5VM-9-12-Hyoshi 3/3/04 5:31 PM Page 1 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 CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: 9 without proper training or instruction.
5VM-9-12-Hyoshi 3/3/04 5:31 PM Page 2
5VM-9-12_1 3/3/04 5:24 PM Page 1 EBU13320 INTRODUCTION Congratulations on your purchase of the Yamaha YFS200. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this ATV.
5VM-9-12_1 3/3/04 5:24 PM Page 2 EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
VM-9-12_1 3/3/04 5:24 PM Page 3 EBU15000 IMPORTANT NOTICE 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.
5VM-9-12_1 3/3/04 5:24 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 .........
5VM-9-12_1 3/3/04 5:24 PM Page 5 Seat ....................................................4-12 Front shock absorber adjustment ........................................4-14 Rear shock absorber adjustment ........................................4-15 5 PRE-OPERATION CHECKS ...................5-1 Front and rear brakes ...........................5-2 Fuel ......................................................5-4 Engine oil.............................................5-6 Transmission oil ......................
5VM-9-12_1 3/3/04 5:24 PM Page 6 Crossing through shallow water .........7-34 Riding over rough terrain ....................7-36 Sliding and skidding ...........................7-38 What to do if... ...................................7-40 What to do... ......................................7-40 8 PERIODIC MAINTENANCE AND ADJUSTMENT .........................................8-1 Owner’s manual and tool kit .................8-1 Periodic maintenance/Lubrication ........8-3 Transmission oil ..................
5VM-9-12_1 3/3/04 5:24 PM Page 7 9 CLEANING AND STORAGE....................9-1 A. Cleaning ...........................................9-1 B. Storage ............................................9-3 10 11 SPECIFICATIONS .................................10-1 NOISE REGULATION............................11-1 12 MAINTENANCE RECORD ....................12-1 13 ATV LIMITED WARRANTY ...................13-1 14 YAMAHA EXTENDED SERVICE (Y.E.S.)...................................................
5VM-9-12_1 3/3/04 5:24 PM Page 8 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 5 4 3 2 1-1
5VM-9-12_1 3/3/04 5:24 PM Page 9 2 Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. qWARNING NEVER ride as a passenger. 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. 1 1 Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.
5VM-9-12_1 3/3/04 5:24 PM Page 10 4 5 qWARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion. 8 Read owner’s manual for instructions. 8 Do not incinerate, puncture or open.
5VM-9-12_1 3/3/04 5:24 PM Page 2-1 EBU13381 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.
5VM-9-12_1 3/3/04 5:24 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, a long-sleeved shirt or a jacket, and long pants.
5VM-9-12_1 3/3/04 5:24 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.
5VM-9-12_1 3/3/04 5:24 PM Page 2-4 8 Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use the proper gear and 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.
5VM-9-12_1 3/3/04 5:24 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 or pulling a trailer. 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.
5VM-9-12_1 3/3/04 5:24 PM Page 2-6 qWARNING When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank. POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. HOW TO AVOID THE HAZARD Always turn off the engine when refueling.
5VM-9-12_1 3/3/04 5:24 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.
5VM-9-12_1 3/3/04 5:24 PM Page 2-8 EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 2 1 3 8 9 0 q 4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 7 65 y u o i Spark arrester Seat Fuel tank cap Headlight Brake pedal Rear brake light switch Kick starter Front shock absorber Front wheel Fuel cock Starter (choke) t 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
5VM-9-12_1 3/3/04 5:24 PM Page 2-9 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.
5VM-9-12_1 3/3/04 5:24 PM Page 2-10 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. 1 q 1. Vehicle identification number NOTE: 1. Model label The vehicle identification number is used to identify your machine.
5VM-9-12_1 3/3/04 5:24 PM Page 4-1 EBU00039 EBU00043 Indicator lights CONTROL FUNCTIONS EBU01274 w Oil level warning light “7” This light comes on when the oil level is low. The light circuit can be checked by the following procedure. Indicates a potential hazard that could result in serious injury or death. EBU00041 cC Main switch Functions of the respective switch positions are as follows: Always make sure there is enough engine oil before starting the engine.
5VM-9-12_1 3/3/04 5:24 PM Page 4-2 EBU00757 Oil level warning light checking method Turn the main switch to “ON” and the engine stop switch to “RUN”. Start the engine. Oil level warning light does not come on (see NOTE). Oil level warning light comes on. Wait a few seconds. The oil level warning light goes off. Ask a Yamaha dealer to inspect the electrical circuit. NOTE: Engine oil level and electrical circuit are OK.
