Yamaha GRIZZLY 125 YFM125GZ Owner's Manual
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Yamaha GRIZZLY 125 YFM125GZ Owner's Manual

Yamaha GRIZZLY 125 YFM125GZ 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
This A
OWNER'S MANUAL
YFM125GZ
1C5-28199-66

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Summary of Contents for Yamaha GRIZZLY 125 YFM125GZ

  • 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 YFM125GZ This A 1C5-28199-66...
  • Page 2 PRINTED IN JAPAN 2009.03-0.1x1 ! (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM125GZ This A 1C5-28199-66-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 98 / 37 /EC, 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM125A ( YFM125G )
  • 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 YFM125GZ OWNER’S MANUAL ©2009 by Yamaha Motor Co., Ltd. 1st edition, February 2009 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 Seat ............4-10 Front carrier ..........4-11 SPECIFICATION LABELS ......1-1 Rear carrier ..........4-11 SAFETY INFORMATION ......2-1 PRE-OPERATION CHECKS ......5-1 Fuel ............5-3 DESCRIPTION ..........3-1 Engine oil ........... 5-3 Left view .............
  • Page 9 RIDING YOUR ATV ........7-1 V-belt case drain plug ......8-23 Adjusting the carburetor ......8-23 GETTING TO KNOW YOUR ATV....7-2 Adjusting the engine idling speed .... 8-23 RIDE WITH CARE AND GOOD JUDGMENT ..........7-2 Adjusting the throttle cable free play ..8-24 BE CAREFUL WHERE YOU RIDE....
  • Page 10 Troubleshooting ........8-47 Troubleshooting chart ......8-49 CLEANING AND STORAGE......9-1 Cleaning ............ 9-1 Storage ............9-2 SPECIFICATIONS ........10-1 CONSUMER INFORMATION ...... 11-1 Identification numbers ......11-1...

  • 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 MODEL : YFM125A MAX. POWER : 6.5 kw MASS IN RUNNING ORDER : 152 kg 1C5-2156A-10 43P-2816R-00 YEAR OF CONSTRUCTION : 2009 YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN 5PG-2817L-10...
  • 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 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. Turning 4WD-LOCK (“DIFF.LOCK”) takes more effort.
  • Page 16 This pictogram shows trailer Hitch Tow weight limit. (Combined weight of the trailer and all cargo in the trailer.) Overloading can cause loss of control. Loss of control can result in severe injury or death. This pictogram shows trailer Hitch Tongue weight limit.

  • Page 17: Safety Information

    EBU17431 SAFETY INFORMATION SAFETY INFORMATION EBU17463 does not have the abilities to operate it safely. Never carry a passenger on an ATV. AN ATV IS NOT A TOY AND CAN BE Always avoid operating an ATV on any paved HAZARDOUS TO OPERATE. surfaces, including sidewalks, driveways, park- An ATV handles differently from other vehicles, in- ing lots and paved streets.
  • Page 18 conditions, and your experience. Always follow proper procedures for climbing Never attempt wheelies, jumps, or other stunts. hills as described in this manual. Check the ter- Always inspect your ATV each time you use it to rain carefully before you start up any hill. Never make sure it is in safe operating condition.
  • Page 19 speed when climbing a hill. If you stall or roll behind you when you operate in reverse. When backwards, follow the special procedure for it is safe to proceed in reverse, go slowly. braking described in this manual. Dismount on Always use the size and type of tires specified in the uphill side or to a side if pointed straight up- this manual.
  • 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 4 5 6 1. Seat 1. Front carrier 2. Drive select lever 2. Starter (choke) 3. Headlight 3. Fuel cock 4. Tail/brake light 5. Rear carrier 6. Spark arrester 7. Footboard...

  • 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 3. Reverse indicator light 4. Neutral indicator light 5. Front brake lever 6. Throttle lever 7.

