Yamaha YFA1R(C) manual

w This ATV should not be ridden by anyone under 16 years of age. PRINTED IN JAPAN 2002·3–0.9 × 1 ! (E) OWNER’S MANUAL 5VJ-28199-10 YFA1R(C) READ THIS MANUAL CAREFULLY! It contains important safety information. PRINTED ON RECYCLED PAPER LIT-11626-16-04 YAMAHA MOT OR CO. , L TD. Improper ATV use can result in SEVERE INJURY or DEATH. q W ARNING [...]

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EBU00941 INTRODUCTION Congratulations on your purchase of the Yamaha YFA1. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader[...]

EBU00801 IMPORT ANT MANUAL INFORMA TION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERI- OUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE- TY IS INVOLVED! w Failure to follow WARNING instru[...]

EBU00011 IMPORT ANT NOTICE This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to oper- ate this machine on any public street, road or highway. This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and regula- tions in effect at the time of manufacture. Please check your local r[...]

LOCATION OF THE WARNING AND SPECIFICATION LABELS .......................1-1 SAFETY INFORMATION .........................2-1 DESCRIPTION AND MACHINE IDENTIFICATION.....................................3-1 Identification number records ...............3-2 Key identification number .....................3-2 Vehicle identification number ...............3-[...]

PRE-OPERATION CHECKS ...................5-1 Front and rear brakes ...........................5-2 Fuel ......................................................5-3 Engine and transmission oill .................5-5 Chain ....................................................5-6 Throttle lever ........................................5-6 Fittings and fasten[...]

PERIODIC MAINTENANCE AND ADJUSTMENT .........................................8-1 Owner’s manual and tool kit .................8-1 Periodic maintenance/Lubrication ........8-3 Engine oil ..............................................8-5 Transmission oil ...................................8-7 Spark plug inspection ...........................8-9 Eng[...]

NOISE REGULATION............................11-1 MAINTENANCE RECORD ....................12-1 ATV LIMITED WARRANTY ...................13-1 YAMAHA EXTENDED SERVICE (Y.E.S.)...................................................14-1 11 12 13 14 5VJ-9-10-1 3/26/02 7:29 PM Page 7[...]

1-1 EBU00464 LOCA TION OF THE W ARNING AND SPECIFICA TION LABELS e w q r t 5VJ-9-10-1 3/26/02 7:29 PM Page 8[...]

1-2 Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. 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 2 1 5FE-21697-01 3FA-21696-41 5VJ-9-10-1 3/26/02 7:29 PM Page 9[...]

1-3 4 3 5 3FA-2151E-A0 DRIVE SELECT LEVER 8 Read owner’s manual carefully before operating. 8 ATV MUST be stopped before shifting select lever. 8 Shifting into reverse is impossible without applying rear brake lever. 5FE-21568-01 q W ARNING NEVER ride as a passenger . Passengers can cause a loss of control, resulting in SEVERE INJUR Y or DEA TH. [...]

2-1 EBU00925 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 pre- cautions. SEVERE INJURY OR DEATH can result i[...]

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 sh[...]

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[...]

2-4 8 Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special proce- dure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and rem[...]

2-5 8 Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY , call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor[...]

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. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling. Never refuel whil[...]

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. q W ARNING 2-7 5VJ-9-10-1 3/26/02 7:29 PM Page 2-7[...]

3-1 1. Seat 11. Footboard 2. Drive select lever 12. Rear brake lever 3. Headlight 13. Parking brake 4. Front cover 14. Reverse indicator light 5. Front wheel 15. Neutral indicator light 6. Starter (choke) 16. Front brake lever 7. Fuel cock 17. Throttle lever 8. Rear wheel 18. Main switch 9. Tail/brake light 19. Fuel tank cap 10. Spark arrester 20. [...]

EBU00600 Identification number records Record the key identification number, vehicle identification number and model label informa- tion 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: 2. VEHICLE IDENTIFICATION NUMBER: 3. MODEL LABEL I[...]

EBU00036 Vehicle identification number The vehicle identification number is stamped into the frame. NOTE: The vehicle identification number is used to identify your machine. EBU00787 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[...]

EBU00039 CONTROL FUNCTIONS w Indicates a potential hazard that could result in serious injury or death. EBU00041 Main switch Functions of the respective switch positions are as follows: ON: Engine can be started only at this position and the headlight and taillight come on when the light switch is on. OFF: All electrical circuits are switched off. [...]