5VM-9-12_1 3/3/04 5:24 PM Page 4-3 EBU00053 EBU01286 Handlebar switches Light switch “LIGHTS” Set the switch to the “LO” position to switch on the low beam and the taillight. Set the switch to the “HI” position to switch on the high beam and the taillight. Set the switch to the “OFF” position to switch off all the lights. EBU01158 Engine stop switch “ENG. STOP” Make sure that the engine stop switch is in the “RUN” position before starting the engine.
5VM-9-12_1 3/3/04 5:24 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.
5VM-9-12_1 3/3/04 5:24 PM Page 4-5 EBU00064 Throttle OverRide System If during operation, the carburetor or the throttle cable should malfunction and will not close fully, take your thumb off the throttle lever. The Throttle OverRide System immediately cuts off the ignition. qWARNING POTENTIAL HAZARD Continuing to ride the ATV after the Throttle OverRide System (T.O.R.S.) has stopped the engine. WHAT CAN HAPPEN Riding with a malfunction increases the chance for an accident and injury.
5VM-9-12_1 3/3/04 5:24 PM Page 4-6 EBU01159 qWARNING Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. a POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result.
5VM-9-12_1 3/3/04 5:24 PM Page 4-7 EBU00068 EBU00988 Clutch lever The clutch lever is located on the left handlebar. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. Brake lever The brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. q q 1. Brake lever 1.
5VM-9-12_1 3/3/04 5:24 PM Page 4-8 EBU00989 EBU00080 Brake pedal The brake pedal is located on the right side of the machine. Push down on the pedal to apply the rear brake. Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Squeeze the clutch lever while pushing the button, then push in the lock plate to apply the parking brake. Squeeze the clutch lever to release the parking brake.
5VM-9-12_1 3/3/04 5:24 PM Page 4-9 qWARNING q 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 disc 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. w 1. Button 2.
5VM-9-12_1 3/3/04 5:24 PM Page 4-10 EBU00082 EBU00089 Shift pedal This machine is equipped with a constant-mesh 6-speed transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting. Kick starter Rotate the kick starter away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine.
5VM-9-12_1 3/3/04 5:24 PM Page 4-11 EBU00092 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 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.
5VM-9-12_1 3/3/04 5:24 PM Page 4-12 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. 1 b 1. Seat lock lever a q 1.
5VM-9-12_1 3/3/04 5:24 PM Page 4-13 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. q w 1. Projection (×2) 2.
5VM-9-12_1 3/3/04 5:24 PM Page 4-14 EBU01104 Front shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direction b. NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment.
5VM-9-12_1 3/3/04 5:24 PM Page 4-15 cC EBU12871 Rear shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows. 1. Loosen the locknut. 2. To increase the spring preload, turn the adjusting nut in direction a. To decrease the spring preload, turn the adjusting nut in direction b. b Never attempt to turn the adjusting nut beyond the maximum or minimum setting.
5VM-9-12_1 3/3/04 5:24 PM Page 4-16 qWARNING POTENTIAL HAZARD a This shock absorber contains highly pressurized nitrogen gas. WHAT CAN HAPPEN The shock absorber could explode, causing injury or property damage. Cylinder damage could also result in poor handling which could cause an accident. a. Spring length 4. Tighten the locknut to the specified torque. HOW TO AVOID THE HAZARD 8 Do not tamper with or attempt to open the cylinder assembly.
5VM-9-12_1 3/3/04 5:24 PM Page 4-17 EBU00112 w Indicates a potential hazard that could result in serious injury or death.
5VM-9-12_2 2/19/04 11:06 AM Page 2 PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE Brakes 9 Check operation, free play, fluid level and fluid leakage. 9 Fill with DOT4 brake fluid if necessary. Clutch 9 Check operation, condition and lever free play. Parking brake 9 Check operation, condition and free play. Fuel 9 Check fuel level. 9 Fill with fuel if necessary. Transmission oil 9 Check oil level. 9 Fill with oil if necessary.
5VM-9-12_2 2/19/04 11:06 AM Page 3 EBU11660 qWARNING Front and rear brakes Brake lever and brake pedal 8 Check that there is no free play in the brake lever. If there is free play, have a Yamaha dealer inspect the brake system. 8 Check for correct brake pedal height. (See page 8-27.) If the pedal height is incorrect, have a Yamaha dealer adjust it. 8 Check the operation of the lever and pedal. They should move smoothly and there should be a firm feeling when the brakes are applied.
