READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35FGY WARNING LIT-11626-22-17 This ATV should not be ridden by anyone under 16 years of age.
U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM EBU17170 INTRODUCTION EBU17271 Congratulations on your purchase of the Yamaha YFM35FGY. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY 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. Obey all safety messages that follow this symbol to avoid possible injury or death.
U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this ATV.
U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17420 TABLE OF CONTENTS SAFETY INFORMATION .............................. 1-1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ............................ 2-1 DESCRIPTION .............................................. 3-1 Left view ...................................................... 3-1 Right view....................................................
U5UH16E0.book Page 2 Wednesday, May 7, 2008 10:35 AM Measuring the tire pressure ....................... 5-6 Tire wear limit ............................................. 5-7 Chassis fasteners ....................................... 5-7 Instruments, lights and switches ................ 5-7 OPERATION .................................................. 6-1 Starting a cold engine ................................ 6-1 Starting a warm engine ..............................
U5UH16E0.book Page 3 Wednesday, May 7, 2008 10:35 AM Checking the front brake pads and rear brake shoes ............................................ 8-28 Checking the brake fluid level .................. 8-29 Changing the brake fluid .......................... 8-30 Checking the front brake lever free play ......................................................... 8-30 Adjusting the brake pedal and rear brake lever free play and checking the brake pedal position .........................................
U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM EBU17430 SAFETY INFORMATION ● EBU17542 AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.
U5UH16E0.book Page 2 Wednesday, May 7, 2008 10:35 AM ● 1 ● ● ● ● ● ● Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful when operating on unfamiliar terrain.
U5UH16E0.book Page 3 Wednesday, May 7, 2008 10:35 AM ● ● ● ● ● roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees.
U5UH16E0.book Page 4 Wednesday, May 7, 2008 10:35 AM HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, seek medical help immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. EWB00021 WARNING 1 POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned.
U5UH16E0.book Page 5 Wednesday, May 7, 2008 10:35 AM WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation.
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U5UH16E0.book Page 2 Wednesday, May 7, 2008 10:35 AM EBU17670 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 replacement label from your Yamaha dealer. 2 1 WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident.
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U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Fuel cock 2. Throttle stop screw 3. Air filter case 4. Fuses 5. Battery 6. Tail/brake light 7. Recoil starter 8. Engine oil filler cap 9. Oil filter cartridge 10.V-belt cooling duct check hose 1. Rear shock absorber assembly spring preload adjusting ring 2. Spark arrester 3. Storage compartment and tool kit 4. Spark plug 5. Front shock absorber assembly spring preload adjusting ring 6.
U5UH16E0.book Page 2 Wednesday, May 7, 2008 10:35 AM EBU17712 Controls and instruments 3 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Parking brake lock plate 5. Drive select lever 6. Main switch 7. Fuel tank cap 8. On-Command four-wheel-drive switch 9. Throttle lever 10.Front brake lever TIP The ATV you have purchased may differ slightly from the figures shown in this manual.
U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM EBU17722 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 4 EBU17760 Main switch The positions of the main switch are as follows: ON All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed. 1. Main switch OFF All electrical systems are off.
U5UH16E0.book Page 2 Wednesday, May 7, 2008 10:35 AM EBU17813 EBU26931 Indicator lights and warning light Oil temperature warning light “ ” This warning light comes on when the engine overheats. When this occurs, stop the engine as soon as it is safe to do so, and allow it to cool. The electrical circuit of the warning light can be checked by turning the key to “ON”, with the engine stop switch set to “ ”, and then pushing the start switch.
U5UH16E0.book Page 3 Wednesday, May 7, 2008 10:35 AM 4 EBU17952 EBU18080 On-Command four-wheel-drive indicator light “ ” This indicator light comes on when the On-Command four-wheel-drive switch is set to the “4WD” position. Engine stop switch “ / ” Set this switch to “ ” before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation.
U5UH16E0.book Page 4 Wednesday, May 7, 2008 10:35 AM ECB00040 NOTICE Do not use the headlights with the engine turned off for an extended period of time, otherwise the battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. 4 EBU28382 On-Command four-wheel-drive switch “2WD”/“4WD” This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice versa.
U5UH16E0.book Page 5 Wednesday, May 7, 2008 10:35 AM Regulate the speed of the ATV by varying the throttle position. Because the throttle is springloaded, the ATV will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. EWB00121 WARNING 4 POTENTIAL HAZARD Changing from two-wheel drive to fourwheel drive or from four-wheel drive to twowheel drive while the ATV is moving.
U5UH16E0.book Page 6 Wednesday, May 7, 2008 10:35 AM WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident. HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can’t find or solve the problem yourself. 4 1. Locknut 2. Adjusting screw 3.
