Мануал yamaha grizzly 125

This Ai TV should not be ridden by anyone under 16 years of age.

OWNERS MANUAL

LIT-11626-20-07 1C5-28199-13

YFM125GW WARNING

READ THIS MANUAL CAREFULLY! It contains important safety information.

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INTRODUCTION

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Congratulations on your purchase of the Yamaha YFM125GW. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this ATV.

This manual includes important safety information. It provides information about special tech- niques and skills necessary to ride the ATV.

It also includes basic maintenance and inspection proce- dures. If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE:

READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE- LY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.

NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMA- TION.

THIS ATV, AND ANY OTHER ATV OVER 90 cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.

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IMPORTANT MANUAL INFORMATION

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FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations:

* Product and specifications are subject to change without notice.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or repairing the ATV.

A CAUTION indicates special precautions that must be taken to avoid damage to the ATV.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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IMPORTANT NOTICE

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Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this ATV.

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AFFIX DEALER

LABEL HERE

YFM125GW OWNERS MANUAL

2006 by Yamaha Motor Corporation, U.S.A. 1st edition, March 2006

All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

is expressly prohibited. Printed in Japan.

P/N LIT-11626-20-07

WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

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TABLE OF CONTENTS

SAFETY INFORMATION ………………………… 1-1

LOCATION OF THE WARNING AND SPECIFICATION LABELS ………………………. 2-1

DESCRIPTION ………………………………………. 3-1 Left view …………………………………………….. 3-1 Right view…………………………………………… 3-1 Controls and instruments ……………………… 3-2

INSTRUMENT AND CONTROL FUNCTIONS ………………………………………….. 4-1

Main switch ……………………………………….. 4-1 Indicator lights ……………………………………. 4-2 Handlebar switches …………………………….. 4-2 Throttle lever ……………………………………… 4-3 Speed limiter ……………………………………… 4-4

Front brake lever …………………………………. 4-5 Rear brake lever …………………………………. 4-5 Parking brake ……………………………………… 4-6 Drive select lever ………………………………… 4-7 Fuel tank cap ……………………………………… 4-7 Fuel …………………………………………………… 4-8 Fuel cock …………………………………………… 4-9 Starter (choke) ………………………………….. 4-11 Seat ………………………………………………… 4-11 Front carrier ……………………………………… 4-12 Rear carrier ………………………………………. 4-12

PRE-OPERATION CHECKS ……………………..5-1 Pre-operation check list ……………………….. 5-1 Fuel …………………………………………………… 5-3 Engine oil …………………………………………… 5-3 Transmission oil ………………………………….. 5-3 Front and rear brakes ………………………….. 5-3 Throttle lever ………………………………………. 5-4 Drive chain …………………………………………. 5-4 Tires ………………………………………………….. 5-5 Measuring the tire pressure ………………….. 5-6 Tire wear limit …………………………………….. 5-7 Chassis fasteners ……………………………….. 5-7 Instruments, lights and switches ……………. 5-7 Battery ………………………………………………. 5-7

OPERATION……………………………………………6-1 Starting a cold engine ………………………….. 6-1

Starting a warm engine ……………………….. 6-3 Operating the drive select lever and

driving in reverse ………………………………. 6-3 Engine break-in ………………………………….. 6-4 Parking ……………………………………………… 6-5 Parking on a slope ……………………………… 6-6 Accessories and loading ……………………… 6-6

RIDING YOUR ATV ……………………………….. 7-1 GETTING TO KNOW YOUR ATV………….. 7-2 RIDE WITH CARE AND GOOD

JUDGEMENT ……………………………………. 7-2 BE CAREFUL WHERE YOU RIDE………. 7-12 TURNING YOUR ATV ……………………….. 7-16 CLIMBING UPHILL ……………………………. 7-17 RIDING DOWNHILL…………………………… 7-21 CROSSING A SLOPE………………………… 7-22 CROSSING THROUGH SHALLOW

WATER ………………………………………….. 7-23 RIDING OVER ROUGH TERRAIN ………. 7-25 SLIDING AND SKIDDING…………………… 7-25 WHAT TO DO IF… …………………………….. 7-27 WHAT TO DO… ………………………………… 7-27

PERIODIC MAINTENANCE AND MINOR REPAIR…………………………………………………. 8-1

Owners manual and tool kit …………………. 8-1 Periodic maintenance chart for the emission

control system ………………………………….. 8-3

General maintenance and lubrication chart …………………………………………………8-5

Checking the spark plug ………………………. 8-8 Engine oil …………………………………………. 8-10 Transmission oil ………………………………… 8-12 Cleaning the engine and V-belt case air

filter elements ………………………………….8-15 Cleaning the spark arrester ………………… 8-21 V-belt case drain plug ………………………… 8-23 Adjusting the carburetor ……………………… 8-23 Adjusting the engine idling speed ………… 8-24 Adjusting the throttle cable free play …….. 8-25 Valve clearance ………………………………… 8-25 Checking the front and rear brake

shoes ……………………………………………..8-26 Adjusting the front brake lever free play .. 8-27 Adjusting the rear brake lever free play … 8-32 Drive chain slack ……………………………….. 8-33 Lubricating the drive chain ………………….. 8-36 Checking and lubricating the cables …….. 8-37 Checking and lubricating the front and

rear brake levers ………………………………8-37 Checking the wheel bearings ………………. 8-38 Lubricating the upper and lower arm

pivots ……………………………………………..8-38 Lubricating the knuckle shafts …………….. 8-39 Lubricating the steering shaft ………………. 8-40 Battery …………………………………………….. 8-40 Replacing the fuse …………………………….. 8-44

Replacing a headlight bulb …………………. 8-44 Adjusting a headlight beam ………………… 8-46 Replacing the tail/brake light bulb ……….. 8-47 Removing a wheel …………………………….. 8-48 Installing a wheel ………………………………. 8-48 Troubleshooting ……………………………….. 8-49 Troubleshooting chart ……………………….. 8-51

CLEANING AND STORAGE…………………….. 9-1 Cleaning ……………………………………………. 9-1 Storage ……………………………………………… 9-2

SPECIFICATIONS ……………………………….. 10-1

CONSUMER INFORMATION …………………. 11-1 Identification numbers ……………………….. 11-1 Noise regulation ……………………………….. 11-3 Maintenance record ………………………….. 11-4 YAMAHA MOTOR CORPORATION,

U.S.A. ATV LIMITED WARRANTY ……. 11-5 YAMAHA EXTENDED SERVICE

(Y.E.S.) ………………………………………….. 11-7

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EBU17430

SAFETY INFORMATION

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AN ATV IS NOT A TOY AND CAN BE HAZARD- OUS TO OPERATE.

An ATV handles differently from other vehicles, in- cluding motorcycles and cars. A collision or roll- over can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precau- tions. SEVERE INJURY OR DEATH can result if you do not follow these instructions:

Read this manual and all labels carefully and fol- low the operating procedures described.

Never operate an ATV without proper training or instruction.

Take a Training Course.

Beginners should receive training from a certified instruc- tor. Contact an authorized ATV dealer or call 1- 800-887-2887 to find out about the training courses nearest you.

Always follow the age recommendation:

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 safely.

Never carry a passenger on an ATV.

Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, park- ing lots and streets.

Never operate an ATV on any public street, road or highway, even a dirt or gravel one.

Never operate an ATV without wearing an ap- proved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or a jacket, and long pants.

Never consume alcohol or drugs before or while operating this ATV.

Never operate at speeds too fast for your skills or the riding conditions. Always go at a speed

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that is proper for the terrain, visibility, operating conditions, and your experience.

Never attempt wheelies, jumps, or other stunts.

Always inspect your ATV each time you use it to make sure it is in safe operating condition. Al- ways follow the inspection and maintenance procedures and schedules described in this manual.

Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation.

Always go slowly and be extra careful when op- erating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

Never operate on excessively rough, slippery or loose terrain until you have learned and prac- ticed the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

Always follow proper procedures 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 before you start up any hill. Never climb hills with excessively slippery or loose sur- faces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ve- hicle to lean sharply to one side. Go straight down the hill where possible.

Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose sur- faces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stall-

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ing, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight up- hill. Turn the ATV around and remount, following the procedure described in this manual.

Always check for obstacles before operating in a new area.

Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obsta- cles as described in this manual.

Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of con- trol.

Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.

Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly.

Always use the size and type of tires specified in this manual.

Always maintain proper tire pressure as de- scribed in this manual.

Never modify an ATV through improper installa- tion or use of accessories.

Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow in- structions in this manual for carrying cargo or pulling a trailer. Allow greater distance for brak- ing.

FOR MORE INFORMATION ABOUT ATV SAFE- TY,

call the Consumer Products Safety Commis- sion at 1-800-638-2772, or the ATV Distributors Safety Hotline at 1-800-852-5344.

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EWB00021

EWB00030

WARNING

POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or ex- haust pipe/muffler when refueling. Never refuel while smoking, or in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heat- ers and clothes dryers. When transporting the ATV in another vehi- cle, be sure it is kept upright and that the fuel cock is in the OFF position. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause inju- ries.

HOW TO AVOID THE HAZARD If you should swallow some gasoline or in- hale a lot of gasoline vapor, or get some gas- oline in your eyes, seek medical help immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

WARNING

POTENTIAL HAZARD Starting or running the engine in a closed ar- ea.

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WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death with- in a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad- equate ventilation.

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LOCATION OF THE WARNING AND SPECIFICATION LABELS

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Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer.

WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. OPERATING TIRE PRESSURE: Set with tires cold Recommended : FRONT : 20 kPa, {0.20 kgf/cm2 } 2.9 psi

REAR : 25 kPa, {0.25 kgf/cm2 } 3.6 psi Minimum : FRONT : 17 kPa, {0.17 kgf/cm2 } 2.5 psi

REAR : 22 kPa, {0.22 kgf/cm2 } 3.2 psi Never set tire pressure below minimum. It could cause the tire to dislodge from the rim.

LOADING Maximum Vehicle Load : 105kg, (231 lbs). Includes weight of operator, cargo and accessories.

WARNING NEVER ride as a

passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.

1C5-21696-00

5FE-2151H-01

3

2 WARNING

UNDER 16

Operating this ATV if you are under

the age of 16 increases your chance

of severe injury or death.

NEVER operate this ATV if you are

under age 16.

5FE-21697-01

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5YT-2151E-30

DRIVE SELECT LEVER

8 Read owners manual carefully before operating.

8 When shifting the drive select lever, always be sure to stop the ATV and apply the rear brake.

5kg 11lbs 3LD-24877-A0

10kg 22lbs 1C5-24877-A0

sit here.NEVER 3MX-24875-A0

q WARNING Improper ATV use can result in SEVERE INJURY or DEATH.

ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE

GEAR NEVER operate : 9 without proper training or instruction. 9 at speeds too fast for your skills or

the conditions. 9 on public roads-a collision can occur

with another vehicle. 9 with a passenger-passengers affect balance

and steering and increase risk of losing control.