5VM-9-12_2 2/19/04 11:06 AM Page 4 qWARNING Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs. Apply the brakes firmly for one minute. If there is any leakage, have a Yamaha dealer inspect the brake system. POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.
5VM-9-12_2 2/19/04 11:06 AM Page 5 EBU13420 Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems. Fuel Make sure there is sufficient gasoline in the tank. Recommended fuel: PREMIUM UNLEADED FUEL Fuel tank capacity: Total: 9 L (1.98 Imp gal, 2.
5VM-9-12_2 2/19/04 11:06 AM Page 6 qWARNING 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. 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.
5VM-9-12_2 2/19/04 11:06 AM Page 7 EBU00448 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. See page 10-2. NOTE: Be sure to push the cap into the filler neck until it is properly seated. Recommended oil: Yamalube 2-cycle oil or 2-stroke engine oil Oil quantity: Total amount: 1.3 L (1.14 Imp qt, 1.37 US qt) EBU12891 Transmission oil Make sure the transmission oil is at the specified level. Add oil as necessary. (See pages 8-6– 8-8.
5VM-9-12_2 2/19/04 11:06 AM Page 8 EBU01162 cC Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. 8 In order to prevent clutch slippage (since the transmission oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified.
5VM-9-12_2 2/19/04 11:06 AM Page 9 EBU00157 Tires 2. The tires should be set to the recommended pressure: 8 Recommended tire pressure Front 30 kPa (0.30 kgf/cm2, 4.4 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 27 kPa (0.27 kgf/cm2, 3.
5VM-9-12_2 2/19/04 11:06 AM Page 10 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 330 kPa (3.3 kgf/cm2, 47 psi) Rear 280 kPa (2.8 kgf/cm2, 40 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 30 kPa (0.30 kgf/cm2, 4.4 psi) 27 kPa (0.27 kgf/cm2, 3.
5VM-9-12_2 2/19/04 11:06 AM Page 11 EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a a.
5VM-9-12_2 2/19/04 11:06 AM Page 12 EBU00161 EBU00511 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.
5VM-9-12_2 2/19/04 11:06 AM Page 6-1 Position 1: Cold engine startambient temperature below 5°C (40°F). Position 2: Cold engine startambient temperature at 0°C (30°F)–30°C (90°F) and warming up position. Position 3: Cold engine startambient temperature above 25°C (80°F) and warm engine start position. 6. Completely close the throttle lever and start the engine by kicking the kick starter. 7.
5VM-9-12_2 2/19/04 11:06 AM Page 6-2 EBU00180 EBU00182 Starting a warm engine To start a warm engine, refer to the “Starting a cold engine” section. The starter (choke) should not be used. The throttle should be opened slightly. Warming up To get maximum engine life, always warm up the engine before starting off. Never accelerate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally with the starter (choke) turned off.
5VM-9-12_2 2/19/04 11:06 AM Page 6-3 EBU01981 cC Shifting This model has a 6-speed forward transmission. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, return the throttle lever to its original position, apply the clutch and repeatedly depress the shift pedal until it stops. When it stops, it will be in first gear. Raise the pedal slightly to neutral.
5VM-9-12_2 2/19/04 11:06 AM Page 6-4 EBU00203 7. Open the throttle part way and gradually release the clutch lever. 8. Follow the same procedure when shifting to the next higher gear. To start out and accelerate: 1. Release the throttle lever. cC Always close the throttle while shifting gears. Otherwise, damage to the engine and drive train may result. qWARNING POTENTIAL HAZARD Opening the throttle abruptly or releasing the clutch lever too quickly. 2. Pull the clutch lever to disengage the clutch.
5VM-9-12_2 2/19/04 11:06 AM Page 6-5 EBU00207 qWARNING To decelerate: When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident. POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high.
5VM-9-12_2 2/19/04 11:06 AM Page 6-6 EBU02092 If any abnormality is noticed during this period, consult a Yamaha dealer. Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running.
5VM-9-12_2 2/19/04 11:06 AM Page 6-7 EBU00212 Parking When parking, stop the engine and shift into low gear. Turn the fuel cock to “OFF” and apply the parking brake. q q 1. Locked position w 1. Button 2.