U5UH16E0.book Page 7 Wednesday, May 7, 2008 10:35 AM EWB00190 WARNING 4 POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in). (See page 8-27.) 1.
U5UH16E0.book Page 8 Wednesday, May 7, 2008 10:35 AM EBU18450 Parking brake Use the parking brake before starting the engine or parking the ATV, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. 4 1. Brake pedal 1. Parking brake lock plate 1.
U5UH16E0.book Page 9 Wednesday, May 7, 2008 10:35 AM EWB00170 WARNING 4 POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake could overheat if you ride the ATV without releasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely.
U5UH16E0.book Page 10 Wednesday, May 7, 2008 10:35 AM EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 4 1. Recoil starter EWB00300 WARNING POTENTIAL HAZARD Starting the engine without shifting into the neutral position. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident. HOW TO AVOID THE HAZARD Shift the drive select lever into the neutral position and apply the parking brake before starting the engine. 1.
U5UH16E0.book Page 11 Wednesday, May 7, 2008 10:35 AM 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. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel.
U5UH16E0.book Page 12 Wednesday, May 7, 2008 10:35 AM OFF WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely.
U5UH16E0.book Page 13 Wednesday, May 7, 2008 10:35 AM ON RES 1. Arrow mark pointing to “ON” 1. Arrow mark pointing to “RES” With the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding. This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding.
U5UH16E0.book Page 14 Wednesday, May 7, 2008 10:35 AM 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. 4 1. Seat 2. Seat lock lever 1. Starter (choke) “ To install the seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. ” EBU18880 Seat TIP Make sure that the seat is securely fitted.
U5UH16E0.book Page 15 Wednesday, May 7, 2008 10:35 AM 4 1. Projection 2. Seat holder 1. Storage compartment ● EBU18911 Storage compartment ● ECB00130 NOTICE Do not store metal or sharply edged objects, like tools, in the storage compartment. If they must be stored, wrap them in appropriate cushion material to prevent damaging the storage compartment. Do not exceed the load limit of 2.0 kg (4 lb) for the storage compartment. Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV.
U5UH16E0.book Page 16 Wednesday, May 7, 2008 10:35 AM EBU18981 Adjusting the front shock absorber assemblies The spring preload can be adjusted to suit the rider’s weight and the riding conditions. Adjust the spring preload as follows. Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to decrease the spring preload and thereby soften the suspension. 1.
U5UH16E0.book Page 17 Wednesday, May 7, 2008 10:35 AM EWB00350 TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment. WARNING POTENTIAL HAZARD Improper shock absorber assembly adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorber assemblies on the left and right side to the same setting. 4 EBU19021 Adjusting the rear shock absorber assembly 1.
U5UH16E0.book Page 18 Wednesday, May 7, 2008 10:35 AM 4 1. Spring preload adjusting ring 2. Position indicator 1. Special wrench Spring preload setting: Minimum (soft): 1 Standard: 2 Maximum (hard): 5 TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment. EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death.
U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM EBU19200 PRE-OPERATION CHECKS EBU19213 Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table. EWB00470 WARNING 5 POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage.
U5UH16E0.book Page 2 Wednesday, May 7, 2008 10:35 AM ITEM Engine oil Final gear oil Differential gear oil Front brake Rear brake Throttle lever Control cables Wheels and tires Brake pedal Brake levers Axle boots Chassis fasteners Instruments, lights and switches ROUTINE • Check oil level in engine, and add recommended oil to specified level if necessary. • Check ATV for oil leakage. Correct if necessary. • Check ATV for oil leakage. Correct if necessary. • Check ATV for oil leakage.
U5UH16E0.book Page 3 Wednesday, May 7, 2008 10:35 AM EBU19530 EBU19590 Fuel Final gear oil Make sure that there is sufficient fuel in the tank. (See page 4-10.) Make sure that the final gear oil is at the specified level. Add oil as necessary. (See page 8-15.) EWB00500 WARNING 5 EBU19600 Differential gear oil POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up.
U5UH16E0.book Page 4 Wednesday, May 7, 2008 10:35 AM WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have a Yamaha dealer check for the cause. Brake fluid level (front brake) Check the brake fluid level. Add fluid if necessary. (See page 8-29.
U5UH16E0.book Page 5 Wednesday, May 7, 2008 10:35 AM EBU19802 Tires EWB00552 WARNING 5 POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. HOW TO AVOID THE HAZARD ● The tires listed below have been approved by Yamaha Motor Manufacturing Corporation of America for this model.