ALWAYS : 9 use proper riding techniques to avoid

vehicle overturns on hills and rough terrain and it turns. 9 avoid paved surfaces-pavement may

seriously affect handling and control. LOCATE AND READ OWNER’S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

5FE-21568-11

(For replacement manual, call 1-800-532-1558)

5FE- 1568-01

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EBU17680

DESCRIPTION

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Left view

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Right view

1. Front carrier 2. Starter (choke) 3. Fuel cock 4. Tail/brake light 5. Rear carrier 6. Spark arrester 7. Footboard

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1. Seat 2. Drive select lever 3. Headlight

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Controls and instruments

NOTE:

The ATV you have purchased may differ slightly

from the figures shown in this manual.

1. Rear brake lever 2. Parking brake 3. Reverse indicator light 4. Neutral indicator light 5. Front brake lever 6. Throttle lever 7. Main switch 8. Fuel tank cap 9. Handlebar switches

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EBU17720

INSTRUMENT AND CONTROL FUNCTIONS

WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

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Main switch

The positions of the main switch are as follows:

ON

All electrical systems are supplied with power, and the engine can be started. The key cannot be re- moved.

OFF

All electrical systems are off. The key can be re- moved.

1. Main switch

OFF ON

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Indicator lights

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Reverse indicator light

This indicator light comes on when the transmis- sion is in the reverse position.

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Neutral indicator light

This indicator light comes on when the transmis- sion is in the neutral position.

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Handlebar switches

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Engine stop switch ENG. STOP

Set this switch to RUN 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 situation. The engine will not start or run when this switch is set to OFF.

1. Reverse indicator light R 2. Neutral indicator light N

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1. Engine stop switch ENG. STOP 2. Start switch START 3. Light switch LIGHTS

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EBU18090

Start switch START

Push this switch to crank the engine with the start- er.

CAUTION:

ECB00050

See the starting instructions on page 6-1 prior

to starting the engine.

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Light switch LIGHTS

Set this switch to LO to turn on the low beams and the taillight. Set the switch to HI to turn on the high beams and the taillight. Set the switch to OFF to turn off all the lights.

CAUTION:

ECB00040

Do not use the headlights with the engine turned off for an extended period of time, oth- erwise the battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and

recharge it.

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Throttle lever

Once the engine is running, movement of the throt-

tle lever will increase the engine speed. Regulate the speed of the ATV by varying the throttle position. Because the throttle is spring- loaded, the ATV will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.

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.

1. Throttle lever

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EWB00200

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Speed limiter

Your ATV was delivered with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power avail-

able and the maximum speed of the ATV, turn the adjusting screw in direction (a). To de-

crease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b).

3. Tighten the locknut.

EWB00190

WARNING

POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident. HOW TO AVOID THE HAZARD Check the operation of the throttle lever be- fore you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you cant find or solve the problem yourself.

1. Adjusting screw 2. Locknut 3. No more than 12 mm (0.47 in)

WARNING

POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle.

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(a) (b)

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EBU18391

Front brake lever

The front brake lever is located on the right handle- bar. To apply the front brake, pull the brake lever toward the handlebar grip.

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Rear brake lever

The rear brake lever is located on the left handle- bar. To apply the rear brake, pull the brake lever to- ward the handlebar grip.

WHAT CAN HAPPEN The throttle cable could be damaged. Im- proper throttle operation could result. You could lose control, have an accident or be in- jured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 1.03.0 mm (0.040.12 in). (See page 8-25.)

1. Front brake lever

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EBU18450

Parking brake

Use the parking brake before starting the engine or parking the ATV, especially on a slope. Apply 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.

EWB00170

1. Rear brake lever

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1. Parking brake lock plate 2. Parking brake lever (locked position)

WARNING

POTENTIAL HAZARD Improper use of the parking brake.

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EBU18581

Drive select lever

The drive select lever is used to shift your ATV into the forward, neutral and reverse positions. See the Operating the drive select lever and driving in re- verse section on page 6-3 for the drive select lever operation.

EBU18720

Fuel tank cap

Remove the fuel tank cap by turning it counter- clockwise.

WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before start- ing the engine. This could cause loss of con- trol or a collision. The brake could overheat if you ride the ATV without releasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely. HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine. Always be sure you have released the park- ing brake before you begin to ride.

1. Neutral N 2. Forward F 3. Reverse R 4. Drive select lever

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EBU18730

Fuel

Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.

CAUTION:

ECB00070

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston

1. Fuel tank cap

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1. Fuel level 2. Fuel tank ller tube

Recommended fuel: UNLEADED GASOLINE ONLY

Fuel tank capacity: 7.0 L (1.85 US gal) (1.54 Imp.gal)

Fuel reserve amount: 1.3 L (0.34 US gal) (0.29 Imp.gal)

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rings, as well as to the exhaust system.

Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research oc- tane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premi- um unleaded fuel. Unleaded fuel will give you long- er spark plug life and reduced maintenance cost.

Gasohol

There are two types of gasohol: gasohol contain- ing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol con- tent does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha be- cause it can cause damage to the fuel system or ATV performance problems.

EWB00270

EBU18820

Fuel cock

The fuel cock supplies fuel from the tank to the car- buretor while also filtering it. The fuel cock lever positions are explained as fol- lows and shown in the illustrations.

WARNING

POTENTIAL HAZARD Improper care when refueling.

WHAT CAN HAPPEN Fuel can spill, which can cause a fire and se- vere injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely. Do not refuel right after the engine has been running and is still very hot.

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OFF

With the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position 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

RES

ON FUEL

OFF

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1. Arrow mark positioned over ON

ON FUEL

RES

OFF

ON

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RES

This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to ON!

EBU18840

Starter (choke)

Starting a cold engine requires a richer air-fuel mix- ture, which is supplied by the starter (choke). Move the starter (choke) in direction (a) to turn on

the starter (choke). Move the starter (choke) in direction (b) to turn off the starter (choke). See the Starting a cold engine section on page 6- 1 for proper operation.

EBU18880

Seat

To remove the seat

Pull the seat lock lever upward and pull up the seat at the rear.

1. Arrow mark positioned over RES

OFF

ON FUEL

RES

RES

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1. Fully open 2. Half open 3. Closed 4. Starter (choke)

(b)

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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.

NOTE:

Make sure that the seat is securely fitted.

EBU18960

Front carrier

Do not exceed the load limit of 5.0 kg (11 lb) for the front carrier.

Do not exceed the maximum load of 105.0 kg (231 lb) for the ATV.

EBU18970

Rear carrier

Do not exceed the load limit of 10.0 kg (22 lb) for the rear carrier.

Do not exceed the maximum load of 105.0 kg

1. Seat lock lever

1

1. Projection 2. Seat holder

1 2

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(231 lb) for the ATV.

WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

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EBU19200

PRE-OPERATION CHECKS

EBU19210

Pre-operation check list

Before operating this ATV, be sure to check the items listed in the following table.

NOTE:

The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the Periodic maintenance and lubrication chart on page 8-3 to determine which service should be performed by a

Yamaha dealer.

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 specied level if necessary.

Check ATV for oil leakage. Correct if necessary. 5-3, 8-10

Transmission oil

Check oil level in transmission case, and add recommended oil to specied level if necessary.

Check ATV for oil leakage. Correct if necessary. 5-3, 8-12

Front brake

Check operation, and correct if necessary.

Lubricate cable if necessary.

Check lever free play, and adjust if necessary. 5-3, 8-26, 8-27

Rear brake

Check operation, and correct if necessary.

Lubricate cable if necessary.

Check lever free play, and adjust if necessary. 5-3, 8-26, 8-32

Throttle lever

Make sure that operation is smooth. Lubricate cable and lever hous- ing if necessary.

Check cable free play, and adjust if necessary. 5-4, 8-25

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EWB00470

Control cables

Make sure that operation is smooth. Lubricate if necessary. 8-37

Drive chain

Check chain slack, and adjust if necessary.

Check chain condition. Lubricate if necessary. 5-4, 8-33, 8-36

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. 5-5, 5-6, 5-7

Brake levers

Make sure that operation is smooth. Lubricate lever pivoting points if necessary. 8-37

Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened. 5-7

Instruments, lights and switches

Check operation, and correct if necessary. 5-7

Battery

Check electrolyte level. Fill with distilled water if necessary. 5-7, 8-40

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Own- ers Manual.

ITEM ROUTINE PAGE

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EBU19530

Fuel

Make sure that there is sufficient fuel in the tank. (See page 4-8.)

EWB00500

EBU19560

Engine oil

Make sure that the engine oil is at the specified lev- el. Add oil as necessary. (See page 8-10.)

EBU19580

Transmission oil

Make sure that the transmission oil is at the speci- fied level. Add oil as necessary. (See page 8-12.)

EBU19640

Front and rear brakes

Brake levers

Check for correct free play in the brake levers. If the free play is incorrect, adjust it. (See pages 8-27 and 8-32.)

Check operation of the levers. They should move smoothly and there should be a firm feel- ing when the brake is applied. If not, have the ATV checked by a Yamaha dealer.

Brake operation

Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, check the brakes for wear. (See page 8-26.)

EWB00530

WARNING

POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and se- vere injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely. Do not refuel right after the engine has been running and is still very hot.

WARNING

POTENTIAL HAZARD Riding with improperly operating brakes.

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EBU19761

Throttle lever

Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary.

EBU19770

Drive chain

Check the condition of the drive chain and check the drive chain slack. Lubricate and adjust the drive chain as necessary. (See page 8-33.)

WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any prob- lem with the brakes. If a problem cannot be corrected by the adjustment procedures pro- vided in this manual, have the ATV checked by a Yamaha dealer.

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EBU19781

Tires

EWB00561

WARNING

POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or opera- tion of this ATV with improper or uneven tire pressure, may cause loss of control, increas- ing your risk of accident. HOW TO AVOID THE HAZARD

The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. Other tire combinations are not recom- mended. Front:

Manufacturer/model: DUNLOP/KT536A

Size: AT20 x 7-8

Type: Tubeless

Rear: Manufacturer/model:

DUNLOP/KT537A Size:

AT22 x 10-8 Type:

Tubeless

The tires should be set to the recommend- ed pressure: Recommended tire pressure:

Front: 20 kPa (2.9 psi) (0.20 kgf/cm

2

) Rear:

25 kPa (3.6 psi) (0.25 kgf/cm

2

)

Check and adjust tire pressures when the tires are cold.

Tire pressures must be equal on both sides.

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EBU19820

Measuring the tire pressure

Use the low-pressure tire gauge.

NOTE:

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.

Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications:

Tire pressure below the minimum speci- fied could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure:

Front: 17 kPa (2.5 psi) (0.17 kgf/cm

2

) Rear:

22 kPa (3.2 psi) (0.22 kgf/cm

2

)

Use no more than the following pressures when seating the tire beads.

Maximum tire seating pressure: Front:

250 kPa (36 psi) (2.5 kgf/cm

2

) Rear:

250 kPa (36 psi) (2.5 kgf/cm

2

) Higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully.

1. Low-pressure tire gauge

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EBU19830

Tire wear limit

Replace the tire when the tire groove decreases to 3 mm (0.12 in).

EBU19840

Chassis fasteners

Make sure that all nuts, bolts and screws are prop- erly tightened.

EBU19850

Instruments, lights and switches

Check that all instruments, lights and switches are working properly. Correct if necessary.

EBU19860

Battery

Check the fluid level in the battery. Fill with distilled water if necessary. (See page 8-40.)