  • Page 23: Instrument And Control Functions

    EBU17733 INSTRUMENT AND CONTROL FUNCTIONS EBU17740 EBU17792 Main switch Indicator lights The positions of the main switch are as follows: All electrical systems are supplied with power, and the engine can be started. The key cannot be re- moved. All electrical systems are off. The key can be re- moved.

  • Page 24: Handlebar Switches

    EBU18061 EBU18101 Handlebar switches Start switch “ ” Push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine. EBU18152 Light switch “ /OFF” Set this switch to “ ”...

  • Page 25: Throttle Lever

    EBU18281 EBU18322 Throttle lever Speed limiter Once the engine is running, movement of the throt- Your ATV was delivered with an adjustable speed tle lever will increase the engine speed. limiter. The speed limiter keeps the throttle from Regulate the speed of the ATV by varying the fully opening, even when the throttle lever is throttle position.

  • Page 26: Front Brake Lever

    1. Front brake lever 1. Adjusting screw 2. Locknut EBU18401 Rear brake lever 3. No more than 12 mm (0.47 in) The rear brake lever is located on the left handle- 3. Tighten the locknut. bar. To apply the rear brake, pull the brake lever to- ward the handlebar grip.

  • Page 27: Parking Brake

    1. Parking brake lock plate 1. Rear brake lever 2. Parking brake lever (locked position) EBU18460 Parking brake EWB00220 WARNING Use the parking brake before starting the engine or parking the ATV, especially on a slope. Apply the Always set the parking brake before starting rear brake lever and push down the lock plate to the engine.

  • Page 28: Drive Select Lever

    accident. You could also wear out the brakes EBU18720 Fuel tank cap prematurely. Remove the fuel tank cap by turning it counter- clockwise. 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 1. Before refueling, turn off the engine and be Recommended fuel: sure that no one is sitting on the vehicle. Nev- Regular unleaded gasoline only with a re- er refuel while smoking, or while in the vicinity search octane number of 91 or higher of sparks, open flames, or other sources of ig- Fuel tank capacity: nition such as the pilot lights of water heaters...

  • Page 30: Fuel Cock

    ECB00070 NOTICE Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. If knocking (or pinging) occurs, use a gasoline of a different brand.

  • Page 31: Starter (Choke)

    FUEL FUEL 1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES” With the fuel cock lever in this position, fuel flows This indicates reserve. With the fuel cock lever in to the carburetor. Turn the fuel cock lever to this this position, the fuel reserve is made available.

  • Page 32: Seat

    the starter (choke). at the rear. 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. 1. Seat lock lever To install the seat Insert the projections on the front of the seat into 1.

  • Page 33: Front Carrier

    (231 lb) for the ATV. 1. Projection 2. Seat holder EBU18962 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. EBU18972 Rear carrier Do not exceed the load limit of 10.0 kg (22 lb) for...

  • 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 Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary. 5-3, 8-24 Check cable free play, and adjust if necessary. Control cables Make sure that operation is smooth. Lubricate if necessary. 8-36 Check chain slack, and adjust 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 pressures must be equal on both sides. tire pressure and use the second reading. Dust or WARNING! Operation of this vehicle with im- dirt in the gauge could cause the first reading to be proper tire pressure may cause severe injury incorrect.

  • Page 38: Chassis Fasteners

    Other tires, rims, sizes, and combinations may not be appropriate. After extensive tests, only the tires listed below have been approved for this model by Yamaha EBU19840 Motor Co., Ltd. Chassis fasteners Make sure that all nuts, bolts and screws are prop-...

  • Page 39: Instruments, Lights And Switches

    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 8-39.)

  • Page 40: Operation

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

  • Page 41: Starting A Warm Engine

    Ambient temp./starter (choke) position as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each 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.

  • 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 moving the drive select lever along the shift 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

    ATV to roll out of control, increasing the Yamaha dealer check the ATV. chance of an accident. If you must park on an incline, place the ATV transversely across the...

