Yamaha GRIZZLY 125 YFM125GB Owner's Manual
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Yamaha GRIZZLY 125 YFM125GB Owner's Manual

Yamaha GRIZZLY 125 YFM125GB Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
LIRE ATTENTIVEMENT CE MANUEL!
Il comprend d'importantes informations de sécurité.
¡LEA ESTE MANUAL ATENTAMENTE!
Contiene indicaciones importantes acerca de la seguridad.
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
OWNER'S MANUAL
YFM125GB
1PY-28199-60

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Summary of Contents for Yamaha GRIZZLY 125 YFM125GB

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. LIRE ATTENTIVEMENT CE MANUEL! Il comprend d’importantes informations de sécurité. ¡LEA ESTE MANUAL ATENTAMENTE! Contiene indicaciones importantes acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM125GB 1PY-28199-60...
  • Page 2 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2011.03-0.2×1 CR IMPRESO EN PAPEL RECICLADO (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM125GB 1PY-28199-60-E0...
  • Page 4 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. EC Declaration of Conformity conforming to Directive 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM125A (YFM125G) (JY4AE02W0B0014406–)
  • Page 5 Yamaha experience in the production of fine sporting, touring, and pacesetting 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.
  • Page 6 EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 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: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 7 Please check your local riding laws and regulations before operating this ATV. EBU17390 YFM125GB OWNER’S MANUAL ©2011 by Yamaha Motor Co., Ltd. 1st edition, February 2011 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS LOCATION OF THE WARNING AND Starter (choke) ..........4-10 SPECIFICATION LABELS ......1-1 Seat ............4-10 Front carrier ..........4-11 SAFETY INFORMATION ......2-1 Rear carrier ..........4-11 DESCRIPTION ..........3-1 PRE-OPERATION CHECKS ......5-1 Left view ............3-1 Fuel .............5-3 Right view............
  • Page 9 Parking on a slope ........6-5 Engine oil ..........8-11 Accessories and loading ......6-6 Transmission oil ........8-14 Cleaning the engine and V-belt case air RIDING YOUR ATV ........7-1 filter elements .........8-17 GETTING TO KNOW YOUR ATV....7-2 Cleaning the spark arrester ......8-23 RIDE WITH CARE AND GOOD V-belt case drain screw ......8-24 JUDGMENT ..........
  • Page 10 Adjusting a headlight beam ...... 8-46 Replacing the tail/brake light bulb .... 8-47 Removing a wheel ........8-47 Installing a wheel ........8-48 Troubleshooting ........8-49 Troubleshooting chart ......8-50 CLEANING AND STORAGE......9-1 Cleaning ............. 9-1 Storage ............9-2 SPECIFICATIONS ........

  • Page 11: Location Of The Warning And Specification Labels

    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.
  • Page 12 < 5 kg ( 11 Ibs ) 1C5-2817R-00 1AS-2816P-00 < 10 kg ( 22 Ibs ) 1C5-2817R-10 20.0 25.0 0.20 kgf/cm 0.25 kgf/cm 1C5-2816M-M0...
  • Page 13 4D3-2816L-20 YFM125A 6.5kW 152kg 1C5-2156A-20 43P-2816R-01 2011 YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN 8AC-2817L-00...
  • Page 14 Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. NEVER permit children under age 12 to operate this ATV. Operation of this ATV by children under the age of 12 increases the risk of severe injury or death.
  • Page 15 NEVER use with drugs or alcohol. Adjust the tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or death. **.* kPa **.* kPa *.** kgf/cm² *.** kgf/cm² *.* psi *.* psi NEVER store fuel or flammable liquids.
  • Page 16 Overloading can cause loss of control. Loss of control can result in severe injury or death. Model Name ****** Max. Power *** kW *** kg Mass In Running Order **** 1 Year of construction YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN...