Recommended pressure: Front

20 kPa (2.9 psi) (0.20 kgf/cm

2

) Rear

25 kPa (3.6 psi) (0.25 kgf/cm

2

) Minimum:

Front 17 kPa (2.5 psi) (0.17 kgf/cm

2

) Rear

22 kPa (3.2 psi) (0.22 kgf/cm

2

) Maximum:

Front 23 kPa (3.3 psi) (0.23 kgf/cm

2

) Rear

28 kPa (4.1 psi) (0.28 kgf/cm

2

)

1. Tire wear limit

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EBU19870

OPERATION

WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

EBU19890

EWB00610

EBU20061

Starting a cold engine

EWB00620

CAUTION:

ECB00150

See the Engine break-in section on page 6-4

prior to operating the engine for the first time.

1. Set the parking brake. 2. Turn the fuel cock to ON. 3. Turn the main switch to ON and the engine

stop switch to RUN. 4. Shift the drive select lever into the neutral po-

sition. The neutral indicator light should come

WARNING

POTENTIAL HAZARD Operating ATV without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an acci- dent or injury. HOW TO AVOID THE HAZARD Read the Owners Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer.

WARNING

POTENTIAL HAZARD Frozen control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or collision. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding.

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on. If the indicator light does not come on, have a Yamaha dealer check the electrical cir- cuit.

NOTE:

The engine can be started only when the drive se-

lect lever is in the neutral position.

5. Use the starter (choke) in reference to the fig- ure:

Position (1):

Cold engine start with ambient temperature be- low 5 C (40 F).

Position (2):

Cold engine start with ambient temperature be- tween 0 C (30 F) and 30 C (90 F).

Position (3):

Cold engine start with ambient temperature above 25 C (80 F).

Ambient temp./starter (choke) position

6. Completely close the throttle lever and start the engine by pushing the start switch.

NOTE:

If the engine fails to start, release the start switch, then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each

1. Fully open 2. Half open 3. Closed 4. Starter (choke)

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1 2 3 1

2 3

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attempt.

7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the engine. If the engine is started with the starter (choke) in position (2), keep the starter (choke) in this position to warm up the engine.

CAUTION:

ECB00160

For maximum engine life, always warm the en- gine up before starting off. Never accelerate

hard when the engine is cold!

8. Continue warming up the engine until it idles smoothly, then return the starter (choke) to position (3) before riding.

NOTE:

The engine is warm when it responds normally to

the throttle with the starter (choke) turned off.

EBU20291

Starting a warm engine

Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open.

EBU20350

Operating the drive select lever and driving in reverse

CAUTION:

ECB00170

Before shifting, stop the ATV, otherwise the

transmission may be damaged.

Shifting: Forward

1. Bring the ATV to a complete stop. 2. Shift from neutral to forward and vice versa by

moving the drive select lever along the shift guide.

NOTE:

Make sure that the drive select lever is completely

shifted into position.

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3. Open the throttle lever gradually.

Shifting: Reverse

1. Bring the ATV to a complete stop. 2. Apply the parking brake. 3. Shift from neutral to reverse and vice versa by

moving the drive select lever along the shift guide.

NOTE:

When in reverse, the reverse indicator light should

come on. If the indicator light does not come on,

have a Yamaha dealer check the electrical circuit.

4. Check behind for people or obstacles, and then release the parking brake.

5. Open the throttle lever gradually and continue to watch to the rear while backing.

NOTE:

If the drive select lever is shifted into reverse while the engine is running, the engine will stop unless

the rear brake lever or parking brake is applied.

EWB00670

EBU20681

Engine break-in

There is never a more important period in the life of

1. Neutral N 2. Forward F 3. Reverse R 4. Drive select lever

1 23

4

WARNING

POTENTIAL HAZARD Improper operation in reverse. WHAT CAN HAPPEN You could hit an obstacle or even a person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no people or obstacles behind you. When it is safe to proceed, go slowly.

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your engine than the first 20 hours of riding. For this reason, you should read the following material carefully. Since the engine is brand new, do not put an ex- cessive load on it for the first 20 hours. The various parts in the engine wear and polish themselves to the correct operating clearances. During this peri- od, prolonged full-throttle operation or any condi- tion that might result in engine overheating must be avoided.

010 hours

Avoid prolonged operation above 1/2 throttle. Vary the speed of the ATV regularly. Do not operate it at one set throttle position.

1020 hours

Avoid prolonged operation above 3/4 throttle. Rev the engine freely, but do not use full throttle at any time.

20 hours and beyond

The ATV can now be operated normally.

CAUTION:

ECB00220

If any engine trouble should occur during the engine break-in period, immediately have a

Yamaha dealer check the ATV.

EBU20700

Parking

When parking the ATV, stop the engine, shift the drive select lever into the forward position, apply the parking brake, and then turn the fuel cock to OFF.

1. Locked position

1

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EBU20730

Parking on a slope

EWB00760

1. Bring the ATV to a stop by applying the brakes in the forward position.

2. Stop the engine. 3. With the rear brake applied, apply the parking

brake.

EBU20910

Accessories and loading

EBU20920

Accessories

Accessories can affect the handling and control of your ATV. Keep the following in mind when consid- ering an accessory or operating an ATV which has accessories.

Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of gen- uine Yamaha accessories. Other accessories may also be available on the market. However, it is not possible for Yamaha to test all non- Yamaha accessories, nor control over their qual-

WARNING

POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the ATV trans- versely across the incline, shift the drive se- lect 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. Do not park the ATV at all on hills that are so steep you could not walk up them easily.

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ity or suitability. Choose a genuine Yamaha ac- cessory, or one that is equivalent in design and quality.

Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV.

Do not mount an accessory where it could inter- fere with your ability to control the ATV. Exam- ples include (but are not limited to) a heavy or bulky object attached to the handlebars which could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view.

Use extra caution when riding an ATV with ac- cessories. The ATV may handle differently than it does without accessories.

EBU21070

Loading

As originally equipped, this ATV is not designed to tow a trailer. If you choose to add accessories so that you can tow a trailer, you must use common sense and good judgment as the stability and han- dling of an ATV can be changed. When adding ac- cessories, 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 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 load does not interfere with con- trols or your ability to see where you are going.

Ride more slowly than you would without a load. The more weight you carry, the slower you should go.

Allow more braking distance. A heavier ATV

MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, cargo, accessories, and tongue):

105.0 kg (231 lb) Front carrier:

5.0 kg (11 lb) Rear carrier:

10.0 kg (22 lb)

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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.

EWB00750

WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

WARNING

POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and se- curely attached. Reduce speed when carrying cargo or pull- ing a trailer. Allow greater distance for brak- ing.

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EBU21131

RIDING YOUR ATV

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WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

EBU21292

GETTING TO KNOW YOUR ATV

This ATV is for recreation and utility use. This sec- tion, Riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your ATV requires special skills acquired through practice over a period of time. Take the time to learn the ba- sic techniques well before attempting more difficult maneuvers. Riding your new ATV can be a very enjoyable ac- tivity, providing you with hours of pleasure. But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely. Before you begin to ride, be sure you have read this Owners Manual completely and un- derstand the operation of the controls. Pay partic- ular attention to the safety information on pages 1-11-5. Please also read all caution and warning labels on your ATV.

RIDE WITH CARE AND GOOD JUDGEMENT

Get training if you are inexperienced.

Beginners should get training from a certified in- structor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not at- tempt to operate at maximum performance until you are totally familiar with the ATVs handling and performance characteristics.

EWB01280

WARNING

POTENTIAL HAZARD Operating this ATV without proper instruc- tion. WHAT CAN HAPPEN 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 terrain.

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Riding your ATV requires skills acquired through practice over a period of time.

Take the time to learn the basic techniques well before attempting more difficult maneuvers.

Not recommended for children under 16 years of age.

EWB00901

This ATV is designed to carry operator and cargo only passengers prohibited.

HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regu- larly practice the skills learned in the course and the operating techniques described in this Owners Manual. For more information about the training course, contact an autho- rized ATV dealer or call 1-800-887-2887.

WARNING

POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recom- mended for their age can lead to severe inju- ry or death of the child.

HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc.

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EWB00910

WARNING

POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passen- ger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying pas- sengers.

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Apparel

EWB00920

WARNING

POTENTIAL HAZARD Operating this ATV without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an acci- dent. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. Operating without protective clothing in- creases your chances of severe injury in the event of an accident.

HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear:

eye protection (goggles or face shield)

gloves

boots

long-sleeved shirt or jacket

long pants

1. Protective clothing 2. Goggles 3. Gloves 4. Boots 5. Helmet

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Do not operate after consuming alcohol or drugs.

The operators performance capability is reduced by the influence of alcohol or drugs.

EWB00930

Pre-operation checks

Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety.

EWB00940

WARNING

POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident.

HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and mainte- nance procedures and schedules described in the Owners Manual.

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EWB00950

WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

Do not operate at speeds too fast for your skills or the conditions.

EWB00960

Speed limiter

For riders less experienced with this model, the throttle lever housing is equipped with a speed lim- iter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and de- creases the maximum speed of the ATV. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (See page 4-4.)

WARNING

POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or opera- tion of this ATV with improper or uneven tire pressure, may cause loss of control, increas- ing your risk of an accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owners Manual for this ATV on page 5-5. Always maintain proper tire pressure as de- scribed in the Owners Manual on page 5-6.

WARNING

POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience.

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Loading and accessories

Use extra caution when riding the ATV with addi- tional loads, such as accessories or cargo. The ATVs handling may be adversely affected. Re- duce your speed when adding additional loads.

EWB00970

1. Adjusting screw 2. Locknut

2

1

MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue):

105.0 kg (231 lb) Front carrier:

5.0 kg (11 lb) Rear carrier:

10.0 kg (22 lb)

WARNING

POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident.

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During operation

Always keep your feet on the footboards during op- eration, otherwise they may contact the rear wheels.

HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and se- curely attached. Reduce speed when carrying cargo or pull- ing a trailer. Allow greater distance for brak- ing. Always follow the instructions in your Own- ers Manual for carrying cargo or pulling a trailer.

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EWB00980

Avoid wheelies and jumping. You may lose control of the ATV or overturn.

EWB00990

Modifications

EWB01000

WARNING

POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident. HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation.

WARNING

POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts.

WHAT CAN HAPPEN Increases the chance of an accident, includ- ing an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Dont try to show off.

WARNING

POTENTIAL HAZARD Operating this ATV with improper modifica- tions.

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Exhaust system

The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it.

EWB01010

WHAT CAN HAPPEN Improper installation of accessories or mod- ification of this ATV may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer.

WARNING

POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible ma- terial accumulated around the engine area could catch fire. Someone touching the exhaust system dur- ing or after operation could be burned. HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV in dry grass or other dry ground cover. Keep the engine area free of dry grass, brush, or other combustible material. Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it.

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BE CAREFUL WHERE YOU RIDE

This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control.

EWB01020

Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles.

WARNING

POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect han- dling and control of the ATV, and may cause the ATV to go out of control.

HOW TO AVOID THE HAZARD Always avoid paved surfaces, including side- walks, driveways, parking lots and streets.

