1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Offroad Vehicle
  5. GRIZZLY 125 YFM125GY
  6. Owner's manual

Yamaha GRIZZLY 125 YFM125GY Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
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
YFM125GY
1C5-28199-65

Advertisement

Table of Contents
loading

Related Manuals for Yamaha GRIZZLY 125 YFM125GY

Summary of Contents for Yamaha GRIZZLY 125 YFM125GY

  • 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 YFM125GY This A 1C5-28199-65...
  • Page 2 PRINTED IN JAPAN 2008.03-0.8x2 ! (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM125GY This A 1C5-28199-65-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 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 IMPORTANT NOTICE EBU17370 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Seat ............4-9 Front carrier ..........4-10 Rear carrier ..........4-10 LOCATION OF THE WARNING AND SPECIFICATION LABELS ......2-1 PRE-OPERATION CHECKS ......5-1 Pre-operation check list ......5-1 DESCRIPTION ..........3-1 Fuel ............5-3 Left view .............
  • Page 9 Parking on a slope ........6-5 Cleaning the engine and V-belt case air filter elements ........8-15 Accessories and loading ......6-6 V-belt case drain plug ......8-21 Adjusting the carburetor ......8-22 RIDING YOUR ATV ........7-1 Adjusting the engine idling speed .... 8-22 GETTING TO KNOW YOUR ATV....
  • Page 10 Installing a wheel ........8-46 Troubleshooting ........8-47 Troubleshooting chart ......8-48 CLEANING AND STORAGE......9-1 Cleaning ............ 9-1 Storage ............9-2 SPECIFICATIONS ........10-1 CONSUMER INFORMATION ...... 11-1 Identification numbers ......11-1...

  • Page 11: Safety Information

    EBU17430 SAFETY INFORMATION SAFETY INFORMATION continued use of an ATV by a child if he or she EBU17462 does not have the abilities to operate it safely. AN ATV IS NOT A TOY AND CAN BE HAZARD- Never carry a passenger on an ATV. OUS TO OPERATE.
  • Page 12 or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills. conditions, and your experience. Always follow proper procedures for climbing Never attempt wheelies, jumps, or other stunts.
  • Page 13 backwards when climbing a hill. To avoid stall- times to let friction dry out the linings. ing, use the proper gear and maintain a steady Always be sure there are no obstacles or people speed when climbing a hill. If you stall or roll behind you when you operate in reverse.
  • Page 14 ers and clothes dryers. Gasoline can catch EWB00070 WARNING fire and you could be burned. When transporting the ATV in another vehi- Always operate your ATV in an area with ade- cle, be sure it is kept upright and that the fuel quate ventilation.

  • Page 15: 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 16 For Oceania For Europe NEVER sit here. 3MX-24875-A0 For Europe and Oceania 5FK-2151H-00 5kg 11lbs 3LD-24877-A0 For Europe and Oceania For Oceania WARNING 10kg 22lbs NEVER ride as a 1C5-24877-A0 passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.
  • Page 17 For Europe For Oceania 0.20 kgf/cm 0.25 kgf/cm 2.9 psi 3.6 psi Set with tires cold. Impostare a pneumatici freddi. Bei kalten Reifen. Wanneer de banden koud zijn. Ajuste con los Regular com pneus neumáticos en frío. frios. Pneus à froid. Ställ in med kalla däck.
  • Page 18 For Oceania For Europe < 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. 5FK-21697-00 4D3-2816L-00 For Europe YAMAHA MOTOR CO., LTD. SHIZUOKA JAPAN 4GB-2155A-00...
  • Page 19 For Oceania For Europe Before you operate this vehicle, read the owner’s manual. Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren. Antes de conducir este vehículo, lea el Manual del Propietario. Lire le manuel du propriétaire avant d’utiliser ce véhicule. Prima di usare il veicolo, leggete il manuale di istruzioni.

  • Page 20: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 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. Footboard...

  • Page 21: Controls And Instruments

    EBU17712 from the figures shown in this manual. Controls and instruments 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.