EBU00043 Indicator lights EBU00044 Reverse indicator light “ REVERSE ” This indicator light comes on when the transmis- sion is in reverse. EBU00045 Neutral indicator light “ NEUTRAL ” This indicator light comes on when the transmis- sion is in neutral. EBU00053 Handlebar switches EBU00054 Engine stop switch “ ENG. STOP ” Make sure that[...]

EBU00056 Start switch “ START ” The starter motor cranks the engine when this switch is pushed. c C See starting instructions prior to starting engine (see page 6-1 for details). NOTE: If the starter switch is pushed with the main switch “ON” and the engine stop switch “OFF”, the starter motor will be activated but the engine will not s[...]

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 [...]

EBU00066 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV. 4-5 a q w POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The th[...]

EBU00070 Front brake lever The front brake lever is located on the right han- dlebar. Pull it toward the handlebar to apply the front brake. EBU00072 Rear brake lever The rear brake lever is located on the left han- dlebar. Pull it toward the handlebar to apply the rear brake. 4-6 q q 1. Front brake lever 1. Rear brake lever 5VJ-9-10-1 3/26/02 7:29[...]

EBU00074 Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. 4-7 q POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV co[...]

4-8 EBU00085 Drive select lever The drive select lever is used for driving the machine either forward or in reverse. Refer to page 6-4 for drive select lever operation. EBU00092 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. q w e a q a. Drive select lever 1. Neutral 2. Forward 3. Reverse 1. Fuel tank cap 5VJ-9-10-1 3/26/0[...]

4-9 RES OFF ON EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is don[...]

EBU00094 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 oper- ation. (See page 6-1.) EBU00567 Seat To remove the seat,[...]

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. 4-11 EBU00112 w Indicates a potential hazard that could result in serious injury or death. 5VJ-9-10-1 3/26/02 7:29 PM Page 4-11[...]

5-1 PRE-OPERA TION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE Brakes • Check operation, condition and free play. 5-2 – 5-3, 8-18 – 8-23 • Adjust if necessary. Fuel • Check fuel level. • Fill with fuel if necessary. 5-3–5-4 Engine oil and • Check oil level. 5-5, 8-5 – 8-9 transmission oil • Fi[...]

5-2 EBU00472 Front and rear brakes 1. Brake levers Check for correct free play in the brake levers. If the free play is incorrect, adjust it. (See pages 8-19 – 8-23.) Check operation of the levers. They should move smoothly and there should be a firm feeling when the brake is applied. If not, have the machine inspected by a Yamaha dealer. 2. Brak[...]

EBU01085 Fuel Make sure there is sufficient gasoline in the tank. 5-3 POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a[...]

c C Use only unleaded gasoline. The use of lead- ed gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. I[...]

EBU01116 Engine and transmission oil Make sure the engine and transmission oil is at the specified level. Add oil as necessary. (See page 8-5.) c C Be sure to use motor oils that do not contain anti-friction modifiers. Passenger car motor oils (often labeled “ ENERGY CONSERVING II ” ) contain anti-friction additives which will cause clutch and/[...]

EBU00498 Chain Check the general condition of the chain and check the chain slack before every ride. Lubricate and adjust the chain as necessary. (See pages 8-22 – 8-25 for details.) EBU01083 Throttle lever Check to see that the throttle lever operates cor- rectly. It must open smoothly and spring back to the idle position when released. Have a Y[...]

EBU00157 Tires 5-7 POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or oper- ation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. HOW TO AVOID THE HAZARD 1 . The tires listed below hav[...]

5-8 EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as stan- dard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set pressure with tires cold. Set tire pressures to the foll[...]

EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. 5-9 a a. 3 mm (0.12 in) 5VJ-9-10-1 3/26/02 7:29 PM Page 5-10[...]

EBU00161 OPERA TION w Indicates a potential hazard that could result in serious injury or death. EBU00509 Starting a cold engine 1. Set the parking brake. 2. Turn the fuel cock to “ON”. 3. Turn the main switch to “ON” and the engine stop switch to “RUN”. 4. Shift the drive select lever to neutral. 6-1 6-1 POTENTIAL HAZARD Operating ATV [...]