  • Page 17: Safety Information

    EBU17431 SAFETY INFORMATION EBU17536 Never carry a passenger on an ATV. Always avoid operating an ATV on any paved AN ATV IS NOT A TOY AND CAN BE HAZARD- surfaces, including sidewalks, driveways, park- OUS TO OPERATE. ing lots and paved streets. An ATV handles differently from other vehicles, in- Never operate an ATV on any paved street, cluding motorcycles and cars.
  • Page 18 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 19 hill. If you stall or roll backwards, follow the spe- Always be sure there are no obstacles or people cial procedure for braking described in this man- behind you when you operate in reverse. When ual. Dismount on the uphill side or to a side if it is safe to proceed in reverse, go slowly.
  • Page 20 to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in en- closed or poorly ventilated areas. If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT. Do not run engine indoors.

  • Page 21: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 5 6 7 1. Owner’s tool kit 1. Front carrier 2. Battery 2. Starter (choke) 3. Drive select lever 3. Fuel cock 4. Spark plug 4. Throttle stop screw 5. Headlight 5. Tail/brake light 6.

  • Page 22: Controls And Instruments

    EBU17712 Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Parking brake lock plate 3. Reverse indicator light 4. Neutral indicator light 5. Front brake lever 6.

  • Page 23: Instrument And Control Functions

    EBU17733 INSTRUMENT AND CONTROL FUNCTIONS EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.

  • Page 24: Indicator Lights

    EBU17793 EBU18061 Indicator lights Handlebar switches 1. Reverse indicator light “R” 1. Horn switch “ ” 2. Neutral indicator light “N” 2. Light switch “ /OFF” 3. Engine stop switch “ ” EBU17860 4. Start switch “ ” Neutral indicator light “ ”...

  • Page 25: Throttle Lever

    EBU18101 EBU18282 Start switch “ ” Throttle lever Push this switch to crank the engine with the start- Once the engine is running, pushing the throttle le- er. See the starting instructions on page 6-1 prior ver will increase the engine speed. to starting the engine.

  • Page 26: Speed Limiter

    EBU18323 Speed limiter Your ATV is equipped 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).

  • Page 27: Rear Brake Lever

    1. Front brake lever 1. Rear brake lever EBU18401 EBU18461 Rear brake lever Parking brake The rear brake lever is located on the left handle- Use the parking brake before starting the engine or bar. To apply the rear brake, pull the brake lever to- after parking the ATV, especially on a slope.

  • Page 28: Drive Select Lever

    braking performance which could cause an accident. You could also wear out the brakes prematurely. 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”...

  • Page 29: Fuel Tank Cap

    EBU18720 1. Before refueling, turn off the engine and be Fuel tank cap sure that no one is sitting on the vehicle. Nev- Remove the fuel tank cap by turning it counter- er refuel while smoking, or while in the vicinity clockwise.

  • Page 30: Fuel Cock

    Fuel reserve amount: 1.3 L (0.34 US gal, 0.29 Imp.gal) Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane 3. Wipe up any spilled fuel immediately.
  • Page 31 FUEL FUEL 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.

  • Page 32: 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. FUEL 1. Arrow mark positioned over “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

  • Page 33: Front Carrier

    1. Seat lock lever 1. Projection 2. Seat holder To install the seat Insert the projections on the front of the seat into EBU18962 Front carrier the seat holders and push down on the seat at the Do not exceed the load limit of 5.0 kg (11 lb) for rear.

  • Page 34: Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 35 ITEM ROUTINE PAGE • Check operation, and correct if necessary. Rear brake • Lubricate cable if necessary. 5-3, 8-27, 8-32 • Check lever free play, and adjust if necessary. • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary.

  • Page 36: Fuel

    Check the operation of the throttle lever. It must open smoothly and spring back to the idle position EBU19580 when released. Have a Yamaha dealer correct if Transmission oil necessary. Make sure that the transmission oil is at the speci- fied level.
  • Page 37 Tire pressure Recommended tire pressure: Use the low-pressure tire gauge to check and ad- Front just tire pressures when the tires are cold. Tire 20.0 kPa (0.200 kgf/cm², 2.9 psi) pressures must be equal on both sides. Rear WARNING! Operation of this vehicle with im- 25.0 kPa (0.250 kgf/cm², 3.6 psi) proper tire pressure may cause severe injury Minimum tire pressure:...
  • Page 38 EWB02551 WARNING Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.