U5UH16E0.book Page 6 Wednesday, May 7, 2008 10:35 AM ● ● ● Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure: Front: 22.0 kPa (0.220 kgf/cm², 3.2 psi) Rear: 22.0 kPa (0.220 kgf/cm², 3.2 psi) Use no more than the following pressures when seating the tire beads. Maximum tire seating pressure: Front: 250 kPa (2.5 kgf/cm², 36 psi) Rear: 250 kPa (2.
U5UH16E0.book Page 7 Wednesday, May 7, 2008 10:35 AM 5 Recommended pressure: Front 25.0 kPa (0.250 kgf/cm², 3.6 psi) Rear 25.0 kPa (0.250 kgf/cm², 3.6 psi) Minimum: Front 22.0 kPa (0.220 kgf/cm², 3.2 psi) Rear 22.0 kPa (0.220 kgf/cm², 3.2 psi) 1. Tire wear limit EBU19830 Tire wear limit EBU19840 Replace the tire when the tire groove decreases to 3 mm (0.12 in). Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened.
U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM EBU19870 OPERATION EBU20021 EWB00010 Starting a cold engine WARNING Indicates a potential hazard that could result in serious injury or death. EWB00620 WARNING POTENTIAL HAZARD Frozen control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or collision. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding.
U5UH16E0.book Page 2 Wednesday, May 7, 2008 10:35 AM Ambient temp./starter (choke) position 4. Shift the drive select lever into the neutral position. The neutral indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 6 TIP The engine can be started under the following conditions: ● The drive select lever is in the neutral position. ● The rear brake lever is applied with the drive select lever in any position.
U5UH16E0.book Page 3 Wednesday, May 7, 2008 10:35 AM ● If the battery is discharged, pull the recoil starter to start the 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. 7.
U5UH16E0.book Page 4 Wednesday, May 7, 2008 10:35 AM TIP When in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 6 1. 2. 3. 4. Drive select lever F (Forward) N (Neutral) R (Reverse) 3. Open the throttle lever gradually. 1. 2. 3. 4. Shifting: Reverse 1. Bring the ATV to a complete stop. 2. Apply the brake pedal. 3.
U5UH16E0.book Page 5 Wednesday, May 7, 2008 10:35 AM Since the engine is brand new, do not put an excessive load on it for the first 320 km (200 mi) or 20 hours. The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided. EWB00670 WARNING POTENTIAL HAZARD Improper operation in reverse.
U5UH16E0.book Page 6 Wednesday, May 7, 2008 10:35 AM 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 transversely across the incline, shift the drive select lever to the forward position, stop the engine, apply the parking brake, and then block the front and rear wheels with rocks or other objects.
U5UH16E0.book Page 7 Wednesday, May 7, 2008 10:35 AM ● ● EBU20910 Accessories and loading ● EBU20920 Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. ● Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market.
U5UH16E0.book Page 8 Wednesday, May 7, 2008 10:35 AM ● MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, cargo, accessories, and tongue): 210.0 kg (463 lb) Front carrier: 40.0 kg (88 lb) Rear carrier: 80.0 kg (176 lb) Storage compartment: 2.0 kg (4 lb) Trailer hitch: Pulling load (total weight of trailer and cargo): 4900 N (500 kgf, 1102 lbf) Tongue weight (vertical weight on trailer hitch point): 147 N (15 kgf, 33 lbf) 6 ● ● ● ● ● ● ● Do not exceed the maximum tongue weight.
U5UH16E0.book Page 9 Wednesday, May 7, 2008 10:35 AM WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. 6 EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death.
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U5UH16E0.book Page 2 Wednesday, May 7, 2008 10:35 AM ular attention to the safety information on pages 1-1–1-5. Please also read all caution and warning labels on your ATV. EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU21442 GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use. This section, Riding your ATV, provides general ATV riding instructions for recreational riding.
U5UH16E0.book Page 3 Wednesday, May 7, 2008 10:35 AM RIDE WITH CARE AND GOOD JUDGEMENT HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating techniques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-8872887. Get training if you are inexperienced.
U5UH16E0.book Page 4 Wednesday, May 7, 2008 10:35 AM WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc.
U5UH16E0.book Page 5 Wednesday, May 7, 2008 10:35 AM This ATV is designed to carry operator and cargo only – passengers prohibited. EWB00910 WARNING 7 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 passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation.
U5UH16E0.book Page 6 Wednesday, May 7, 2008 10:35 AM Apparel HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear: ● eye protection (goggles or face shield) ● gloves ● boots ● long-sleeved shirt or jacket ● long pants EWB00920 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing.
U5UH16E0.book Page 7 Wednesday, May 7, 2008 10:35 AM Do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety. EWB00940 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating.
U5UH16E0.book Page 8 Wednesday, May 7, 2008 10:35 AM Do not operate at speeds too fast for your skills or the conditions. EWB00950 WARNING EWB00960 POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident.
