Yamaha YFZ05YYXH Owner'S Manual Download

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DIC183

YFZ05YYXH

OWNER’S MANUAL

MANUEL DU PROPRIÉTAIRE

MANUAL DEL PROPIETARIO

BW4-F8199-60

READ THIS MANUAL CAREFULLY!

It contains important safety information.

LIRE ATTENTIVEMENT CE MANUEL!

Il comprend d’importantes informations de sécurité.

¡LEA ESTE MANUAL ATENTAMENTE!

Contiene indicaciones importantes acerca de la seguridad.

Summary of Contents for YFZ05YYXH

Page 1: ... DEL PROPIETARIO BW4 F8199 60 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad ...

Page 2: ...DIC183 Original instructions Notice originale Manual original PRINTED IN TAIWAN 2016 04 ...

Page 3: ...NUAL CAREFULLY It contains important safety information WARNING OWNER S MANUAL YFZ05YYXH This ATV should not be ridden by anyone under 6 years of age BW4 F8199 60 E0 UBW460E0 book Page 1 Monday May 23 2016 11 12 AM ...

Page 4: ...UROPE N V Koolhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Akihiro Tsuzuki Date of Issue If applicable and to the other relevant Directives of EEC to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the followi...

Page 5: ...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 6: ...s 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 you...

Page 7: ... 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 vehicle or other property A TIP provides key info...

Page 8: ... road or motorway Please check your local riding laws and regulations before operating this ATV EBU33790 YFZ05YYXH OWNER S MANUAL 2016 by Yamaha Motor Co Ltd 1st edition March 2016 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Taiwan UBW460E0 book Page 1 Monday May 23 2016 11 12 AM ...

Page 9: ...ke lever 4 6 Parking brake 4 6 Kickstarter 4 7 Fuel tank cap 4 8 Fuel 4 8 Fuel cock 4 10 Starter choke 4 11 Seat 4 12 Adjusting the rear shock absorber assembly 4 13 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Transmission oil 5 3 Front and rear brakes 5 3 Throttle lever 5 3 Drive chain 5 3 Tires 5 3 Chassis fasteners 5 6 Instruments and switches 5 6 OPERATION 6 1 Starting a cold engine 6 1 S...

Page 10: ...er element 8 16 Cleaning the spark arrester 8 19 Adjusting the carburetor 8 20 Adjusting the engine idling speed 8 20 Adjusting the throttle lever free play 8 21 Valve clearance 8 22 Brakes 8 22 Checking the front and rear brake shoes 8 22 Adjusting the front brake lever free play 8 23 Adjusting the rear brake lever free play 8 25 Drive chain slack 8 26 Cleaning and lubricating the drive chain 8 2...

Page 11: ...CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 INDEX 12 1 UBW460E0 book Page 3 Monday May 23 2016 11 12 AM ...

Page 12: ... all of the labels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a re placement label from your Yamaha dealer UBW460E0 book Page 1 Monday May 23 2016 11 12 AM ...

Page 13: ...1 2 1 For Europe 6 7 1 4 5 2 3 UBW460E0 book Page 2 Monday May 23 2016 11 12 AM ...

Page 14: ...1 3 1 BD3 F816R 20 BW4 F816L 50 1 3 2 UBW460E0 book Page 3 Monday May 23 2016 11 12 AM ...

Page 15: ...BW4 F156A 10 YFZ50 2 0 kW 100 kg BD3 F817L 20 YAMAHAMOTORCO LTD 2500SHINGAI IWATA JAPAN 2016 13 8 kPa 0 14 kgf cm 2 0 psi 13 8 kPa 0 14 kgf cm 2 0 psi BW4 F816M M0 5 4 7 6 UBW460E0 book Page 4 Monday May 23 2016 11 12 AM ...

Page 16: ...equired for children under age 16 Use from 16 years old Operating this ATV if you are under the age of 16 increases your chance of severe injury or death Use from 6 years old Operating this ATV if you are under the age of 6 increases your chance of severe injury or death Adult supervision required for children under age 16 Use from 10 years old Operating this ATV if you are under the age of 10 inc...

Page 17: ... tires are cold Turning the ATV in 4WD LOCK DIFF LOCK takes more effort Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control Adjust the tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death NEVER store fuel or flammable liquids NEVER use with drugs or alcohol UBW460E0 book Page 6 Monday May 23...

Page 18: ...ight limit Weight on the trailer tongue Overloading can cause loss of control Loss of control can result in severe injury or death This pictogram shows the loading limits and or maximum load capacity for this ATV Follow all load limits and other loading guidelines in this manual Load may include the driver passenger human protective gear accessories goods luggage and all other load related items M...