NOTE: 8 The engine can be started only when the drive select lever is in neutral. 8 When the drive select lever is in neutral, the neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it. 5. Use the starter (choke) in reference to the figure: Position 1 : Cold engine start- ambient temperature below [...]

NOTE: If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to pre- serve battery energy. Do not crank the engine more than 10 seconds on each attempt. 7 . If the engine is started with the starter (choke) in position 1 , th[...]

EBU01152 Drive select lever operation and reverse driving c C Before shifting, stop the machine and return the throttle lever to its closed position, other- wise, the transmission may be damaged. Shifting: forward 1. Bring the machine to a complete stop and return the throttle lever to the closed posi- tion. 2. Shift the gear from neutral to forwar[...]

NOTE: When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect the ATV. 4. Check behind for people or obstacles, then release the parking brake. 5. Open the throttle lever gradually and contin- ue to watch to the rear while backing. NOTE: If the drive select lever is shifted into rever[...]

EBU00209 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. During the first 20 hours, th[...]

EBU00211 Parking When parking, stop the engine and shift into neutral. Turn the fuel cock to “OFF” and apply the parking brake. 6-7 q 1. Lock plate 2. 10 – 20 hours: Avoid prolonged operation above 3/4 throt- tle. Rev the machine freely through the gears but do not use full throttle at any time. 3. After break-in: Avoid prolonged full throttl[...]

EBU00215 Parking on a slope 1. Bring the machine to a stop by applying the brakes. 2. Stop the engine. 3. With the rear brake applied, apply the park- ing brake. 6-8 POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increas- ing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on[...]

EBU00221 Accessories and loading EBU00222 Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. 8 Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other acces- sories ma[...]

EBU00585 Loading 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. Keep the following points in mind: 8 Never exceed the weight limits shown. An overloaded ATV can be unstable. 8 Load cargo on t[...]

6-11 POTENTIAL HAZARD Overloading this ATV or carrying or tow- ing 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 pull[...]

6-12 EBU00893 w Indicates a potential hazard that could result in serious injury or death. 5VJ-9-10-1 3/26/02 7:29 PM Page 6-12[...]

7 7-1 Riding Y our AT V 5VJ-9-10-2 3/26/02 7:30 PM Page 7-1[...]

7-2 5VJ-9-10-2 3/26/02 7:30 PM Page 7-2[...]

this Owner's Manual completely and understand the operation of the controls. Pay particular attention to the safety information on pages 2-1 – 2-7. Please also read all caution and warning labels on your ATV. w Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is for recreation and u[...]

7-4 RIDE WITH CARE AND GOOD JUDGEMENT 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 perfor- mance until you are totally familiar with the ATV's handling and perfor[...]

7-5 Not recommended for children under 16 years of age. POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not rec- ommended 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 great[...]

7-6 This ATV is designed to carry operator only - passengers prohibited. POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an acci- dent, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allo[...]

Apparel POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protec- tion and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcy- cle 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 inc[...]

7-8 Do not operate after consuming alcohol or drugs. Operator's performance capability is reduced by the influence of alcohol or drugs. POTENTIAL HAZARD Operating this ATV after consuming alco- hol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Cou[...]

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. POTENTIAL HAZARD Failure to inspect the ATV before operat- ing. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always in[...]

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 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 s[...]

7-11 Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATV's handling may be adversely affected. Reduce your speed when adding additional loads. MAXIMUM LOADING LIMIT Vehicle loading limit (total weight of cargo, rider and accessories): 100 kg (220 lb) POTENTIAL HAZARD Overlo[...]

7-12 During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. 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 a[...]

7-13 Avoid wheelies and jumping. You may lose con- trol of the ATV or overturn. 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. q W ARNING 5VJ-9-10-2 3/26/02 [...]

7-14 Modifications POTENTIAL HAZARD Operating this ATV with improper modifi- cations. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situa- tions could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessori[...]

Exhaust system The exhaust system on the ATV is very hot dur- ing 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. 7-15 POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated aroun[...]

BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of con- trol. POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect han- dling and control of the ATV, and may cause the vehicle to go out of cont[...]

7-17 Do not ride on any public road, street, or high- way. Riding on public roads can result in collisions with other vehicles. 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 d[...]

Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden haz- ards which may cause the ATV to upset. 7-18 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, witho[...]

7-19 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, slip- pery or loose terrain until you have learned and[...]