5VM-9-12_2 2/19/04 11:06 AM Page 6-8 EBU01174 Parking on a slope 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 1. Bring the machine to a stop by applying the brakes in low gear. 2. Stop the engine and release the clutch lever. 3. With the rear brake applied, apply the parking brake and slowly release the brake pedal. Avoid parking on hills or other inclines.
5VM-9-12_2 2/19/04 11:06 AM Page 6-9 EBU00221 8 Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV. 8 Do not mount an accessory where it could interfere with your ability to control the ATV.
5VM-9-12_2 2/19/04 11:06 AM Page 6-10 EBU00584 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.
5VM-9-12_2 2/19/04 11:06 AM 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.
5VM-9-12_2 2/19/04 11:06 AM Page 6-12 EBU13552 w Indicates a potential hazard that could result in serious injury or death.
5VM-9-12_3 2/19/04 11:07 AM Page 7-1 Riding Your ATV 7-1 7
5VM-9-12_3 2/19/04 11:07 AM Page 7-3 w Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is intended for recreational use by experienced operators only. Even though you are an experienced operator of all other all terrain vehicles or motorcycles, riding the ATV requires special skills acquired through practice. Take your time to fully learn techniques before attempting more difficult maneuvers. controls.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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 POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV.
5VM-9-12_3 2/19/04 11:07 AM 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 adjusting screw in decreases the top speed, and turning it out increases the top speed. (See page 4-6 for details.) w Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions.
5VM-9-12_3 2/19/04 11:07 AM Page 7-11 Loading and accessories As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM Page 7-21 With the engine idling, pull the clutch lever to disengage the clutch and shift into 1st gear, and then release the parking brake. Open the throttle gradually, and at the same time, release the clutch lever slowly. Once the ATV has attained adequate speed, release the throttle lever and at the same time, quickly pull in the clutch lever and shift into 2nd gear. Open the throttle part way and gradually release the clutch.
5VM-9-12_3 2/19/04 11:07 AM Page 7-22 evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident. qWARNING POTENTIAL HAZARD Opening the throttle abruptly or releasing the clutch lever too quickly. WHAT CAN HAPPEN The ATV could wheelie.
5VM-9-12_3 2/19/04 11:07 AM Page 7-23 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.
5VM-9-12_3 2/19/04 11:07 AM Lean towards inside of turn. Page 7-24 Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Support your weight on the outer footrest. 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.
5VM-9-12_3 2/19/04 11:07 AM Page 7-25 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.
5VM-9-12_3 2/19/04 11:07 AM Page 7-26 qWARNING Never go over the top of any hill at high speed. 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. 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.
5VM-9-12_3 2/19/04 11:07 AM Page 7-27 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.
5VM-9-12_3 2/19/04 11:07 AM Page 7-28 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. qWARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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. Choose a low gear which will allow the engine compression to do most of the braking for you. 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.
5VM-9-12_3 2/19/04 11:07 AM Page 7-31 7-31
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM Page 7-33 Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
5VM-9-12_3 2/19/04 11:07 AM Page 7-34 CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 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. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_3 2/19/04 11:07 AM Page 7-39 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. qWARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV.
5VM-9-12_3 2/19/04 11:07 AM 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 ...
5VM-9-12_3 2/19/04 11:07 AM 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.
5VM-9-12_4 3/3/04 5:25 PM Page 2 EBU00515 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. qWARNING HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified.
5VM-9-12_4 3/3/04 5:25 PM Page 3 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. qWARNING POTENTIAL HAZARD Operating this ATV with improper modifications.
5VM-9-12_4 3/3/04 5:25 PM Page 4 EBU02611 PERIODIC MAINTENANCE/LUBRICATION NOTE: 8 For vehicles not equipped with an odometer or an hour meter, follow the month maintenance intervals. 8 For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the vehicle isn’t used for a long period of time, the month maintenance intervals should be followed.
5VM-9-12_4 3/3/04 5:25 PM ITEM Page 5 ROUTINE Whichever comes first month 1 INITIAL 3 6 6 EVERY 12 km (mi) 320 (200) 1200 (750) 2400 (1500) 2400 (1500) 4800 (3000) hours 20 75 150 150 300 2 2 2 2 2 2 2 2 * Front and rear brake operation 9 Check operation/fluid leakage. 9 Correct if necessary. * Front and rear brake pads 9 Check pad wear. 9 Replace if necessary. * Clutch 9 Inspect free play and operation. 9 Replace if necessary.