  • Page 39: Chassis Fasteners

    EBU19850 Front: Instruments, lights and switches Manufacturer/model: Check that all instruments, lights and switches are DUNLOP/KT536A working properly. Correct if necessary. Size: AT20 x 7-8 EBU19860 Battery Type: Tubeless Check the fluid level in the battery. Fill with distilled Rear: water if necessary.

  • Page 40: Operation

    Read the Owner’s Manual carefully before riding on. If the indicator light does not come on, the ATV. If there is a control or function you do not have a Yamaha dealer check the electrical cir- understand, ask your Yamaha dealer. cuit.

  • Page 41: Starting A Warm Engine

    Ambient temp./starter (choke) position 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.

  • Page 42: Operating The Drive Select Lever And Driving In Reverse

    EBU20361 Operating the drive select lever and driving in reverse ECB00170 NOTICE 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 1.

  • Page 43: Engine Break-In

    If the indicator light does not come on, cessive load on it for the first 320 km (200 mi) or 20 have a Yamaha dealer check the electrical circuit. hours. The various parts in the engine wear and polish themselves to the correct operating clear- 4.

  • Page 44: Parking

    If any engine trouble should occur during the WARNING engine break-in period, immediately have a Avoid parking on hills or other inclines. Park- Yamaha dealer check the ATV. ing on a hill or other incline could cause the ATV to roll out of control, increasing the EBU30020 chance of an accident.

  • Page 45: Accessories And Loading

    An accessory which can shift position sories or offer other modifications for Yamaha or come off while you are riding could affect your vehicles. Yamaha is not in a position to test the ability to control the ATV. products that these aftermarket companies pro-...
  • Page 46 Do not mount an accessory where it could inter- sense and good judgment as the stability and han- fere with your ability to control the ATV. Exam- dling of an ATV can be changed. When adding ac- ples include (but are not limited to) a heavy or cessories, keep the following points in mind: bulky object attached to the handlebars which Never exceed the weight limits shown.
  • Page 47 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 takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully.

  • Page 48: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 49: Getting To Know Your Atv

    EBU21316 RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is for recreation and utility use. This sec- WARNING tion, Riding your ATV, provides general ATV riding Do not operate this ATV or allow anyone else instructions for recreational riding.
  • Page 50 Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics. Take the time to learn the basic techniques well before attempting more difficult maneuvers.
  • Page 51 Apparel Always wear the following to reduce risk of injury in an accident: Approved motorcycle helmet that fits properly Eye protection (goggles, helmet face shield, or protective eyewear) Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
  • Page 52 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance Do not operate after or while consuming alco- procedures and schedules described in the Own- hol or drugs.
  • Page 53 opening, even when the throttle lever is pushed to EWB01462 WARNING the maximum. Turning in the adjusting screw limits the maximum engine power available and de- Improper loading or towing can increase the creases the maximum speed of the ATV. Turning risk of loss of control, an overturn, or other ac- in the adjusting screw decreases top speed, and cident.
  • Page 54 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) Drive more slowly than you would without a load. The more weight you carry, the slower you should go.
  • Page 55 ATV should be The muffler and other engine parts become ex- genuine Yamaha or equivalent components de- tremely hot during operation and remain hot after signed for use on this ATV and should be installed the engine has stopped.

  • Page 56: Be Careful Where You Ride

    To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for use on unpaved surfaces children are not likely to touch it. only. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control.
  • Page 57 Watch carefully for other vehicles. Make sure you bumps, or holes. Go slowly and be extra care- know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do not ways be alert to changing terrain conditions ride on any paved public street, road or motorway.
  • Page 58 loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. [EWB01541] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.