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EWB01030

Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for

holes, rocks, or roots

in the terrain, and

other hidden hazards

which may cause the ATV to upset.

EWB01040

WARNING

POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.

WARNING

POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operat- ing on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

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EWB01050

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

POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or ATV control, which could result in an accident, including an overturn.

HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especial- ly cautious on these kinds of terrain.

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EWB01060

Do not ride in areas posted no trespassing. Do not ride on private property without getting per- mission.

Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Always avoid riding on paved surfaces: the ATV is designed for off-road use only, and handling maneuvers are more difficult to perform on pavement. 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

WARNING

POTENTIAL HAZARD Operating in areas where you might not be seen by other off-road vehicles. WHAT CAN HAPPEN You could be in a collision. You could be in- jured. HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles.

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hot when riding and afterwards; do not allow skin or clothing to come in contact with these compo- nents. With the engine idling, return the starter knob to the closed position and shift the drive select lever into the forward position. Then release the parking brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is applied too abruptly, the front wheels may lift off the ground, resulting in a loss of directional control. Avoid higher speeds un- til you are thoroughly familiar with the operation of your ATV. When slowing down or stopping, release the throt- tle and apply the brakes smoothly and evenly. Im- proper use of the brakes can cause the tires to lose traction, reducing control and increasing the possi- bility of an accident.

TURNING YOUR ATV

To achieve maximum traction while riding off-road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. There- fore, unless the wheel on the inside of the turn is al- lowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and

easily. It is essential that this skill be learned first at low speed.

EWB01080

As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the footboard to the out- side of the turn (opposite your desired direction) and lean your upper body into the turn. Use the throttle to maintain an even speed through the turn. This maneuver will let the wheel on the inside of the turn slip slightly, allowing the ATV to make the turn properly.

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a colli- sion or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owners Manual. Prac- tice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the condi- tions.

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This procedure should be practiced at slow speed many times in a large off-road area with no obsta- cles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesnt turn, come to a stop and then practice the proce- dure again. If the riding surface is slippery or loose, it may help to position more of your weight over the front wheels by moving forward on the seat. Once you have learned this technique, you should be able to perform it at higher speeds or in tighter

curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be necessary to gradually let off on the throttle and steer to the out- side of the turn to avoid tipping over. Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your ATV.

CLIMBING UPHILL

Use proper riding techniques to avoid ATV over- turns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any in- cline and then practice riding first on gentle slopes. Try more difficult climbs only after you have devel- oped your skill. In all cases avoid inclines with slip- pery or loose surfaces, or obstacles that might cause you to lose control.

1. Lean towards inside of turn. 2. Support your weight on the outer footboard.

1

2

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EWB01090

It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars.

EWB01180

WARNING

POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The ATV can overturn more easily on ex- tremely steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting large hills.

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD Always follow proper procedures for climb- ing hills as described in this Owners Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

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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.

EWB01190

WARNING

POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owners 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: Always follow proper procedures as de- scribed in the Owners Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

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If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the up- hill side. Physically turn the ATV around and then descend the hill. If you start to roll backwards, DO NOT apply the rear brake to stop or try to put the ATV in gear. The ATV could easily tip over backwards. Instead, ap- ply the front brake gradually, or dismount the ATV immediately on the uphill side.

EWB01341

WARNING

POTENTIAL HAZARD Stalling, rolling backwards or improperly dis- mounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. If you lose all forward speed:

Keep weight uphill.

Apply the brakes.

Lock the parking brake after you are stopped.

If you begin rolling backwards:

Keep weight uphill.

Never apply the rear brake while rolling backwards. Apply the front brake.

When fully stopped, apply the rear brake as well, and then lock the parking brake.

Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and re- mount, following the procedure described in the Owners Manual.

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RIDING DOWNHILL

When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as pos- sible. Move back on the seat and sit with your arms straight. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. 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.

EWB01130

WARNING

POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owners Man- ual. Note: a special technique is required when braking as you go down a hill. Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side. Go straight down the hill where possi- ble.

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CROSSING A SLOPE

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

EWB01141

WARNING

POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owners Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.

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CROSSING THROUGH SHALLOW WATER

The ATV can be used to cross slow moving, shal- low water of up to a maximum of 20 cm (8 in) in depth. Before entering the water, choose your path

carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and care- fully.

EWB01150

When crossing the side of a hill: Always follow proper procedures as de- scribed in the Owners Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

WARNING

POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an acci- dent. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owners Manual. Remember that wet brakes may have re- duced stopping ability. Test your brakes af- ter leaving water. If necessary, apply them several times to let friction dry out the lin- ings.

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Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability.

CAUTION:

ECB00800

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 and the V-belt case drain plug. Wash the ATV in fresh water if it has been operated in salt water or muddy

conditions.

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RIDING OVER ROUGH TERRAIN

Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may re- sult.

EWB01160

SLIDING AND SKIDDING

Care should be used when riding on loose or slip- pery surfaces since the ATV may slide. If unex-

1. Air lter case check hose

1. V-belt case drain plug

1

1

WARNING

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for ob- stacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper pro- cedures as described in the Owners Manual.

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pected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help.

If the rear wheels of your ATV start to slide side- ways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide.

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 re- duced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost.

EWB01170

WARNING

POTENTIAL HAZARD Skidding or sliding improperly.

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WHAT TO DO IF…

This section is designed to be a reference guide only. Be sure to read each section on riding tech- niques completely.

WHAT TO DO…

If your ATV doesnt turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See page 7-16.)

If your ATV begins to tip while turning:

Lean more into the turn to regain balance. If nec- essary, gradually let off the throttle and/or steer to the outside of the turn. (See page 7-16.)

If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See page 7-25.)

If your ATV cant make it up a hill you are trying to climb: Turn the ATV around if you still have forward speed. If not, stop, dismount on the uphill side of the ATV and physically turn the ATV around. If the ATV starts to slip backwards, DO NOT USE THE REAR BRAKE the ATV may tip over on top of you. Dismount the ATV on the uphill side. (See page 7-17.)

If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See page 7-17.)

If your ATV encounters shallow water:

WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of control.

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Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let wa- ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See page 7-23.)

WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

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EBU21640

PERIODIC MAINTENANCE AND MINOR REPAIR

EBU21660

Safety is an obligation of the owner. Periodic in- spection, adjustment and lubrication will keep your ATV in the safest and best operating condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages. The intervals given in the periodic maintenance and lubrication chart should be considered as a general guide under normal riding conditions. However, DEPENDING ON THE WEATHER, TERRAIN, GEOGRAPHICAL LOCATION, AND INDIVIDUAL USE, THE MAINTENANCE INTER- VALS MAY NEED TO BE SHORTENED.

EWB01820

EBU27100

Owners manual and tool kit

Be sure to put this owners manual in the plastic bag and to always carry it as well as the owners tool kit and the low-pressure tire gauge in their re- spective compartments under the seat.

WARNING

POTENTIAL HAZARD Servicing an engine while it is running. WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body, causing injury. Electrical components can cause shocks or start fires.

HOW TO AVOID THE HAZARD Turn off the engine when performing mainte- nance unless otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with maintenance work.

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The service information included in this manual and the tools provided in the owners tool kit are in- tended to assist you in the performance of preven- tive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.

NOTE:

If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform

it for you.

EWB01830

1. Owners manual 2. Low-pressure tire gauge 3. Owners tool kit

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23

WARNING

POTENTIAL HAZARD Operating this ATV with improper modifica- tions. WHAT CAN HAPPEN Improper installation of accessories or mod- ification of this ATV may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized Yamaha ATV dealer.

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EBU21741

Periodic maintenance chart for the emission control system

NOTE:

For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.

For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter- vals. However, keep in mind that if the ATV isnt used for a long period of time, the month maintenance intervals should be followed.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,

data and technical skills.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

rst

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

1

*

Fuel line

Check fuel hoses for cracks or other damage, and replace if necessary.

2 Spark plug

Check condition and clean, regap, or replace if necessary.

3

*

Valves

Check valve clearance and adjust if necessary.

4

*

Carburetor

Check starter (choke) operation and correct if nec- essary.

Check engine idling speed and adjust if neces- sary.

5

*

Crankcase breather system

Check breather hose for cracks or other damage, and replace if necessary.

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6

*

Exhaust system

Check for leakage and replace gasket(s) if neces- sary.

Check for looseness and tighten all screw clamps and joints if necessary.

7 Spark arrester

Clean.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

rst

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

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EBU21862

General maintenance and lubrication chart

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

rst

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

1 Engine and V-belt case air lter ele- ment

Clean and replace if necessary. Every 2040 hours (more often in wet or dusty areas)

2

*

Front brake

Check operation and correct if necessary.

Check brake lever free play and adjust if neces- sary.

Replace brake shoes. Whenever worn to the limit

3

*

Rear brake

Check operation and correct if necessary.

Check brake lever free play and adjust if neces- sary.

Replace brake shoes. Whenever worn to the limit

4

*

Wheels

Check runout and for damage, and replace if nec- essary.

5

*

Tires

Check tread depth and for damage, and replace if necessary.

Check air pressure and balance, and correct if necessary.

6

*

Wheel bearings

Check for looseness or damage, and replace if necessary.

7 Drive chain

Check chain slack and adjust if necessary.

Check rear wheel alignment and correct if necess- sary.

Clean and lubricate.

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8

*

V-belt

Check for wear, cracks or other damage, and replace if necessary.

9

*

Chassis fasteners

Make sure that all nuts, bolts, and screws are properly tightened.

10

*

Shock absorber assemblies

Check operation and correct if necessary.

Check for oil leakage and replace if necessary.

11

*

Knuckle shafts

Lubricate with lithium-soap-based grease.

12

*

Steering shaft

Lubricate with lithium-soap-based grease.

13

*

Steering system

Check operation and repair or replace if damaged.

Check toe-in and adjust if necessary.

14 Engine oil

Change.

Check ATV for oil leakage, and correct if neces- sary.

15 Engine oil strainer

Clean.

16 Transmission oil

Change.

Check ATV for oil leakage, and correct if neces- sary.

17

*

Throttle lever hous- ing and cable

Check operation and correct if necessary.

Check throttle cable free play and adjust if neces- sary.

Lubricate throttle lever housing and cable.

18

*

Front and rear brake switches

Check operation and correct if necessary.

19

*

Lights and switches

Check operation and correct if necessary.

Adjust headlight beams.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

rst

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

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EBU23060

NOTE:

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

20

*

Battery

Check electrolyte level and specic gravity, and correct if necessary.

Make sure that the breather hose is properly routed.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

rst

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

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WARNING

EWB00010

Indicates a potential hazard that could result in serious injury or death.

EBU23210

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 accor- dance with the periodic maintenance and lubrica- tion chart. In addition, the condition of the spark plug can reveal the condition of the engine.

To remove the spark plug

1. Remove the spark plug cap.

2. Remove the spark plug as shown, with the spark plug wrench included in the owners tool kit.

1. Spark plug cap

1

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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).

NOTE:

If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to di- agnose such problems yourself. Instead, have a

Yamaha dealer check the ATV.

2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and

replace it if necessary.

To install the spark plug

1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.