5VM-9-12_4 3/3/04 5:25 PM Page 6 NOTE: 8 Recommended brake fluid: DOT 4 8 Brake fluid replacement: 9 When disassembling the master cylinders or caliper cylinders, replace the brake fluid. Normally check the brake fluid level and add fluid as required. 9 On the inner parts of the master cylinders and caliper cylinders, replace the oil seals every two years. 9 Replace the brake hoses every four years, or if cracked or damaged. w Indicates a potential hazard that could result in serious injury or death.
5VM-9-12_4 3/3/04 5:25 PM Page 7 EBU12771 Transmission oil Transmission oil measurement 1. Place the machine on a level surface. 2. Warm up the engine for several minutes, and stop it. 3. Check the oil level through the level window located at the right side crankcase cover. 2 3 1 1. Level window 3. Minimum level mark NOTE: Wait a few minutes until the oil level settles before checking. 4. The oil level should be between the minimum and maximum level marks.
5VM-9-12_4 3/3/04 5:25 PM Page 8 4. Remove the oil filler cap and the drain bolt to drain the oil. 5. Install the drain bolt and tighten it to the specified torque. Tightening torque Drain bolt: 20 Nm (2.0 m0kgf, 14 ft0lbf) 6. Fill the engine with the recommended oil, and then install the oil filler cap. Recommended oil: See page 10-2. Oil quantity: Periodic oil change: 0.6 L (0.57 Imp qt, 0.69 US qt) 1 1. Transmisson oil filler cap q 1.
5VM-9-12_4 3/3/04 5:25 PM Page 9 EBU00680 cC Spark plug inspection Removal 1. Remove the spark plug cap. 8 In order to prevent clutch slippage (since the transmission oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. 8 Make sure that no foreign material enters the crankcase. 1 1. Spark plug cap 7.
5VM-9-12_4 3/3/04 5:25 PM Page 10 Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug. 1 Standard spark plug: BR8ES (NGK) 1. Spark plug wrench Inspection The spark plug is an important engine component and is easy to inspect.
5VM-9-12_4 3/3/04 5:25 PM Page 11 EBU12902 Installation 1. Measure the electrode gap with a wire thickness gauge and, if necessary, adjust the gap to specification. Air filter cleaning NOTE There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the sponge material and air filter case. Spark plug gap: 0.7–0.8 mm (0.028–0.031 in) 2. Clean the gasket surface. Wipe off any grime from the threads. 3.
5VM-9-12_4 3/3/04 5:25 PM Page 12 4. Wash the sponge material gently but thoroughly in solvent. 1 qWARNING 2 POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material. 2 1. Air filter case cover WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. 2. Screw (×4) HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material. 3.
5VM-9-12_4 3/3/04 5:25 PM Page 13 7. Apply Yamaha foam air filter oil or other quality foam air filter oil to the sponge material. 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 filter case for obstructions.
5VM-9-12_4 3/3/04 5:25 PM Page 14 EBU13611 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe. Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the screws. q w e q 1. Tailpipe 2. Spark arrester 3. Gasket 1. Screw (×3) 4.
5VM-9-12_4 3/3/04 5:25 PM Page 15 qWARNING 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.
5VM-9-12_4 3/3/04 5:25 PM Page 16 EBU12821 Carburetor settings In extremely cold weather, it is necessary to change the carburetor settings to maintain optimum engine performance and to prevent engine damage. unless you have mechanical knowledge and the necessary tools. Do not perform these procedures while the engine is hot. Place a rag under the carburetor to catch any fuel. Wipe up any spilled fuel completely.
5VM-9-12_4 3/3/04 5:25 PM Page 17 Carburetor setting chart q Temperature Main jet Jet needle Pilot air screw 0°C (32°F) above (Standard) #230 2nd groove 1 1/2 turns out +5°C –15°C (41°F) – (5°F) #230 2nd groove 1 1/2 turns out –10°C –30°C (14°F) – (–22°F) #240 3rd groove 1 1/2 turns out Changing the carburetor settings Disassembling the carburetor 1. Turn the fuel cock to the “OFF” position. 2. Loosen the carburetor float bowl drain screw and drain the fuel. 1.
5VM-9-12_4 3/3/04 5:25 PM Page 18 3. Disconnect the fuel hose and the oil hose. 4. Loosen the clamp screws on each side of the carburetor, and then remove the carburetor. 5. Remove the securing plate by removing the screw. 6. Remove the mixing chamber cap by unscrewing it. q w 1 1. Fuel hose 4 2 3 2. Oil hose 1 1. Clamp screw (×2) 3. Screw 8-17 2. Securing plate 4.