Page 19: ...1 8 1 For Mexico 1 3 4 2 UBW460E0 book Page 8 Monday May 23 2016 11 12 AM ...

Page 20: ...1 9 1 BD3 F816R 20 BW4 F816L 50 1 2 UBW460E0 book Page 9 Monday May 23 2016 11 12 AM ...

Page 21: ...1 10 1 BD3 F816P 50 13 8 kPa 0 14 kgf cm 2 0 psi 13 8 kPa 0 14 kgf cm 2 0 psi BW4 F816M M0 3 4 UBW460E0 book Page 10 Monday May 23 2016 11 12 AM ...

Page 22: ...1 11 1 For Oceania 1 3 4 2 UBW460E0 book Page 11 Monday May 23 2016 11 12 AM ...

Page 23: ... 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 24: ...ER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH BD3 F151H 00 2 0 13 8 2 0 13 8 1 8 12 4 1 8 12 4 90 41 BW4 F816M 60 3 4 UBW460E0 book Page 13 Monday May 23 2016 11 12 AM ...

Page 25: ...ine 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 safel...

Page 26: ...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 27: ...h 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 and...

Page 28: ...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 nigh...

Page 29: ...d 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 provided un der Loading when mounting accessories 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 ...

Page 30: ... 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 31: ... adjusted and the engine speed limiter plate is installed to limit the ATV to a walking speed See page 4 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 32: ...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 33: ...tch with cord lanyard 5 Rear shock absorber assembly spring preload adjusting ring 6 Kickstarter lever cap 7 Throttle stop screw 1 2 4 5 3 6 7 1 Spark arrester 2 Owner s tool kit 3 Fuse 4 Battery 5 Spark plug 6 Engine oil filler cap 7 Transmission oil filler cap 1 2 3 4 5 6 7 UBW460E0 book Page 1 Monday May 23 2016 11 12 AM ...

Page 34: ...urchased may differ slightly from the figures shown in this manual 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 1 2 3 7 6 5 4 UBW460E0 book Page 2 Monday May 23 2016 11 12 AM ...

Page 35: ...systems are off The key can be re moved EBU18066 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 UBW4...

Page 36: ...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 37: ...will return to an idle any time the throttle lever is re leased Before starting the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released EBU36330 Speed limiter Your ATV was delivered with two speed limiter de vices A vehicle speed limiter adjusting screw and a removable engine speed limiter plate Yamaha recommends ...

Page 38: ...djust 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 turn the adjusting screw in direction a To decrease the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction b Do not turn the adjusting screw out more than 11 mm 0 43 in or the thro...

Page 39: ...emove the plate as shown 3 Tighten the screws 4 Install the panel TIP Store the engine speed limiter plate with the own er s manual so that it is readily available whenever you want to reduce top engine speed EBU18392 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 pla...

Page 40: ...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 41: ...battery voltage is low The kickstarter lever is lo cated under the seat See page 4 12 1 Remove the kickstarter lever cap 2 Install the kickstarter lever 3 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 UBW460E0 book Page 7 Monday May 23 2016 11 12 AM ...

Page 42: ...turning it counter clockwise EBU18757 Fuel Make sure there is sufficient gasoline in the tank 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 th...

Page 43: ...ce fuel may deteriorate painted surfaces or plastic parts ECB00982 4 Turn the fuel tank cap fully clockwise to make sure it is securely closed WARNING EWB02532 Gasoline is poisonous and can cause injury or death Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor 1 Maximum f...

Page 44: ...e number of 91 or higher 95 or higher for Europe If knocking or pinging occurs use a gasoline of a different brand Use of unleaded fuel will extend spark plug life and reduce maintenance costs 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 OFF With the fuel...

Page 45: ...e fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18851 Starter choke Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke 1 Arrow mark positioned over ON 1 1 Arrow mark ...

Page 46: ...While pushing the rear of the seat down pull the seat lock lever upward and then pull up the seat at the rear To install the seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear Make sure that the seat is securely fitted 1 Starter choke 1 a b 1 Seat 2 Seat lock lever 1 2 UBW460E0 book Page 12 Monday May 23 2016 11 12 AM ...

Page 47: ...ng 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 TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Projection 2 Seat holder 2 1 1 Spring preload adjusting ring 2 Position indicator 1 2 3 4 5 ...

Page 48: ...4 14 4 1 Special wrench Spring preload setting Minimum soft 1 Standard 1 Maximum hard 5 1 UBW460E0 book Page 14 Monday May 23 2016 11 12 AM ...

