READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFZ450RY WARNING LIT-11626-22-75 This ATV A should not be ridden by anyone under 16 years of age.
EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
EBU17170 INTRODUCTION EBU17301 Congratulations on your purchase of the Yamaha YFZ450RY. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this ATV.
EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this ATV.
EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17420 TABLE OF CONTENTS SAFETY INFORMATION .............................. 1-1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ............................ 2-1 DESCRIPTION .............................................. 3-1 Left view ..................................................... 3-1 Right view................................................... 3-1 Controls and instruments ...........................
OPERATION .................................................. 6-1 Starting the engine .................................... 6-1 Shifting ...................................................... 6-2 Engine break-in ......................................... 6-4 Parking ...................................................... 6-5 Parking on a slope .................................... 6-6 Accessories and loading ........................... 6-6 RIDING YOUR ATV ......................................
Lubricating the swingarm pivots .............. Lubricating the upper and lower arm pivots ..................................................... Battery ..................................................... Replacing the fuse .................................. Replacing a headlight bulb ...................... Adjusting a headlight beam ..................... Tail/brake light ......................................... Removing a wheel ................................... Installing a wheel ......................
EBU17430 SAFETY INFORMATION SAFETY INFORMATION EBU29350 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.
1 2 ● ● 3 4 ● 5 6 ● 7 8 ● 9 10 11 ● ● that is proper for the terrain, visibility, operating conditions, and your experience. Never attempt wheelies, jumps, or other stunts. Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation.
● ● ● ● ● ing, 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. Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees.
EWB02320 HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, seek medical help immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. WARNING 1 2 3 4 5 6 7 8 9 10 11 POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling.
EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 5 4 3 2 3 2 4 1 5 6 7 8 6 6 9 10 11 2-1
EBU17670 1 2 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replacement label from your Yamaha dealer.
2 1 1 WARNING WARNING Improper ATV use can result in SEVERE INJURY or DEATH. 2 UNDER 3 16 4 ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. NEVER USE NEVER CARRY NEVER USE ON PUBLIC PASSENGERS WITH DRUGS ROADS OR ALCOHOL NEVER operate : without proper training or instruction. at speeds too fast for your skills or the conditions.
1 2 3 4 5 6 5 4 WARNING WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. OPERATING TIRE PRESSURE : Set with tires cold Recommended : Front : 4.0 psi (27.5 kPa) Rear : 4.4 psi (30.0 kPa) : Front : 3.6 psi (24.5 kPa) Minimum Rear : 4.0 psi (27.0 kPa) Never set tire pressure below minimum. It could cause the tire to dislodge from the rim. LOADING Maximum weight capacity : 220 lbs.
EBU17680 DESCRIPTION 1 EBU17690 EBU17700 Left view Right view 1 23 4 5 6 1 2 2 3 4 5 6 7 3 4 5 6 7 9 8 7 10 9 8 8 1. Front shock absorber assembly compression damping force adjusting bolt (for fast compression damping) 2. Front shock absorber assembly compression damping force adjusting screw (for slow compression damping) 3. Headlights 4. Front shock absorber assembly spring preload adjusting nut 5. Engine oil tank filler cap 6. Tail/brake light 7. Shift pedal 8. Coolant reservoir 9.
EBU17712 Controls and instruments 1 1 2 3 4 5 6 7 2 3 4 5 6 7 8 9 10 11 1. 2. 3. 4. 5. 6. 7. Clutch lever Parking brake lever Left handlebar switches Fuel tank cap Main switch Throttle lever Brake lever TIP The ATV you have purchased may differ slightly from the figures shown in this manual.
EBU17724 INSTRUMENT AND CONTROL FUNCTIONS 1 EWB00010 WARNING OFF Indicates a potential hazard that could result in serious injury or death. 2 ON 3 1 EBU17760 Main switch 4 The positions of the main switch are as follows: 5 ON All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed. 6 7 1. Main switch 8 9 OFF All electrical systems are off. The key can be removed.
engine as soon as it is safe to do so and allow it to cool down for about 10 minutes. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on, and then go off, have a Yamaha dealer check the electrical circuit. EBU29380 Indicator light and warning lights 1 1 2 3 4 2 3 ECB00010 NOTICE 4 ● 5 ● 6 7 8 9 10 11 1. 2. 3. 4.
EBU26720 EBU18080 Engine trouble warning light “ ” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the self-diagnosis system. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on, then go off, have a Yamaha dealer check the electrical circuit. Engine stop switch “ / ” Set this switch to “ ” before starting the engine.
1 2 3 4 5 6 7 turned off for an extended period of time, otherwise the battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. EBU18270 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the ATV by varying the throttle position.
HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can’t find or solve the problem yourself. 3 1 1 (a) EBU18311 Speed limiter 2 2 (b) 3 4 5 Your ATV was delivered with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut.
off system.) EWB00190 WARNING 1 2 3 4 5 6 7 POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 2.0–4.0 mm (0.08–0.16 in). (See page 8-29.) 1.
2 3 1 1 1 4 2 3 4 5 1. 2. 3. 4. Brake lever Locknut Brake lever position adjusting bolt Distance between brake lever and handlebar grip 1. Brake pedal EBU18510 6 7 Parking brake lever Use the parking brake before starting the engine or parking the ATV, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a). To release the parking brake, move the parking brake lever in direction (b).