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. Do not ride in areas posted "no trespassing". Do not ride on private property without getting per- mission. POTENTIAL HAZARD Operating in areas where you might not be[...]

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. Always avoid riding on paved surfaces: the ATV is designed for off-ro[...]

7-22 TURNING YOUR ATV To achieve maximum traction while riding off- road, 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 m[...]

This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesn't turn, come to a stop and then practice the procedure again. If the riding surface is slip- pery or loose, it may help to position more of your weight[...]

7-24 CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneu- ver your ATV well on flat ground before attempt- ing 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 su[...]

7-25 7-25 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. Never climb hills with excessively slipp[...]

7-26 7-26 If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of con[...]

7-27 7-27 5VJ-9-10-2 3/26/02 7:30 PM Page 7-27[...]

7-28 If your ATV has stalled or stopped and you believe you can continue up the hill, restart care- fully 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. If you start to roll [...]

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 proce- dure described in the Owner's Manual. 5VJ-9-10-2 3/26/02 7:30 PM Page 7-29[...]

7-30 7-30 RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely[...]

7-31 7-31 OK 5VJ-9-10-2 3/26/02 7:30 PM Page 7-31[...]

7-32 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 ter- rain that may upset your balance. As you tr[...]

7-33 7-33 Shift your weight to the uphill side of the ATV. OK 5VJ-9-10-2 3/26/02 7:30 PM Page 7-33[...]

7-34 7-34 CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 20 cm (7.9 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and carefully. POTE[...]

Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. c C 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[...]

7-36 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. POTENTIAL HAZ[...]

7-37 7-37 5VJ-9-10-2 3/26/02 7:30 PM Page 7-37[...]

7-38 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. If the rear w[...]

7-39 7-39 With practice, over a period of time, skill at con- trolled 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 maneu- vers should always be avoided on extremely slippery surfaces such as ice, since all control may be los[...]

7-40 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. WHAT TO DO ... 8 If your ATV doesn't turn when you want it to: Bring the ATV to a stop and practice the turn- ing maneuvers again. Be sure you are putting your weight on the footboard to the outside o[...]

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 [...]

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 obliga- tion of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages. EBU00257 Owner’s [...]

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 suffi- cient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts. NOTE[...]

8-3 EBU00261 PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY ITEM ROUTINE 1366 1 month months months months year Valves* • Check valve clearance. 11 1 1 • Adjust if necessary. • Check condition. Spark plug • Adjust gap and clean. 1111 1 • Replace if necessary. Air filter element • Clean. Every 20 – 40 hours (for engine and V-belt • R[...]

8-4 INITIAL EVERY ITEM ROUTINE 1366 1 month months months months year Brakes* • Check operation. 1111 1 • Adjust if necessary. V-belt* • Check operation • Replace if damage or excessive wear. 11 Wheels* • Check balance/damage/runout. 11 1 1 • Replace if necessary. Wheel bearings* • Check bearing assembly for looseness/damage. 11 1 1 ?[...]

EBU00896 Engine oil Engine oil level measurement 1. Place the machine on a level surface. 2. Warm up the engine for several minutes and stop it. 3 . Remove the dipstick and wipe it off with a clean rag. Insert the dipstick in the filler hole without screwing it in. NOTE: Wait a few minutes until the oil level settles before checking. 4. Remove the [...]

4. Remove the dipstick and drain bolt to drain the oil. c C When removing the drain bolt, the compres- sion spring, oil strainer and O-ring will fall out. Take care not to lose these parts. 5. Clean the oil strainer with solvent. 6. Inspect the O-ring and replace it if damaged. 7. Install the O-ring, oil strainer, compression spring and drain bolt.[...]

EBU00891 Transmission oil Transmission oil measurement 1. Place the machine on a level surface. 2. Remove the screw and check the oil level. It should be up to the brim of the hole. If the level is low, remove the oil filler bolt and add oil to raise it to the proper level. 8. Fill the engine with oil and install the dipstick. c C Be sure no foreig[...]

3 Install the screw and oil filler bolt and tighten to specification. Transmission oil replacement 1. Place the machine on a level surface. 2. Place a container under the engine. 3 . Remove the oil filler bolt and drain bolt to drain the oil. 4. Install the drain bolt and tighten to specifica- tion. 8-8 q Tightening torque: Screw: 16 Nm (1.6 m 0 kg[...]

