EBU00438 READ THIS MANUAL CAREFULLY! It contains important safety information. qWARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER operate: 9 without proper training or instruction. 9 at speeds too fast for your skills or the conditions. 9 on public roads - a collision can occur with another vehicle. 9 with a passenger - passengers affect balance and steering and increase risk of losing control.
5VJ-9-10-1 3/26/02 7:29 PM Page 1 EBU00941 INTRODUCTION Congratulations on your purchase of the Yamaha YFA1. It 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.This manual will provide you with a good basic understanding of the features and operation of this ATV.
5VJ-9-10-1 3/26/02 7:29 PM Page 2 EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
VJ-9-10-1 3/26/02 7:29 PM Page 3 EBU00011 IMPORTANT NOTICE This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this machine on any public street, road or highway. This machine 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 machine.
5VJ-9-10-1 3/26/02 7:29 PM Page 4 EBU00014 w Indicates a potential hazard that could result in serious injury or death. CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS .......................1-1 2 SAFETY INFORMATION .........................2-1 3 DESCRIPTION AND MACHINE IDENTIFICATION.....................................3-1 Identification number records ...............3-2 Key identification number .....................3-2 Vehicle identification number ...............3-3 Model label .......
5VJ-9-10-1 3/26/02 7:29 PM Page 5 5 PRE-OPERATION CHECKS ...................5-1 Front and rear brakes ...........................5-2 Fuel ......................................................5-3 Engine and transmission oill.................5-5 Chain ....................................................5-6 Throttle lever ........................................5-6 Fittings and fasteners ...........................5-6 Lights ....................................................5-6 Switches ...................
5VJ-9-10-1 3/26/02 7:29 PM Page 6 8 PERIODIC MAINTENANCE AND ADJUSTMENT .........................................8-1 Owner’s manual and tool kit .................8-1 Periodic maintenance/Lubrication ........8-3 Engine oil..............................................8-5 Transmission oil ...................................8-7 Spark plug inspection ...........................8-9 Engine and V-bet compartment air filter element cleaning .................8-11 Idle speed adjustment ........................
5VJ-9-10-1 3/26/02 7:29 PM Page 7 11 NOISE REGULATION............................11-1 12 MAINTENANCE RECORD ....................12-1 13 ATV LIMITED WARRANTY ...................13-1 14 YAMAHA EXTENDED SERVICE (Y.E.S.)...................................................
5VJ-9-10-1 3/26/02 7:29 PM Page 8 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS q r we 1-1 t
5VJ-9-10-1 3/26/02 7:29 PM Page 9 Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. 1 Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.
5VJ-9-10-1 3/26/02 7:29 PM Page 10 3 4 qWARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 5FE-2151H-01 5 DRIVE SELECT LEVER 8 Read owner’s manual carefully before operating. 8 ATV MUST be stopped before shifting select lever. 8 Shifting into reverse is impossible without applying rear brake lever.
5VJ-9-10-1 3/26/02 7:29 PM Page 2-1 EBU00925 q SAFETY INFORMATION 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.
5VJ-9-10-1 3/26/02 7:29 PM Page 2-2 8 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. 8 Never operate an ATV on any public street, road or highway, even a dirt or gravel one. 8 Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.
5VJ-9-10-1 3/26/02 7:29 PM Page 2-3 8 Never 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. 8 Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. 8 Never operate the ATV on hills too steep for the ATV or for your abilities.
5VJ-9-10-1 3/26/02 7:29 PM Page 2-4 8 Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or 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. 8 Always check for obstacles before operating in a new area.
5VJ-9-10-1 3/26/02 7:29 PM Page 2-5 8 Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY , call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.
5VJ-9-10-1 3/26/02 7:29 PM Page 2-6 qWARNING Otherwise, fuel may leak out of the carburetor or fuel tank. POTENTIAL HAZARD WHAT CAN HAPPEN Improper handling of gasoline. Gasoline is poisonous and can cause injuries. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. 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, see your doctor immediately. If gasoline spills on your skin, wash with soap and water.
5VJ-9-10-1 3/26/02 7:29 PM Page 2-7 qWARNING POTENTIAL HAZARD Starting or running the engine in a closed area. 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.