  • 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- Do not mount an accessory where it could inter- duce.
  • Page 46 ples include (but are not limited to) a heavy or Never exceed the weight limits shown. An over- bulky object attached to the handlebars which loaded ATV can be unstable. could make steering difficult, an accessory that MAXIMUM LOADING LIMIT limits your ability to move around on the seat, or ATV loading limit (total weight of rider, cargo, one that limits your view.
  • Page 47 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. Added weight affects the stability and handling of the ATV.

  • Page 48: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 49: Getting To Know Your Atv

    EBU21314 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 handling and performance characteristics. Take This ATV is designed to carry the operator the time to learn the basic techniques well before and cargo only – passengers prohibited. attempting more difficult maneuvers. Become fa- The long seat is to allow the operator to shift posi- miliar with this ATV at slow speeds first, even if you tion as needed during operation.
  • Page 51 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 accident. [EWB01421] 1. Protective clothing 2. Goggles Pre-operation checks 3. Gloves Always inspect your ATV each time you use it to 4. Boots make sure the ATV is in safe operating condition. 5. Helmet Perform the pre-operation checks listed on page 5-1.
  • Page 53 iter. The speed limiter keeps the throttle from fully EWB01461 WARNING opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits Improper loading or towing can increase the the maximum engine power available and de- risk of loss of control, an overturn, or other ac- creases the maximum speed of the ATV.
  • Page 54 Turn gradually and go slowly. injure you or cause an accident. [EWB01471] 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.
  • Page 55 ATV should be tremely hot during operation and remain hot after genuine Yamaha or equivalent components de- the engine has stopped. To reduce the risk of fire signed for use on this ATV and should be installed during operation or after leaving the ATV, do not let and used according to instructions.

  • Page 56: Be Careful Where You Ride

    children are not likely to touch it. BE CAREFUL WHERE YOU RIDE This ATV is designed for use on unpaved surfaces While riding on unpaved public streets or roads only. WARNING! Paved surfaces may seriously may be legal in your area, such operation can in- affect handling and control of the ATV, and crease the risk of collision with other vehicles.
  • Page 57 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. WARNING! Do not operate on rough, slippery, or loose terrain The ATV could go out of control if you do not until you have learned and practiced the skills nec- have enough time to react to hidden rocks,...
  • Page 58 When riding in an area where you might not easily Do not ride in areas posted “no trespassing”. be seen, such as desert terrain, mount a caution Do not ride on private property without getting per- flag on the ATV. DO NOT use the flag pole bracket mission.

  • 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: Climbing Uphill

    As you approach a curve, slow down and begin to many times in a large unpaved area with no obsta- turn the handlebars in the desired direction. As you cles. If an incorrect technique is used, your ATV do so, put your weight on the footboard to the out- may continue to go straight.
  • Page 61 Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
  • Page 62 Do not attempt to climb hills until you have mas- to do so) and go down the hill. tered basic maneuvers on flat ground. Always If your ATV has stalled or stopped and you believe check the terrain carefully before attempting any you can continue up the hill, restart carefully to hill.

  • Page 63: Riding Downhill

    side of the hill. 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. Improper braking can cause the wheels on the uphill side to come off the ground or cause loss of traction.

  • Page 64: Crossing A Slope

    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 65: 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.
  • Page 66 of control. [EWB02621] 1. Air filter case check hose 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. Also, remove the V-belt case drain plug to drain any water that may have accumulated.

  • Page 67: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN practicing at low speeds and on level, EWB01651 smooth terrain. WARNING On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- Riding improperly over obstacles could cause duce the chance of skidding or sliding out of loss of control or a collision.

  • Page 68: What To Do If

    ways, control can usually be regained (if there is only. Be sure to read each section on riding tech- room to do so) by steering in the direction of the niques completely. slide. Applying the brakes or accelerating is not WHAT TO DO...
  • Page 69 (See page 7-13.) If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.

  • Page 70: Periodic Maintenance And Adjustment

    If you are not fa- EBU27111 Owner’s manual and tool kit miliar with vehicle service, have a Yamaha dealer perform the service. Be sure to put this owner’s manual in the plastic bag and to always carry it as well as the owner’s...
  • Page 71 However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform...