  • Page 59: Turning Your Atv

    a loss of directional control. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. When slowing down or stopping, release the 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.
  • Page 60 As you approach a curve, slow down and begin to This procedure should be practiced at slow speed turn the handlebars in the desired direction. As you many times in a large unpaved area with no obsta- do so, put your weight on the footboard to the out- cles.

  • Page 61: Climbing Uphill

    CLIMBING UPHILL Avoid crossing the side of a steep hill if pos- sible. When crossing the side of a hill, shift EWB01671 WARNING your weight to the uphill side of the ATV. Climbing hills improperly can cause overturns or loss of control. Use proper riding tech- niques described in this Owner’s Manual.
  • Page 62 on steeper inclines, standing on the footboards and leaning forward over the handlebars. Whenev- er possible, ride straight up hills. Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side – there could be another person, an obstacle, or a sharp drop-off.

  • Page 63: Riding Downhill

    mediately on the uphill side or to a side if pointed RIDING DOWNHILL straight uphill. Turn the ATV around and remount, EWB01131 WARNING following the procedure described in the Owner’s Manual. WARNING! Stalling, rolling backwards Going down a hill improperly could cause or improperly dismounting while climbing a hill overturns or loss of control.

  • Page 64: Crossing A Slope

    When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as pos- sible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you.

  • Page 65: Crossing Through Shallow Water

    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 as described in the Owner’s Manual on level ground. Be very careful when turning on any hill.
  • Page 66 The ATV can be used to cross slow moving, shal- ability. WARNING! Wet brakes may have re- low water of up to a maximum of 20 cm (8 in) in duced stopping ability, which could cause loss depth. Before entering the water, choose your path of control.

  • Page 67: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN EWB01651 WARNING Riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual.
  • Page 68 Learn to safely control skidding or sliding by If the rear wheels of your ATV start to slide side- practicing at low speeds and on level, ways, control can usually be regained (if there is smooth terrain. room to do so) by steering in the direction of the On extremely slippery surfaces, such as ice, slide.

  • Page 69: What To Do If

    WHAT TO DO IF... THE REAR BRAKE – the ATV may tip over on This section is designed to be a reference guide top of you. Dismount the ATV on the uphill side. only. Be sure to read each section on riding tech- (See page 7-14.) niques completely.

  • Page 70: Periodic Maintenance And Adjustment

    The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.

  • Page 71: Owner's Manual And Tool Kit

    If you do not have the tools or experience required spective compartments under the seat. for a particular job, have a Yamaha dealer perform it for you. 1. Owner’s manual 2.

  • Page 72: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t 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.
  • Page 73 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 74: General Maintenance And Lubrication Chart

    However, keep in mind that if the ATV isn’t 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.
  • Page 75 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check runout and for damage, and replace if nec- √ √ √ √ Wheels essary. • Check tread depth and for damage, and replace if necessary.
  • Page 76 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation and repair or replace if damaged. √ √ √ √ √ Steering system • Check toe-in and adjust if necessary. •...
  • Page 77 EBU23061 Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle.

  • Page 78: Checking The Spark Plug

    EBU23213 2. Remove the spark plug as shown, with the Checking the spark plug spark plug wrench included in the owner’s tool The spark plug is an important engine component, kit. 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-...
  • Page 79 If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

  • Page 80: Engine Oil

    Tightening torque: Spark plug: If the engine was started before checking the oil 13 Nm (1.3 m·kgf, 9.4 ft·lbf) level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading. If a torque wrench is not available when installing 3.
  • Page 81 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.
  • Page 82 Tightening torque: Engine oil drain bolt: 32 Nm (3.2 m·kgf, 23 ft·lbf) 8. Refill with the specified amount of the recom- mended engine oil, and then install and tight- en the engine oil filler cap. Recommended oil: See page 10-1. Oil quantity: 1.25 L (1.32 US qt, 1.10 Imp.qt) 1.