5VJ-9-10-1 3/26/02 7:29 PM Page 3-2 EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION q w t e r i yu o !0 !1 !2 !3 !4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. !6 !5 Seat Drive select lever Headlight Front cover Front wheel Starter (choke) Fuel cock Rear wheel Tail/brake light Spark arrester 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
5VJ-9-10-1 3/26/02 7:29 PM Page 3-3 EBU00600 EBU00035 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: Key identification number The key identification number is stamped on the key as shown in the following illustration. This number can be used for ordering a new key.
5VJ-9-10-1 3/26/02 7:29 PM Page 3-4 EBU00036 EBU00787 Vehicle identification number The vehicle identification number is stamped into the frame. Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. q q 1. Vehicle identification number NOTE: The vehicle identification number is used to identify your machine. 1.
5VJ-9-10-1 3/26/02 7:29 PM Page 4-1 EBU00039 CONTROL FUNCTIONS OFF ON w Indicates a potential hazard that could result in serious injury or death. 4 EBU00041 Main switch Functions of the respective switch positions are as follows: ON: Engine can be started only at this position and the headlight and taillight come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position.
5VJ-9-10-1 3/26/02 7:29 PM Page 4-2 EBU00043 EBU00053 Indicator lights Handlebar switches w q e w q e 1. Main switch 2. Reverse indicator light “REVERSE” 3. Neutral lindicator light “NEUTRAL“ 1. Engine stop switch “ENG. STOP“ 2. Lights switch “LIGHTS” 3. Start switch “START“ EBU00044 EBU00054 Reverse indicator light “REVERSE” This indicator light comes on when the transmission is in reverse. Engine stop switch “ENG. STOP” Make sure that the engine stop switch is in the "RUN" position.
5VJ-9-10-1 3/26/02 7:29 PM Page 4-3 EBU00056 EBU01128 Start switch “START” The starter motor cranks the engine when this switch is pushed. Light switch "LIGHTS" Turn the switch to the "LO" position to switch on the low beam and the tail/brake light. Turn the switch to the "HI" position to switch on the high beam and the tail/brake light. Turn the switch to the "OFF" position to switch off the headlight and the tail/brake light.
5VJ-9-10-1 3/26/02 7:29 PM Page 4-4 EBU00062 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. Before starting the engine, check the throttle to be sure it is operating smoothly.
5VJ-9-10-1 3/26/02 7:29 PM Page 4-5 EBU00066 qWARNING Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV. POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result.
5VJ-9-10-1 3/26/02 7:29 PM Page 4-6 EBU00070 EBU00072 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. Rear brake lever The rear brake lever is located on the left handlebar. Pull it toward the handlebar to apply the rear brake. q q 1. Front brake lever 1.
5VJ-9-10-1 3/26/02 7:29 PM Page 4-7 EBU00074 qWARNING Parking brake Use the parking brake when you have to start the engine or park the machine, 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. 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.
5VJ-9-10-1 3/26/02 7:29 PM Page 4-8 EBU00085 EBU00092 Drive select lever The drive select lever is used for driving the machine either forward or in reverse. Refer to page 6-4 for drive select lever operation. Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. q e w q a a. Drive select lever 2. Forward 1. Neutral 3. Reverse 1.
5VJ-9-10-1 3/26/02 7:29 PM Page 4-9 EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES: This indicates reserve. If you run out of fuel while riding, turn the lever to this position.
5VJ-9-10-1 3/26/02 7:29 PM Page 4-10 EBU00094 EBU00567 Starter (choke) Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to “Starting a cold engine” for proper operation. (See page 6-1.) Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. q A b 1. Seat lock lever a e w q 1. Fully open 3.
5VJ-9-10-1 3/26/02 7:29 PM Page 4-11 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. NOTE: Make sure that the seat is securely fitted. EBU00112 w Indicates a potential hazard that could result in serious injury or death.
5VJ-9-10-1 3/26/02 7:29 PM Page 5-2 PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE Brakes • Check operation, condition and free play. • Adjust if necessary. Fuel • Check fuel level. • Fill with fuel if necessary. Engine oil and transmission oil • Check oil level. • Fill with oil if necessary. Drive chain • Check chain slack and condition. • Adjust if necessary. Throttle • Check for proper throttle cable operation.
5VJ-9-10-1 3/26/02 7:29 PM Page 5-3 EBU00472 qWARNING Front and rear brakes 1. Brake levers Check for correct free play in the brake levers. If the free play is incorrect, adjust it. (See pages 8-19 – 8-23.) POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Check operation of the levers. They should move smoothly and there should be a firm feeling when the brake is applied. If not, have the machine inspected by a Yamaha dealer.