  • 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 er comes ITEM 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

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Engine and V-belt Every 20–40 hours (more often in wet or case air filter ele- Clean and replace if necessary.
  • Page 75 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check chain slack and adjust if necessary. Check rear wheel alignment and correct if neces- √ √ √ √...
  • Page 76 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check operation and correct if necessary. Throttle lever hous- Check throttle cable free play and adjust if neces- √...

  • Page 77: Checking The Spark Plug

    If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not 1. Spark plug cap attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Remove the spark plug as shown, with the...

  • Page 78: Engine Oil

    2. Check the spark plug for electrode erosion 2. Clean the surface of the spark plug gasket and excessive carbon or other deposits, and and its mating surface, and then wipe off any replace it if necessary. grime from the spark plug threads. 3.
  • Page 79 To check the engine oil level 4. Insert the dipstick into the filler hole (without 1. Place the ATV on a level surface. screwing it in), and then remove it again to 2. Check the engine oil level on a cold engine. check the oil level.
  • Page 80 may result. [ECB00851] 6. 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.

  • Page 81: Transmission Oil

    9. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil Tightening torque: is leaking, immediately turn the engine off and Engine oil drain bolt: check for the cause. 32 Nm (3.2 m·kgf, 23.1 ft·lbf) 10.
  • Page 82 1. Transmission oil check screw 1. Transmission oil filler bolt 2. Transmission oil level check hole 5. Pour the recommended type of oil in the trans- 3. Correct oil level mission oil filler hole until it flows out of the 4.
  • Page 83 To change the transmission oil 1. Place the ATV on a level surface. Tightening torque: 2. Start the engine, warm it up for several min- Transmission oil drain bolt: utes, and then turn it off. 23 Nm (2.3 m·kgf, 16.6 ft·lbf) 3.

  • Page 84: Cleaning The Engine And V-Belt Case Air Filter Elements

    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. EBU23843 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...
  • Page 85 1. Breather hose 1. Air filter case cover 2. Clamp screw 2. Screw 4. Remove the air filter case cover by removing 5. Pull the air filter element out of the air filter the screws. case. 6. Remove the bolt and washer shown, and then pull the sponge material off from the air filter element frame.
  • Page 86 9. Check the sponge material and replace it if 2. Washer damaged. 3. Sponge material 10. Apply Yamaha foam air filter oil or other qual- 4. Air filter element frame ity foam air filter oil to the sponge material. 7. Wash the sponge material gently but thor- oughly in solvent.

  • Page 87: Clamp Screw

    15. Install the breather hose and then tighten the clamp screw. 16. Install the seat. 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.
  • Page 88 1. Bolt 1. Panel 2. Front carrier 2. Quick fastener 3. Remove the panel shown by removing the 4. Disconnect the coupler shown. quick fasteners. 8-19...

  • Page 89: Remove The Air Filter Case Cover By Removing

    1. Panel 1. Air filter case cover 2. Coupler 2. Screw 5. Remove the air filter case cover by removing 6. Remove the air filter element. the screw. 8-20...

  • Page 90: Cleaning The Spark Arrester

    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 91 fore cleaning the spark arrester. 1. Remove the screws. 1. Screw 2. Gasket 1. Screw 3. Tailpipe 4. Spark arrester 2. Remove the tailpipe by pulling it out of the muffler. 4. Insert the tailpipe into the muffler and align the 3.

  • Page 92: V-Belt Case Drain Plug

    Yamaha dealer, who has the necessary profes- If water drains from the V-belt case after removing sional knowledge and experience. The adjustment the plug, have a Yamaha dealer check the ATV as described in the following section, however, may the water may affect other engine parts.

  • Page 93: Adjusting The Throttle Cable Free Play

    (a), and to decrease it, turn the screw in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. EBU24045 Adjusting the throttle cable free play...