  • Page 83: Transmission Oil

    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, wait at least ten minutes, and then check the oil level and correct it if necessary.
  • Page 84 8. Install the transmission oil filler bolt and its gasket, and then tighten the bolt to the speci- fied torque. Tightening torque: Transmission oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) To change the transmission oil 1. Place the ATV on a level surface. 2.
  • Page 85 Recommended transmission oil: See page 10-1. Oil quantity: 0.6 L (0.63 US qt, 0.53 Imp.qt) 7. Check the oil filler bolt gasket for damage, and replace it if necessary. 8. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.

  • Page 86: Cleaning The Engine And V-Belt Case Air Filter Elements

    EBU2384B 1. Place the ATV on a level surface. Cleaning the engine and V-belt case air 2. Remove the seat. (See page 4-10.) filter elements 3. Remove the breather hose by pulling it out, Both air filter elements should be cleaned at the and then loosen the air filter joint screw.
  • Page 87 1. Screw 1. Air filter case cover 2. Washer 2. Screw 3. Sponge material 5. Remove the screw and washer shown, and 4. Air filter element frame then pull the sponge material off from the air 5. Air filter case cover filter element frame.
  • Page 88 12. Install the air filter element into the air filter damaged. case. NOTICE: Make sure that the air filter 9. Apply Yamaha foam air filter oil or other qual- element is properly seated in the air filter ity foam air filter oil to the sponge material.
  • Page 89 13. Connect the air filter case cover to the air filter joint. 14. Install the air filter case cover by installing the screws, and then tighten the air filter joint screw. 15. Install the breather hose. 16. Install the seat. The air filter element should be cleaned every 20–...
  • Page 90 5. Remove the air filter case cover by removing the screw. 1. Panel 2. Quick fastener 1. Air filter case cover 4. Disconnect the coupler shown. 2. Screw 6. Remove the air filter element. 1. Coupler 8-21...
  • Page 91 1. Air filter element 1. Air filter element 8. Check the air filter element and replace it if 7. Tap the air filter element lightly to remove damaged. most of the dust and dirt. Blow out the remain- 9. Install the air filter element into the air filter ing dirt with compressed air as shown.

  • Page 92: Cleaning The Spark Arrester

    EBU27632 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be- fore cleaning the spark arrester. 1. Remove the tailpipe screws and their gasket. 1. Tailpipe screw 2. Gasket 3. Tailpipe 4. Spark arrester 4. Insert the tailpipe into the muffler and align the 1.

  • Page 93: V-Belt Case Drain Screw

    If water drains from the V-belt case after removing 2. Place a container under the V-belt case, and the screw, have a Yamaha dealer check the ATV then remove the V-belt case drain screw and as the water may affect other engine parts.

  • Page 94: Adjusting The Carburetor

    1. Start the engine and warm it up. requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary profes- The engine is warm when it quickly responds to the sional knowledge and experience. The adjustment throttle.

  • Page 95: Adjusting The Throttle Lever Free Play

    (a). To decrease the throttle lever free 1650–1750 r/min play, turn the adjusting bolt in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. EBU24047 Adjusting the throttle lever free play...

  • Page 96: Valve Clearance

    Yamaha dealer at the inter- line or mark, have a Yamaha dealer replace the vals specified in the periodic maintenance and lu- brake shoes as a set.

  • Page 97: Adjusting The Front Brake Lever Free Play

    Front brake Rear brake 1. Wear limit line 1. Wear limit line 2. Wear indicator 2. Wear indicator EBU24374 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.
  • Page 98 The brake lever free play should measure 5.0–8.0 mm (0.20–0.31 in) as shown. If the free play is in- correct, adjust it as follows. 1. Front carrier 2. Front carrier bolt 2. Remove the panel by removing the quick fas- 1.
  • Page 99 4. Remove the V-belt air filter element cover by removing the screw. 1. Panel 2. Quick fastener 1. V-belt air filter element cover 3. Disconnect the coupler shown. 2. Screw 5. Loosen the locknut and fully turn in the brake lever free play adjusting bolt at the brake le- ver.
  • Page 100 a=a' 1. Locknut 1. Brake equalizer 2. Brake lever free play adjusting bolt 2. Cable joint 6. Make sure the brake cable joint in the equaliz- er is straight when the brake is applied. If the cable joint isn’t straight, loosen the locknuts, and then turn the adjusting nuts on the front brake cables until the cable joint becomes straight.