5VJ-9-10-1 3/26/02 7:29 PM Page 5-4 EBU01085 qWARNING Fuel Make sure there is sufficient gasoline in the tank. POTENTIAL HAZARD Riding with improperly operating brakes. 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.
5VJ-9-10-1 3/26/02 7:29 PM Page 5-5 cC qWARNING 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. 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. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun.
5VJ-9-10-1 3/26/02 7:29 PM Page 5-6 EBU01116 cC Engine and transmission oil Make sure the engine and transmission oil is at the specified level. Add oil as necessary. (See page 8-5.) Be sure to use motor oils that do not contain anti-friction modifiers. Passenger car motor oils (often labeled “ ENERGY CONSERVING II ”) contain anti-friction additives which will cause clutch and/or starter clutch slippage, resulting in reduced component life and poor engine performance.
5VJ-9-10-1 3/26/02 7:29 PM Page 5-7 EBU00498 EBU00803 Chain Check the general condition of the chain and check the chain slack before every ride. Lubricate and adjust the chain as necessary. (See pages 8-22 – 8-25 for details.) Lights Check the headlight and tail/brake light to make sure they are in working condition. Repair as necessary for proper operation. EBU01082 Switches Check the operation of all switches. Repair as necessary for proper operation.
5VJ-9-10-1 3/26/02 7:29 PM Page 5-8 EBU00157 Tires 2. The tires should be set to the recommended pressure: 8 Recommended tire pressure Front 20 kPa (0.20 kgf/cm2, 2.9 psi) Rear 25 kPa (0.25 kgf/cm2, 3.6 psi) 8 Check and adjust tire pressures when the tires are cold. 8 Tire pressures must be equal on both sides. 3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums: Front 17 kPa (0.17 kgf/cm2, 2.
5VJ-9-10-1 3/26/02 7:29 PM Page 5-9 Set pressure with tires cold. Set tire pressures to the following specifications: 4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst. Recommended pressure Minimum Maximum Front 20 kPa (0.20 kgf/cm2, 2.9 psi) 17 kPa (0.17 kgf/cm2, 2.
5VJ-9-10-1 3/26/02 7:29 PM Page 5-10 EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a a. 3 mm (0.
5VJ-9-10-1 3/26/02 7:29 PM Page 6-1 EBU00161 EBU00509 Starting a cold engine OPERATION qWARNING w POTENTIAL HAZARD Indicates a potential hazard that could result in serious injury or death. Freezing control cables in cold weather. WHAT CAN HAPPEN qWARNING You could be unable to control the ATV, which could lead to an accident or collision. POTENTIAL HAZARD Operating ATV without being familiar with all controls.
5VJ-9-10-1 3/26/02 7:29 PM Page 6-2 NOTE: AMBIENT TEMP./STARTER (CHOKE) POSITION 8 The engine can be started only when the drive select lever is in neutral. 8 When the drive select lever is in neutral, the neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it. 5. Use the starter (choke) in reference to the figure: Position 1: Cold engine startambient temperature below 5°C (40°F).
5VJ-9-10-1 3/26/02 7:29 PM Page 6-3 NOTE: cC If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. See the “Engine break-in” section prior to operating engine for the first time. EBU00180 Starting a warm engine To start a warm engine, refer to the “Starting a cold engine” section.
5VJ-9-10-1 3/26/02 7:29 PM Page 6-4 EBU01152 Drive select lever operation and reverse driving q e cC w Before shifting, stop the machine and return the throttle lever to its closed position, otherwise, the transmission may be damaged. a Shifting: forward 1. Bring the machine to a complete stop and return the throttle lever to the closed position. 2. Shift the gear from neutral to forward and vice versa by moving the drive select lever along the shift guide. a. Drive select lever 2. Forward ”F” 1.
5VJ-9-10-1 3/26/02 7:29 PM Page 6-5 qWARNING NOTE: When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect the ATV. POTENTIAL HAZARD Improper operation in reverse. WHAT CAN HAPPEN 4. Check behind for people or obstacles, then release the parking brake. 5. Open the throttle lever gradually and continue to watch to the rear while backing. You could hit an obstacle or person behind you, resulting in serious injury.
