Yamaha YFM90RY Owner's Manual
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Yamaha YFM90RY Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM90RY
This A
WARNING
This ATV should not be ridden by anyone under 12 years of age.
LIT-11626-22-13
43D-F8199-10

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  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM90RY This A WARNING This ATV should not be ridden by anyone under 12 years of age. LIT-11626-22-13 43D-F8199-10...
  • Page 2 Read this manual carefully before operating this vehicle.This manual should stay with this ve- hicle if it is sold.
  • Page 3 INTRODUCTION Congratulations on your purchase of the Yamaha YFM90RY. This ATV represents the result of many years of 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 4 ATV safely. Your ATV was delivered with an adjustable speed limiter . Yamaha recommends that all beginners start off to limit the amount of speed available while they learn. The adjusting screw may be gradually turned out as the beginner becomes more familiar with operating the ATV.
  • Page 5 IMPORTANT MANUAL INFORMATION 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 personal injury hazards.
  • Page 6 IMPORTANT NOTICE Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

  • Page 7: Table Of Contents

    Rear brake lever ........4-6 WARNING Parking brake ..........4-7 A WARNING indicates a hazardous situation Fuel tank cap ..........4-8 Fuel ............4-8 which, if not avoided, could result in death Fuel cock ..........4-10 or serious injury. Choke ............. 4-11 Seat ............
  • Page 8 Cleaning the spark arrester ...... 8-19 RIDING YOUR ATV ........7-1 Adjusting the carburetor ......8-20 GETTING TO KNOW YOUR ATV....7-2 Adjusting the engine idling speed .... 8-20 RIDE WITH CARE AND GOOD Checking the throttle cable free play ..8-21 JUDGEMENT..........
  • Page 9 SPECIFICATIONS ........10-1 CONSUMER INFORMATION ..... 11-1 Identification numbers ......11-1 Noise regulation ........11-3 Maintenance record ....... 11-4 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY ..11-5 YAMAHA EXTENDED SERVICE (Y.E.S.) ..........11-7...

  • Page 10: Safety Information

    SAFETY INFORMATION – A child under 12 years old should never oper- AN ATV IS NOT A TOY AND CAN BE HAZARD- ate an ATV with engine size greater than 70 cc. OUS TO OPERATE. – A child under 16 years old should never oper- An ATV handles differently from other vehicles, in- ate an ATV with engine size greater than 90 cc.
  • Page 11 operating this ATV. speeds and never turn at excessive speeds. Never operate at speeds too fast for your skills Never operate the ATV on hills too steep for the 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.
  • Page 12 Avoid crossing the side of a steep hill if possible. reduced stopping ability. Test your brakes after Always use proper procedures if you stall or roll leaving water. If necessary, apply them several backwards when climbing a hill. To avoid stall- times to let friction dry out the linings.
  • Page 13 HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or ex- haust pipe/muffler when refueling. Never refuel while smoking, or in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heat-...

  • Page 14: 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 17: Description

    DESCRIPTION Left view Right view 1. Fuel cock 1. Spark arrester 2. Rear wheel 2. Seat 3. Footrest 3. Footrest 4. Front wheel...

  • Page 18: Controls And Instruments

    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. Front brake lever 4. Throttle lever 5. Main switch 6. Fuel tank cap 7. Handlebar switches 8.

  • Page 19: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS WARNING A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. Main switch The positions of the main switch are as follows: All electrical systems are supplied with power, and the engine can be started.

  • Page 20: Handlebar Switches

    Handlebar switches Start switch “START” Push this switch to crank the engine with the start- See the starting instructions on page 6-1 prior to starting the engine. 1. Engine stop switch “ENG. STOP” 2. Start switch “START” Engine stop switch “ENG. STOP” Set this switch to “RUN”...

  • Page 21: Throttle Lever

    If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can’t find or solve the problem yourself. Speed limiters Your ATV was delivered with two speed limiter devices.

  • Page 22: Vehicle Speed Limiter

    The vehicle speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. The adjusting screw may be gradually turned out as the beginner becomes more familiar with operating the ATV. Parents should decide when to adjust the ATV for more power as their youngster’s riding skills improve.