  • Page 101: Adjusting The Rear Brake Lever Free Play

    7. Tighten the locknut on each brake cable. Tightening torque: 8. Turn the brake lever free play adjusting bolt in Front carrier bolt: direction (a) to increase the free play, and in 7 Nm (0.7 m·kgf, 5.1 ft·lbf) direction (b) to decrease it. EBU30440 Adjusting the rear brake lever free play The brake lever free play must be checked and, if...
  • Page 102 1. Brake lever free play 1. Locknut 2. Brake lever free play adjusting bolt 1. Loosen the locknut. 3. If the correct free play cannot be obtained as 2. Turn the brake lever free play adjusting bolt in described above, turn the adjusting bolt fully in direction (a) to increase the free play, and in direction (a), and then adjust the free play us- direction (b) to decrease it.

  • Page 103: Drive Chain Slack

    5. Use the adjusting bolt to obtain a precise ad- justment if necessary, and then tighten the locknut. If the correct free play cannot be ob- tained, have a Yamaha dealer adjust it. EBU24874 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary.
  • Page 104 To adjust the drive chain slack the engine as well as other vital parts of 1. Place the ATV on a level surface. the ATV and can lead to drive chain slip- 2. Loosen the hub stopper bolt locknut and then page or breakage.

  • Page 105: Lubricating The Drive Chain

    27 mm (1.06 in), have a the intervals specified in the periodic maintenance Yamaha dealer replace the drive chain. and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas.

  • Page 106: Checking And Lubricating The Cables

    If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil EWB02581 WARNING Inspect cables frequently and replace if dam- aged. Corrosion can result when the cable sheaths become damaged, and cables can 1.

  • Page 107: Checking And Lubricating The Front And Rear Brake Levers

    The front and rear wheel hub 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 hub bear- ings. 8-38...

  • Page 108: Lubricating The Lower Arm Pivots

    Left side EBU30380 1. Grease nipple Lubricating the lower arm pivots The lower arm pivots must be lubricated at the in- Right side tervals specified in the periodic maintenance and lubrication chart. For parts equipped with a grease nipple, use a grease gun.

  • Page 109: Lubricating The Front Knuckle Pivots

    Lubricating the front knuckle pivots Lubricating the steering shaft The front knuckle pivots must be lubricated at the The steering shaft must be lubricated by a Yamaha intervals specified in the periodic maintenance and dealer at the intervals specified in the periodic lubrication chart.

  • Page 110: Battery

    EBU25129 Batteries produce explosive gases. Keep Battery sparks, flame, cigarettes or other sources of ig- The battery is located under the seat. (See page nition away. Ventilate when charging or using 4-10.) in an enclosed space. A poorly maintained battery will corrode and dis- KEEP OUT OF REACH OF CHILDREN.
  • Page 111 3. If the electrolyte is at or below the minimum To remove the battery level mark, add distilled water to raise it to the 1. Disconnect the negative lead first and then the maximum level mark. NOTICE: Use only dis- positive lead.
  • Page 112 If the battery will be stored for more than two months, check the specific gravity of the electro- lyte at least once a month and fully charge the battery whenever necessary. ECB01100 NOTICE Always keep the battery charged. Storing a discharged battery can cause permanent battery damage.

  • Page 113: Replacing The Fuse

    1. Turn the key to “OFF” and turn off all electrical 4. If the fuse immediately blows again, have a circuits. Yamaha dealer check the electrical system. EBU25481 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
  • Page 114 1. Remove the cover at the rear of the headlight by pulling it off. 1. Headlight bulb holder cover 2. Headlight bulb holder 1. Cover at the rear of the headlight 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. 2.