5VJ-9-10-1 3/26/02 7:29 PM Page 6-6 EBU00209 Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r/min so the engine can rid itself of the temporary build up of heat. If any abnormality is noticed during this period, consult a Yamaha dealer. 1. 0 – 10 hours: Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of operation.
5VJ-9-10-1 3/26/02 7:29 PM Page 6-7 EBU00211 2. 10 – 20 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely through the gears but do not use full throttle at any time. 3. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally. Parking When parking, stop the engine and shift into neutral. Turn the fuel cock to “OFF” and apply the parking brake. q 1.
5VJ-9-10-1 3/26/02 7:29 PM Page 6-8 EBU00215 Parking on a slope 1. Bring the machine to a stop by applying the brakes. 2. Stop the engine. 3. With the rear brake applied, apply the parking brake. qWARNING 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.
5VJ-9-10-1 3/26/02 7:29 PM Page 6-9 EBU00221 8 Do not mount an accessory where it could interfere with your ability to control the ATV. Examples include (but are not limited to) a heavy or bulky object attached to the handlebars which could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view. 8 Use extra caution when riding an ATV with accessories. The ATV may handle differently than it does without accessories.
5VJ-9-10-1 3/26/02 7:29 PM Page 6-10 EBU00585 8 Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident. 8 Make sure the load does not interfere with controls or your ability to see where you are going. 8 Ride more slowly than you would without a load. The more weight you carry, the slower you should go. 8 Allow more braking distance. A heavier vehicle takes longer to stop. 8 Avoid making sharp turns unless at very slow speeds.
5VJ-9-10-1 3/26/02 7:29 PM Page 6-11 qWARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle 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.
5VJ-9-10-1 3/26/02 7:29 PM Page 6-12 EBU00893 w Indicates a potential hazard that could result in serious injury or death.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-1 Riding Your ATV 7-1 7
5VJ-9-10-2 3/26/02 7:30 PM Page 7-2 7-2
5VJ-9-10-2 3/26/02 7:30 PM Page 7-3 w Indicates a potential hazard that could result in serious injury or death. 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. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your ATV requires special skills acquired through practice over a period of time.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-4 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 1-800-887-2887. Get training if you are inexperienced.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-5 Not recommended for children under 16 years of age. qWARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. 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 90cc.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-6 This ATV is designed to carry operator only passengers prohibited. qWARNING 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. It is not for carrying passengers.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-7 Apparel Operating without protective clothing increases your chances of severe injury in the event of an accident. qWARNING POTENTIAL HAZARD HOW TO AVOID THE HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. Always wear an approved motorcycle helmet that fits properly.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-8 Do not operate after consuming alcohol or drugs. Operator's performance capability is reduced by the influence of alcohol or drugs. qWARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-9 Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the ATV. qWARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. qWARNING 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.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-10 Speed limiter For riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits the power and top speed of the ATV. Turning the screw in decreases top speed, and turning it out increases top speed. w Indicates a potential hazard that could result in serious injury or death.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-11 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. qWARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-12 During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. qWARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. 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.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-13 Avoid wheelies and jumping. You may lose control of the ATV or overturn. qWARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don't try to show off.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-14 Modifications qWARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle 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.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-15 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. HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV in dry grass or other dry ground cover. Keep the engine area free of dry grass, brush, or other combustible material. Do not touch the hot exhaust system.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-16 BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. qWARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-17 Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. qWARNING 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.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-18 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. qWARNING 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.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-19 qWARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. 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.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-20 When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. WHAT CAN HAPPEN You could be in a collision. You could be injured. HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles. Do not ride in areas posted "no trespassing". Do not ride on private property without getting permission.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-21 With the engine idling, return the starter knob to the closed position and shift the drive select lever into the forward position. Then release the parking brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is applied too abruptly, the front wheels may lift off the ground resulting in a loss of directional control.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-22 TURNING YOUR ATV To achieve maximum traction while riding offroad, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-23 Lean towards inside of turn. Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. 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.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-24 CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control. qWARNING POTENTIAL HAZARD Operating on excessively steep hills.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-25 qWARNING An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. OK 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.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-26 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.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-27 7-27
5VJ-9-10-2 3/26/02 7:30 PM Page 7-28 qWARNING If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then descend the hill. POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-29 When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner's Manual.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-30 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. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. Whenever possible, ride your ATV straight downhill.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-31 OK 7-31
5VJ-9-10-2 3/26/02 7:30 PM Page 7-32 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. qWARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-33 Shift your weight to the uphill side of the ATV.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-34 CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 20 cm (7.9 inches) 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. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-35 cC Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. 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. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. q 1.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-36 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. qWARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-37 7-37
5VJ-9-10-2 3/26/02 7:30 PM Page 7-38 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.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-39 qWARNING With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost. POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV.