EBU00870 Spark plug inspection The spark plug is an important engine compo - nent and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder. Do not attempt to diagnose such pro[...]

Before installing the spark plug, measure the electrode gap with a feeler gauge and adjust to specification. When installing the spark plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads and tighten to the specified torque. 8-10 a Spark plug gap: 0.6 – 0.7 mm (0.02 – 0.03 in) Tightening torque: Spark [...]

8-11 1. Remove the seat. 2. Remove the breather hose, and then loosen the clamp screw. 3. Remove the air filter case cover. w e q 1. Air filter case cover 2. Breather hose 3. Clamp EBU01142 Engine and V-belt case air filter element cleaning Both air filter elements should be cleaned at the specified intervals in the periodic maintenance chart. Engi[...]

4. Remove the air filter element, and separate it from the frame. 5. Wash the element gently but thoroughly in solvent. 6. Squeeze the excess solvent out of the air fil- ter element and let it dry. c C Do not twist the air filter element when squeezing it. 8-12 POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter elem[...]

7. Inspect the air filter element. If damaged, replace it. 8 . Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter ele- ment. If foam air filter oil is not available, engine oil may be used. NOTE: The element should be wet but not dripping. 9. Install the air filter element on the frame. 10. Install the air filte[...]

NOTE: The air filter element should be cleaned every 20 – 40 hours. It should be cleaned and lubricat- ed more often if the machine is operated in extremely dusty areas. Each time air filter ele- ment maintenance is performed, check the air inlet to the air filter case for obstructions. Check the air cleaner rubber joint to the carburetor and man[...]

2. Remove the air filter element cover. 3. Pull out the air filter element. 4. Tap the element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air. If the air filter element is damaged, replace it. 5. Assemble by reversing the removal proce- dure. Be sure the air filter element is seated properly against the[...]

2. Connect the tachometer to the spark plug lead, and then set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw in direction a to increase the engine speed, and in direction b to decrease the engine speed. EBU00303 Valve clearance adjustment The correct valve clearance changes with use, resulting in improp[...]

EBU00307 Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 3 – 5 mm (0.12 – 0.20 in). 3. Tighten the locknut. 8-17 a q w 1. Locknut 2. Adjusting bolt a. Free play 5VJ-9-10-3 3/26/02 7:31 PM Page 8-1[...]

EBU00308 Front and rear brake shoe inspection A wear indicator is provided on each brake. The indicators allows checking of brake shoe wear without disassembling the brake. Apply the brake and check the position of the indicator. If the indicator reaches the wear limit line, ask a Yamaha dealer to replace the shoes as a set. 8-18 q w w q Front Rear[...]

8-19 EBU01149 Front brake lever free play adjustment NOTE: Before adjusting the brake lever free play, inspect the front brake shoes. The front brake lever free play should be adjust- ed to 5 – 8 mm (0.2 – 0.3 in) at the brake lever pivot. If the free play is incorrect, adjust it as fol- lows. 1 . Remove the front cover by removing the screws a[...]

3 . Loosen the locknut and fully turn in the adjusting bolt at the front brake lever. 8-20 w e w e q 1. Locknut 2. Adjusting bolt q w 1. Front fender 2. Bolt ( × 2) 3. Screw ( × 6) 5VJ-9-10-3 3/26/02 7:31 PM Page 8-21[...]

4. Make sure the brake cable joint in the equal- izer is straight when the brake is applied. If not, loosen the locknut and turn the adjust- ing nuts at the front brake cables until the cable joint becomes straight. 5. Tighten the locknut on each brake cable. 8-21 q w q w 1. Locknut ( × 2) 2. Adjusting nut ( × 2) q w a = a ´ a a ´ 1. Equalizer [...]

6. Turn the adjusting bolt at the brake lever until the specified free play is obtained. 7. Tighten the locknut at the brake lever. 8. Install by reversing the removal procedure. 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 H[...]

8-23 EBU00965 Rear brake adjustment Brake lever free play should be 5 – 8 mm (0.2 – 0.3 in) at the brake lever pivot. If the free play is incorrect, adjust as follows: Turn the adjusting nut on the brake hub in direc- tion a to decrease play, and in direction b to increase play. a a b q a. Free play 1. Adjusting nut 5VJ-9-10-3 3/26/02 7:31 PM P[...]