EWB00170 WARNING 1 POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake could overheat if you ride the ATV without releasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely.
1 1 2 3 4 5 1 1. Shift pedal 1. Fuel tank cap 6 7 EBU18720 EBU18800 Fuel tank cap Fuel Remove the fuel tank cap by turning it counterclockwise. Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.
rings, as well as to the exhaust system. 1 1 2 Your Yamaha engine has been designed to use premium unleaded gasoline with a pump octane number [(R+M)/2] of 91 or higher, or a research octane number of 97 or higher. If knocking or pinging occurs, use a different brand of gasoline. Unleaded fuel will give you longer spark plug life and reduced maintenance cost. 2 3 4 Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol.
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. Do not refuel right after the engine has been running and is still very hot. 1 1 2 3 4 5 1.
EWB00360 1 WARNING 1 POTENTIAL HAZARD These shock absorber assemblies contain highly pressurized nitrogen gas. WHAT CAN HAPPEN The shock absorber assemblies could explode, causing injury or property damage. Cylinder damage could also result in poor handling which could cause an accident. HOW TO AVOID THE HAZARD ● Do not tamper with or attempt to open the cylinder assemblies. ● Do not subject the shock absorber assemblies to an open flame or other high heat.
the suspension, and in direction (b) to decrease the spring preload and thereby soften the suspension. (a) adjusting nut, distance A is changed by 1.5 mm (0.06 in). 1 Spring preload setting: Minimum (soft): Distance A = 299.8 mm (11.80 in) Standard: Distance A = 289.8 mm (11.41 in) Maximum (hard): Distance A = 279.8 mm (11.02 in) 2 1 2 3 4 5 6 (b) 3 7 1. Spring preload adjusting nut 2. Locknut 3.
3. Tighten the locknut to the specified torque. 1 2 3 Tightening torque: Locknut: 50 Nm (5.0 m·kgf, 36 ft·lbf) ECB00080 4 5 6 7 8 9 (a) (b) NOTICE Always tighten the locknut against the adjusting nut, and then tighten it to the specified torque. 1 1.
Compression damping force Compression damping setting (for fast compression damping): Minimum (soft): 2 turn(s) out from the fully turned in position Standard: 1 turn(s) out from the fully turned in position Maximum (hard): Fully turned in Compression damping force (for fast compression damping) To increase the compression damping force and thereby harden the compression damping, turn the adjusting bolt in direction (a).
ECB00090 NOTICE 1 (b) 2 3 Never turn an adjusting mechanism beyond the minimum and maximum settings. (a) TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjusting range.
force adjusting screw, with a compression damping force adjusting bolt (for fast compression damping), and a compression damping force adjusting screw (for slow compression damping). HOW TO AVOID THE HAZARD Never touch the compression damping force adjusting bolt and screw, rebound damping force adjusting screw or oil reservoir with your bare hand or skin until suspension components have cooled. 2 EWB00380 WARNING POTENTIAL HAZARD This shock absorber assembly contains highly pressurized nitrogen gas.
1 2 Spring preload 1. Remove panel C. (See page 8-8.) 2. Loosen the clamp screw at the throttle body side, and then disconnect the air intake duct from the throttle body. 1 3 1 4 5 6 1. Coupler 7 4. Loosen the clamp screw at the air filter case side, and then disconnect the air intake duct from the air filter case. 8 9 10 1. Clamp screw 3. Disconnect the coupler.
1 3 1 2 1 2 3 4 1 1. Clamp screw 1. Bolt 2. Collar 3. Air filter case holding plate 5. Remove the air filter case holding plate by removing the bolts and collars. 6. Remove the blow-by gas chamber by removing the bolt.
2 1 1 2 3 4 6 2 2 5 1 1. Air filter case 2. Bolt 1. Blow-by gas chamber 2. Bolt 7 8 8. Loosen the locknut. 9. Turn the adjusting nut in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to decrease the spring preload and thereby soften the suspension. 7. Remove the air filter case by removing the bolts.
(0.06 in). Spring preload setting: Minimum (soft): Distance A = 273.5 mm (10.77 in) Standard: Distance A = 265.0 mm (10.43 in) Maximum (hard): Distance A = 253.5 mm (9.98 in) (a) 2 1 (b) 3 1 2 3 4 5 6 1. Spring preload adjusting nut 2. Locknut 3. Special wrench 7 TIP ● A special wrench can be obtained at a Yamaha dealer to make this adjustment. ● The spring preload setting is determined by measuring distance A, shown in the illustration.
10. Tighten the locknut to the specified torque. 1 2 3 clamp screw is tightened securely. 13. Install the blow-by gas chamber by installing the bolt, and then tighten it to the specified torque. Tightening torque: Locknut: 30 Nm (3.0 m·kgf, 22 ft·lbf) Tightening torque: Bolt: 6.5 Nm (0.7 m·kgf, 4.7 ft·lbf) ECB00080 NOTICE 4 5 6 7 8 9 10 11 Always tighten the locknut against the adjusting nut, and then tighten it to the specified torque. 14.
rebound damping force and thereby soften the damping. 2 TIP Make sure that the position indicator marks are aligned when the shock absorber assembly is set to the standard setting. (b) 1 (a) 1. Position indicator marks 2.