5VJ-9-10-2 3/26/02 7:30 PM Page 7-40 WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. 8 If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See pages 7-38 – 7-39.) WHAT TO DO ...
5VJ-9-10-2 3/26/02 7:30 PM Page 7-41 8 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 7-32 – 7-33.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-2 EBU00515 Have a Yamaha dealer perform service if you are not familiar with machine service. PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-3 qWARNING The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the Owner’s tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts. POTENTIAL HAZARD Operating this ATV with improper modifications.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-4 EBU00261 PERIODIC MAINTENANCE/LUBRICATION INITIAL ITEM ROUTINE EVERY 1 3 6 6 month months months months Valves* • Check valve clearance. • Adjust if necessary. 1 Spark plug • Check condition. • Adjust gap and clean. • Replace if necessary. 1 Air filter element (for engine and V-belt compartment) • Clean. • Replace if necessary. Carburetor* • Check idle speed/starter operation. • Adjust if necessary.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-5 INITIAL ITEM ROUTINE EVERY 1 3 6 6 month months months months 1 year Brakes* • Check operation. • Adjust if necessary. 1 V-belt* • Check operation • Replace if damage or excessive wear. 1 Wheels* • Check balance/damage/runout. • Replace if necessary. 1 1 1 1 Wheel bearings* • Check bearing assembly for looseness/damage. • Replace if damaged. 1 1 1 1 Steering system* • • • • 1 1 1 1 Knuckle shafts/ steering shaft* • Lubricate every 6 months.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-6 EBU00896 Engine oil Engine oil level measurement 1. Place the machine on a level surface. 2. Warm up the engine for several minutes and stop it. 3. Remove the dipstick and wipe it off with a clean rag. Insert the dipstick in the filler hole without screwing it in. q w e NOTE: 1. Dipstick 3. Minimum level mark Wait a few minutes until the oil level settles before checking. 2. Maximum level mark cC 4. Remove the dipstick and inspect the oil level. 5.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-7 4. Remove the dipstick and drain bolt to drain the oil. 5. Clean the oil strainer with solvent. 6. Inspect the O-ring and replace it if damaged. 7. Install the O-ring, oil strainer, compression spring and drain bolt. Tighten the drain bolt to specification. q cC Before installing the drain bolt, be sure to install the O-ring, compression spring and oil strainer. r e 1. Drain bolt 3. Compression spring w q 2. O-ring 4.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-8 EBU00891 8. Fill the engine with oil and install the dipstick. Transmission oil Transmission oil measurement 1. Place the machine on a level surface. 2. Remove the screw and check the oil level. It should be up to the brim of the hole. If the level is low, remove the oil filler bolt and add oil to raise it to the proper level. Recommended oil: See page 10-2. Oil quantity: Periodic oil change 1.25 L (1.10 Imp qt, 1.32 US qt) Total amount: 1.45 L (1.28 Imp qt, 1.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-9 3. Remove the oil filler bolt and drain bolt to drain the oil. q q 1. Oil filler bolt 3 Install the screw and oil filler bolt and tighten to specification. 1. Drain bolt Tightening torque: Screw: 16 Nm (1.6 m0kgf, 11 ft0lbf) Oil filler bolt: 23 Nm (2.3 m0kgf, 17 ft0lbf) 4. Install the drain bolt and tighten to specification. Tightening torque Drain bolt: 23 Nm (2.3 m0kgf, 17 ft0lbf) Transmission oil replacement 1. Place the machine on a level surface. 2.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-10 EBU00870 5. Fill the engine with oil and install the oil filler bolt. Spark plug inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder. Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-11 Before installing the spark plug, measure the electrode gap with a feeler gauge and adjust to specification. q Spark plug gap: 0.6 – 0.7 mm (0.02 – 0.03 in) 1. Spark plug wrench Tightening torque: Spark plug: 12.5 Nm (1.25 m0kgf, 9.1 ft0lbf) a a. Spark plug gap When installing the spark plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads and tighten to the specified torque.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-12 EBU01142 1. Remove the seat. 2. Remove the breather hose, and then loosen the clamp screw. 3. Remove the air filter case cover. Engine and V-belt case air filter element cleaning Both air filter elements should be cleaned at the specified intervals in the periodic maintenance chart. Engine air filter element q NOTE: There is a check hose at the bottom of the air filter case.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-13 qWARNING 4. Remove the air filter element, and separate it from the frame. POTENTIAL HAZARD w Using low flash point solvents or gasoline to clean the air filter element. q WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD 1. Air filter element Use parts cleaning solvent to clean the air filter element. 