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: 8 Make sure the brakes operate smoothly and that the free play is correct. 8 Make sure the brakes do not drag. Replacement of brake components requires prof[...]

8-25 EBU01146 Drive chain slack adjustment 1 . Loosen the hub stopper bolt locknut and then the hub stopper bolt. 2 . Loosen the upper and lower axle holding bolts. 3 . Loosen the locknut. To tighten the drive chain, turn the adjusting bolt in direction a . To loosen the drive chain, turn the adjusting bolt in direction b , and then push the wheels[...]

4. After adjusting, be sure to tighten the lock- nut and the axle holding bolts. 5. Finger tighten the hub stopper bolt and tight- en the hub stopper bolt locknut. c C If measurement A A of the drive chain adjust- ing bolt is less than 27 mm (1.06 in), ask a Yamaha dealer to replace the drive chain. Tightening torque: Locknut: 15.5 Nm (1.55 m 0 kgf[...]

8-27 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant. c C Do not use engine oil or any other lubricants for the drive chain, as they may contain sub- stances that could damage the O-rings. EBU00805 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals s[...]

EBU00355 Draining the V-belt compartment If water leaks into the V-belt compartment such as when the machine is driven in water, remove the drain screw on the bottom of compartment and drain the water. Be sure to drive slowly until the V-belt becomes dry. If slipping is noticed, ask a Yamaha dealer to inspect. EBU00356 Cable inspection and lubricat[...]

8-29 EBU00725 Brake lever lubrication Lubricate the pivoting parts of the brake levers. EBU00728 Knuckle shaft, lower arms and steering shaft lubrication Lubricate the pivot points using a grease gun. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Recommended lubricant: Lithium-soap-based grease 5VJ-9-10-3 3/26/02 7:31 PM Pag[...]

EBU01112 Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. EBU01150 Wheel installation 1. Install the wheel and the nuts. NOTE: Tapered wheel nuts are used for both front and rear wheels. Install the nut with its tapered side towards the whe[...]

8-31 EBU00378 Battery Check the level of the battery fluid and see if the terminals are tight. Add distilled water if the fluid level is low. c C Do not leave or store the battery on its side. When inspecting the battery, be sure the breather hose is routed correctly. If it touch- es the frame or exists in such a way as to cause battery electrolyte[...]

POTENTIAL HAZARD Failure to handle batteries or battery elec- trolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in bat- tery 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[...]

8-33 EBU00382 Replenishing the battery fluid A poorly maintained battery will corrode and dis- charge quickly. The battery fluid should be checked at least once a month. 1. The level should be between the upper and lower level marks. Use only distilled water if refilling is necessary. 2. Disconnect the negative ( – ) lead. 3. Disconnect the posit[...]

EBU00388 Fuse replacement 1. The fuse case is located on the right side of the machine. 2. If the fuse is blown, turn off the main switch and install a new fuse of the specified amperage. Then turn on the switches, if the fuse immediately blows again, consult a Yamaha dealer. c C To prevent accidental short-circuiting, turn off the main switch when[...]

8-35 EBU01151 Replacing the headlight bulb If the headlight bulb burns out, replace the bulb as follows. 1. Remove the screws holding the headlight unit assembly to the headlight body. 2 . Remove the headlight bulb holder cover, turn the bulb holder counterclockwise and remove the defective bulb. 1 1 1. Screw ( × 2) 1. Headlight bulb holder 5VJ-9-[...]

3. Put a new headlight bulb into position and secure it in place with the bulb holder. 4. Install the headlight bulb holder cover. c C Make sure the bulb holder cover is securely fitted over the bulb holder and seated against the reflector. 5 . Install the headlight unit assembly by installing the screws. 6. Adjust the headlight beam if necessary. [...]

8-37 EBU00861 Tail/brake light bulb replacement 1 . Remove the bulb holder (together with the bulb) by turning it counterclockwise. 2 . Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 3. Install a new bulb in the bulb holder by push- ing it inward and turning it clockwise. 4. Install the bulb hol[...]

EBU01155 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the screws. 1. Screw ( × 2) q EBU00410 Headlight beam adjustment c C It is advisable to have a Yamaha dealer make this adjustment. Vertical adjustment: To raise the beam, loosen the adjusting screw and pull the headlight ass[...]