  • Page 23: Engine Speed Limiter Plate

    4. Tighten the screw. WARNING 5. Install the seat. POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Im- proper throttle operation could result. The child could lose control, have an accident or be injured.

  • Page 24: Front Brake Lever

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

  • Page 25: Parking Brake

    Parking brake WARNING Use the parking brake before starting the engine or POTENTIAL HAZARD parking the ATV, especially on a slope. Apply the Improper use of the parking brake. front bake lever and push down the lock button to WHAT CAN HAPPEN apply the parking brake.

  • Page 26: Fuel Tank Cap

    Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. 1. Fuel level 2. Filler tube Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 4.8 L (1.27 US gal) (1.06 Imp.gal) 1. Fuel tank cap Fuel reserve amount: 1.0 L (0.26 US gal) (0.22 Imp.gal) Fuel Make sure that there is sufficient fuel in the tank.
  • Page 27 Fuel can spill, which can cause a fire and se- vere injury. Your Yamaha engine has been designed to use Fuel expands when it heats up. If the fuel regular unleaded gasoline with a pump octane...

  • Page 28: Fuel Cock

    With the fuel cock lever in this position, fuel flows Fuel cock to the carburetor. Turn the fuel cock lever to this The fuel cock supplies fuel from the tank to the car- position when starting the engine and riding. buretor while also filtering it.

  • Page 29: Choke

    Choke Seat The choke is used to start a cold engine. To remove the seat Move the choke in direction (a) to turn on the Pull the seat lock lever upward and pull up the seat choke. at the rear. Move the choke in direction (b) to turn off the choke.

  • Page 30: Kickstarter

    To install the seat 2. Move the kickstarter lever down lightly with your Insert the projection on the front of the seat into the foot until the gears engage, and then push it seat holder and push down on the seat at the rear. down smoothly but forcefully.

  • Page 31: Pre-Operation Checks

    Always follow the inspection and maintenance procedures and schedules described in the Own- er's Manual. The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the "Periodic maintenance and lubrication charts" on page 8-3 to determine which service should be performed by a...
  • Page 32 Front brake Lubricate cable if necessary. 5-3, 8-22, 8-23 Check lever free play, and adjust if necessary. Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear, and replace if necessary. Rear brake...

  • Page 33: Fuel

    Fuel expands when it heats up. If the fuel ing when the brakes are applied. If not, have the tank is overfilled, fuel could spill out due to ATV checked by a Yamaha dealer. heat from the engine or the sun. HOW TO AVOID THE HAZARD Brake fluid level Do not overfill the fuel tank.

  • Page 34: Throttle Lever

    The tires listed below have been approved Always check the brakes at the start of every by Yamaha Motor Co., Ltd. for this model. ride. Do not ride the ATV if you find any prob- Other tire combinations are not recom- lem with the brakes.

  • Page 35: Measuring The Tire Pressure

    Rear: Tire pressure below the minimum speci- Manufacturer/model: fied could cause the tire to dislodge from MAXXIS/M940 the rim under severe riding conditions. Size: Minimum tire pressure: AT18 x 9-8 Front: Type: 22 kPa (3.2 psi) (0.22 kgf/cm Tubeless Rear: The tires should be set to the recommend- 22 kPa (3.2 psi) (0.22 kgf/cm ed pressure:...

  • Page 36: Specifications

    dirt in the gauge could cause the first reading to be incorrect. Recommended pressure: Front 25 kPa (3.6 psi) (0.25 kgf/cm Rear 25 kPa (3.6 psi) (0.25 kgf/cm Minimum: Front 22 kPa (3.2 psi) (0.22 kgf/cm Rear 22 kPa (3.2 psi) (0.22 kgf/cm 1.

  • Page 37: Chassis Fasteners

    1. Tire wear limit Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. Instruments and switches Check that all instruments and switches are working properly. Correct if necessary.