Page 49: ...ore using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 8 5 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 5 3 8 11 Transmission oil Check ATV for oil leakage Correct i...

Page 50: ...icate if necessary 5 3 8 26 8 28 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 5 3 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 29 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 5 6 Instruments and swi...

Page 51: ...ake 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 8 22 EBU19762 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when rel...

Page 52: ...ditions EWB02542 Set tire pressures to the following specifications The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Recommended tire pressure Front 13 8 kPa 0 14 kgf cm 2 0 psi Rear 13 8 kPa 0 14 kgf cm 2 0 psi Minimum tire pressure Front 12 4...

Page 53: ...tubeless tires with valves WARNING EWB02552 Use of improper tires on this ATV may cause loss of control increasing your risk of an acci dent After extensive tests only the tires listed below have been approved for this model by Yamaha Motor Co Ltd 1 Low pressure tire gauge 1 1 Tire wear limit UBW460E0 book Page 5 Monday May 23 2016 11 12 AM ...

Page 54: ...ombinations may not be appropriate EBU19841 Chassis fasteners 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 Front Manufacturer model DURO DI2040 Size AT16 x 6 5 7 Type Tubeless Rear Manufacturer model DURO DI2041 Size AT16 x 7 7 Type Tubeless UBW460E0 book Page 6 M...

Page 55: ...See the Engine break in section on page 6 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 Use the starter choke in reference to the fi gure Position 1 Cold engine start with ambient temperature below 5 C 40 F Position 2 ...

Page 56: ...ine is started with the starter choke in position 1 the starter choke should be returned to position 2 to warm up the en gine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 7 Continue warming up the engine until it idles smoothly then return the starter choke to position 3 before riding TIP The engine is warm when it resp...

Page 57: ...0 mi or 20 hours The various parts in the engine wear and polish themselves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in en gine overheating must be avoided 0 120 km 0 75 mi or 0 10 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 ...

Page 58: ...ross 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 Parking...

Page 59: ...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 consideri...

Page 60: ... 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 61: ...7 1 7 EBU21142 RIDING YOUR ATV UBW460E0 book Page 1 Monday May 23 2016 11 12 AM ...

Page 62: ...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 63: ...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 64: ...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 65: ...ecreases the maximum speed of the ATV Turning in the adjusting screw decreases top speed and turning it out increases top speed See page 4 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 lim...

Page 66: ...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 67: ...ng 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 equivalen...

Page 68: ... 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 69: ...s 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 f...

Page 70: ...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 71: ...efore trying more difficult ter rain Set the parking brake and follow the instruction on page 6 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 72: ...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 ski...

Page 73: ...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 contro...

Page 74: ... 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 UBW460E0 book Page 14 Monday May 23 2016 ...

Page 75: ...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 hil...

Page 76: ...lls 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 77: ...ly 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 78: ...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 79: ...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 da...

Page 80: ...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 81: ...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 82: ...orward 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 7 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 83: ...urn 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 2 8 for more information about carbon monoxide WARNING EWB02691 ...

Page 84: ... are intended to assist you in the performance of pre ventive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP There is a low pressure tire gauge located 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 Owner s tool kit...

Page 85: ...equire special tools data and technical 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 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adju...

Page 86: ...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 20 80 160 160 320 UBW460E0 book Page 4 Tuesday June 7 2016 4 17 PM ...

Page 87: ...ols data and technical 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 20 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 ...

Page 88: ...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 89: ... 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 90: ...8 8 8 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 UBW460E0 book Page 8 Monday May 23 2016 11 12 AM ...

Page 91: ...the panel Place the panel in the original position and install the bolts EBU23214 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 and lubri cation chart In addition the condition of the spark plug ...

Page 92: ...ulator 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 UBW460E0 book Page 10 Monday May 23 2016...

Page 93: ...ecified 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 EBU36791 Engine oil The engine oil level should be checked before each ride In addition the oil must be changed at the interv...

Page 94: ...en wipe the engine oil dipstick off with a clean rag 4 Insert the dipstick into the filler hole screw it in and then remove it again to check the oil level TIP The engine oil should be between the minimum and maximum level marks 5 If the engine oil is at or below the minimum level mark add sufficient oil of the recom mended type to raise it to the correct level 1 Engine oil filler cap 1 1 Engine o...

Page 95: ...ne oil drain bolt to drain the oil from the crankcase NOTICE When remov ing the engine oil drain bolt the compres sion spring oil strainer and O ring will fall out Take care not to lose these parts ECB00312 5 Clean the oil strainer with solvent 6 Apply a thin coat of clean engine oil to a new O ring 7 Install the oil strainer the compression spring the new O ring and the engine oil drain bolt Tigh...