Compression damping force (for slow compression damping) To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw in direction (b). 1 1 2 (b) (a) 3 4 5 1 2 (a) 6 7 8 9 10 11 1. Compression damping force adjusting bolt (for fast compression damping) 2.
be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary. Compression damping setting (for slow compression damping): Minimum (soft): 18 click(s) in direction (b)* Standard: 8 click(s) in direction (b)* Maximum (hard): 1 click(s) in direction (b)* * With the adjusting screw fully turned in direction (a) EWB00370 WARNING POTENTIAL HAZARD Suspension components become hot during operation. WHAT CAN HAPPEN You could be burned.
1 1 2 3 4 5 1. Handlebar 6 7 EWB00010 8 9 WARNING Indicates a potential hazard that could result in serious injury or death.
EBU19200 PRE-OPERATION CHECKS 1 EBU19213 Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table. EWB00470 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition.
ITEM 1 ROUTINE ● Fuel ● 2 ● Engine oil ● 3 ● 4 Coolant ● ● 5 Front brake 6 ● ● ● 7 8 ● Rear brake 9 ● ● ● ● 10 Clutch ● ● 11 ● Throttle lever ● Control cables Drive chain ● ● ● Check fuel level in fuel tank, and add recommended fuel if necessary. Check fuel line for leakage. Correct if necessary. Check oil level in engine, and add recommended oil to specified level if necessary. Check ATV for oil leakage. Correct if necessary.
ITEM ROUTINE ● Check wheel condition, and replace if damaged. Check tire condition and tread depth. Replace if necessary. Check air pressure. Correct if necessary. Make sure that operation is smooth. Correct if necessary. Make sure that operation is smooth. Lubricate pedal pivoting point if necessary. Make sure that operation is smooth. Lubricate lever pivoting points if necessary. Make sure that all nuts, bolts and screws are properly tightened. ● Check operation, and correct if necessary.
EBU19530 EBU19620 Fuel Coolant 1 Make sure that there is sufficient fuel in the tank. (See page 4-9.) Make sure that the coolant is at the specified level. Add coolant as necessary. (See page 8-19.) 2 EWB00500 TIP The coolant level must be checked on a cold engine since the level varies with engine temperature. WARNING 3 4 5 6 7 8 9 10 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.
tem. EBU19700 Front and rear brakes Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, check the brake pads for wear. (See page 8-30.) Brake lever and brake pedal ● Check that there is no free play in the brake lever. If there is free play, have a Yamaha dealer check the brake system. ● Check for correct brake pedal height. (See page 8-34.
necessary. 1 2 3 4 5 HOW TO AVOID THE HAZARD The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. Other tire combinations are not recommended. Front: Manufacturer/model: DUNLOP/KT351 Radial Size: AT21 x 7R-10 Type: Tubeless Rear: Manufacturer/model: DUNLOP/KT356 Radial Size: AT20 x 10R-9 Type: Tubeless ● EBU19770 Drive chain Check the condition of the drive chain and check the drive chain slack. Lubricate and adjust the drive chain as necessary. (See page 8-38.
● ● The tires should be set to the recommended pressure: Recommended tire pressure: Front: 27.5 kPa (0.275 kgf/cm2, 4.0 psi) Rear: 30.0 kPa (0.300 kgf/cm2, 4.4 psi) Check and adjust tire pressures when the tires are cold. Tire pressures must be equal on both sides. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure: Front: 24.5 kPa (0.245 kgf/cm2, 3.6 psi) Rear: 27.0 kPa (0.270 kgf/cm2, 4.
EBU19830 Tire wear limit 1 Replace the tire when the tire groove decreases to 3 mm (0.12 in). 1 2 3 4 5 6 7 8 9 10 11 1. Low-pressure tire gauge Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: 1. Tire wear limit Recommended pressure: Front 27.5 kPa (0.275 kgf/cm2, 4.0 psi) Rear 30.0 kPa (0.300 kgf/cm2, 4.4 psi) Minimum: Front 24.5 kPa (0.245 kgf/cm2, 3.6 psi) Rear 27.0 kPa (0.270 kgf/cm2, 4.
EBU19871 OPERATION 1 EWB00010 EBU29472 Starting the engine WARNING 2 EWB00620 Indicates a potential hazard that could result in serious injury or death. WARNING POTENTIAL HAZARD Frozen control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or collision. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding.
1 2 3 4 5 6 7 8 9 10 11 level warning light and engine trouble warning light should come on, then go off. If a warning light does not go off, see page 4-2 for the corresponding warning light circuit check. crank the engine more than 10 seconds on each attempt. ECB00161 NOTICE For maximum engine life, never accelerate hard when the engine is cold! 3. Shift the transmission into neutral. The neutral indicator light should come on, if it does not come on, have a Yamaha dealer check the electrical circuit.
time, release the clutch lever slowly. 5. Once the ATV has attained adequate speed, release the throttle, and at the same time, quickly pull in the clutch lever. 6. Shift the transmission into second gear. (Make sure not to shift the transmission into neutral) 7. Open the throttle part way and gradually release the clutch lever. 8. Follow the same procedure when shifting to the next higher gear. 5 4 3 2 N 1 2 1 EWB00680 1. Shift pedal 2.