  • Page 22: Instrument And Control Functions

    EBU17732 INSTRUMENT AND CONTROL FUNCTIONS EBU17740 EBU17791 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 23: Handlebar Switches

    EBU18061 EBU18090 Handlebar switches Start switch “START” Push this switch to crank the engine with the start- ECB00050 NOTICE See the starting instructions on page 6-1 prior to starting the engine. EBU18140 Light switch “LIGHTS” Set this switch to “LO” to turn on the low beams and the taillight.

  • Page 24: Throttle Lever

    Correct the problem be- the throttle lever. fore riding the ATV or consult a Yamaha dealer. EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter.

  • Page 25: Front Brake Lever

    (See page 8-23.) 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. 1. Adjusting screw 2. Locknut 3. No more than 12 mm (0.47 in) 3.

  • Page 26: 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 27: 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 28: Fuel Cock

    of gasoline or higher octane grade. 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. EWB00310 WARNING Do not overfill the fuel tank.
  • Page 29 The fuel cock lever positions are explained as fol- lows and shown in the illustrations. FUEL FUEL 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel flows 1. Arrow mark positioned over “OFF” to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding.

  • Page 30: Starter (Choke)

    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. 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 31: 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 EBU18961 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) rear.
  • Page 32 (231 lb) for the ATV. 4-11...

  • Page 33: Pre-Operation Checks

    Manual. Failure to inspect increases the possibility of an accident or equipment damage. The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 34 ITEM ROUTINE PAGE Check operation, and correct if necessary. Rear brake Lubricate cable if necessary. 5-3, 8-24, 8-30 Check lever free play, and adjust if necessary. Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary. 5-4, 8-23 Check cable free play, and adjust if necessary.

  • Page 35: Front And Rear Brakes

    EBU19580 Transmission oil ment procedures provided in this manual, have the ATV checked by a Yamaha dealer. Make sure that the transmission oil is at the speci- fied level. Add oil as necessary. (See page 8-12.)

  • Page 36: Throttle Lever

    Front: Throttle lever Manufacturer/model: Check the operation of the throttle lever. It must DUNLOP/KT536A open smoothly and spring back to the idle position Size: when released. Have a Yamaha dealer correct if AT20 x 7-8 necessary. Type: Tubeless EBU19770 Rear:...

  • Page 37: Measuring The Tire Pressure

    fied could cause the tire to dislodge from incorrect. the rim under severe riding conditions. Minimum tire pressure: Front: 17.0 kPa (0.170 kgf/cm , 2.5 psi) Rear: 22.0 kPa (0.220 kgf/cm , 3.2 psi) Use no more than the following pressures when seating the tire beads.

  • Page 38: Tire Wear Limit

    Recommended pressure: Front 20.0 kPa (0.200 kgf/cm , 2.9 psi) Rear 25.0 kPa (0.250 kgf/cm , 3.6 psi) Minimum: Front 17.0 kPa (0.170 kgf/cm , 2.5 psi) Rear 22.0 kPa (0.220 kgf/cm , 3.2 psi) 1. Tire wear limit EBU19830 Tire wear limit EBU19840 Chassis fasteners...

  • Page 39: Operation

    4. Shift the drive select lever into the neutral po- accident or injury. If there is a control or func- sition. The neutral indicator light should come tion you do not understand, ask your Yamaha on. If the indicator light does not come on, dealer.
  • Page 40 Position (2): Cold engine start with ambient temperature be- If the engine fails to start, release the start switch, tween 0 °C (30 °F) and 30 °C (90 °F). then push it again. Pause a few seconds before the next attempt. Each cranking should be as short Position (3): as possible to preserve battery energy.

  • Page 41: Starting A Warm Engine

    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. EBU20360 Operating the drive select lever and driving in reverse ECB00170...

  • Page 42: Engine Break-In

    If the indicator light does not come on, figures given in hours. have a Yamaha dealer check the electrical circuit. For ATVs not equipped with an odometer or hour meter, follow the figures given in hours. 4. Check behind for people or obstacles, and then release the parking brake.