U5UH16E0.book Page 9 Wednesday, May 7, 2008 10:35 AM Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Reduce your speed when adding additional loads. Speed limiter For riders less experienced with this model, the throttle lever housing is equipped with a speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum.
U5UH16E0.book Page 10 Wednesday, May 7, 2008 10:35 AM EWB00970 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.
U5UH16E0.book Page 11 Wednesday, May 7, 2008 10:35 AM During operation Always keep your feet on the footboards during operation, otherwise they may contact the rear wheels. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.
U5UH16E0.book Page 12 Wednesday, May 7, 2008 10:35 AM HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer. Modifications EWB01000 7 WARNING POTENTIAL HAZARD Operating this ATV with improper modifications.
U5UH16E0.book Page 13 Wednesday, May 7, 2008 10:35 AM Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. EWB01010 WARNING 7 POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire.
U5UH16E0.book Page 14 Wednesday, May 7, 2008 10:35 AM HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets. EWB01030 WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
U5UH16E0.book Page 15 Wednesday, May 7, 2008 10:35 AM Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. EWB01040 WARNING 7 POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control.
U5UH16E0.book Page 16 Wednesday, May 7, 2008 10:35 AM HOW TO AVOID THE HAZARD 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. Always be especially cautious on these kinds of terrain. 7 EWB01060 WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off-road vehicles. WHAT CAN HAPPEN You could be in a collision. You could be injured.
U5UH16E0.book Page 17 Wednesday, May 7, 2008 10:35 AM hot when riding and afterwards; do not allow skin or clothing to come in contact with these components. With the engine idling, return the starter (choke) to the closed position, shift the drive select lever into the forward position, and then release the parking brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate.
U5UH16E0.book Page 18 Wednesday, May 7, 2008 10:35 AM used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. EWB01080 WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN 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. Practice turning at low speeds before attempting to turn at faster speeds.
U5UH16E0.book Page 19 Wednesday, May 7, 2008 10:35 AM Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over.
U5UH16E0.book Page 20 Wednesday, May 7, 2008 10:35 AM HOW TO AVOID THE HAZARD Always follow proper procedures for climbing 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. The ATV could flip over backwards. Never go over the top of any hill at high speed.
U5UH16E0.book Page 21 Wednesday, May 7, 2008 10:35 AM If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
U5UH16E0.book Page 22 Wednesday, May 7, 2008 10:35 AM If you start to roll backwards, DO NOT apply either brake abruptly. If you are in 2WD, apply only the front brake. If you are in 4WD, because all wheels are interconnected by the drive train, applying either brake will brake all wheels, therefore, avoid sudden application of either the front or rear brake as the wheels on the uphill side could come off the ground. The ATV could easily tip over backwards.
U5UH16E0.book Page 23 Wednesday, May 7, 2008 10:35 AM 7 Whenever possible, ride your ATV straight downhill. 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 obstacles which may appear. RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight.
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U5UH16E0.book Page 25 Wednesday, May 7, 2008 10:35 AM 7 CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. As you travel across a slope, lean your body in the uphill direction.
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U5UH16E0.book Page 27 Wednesday, May 7, 2008 10:35 AM CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and carefully. EWB01150 WARNING 7 POTENTIAL HAZARD Operating this ATV through deep or fast flowing water.
U5UH16E0.book Page 28 Wednesday, May 7, 2008 10:35 AM 1. Air filter case check hose ECB00280 7 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, the V-belt cooling duct check hose, the drive select lever box check hose and the storage compartment check hose. Also, remove the V-belt case drain plug to drain any water that may have accumulated.
U5UH16E0.book Page 29 Wednesday, May 7, 2008 10:35 AM 1. V-belt case drain plug 1. Drive select lever box check hose RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result.
U5UH16E0.book Page 30 Wednesday, May 7, 2008 10:35 AM 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 obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual.
U5UH16E0.book Page 31 Wednesday, May 7, 2008 10:35 AM SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help. With practice, over a period of time, skill at controlled sliding can be developed.
U5UH16E0.book Page 32 Wednesday, May 7, 2008 10:35 AM ● WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. ● ● WHAT TO DO IF...
U5UH16E0.book Page 33 Wednesday, May 7, 2008 10:35 AM ● If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See page 7-27.) EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death.
U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM EBU21648 PERIODIC MAINTENANCE AND MINOR REPAIR HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with maintenance work. EBU21660 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your ATV in the safest and best operating condition possible.
U5UH16E0.book Page 2 Wednesday, May 7, 2008 10:35 AM EWB01830 WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this ATV may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories.