1 2 3 4 5 6 7 8 9 tle 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. ● EWB00650 ning. Inadequate lubrication may damage the transmission. Always use the clutch when changing gears.
operation or any condition that might result in engine overheating must be avoided. 1 0–160 km (0–100 mi) or 0–10 hours Avoid prolonged operation above 1/2 throttle. Vary the speed of the ATV regularly. Do not operate it at one set throttle position. 1 2 3 4 160–320 km (100–200 mi) or 10–20 hours Avoid prolonged operation above 3/4 throttle. Rev the engine through the gears freely, but do not use full throttle at any time. 5 1.
EBU20850 Parking on a slope 1 EWB00790 WARNING 2 3 4 5 6 7 8 9 10 11 POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the ATV transversely across the incline, shift into first gear, stop the engine, apply the parking brake, and then block the front and rear wheels with rocks or other objects.
● ● ● ● ity or suitability. Choose a genuine Yamaha accessory, or one that is equivalent in design and quality. 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. Do not mount an accessory where it could interfere with your ability to control the ATV.
● 1 2 3 4 5 6 7 8 9 10 11 ● takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV. EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EWB00750 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident.
EBU21131 RIDING YOUR ATV 1 2 3 4 5 6 7 8 9 10 11 7-1
RIDE WITH CARE AND GOOD JUDGEMENT EWB00010 WARNING 1 2 Get training if you are inexperienced. Beginners should get training from a certified instructor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum performance until you are totally familiar with the ATV’s handling and performance characteristics. Indicates a potential hazard that could result in serious injury or death.
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. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc.
This ATV is designed to carry operator only – passengers prohibited. 1 EWB00910 WARNING 2 3 4 5 6 7 8 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.
WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. Operating without protective clothing increases your chances of severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly.
Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety. 1 2 EWB00940 WARNING 3 POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
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. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner’s Manual for this ATV on page 5-6. Always maintain proper tire pressure as described in the Owner’s Manual on page 5-7.
1 MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 100.0 kg (220 lb) 2 1 2 3 EWB00970 WARNING 4 POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer.
During operation Always keep your feet on the footboards during operation, otherwise they may contact the rear wheels. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.
HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer. 1 2 3 4 5 Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system.
EWB01020 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. Do not park the ATV in a place where others might be likely to touch it. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only.
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. 1 2 3 4 5 6 7 8 9 10 11 Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. EWB01030 WARNING Know the terrain where you ride. Ride cautiously in unfamiliar areas.
EWB01040 WARNING 1 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. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.
EWB01050 WARNING 1 2 3 4 5 6 7 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 ATV 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. Always be especially cautious on these kinds of terrain.
Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. 1 2 3 4 5 6 7 EWB01060 Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain.
1 2 3 4 5 6 7 8 9 10 11 the shift pedal. Remember that the engine and exhaust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components. 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.
EWB01070 EWB01220 WARNING WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear.
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. It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over. Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your ATV.
WHAT CAN HAPPEN The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting large hills. 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.
WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. 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.
immediately on the uphill side. EWB01251 WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in the ATV overturning. HOW TO AVOID THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill. If you lose all forward speed: ● Keep weight uphill. ● Apply the brakes. ● Lock the parking brake after you are stopped. If you begin rolling backwards: ● Keep weight uphill.
braking may also cause a loss of traction. Whenever possible, ride your ATV straight downhill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear. 1 2 3 EWB01130 WARNING 4 POTENTIAL HAZARD Going down a hill 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 going down hills as described in this Owner’s Manual. Note: a special technique is required when braking as you go down a hill. Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side. Go straight down the hill where possible.
1 2 3 4 5 6 7 8 9 10 11 steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes, be sure not to make sharp turns either up or down hill. If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you wish to travel. When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual.
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. 1 2 EWB01150 3 WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident.
1 2 1 3 4 5 6 1. Air filter case check hose 7 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.
WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual. 1 2 3 4 5 SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide.
WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. 1 2 3 4 5 6 7 8 9 10 11 WHAT TO DO IF... This section is designed to be a reference guide only.
● ● ● ● Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See page 7-24.) Lean more into the turn to regain balance. If necessary, gradually let off the throttle and/or steer to the outside of the turn. (See page 7-17.
EBU21648 PERIODIC MAINTENANCE AND MINOR REPAIR 1 EBU21660 2 3 4 5 6 7 8 9 10 11 HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with maintenance work. Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your ATV in the safest and best operating condition possible.
it for you. EWB01830 WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this ATV may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories.
EBU21743 Periodic maintenance chart for the emission control system 1 2 3 4 TIP ● For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
EBU21864 General maintenance and lubrication chart INITIAL NO. 1 2 * ITEM CHECK OR MAINTENANCE JOB * 3 6 6 12 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 Clean and replace if necessary. Clutch ● Check operation and adjust if necessary. Check operation and correct if necessary. Check fluid level and ATV for fluid leakage, and correct if necessary. Replace brake pads. Check operation and correct if necessary.