2. Element frame 5. Wash the element gently but thoroughly in solvent. 6.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-14 cC 7. Inspect the air filter element. If damaged, replace it. 8. Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter element. If foam air filter oil is not available, engine oil may be used. Install the washer with the bent edge facing upward as shown. q NOTE: The element should be wet but not dripping. 9. Install the air filter element on the frame. 10.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-15 V-belt case air filter element 1. Remove the front cover by removing the screws and bolts. NOTE: The air filter element should be cleaned every 20 – 40 hours. It should be cleaned and lubricated more often if the machine is operated in extremely dusty areas. Each time air filter element maintenance is performed, check the air inlet to the air filter case for obstructions. Check the air cleaner rubber joint to the carburetor and manifold fittings for an airtight seal.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-16 EBU01143 2. Remove the air filter element cover. 3. Pull out the air filter element. Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. w e q 1. Element cover 2. Screw 3. Element 4.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-17 EBU00303 2. Connect the tachometer to the spark plug lead, and then set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw in direction a to increase the engine speed, and in direction b to decrease the engine speed. Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-18 EBU00307 Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 3 – 5 mm (0.12 – 0.20 in). 3. Tighten the locknut. q w a 1. Locknut a. Free play 2.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-19 EBU00308 Rear Front and rear brake shoe inspection A wear indicator is provided on each brake. The indicators allows checking of brake shoe wear without disassembling the brake. Apply the brake and check the position of the indicator. If the indicator reaches the wear limit line, ask a Yamaha dealer to replace the shoes as a set. q w Front 1. Wear limit line w q 1. Wear limit line 2. Wear indicator 8-18 2.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-20 EBU01149 1. Remove the front cover by removing the screws and bolts. (See page 8-14 for removal and installation procedures.) 2. Remove the air filter element cover. (See page 8-15 for removal and installation procedures.) Front brake lever free play adjustment NOTE: Before adjusting the brake lever free play, inspect the front brake shoes. The front brake lever free play should be adjusted to 5 – 8 mm (0.2 – 0.3 in) at the brake lever pivot.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-21 e 3. Loosen the locknut and fully turn in the adjusting bolt at the front brake lever. e q q w w w 1. Front fender 3. Screw (× 6) 2. Bolt (× 2) 1. Locknut 8-20 2.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-22 4. Make sure the brake cable joint in the equalizer is straight when the brake is applied. If not, loosen the locknut and turn the adjusting nuts at the front brake cables until the cable joint becomes straight. w q w q w q a´ 1. Locknut (× 2) 2. Adjusting nut (× 2) a 5. Tighten the locknut on each brake cable. a = a´ 1. Equalizer 2.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-23 qWARNING 6. Turn the adjusting bolt at the brake lever until the specified free play is obtained. POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. a q WHAT CAN HAPPEN w You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD 1. Locknut a. Free play After servicing: 8 Make sure the brakes operate smoothly and that the free play is correct. 8 Make sure the brakes do not drag.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-24 EBU00965 Rear brake adjustment Brake lever free play should be 5 – 8 mm (0.2 – 0.3 in) at the brake lever pivot. If the free play is incorrect, adjust as follows: Turn the adjusting nut on the brake hub in direction a to decrease play, and in direction b to increase play. a ba q 1. Adjusting nut a.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-25 EBU01144 qWARNING Drive chain slack check NOTE: POTENTIAL HAZARD Move the ATV back and forth and find the tightest position of the drive chain. Check and/or adjust the chain slack while it is in this tightest position. Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. To check the drive chain slack, all tires must be touching the ground and there should be no weight on it.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-26 EBU01146 Drive chain slack adjustment 1. Loosen the hub stopper bolt locknut and then the hub stopper bolt. 3. Loosen the locknut. To tighten the drive chain, turn the adjusting bolt in direction a. To loosen the drive chain, turn the adjusting bolt in direction b, and then push the wheels forward. e q w 1. Hub stopper bolt 2. Locknut e a b 3. Axle holding bolt (× 4) q w 2. Loosen the upper and lower axle holding bolts. 