U5UH16E0.book Page 3 Wednesday, May 7, 2008 10:35 AM EBU21742 Periodic maintenance chart for the emission control system TIP ● For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
U5UH16E0.book Page 4 Wednesday, May 7, 2008 10:35 AM INITIAL NO. 6 7 * ITEM Exhaust system Spark arrester CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 • Check for leakage and replace gasket(s) if necessary. • Check for looseness and tighten all screw clamps and joints if necessary. • Clean.
U5UH16E0.book Page 5 Wednesday, May 7, 2008 10:35 AM EBU21864 General maintenance and lubrication chart INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) 20 80 hours 1 2 3 4 Air filter element * * * Front brake Rear brake Brake hoses 5 * Wheels 6 * Tires 7 * Wheel hub bearings 8 * Swingarm • Clean and replace if necessary. • Check operation and correct if necessary.
U5UH16E0.book Page 6 Wednesday, May 7, 2008 10:35 AM INITIAL NO. 8 ITEM 9 * V-belt 10 * Chassis fasteners 11 * 12 * Shock absorber assemblies Steering shaft 13 * Steering system 14 * Engine mount 15 * Axle boots 16 Engine oil 17 Engine oil filter cartridge 18 Differential gear oil 19 Final gear oil month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 • Check for wear, cracks or other damage, and replace if necessary.
U5UH16E0.book Page 7 Wednesday, May 7, 2008 10:35 AM INITIAL NO. ITEM Moving parts and cables Drive select lever safety system cable 20 * 21 * 22 * Throttle lever housing and cable 23 * Front and rear brake switches 24 * Lights and switches CHECK OR MAINTENANCE JOB Whichever comes first EVERY month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 160 160 320 √ √ √ √ √ √ √ • Lubricate. • Check operation and adjust or replace if necessary.
U5UH16E0.book Page 8 Wednesday, May 7, 2008 10:35 AM EWB00010 EBU23111 Panel A WARNING Indicates a potential hazard that could result in serious injury or death. To remove the panel Remove the bolt, and then take the panel off. EBU23080 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. 8 1. Panel A 2.
U5UH16E0.book Page 9 Wednesday, May 7, 2008 10:35 AM 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. EBU23211 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 accordance with the periodic maintenance and lubrication chart.
U5UH16E0.book Page 10 Wednesday, May 7, 2008 10:35 AM 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/DR8EA To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 1. Spark plug gap Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) 2.
U5UH16E0.book Page 11 Wednesday, May 7, 2008 10:35 AM 3. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag. TIP If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4. Install the spark plug cap. EBU23315 Engine oil and oil filter cartridge The engine oil level should be checked before each ride.
U5UH16E0.book Page 12 Wednesday, May 7, 2008 10:35 AM To change the engine oil (with or without oil filter cartridge replacement) 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap, and then remove the engine oil drain bolt to drain the oil from the crankcase. 1. Dipstick 2. Maximum level mark 3.
U5UH16E0.book Page 13 Wednesday, May 7, 2008 10:35 AM 4. Remove the oil filter cartridge with an oil filter wrench. TIP An oil filter wrench is available at a nearby Yamaha dealer. 5. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. TIP Make sure that the O-ring is properly seated. 1. Oil filter cartridge 8 1. O-ring 6. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. 1.
U5UH16E0.book Page 14 Wednesday, May 7, 2008 10:35 AM Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.20 L (2.33 US qt, 1.94 Imp.qt) With oil filter cartridge replacement: 2.30 L (2.43 US qt, 2.02 Imp.qt) TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down. 1. Torque wrench ECB00300 8 Tightening torque: Oil filter cartridge: 17 Nm (1.
U5UH16E0.book Page 15 Wednesday, May 7, 2008 10:35 AM dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart. 1 To check the final gear oil level 1. Place the ATV on a level surface. TIP The final gear oil level must be checked on a cold engine. 2 2. Remove the final gear oil filler bolt, and then check the oil level in the final gear case. 1. “CD” specification 2.
U5UH16E0.book Page 16 Wednesday, May 7, 2008 10:35 AM 2. Remove the final gear case guard by removing the bolts. 1. Final gear oil 2. Final gear oil filler bolt 3. Correct oil level 8 1. Final gear case guard 2. Bolt 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. 4. Install the oil filler bolt, and then tighten it to the specified torque. 3. Place an oil pan under the final gear case to collect the used oil. 4.
U5UH16E0.book Page 17 Wednesday, May 7, 2008 10:35 AM 1. Final gear oil drain bolt 1. Final gear oil 2. Final gear oil filler bolt 3. Correct oil level 5. Install the drain bolt, and then tighten it to the specified torque. Recommended final gear oil: See page 10-1. Tightening torque: Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) ECB00420 NOTICE Be sure no foreign material enters the final gear case. 6. Refill with the recommended final gear oil to the brim of the filler hole as shown. 7.