INITIAL 1 NO. ITEM CHECK OR MAINTENANCE JOB 2 3 10 * 11 * 5 6 12 Drive chain 13 14 * * 8 15 * 16 * 17 * 9 10 11 Drive chain rollers Chassis fasteners Shock absorber assemblies Rear suspension relay arm and connecting arm pivoting points Steering shaft 18 * Steering system 19 * Engine mount 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 320 √ √ √ ● ● Lubricate with lithium-soap-based grease.
INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first EVERY month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 √ √ Engine oil ● Change. Check ATV for oil leakage, and correct if necessary. √ √ 21 Engine oil filter element ● Replace. √ √ ● √ ● Check coolant level and ATV for coolant leakage, and correct if necessary. Replace coolant. ● Lubricate. ● ● Check operation and correct if necessary.
EBU29430 1 2 3 4 TIP Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. ● Replace the fuel hose every five years and if cracked or damaged. ● Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged.
EWB00010 1 WARNING 2 3 1 Indicates a potential hazard that could result in serious injury or death. 2 EBU23090 Removing and installing panels 3 The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1 2 4 5 3 1. Panel D 2. Panel E 3. Panel F EBU29531 6 7 8 9 Panel A 10 To remove the panel 1. Remove the seat. (See page 4-11.) 2. Remove the fuel tank cap. (See page 4-9.
1 2 3 1 4 1 1 5 6 7 8 1. Bolt 1. Quick fastener 4. Remove the quick fasteners, and then slide the panel backward and pull upward. To install the panel 1. Place the panel in the original position, and then install the quick fasteners.
2. Pull the panel off. 1 1 1 2 3 4 2 5 6 1. Projection 2. Slot To install one of the panels 1. Place the panel in its original position. ECB00380 7 8 NOTICE 9 When installing the panel, be sure not to pinch the cables or wires. 10 2. Install the bolts. 3. Install the fuel tank cap. 11 Panels B and D To remove one of the panels 1. Remove panel A.
2. Install panel A. 1 1 Panel C 2 To remove the panel 1. Remove panels A, B and D. 2. Remove the bolts, and then take the panel off. 3 1 4 1 5 6 1. Bolt 7 1 To install the panel Place the panel in its original position, and then install the bolts. 8 9 Panel E 1. Bolt 10 To remove the panel 1. Remove panel A. 2. Remove the bolts, and then take the panel off.
1 To install the panel 1. Place the panel in the original position and install the bolts. 2. Install panel A. 1 1 2 Panel F 3 To remove the panel 1. Remove panel E. 2. Remove the bolts, and then take the panel off. 4 5 6 1. Bolt 1 1 7 8 9 10 1. Bolt 1 1 To install the panel 1. Place the panel in the original position and install the bolts. 1.
Before installing a spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification. 2. Install panel E. 1 2 3 4 5 6 7 8 9 10 11 EBU29440 Checking the spark plug The spark plug is an important engine component, which should be checked periodically, preferably by a Yamaha dealer.
perature. TIP If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 3. Remove the engine oil tank filler cap, and wipe the dipstick off with a clean rag. 1 2 1 1 3 EBU29492 2 3 Engine oil and oil filter element The engine oil level should be checked before each ride.
and maximum level marks. 1 2 3 4 5 6 7 8 9 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type through the engine oil tank filler hole to raise it to the correct level. TIP When adding oil, be careful not to overfill the engine oil tank; the oil level rises faster starting from the half-level-portion on the dipstick. 2 6. Insert the dipstick into the engine oil tank filler hole, and then tighten the engine oil tank filler cap. 1 1. Engine guard 2.
1 2 3 1 1 4 5 1. Engine oil tank drain bolt 1. Crankcase engine oil drain bolt 7. Check the washers for damage, and replace if necessary. 6. Remove the engine oil tank filler cap and the engine oil tank drain bolt. TIP Skip steps 8–11 if the oil filter element is not being replaced. 8. Remove the oil filter element cover by removing the bolts, and then remove the oil filter element.
1 1 2 1 2 2 3 2 4 5 6 1. Oil filter element cover 2. Bolt 1. Oil filter element 2. O-ring 7 8 9. Check the O-rings for damage, and replace them if necessary. 10. Install a new oil filter element and the O-rings. TIP Make sure that the O-rings are properly seated. 9 11. Install the oil filter element cover by installing the bolts, and then tighten them to the specified torque. 10 11 Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.
12. Install the crankcase engine oil drain bolt and the engine oil tank drain bolt, and then tighten them to their specified torques. ECB00300 NOTICE ● Tightening torques: Crankcase engine oil drain bolt: 20 Nm (2.0 m·kgf, 14 ft·lbf) Engine oil tank drain bolt: 20 Nm (2.0 m·kgf, 14 ft·lbf) ● 13. Pour the specified amount of the recommended engine oil through the engine oil tank filler hole, and then install and tighten the engine oil tank filler cap.
1 2 3 4 5 6 7 8 9 10 11 minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 15. Turn the engine off, and then check the oil level and correct it if necessary. 16. Install the engine guard by installing the bolts, and then tighten them to the specified torque. TIP The coolant level must be checked on a cold engine since the level varies with engine temperature. 2. Check the coolant level in the coolant reservoir.