2. Clean the surface of the spark plug gasket

1. Spark plug wrench

1

Specified spark plug: NGK/CR7HSA

Spark plug gap: 0.60.7 mm (0.0240.028 in)

1. Spark plug gap

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and its mating surface, and then wipe off any grime from the spark plug threads.

3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque.

NOTE:

If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/41/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as

soon as possible.

4. Install the spark plug cap.

EBU23261

Engine oil

The engine oil level should be checked before each ride. In addition, the oil must be changed at the intervals specified in the periodic maintenance and lubrication chart.

To check the engine oil level

1. Place the ATV on a level surface.

2. Start the engine, warm it up for several min- utes, and then turn it off.

3. Wait a few minutes until the oil settles before checking.

4. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag.

5. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level.

Tightening torque: Spark plug:

12.5 Nm (1.3 mkgf, 9.0 ftlbf)

1. Dipstick

1

8-11

1

2

3

4

5

6

7

8

9

10

11

NOTE:

The engine oil should be between the minimum

and maximum level marks.

6. 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.

7. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap.

To change the engine oil

1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min-

utes, and then turn it off. 3. Place an oil pan under the engine to collect

the used oil. 4. Remove the engine oil filler cap, and then re-

move the engine oil drain bolt to drain the oil from the crankcase.

CAUTION:

ECB00310

When removing the engine oil drain bolt, the compression spring, oil strainer and O-ring will

1. Maximum level mark 2. Minimum level mark

1

2

1. Engine oil drain bolt 2. O-ring 3. Spring 4. Oil strainer

1

4

3 2 1

8-12

1

2

3

4

5

6

7

8

9

10

11

fall out. Take care not to lose these parts.

5. Clean the oil strainer with solvent. 6. Check the O-ring for damage and replace it if

necessary. 7. Install the O-ring, oil strainer, compression

spring and drain bolt. Tighten the engine oil drain bolt to the specified torque.

CAUTION:

ECB00320

Before installing the engine oil drain bolt, be sure to install the O-ring, compression spring

and oil strainer.

8. Add the specified amount of the recommend- ed engine oil, and then install and tighten the engine oil filler cap.

CAUTION:

ECB00330

Do not use oils with a diesel specification of CD or oils of a higher quality than speci- fied. In addition, do not use oils labeled EN- ERGY CONSERVING II or higher.

Make sure that no foreign material enters the

crankcase.

9. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause.

10. Turn the engine off, and then check the oil lev- el and correct it if necessary.

EBU27021

Transmission oil

The transmission oil level should be checked be- fore each ride. In addition, the transmission oil must be changed at the intervals specified in the

Tightening torque: Engine oil drain bolt:

32 Nm (3.2 mkgf, 23.1 ftlbf)

Recommended oil: See page 10-1.

Oil quantity: 1.25 L (1.32 US qt) (1.10 Imp.qt)

8-13

1

2

3

4

5

6

7

8

9

10

11

periodic maintenance and lubrication chart.

To check the transmission oil level

1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min-

utes, and then turn it off. 3. Wait a few minutes until the oil settles, and

then remove the screw located at the right side of the crankcase.

4. Check the transmission oil level.

NOTE:

The transmission oil should be at the brim of the

hole.

5. If the transmission oil level is below the brim of the hole, remove the oil filler bolt, add suffi- cient oil of the recommended type to raise it to the correct level, and then install and tighten the screw and the oil filler bolt.

1. Screw 2. Transmission oil level check window 3. Correct oil level

1

3 2

1. Transmission oil ller bolt

1

8-14

1

2

3

4

5

6

7

8

9

10

11

To change the transmission oil

1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min-

utes, and then turn it off. 3. Place an oil pan under the transmission to col-

lect the used oil. 4. Remove the oil filler bolt and the drain bolt to

drain the oil from the transmission case.

5. Install the drain bolt, and then tighten it to the specified torque.

6. Add the specified amount of the recommend- ed transmission oil, and then install and tight- en the oil filler bolt.

Tightening torque: Screw:

16 Nm (1.6 mkgf, 11.6 ftlbf) Oil filler bolt:

23 Nm (2.3 mkgf, 16.6 ftlbf)

1. Transmission oil drain bolt

Tightening torque: Transmission oil drain bolt:

23 Nm (2.3 mkgf,16.6 ftlbf)

1

8-15

1

2

3

4

5

6

7

8

9

10

11

CAUTION:

ECB00790

Make sure that no foreign material enters the transmission case.

Make sure that no oil gets on the tires or

wheels.

7. Start the engine, and then let it idle for several minutes while checking the transmission for oil leakage. If oil is leaking, immediately turn off the engine and check for the cause.

8. Turn the engine off, and then check the oil lev- el and correct it if necessary.

EBU23830

Cleaning the engine and V-belt case air filter elements

Both air filter elements should be cleaned at the specified intervals in the periodic maintenance chart.

Engine air filter element

NOTE:

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.

Recommended transmission oil: See page 10-1.

Oil quantity: 0.6 L (0.63 US qt) (0.53 Imp.qt)

Tightening torque: Oil filler bolt:

23 Nm (2.3 mkgf,16.6 ftlbf)

1. Check hose

1

8-16

1

2

3

4

5

6

7

8

9

10

11

1. Remove the seat. (See page 4-11.) 2. Remove the breather hose, and then loosen

the clamp screw.

3. Remove the air filter case cover by removing the screws.

4. Pull the air filter element out of the air filter case.

5. Remove the bolt and washer shown, and then pull the sponge material off from the air filter element frame.

1. Breather hose 2. Clamp screw

1

2

1. Air lter case cover 2. Screw

12 2

2 2

8-17

1

2

3

4

5

6

7

8

9

10

11

6. Wash the sponge material gently but thor- oughly in solvent.

EWB01900

7. Squeeze the excess solvent out of the sponge material and let it dry.

CAUTION:

ECB00440

Do not twist the sponge material when squeez-

ing it.

8. Check the sponge material and replace it if damaged.

9. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material.

NOTE:

The sponge material should be wet but not drip-

ping.

10. Pull the sponge material over the air filter ele- ment frame.

11. Install the washer and bolt.

CAUTION:

ECB00450

Be sure to install the washer with the bent edge

facing upward as shown.

1. Bolt 2. Washer 3. Sponge material 4. Air lter element frame

WARNING

POTENTIAL HAZARD Using low-flash-point solvents or gasoline to clean the sponge material. WHAT CAN HAPPEN Low-flash-point solvents or gasoline can catch fire or explode.

34

2 1

HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material.

8-18

1

2

3

4

5

6

7

8

9

10

11

12. Install the air filter element into the air filter case.

13. Install the air filter case cover by installing the screws.

14. Install the breather hose and then tighten the clamp screw.

15. Install the seat.

NOTE:

The air filter element should be cleaned every 20 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar- eas. Each time the air filter element maintenance

is performed, check the air inlet of the air filter case for obstructions. Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air-tight seal. Tighten all fit- tings securely to avoid the possibility of unfiltered

air entering the engine.

CAUTION:

ECB00460

Make sure that the air filter element is prop- erly seated in the air filter case.

Never operate the engine with the air filter el- ement removed. This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage. Addition- ally, operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine over-

heating.

V-belt case air filter element

1. Remove the front carrier by removing the bolts.

1. Washer

1

8-19

1

2

3

4

5

6

7

8

9

10

11

2. Remove the panel shown by removing the quick fasteners.

3. Disconnect the coupler shown.

1. Bolt 2. Front carrier

2

1

1

1

1. Panel 2. Quick fastener

1

2 2

1

8-20

1

2

3

4

5

6

7

8

9

10

11

4. Remove the air filter case cover by removing the screw.

5. Remove the air filter element.

1. Panel 2. Coupler

1

2

1. Air lter case cover 2. Screw

1

2

8-21

1

2

3

4

5

6

7

8

9

10

11

6. Tap the air filter element lightly to remove most of the dust and dirt. Blow out the remain- ing dirt with compressed air as shown.

7. Check the air filter element and replace it if damaged.

8. Install the air filter element into the air filter case.

9. Install the air filter case cover by installing the screw.

10. Connect the coupler, and then install the pan- el by installing the quick fasteners.

11. Install the front carrier by installing the bolts.

EBU23891

Cleaning the spark arrester

Be sure the exhaust pipe and muffler are cool be-

1. Air lter element

1

1. Air lter element

1

8-22

1

2

3

4

5

6

7

8

9

10

11

fore cleaning the spark arrester. 1. Remove the screws.

2. Remove the tailpipe by pulling it out of the muffler.

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. Insert the tailpipe into the muffler and align the screw holes.

5. Install the screws and tighten them.

EWB01910

1. Screw

1

1. Screw 2. Gasket 3. Tailpipe 4. Spark arrester

WARNING

POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system.

3

4 2 1

8-23

1

2

3

4

5

6

7

8

9

10

11

EBU23930

V-belt case drain plug

After riding in water deep enough to allow it to en- ter the V-belt case, remove this plug to drain the water from the case.

NOTE:

If water drains from the V-belt case after removing the plug, have a Yamaha dealer check the ATV as

the water may affect other engine parts.

EBU23940

Adjusting the carburetor

The carburetor should be checked and, if neces- sary, adjusted at the intervals specified in the peri- odic maintenance and lubrication chart. The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary profes- sional knowledge and experience. The adjustment described in the following section, however, may be performed by the owner as part of routine main- tenance.

WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components. Do not start the engine when cleaning the ex- haust system.

1. V-belt case drain plug

1

8-24

1

2

3

4

5

6

7

8

9

10

11

CAUTION:

ECB00480

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.

EBU24000

Adjusting the engine idling speed

The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrica- tion chart.

NOTE:

A diagnostic tachometer is needed to make this

adjustment.

1. Start the engine and warm it up.

NOTE:

The engine is warm when it quickly responds to the

throttle.

2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if neces-

sary, adjust it to specification by turning the throttle stop screw at the carburetor. To in- crease the engine idling speed, turn the throt- tle stop screw in direction (a), and to decrease it, turn the screw in direction (b).

NOTE:

If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the

adjustment.

1. Throttle stop screw

Engine idling speed: 16501750 r/min

(a) (b)

1

8-25

1

2

3

4

5

6

7

8

9

10

11

EBU24043

Adjusting the throttle cable free play

The throttle cable free play should be checked and, if necessary, adjusted at the intervals speci- fied in the periodic maintenance and lubrication chart. The throttle cable free play should measure 1.0 3.0 mm (0.040.12 in) at the throttle lever. Period- ically check the throttle cable free play and, if nec- essary, adjust it as follows.

NOTE:

The engine idling speed must be checked, and ad- justed if necessary, before adjusting the throttle ca-

ble free play.

1. Loosen the locknut. 2. To increase the throttle cable free play, turn

the adjusting bolt in direction (a). To decrease the throttle cable free play, turn the adjusting bolt in direction (b).

3. Tighten the locknut.

EBU24060

Valve clearance

The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart.

1. Locknut 2. Throttle cable free play adjusting bolt 3. Throttle cable free play

3

1

2

(a)

(b)

8-26

1

2

3

4

5

6

7

8

9

10

11

EBU24090

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. Each brake is provided with a wear indicator, which allows you to check the brake shoe wear without having to dis- assemble the brake. To check the brake shoe wear, check the position of the wear indicator while applying the brake. If a brake shoe has worn to the point that the wear indicator reaches the wear limit line or mark, have a Yamaha dealer replace the brake shoes as a set.