5VM-9-12_4 3/3/04 5:25 PM Page 19 7. Disconnect the throttle cable from the throttle valve by removing the holder screws and holder. 1 5 4 8. Remove the float chamber by removing the screws. 3 2 1. Mixing chamber cap 3. Holder 5. Throttle cable 2 2. Throttle valve 4. Screw (×2) 2 1 2 1. Float chamber 8-18 2.
5VM-9-12_4 3/3/04 5:25 PM Page 20 Assembling the carburetor 1. Install the needle valve by hooking it onto the float arm. 2. Install the float by inserting the pin into the holder. 3. Install the float chamber by installing the screws. 4. Connect the throttle cable onto the throttle valve by installing the holder and the screws. 9. Remove the float by removing the pin. 10. Remove the needle valve by unhooking it from the float arm. 11. Change the main jet and the jet needle clip position.
5VM-9-12_4 3/3/04 5:25 PM Page 21 5. Install the mixing chamber cap and tighten it. 6. Install the securing plate by installing the screw. 7. Install the carburetor and tighten the clamp screws. 8. Connect the fuel hose and the oil hose. 9. Tighten the carburetor float bowl drain screw. NOTE: When installing the securing plate, align the slot in the securing plate with a projection on the carburetor mixing chamber cap. 1. Screw 2. Projection 3.
5VM-9-12_4 3/3/04 5:25 PM Page 22 EBU13020 Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. b 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. 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.
5VM-9-12_4 3/3/04 5:25 PM Page 23 EBU00307 EBU13040 Throttle lever adjustment Brake fluid level check Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn 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.
5VM-9-12_4 3/3/04 5:25 PM Page 24 8 Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance. 8 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. 8 Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.
5VM-9-12_4 3/3/04 5:25 PM Page 25 EBU01186 EBU13090 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. 8 Replace the oil seals every two years. 8 Replace the brake hoses every four years. Front brake pad check Check the brake pads for damage and wear. If a brake pad thickness is less than 1 mm (0.
5VM-9-12_4 3/3/04 5:25 PM Page 26 EBU00314 Rear brake pad inspection A wear indicator is provided on each brake pad. This indicator allows checking of brake pad wear without disassembling the brake. Apply the brake and inspect the wear indicator. If the brake pads are worn to the wear limit, have a Yamaha dealer replace the pads. q q 1.
5VM-9-12_4 3/3/04 5:25 PM Page 27 EBU01189 qWARNING Front brake lever free play The front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a Yamaha dealer adjust it. POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN a You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: 8 Make sure the brakes operate smoothly and that the free play is correct.
5VM-9-12_4 3/3/04 5:25 PM Page 28 EBU01191 qWARNING Brake pedal height adjustment The top of the brake pedal should be positioned 0–10 mm (0–0.4 in) below the top of the footrest. If not, have a Yamaha dealer adjust it. POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD a After servicing: 8 Make sure the brakes operate smoothly and that the brake pedal position is correct.
5VM-9-12_4 3/3/04 5:25 PM Page 29 EBU01193 Parking brake adjustment Parking brake adjustment may be required if the parking brake does not hold properly. The cable length “A” should be adjusted to 64–68 mm (2.52–2.68 in). 1 2 a b 1. Locknut 2. Adjusting bolt 2. Loosen the locknut and the adjusting bolt at the rear brake caliper. 3. Turn the adjusting bolt at the clutch lever in direction a to increase the cable length or in direction b to decrease the cable length. A A. Cable length 1.
5VM-9-12_4 3/3/04 5:25 PM Page 30 NOTE If the cable cannot be adjusted to specification, consult a Yamaha dealer. 4. Tighten the locknut at the clutch lever. 5. Screw in the adjusting bolt at the rear brake caliper by hand until it feels tight, then screw it out 1/8 turn. Tighten the locknut to the specified torque. q 1. Adjusting bolt Tightening torque: Locknut: 16 Nm (1.6 m0kgf, 11 ft0lbf) w 2.
5VM-9-12_4 3/3/04 5:25 PM Page 31 EBU00833 qWARNING Adjusting the rear brake light switch POTENTIAL HAZARD 1 Operating with improperly adjusted brakes. a b WHAT CAN HAPPEN 2 The brakes could malfunction, causing reduced braking performance. This could increase the chance of a collision or accident. 1. Rear brake light switch HOW TO AVOID THE HAZARD 2.