1 ● 2 3 place it with coolant as soon as possible, otherwise the cooling system will not be protected against frost and corrosion. If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. TIP If the engine overheats, see page 8-53 for further instructions. 1. Coolant reservoir cap 2. Maximum level mark 3.
EBU23551 To change the coolant 1 2 3 4 5 6 7 8 9 10 11 EWB01880 WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always place a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap. 1 2 1. Coolant drain bolt 2. Trough 4.
5. Remove the coolant reservoir by removing the bolts. 6. Remove the coolant reservoir cap, and then turn the coolant reservoir upside down to empty it. then tighten it to the specified torque. Tightening torque: Coolant drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 1 2 3 3 1. Coolant reservoir cap 2. Coolant reservoir 3. Bolt 7. After draining the coolant, thoroughly flush the cooling system with clean tap water. 8. Install the coolant reservoir by installing the bolts. 9.
check the cooling system. ECB00401 NOTICE 1 ● 2 3 ● 4 5 6 7 8 9 10 11 ● 15. Install the panel. If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine. If water has been used instead of coolant, replace it with coolant as soon as possible, otherwise the cooling system will not be protected against frost and corrosion.
2 1 2 1 3 1 4 5 1. Air filter case check hose 1. Air filter case cover 2. Air filter case cover holder 6 7 1. Place the ATV on a level surface. 2. Remove the seat. (See page 4-11.) 3. Remove the air filter case cover by unhooking the holders. 4. Loosen the wing bolt. 5. Remove the air filter element together with the wing bolt and washer.
2 1 2 2 3 1 4 1 5 6 1. Wing bolt 2. Air filter element 1. Sponge material 2. Air filter element frame 7 8 9 6. Remove the wing bolt and washer from the air filter element. 7. Remove the sponge material from the air filter element frame. 8. Wash the sponge material gently but thoroughly in solvent. EWB01900 WARNING POTENTIAL HAZARD Using low-flash-point solvents or gasoline to clean the sponge material. WHAT CAN HAPPEN Low-flash-point solvents or gasoline can catch fire or explode.
TIP HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material. The sponge material should be wet but not dripping. 12. Pull the sponge material over the air filter element frame. 13. Install the washer onto the air filter element frame, and then insert the wing bolt into the hole in the air filter element frame. 9. Squeeze the excess solvent out of the sponge material and let it dry. ECB00440 NOTICE Do not twist the sponge material when squeezing it.
1 2 3 4 5 6 7 8 9 10 11 14. Insert the air filter element into the air filter case, and then tighten the wing bolt. 15. Install the air filter case cover by hooking the holders onto the air filter case. 16. Install the seat. will affect the fuel injection system with subsequent poor performance and possible engine overheating. EBU23873 Cleaning the spark arrester TIP The air filter element should be cleaned every 20– 40 hours.
6. Remove the purging bolt. brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 1 2 3 1 2 4 1 5 2 6 1. Purging bolt 2. Gasket 1. Tailpipe 2. Spark arrester 7. Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel. 8. Stop the engine and allow the exhaust pipe to cool. 9.
EBU24045 Adjusting the throttle cable free play 1 2 3 Tightening torque: Purging bolt: 27 Nm (2.7 m·kgf, 19 ft·lbf) The throttle cable free play should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The throttle cable free play should measure 2.0– 4.0 mm (0.08–0.16 in) at the throttle lever. Periodically check the throttle cable free play and, if necessary, adjust it as follows.
brication chart. (b) EBU24130 Checking the front and rear brake pads 1 (a) 2 3 1. 2. 3. 4. The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. 2 EBU29560 4 Front brake pads Each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves.
pads as a set. 1 1 1 2 3 4 5 6 1. Wear indicator groove 1. Wear indicator groove 7 8 TIP The wheels need to be removed to check the brake pads. (See page 8-50.) TIP The wheels need to be removed to check the brake pads. (See page 8-50.) 9 EBU26460 10 11 Rear brake pads Each rear brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves.
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. Rear brake 1 Front brake 1 2 3 4 1 5 6 1. Minimum level mark 7 TIP To check the rear brake fluid level, remove the seat. (See page 4-11.) 1. Minimum level mark Observe these precautions: ● When checking the fluid level, make sure that the top of the brake fluid reservoir is level.
● 1 2 ● 3 4 5 6 7 8 9 10 11 ● ● Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.
WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that there is no free play. ● Make sure the brakes do not drag. ● Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. 1 2 3 1 4 5 1.
2.0 in). Adjust the parking brake free play as follows. EWB02060 WARNING 1 2 3 4 5 6 7 8 9 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 After servicing: ● Make sure the brakes operate smoothly and that the brake pedal position is correct. ● Make sure the brakes do not drag. ● Make sure the brakes are not spongy. All air must be bled from the brake system.
together with the locknut. (a) Tightening torque: Locknut (rear brake caliper): 16 Nm (1.6 m·kgf, 11 ft·lbf) (b) 2 WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN The brakes could malfunction, causing reduced braking performance. This could increase the chance of a collision or accident. HOW TO AVOID THE HAZARD After adjusting the parking brake free play, block the rear of the ATV off the ground and spin the rear wheels.
1 2 3 4 vals specified in the periodic maintenance and lubrication chart. The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. 1 2 TIP The brake light switch is properly adjusted when the brake light comes on just before braking takes effect. (a) (b) 5 6 7 Turn the adjusting nut while holding the brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a).