  • Page 115: Adjusting A Headlight Beam

    EBU25551 Adjusting a headlight beam ECB00690 NOTICE It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b).

  • Page 116: Replacing The Tail/Brake Light Bulb

    EBU25613 Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as follows. 1. Remove the tail/brake light bulb holder (to- gether with the bulb) by turning it counter- clockwise. 1. Tail/brake light bulb 2. Tail/brake light bulb holder 4.

  • Page 117: Installing A Wheel

    Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Wheel nut 3. Elevate the ATV and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5.

  • Page 118: Troubleshooting

    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.

  • Page 119: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.

  • Page 120: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25902 may cause water seepage and deteriora- Cleaning tion of wheel bearings, brakes, transmis- Frequent, thorough cleaning of your ATV will not sion seals and electrical devices. Many only enhance its appearance but will improve its expensive repair bills have resulted from general performance and extend the useful life of improper high-pressure detergent applica-...

  • Page 121: Storage

    EBU30360 Specified amount: Storage 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel) Short-term Always store your ATV in a cool, dry place and, if 5. Perform the following steps to protect the cyl- necessary, protect it against dust with a porous inder, piston rings, etc.
  • Page 122 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.

  • Page 123: Specifications

    EBU25961 SPECIFICATIONS Dimensions: Cylinder arrangement: Forward-inclined single cylinder Overall length: Displacement: 1700 mm (66.9 in) 124 cm³ Overall width: Bore × stroke: 990 mm (39.0 in) 49.0 × 66.0 mm (1.93 × 2.60 in) Overall height: Compression ratio: 980 mm (38.6 in) 9.00 : 1 Seat height: Starting system:...
  • Page 124 Type: Fuel: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- Recommended fuel: Regular unleaded gasoline only Fuel tank capacity: 7.0 L (1.85 US gal, 1.54 Imp.gal) 50 ˚C Fuel reserve amount: 1.3 L (0.34 US gal, 0.29 Imp.gal) SAE 5W-30 Carburetor: Type ×...
  • Page 125 Reverse gear: Rear: 49/14 × 49/15 × 40/17 (26.902) 25.0 kPa (0.250 kgf/cm², 3.6 psi) Chassis: Minimum: Front: Frame type: 17.0 kPa (0.170 kgf/cm², 2.5 psi) Steel tube frame Rear: Caster angle: 22.0 kPa (0.220 kgf/cm², 3.2 psi) 6.0 ° Front wheel: Trail: 15.0 mm (0.59 in)
  • Page 126 Spring/shock absorber type: Reverse indicator light: 12 V, 1.7 W × 1 Coil spring/oil damper Wheel travel: Fuses: 70 mm (2.8 in) Main fuse: Rear suspension: 15.0 A Type: Swingarm EBU30400 Spring/shock absorber type: Coil spring/oil damper For EUR only Wheel travel: The figures quoted are emission levels and are not 80 mm (3.1 in)

  • Page 127: Consumer Information

    Record the vehicle identification number and mod- el label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number...
  • Page 128 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- 11-2...
  • Page 129 INDEX Engine, cold start ............6-1 Engine idling speed ............. 8-25 Accessories and loading ..........6-6 Engine oil .............. 5-3, 8-11 Air filter elements, engine and V-belt filter cleaning ..8-17 Engine, starting a warm ..........6-2 Engine stop switch ............4-2 Battery ..............
  • Page 130 Neutral indicator light ............. 4-2 Valve clearance ............8-27 V-belt case drain screw ..........8-24 Vehicle identification number ........11-1 Owner’s manual and tool kit ........... 8-2 Wheel hub bearings, checking ........8-38 Parking ................6-5 Wheel, installing ............8-48 Parking brake ..............
  • Page 132 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2011.03-0.2×1 CR...

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