5VM-9-12_4 3/3/04 5:25 PM Page 32 EBU00539 EBU00349 Clutch adjustment The clutch lever free play should be 5–10 mm (0.20–0.39 in). If the free play is incorrect, adjust as follows. Autolube pump adjustment The Autolube pump is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. 1. Loosen the locknut. 2. Turn the adjusting bolt so that clutch lever free play is 5–10 mm (0.
5VM-9-12_4 3/3/04 5:25 PM Page 33 EBU01144 EBU00351 Drive chain slack check Drive chain slack adjustment 1. Loosen the rear wheel hub bolts. NOTE 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. q To check the drive chain slack, all tires must be touching the ground and there should be no weight on it.
5VM-9-12_4 3/3/04 5:25 PM Page 34 EBU00805 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. e q w q w 1. Locknut 2. Chain adjuster cC The drive chain must be lubricated after washing the ATV or riding in the rain. 3. Alignment marks 3.
5VM-9-12_4 3/3/04 5:25 PM Page 35 cC Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings. q 1. O-rings cC To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate solvents. 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant.
5VM-9-12_4 3/3/04 5:25 PM Page 36 EBU00356 EBU00737 Cable inspection and lubrication Brake and shift pedal/brake and clutch lever lubrication Lubricate the pivoting parts of each lever and pedal. qWARNING POTENTIAL HAZARD Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked.
5VM-9-12_4 3/3/04 5:25 PM Page 37 EBU14060 Steering shaft lubrication Lubricate the pivot point with a grease gun. Left side 1 Recommended lubricant: Lithium-soap-based grease (all purpose grease) 1. Grease nipple (×3) Right side 1 1 1. Grease nipple 1.
5VM-9-12_4 3/3/04 5:25 PM Page 38 EBU01112 Rear 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. Front EBU01300 Wheel installation 1. Install the wheel and the nuts. 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified torque. Tightening torque: Front wheel nut: 45 Nm (4.5 m0kgf, 32 ft0lbf) Rear wheel nut: 45 Nm (4.
5VM-9-12_4 3/3/04 5:25 PM Page 39 EBU01292 Replacing a headlight bulb If a headlight bulb burns out, replace the bulb as follows. 1. Remove the front panel by removing the screws. 2 1 4 3 2 2 1. Headlight beam adjusting screw 2. Washer 3. Spring 4. Nut 3. Disconnect the main switch leads. 1 1. Front panel 1 2. Screw (×4) 2. Remove the headlight beam adjusting screw, the washer, the spring and the nut.
5VM-9-12_4 3/3/04 5:25 PM Page 40 4. Remove the headlight unit assembly from the headlight body by removing the screws. 2 1 1 1 2 1. Headlight bulb holder cover 2. Headlight bulb holder 2 2 1. Headlight unit assembly 2. Screw (×2) 5. Remove the headlight bulb holder cover. 6. Turn the headlight bulb holder counterclockwise, and then remove the defective bulb. 1 1. Headlight bulb holder 8-39 2.
5VM-9-12_4 3/3/04 5:25 PM Page 41 qWARNING a 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 a. Do not touch the glass part of the headlight bulb. Wait for the bulb to cool before touching or removing it.
5VM-9-12_4 3/3/04 5:25 PM Page 42 8. Install the headlight bulb holder cover. 10. Install the headlight beam adjusting screw, the washer, the spring and the nut. cC Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 2 1 9. Install the headlight unit assembly by installing the screws. 4 3 1 1 1. Headlight beam adjusting screw 2. Washer 3. Spring 2 1. Headlight unit assembly 4. Nut 11. Connect the main switch leads. 12.
5VM-9-12_4 3/3/04 5:25 PM Page 43 EBU01089 EBU00861 Headlight beam adjustment Tail/brake light bulb replacement 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. cC It is advisable to have a Yamaha dealer make this adjustment. To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b. q 1. Bulb holder a b 1 1.
5VM-9-12_4 3/3/04 5:25 PM Page 44 EBU00412 2. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 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.
5VM-9-12_4 3/3/04 5:25 PM Page 45 qWARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe injury or property damage. 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.
5VM-9-12_4 3/3/04 5:25 PM Page 46 EBU00440 Troubleshooting chart Remove the fuel pipe 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 Water or dirt mixed in fuel Clean the fuel tank Turn the fuel cock to “ON” Check fuel flow No fuel Fuel cock clogged Restart engine Clean the fuel cock 2. Compression Kick the kick lever to see if there is compression 3.