  • Page 43: 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 44: Accessories And Loading

    However, dling of an ATV can be changed. When adding ac- it is not possible for Yamaha to test all non- cessories, keep the following points in mind: Yamaha accessories, nor control over their qual-...
  • Page 45 loaded ATV can be unstable. takes longer to stop. Avoid making sharp turns unless at very slow MAXIMUM LOADING LIMIT speeds. ATV loading limit (total weight of rider, cargo, Avoid hills and rough terrain. Choose terrain accessories, and tongue): carefully. Added weight affects the stability and 105.0 kg (231 lb) handling of the ATV.

  • Page 46: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 47: Getting To Know Your Atv

    EBU21313 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV Beginners should get training from a certified in- This ATV is for recreation and utility use. This sec- structor. tion, Riding your ATV, provides general ATV riding Become familiar with this ATV at slow speeds first, instructions for recreational riding.
  • Page 48 Not recommended for children under 16 years during operation. It is not for carrying passen- of age. gers. Carrying a passenger on this ATV greatly EWB01390 reduces your ability to balance and control this WARNING ATV. It could cause an accident, resulting in harm to you and/or your passenger.
  • Page 49 Apparel 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...
  • Page 50 EWB01410 WARNING Never operate this ATV without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. Operating without an ap- proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and in- creases your chances of a severe injury in the event of an accident.
  • Page 51 in the Owner’s Manual. Failure to inspect the Speed limiter ATV before operating or failure to properly For riders less experienced with this model, the maintain the ATV increases the possibility of throttle lever housing is equipped with a speed lim- an accident or equipment damage.
  • Page 52 Loading and accessories trailer. Use extra caution when riding the ATV with addi- tional loads, such as accessories or cargo. The During operation ATV’s handling may be adversely affected. Re- Always keep your feet on the footboards during op- duce your speed when adding additional loads. eration, otherwise they may contact the rear wheels.
  • Page 53 All parts and you or cause an accident. accessories added to this ATV should be gen- uine Yamaha or equivalent components de- Avoid wheelies and jumping. You may lose control signed for use on this ATV and should be of the ATV or overturn.

  • Page 54: Be Careful Where You Ride

    EWB01500 control. WARNING EWB01510 WARNING Do not touch the hot exhaust system. Do not park the ATV during or after operation Always avoid paved surfaces, including side- in a place where others might be likely to walks, driveways, parking lots and streets. touch it.
  • Page 55 While riding on unpaved public streets or roads may be legal in your area, such operation can in- crease the risk of collision with other vehicles. Watch carefully for other vehicles. Make sure you know your country’s laws and regulations before you ride on unpaved public streets or roads.
  • Page 56 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 EWB01540 as a trailer hitch. WARNING Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.
  • Page 57 Select a large, flat, unpaved area to become famil- iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice EWB01550 control of the throttle, brakes, shifting procedures, WARNING and turning techniques in this area before trying more difficult terrain.

  • Page 58: Turning Your Atv

    With the engine idling, return the starter knob to the EWB01570 WARNING closed position and shift the drive select lever into the forward position. Then release the parking Always follow proper procedures for turning brake. Apply the throttle slowly and smoothly. The as described in this Owner’s Manual.

  • Page 59: Climbing Uphill

    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.
  • Page 60 er hills before attempting large hills. 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.
  • Page 61 any hill. Avoid crossing the side of a steep hill hill side. Physically turn the ATV around and then if possible. descend the hill. When crossing the side of a hill: If you start to roll backwards, DO NOT apply the Always follow proper procedures as de- rear brake to stop or try to put the ATV in gear.

  • Page 62: Riding Downhill

    stacles which may appear. EWB01620 WARNING Always follow proper procedures for going down hills as described in this Owner’s Manu- 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.

  • Page 63: Crossing A Slope

    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.

  • Page 64: Crossing Through Shallow Water

    Owner’s 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 lin- ings. If the ATV is operated through deep or fast flowing water, the tires may float, causing loss of traction and loss of control, which could lead to an accident.
  • Page 65 1. Air filter case check hose ECB00800 NOTICE 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.