  • Page 94: 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- 8-25...

  • Page 95: Brakes

    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. 8-26...

  • Page 96: Adjusting The Front Brake Lever Free Play

    Rear brake mm (0.20–0.31 in) as shown. If the free play is in- correct, adjust it as follows. 1. Wear limit line 2. Wear indicator 1. Brake lever free play EBU24371 1. Remove the front carrier by removing the Adjusting the front brake lever free bolts.
  • Page 97 1. Front carrier 1. Panel 2. Bolt 2. Quick fastener 2. Remove the panel shown by removing the quick fasteners, then disconnect the coupler shown. 8-28...
  • Page 98 1. Panel 1. V-belt air filter element cover 2. Coupler 2. Screw 3. Remove the V-belt air filter element cover by 4. Loosen the locknut and fully turn in the adjust- removing the screw. ing bolt at the brake lever. 8-29...
  • Page 99 a=a' 1. Locknut 1. Brake equalizer 2. Brake lever free play adjusting bolt 2. Cable joint 5. 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 100: Adjusting The Rear Brake Lever Free Play

    1. Locknut 1. Locknut 2. Adjusting nut 2. Brake lever free play adjusting bolt 3. Brake lever free play 6. Tighten the locknut on each brake cable. 7. Turn the adjusting bolt in direction (a) to in- 8. Tighten the locknut at the brake lever. crease the free play, and in direction (b) to de- 9.

  • Page 101: Drive Chain Slack

    (b) to decrease it. slack, there should be no weight on the ATV and If the correct free play cannot be obtained, have a all tires must be touching the ground. Yamaha dealer adjust it. 8-32...
  • Page 102 2. Move the ATV back and forth to locate the the hub stopper bolt. tightest portion of the drive chain, and then 3. Loosen the axle holding bolts. measure the drive chain slack as shown. Drive chain slack: 30.0 mm (1.18 in) 1.
  • Page 103 NOTICE 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 5. Tighten the locknut and the axle holding bolts to the specified torques.

  • Page 104: Lubricating The Drive Chain

    1. Measurement A 1. O-ring 6. Tighten the hub stopper bolt, and then its lock- ECB00560 NOTICE nut. The drive chain must be lubricated after wash- EBU24881 ing the ATV or riding in the rain. Lubricating the drive chain 1. Clean the drive chain with kerosene and a The drive chain must be cleaned and lubricated at small soft brush.

  • Page 105: Checking And Lubricating The Cables

    If a cable is damaged or does not move pivots should be lubricated if necessary. smoothly, have a Yamaha dealer check or replace Recommended lubricant: Lithium-soap-based grease Recommended lubricant:...

  • Page 106: Checking The Wheel Hub Bearings

    If there is play in a wheel hub or if a wheel does not turn smoothly, 1. Grease nipple have a Yamaha dealer check the wheel hub bear- ings. EBU25032 Lubricating the upper and lower arm...

  • Page 107: Lubricating The Front Knuckle Pivots

    Right side 1. Grease nipple 1. Grease nipple EBU25090 Lubricating the steering shaft EBU28822 Lubricating the front knuckle pivots The steering shaft must be lubricated at the inter- The front knuckle pivots must be lubricated at the vals specified in the periodic maintenance and lu- intervals specified in the periodic maintenance and brication chart.

  • Page 108: Battery

    1. Grease nipple 1. Battery 2. Battery breather hose EBU25122 3. Guide Battery A poorly maintained battery will corrode and dis- charge quickly. The electrolyte level, battery lead The electrolyte should be between the minimum connections and breather hose routing should be and maximum level marks.
  • Page 109 EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes or other sources of ig- nition away. Ventilate when charging or using in an enclosed space. KEEP OUT OF REACH OF CHILDREN. 4.
  • Page 110 To install the battery 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. NOTICE: If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the bat-...