U5UH16E0.book Page 18 Wednesday, May 7, 2008 10:35 AM 3. Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case. Tightening torque: Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 8. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 9. Install the final gear case guard by installing the bolts and tightening them to the specified torque.
U5UH16E0.book Page 19 Wednesday, May 7, 2008 10:35 AM ● The differential gear case capacity is greater than the recommended oil quantity, therefore the oil level cannot be accurately checked from the oil filler hole. Recommended differential gear oil: See page 10-1. Oil quantity: 0.35 L (0.37 US qt, 0.31 Imp.qt) ECB00410 NOTICE Be sure no foreign material enters the differential gear case. 1. Differential gear oil drain bolt 4. Install the drain bolt, and then tighten it to the specified torque. 6.
U5UH16E0.book Page 20 Wednesday, May 7, 2008 10:35 AM 2. Remove the seat. (See page 4-14.) 3. Remove the air filter case cover by unhooking the air filter case cover holders. EBU23635 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean or, if necessary, replace the air filter element more frequently if you are riding in unusually wet or dusty areas.
U5UH16E0.book Page 21 Wednesday, May 7, 2008 10:35 AM 1. Air filter element 1. Air filter element frame 2. Sponge material 3. Air filter element lock plate 5. Pull off the air filter element lock plate, and then remove the sponge material from the air filter element frame. 6. Wash the sponge material gently but thoroughly in solvent.
U5UH16E0.book Page 22 Wednesday, May 7, 2008 10:35 AM EWB01900 WARNING POTENTIAL HAZARD Using low-flash-point solvents or gasoline to clean the sponge material. WHAT CAN HAPPEN Low-flash-point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material. 8. Check the sponge material and replace it if damaged. 9. Apply Yamaha foam air filter oil or other quality foam air filter oil to the sponge material. 7.
U5UH16E0.book Page 23 Wednesday, May 7, 2008 10:35 AM EBU23882 TIP 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 areas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions. Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air-tight seal.
U5UH16E0.book Page 24 Wednesday, May 7, 2008 10:35 AM EWB01910 WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system. WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components. Do not start the engine when cleaning the exhaust system. 1. Tailpipe 2.
U5UH16E0.book Page 25 Wednesday, May 7, 2008 10:35 AM 1. V-belt cooling duct check hose (left front side of ATV) 1. V-belt case drain plug EBU23930 EBU23940 V-belt case drain plug Adjusting the carburetor After riding in water deep enough to allow it to enter the V-belt case, remove this plug to drain the water from the case. The carburetor should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.
U5UH16E0.book Page 26 Wednesday, May 7, 2008 10:35 AM crease the engine idling speed, turn the throttle stop screw in direction (a), and to decrease it, turn the screw in direction (b). ECB00480 NOTICE The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine.
U5UH16E0.book Page 27 Wednesday, May 7, 2008 10:35 AM EBU24044 Adjusting the throttle cable free play The throttle cable free play should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The throttle cable free play should measure 3.0– 5.0 mm (0.12–0.20 in) at the throttle lever. Periodically check the throttle cable free play and, if necessary, adjust it as follows.
U5UH16E0.book Page 28 Wednesday, May 7, 2008 10:35 AM EBU24071 Adjusting the drive select lever safety system cable The drive select lever safety system cable stretches with use, which can result in improper function. Therefore, the safety system cable should be checked and adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. EBU24120 Checking the front brake pads and rear brake shoes 8 1. Brake pad 2.
U5UH16E0.book Page 29 Wednesday, May 7, 2008 10:35 AM 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. brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. 1. Wear limit line 2. Wear indicator 1.
U5UH16E0.book Page 30 Wednesday, May 7, 2008 10:35 AM ● ● ● ● 8 Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.
U5UH16E0.book Page 31 Wednesday, May 7, 2008 10:35 AM ● WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that there is no free play. ● Make sure the brakes do not drag. ● Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer.
U5UH16E0.book Page 32 Wednesday, May 7, 2008 10:35 AM 1. Brake pedal free play adjusting nut 2. Brake lever free play adjusting nut 8 1. Brake lever free play 2. Locknut 3. Brake lever free play adjusting bolt Adjusting the brake lever free play The brake lever free play should measure 3.0–5.0 mm (0.12–0.20 in) as shown. If the free play is incorrect, adjust it as follows. 1. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjusting bolt. 2.
U5UH16E0.book Page 33 Wednesday, May 7, 2008 10:35 AM 1. Brake lever free play adjusting nut 2. Gap “A” 1. Locknut 2. Brake lever free play adjusting bolt 3. Turn the brake lever free play adjusting bolt at the brake lever in direction (a) to increase the free play, and in direction (b) to decrease it. 4. Tighten the locknut at the brake lever. TIP When adjusting the rear brake lever free play: ● Be sure not to step on the brake pedal. ● Make sure the brake pedal does not move.