  • Page 66: Riding Over Rough Terrain

    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.

  • Page 67: What To Do If

    go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of control. 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.
  • Page 68 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.

  • Page 69: Periodic Maintenance And Minor Repair

    1. Owner’s manual can cause shocks or start fires. Turn off the en- 2. Low-pressure tire gauge gine when performing maintenance unless 3. Owner’s tool kit otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with...
  • Page 70 If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING...

  • Page 71: 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 72 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 73: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 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 74 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 necess- √ √ √ √...
  • 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 operation and correct if necessary. Throttle lever hous- Check throttle cable free play and adjust if neces- √...

  • Page 76: 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 77: 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 78 To check the engine oil level screwing it in), and then remove it again to 1. Place the ATV on a level surface. check the oil level. 2. Check the engine oil level on a cold engine. If the engine was started before checking the oil 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.
  • Page 79 To change the engine oil ECB00310 NOTICE 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min- When removing the engine oil drain bolt, the utes, and then turn it off. compression spring, oil strainer and O-ring will 3.

  • Page 80: Transmission Oil

    Recommended oil: See page 10-1. Oil quantity: 1.25 L (1.32 US qt, 1.10 Imp.qt) ECB00330 NOTICE 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- 1.
  • Page 81 periodic maintenance and lubrication chart. The transmission oil should be at the brim of the To check the transmission oil level hole. 1. Place the ATV on a level surface. 5. If the transmission oil level is below the brim of 2.
  • Page 82 5. Install the drain bolt, and then tighten it to the Tightening torque: specified torque. Screw: 16 Nm (1.6 m·kgf, 11.6 ft·lbf) Tightening torque: Oil filler bolt: Transmission oil drain bolt: 23 Nm (2.3 m·kgf, 16.6 ft·lbf) 23 Nm (2.3 m·kgf, 16.6 ft·lbf) To change the transmission oil 6.

  • Page 83: Cleaning The Engine And V-Belt Case Air Filter Elements

    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. EBU23841 Cleaning the engine and V-belt case air filter elements Both air filter elements should be cleaned at the...
  • Page 84 1. Breather hose 1. Air filter case cover 2. Clamp screw 2. Screw 3. Remove the air filter case cover by removing 4. Pull the air filter element out of the air filter the screws. case. 5. Remove the bolt and washer shown, and then pull the sponge material off from the air filter element frame.
  • Page 85 material and let it dry. ECB00440 NOTICE Do not twist the sponge material when squeez- ing it. 1. Bolt 2. Washer 3. Sponge material 4. Air filter element frame 6. Wash the sponge material gently but thor- 8. Check the sponge material and replace it if oughly in solvent.
  • Page 86 ment frame. 15. Install the seat. 11. Install the washer and bolt. ECB00450 The air filter element should be cleaned every 20– NOTICE 40 hours. It should be cleaned and lubricated more Be sure to install the washer with the bent edge often if the ATV is operated in extremely dusty ar- facing upward as shown.
  • Page 87 V-belt case air filter element 1. Remove the front carrier by removing the bolts. 1. Panel 2. Quick fastener 3. Disconnect the coupler shown. 1. Bolt 2. Front carrier 2. Remove the panel shown by removing the quick fasteners. 8-19...
  • Page 88 1. Panel 1. Air filter case cover 2. Coupler 2. Screw 4. Remove the air filter case cover by removing 5. Remove the air filter element. the screw. 8-20...

  • Page 89: V-Belt Case Drain Plug

    1. Air filter element 1. Air filter element 7. Check the air filter element and replace it if 6. Tap the air filter element lightly to remove damaged. most of the dust and dirt. Blow out the remain- 8. Install the air filter element into the air filter ing dirt with compressed air as shown.

  • Page 90: Adjusting The Carburetor

    If water drains from the V-belt case after removing described in the following section, however, may the plug, have a Yamaha dealer check the ATV as be performed by the owner as part of routine main- the water may affect other engine parts.