  • Page 38: Operation

    See the “Engine break-in” section on page 6-4 a control or function you do not understand, prior to operating the engine for the first time. ask your Yamaha dealer. 1. Set the parking brake. 2. Turn the fuel cock to “ON”.
  • Page 39 Ambient temp./choke position This model is equipped with an ignition circuit cut- off system. The engine can be started only when 0° 10° 20° 30° °C the rear brake lever is applied. 90° °F 30° 50° 70° 4. Use the choke in reference to the figure: Position (1): Cold engine start with ambient temperature be- low 30 °C (90 °F).

  • Page 40: Starting A Warm Engine

    crank the engine more than 10 seconds on each To start out and accelerate attempt. 1. Squeeze the front brake lever to release the 6. If the engine is started with the choke in posi- parking brake. tion (1), the choke should be returned to posi- 2.

  • Page 41: Engine Break-In

    Since the engine is brand new, do not put an ex- Yamaha dealer check the ATV. cessive load on it for the first 320 km (200 mi) or 20 hours. The various parts in the engine wear and...

  • Page 42: Parking On A Slope

    Parking on a slope WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the ATV trans- 1.

  • Page 43: Accessories And Loading

    Yamaha accessories. Other accessories judgment as the stability and handling of an ATV may also be available on the market. However, can be changed. When adding accessories, keep it is not possible for Yamaha to test all non-...
  • Page 44 the following points in mind: speeds. Never exceed the weight limits shown. An over- Avoid hills and rough terrain. Choose terrain loaded ATV can be unstable. carefully. Added weight affects the stability and handling of the ATV. MAXIMUM LOADING LIMIT WARNING ATV loading limit (total weight of rider, cargo, accessories, and tongue):...

  • Page 45: Riding Your Atv

    RIDING YOUR ATV...

  • Page 46: Getting To Know Your Atv

    RIDE WITH CARE AND GOOD JUDGEMENT WARNING A WARNING indicates a hazardous situation Get training if you are inexperienced. which, if not avoided, could result in death Beginners should get training from a certified in- or serious injury. structor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator.
  • Page 47 HOW TO AVOID THE HAZARD should complete the certified training course A child under 12 should never operate an ATV offered by Yamaha. They should then regu- with engine size greater than 70 cc. larly practice the skills learned in the course and the operating techniques described in this Owner’s Manual.
  • Page 48 This ATV is designed to carry operator only – passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passen- ger.
  • Page 49 Apparel HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet WARNING that fits properly. POTENTIAL HAZARD You should also wear: Operating this ATV without wearing an ap- eye protection (goggles or face shield) proved motorcycle helmet, eye protection gloves and protective clothing.
  • Page 50 Do not operate after consuming alcohol or HOW TO AVOID THE HAZARD drugs. Never consume alcohol or drugs before or The operator’s performance capability is reduced while driving this ATV. by the influence of alcohol or drugs. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety.
  • Page 51 This model also has an engine speed limiter plate to limit the amount of engine power available. Do not operate at speeds too fast for your Yamaha recommends that all beginning riders start skills or the conditions. off with the vehicle speed limiter turned in and the...
  • Page 52 engine speed limiter plate installed to limit the amount Loading and accessories of speed available while they learn. The vehicle speed Use extra caution when riding the ATV with addi- limiter may be gradually adjusted to increase maximum tional loads, such as accessories or cargo. The speed as the beginner becomes more familiar with ATV’s handling may be adversely affected.
  • Page 53 Cargo should be properly distributed and se- WARNING curely attached. POTENTIAL HAZARD Reduce speed when carrying cargo or pull- Removing hands from handlebars or feet ing a trailer. Allow greater distance for brak- from footboards during operation. ing. WHAT CAN HAPPEN Always follow the instructions in your Own- Removing even one hand or foot can reduce er’s Manual for carrying cargo or pulling a...
  • Page 54 Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions.

  • Page 55: Be Careful Where You Ride

    WARNING POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible ma- terial accumulated around the engine area could catch fire. Someone touching the exhaust system dur- ing or after operation could be burned. HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV in dry grass or other dry ground cover.
  • Page 56 HOW TO AVOID THE HAZARD WARNING Always avoid paved surfaces, including side- POTENTIAL HAZARD walks, driveways, parking lots and streets. Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one.
  • 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 POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 58 HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especial- ly cautious on these kinds of terrain. WARNING POTENTIAL HAZARD Operating in areas where you might not be...