Front brake

1. Wear limit line 2. Wear indicator

1

2

8-27

1

2

3

4

5

6

7

8

9

10

11

Rear brake

EBU24360

Adjusting the front brake lever free play

The brake lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.

NOTE:

Before adjusting the brake lever free play, check

the front brake shoes for wear.

The brake lever free play should measure 5.08.0

mm (0.200.31 in) as shown. If the free play is in- correct, adjust it as follows.

1. Remove the front carrier by removing the bolts.

1. Wear limit line 2. Wear indicator

1

2

1. Brake lever free play

1

8-28

1

2

3

4

5

6

7

8

9

10

11

2. Remove the panel shown by removing the quick fasteners, then disconnect the coupler shown.

1. Front carrier 2. Bolt

1

2

2

2

1. Panel 2. Quick fastener

1

2 2

1

8-29

1

2

3

4

5

6

7

8

9

10

11

3. Remove the V-belt air filter element cover by removing the screw.

4. Loosen the locknut and fully turn in the adjust- ing bolt at the brake lever.

1. Panel 2. Coupler

1

2

1. V-belt air lter element cover 2. Screw

1

2

8-30

1

2

3

4

5

6

7

8

9

10

11

5. Make sure the brake cable joint in the equaliz- er is straight when the brake is applied. If the cable joint isnt straight, loosen the locknuts, and then turn the adjusting nuts on the front brake cables until the cable joint becomes straight.

1. Locknut 2. Brake lever free play adjusting bolt

1 2

1. Brake equalizer 2. Cable joint

a a’

a=a’

12

8-31

1

2

3

4

5

6

7

8

9

10

11

6. Tighten the locknut on each brake cable. 7. Turn the adjusting bolt in direction (a) to in-

crease the free play, and in direction (b) to de- crease it.

8. Tighten the locknut at the brake lever. 9. Install the V-belt air filter element cover by in-

stalling the screw. 10. Connect the coupler, and then install the pan-

el by installing the quick fasteners. 11. Install the front carrier by installing the bolts.

1. Locknut 2. Adjusting nut

1

2 2 1

1. Locknut 2. Brake lever free play adjusting bolt 3. Brake lever free play

31 2

(b)

(a)

8-32

1

2

3

4

5

6

7

8

9

10

11

EWB02020

EBU24481

Adjusting the rear brake lever free play

The brake lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.

NOTE:

Before adjusting the brake lever free play, check

the rear brake shoes for wear.

The brake lever free play should measure 5.08.0 mm (0.200.31 in) as shown. If the free play is in- correct, adjust it as follows.

Turn the brake lever free play adjusting nut on the rear wheel hub in direction (a) to increase the free play, and in direction (b) to decrease it. If the correct free play cannot be obtained, have a Yamaha dealer adjust it.

WARNING

POTENTIAL HAZARD Operating with improperly serviced or ad- justed brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing:

Make sure the brakes operate smoothly and that the free play is correct.

Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer.

1. Brake lever free play

1

8-33

1

2

3

4

5

6

7

8

9

10

11

EWB02020

EBU24871

Drive chain slack

The drive chain slack should be checked before each ride and adjusted if necessary.

To check the drive chain slack

1. Place the ATV on a level surface.

NOTE:

When 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.

1. Brake lever free play adjusting nut

WARNING

POTENTIAL HAZARD Operating with improperly serviced or ad- justed brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.

1

(a)

(b)

HOW TO AVOID THE HAZARD After servicing:

Make sure the brakes operate smoothly and that the free play is correct.

Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer.

8-34

1

2

3

4

5

6

7

8

9

10

11

3. If the drive chain slack is incorrect, adjust it as follows.

To adjust the drive chain slack

1. Loosen the hub stopper bolt locknut and then the hub stopper bolt.

2. Loosen the axle holding bolts.

3. Loosen the chain adjusting bolt locknut. To tighten the drive chain, turn the adjusting bolt in direction (a). To loosen the drive chain, turn the adjusting bolt in direction (b), and then push the wheels forward.

Drive chain slack: 30.0 mm (1.18 in)

1. Drive chain slack

1

1. Hub stopper bolt 2. Locknut 3. Axle holding bolt (lower) 4. Axle holding bolt (upper)

1 2 3

4

8-35

1

2

3

4

5

6

7

8

9

10

11

CAUTION:

ECB00541

Improper drive chain slack will overload the en- gine as well as other vital parts of the ATV and can lead to drive chain slippage or breakage. To prevent this from occurring, keep the drive

chain slack within the specified limits.

4. Tighten the locknut and the axle holding bolts to the specified torques.

CAUTION:

ECB00550

If measurement A of the drive chain adjust- ing bolt is less than 27 mm (1.06 in), have a

Yamaha dealer replace the drive chain.

1. Locknut 2. Drive chain slack adjusting bolt

1

2

(a) (b)

Tightening torques: Chain adjusting bolt locknut:

15.5 Nm (1.6 mkgf, 11.2 ftlbf) Axle holding bolt (upper):

85 Nm (8.5 mkgf, 61.5 ftlbf) Axle holding bolt (lower):

60 Nm (6.0 mkgf, 43.4 ftlbf)

8-36

1

2

3

4

5

6

7

8

9

10

11

5. Tighten the hub stopper bolt, and then its lock- nut.

EBU24880

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.

CAUTION:

ECB00560

The drive chain must be lubricated after wash-

ing the ATV or riding in the rain.

1. Clean the drive chain with kerosene and a small soft brush.

CAUTION:

ECB00570

To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pres-

sure washers or inappropriate solvents.

2. Wipe the drive chain dry.

1. Measurement A

1

1. O-ring

1

8-37

1

2

3

4

5

6

7

8

9

10

11

3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant.

CAUTION:

ECB00580

Do not use engine oil or any other lubricants for the drive chain, as they may contain sub-

stances that could damage the O-rings.

EBU24890

Checking and lubricating the cables

The operation and the condition of all control ca- bles should be checked before each ride, and the cables and cable ends should be lubricated if nec- essary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.

EWB02120

EBU24911

Checking and lubricating the front and rear brake levers

The operation of the front and rear brake levers should be checked before each ride, and the lever pivots should be lubricated if necessary.

Recommended lubricant: Engine oil

WARNING

POTENTIAL HAZARD Damaged control cables.

WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged, and cables can also be- come frayed or kinked, which could restrict the operation of controls and lead to an acci- dent or injury. HOW TO AVOID THE HAZARD Inspect cables frequently. Replace damaged cables.

Recommended lubricant: Lithium-soap-based grease (all-purpose grease)

8-38

1

2

3

4

5

6

7

8

9

10

11

Front brake lever

Rear brake lever

EBU24961

Checking the wheel bearings

The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings.

EBU25030

Lubricating the upper and lower arm pivots

The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Lubricate the pivoting points using a grease gun.

Recommended lubricant: Lithium-soap-based grease

8-39

1

2

3

4

5

6

7

8

9

10

11

Left side Right side

EBU25070

Lubricating the knuckle shafts

The knuckle shafts must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart. Lubricate the knuckle shafts using a grease gun.

1. Grease nipple

1

1

1. Grease nipple

Recommended lubricant: Lithium-soap-based grease

1

1

8-40

1

2

3

4

5

6

7

8

9

10

11

EBU25090

Lubricating the steering shaft

The steering shaft must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart. Lubricate the steering shaft using a grease gun.

EBU25111

Battery

A poorly maintained battery will corrode and dis- charge quickly. The electrolyte level, battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrica- tion chart.

To check the electrolyte level

1. Place the ATV on a level surface. 2. Check the electrolyte level in the battery.

1. Grease nipple

Recommended lubricant: Lithium-soap-based grease

1

1. Grease nipple

1

8-41

1

2

3

4

5

6

7

8

9

10

11

NOTE:

The electrolyte should be between the minimum

and maximum level marks.

3. If the electrolyte is at or below the minimum level mark, add distilled water to raise it to the maximum level mark.

CAUTION:

ECB00590

Use only distilled water, as tap water contains

minerals that are harmful to the battery.

1. Battery 2. Battery breather hose 3. Guide

12

3

1. Maximum level mark 2. Minimum level mark

1

2

8-42

1

2

3

4

5

6

7

8

9

10

11

EWB02140

4. Check and, if necessary, tighten the battery lead connections and correct the breather

hose routing.

To store the battery

If the ATV will not be used for more than one month, the battery will need to be removed and stored as follows. 1. Disconnect the negative lead first and then the

positive lead.

2. Remove the battery, fully charge it, and then place it in a cool, dry place.

WARNING

POTENTIAL HAZARD Failure to handle batteries or battery electro- lyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severe- ly burned by the sulfuric acid in battery elec- trolyte. Batteries produce explosive gases. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Al- ways shield eyes when working near batter- ies. Keep out of reach of children. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Get prompt medical at- tention. EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batteries away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed space.

1. Battery 2. Negative lead 3. Positive lead

1 2

3

8-43

1

2

3

4

5

6

7

8

9

10

11

CAUTION:

ECB00600

Do not leave or store the battery on its side.

3. If the battery will be stored for more than two months, check the specific gravity of the elec- trolyte at least once a month and fully charge the battery whenever necessary.

To install the battery

NOTE:

Be sure the battery is fully charged.

1. Install the battery. 2. Connect the positive lead first, and then con-

nect the negative lead. 3. Make sure that the breather hose is properly

routed, in good condition, and not obstructed.

CAUTION:

ECB00610

If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the battery, the frame could suf-

fer structural and external damages.

1. Battery 2. Negative lead 3. Positive lead

1 2

3

8-44

1

2

3

4

5

6

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EBU25252

Replacing the fuse

The fuse holder is located on the right side of the ATV. If the fuse is blown, replace it as follows. 1. Turn the key to OFF and turn off all electrical

circuits.

CAUTION:

ECB00640

To prevent accidental short-circuiting, turn off the main switch when checking or replacing a

fuse.

2. Remove the blown fuse, and then install a new fuse of the specified amperage.

EWB02151

3. Turn the key to ON and turn on the electrical circuits to check if the devices operate.

4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.

EBU25350

Replacing a headlight bulb

If a headlight bulb burns out, replace it as follows.

1. Fuse 2. Spare fuse

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2

Specified fuse: 15.0 A

WARNING

POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system, which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse.

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1. Remove the cover at the rear of the headlight by pulling it off.

2. Remove the bulb holder cover by pulling it off. 3. Remove the bulb holder by pushing it inward

and turning it counterclockwise. 4. Remove the defective headlight bulb by pull-

ing it out of the socket.

1. Cover at the rear of the headlight

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1. Headlight bulb holder cover 2. Headlight bulb holder

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EWB02190

5. Place a new bulb into position.

6. Install the bulb holder by pushing it inward and turning it clockwise.

7. Install the bulb holder cover. 8. Install the cover at the rear of the headlight. 9. Adjust the headlight beam if necessary.

EBU25550

Adjusting a headlight beam

CAUTION:

ECB00690

It is advisable to have a Yamaha dealer make

this adjustment.

To raise a headlight beam, turn the adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b).