1. Locknut 2.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-27 cC 4. After adjusting, be sure to tighten the locknut and the axle holding bolts. If measurement A of the drive chain adjusting bolt is less than 27 mm (1.06 in), ask a Yamaha dealer to replace the drive chain. Tightening torque: Locknut: 15.5 Nm (1.55 m0kgf, 11.2 ft0lbf) Axle holding bolts (upper): 85 Nm (8.5 m0kgf, 61 ft0lbf) Axle holding bolts (lower): 60 Nm (6.0 m0kgf, 43 ft0lbf) A 5. Finger tighten the hub stopper bolt and tighten the hub stopper bolt locknut.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-28 EBU00805 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant. Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-29 EBU00355 EBU00356 Draining the V-belt compartment If water leaks into the V-belt compartment such as when the machine is driven in water, remove the drain screw on the bottom of compartment and drain the water. Be sure to drive slowly until the V-belt becomes dry. If slipping is noticed, ask a Yamaha dealer to inspect. Cable inspection and lubrication qWARNING POTENTIAL HAZARD Damaged control cables.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-30 EBU00725 EBU00728 Brake lever lubrication Lubricate the pivoting parts of the brake levers. Knuckle shaft, lower arms and steering shaft lubrication Lubricate the pivot points using a grease gun.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-31 EBU01112 Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified torque. q 1. Wheel nut Tightening torque: Front wheel nut: 55 Nm (5.5 m0kgf, 40 ft0lbf) Rear wheel nut: 55 Nm (5.5 m0kgf, 40 ft0lbf) EBU01150 Wheel installation 1. Install the wheel and the nuts.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-32 EBU00378 Battery Check the level of the battery fluid and see if the terminals are tight. Add distilled water if the fluid level is low. w q cC Do not leave or store the battery on its side. When inspecting the battery, be sure the breather hose is routed correctly. If it touches the frame or exists in such a way as to cause battery electrolyte or gas to exit onto the frame, structural and cosmetic damage to the machine can occur. e 1. Battery 8-31 2.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-33 qWARNING EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batteries away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed space. POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-34 EBU00382 cC Replenishing the battery fluid A poorly maintained battery will corrode and discharge quickly. The battery fluid should be checked at least once a month. 1. The level should be between the upper and lower level marks. Use only distilled water if refilling is necessary. Normal tap water contains minerals which are harmful to a battery. Therefore, refill only with distilled water. 4.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-35 EBU00388 Fuse replacement 1. The fuse case is located on the right side of the machine. 2. If the fuse is blown, turn off the main switch and install a new fuse of the specified amperage. Then turn on the switches, if the fuse immediately blows again, consult a Yamaha dealer. Specified fuse: 5A qWARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-36 EBU01151 Replacing the headlight bulb If the headlight bulb burns out, replace the bulb as follows. 1. Remove the screws holding the headlight unit assembly to the headlight body. 2. Remove the headlight bulb holder cover, turn the bulb holder counterclockwise and remove the defective bulb. 1 1 1. Headlight bulb holder 1.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-37 5. Install the headlight unit assembly by installing the screws. 6. Adjust the headlight beam if necessary. qWARNING POTENTIAL HAZARD The 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. 3.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-38 EBU00861 Tail/brake light bulb replacement 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 3. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise. q w q 1. Bulb 2. Bulb holder 1. Bulb holder 4. Install the bulb holder (together with the bulb). 2. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-39 EBU00410 EBU01155 Headlight beam adjustment Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the screws. cC It is advisable to have a Yamaha dealer make this adjustment. Vertical adjustment: To raise the beam, loosen the adjusting screw and pull the headlight assembly toward you. To lower the beam, push it away from you. After adjusting, be sure to tighten the screw. q 1. Screw (× 2) q 1.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-40 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe. qWARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system WHAT CAN HAPPEN q Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-41 EBU00412 qWARNING Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer.