  • Page 91: Adjusting The Throttle Cable Free Play

    The engine is warm when it quickly responds to the If the specified idling speed cannot be obtained as throttle. described above, have a Yamaha dealer make the adjustment. 2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if neces-...

  • Page 92: 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.

  • Page 93: 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 EBU24370 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 94 mm (0.20–0.31 in) as shown. If the free play is in- correct, adjust it as follows. 1. Front carrier 2. Bolt 1. Brake lever free play 2. Remove the panel shown by removing the quick fasteners, then disconnect the coupler 1.
  • Page 95 1. Panel 1. Panel 2. Quick fastener 2. Coupler 3. Remove the V-belt air filter element cover by removing the screw. 8-27...
  • Page 96 1. Locknut 1. V-belt air filter element cover 2. Brake lever free play adjusting bolt 2. Screw 5. Make sure the brake cable joint in the equaliz- 4. Loosen the locknut and fully turn in the adjust- er is straight when the brake is applied. If the ing bolt at the brake lever.
  • Page 97 a=a' 1. Brake equalizer 1. Locknut 2. Cable joint 2. Adjusting nut 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.

  • Page 98: Adjusting The Rear Brake Lever Free Play

    Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24491 Adjusting the rear brake lever free play The brake lever free play must be checked and, if necessary, adjusted at the intervals specified in 1.
  • Page 99 (b) to decrease it. WARNING If the correct free play cannot be obtained, have a Operating with improperly serviced or adjust- Yamaha dealer adjust it. ed brakes could cause loss of braking ability, which could lead to an accident. After servicing: Make sure the brakes operate smoothly and that the free play is correct.

  • Page 100: Drive Chain Slack

    Yamaha dealer. EBU24872 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. When checking and adjusting the drive chain slack, there should be no weight on the ATV and 1.
  • Page 101 1. Hub stopper bolt 1. Locknut 2. Locknut 2. Drive chain slack adjusting bolt 3. Axle holding bolt (lower) 4. Axle holding bolt (upper) ECB00541 NOTICE 4. Loosen the chain adjusting bolt locknut. To Improper drive chain slack will overload the en- tighten the drive chain, turn the adjusting bolt gine as well as other vital parts of the ATV and in direction (a).

  • Page 102: Lubricating The Drive Chain

    If measurement “A” of the drive chain adjust- 1. Measurement A ing bolt is less than 27 mm (1.06 in), have a 6. Tighten the hub stopper bolt, and then its lock- Yamaha dealer replace the drive chain. nut. EBU24880 Lubricating the drive chain...

  • Page 103: Checking And Lubricating The Cables

    If a cable is damaged or does not move ECB00560 smoothly, have a Yamaha dealer check or replace NOTICE The drive chain must be lubricated after wash- ing the ATV or riding in the rain.

  • Page 104: Checking And Lubricating The Front And Rear Brake Levers

    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. EBU25032 Lubricating the upper and lower arm...

  • Page 105: Lubricating The Front Knuckle Pivots

    nance and lubrication chart. Right side Lubricate the pivoting points using a grease gun. Recommended lubricant: Lithium-soap-based grease Left side 1. Grease nipple EBU28821 Lubricating the front knuckle pivots The front knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and 1.

  • Page 106: Lubricating The Steering Shaft

    EBU25121 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.
  • Page 107 1. Maximum level mark 1. Battery 2. Minimum level mark 2. Battery breather hose 3. Guide ECB00590 NOTICE The electrolyte should be between the minimum Use only distilled water, as tap water contains and maximum level marks. minerals that are harmful to the battery. EWB02160 3.
  • Page 108 Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call a physician immediately. EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes or other sources of ig- nition away.

  • Page 109: Replacing The Fuse

    To install the battery ECB00610 NOTICE If the breather hose is positioned in such a way Be sure the battery is fully charged. that the frame is exposed to electrolyte or gas expelled from the battery, the frame could suf- 1.