WARNING

POTENTIAL HAZARD A headlight bulb is hot when it is on and im- mediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the headlight bulb to cool before touching or removing it.

1. Headlight bulb

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EBU25610

Replacing the tail/brake light bulb

If the tail/brake light bulb burns out, replace it as follows. 1. Remove the bulb holder (together with the

bulb) by turning it counterclockwise.

2. Remove the defective bulb by pushing it in and turning it counterclockwise.

1. Headlight beam adjusting screw

1

(a)(b)

1. Tail/brake light bulb holder

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3. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops.

4. Install the bulb holder (together with the bulb) by turning it clockwise.

EBU25650

Removing a wheel

1. Loosen the wheel nuts.

2. Elevate the ATV and place a suitable stand under the frame.

3. Remove the nuts from the wheel. 4. Remove the wheel.

EBU25690

Installing a wheel

1. Install the wheel and the nuts.

NOTE:

Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to-

wards the wheel.

1. Tail/brake light bulb 2. Tail/brake light bulb holder

1 2

1. Wheel nut

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2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified

torques.

EBU25710

Troubleshooting

Although Yamaha ATVs receive a thorough in-

spection before shipment from the factory, trouble may occur during operation. Any problem in the fu- el, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly. Use only genuine Yamaha replacement parts. Im- itation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills.

1. Tapered nut

Tightening torques: Front wheel nut:

55 Nm (5.5 mkgf, 39.8 ftlbf) Rear wheel nut:

55 Nm (5.5 mkgf, 39.8 ftlbf)

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EWB02260

WARNING

POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe in- jury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys- tem. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces.

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EBU25791

Troubleshooting chart

Check the fuel level in the fuel tank.

1. Fuel There is enough fuel.

There is no fuel.

Check the compression.

Supply fuel. The engine does not start. Check the compression.

Operate the electric starter.

2. Compression There is compression.

There is no compression.

Check the ignition.

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. Have a Yamaha dealer check the ATV.

The engine does not start. Check the battery.

Operate the electric starter.

4. Battery The engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the electrolyte level, recharge the battery and check the lead connections.

Dry

Wet Open the throttle halfway and operate the electric starter.

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EBU25860

CLEANING AND STORAGE

EBU25890

Cleaning

Frequent, thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the ATV:

a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may be used.

b. Make sure the spark plug and all filler caps are properly installed.

2. If the engine case is excessively greasy, apply degreaser with a paint brush. Do not apply de- greaser to the chain, sprockets or wheel ax- les.

3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure to do the job.

CAUTION:

ECB00710

Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical de- vices. Many expensive repair bills have result-

ed from improper high-pressure detergent applications such as those available in coin-

operated car washers.

4. Once most of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bot- tle brush is handy for hard-to-reach places.

5. Rinse the ATV off immediately with clean wa- ter and dry all surfaces with a chamois, clean towel or soft absorbing cloth.

6. Dry the chain and lubricate it to prevent it from rusting.

7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.

8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protec- tive finish. When finished cleaning, start the engine and let it idle for several minutes.

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EWB02300

EBU25932

Storage

Short-term

Always store your ATV in a cool, dry place and, if necessary, protect it against dust with a porous cover.

CAUTION:

ECB00720

Storing the ATV in a poorly ventilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust.

To prevent corrosion, avoid damp cellars,

stables (because of the presence of ammo- nia) and areas where strong chemicals are

stored.

Long-term

Before storing your ATV for several months: 1. Follow all the instructions in the Cleaning

section of this chapter. 2. Turn the fuel cock lever to OFF. 3. Drain the carburetor float chamber by loosen-

ing the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank.

4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel from deteriorat- ing.

5. Perform the following steps to protect the cyl- inder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark

plug. b. Pour a teaspoonful of engine oil into the

spark plug bore.

WARNING

POTENTIAL HAZARD Operation with wet brakes after washing. WHAT CAN HAPPEN Wet brakes may have reduced stopping abil- ity, increasing the chance of an accident. HOW TO AVOID THE HAZARD Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings.

Specified amount: 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel)

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c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.)

d. Turn the engine over several times with the starter. (This will coat the cylinder wall with oil.)

e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap.

6. Lubricate all control cables and the pivoting points of all levers and pedals.

7. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that all of its wheels are off the ground. Alternative- ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.

8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it.

9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it 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 in-

formation on storing the battery, see page 8-40.

NOTE:

Make any necessary repairs before storing the

ATV.

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EBU25960

SPECIFICATIONS

EBU25974

Dimensions:

Overall length: 1700 mm (66.9 in)

Overall width: 990 mm (39.0 in)

Overall height: 980 mm (38.6 in)

Seat height: 685 mm (27.0 in)

Wheelbase: 1080 mm (42.5 in)

Ground clearance: 145 mm (5.7 in)

Minimum turning radius: 2900 mm (114 in)

Weight:

With oil and fuel: 148.0 kg (326 lb)

Engine:

Engine type: Air cooled 4-stroke, SOHC

Cylinder arrangement: Forward-inclined single cylinder

Displacement: 124.0 cm

3

(7.57 cu.in) Bore

stroke: 49.0

66.0 mm (1.93

2.60 in)

Compression ratio: 9.00 :1

Starting system: Electric starter

Lubrication system: Wet sump

Engine oil:

Type: YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40

Recommended engine oil grade: API service SE, SF, SG type or higher

0 10 30 50 70 90 110 130F

YAMALUBE 4 (10W30) or SAE 10W30

SAE 5W30

-20 -10 0 10 20 30 40 50C

YAMALUBE 4 (20W40) or SAE 20W40

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Engine oil quantity: Periodic oil change:

1.25 L (1.32 US qt) (1.10 Imp.qt)

Transmission oil:

Quantity: 0.6 L (0.63 US qt) (0.53 Imp.qt)

Air filter:

Air filter element: Wet element

Fuel:

Recommended fuel: Unleaded gasoline only

Fuel tank capacity: 7.0 L (1.85 US gal) (1.54 Imp.gal)

Fuel reserve amount: 1.3 L (0.34 US gal) (0.29 Imp.gal)

Carburetor:

Manufacturer: MIKUNI

Type x quantity: VM18SH x 1

Spark plug (s):

Manufacturer/model: NGK/CR7HSA

Spark plug gap: 0.60.7 mm (0.0240.028 in)

Clutch:

Clutch type: Dry, centrifugal automatic

Transmission:

Primary reduction system: Helical gear/spur gear

Primary reduction ratio: 43/14

40/17 (7.226) Secondary reduction system:

Chain drive Secondary reduction ratio:

32/12 (2.666) Transmission type:

V-belt automatic Operation:

Centrifugal automatic type Reverse gear:

49/14

49/15

40/17 (26.902)

Chassis:

Frame type: Steel tube frame

Caster angle: 6.0

Trail: 15.0 mm (0.59 in)

Front tire:

Type: Tubeless

Size: AT20 x 7-8

Manufacturer/model: DUNLOP/KT536A

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Rear tire:

Type: Tubeless

Size: AT22 x 10-8

Manufacturer/model: DUNLOP/KT537A

Loading:

Maximum load: 105.0 kg (231 lb) (Total weight of rider, cargo, accessories, and tongue)

Tire air pressure (measured on cold tires):

Recommended:

Front: 20 kPa (2.9 psi) (0.20 kgf/cm

2

) Rear:

25 kPa (3.6 psi) (0.25 kgf/cm

2

)

Minimum:

Front: 17 kPa (2.5 psi) (0.17 kgf/cm

2

) Rear:

22 kPa (3.2 psi) (0.22 kgf/cm

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)

Maximum:

Front: 23 kPa (3.3 psi) (0.23 kgf/cm

2

) Rear:

28 kPa (4.1 psi) (0.28 kgf/cm

2

)

Front wheel:

Wheel type: Panel wheel

Rim size: 8×5.5AT

Rear wheel:

Wheel type: Panel wheel

Rim size: 8×8.0AT

Front brake:

Type: Drum brake

Operation: Right hand operation

Rear brake:

Type: Drum brake

Operation: Left hand operation

Front suspension:

Type: Swing axle

Spring/shock absorber type: Coil spring/oil damper

Wheel travel: 70 mm (2.8 in)

Rear suspension:

Type: Swingarm

Spring/shock absorber type: Coil spring/oil damper

Wheel travel: 80 mm (3.1 in)

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Electrical system:

Ignition system: DC. CDI

Charging system: AC magneto

Battery:

Model: 12N12C-4A-2

Voltage, capacity: 12 V, 12.0 Ah

Headlight:

Bulb type: Krypton bulb

Bulb voltage, wattage x quantity:

Headlight: 12 V, 30 W/30.0 W

2 Tail/brake light:

12 V, 5.0/21.0 W

1 Neutral indicator light:

12 V, 1.7 W

1 Reverse indicator light:

12 V, 1.7 W

1

Fuses:

Main fuse: 15.0 A

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EBU25981

CONSUMER INFORMATION

EBU26011

Identification numbers

Record the key identification number, vehicle iden- tification number and model label information in the spaces provided below for assistance when or- dering spare parts from a Yamaha dealer or for ref- erence in case the ATV is stolen.

KEY IDENTIFICATION NUMBER:

VEHICLE IDENTIFICATION NUMBER:

MODEL LABEL INFORMATION:

EBU26020

Key identification number

The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key.

EBU26030

Vehicle identification number

The vehicle identification number is stamped into the frame.

1. Key identication number

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NOTE:

The vehicle identification number is used to identi-

fy your ATV.

EBU26050

Model label

The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- er.

1. Vehicle identication number

1

1. Model label

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EBU26060

Noise regulation

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW. These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust system

Mufer

Exhaust pipe

Silencer

Intake system

Air cleaner case

Air cleaner element

Intake duct

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EBU26080

Maintenance record

Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER

NAME AND ADDRESS REMARKS month km (mi) hours

1 320 (200) 20 3 1300 (800) 80 6 2500 (1600) 160 12 5000 (3200) 320 18 7500 (4800) 480 24 10000 (6400) 640 30 12500 (8000) 800 36 15000 (9600) 960 42 17500 (11200) 1120 48 20000 (12800) 1280 54 22500 (14400) 1440 60 25000 (16000) 1600

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EBU26501

YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY

Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha ATVs purchased from an authorized Yamaha ATV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, sub- ject to certain stated limitations.

THE PERIOD OF WARRANTY for Yamaha ATVs shall be six (6) months from the date of purchase.

DURING THE PERIOD OF WARRANTY any authorized Yamaha ATV dealer will, free of charge, repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the products warranty period. All parts replaced under warranty become property of Yamaha Motor Corp. U.S.A.

GENERAL EXCLUSIONS from this warranty shall include any failures caused by: a. Competition or racing use. b. Installation of parts or accessories that are not

qualitatively equivalent to genuine Yamaha parts. c. Abnormal strain, neglect, or abuse. d. Lack of proper maintenance. e. Accident or collision damage. f. Modification to original parts. g. Damage due to improper transportation.

SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance, such as spark plugs, oil, oil filter, air filter, and brake shoes.