8-39 2. Remove the tailpipe by pulling it out of the muffler. 3 . Tap the tailpipe lightly, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe. 4. Insert the tailpipe into the muffler and align the screw holes. 5. Install the screws and tighten them. 1. Tailpipe 2. Spark arrester w q POTENTIAL HAZARD[...]

EBU00412 Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any prob- lem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requi[...]

EBU00440 Troubleshooting chart 1. Fuel Check if there is fuel in the fuel tank. 2. Compression Use electric starter to see if there is compression. 3. Ignition Remove plug and check electrodes. Wet Wipe clean with dry cloth. Dry Attach plug cap and ground to chassis. Use electric starter. Spark weak. Spark good. Ignition system normal. No spark. As[...]

EBU00417 CLEANING AND STORAGE A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may b[...]

7. Clean the seat with a vinyl upholstery clean- er to keep the cover pliable and glossy. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or pro- tective finish. When finished, start the engine and let it idle for several minutes. 9-2 PO[...]

EBU00525 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive proce- dures to guard against deterioration. After thor- oughly cleaning the machine, prepare for stor- age as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equivalent pro[...]

EBU00428 SPECIFICA TIONS Model YFA1 Dimension: Overall length 1,640 mm (64.6 in) Overall width 965 mm (38.0 in) Overall height 980 mm (38.6 in) Seat height 690 mm (27.2 in) Wheel base 1,080 mm (42.5 in) Minimum ground clearance 145 mm ( 5.7 in) Minimum turning radius 2,900 mm (114.2 in) Basic weight: With oil and full fuel tank 144 kg (318 lb) Engi[...]

Model YFA1 Engine oil/transmission oil: Type Recommended engine oil/transmission API Service SE, SF, SG type or higher oil classification: Quantity Engine oil: Periodic oil change 1.25 L (1.10 lmp qt, 1.32 US qt) Total amount 1.45 L (1.28 lmp qt, 1.53 US qt) Transmission oil: 0.6 L (0.53 lmp qt, 0.63 US qt) c C Be sure to use motor oils that do not[...]

Model YFA1 Air filter: for engine Wet type element for V-belt compartment Dry type element Fuel: Type UNLEADED GASOLINE ONLY Tank capacity 7.0 L (1.54 Imp gal, 1.8 US gal) Reserve amount 1.3 L (0.29 Imp gal, 0.34 US gal) Carburetor: Type/manufacturer VM18SH/MIKUNI Spark plug: Type/manufacturer CR7HS/NGK Gap 0.6 – 0.7 mm (0.02 – 0.03 in) Clutch:[...]

Model YFA1 Chassis: Frame type Steel tube Caster angle 6 ° Trail 15 mm (0.59 in) Tire: Type Tubeless Size: Front AT20 × 7 - 8 Rear AT22 × 10 - 8 Manufacturer/type: Front DUNLOP/KT536A Rear DUNLOP/KT537A Brake: Front brake type Drum brake Operation Right hand operation Rear brake type Drum brake Operation Left hand operation Suspension: Front Swi[...]

Model YFA1 Wheel travel: Front 70 mm (2.8 in) Rear 80 mm (3.2 in) Electrical: Ignition system C.D.I. Charging system A.C. Magneto Battery type/voltage, capacity 12N12C-4A-2/12V, 12Ah Headlight type: Bulb Bulb voltage, wattage × quantity: Headlight 12V, 25 W/25 W × 1 Tail/brake light 12V, 5 W/21W × 1 Indicator light: Neutral 12V, 3.4 W × 1 Rever[...]

EBU00430 NOISE REGULA TION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inopera- tive 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 no[...]

EBU00431 MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work. MAINTENACE INTERVAL 1 Month 3 [...]

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EBU00436 w Indicates a potential hazard that could result in serious injury or death. 5VJ-9-10-3 3/26/02 7:32 PM Page 14-4[...]

EBU00437 PROTECT YOUR INVESTMENT 5VJ-9-10-3 3/26/02 7:32 PM Page 14-6[...]

w This ATV should not be ridden by anyone under 16 years of age. PRINTED IN JAPAN 2002·3–0.9 × 1 ! (E) OWNER’S MANUAL 5VJ-28199-10 YFA1R(C) READ THIS MANUAL CAREFULLY! It contains important safety information. PRINTED ON RECYCLED PAPER LIT-11626-16-04 YAMAHA MOT OR CO. , L TD. Improper ATV use can result in SEVERE INJURY or DEATH. q W ARNING [...]