  • Page 111: Replacing The Fuse

    EBU25263 Replacing the fuse 1. Battery 2. Negative battery lead (black) 3. Positive battery lead (red) 1. Fuse 2. Spare fuse The fuse holder is located on the right side of the ATV. If the fuse is blown, replace it as follows. 1.

  • Page 112: Replacing A Headlight Bulb

    4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU25481 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
  • Page 113 1. Headlight bulb holder cover 1. Headlight bulb 2. Headlight bulb holder 6. Install the bulb holder by pushing it in and turn- 3. Remove the headlight bulb holder by pushing ing it clockwise. it in and turning it counterclockwise. 7.

  • Page 114: Adjusting A Headlight Beam

    1. Remove the bulb holder (together with the ECB00690 bulb) by turning it counterclockwise. 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).

  • Page 115: Removing A Wheel

    1. Tail/brake light bulb 1. Wheel nut 2. Tail/brake light bulb holder 3. Elevate the ATV and place a suitable stand 3. Insert a new bulb into the bulb holder, push it under the frame. in, and then turn it clockwise until it stops. 4.

  • Page 116: Troubleshooting

    1. Tapered nut systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose 4. Lower the ATV to the ground. skilled technicians have the necessary tools, expe- 5.
  • Page 117 EWB02280 WARNING Do not smoke when checking the fuel system. Fuel can ignite or explode, causing severe inju- ry or property damage. Make sure there are no open flames or sparks in the area, including pi- lot lights from water heaters or furnaces. 8-48...

  • Page 118: 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 119: Cleaning And Storage

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

  • Page 120: Storage

    EBU25933 Storage Specified amount: Short-term 7.5 ml of stabilizer to each liter of fuel (or 1 oz Always store your ATV in a cool, dry place and, if of stabilizer to each gallon of fuel) necessary, protect it against dust with a porous 5.
  • Page 121 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.

  • Page 122: Specifications

    EBU25960 SPECIFICATIONS EBU2597E Dimensions: Cylinder arrangement: Forward-inclined single cylinder Overall length: Displacement: 1700 mm (66.9 in) 124 cm 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 123 Fuel tank capacity: 50 ˚C 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) SAE 5W-30 Carburetor: SAE 10W-30 Type × quantity: VM18SH x 1 SAE 10W-40 Spark plug (s): SAE 15W-40 Manufacturer/model: NGK/CR7HSA SAE 20W-40...
  • Page 124 Chassis: Minimum: Front: Frame type: 17.0 kPa (0.170 kgf/cm , 2.5 psi) Steel tube frame Rear: Caster angle: 22.0 kPa (0.220 kgf/cm , 3.2 psi) 6.0 ° Front wheel: Trail: 15.0 mm (0.59 in) Wheel type: Front tire: Panel wheel Rim size: Type: 8 x 5.5AT...
  • Page 125 Wheel travel: Fuses: 70 mm (2.8 in) Main fuse: Rear suspension: 15.0 A Type: Swingarm Spring/shock absorber type: Coil spring/oil damper Wheel travel: 80 mm (3.1 in) Electrical system: Ignition system: DC. CDI Charging system: AC magneto Battery: Model: 12N12C-4A-2 Voltage, capacity: 12 V, 12.0 Ah Headlight:...

  • Page 126: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 127 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 128 1. Model label 11-3...
  • Page 129 INDEX Accessories and loading ..........6-6 Engine break-in .............. 6-4 Air filter elements, engine and V-belt filter Engine, cold start ............6-1 cleaning..............8-15 Engine idling speed............8-23 Engine oil ............... 5-3 Engine, starting a warm ..........6-2 Battery..............5-6 8-39 Engine stop switch ............
  • Page 130 Main switch ..............4-1 Tail/brake light bulb, replacing ........8-45 Maintenance and lubrication chart ......... 8-5 Throttle cable free play, adjusting ........ 8-24 Maintenance chart, emission control system ....8-3 Throttle lever ............4-3 Model label..............11-2 Tires ................5-3 Transmission oil ...........
  • Page 132 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2009.03-0.1x1 !

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