  • Page 59: Turning Your Atv

    Do not ride in areas posted “no trespassing”. member that the engine and exhaust pipe will be Do not ride on private property without getting per- hot when riding and afterwards; do not allow skin mission. or clothing to come in contact with these compo- nents.
  • Page 60 low speed. WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN The ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner’s Manual. Prac- tice turning at low speeds before attempting to turn at faster speeds.

  • Page 61: Climbing Uphill

    curves. WHAT CAN HAPPEN Improper riding procedures such as abrupt throttle The ATV can overturn more easily on ex- changes, excessive braking, incorrect body move- tremely steep hills than on level surfaces or ments, or too much speed for the sharpness of the small hills.
  • Page 62 HOW TO AVOID THE HAZARD Always follow proper procedures for climb- ing hills as described in this Owner’s Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly.
  • Page 63 WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground.

  • Page 64: Riding Downhill

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

  • Page 65: Crossing A Slope

    hill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- stacles which may appear. WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.

  • Page 66: Crossing Through Shallow Water

    slopes, be sure not to make sharp turns either up When crossing the side of a hill: or down hill. Always follow proper procedures as de- If your ATV does begin to tip over, gradually steer scribed in the Owner’s Manual. in the downhill direction if there are no obstacles in Avoid hills with excessively slippery or loose your path.
  • Page 67 carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and care- fully. WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an acci-...

  • Page 68: Riding Over Rough Terrain

    1. Air filter case check hose RIDING OVER ROUGH TERRAIN NOTICE Riding over rough terrain should be done with cau- After riding your ATV in water, be sure to drain tion. Look out for obstacles which could cause the trapped water by removing the check hose damage to the ATV or could lead to an upset or ac- at the bottom of the air filter case.

  • Page 69: Sliding And Skidding

    WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for ob- stacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees.

  • Page 70: What To Do If

    WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain.
  • Page 71 Lean more into the turn to regain balance. If nec- If your ATV encounters shallow water: essary, gradually let off the throttle and/or steer Ride slowly and carefully through slow moving to the outside of the turn. (See page 7-15.) water, watching for obstacles.

  • Page 72: Periodic Maintenance And Minor Repair

    Safety is an obligation of the owner. Periodic in- nance unless otherwise specified. Have a spection, adjustment and lubrication will keep your Yamaha dealer perform the service if you are ATV in the safest and best operating condition not familiar with maintenance work.
  • Page 73 If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. WARNING POTENTIAL HAZARD Operating this ATV with improper modifica- tions. WHAT CAN HAPPEN Improper installation of accessories or mod-...

  • Page 74: 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 75 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 76: General Maintenance And Lubrication Chart

    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 Check chain tension. Timing chain √ √ √ √ Adjust if necessary. Every 20–40 hours (more often in wet or Air filter element Clean and replace if necessary.
  • Page 77 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check for looseness or damage, and replace if √ √ √ √ Wheel hub bearings necessary. Make sure that all nuts, bolts, and screws are √...
  • Page 78 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Drive select lever • Check operation and adjust or replace if neces- √ √ √ safety system cable sary.
  • Page 79 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.

  • Page 80: Checking The Spark Plug

    WARNING A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- tion chart.
  • Page 81 If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 1. Spark plug gap 2. Check the spark plug for electrode erosion...

  • Page 82: Engine Oil

    To check the engine oil level 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any 1. Place the ATV on a level surface. grime from the spark plug threads. 2. Check the engine oil level on a cold engine. 3.
  • Page 83 To change the engine oil 4. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to 1. Place the ATV on a level surface. check the oil level. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 84 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. 8 Nm (0.8m·kgf, 5.8 ft·lbf) 9. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if 7.