U5UH16E0.book Page 34 Wednesday, May 7, 2008 10:35 AM HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct. ● Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. 1 EBU24230 Axle boots 1.
U5UH16E0.book Page 35 Wednesday, May 7, 2008 10:35 AM 1 TIP The brake light switch is properly adjusted when the brake light comes on just before braking takes effect. 1 2. Turn the brake light switch adjusting nut while holding the brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a). To make the brake light come on later, turn the adjusting nut in direction (b). 1.
U5UH16E0.book Page 36 Wednesday, May 7, 2008 10:35 AM EBU24890 EBU28711 Checking and lubricating the cables Checking and lubricating the front and rear brake levers The operation and the condition of all control cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.
U5UH16E0.book Page 37 Wednesday, May 7, 2008 10:35 AM Rear brake lever EBU24962 Checking the wheel hub bearings EBU28832 Checking and lubricating the brake pedal The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bearings.
U5UH16E0.book Page 38 Wednesday, May 7, 2008 10:35 AM HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Get prompt medical attention. EYES: Flush with water for 15 minutes and get prompt medical attention.
U5UH16E0.book Page 39 Wednesday, May 7, 2008 10:35 AM To store the battery ● If the ATV will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. ● If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary. 3 4 1 1. 2. 3. 4. 2 To install the battery TIP Be sure the battery is fully charged. Bolt Battery holding plate Negative battery lead (black) Positive battery lead (red) 1.
U5UH16E0.book Page 40 Wednesday, May 7, 2008 10:35 AM the battery. If you do not have access to a constant-voltage battery charger, have a Yamaha dealer charge your battery. 2 1 EBU25313 Replacing a fuse 1. Positive battery lead (red) 2. Negative battery lead (black) 8 3. Install the battery holding plate by installing the bolts. 4. Install the seat. (See page 4-14.) ECB00632 1. Main fuse 2. Spare main fuse 3. Fuse box NOTICE ● Always keep the battery charged.
U5UH16E0.book Page 41 Wednesday, May 7, 2008 10:35 AM 2. Remove the blown fuse, and then install a new fuse of the specified amperage. 1. 2. 3. 4. 5. Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Ignition fuse: 15.0 A Four-wheel-drive motor fuse: 3.0 A Signaling system fuse: 10.0 A Headlight fuse Ignition fuse Four-wheel-drive motor fuse Signaling system fuse Spare fuse EWB02151 WARNING The main fuse and the fuse box are located under the seat. (See page 4-14.
U5UH16E0.book Page 42 Wednesday, May 7, 2008 10:35 AM 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. EBU25470 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the cover at the rear of the headlight by pulling it off. 1. Headlight bulb holder cover 3.
U5UH16E0.book Page 43 Wednesday, May 7, 2008 10:35 AM 4. Remove the defective bulb by pulling it out. EWB02180 WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it. 1. Do not touch the glass part of the bulb. ECB00650 5.
U5UH16E0.book Page 44 Wednesday, May 7, 2008 10:35 AM ECB00670 NOTICE Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 8. Adjust the headlight beam if necessary. EBU25551 Adjusting a headlight beam ECB00690 NOTICE It is advisable to have a Yamaha dealer make this adjustment. 8 1. Headlight beam adjusting screw EBU25580 Replacing the tail/brake light bulb To raise a headlight beam, turn the headlight beam adjusting screw in direction (a).
U5UH16E0.book Page 45 Wednesday, May 7, 2008 10:35 AM ● Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel. 1. Wheel nut 3. Elevate the ATV and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. 1. Arrow mark 8 EBU25701 Installing a wheel 1. Place the ATV on a level surface. 2. Install the wheel and the nuts.
U5UH16E0.book Page 46 Wednesday, May 7, 2008 10:35 AM EBU25710 Troubleshooting Although Yamaha ATVs receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself.
U5UH16E0.book Page 47 Wednesday, May 7, 2008 10:35 AM HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces.
U5UH16E0.book Page 48 Wednesday, May 7, 2008 10:35 AM EBU25751 Troubleshooting chart 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the ATV. Check the fuel level in the fuel tank. The engine does not start. Check the compression. 2. Compression Operate the electric starter. 3.
U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM EBU25860 CLEANING AND STORAGE ed from improper high-pressure detergent applications such as those available in coinoperated car washers. EBU25870 Cleaning Frequent, thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the ATV: a. Block off the end of the exhaust pipe to prevent water entry.