  • Page 110: Replacing A Headlight Bulb

    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. 8-42...
  • Page 111 er by pushing it in. 1. Headlight bulb holder cover 2. Headlight bulb holder 1. Headlight bulb 3. Remove the headlight bulb holder by pushing ECB00650 NOTICE it in and turning it counterclockwise. 4. Remove the defective bulb by pulling it out. Do not touch the glass part of the headlight EWB02220 bulb to keep it free from oil, otherwise the...

  • Page 112: Adjusting A Headlight Beam

    EBU25551 Adjusting a headlight beam ECB00690 1. Headlight beam adjusting screw NOTICE It is advisable to have a Yamaha dealer make EBU25610 Replacing the tail/brake light bulb this adjustment. If the tail/brake light bulb burns out, replace it as To raise a headlight beam, turn the headlight beam follows.

  • Page 113: Removing A Wheel

    1. Tail/brake light bulb holder 1. Tail/brake light bulb 2. Tail/brake light bulb holder 2. Remove the defective bulb by pushing it in 3. Insert a new bulb into the bulb holder, push it and turning it counterclockwise. in, and then turn it clockwise until it stops. 4.

  • Page 114: Installing A Wheel

    Front 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. 1.

  • Page 115: 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 116: 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 117: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25900 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.

  • Page 118: Storage

    increasing the chance of an accident. Test the section of this chapter. brakes after washing. Apply the brakes several 2. Turn the fuel cock lever to “OFF”. times at slow speeds to let friction dry out the 3. Drain the carburetor float chamber by loosen- linings.
  • Page 119 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.

  • Page 120: Specifications

    EBU25960 SPECIFICATIONS EBU2597B Engine: Engine type: Air cooled 4-stroke, SOHC Dimensions: Cylinder arrangement: Overall length: Forward-inclined single cylinder 1700 mm (66.9 in) Displacement: Overall width: 124.0 cm 990 mm (39.0 in) Bore × stroke: Overall height: 49.0 × 66.0 mm (1.93 × 2.60 in) 980 mm (38.6 in) Compression ratio: Seat height:...
  • Page 121 Fuel: 50 ˚C Recommended fuel: Regular unleaded gasoline only (EUR) Unleaded gasoline only (AUS)(NZL) SAE 5W-30 Fuel tank capacity: SAE 10W-30 7.0 L (1.85 US gal, 1.54 Imp.gal) Fuel reserve amount: SAE 10W-40 1.3 L (0.34 US gal, 0.29 Imp.gal) SAE 15W-40 Carburetor: Manufacturer:...
  • Page 122 Transmission type: Tire air pressure (measured on cold tires): V-belt automatic Recommended: Operation: Front: Centrifugal automatic type 20.0 kPa (0.200 kgf/cm , 2.9 psi) Reverse gear: Rear: 49/14 × 49/15 × 40/17 (26.902) 25.0 kPa (0.250 kgf/cm , 3.6 psi) Chassis: Minimum: Frame type:...
  • Page 123 Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Type: Neutral indicator light: Swing axle 12 V, 1.7 W × 1 Spring/shock absorber type: Reverse indicator light: Coil spring/oil damper 12 V, 1.7 W × 1 Wheel travel: Fuses: 70 mm (2.8 in) Rear suspension: Main fuse:...

  • Page 124: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 125 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 126 1. Model label 11-3...
  • Page 127 INDEX Accessories and loading ..........6-6 Engine break-in .............. 6-4 Air filter elements, engine and V-belt filter cleaning ..8-15 Engine, cold start ............6-1 Engine idling speed............8-22 Engine oil ............... 5-3 Battery..............5-6 8-38 Engine, starting a warm ..........6-3 Brake lever free play, adjusting the front......
  • Page 128 Main switch ..............4-1 Tail/brake light bulb, replacing ........8-44 Maintenance and lubrication chart ......... 8-5 Throttle cable free play, adjusting ........ 8-23 Maintenance chart, emission control system ....8-3 Throttle lever ............4-3 Model label..............11-2 Tire pressure, measuring ..........5-5 Tires ................
  • Page 130 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2008.03-0.8x2 !

Table of Contents