  • Page 85: Final Transmission Oil

    The final transmission case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the final transmission oil must be changed at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 86: Cleaning The Air Filter Element

    Tightening torque: Cleaning the air filter element Final transmission oil drain bolt: The air filter element should be cleaned at the in- 15 Nm (1.5 m·kgf, 10.8 ft·lbf) tervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more 5.
  • Page 87 1. Air filter case check hose (right) 1. Air filter case cover (right) 2. Bolts 1. Remove the air filter case cover by remov- ing the bolts. 1. Air filter case cover (left) 2. Bolts 8-16...
  • Page 88 2. Remove the air filter element by removing the WHAT CAN HAPPEN screw, and then pull off the sponge material Low-flash-point solvents or gasoline can from the air filter element holder. catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material.
  • Page 89 This will allow unfiltered air 6. Apply Yamaha foam air filter oil or other qual- to enter the engine, causing rapid engine ity foam air filter oil to the sponge material. wear and possible engine damage. Addition- ally, operation without the air filter element...

  • Page 90: Cleaning The Spark Arrester

    Cleaning the spark arrester 2. Remove the spark arrester by pulling it out of the muffler. Be sure the exhaust pipe and muffler are cool be- 3. Tap the spark arrester lightly, and then use fore cleaning the spark arrester. a wire brush to remove any carbon deposits.

  • Page 91: Adjusting The Carburetor

    Therefore, Could injure the eyes. most carburetor adjustments should be left to a Could cause burns. Yamaha dealer, who has the necessary profes- Could cause carbon monoxide poisoning, sional knowledge and experience. The adjustment possibly leading to death.

  • Page 92: Checking 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. Checking the throttle cable free play...

  • Page 93: Timing Chain

    To essary, have a Yamaha dealer adjust it. 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 94: Adjusting The Front Brake Lever Free Play

    The brake lever free play should measure 4.0– 12mm (0.47in), the brake shoes should be replaced 6.0 mm (0.16–0.24 in) as shown. If the free play as a set by Yamaha dealer. is incorrect, adjust it as follows. 1. Upper adjusting bolt 2.
  • Page 95 1. Cable joint 1. Upper locknut 2. Upper adjusting bolt 3. Lower locknut 6. Tighten the upper locknut. 4. Lower adjusting bolt WARNING 4. Tighten the lower locknut. POTENTIAL HAZARD 5. While applying the front brake, turn out the up- Operating with improperly serviced or ad- per adjusting bolt until the upper and lower ca- justed brakes.

  • Page 96: Checking The Rear Brake Pads

    A low brake fluid level may indicate worn brake pads have a Yamaha dealer replace the brake pads as a and/or brake system leakage. If the brake fluid level set.

  • Page 97: Changing The Rear Brake Fluid

    The brake lever free play should measure 0 –1.5 mm (0 –0.06 in) as shown. If the free play is incorrect, have a Yamaha dealer check the brake system. 1. Minimum level mark...

  • Page 98: Checking And Lubricating The Cables

    If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace 8-27...

  • Page 99: Checking The Wheel Hub Bearings

    HOW TO AVOID THE HAZARD 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 bearings. 8-28...
  • Page 100 To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electrical accessories.

  • Page 101: Replacing The Fuse

    If you fuse. do not have access to a constant-voltage 2. Remove the blown fuse, and then install a battery charger, have a Yamaha dealer charge new fuse of the specified amperage. your battery. Specified fuse:...
  • Page 102 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. 8-31...

  • Page 103: Removing A Wheel

    Removing a wheel 2. Elevate the ATV and place a suitable stand under the frame. 1. Loosen the wheel nuts. 3. Remove the nuts from the wheel. 4. Remove the wheel. 1. Wheel nuts 8-32...

  • Page 104: Installing A Wheel

    Installing a wheel 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified 1. Install the wheel and the nuts. torques. When installing the wheel, make sure its arrow Tightening torques: mark points toward the rotating direction of the Front wheel nut: 45 Nm (4.5 m·kgf, 33 ft·lbf) wheel.