(a) 1 1 (a) (b) 1 2 (b) 2 3 4 2 5 1. Clutch lever free play 2. Clutch lever free play adjusting nut 1. Locknut 2. Clutch lever free play adjusting nut (crankcase) 6 7 1. To increase the clutch lever free play, turn the adjusting nut at the clutch lever in direction (a), and to decrease it, turn the nut in direction (b). If the specified free play cannot be obtained, proceed with the following steps. 2. Fully turn the adjusting nut at the clutch lever in direction (a) to loosen the clutch cable. 3.
3. If the drive chain slack is incorrect, adjust it as follows. To check the drive chain slack 1. Place the ATV on a level surface. 1 2 3 4 5 6 TIP When checking and adjusting the drive chain slack, there should be no weight on the ATV and all tires must be touching the ground. To adjust the drive chain slack 1. Place the ATV on a level surface. 2. Loosen the rear wheel axle pinch bolts. 3. Insert a rod of a diameter of 8 mm (0.
TIP A rod can be obtained at a Yamaha dealer to make this adjustment. 1 4. Shift the transmission into neutral. 5. To tighten the drive chain, push the ATV backward. To loosen the drive chain, push the ATV forward. 2 3 4 ECB00541 NOTICE 3 1 2 4 Improper drive chain slack will overload the engine as well as other vital parts of the ATV and can lead to drive chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits.
3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant. 1 ECB00580 NOTICE 2 Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings. 1 3 4 EBU24890 Checking and lubricating the cables 5 6 7 8 9 10 The operation and the condition of all control cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary.
Brake lever EWB02120 WARNING 1 POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could restrict the operation of controls and lead to an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently. Replace damaged cables.
EBUM0170 EBU24962 Checking the shift pedal Checking the wheel hub bearings 2 The operation of the shift pedal should be checked before each ride. If operation is not smooth, have a Yamaha dealer check the vehicle. 3 EBU28871 The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bearings.
Left side 1 1 2 2 3 4 2 5 6 EBU25032 1. Upper grease nipple 2. Lower grease nipple Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Lubricate the pivoting points using a grease gun.
Right side EWB02140 WARNING 1 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. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk.
To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electrical accessories. To remove the battery 1. Remove the seat. (See page 4-11.) 2. Remove the battery holding plate by removing the bolts. 3. Disconnect the negative battery lead first, then the positive battery lead by removing their bolt.
the bolts. 4. Install the seat. (See page 4-11.) charged battery can cause permanent battery damage. 1 2 3 4 5 EBU25232 To install the battery Replacing the fuse TIP Be sure the battery is fully charged. 1 1. Place the battery in its compartment. 2. Connect the positive battery lead first, then the negative battery lead by installing their bolt. 6 2 7 2 8 1. Fuse 2. Spare fuse 9 10 The fuse holder is located under the seat. (See page 4-11.) If the fuse is blown, replace it as follows. 1.
Yamaha dealer check the electrical system. ECB00640 NOTICE EBU29450 To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove panel E. (See page 8-8.) 2. Remove the headlight bulb holder cover. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. 1 2 3 4 Specified fuse: 20.0 A 5 EWB02151 6 WARNING POTENTIAL HAZARD Using an improper fuse.
1 1 2 3 4 5 6 7 8 9 10 11 1. Headlight bulb holder 1. Do not touch the glass part of the bulb. EWB02180 ECB00650 NOTICE WARNING Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner.
7. Install the panel. 8. Adjust the headlight beam if necessary. EBU26920 Tail/brake light This model is equipped with an LED type of tail/ brake light. If the tail/brake light does not come on, have a Yamaha dealer check it. EBU25551 Adjusting a headlight beam ECB00690 NOTICE 1 2 3 EBU25651 It is advisable to have a Yamaha dealer make this adjustment. Removing a wheel 1. Place the ATV on a level surface. 2. Loosen the wheel nuts.
Rear ● 1 of the wheel. When installing a rear wheel, make sure its wording “SIDE FACING OUTWARDS” faces outwards. 2 3 4 5 6 1. Wheel nut 7 8 9 10 11 3. Elevate the ATV and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. 1. Arrow mark 3. Lower the ATV to the ground. 4. Tighten the wheel nuts to the specified torques. EBU25681 Installing a wheel 1. Place the ATV on a level surface. 2. Install the wheel and the nuts.
EWB02260 WARNING Tightening torques: Front wheel nut: 45 Nm (4.5 m·kgf, 32 ft·lbf) Rear wheel nut: 45 Nm (4.5 m·kgf, 32 ft·lbf) 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.
EBU27681 Troubleshooting charts 1 Starting problems or poor engine performance 2 3 4 1. Fuel Check the fuel level in the fuel tank. There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the ATV. The engine does not start. Check the compression. 5 2. Compression 6 Operate the electric starter. 7 8 3. Ignition 9 Remove the spark plug and check the electrodes. 10 11 4.
Engine overheating EWB02270 WARNING 1 POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap. 2 3 4 5 6 The coolant level is low. Check the cooling system for leakage.