U5UH16E0.book Page 2 Wednesday, May 7, 2008 10:35 AM ● EWB02300 WARNING POTENTIAL HAZARD Operation with wet brakes after washing. WHAT CAN HAPPEN Wet brakes may have reduced stopping ability, increasing the chance of an accident. HOW TO AVOID THE HAZARD Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings. Long-term Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” section of this chapter. 2.
U5UH16E0.book Page 3 Wednesday, May 7, 2008 10:35 AM 6. 7. 8. 9. sively cold or warm place [less than 0 °C (30 °F) or more than 30 °C (90 °F)]. For more information on storing the battery, see page 8-38. b. Pour a teaspoonful of engine oil into the spark plug bore. c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d.
U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Starting system: Electric and recoil starter Lubrication system: Wet sump Overall length: 1984 mm (78.1 in) Overall width: 1085 mm (42.7 in) Overall height: 1120 mm (44.1 in) Seat height: 827 mm (32.6 in) Wheelbase: 1233 mm (48.5 in) Ground clearance: 245 mm (9.
U5UH16E0.book Page 2 Wednesday, May 7, 2008 10:35 AM Spark plug (s): Engine oil quantity: Without oil filter cartridge replacement: 2.20 L (2.33 US qt, 1.94 Imp.qt) With oil filter cartridge replacement: 2.30 L (2.43 US qt, 2.02 Imp.qt) Manufacturer/model: NGK/DR8EA Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) Final gear oil: Clutch: Type: SAE 80 API GL-4 Hypoid gear oil Quantity: 0.23 L (0.24 US qt, 0.20 Imp.
U5UH16E0.book Page 3 Wednesday, May 7, 2008 10:35 AM Front tire: Front wheel: Type: Tubeless Size: AT25 x 8-12 Manufacturer/model: MAXXIS/M979 Wheel type: Panel wheel Rim size: 12 x 6.0AT Rear wheel: Wheel type: Panel wheel Rim size: 12 x 7.5AT Rear tire: Type: Tubeless Size: AT25 x 10-12 Manufacturer/model: MAXXIS/M980 Front brake: Type: Dual disc brake Operation: Right hand operation Recommended fluid: DOT 4 Loading: Maximum loading limit: 210.
U5UH16E0.book Page 4 Wednesday, May 7, 2008 10:35 AM Rear suspension: On-command four-wheel-drive indicator light: 12 V, 1.7 W × 1 Type: Swingarm (monocross) Spring/shock absorber type: Coil spring/oil damper Wheel travel: 180 mm (7.1 in) Fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: 10.0 A Ignition fuse: 15.0 A Four-wheel-drive motor fuse: 3.0 A Electrical system: Ignition system: DC. CDI Charging system: AC magneto Battery: Model: YTX14AH Voltage, capacity: 12 V, 12.
U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM EBU25981 CONSUMER INFORMATION EBU26011 EBU26020 Identification numbers Key identification number The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key.
U5UH16E0.book Page 2 Wednesday, May 7, 2008 10:35 AM 1. Vehicle identification number (front left side) 1. Model label TIP The vehicle identification number is used to identify your ATV. EBU26050 Model label The model label is affixed at the location in the illustration. Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
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U5UH16E0.book Page 4 Wednesday, May 7, 2008 10:35 AM EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
U5UH16E0.book Page 5 Wednesday, May 7, 2008 10:35 AM EBU26501 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha ATVs purchased from an authorized Yamaha ATV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations. THE PERIOD OF WARRANTY for Yamaha ATVs shall be six (6) months from the date of purchase.
U5UH16E0.book Page 6 Wednesday, May 7, 2008 10:35 AM WARRANTY QUESTIONS AND ANSWERS CUSTOMER SERVICE Q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes. If your machine requires warranty service, you must take it to any authorized Yamaha ATV dealer within the continental United States.
U5UH16E0.book Page 7 Wednesday, May 7, 2008 10:35 AM EBU26122 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Ser vice (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
U5UH16E0.book Page 8 Wednesday, May 7, 2008 10:35 AM We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. You can also save money: Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number).
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U5UH16E0.book Page 1 Wednesday, May 7, 2008 10:35 AM INDEX A Accessories and loading ................................................ 6-7 Air filter element, cleaning ............................................ 8-20 Axle boots .................................................................... 8-34 Drive select lever ........................................................... 4-9 Drive select lever and driving in reverse ........................ 6-3 Drive select lever safety system cable, adjusting ....
U5UH16E0.book Page 2 Wednesday, May 7, 2008 10:35 AM L Spark arrester, cleaning ............................................... 8-23 Spark plug, checking ...................................................... 8-9 Specifications ............................................................... 10-1 Speed limiter .................................................................. 4-6 Starter (choke) ............................................................. 4-13 Start switch ................................
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EBU26151 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. BEER BEER ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns.