  • Page 105: 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 106: 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 107: Cleaning And Storage

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

  • Page 108: Storage

    nia) and areas where strong chemicals are WARNING stored. POTENTIAL HAZARD Operation with wet brakes after washing. Long-term WHAT CAN HAPPEN Before storing your ATV for several months: Wet brakes may have reduced stopping abil- 1. Follow all the instructions in the “Cleaning” ity, increasing the chance of an accident.
  • Page 109 plug, and then place the spark plug on the cylinder head so that the electrodes are Make any necessary repairs before storing the grounded. (This will limit sparking during ATV. the next step.) d. Turn the engine over several times with the starter.

  • Page 110: Specifications

    SPECIFICATIONS Compression ratio: Dimensions: 10.2 : 1 Overall length: Starting system: 1490 mm (58.7 in) Electric starter & kickstarter Overall width: Lubrication system: 885 mm (34.8 in) Wet sump Overall height: 910 mm (35.8 in) Seat height: Engine oil: 654 mm (25.7 in) Type: Wheelbase: YAMALUBE 4, SAE5W-30 or SAE10W-40 or SAE20W-50...
  • Page 111 Transmission: Engine oil quantity: Periodic oil change: Primary reduction system: 0.8 L (0.84 US qt) (0.70 Imp.qt) V-belt Final transmission oil: Primary reduction ratio: 2.47-0.61:1 Type: Secondary reduction system: SAE80 API GL-4 Hypoid gear oil Spur Quantity: Secondary reduction ratio: 0.30 L (0.32 US qt) (0.27 Imp.qt) 41/15 ×...
  • Page 112 Front wheel: Rear tire: Wheel type: Type: Panel wheel Tubeless Rim size: Size: 8 x 5.5AT AT18 x 9-8 Rear wheel: Manufacturer/model: Wheel type: MAXXIS/M940 Panel wheel Loading: Rim size: Maximum loading limit: 8 x 7AT 70.0 kg (154 lb) Front brake: (Total weight of rider, cargo, accessories, and tongue) Type:...
  • Page 113 Wheel travel: 111 mm (4.4 in) Rear suspension: Type: Swingarm Spring/shock absorber type: Coil spring/oil damper Wheel travel: 83 mm (3.3 in) Electrical system: Ignition system: Charging system: AC magneto Battery: Model: GTX5L-BS Voltage, capacity: 12 V, 4.0 AH Fuses: Main fuse: 10 A 10-4...

  • Page 114: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 115 ATV. 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 116: Noise Regulation

    Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 117: Maintenance Record

    Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.

  • Page 118: Yamaha Motor Corporation, U.s.a. Atv Limited Warranty

    (6) months from the date of purchase. appropriate owner’s manual; YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 2. Give notice to an authorized Yamaha ATV dealer OTHER WARRANTY OF ANY KIND, EXPRESSED OR of any and all apparent defects within ten (10) days DURING THE PERIOD OF WARRANTY any authorized IMPLIED.
  • Page 119 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

  • Page 120: Yamaha Extended Service (Y.e.s.)

    Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn ’t limited to much more valuable! “moving par ts”...
  • Page 121 Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
  • Page 122 11-9...
  • Page 123 INDEX Engine oil............5-3, 8-11 Accessories and loading ..........6-6 Engine, starting a warm..........6-3 Air filter element, cleaning..........8-15 Engine stop switch............4-2 Engine speed limiter plate..........4-5 Battery................8-28 Brake lever, front.............4-6 Final transmission oil ........... 5-3, 8-14 Brake lever, rear............4-6 Brake lever free play, checking the rear......8-26 Fuel................4-8, 5-3 Brake lever free play, adjusting the front......8-23 Fuel cock..............4-10...
  • Page 124 Valve clearance............8-22 Owner’s manual and tool kit........... 8-1 Vehicle identification number ........11-1 Vehicle speed limiter ............4-4 Parking ................6-4 Parking brake ..............4-7 Parking on a slope ............6-5 Wheel hub bearings, checking ........8-28 Part locations ..............3-1 Wheel, installing ............
  • Page 125 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED IN TAIWAN PRINTED ON RECYCLED PAPER 2008.07...
  • Page 127 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES FIRST CLASS PERMIT NO. 4 CYPRESS, CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U.S.A. P.O. BOX 6555 CYPRESS, CALIFORNIA 90630-9989 ATTN: SALES ADMINISTRATION...

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