EBU25860 CLEANING AND STORAGE 1 ed from improper high-pressure detergent applications such as those available in coinoperated car washers. EBU25890 2 3 4 5 6 7 8 9 10 11 Cleaning Frequent, thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the ATV: a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may be used. b.
nia) and areas where strong chemicals are stored. EWB02300 WARNING 1 POTENTIAL HAZARD Operation with wet brakes after washing. WHAT CAN HAPPEN Wet brakes may have reduced stopping ability, increasing the chance of an accident. HOW TO AVOID THE HAZARD Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings. Long-term Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” section of this chapter. 2.
1 2 3 4 4. 5. 5 6 7 6. 8 7. 9 10 11 the starter. (This will coat the cylinder wall with oil.) e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. Lubricate all control cables and the pivoting points of all levers and pedals. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that all of its wheels are off the ground.
EBU25960 SPECIFICATIONS 1 Bore × stroke: 95.0 × 63.4 mm (3.74 × 2.50 in) Compression ratio: 11.60 :1 Starting system: Electric starter Lubrication system: Dry sump EBU2597D Dimensions: Overall length: 1795 mm (70.7 in) Overall width: 1240 mm (48.8 in) Overall height: 1065 mm (41.9 in) Seat height: 810 mm (31.9 in) Wheelbase: 1270 mm (50.0 in) Ground clearance: 235 mm (9.
1 2 3 4 Clutch: Engine oil quantity: Without oil filter element replacement: 1.40 L (1.48 US qt, 1.23 Imp.qt) With oil filter element replacement: 1.45 L (1.53 US qt, 1.28 Imp.qt) Clutch type: Wet, multiple-disc Transmission: Primary reduction system: Spur gear Primary reduction ratio: 61/23 (2.652) Secondary reduction system: Chain drive Secondary reduction ratio: 38/14 (2.714) Transmission type: Constant mesh 5-speed Operation: Left foot operation 1st: 35/14 (2.500) 2nd: 30/15 (2.000) 3rd: 31/19 (1.
Front wheel: Trail: 21.0 mm (0.83 in) Wheel type: Panel wheel Rim size: 10 x 5.5AT Front tire: Type: Tubeless Size: AT21 x 7R-10 Manufacturer/model: DUNLOP/KT351 Radial Rear wheel: Wheel type: Panel wheel Rim size: 9 x 8.5AT Rear tire: 1 2 3 4 Front brake: Type: Tubeless Size: AT20 x 10R-9 Manufacturer/model: DUNLOP/KT356 Radial Type: Dual disc brake Operation: Right hand operation Recommended fluid: DOT 4 Loading: Rear brake: Maximum loading limit: 100.
Rear suspension: 1 2 3 4 5 Engine trouble warning light: LED Type: Swingarm (link suspension) Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: 280 mm (11.0 in) Fuses: Main fuse: 20.0 A Electrical system: Ignition system: TCI (digital) Charging system: AC magneto Battery: 6 7 8 9 10 11 Model: YTZ-7S Voltage, capacity: 12 V, 6.
EBU25981 CONSUMER INFORMATION 1 EBU26011 EBU26020 Identification numbers Key identification number The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key. Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen.
1 2 3 1 4 1 5 6 7 8 1. Model label 1. Vehicle identification number TIP The vehicle identification number is used to identify your ATV. 9 EBU26050 10 11 Model label The model label is affixed at the location in the illustration. Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
EBU26060 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 such device or element of design has b
EBU26080 Maintenance record 1 2 3 4 5 6 7 8 9 10 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.
EBU26501 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 1 Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha ATVs purchased from an authorized Yamaha ATV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations. THE PERIOD OF WARRANTY for Yamaha ATVs shall be six (6) months from the date of purchase.
WARRANTY QUESTIONS AND ANSWERS 1 2 3 4 5 6 7 8 9 10 11 CUSTOMER SERVICE Q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes. If your machine requires warranty service, you must take it to any authorized Yamaha ATV dealer within the continental United States.
EBU26122 YAMAHA EXTENDED SERVICE (Y.E.S.) 1 Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Ser vice (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost. TRIP gives you up to $150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home.
1 2 3 4 5 6 We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. You can also save money: Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S.
EBU26132 1 2 3 4 5 6 7 8 9 10 11 11-9
INDEX A Accessories and loading ................................................ 6-6 Air filter element, cleaning............................................ 8-23 Drive chain, lubricating................................................. 8-40 Drive chain slack .......................................................... 8-38 E B Battery.......................................................................... 8-45 Brake and clutch levers, checking and lubricating ....... 8-42 Brake fluid, changing..........
L Shock absorber assembly, adjusting the rear.............. 4-17 Spark arrester, cleaning............................................... 8-27 Spark plug, checking.................................................... 8-13 Specifications............................................................... 10-1 Speed limiter .................................................................. 4-5 Start switch .................................................................... 4-3 Storage .............................
EBU26141 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. BEER BEER ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns.
8 READ YOUR OWNER’S MANUAL 8 A CHILD UNDER 6 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 50CC OR GREATER 8 A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER 8 A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER THAN 90CC 8 TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA – ASK YOUR DEALER FOR DETAILS OR CALL 1-800-887-2887 If you have any questions about these points, or if you purchased your ATV from an authorized Yamaha dealers
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.