Page 96: ...iately turn the engine off and check for the cause 12 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary EBU34472 Transmission oil The transmission case must be checked for oil leakage before each ride If any leakage is found have a Yamaha dealer check and repair the ATV In addition the transmission oil must be changed at the intervals specified ...

Page 97: ...ten the bolt to the specified torque 6 Refill with the specified amount of the recom mended oil NOTICE Make sure that no foreign material enters the transmission case ECB03380 1 Transmission oil filler cap 2 O ring 1 2 1 Transmission oil drain bolt 2 Gasket Tightening torque Transmission oil drain bolt 30 N m 3 0 kgf m 22 lb ft 1 2 UBW460E0 book Page 15 Monday May 23 2016 11 12 AM ...

Page 98: ...necessary replace the air filter element more frequently if you are rid ing in unusually 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 element and air fil ter case 1 Park the ATV on a level surface 2 Remove the seat See page 4 12 3 Remove the air filter case cover by unhooking the air...

Page 99: ...or gasoline to clean the air filter element because the engine could catch fire or ex plode EWB03540 5 Squeeze the excess solvent out of the air filter element and let it dry NOTICE Do not twist the air filter element when squeezing it ECB02310 1 Air filter case cover 2 Air filter case cover holder 1 2 1 Air filter element 1 UBW460E0 book Page 17 Monday May 23 2016 11 12 AM ...

Page 100: ...lement is properly seated in the air filter case Never operate the engine with the air filter ele ment removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Addi tionally operation without the air filter ele ment will affect carburetor jetting with subsequent poor performance and possi ble engine overheating ECB00462 10 Install the seat TIP...

Page 101: ...d then remove the gasket 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 4 Check the gasket for damage and replace it if necessary 5 Make sure the gasket is properly positioned then insert the tailpipe into the muffler and align the bolt holes 6 Install the bolts and tighten them t...

Page 102: ...and experience The adjust ment 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 knowl edge may result in poor performance of or damage to the engine EBU24001 Adjusting the engine idling speed The engine ...

Page 103: ... the intervals specified in the periodic maintenance and lubrication chart The throttle lever free play should measure 2 0 3 2 mm 0 08 0 13 in as shown Periodically check the throttle lever free play and if necessary adjust it as follows TIP The engine idling speed must be checked and adjusted if necessary before adjusting the throttle lever free play 1 Slide the rubber covers apart 2 Loosen the l...

Page 104: ...perly serviced or adjust ed brakes could lead to a loss in braking ability and an accident EBU34511 Checking the front and rear brake shoes The front and rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart Without disas sembling the brake this can be performed by checking the position of the brake lever free play adjusting bolts or...

Page 105: ...play must be checked and if necessary adjusted at the intervals speci fied in the periodic maintenance and lubrication chart The brake lever free play should measure 9 3 13 3 mm 0 37 0 52 in as shown If the free play is in correct adjust it as follows 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...

Page 106: ...nd 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 1 1 Upper locknut 2 Upper adjusting bolt 3 Lower locknut 4 Lower adjusting bolt 1 2 4 3 a b UBW460E0 book Page 24 Monday May 23 2016 11 12 AM ...

Page 107: ...y adjusted at the intervals speci fied in the periodic maintenance and lubrication chart The brake lever free play should measure 7 6 12 9 mm 0 30 0 51 in as shown If the free play is in correct adjust it as follows 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 1 UBW460E0 book Page...

Page 108: ...checking and adjusting the drive chain slack there should be no weight on the ATV and all tires must be touching the ground 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 1 Rear brake lever free play adjusting nut 1 a b Drive chain slack 6 0 12 0 mm 0 24 0 4...

Page 109: ... chain slack 1 Loosen the bolts and nuts 2 Loosen the rear 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 UBW460E0 book Page 27 Monday May 23 2016 11 12 AM ...

Page 110: ... rear brake lever free play See page 8 25 EBU36480 Cleaning and lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication 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 must be lubricated after wash ing the...

Page 111: ... 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 control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead ...

Page 112: ...periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smooth ly have a Yamaha dealer check the wheel hub bearings EBU36390 Lubricating the front arm pivots The front arm pivots must be lubricated at the in tervals specified in the periodic maintenance and lubrication chart UBW460E0 book Page 30 Monday May 23 2016 11 12 AM ...

