wednesday June 2 2021 9 53 AM ...

Page 105: ...e chart 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 1 Grease nipple Recommended lubricant Lithium soap based grease 1 1 1 Grease nipple Recommended lubricant Lithium soap based grease 1 UBD321E0 book Page 30 Wednesday June 2...

Page 106: ... a Yamaha dealer WARNING EWB02161 Battery electrolyte is poisonous and danger ous as it contains sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediate...

Page 107: ...as specified on the battery itself Select a suitable charger and follow the manu facturer s instructions NOTICE ECB00933 To charge a VRLA valve regulated lead acid battery a special battery charger is required Using a conventional battery charger will dam age the battery To store the battery If the ATV will not be used for more than one month remove the battery fully charge it and then place it in...

Page 108: ...ct the positive battery lead first then connect the negative battery lead by installing their bolt NOTICE When installing the bat tery the main switch must be off and the positive lead must be connected before the negative lead ECB01111 3 Hook the battery band 4 Install the seat See page 5 13 TIP Make sure the positive and negative battery leads are installed as shown Fully charge the battery befo...

Page 109: ...e specified amperage WARNING Always use a fuse of the spec ified rating and never use a substitute ob ject in place of the proper fuse An improper fuse or a substitute object can cause damage to the electrical system which could lead to a fire EWB02173 4 Turn on the main switch and start the engine 5 Install the seat 6 If the fuse immediately blows again have a Yamaha dealer check the vehicle EBU3...

Page 110: ...ng in the forward rotating direction of the wheel and then install the wheel bolts 2 Lower the ATV to the ground 3 Tighten the wheel bolts to the specified torques 1 Wheel bolt 1 1 1 Arrow mark 2 Forward rotating direction 3 Wheel bolt Tightening torques Front wheel bolt 45 N m 4 5 kgf m 33 lb ft Rear wheel bolt 45 N m 4 5 kgf m 33 lb ft 3 1 2 UBD321E0 book Page 35 Wednesday June 2 2021 9 53 AM ...

Page 111: ...ny repair take it to a Yamaha dealer whose 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 o...

Page 112: ...V 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 battery lea...

Page 113: ...akes 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 dir...

Page 114: ... 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 Pe...

Page 115: ...rame 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 31 UBD321E0 book Page 3 Wednesday June 2 2021 9 53 AM ...

Page 116: ...aximum load 82 0 kg 181 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 90 cm Bore stroke 47 0 51 8 mm 1 85 2 04 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 UBD321E0 book...

Page 117: ...amount 0 9 L 0 24 US gal 0 20 Imp gal Carburetor Type quantity H66D16 1 Front tire Size AT18 x 7 8 Manufacturer model DURO DI2017 Rear tire Size AT18 x 9 8 Manufacturer model DURO DI2016 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 118: ...11 3 11 Battery Model GTX5L BS Voltage capacity 12 V 4 0 Ah UBD321E0 book Page 3 Wednesday June 2 2021 9 53 AM ...

Page 119: ...in reverse 7 3 E Engine break in 7 4 Engine cold start 7 1 Engine idling speed 9 19 Engine oil 6 3 9 10 Engine starting a warm 7 3 Engine stop switch 5 2 F Front and rear brake shoes checking 9 21 Front arm pivots lubricating 9 29 Front knuckle pivots lubricating 9 30 Fuel 5 9 6 3 Fuel cock 5 10 Fuel tank cap 5 8 Fuse replacing 9 34 H Handlebar switches 5 2 I Identification numbers 1 1 Indicator l...

Page 120: ...ifications 11 1 Speed limiter 5 3 Starter choke 5 12 Start switch 5 2 Steering shaft lubricating 9 30 Storage 10 2 T Throttle lever 5 2 6 3 Throttle lever free play adjusting 9 20 Tires 6 3 Transmission 6 3 Transmission oil 9 14 Troubleshooting 9 36 Troubleshooting chart 9 37 V Valve clearance 9 21 Vehicle identification number 1 1 W Wheel hub bearings checking 9 29 Wheel installing 9 35 Wheel rem...

Page 121: ...UBD321E0 book Page 3 Wednesday June 2 2021 9 53 AM ...

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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