THE CUSTOMERS RESPONSIBILITY under this war- ranty shall be to: 1. Operate and maintain the ATV as specified in the

appropriate owners manual; 2. Give notice to an authorized Yamaha ATV dealer

of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealers place of business.

WARRANTY TRANSFER: To transfer the warranty from the original purchaser to any subsequent pur- chaser(s), it is imperative that the machine be inspected and registered for warranty by an autho- rized Yamaha ATV dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. An inspection and registration fee will be charged for this service.

EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation, USA also warrants to the ultimate purchaser and each subsequent pur- chaser of each 2006 and later model Yamaha ATV covered by this warranty that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards

within the period listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty.

All Models Thirty (30) months from the original purchase date

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

YAMAHA MOTOR CORPORATION, U.S.A. P.O. Box 6555

Cypress, California 90630

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WARRANTY QUESTIONS AND ANSWERS

Q. What costs are my responsibility during the warranty period? A. The customers responsibility includes all costs of normal maintenance services,

non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes.

Q. What are some examples of abnormal strain, neglect, or abuse? A. These terms are general and overlap each other in areas. Specific examples include:

Running the machine out of oil, sustained high rpm, full-throttle, operating the machine with a broken or damaged part which causes another part to fail, damage or failure due to improper or careless transportation and or tie-down. If you have any specific questions on operation or maintenance, please contact your dealer for advice.

Q. Does the warranty cover incidental costs such as towing or transportation due to a failure?

A. No. The warranty is limited to repair of the machine itself.

Q. May I perform any or all of the recommended maintenance shown in the Owners Manual instead of having the dealer do them?

A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owners and Service Manual. We do recommend, however, that items requiring special tools or equipment be done by a Yamaha ATV dealer.

Q. Will the warranty be void or cancelled if I do not operate or maintain my new ATV exactly as specified in the Owners Manual?

A. No. The warranty on a new ATV cannot be voided or cancelled. However, if a particular failure is caused by operation or maintenance other than as described in the Owners Manual, that failure may not be covered under warranty.

Q. What responsibility does my dealer have under this warranty? A. Each Yamaha ATV dealer is expected to:

1. Completely set up every new machine before sale. 2. Explain the operation, maintenance, and warranty requirements to your satis-

faction at the time of sale, and upon your request at any later date. 3. Each Yamaha ATV dealer is held responsible for his setup, service and war-

ranty repair work.

Q. Is the warranty transferable to second owners? A. Yes. The remainder of the existing warranty can be transferred upon request. The

unit has to be inspected and re-registered by an authorized Yamaha ATV dealer for the policy to remain effective.

CUSTOMER SERVICE

If your machine requires warranty service, you must take it to any authorized Yamaha ATV dealer within the continental United States. Be sure to bring your warranty registration card or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write:

YAMAHA MOTOR CORPORATION U.S.A. CUSTOMER RELATIONS DEPARTMENT

P.O. Box 6555 Cypress, California 90630

When contacting Yamaha Motor Corporation, U.S.A. dont forget to include any important information such as names, addresses, model, V.I.N. (frame number), dates, and receipts.

CHANGE OF ADDRESS

The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related defect and recall. This list is compiled from the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase.

If you should move after you have purchased your new ATV, please advise us of your new address by sending a postcard listing your ATV model name, V.I.N. (frame number), dealer number (or dealers name) as it is shown on your warranty card, your name and new mailing address. Mail to:

YAMAHA MOTOR CORPORATION, U.S.A. P.O. Box 6555

Cypress, California 90630 Attention: Warranty Department

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

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EBU26122

YAMAHA EXTENDED SERVICE (Y.E.S.)

Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.).

Y.E.S. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get uninterrupted factory-backed coverage for extra peace of mind.

Y. E. S. is flexible. You choose the plan thats right for you: 12 months, 24 months, or 36 months beyond your warranty period.

Y.E.S. is designed and administered by the same Yamaha people who handle your warranty and i t shows in the comprehensive coverage benefits. There are no mileage l imitat ions. Coverage isn t l imited to moving par ts or the drive train l ike many other plans. And Y.E.S. covers manufacturing defects just l ike the warranty. See the sample contract at your Yamaha dealer to see how comfor t ing uninterrupted factory- backed protection can be.

You don t have to pay anything for covered repairs. There s no deduc t ib le to pay, and repa i rs a ren t pro-rated. You don t have any out-of-pocket expenses for covered repairs.

In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost. TRIP gives you up to $150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb coverage goes into effect when you purchase Y.E.S., so it applies to any warranty repairs as well as covered repairs during your entire Y.E.S. plan period.

Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide.

Y.E.S. coverage is transferable to a new owner if you sell or trade in your ATV. That can make your Yamaha much more valuable!

This excellent Y.E.S. plan coverage is only available to Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha Extended Service.

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We urge you to act now. Youll get the excellent benefits of TRIP coverage r ight away, and you l l rest easy knowing you l l have strong factory-backed protection even after your Yamaha Limited Warranty expires. You can also save money: Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today!

A special note: If visiting your dealer isnt convenient, contact Yamaha with your Pr imary ID number (your frame number). We l l be happy to help you get the Y.E.S. coverage you need.

Yamaha Service Marketing P.O. Box 6555 Cypress, CA 90630

Indicates a potential hazard that could result in serious injury or death.

WARNING

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EBU26132

INDEX

A

Accessories and loading ………………………………………… 6-6 Air filter elements, engine and V-belt filter cleaning ….. 8-15

B

Battery………………………………………………………… 5-7

,

8-40 Brake lever free play, adjusting the front…………………. 8-27 Brake lever free play (rear), adjusting …………………….. 8-32 Brake lever, front…………………………………………………… 4-5 Brake lever, rear……………………………………………………. 4-5 Brake levers, checking and lubricating……………………. 8-37 Brakes, front and rear ……………………………………………. 5-3 Brake shoes, checking the front and rear ……………….. 8-26

C

Cables, checking and lubricating …………………………… 8-37 Carburetor, adjusting……………………………………………. 8-23 Carrier, front ……………………………………………………….. 4-12 Carrier, rear………………………………………………………… 4-12 Chassis fasteners………………………………………………….. 5-7 Cleaning ………………………………………………………………. 9-1

D

Drive chain …………………………………………………………… 5-4 Drive chain, lubricating…………………………………………. 8-36 Drive chain slack …………………………………………………. 8-33 Drive select lever…………………………………………………… 4-7 Drive select lever and driving in reverse …………………… 6-3

E

Engine break-in …………………………………………………….. 6-4 Engine, cold start ………………………………………………….. 6-1 Engine idling speed……………………………………………… 8-24 Engine oil ……………………………………………………..5-3

,

8-10 Engine, starting a warm …………………………………………. 6-3 Engine stop switch ………………………………………………… 4-2

F

Fuel ……………………………………………………………….4-8

,

5-3 Fuel cock……………………………………………………………… 4-9 Fuel tank cap………………………………………………………… 4-7 Fuse, replacing……………………………………………………. 8-44

H

Handlebar switches……………………………………………….. 4-2 Headlight beam, adjusting ……………………………………. 8-46 Headlight bulb, replacing ……………………………………… 8-44

I

Identification numbers………………………………………….. 11-1 Indicator lights ………………………………………………………. 4-2 Instruments, lights and switches ……………………………… 5-7

K

Key identification number……………………………………… 11-1 Knuckle shafts, lubricating ……………………………………. 8-39

L

Label locations ……………………………………………………… 2-1 Light switch ………………………………………………………….. 4-3

M

Main switch ……………………………………………………………4-1 Maintenance and lubrication chart …………………………….8-5 Maintenance chart, emission control system………………8-3 Maintenance record ………………………………………………11-4 Model label…………………………………………………………..11-2

N

Neutral indicator light ………………………………………………4-2 Noise regulation……………………………………………………11-3

O

Owners manual and tool kit……………………………………..8-1

P

Parking………………………………………………………………….6-5 Parking brake…………………………………………………………4-6 Parking on a slope ………………………………………………….6-6 Part locations …………………………………………………………3-1 Pre-operation check list …………………………………………..5-1

R

Reverse indicator light …………………………………………….4-2 Riding your ATV……………………………………………………..7-1

S

Safety information…………………………………………………..1-1 Seat…………………………………………………………………….4-11 Spark arrester, cleaning…………………………………………8-21 Spark plug, checking……………………………………………….8-8 Specifications……………………………………………………….10-1 Speed limiter ………………………………………………………….4-4 Starter (choke) ……………………………………………………..4-11 Start switch ……………………………………………………………4-3 Steering shaft, lubricating ………………………………………8-40 Storage …………………………………………………………………9-2

Suspension, lubricating the upper and lower arm pivots ………………………………………………………………..8-38

T

Tail/brake light bulb, replacing ………………………………..8-47 Throttle cable free play, adjusting……………………………8-25 Throttle lever…………………………………………………..4-3

,

5-4 Tire pressure, measuring…………………………………………5-6 Tires……………………………………………………………………..5-5 Tire wear limit ………………………………………………………..5-7 Transmission oil …………………………………………….5-3

,

8-12 Troubleshooting ……………………………………………………8-49 Troubleshooting chart ……………………………………………8-51

V

Valve clearance ……………………………………………………8-25 V-belt case drain plug ……………………………………………8-23 Vehicle identification number………………………………….11-1

W

Warranty, extended ………………………………………………11-7 Warranty, limited…………………………………………………..11-5 Wheel bearings, checking………………………………………8-38 Wheel, installing……………………………………………………8-48 Wheel, removing…………………………………………………..8-48

PRINTED IN JAPAN 2006.03-0.6×1 !

(E)

YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER

LOCATE AND READ OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558)

WARNING

ALWAYS: use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns. avoid paved surfaces-pavement may seriously affect handling and control.

Improper ATV use can result in SEVERE INJURY or DEATH.

NEVER operate: without proper training or instruction. at speeds too fast for your skills or the conditions. on public roads-a collision can occur with another vehicle. with a passenger-passengers affect balance and steering and increase risk of losing control.

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR

NEVER USE ON PUBLIC

ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

B EE R

B EE R

EBU26141

Dear New Yamaha ATV Owner:

CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV. You have purchased a quality Yamaha product that, with proper use and care, will provide hours of riding pleasure. BEFORE YOU OPERATE YOUR NEW ATV, Yamaha recommends these important points:

8 READ YOUR OWNERS MANUAL

8 A CHILD UNDER 6 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 50CC OR GREATER

8 A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER

8 A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER THAN 90CC

8 TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA ASK YOUR DEALER FOR DETAILS OR CALL 1-800-887-2887

If you have any questions about these points, or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership, please fill out the information below and mail this card to yamaha today.

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Name:

Address:

Telephone:

Dealer Name & Address:

Primary I.D. [Engine Number]:

ATV Model: Purchase Date:

MO. DAY YR.

[ ]

ATV card for US 4/2/03 9:06 AM Page 1

NO POSTAGE NECESSARY IF MAILED

IN THE UNITED STATES

FIRST CLASS PERMIT NO. 4 CYPRESS, CA

POSTAGE WILL BE PAID BY ADDRESSEE

YAMAHA MOTOR CORPORATION U.S.A.

P.O. BOX 6555

CYPRESS, CALIFORNIA 90630-9989

ATTN: SALES ADMINISTRATION

ATV card for US 4