Page 113: ...ion chart TIP For parts equipped with a grease nipple use a grease gun EBU25094 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the pe riodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease 1 Grease nipple 1 Recommended lubricant Lithium soap based grease 1 Grease nipple 1 UBW460E0 book Page 31 ...

Page 114: ...acid which can cau se 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 immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gase...

Page 115: ...ssible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional elec trical accessories NOTICE ECB00932 To charge a VRLA Valve Regulated Lead Acid battery a special constant voltage battery charger is required Using a conventional bat tery charger will damage the battery To store the battery If the ATV will not be used for mo...

Page 116: ... compartment 2 Connect 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 panel 1 Positive battery lead red 2 Negative battery lead black 2 1 UBW460E0 book Page 34 Monday May 23 2...

Page 117: ...RNING 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 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical s...

Page 118: ... bolts TIP When installing the wheel make sure its arrow mark points toward the rotating direction of the wheel 2 Lower the ATV to the ground 3 Tighten the wheel bolts to the specified torques 1 Wheel bolt 1 1 1 Arrow mark 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 1 UBW460E0 book Page 36 Monday May 23 2016 11 12 AM ...

Page 119: ...any 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 ...

Page 120: ...TV 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 le...

Page 121: ...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 122: ... this will prevent fuel depos its from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spa...

Page 123: ...ot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more infor mation on storing the battery see page 8 32 TIP Make any necessary repairs before storing the ATV...

Page 124: ...easurement 2 0 dB A EUR FRA GBR Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s EUR FRA GBR Uncertainty of measurement 0 1 m s EUR FRA GBR Vibration on handle EN1032 ISO5008 4 7 m s EUR FRA GBR Uncertainty of measurement 0 4 m s EUR FRA GBR Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder Displacement 49 cm Bore stroke 39 0 41 4 mm 1 54 1 63 in Compression ...

Page 125: ... 1 48 US gal 1 23 Imp gal Fuel reserve amount 0 7 L 0 18 US gal 0 15 Imp gal Carburetor Type quantity VM12 Spark plug s Manufacturer model NGK CR6HSA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Dry centrifugal automatic Transmission Secondary reduction system Chain drive Secondary reduction ratio 38 13 2 920 Transmission type V belt automatic Operation Centrifugal automatic type Ch...

Page 126: ...gf cm 2 0 psi Rear 13 8 kPa 0 14 kgf cm 2 0 psi Minimum Front 12 4 kPa 0 124 kgf cm 1 8 psi Rear 12 4 kPa 0 124 kgf cm 1 8 psi Front wheel Wheel type Panel wheel Rim size 7 x 5 2AT Rear wheel Wheel type Panel wheel Rim size 7 x 5 2AT Front brake Type Mechanical leading trailing drum brake Operation Right hand operation Rear brake Type Mechanical leading trailing drum brake Operation Left hand oper...

Page 127: ...sion and exposure levels this cannot be used reliably to determine whether or not further precautions are required Factors that influence the actual level of exposure of work force include the characteristics of the work room the other sources of noise etc i e the number of machines and other adjacent process es and the length of time for which an operator is exposed to the noise Also the permissi...

Page 128: ...BER MODEL LABEL INFORMATION EBU26031 Vehicle identification number The vehicle identification number is stamped into the frame TIP The vehicle identification number is used to iden tify your ATV EBU26051 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts fr...

Page 129: ...11 2 11 1 Model label 1 UBW460E0 book Page 2 Monday May 23 2016 11 12 AM ...

Page 130: ...6 1 Engine idling speed 8 20 Engine oil 5 3 8 11 Engine starting a warm 6 3 Engine stop switch 4 1 Engine stop switch with lanyard 4 2 F Front and rear brake shoes checking 8 22 Front arm pivots lubricating 8 30 Front knuckle pivots lubricating 8 31 Fuel 4 8 5 3 Fuel cock 4 10 Fuel tank cap 4 8 Fuse replacing 8 35 H Handlebar switches 4 1 I Identification numbers 11 1 Instruments and switches 5 6 ...

Page 131: ...r 4 3 Starter choke 4 11 Start switch 4 2 Steering shaft lubricating 8 31 Storage 9 2 T Throttle lever 4 3 5 3 Throttle lever free play adjusting 8 21 Tires 5 3 Transmission oil 5 3 8 14 Troubleshooting 8 37 Troubleshooting chart 8 38 V Valve clearance 8 22 Vehicle identification number 11 1 W Wheel hub bearings checking 8 30 Wheel installing 8 36 Wheel removing 8 35 UBW460E0 book Page 2 Monday Ma...

Page 132: ... 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 FOLLOW ALL INSTRUCTIONS ...

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