5VM-9-12_4 3/3/04 5:25 PM Page 47 EBU00414 No spark Throttle OverRide System (T.O.R.S.) is incorporated in the ignition circuit, and if the system should fail, the spark plug will not spark. HOW TO AVOID THE HAZARD Have the system checked by a Yamaha dealer. Before bypassing T.O.R.S., be sure the throttle closes properly when the throttle lever is released. If the machine must be ridden, ride as slowly as possible. Do not touch the exhaust pipe when disconnecting the wire coupler.
5VM-9-12_5 3/10/04 8:56 PM Page 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.
5VM-9-12_5 3/10/04 8:56 PM Page 3 4. Once the majority of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bottle brush is handy for hard-to-get-at places. 5. Rinse the machine off immediately with clean water and dry all surfaces with a chamois, clean towel or soft absorbent cloth. 6. Dry the chain and lubricate it to prevent rust. 7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 8.
5VM-9-12_5 3/10/04 8:56 PM Page 4 EBU00527 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. 2.
5VM-9-12_5 3/10/04 8:56 PM Page 10-1 EBU00428 SPECIFICATIONS Model YFS200 Dimension: Overall length Overall width Overall height Seat height Wheel base Ground clearance Minimum turning radius 1,735 mm (68.3 in) 1,035 mm (40.7 in) 1,040 mm (40.9 in) 740 mm (29.1 in) 1,100 mm (43.3 in) 120 mm (4.72 in) 3,000 mm (118.
5VM-9-12_5 3/10/04 8:56 PM Page 10-2 Model Engine oil (2-cycle): Type Quantity Transmission oil: Type Recommended transmission oil classification YFS200 Yamalube 2 or air cooled 2-stroke engine oil 1.3 L (1.14 Imp qt, 1.37 US qt) Yamalube 4 (10W30) or SAE 10W30 type SE motor oil API Service SE, SF, SG type or higher cC In order to prevent clutch slippage (since the transmission oil also lubricates the clutch), do not mix any chemical additives.
5VM-9-12_5 3/10/04 8:56 PM Page 10-3 Model YFS200 Air filter: Wet type element Fuel: Type Tank capacity Reserve amount PREMIUM UNLEADED GASOLINE ONLY 9.0 L (1.98 Imp gal, 2.38 US gal) 2.0 L (0.44 Imp gal, 0.53 US gal) Carburetor: Type/manufacturer Spark plug: Type/manufacturer Gap BR8ES (NGK) 0.7–0.8 mm (0.028–0.
5VM-9-12_5 3/10/04 8:56 PM Page 10-4 Model Gear ratio 1st 2nd 3rd 4th 5th 6th YFS200 34/11 (3.091) 31/14 (2.214) 25/15 (1.667) 20/16 (1.250) 19/18 (1.056) 19/21 (0.905) Chassis: Frame type Caster angle Trail Steel Tube Frame 9.0° 40 mm (1.
5VM-9-12_5 3/10/04 8:56 PM Page 10-5 Model YFS200 Suspension: Front Rear Double wishbone Swingarm (monocross) Shock Absorber: Front Rear Coil spring, Oil damper Coil spring, Gas-Oil damper Wheel travel: Front Rear 180 mm (7.09 in) 180 mm (7.09 in) Electrical: Ignition system Generator system C.D.I. C.D.I. Magneto Headlight Type: Bulb type Bulb voltage, wattage × quantity Headlight Tail/brake light Oil level warning light 12V, 35W/36.5W × 1 12V, 5/21W × 1 12V, 3.
5VM-9-12_5 3/10/04 8:56 PM Page 11-2 EBU13640 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 afte
5VM-9-12_5 3/10/04 8:56 PM Page 12-1 EBU13670 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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5VM-9-12_5 3/10/04 8:57 PM Page 14-4 EBU00436 w Indicates a potential hazard that could result in serious injury or death.
5VM-9-12_5 3/10/04 8:57 PM Page 14-6 EBU00437 PROTECT YOUR INVESTMENT
5VM-9-12-Hyoshi 3/3/04 5:31 PM Page 1 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 CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: 9 without proper training or instruction.
4/2/03 9:06 AM Page 1 CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV. You have purchased a quality Yamaha product that, with proper use and care, will provide hours of riding pleasure.
ATV card for US 4/2/03 9:06 AM Page 2 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES FIRST CLASS PERMIT NO. 4 CYPRESS, CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U.S.A. P.O.