5VJ-9-10-3 3/26/02 7:31 PM Page 8-42 EBU00440 Remove the fuel hose from the fuel cock. Troubleshooting chart Water or dirt mixed in fuel. Turn the fuel cock to “ON”. 1. Fuel Check if there is fuel in the fuel tank. There is fuel. Turn the fuel cock to “OFF”. Some fuel. Turn the fuel cock to “RES”. No fuel. Supply fuel. Clean the fuel filter and the fuel tank. Check fuel flow. No fuel. Fuel cock clogged. Clean fuel cock. Restart engine. 2.
5VJ-9-10-3 3/26/02 7:31 PM Page 9-2 EBU00417 cC CLEANING AND STORAGE Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers. A.
5VJ-9-10-3 3/26/02 7:31 PM Page 9-3 qWARNING 7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes. POTENTIAL HAZARD Operation with wet brakes after washing.
5VJ-9-10-3 3/26/02 7:31 PM Page 9-4 EBU00525 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equivalent product. 3. 4. 5. 6. Specified amount: 1 oz of stabilizer to each gallon of fuel (or 7.
5VJ-9-10-3 3/26/02 7:31 PM Page 10-1 EBU00428 SPECIFICATIONS Model YFA1 Dimension: Overall length Overall width Overall height Seat height Wheel base Minimum ground clearance Minimum turning radius 1,640 mm (64.6 in) 965 mm (38.0 in) 980 mm (38.6 in) 690 mm (27.2 in) 1,080 mm (42.5 in) 145 mm ( 5.7 in) 2,900 mm (114.
5VJ-9-10-3 3/26/02 7:31 PM Page 10-2 Model YFA1 Engine oil/transmission oil: Type 0° 10° 30° 50° 70° 90° 110° 130°F YAMALUBE 4 (20W40) or SAE20W40 YAMALUBE 4 (10W30) or SAE10W30 SAE 5W30 –20° Recommended engine oil/transmission oil classification: –10° 0° 10° 20° 30° 40° 50°C API Service SE, SF, SG type or higher cC Be sure to use motor oils that do not contain anti-friction modifiers.
5VJ-9-10-3 3/26/02 7:31 PM Page 10-3 Model YFA1 Air filter: for engine for V-belt compartment Wet type element Dry type element Fuel: Type Tank capacity Reserve amount UNLEADED GASOLINE ONLY 7.0 L (1.54 Imp gal, 1.8 US gal) 1.3 L (0.29 Imp gal, 0.34 US gal) Carburetor: Type/manufacturer VM18SH/MIKUNI Spark plug: Type/manufacturer Gap CR7HS/NGK 0.6 – 0.7 mm (0.02 – 0.
5VJ-9-10-3 3/26/02 7:31 PM Page 10-4 Model Chassis: Frame type Caster angle Trail Tire: Type Size: Front Rear Manufacturer/type: Front Rear YFA1 Steel tube 6° 15 mm (0.
5VJ-9-10-3 3/26/02 7:31 PM Page 10-5 Model YFA1 Wheel travel: Front Rear 70 mm (2.8 in) 80 mm (3.2 in) Electrical: Ignition system Charging system Battery type/voltage, capacity C.D.I. A.C. Magneto 12N12C-4A-2/12V, 12Ah Headlight type: Bulb Bulb voltage, wattage × quantity: Headlight Tail/brake light Indicator light: Neutral Reverse Fuse: 12V, 25 W/25 W × 1 12V, 5 W/21W × 1 12V, 3.4 W × 1 12V, 3.
5VJ-9-10-3 3/26/02 7:31 PM Page 11-1 EBU00430 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 design 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
5VJ-9-10-3 3/26/02 7:31 PM Page 12-1 EBU00431 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.
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5VJ-9-10-3 3/26/02 7:32 PM Page 13-2 EBU00432 13-1
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5VJ-9-10-3 3/26/02 7:32 PM Page 14-2 EBU00435 14-1
5VJ-9-10-3 3/26/02 7:32 PM Page 14-3 14 14-2
5VJ-9-10-3 3/26/02 7:32 PM Page 14-4 EBU00436 w Indicates a potential hazard that could result in serious injury or death.
5VJ-9-10-3 3/26/02 7:32 PM Page 14-6 EBU00437 PROTECT YOUR INVESTMENT
EBU00438 READ THIS MANUAL CAREFULLY! It contains important safety information. qWARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER operate: 9 without proper training or instruction. 9 at speeds too fast for your skills or the conditions. 9 on public roads - a collision can occur with another vehicle. 9 with a passenger - passengers affect balance and steering and increase risk of losing control.