Yamaha YFM80GW manual

This A This ATV should not be ridden by anyone under 12 years of age. OWNER’S MANUAL LIT -1 1626-20-06 2D3-28199-13 YFM80GW WARNING READ THIS MANUAL CAREFULLY! It contains important safety information.[...]

EBU17091[...]

EBU17170 INTRODUCTION EBU17240 Congratulations on your purchase of the Yamaha YFM80GW. 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 mad[...]

in skills, physical abilities and judgment. Some children may not be able to operate an ATV safely. Parents should supervise their child’s use of the ATV at all times. Parents should permit continued use only if they determine that the child has the ability to operate the ATV safely. Your ATV was delivered with an adjustable speed limiter and als[...]

EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: * Product and specifications are subject to change without notice. The Safety Alert Symbol means A TTENTION! BE[...]

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 m[...]

W ARNING EWB00010 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 .....................[...]

Starting a warm engine ............................. 6-3 Shifting ...................................................... 6-3 Engine break-in ......................................... 6-5 Parking ...................................................... 6-6 Parking on a slope .................................... 6-6 Accessories and loading ............[...]

Removing a wheel ................................... 8-36 Installing a wheel ..................................... 8-36 Troubleshooting ...................................... 8-37 Troubleshooting chart ............................. 8-38 CLEANING AND STORAGE .......................... 9-1 Cleaning ....................................................[...]

1-1 1 2 3 4 5 6 7 8 9 10 11 EBU17430 SAFETY INFORMATION EBU17601 AN ATV IS NOT A TOY AND CAN BE HAZARD- OUS 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 pr[...]

1-2 1 2 3 4 5 6 7 8 9 10 11 or the riding conditions. Always go at a speed 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. Al- ways follow the inspection and main[...]

1-3 1 2 3 4 5 6 7 8 9 10 11 backwards when climbing a hill. To avoid stall- 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 up- hill. Turn the ATV around and remou[...]

1-4 1 2 3 4 5 6 7 8 9 10 11 EWB00030 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 ex- haust pipe/muffler when refueling. Never refuel while smoking, or in the vicinity of sparks, open flames, or other sources of [...]

2-1 1 2 3 4 5 6 7 8 9 10 11 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 2 3 4 5 6[...]

2-2 1 2 3 4 5 6 7 8 9 10 11 EBU17670 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer. W ARNING UNDER 12 12 NEVER 12 16 W ARNING I[...]

2-3 1 2 3 4 5 6 7 8 9 10 11 W ARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS O F CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. OPERATING TIRE PRESSURE : Set with tires cold Recommended : FRONT : 20 kPa, { 0.20 kgf/cm 2 } 2.9 psi REAR : 20 kPa, { 0.20 kgf/cm 2 } 2.9 psi Minimum : FRONT : 17 kPa, { 0.17 kgf/cm 2 } 2.5 ps[...]

3-1 1 2 3 4 5 6 7 8 9 10 11 EBU17680 DESCRIPTION EBU17690 Left view EBU17700 Right view 1. Fuel coc k 2. Rear carrier 3. Rear wheel 4. F ootboard 5. Shift pedal 6. Chok e 7. F ront wheel 1 3 4 5 7 2 6 1. Spark arrester 2. Seat 3. P anel 4. Brak e pedal 5. F ootboard 1 2 3 4 5[...]

3-2 1 2 3 4 5 6 7 8 9 10 11 EBU17712 Controls and instruments NO TE: The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake le v er 2. P arking brak e 3. Neutral indicator light 4. F ront brak e lev er 5. Throttle le v er 6. Main s witch 7. Fuel tank cap 8. Handlebar s witches 1 2 3 4 5 6 7 8[...]

4-1 1 2 3 4 5 6 7 8 9 10 11 EBU17720 INSTRUMENT AND CONTROL FUNCTIONS W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU17740 Main switch The positions of the main switch are as follows: ON All electrical systems are supplied with power, and the engine can be started. The key cannot be re- moved. OFF Al[...]

4-2 1 2 3 4 5 6 7 8 9 10 11 EBU17780 Indicator light EBU17860 Neutral indicator light “ ” This indicator light comes on when the transmis- sion is in the neutral position. EBU18060 Handlebar switches EBU18070 Engine stop switch “ENG. STOP” Set this switch to “RUN” before starting the engine. The engine stop switch controls the ignition [...]

4-3 1 2 3 4 5 6 7 8 9 10 11 EBU18090 Start switch “START” Push this switch to crank the engine with the start- er. CAUTION: ECB00050 See the starting instructions on page 6-1 prior to starting the engine. EBU18270 Throttle lever Once the engine is running, movement of the throt- tle lever will increase the engine speed. Regulate the speed of th[...]

4-4 1 2 3 4 5 6 7 8 9 10 11 EWB00200 EBU18331 Speed limiter and air intake restrictor plate Your ATV was delivered with an adjustable speed limiter and an air intake restrictor plate. Yamaha recommends that all beginning riders start off with the speed limiter adjusting screw fully turned in and the air intake restrictor plate installed to limit th[...]

4-5 1 2 3 4 5 6 7 8 9 10 11 3. Tighten the locknut. EWB00180 EBU18391 Front brake lever The front brake lever is located on the right handle- bar. To apply the front brake, pull the brake lever toward the handlebar grip. EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is loc[...]

4-6 1 2 3 4 5 6 7 8 9 10 11 handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip. EBU18450 Parking brake Use the parking brake before starting the engine or parking the ATV, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze[...]

4-7 1 2 3 4 5 6 7 8 9 10 11 EWB00170 EBU18550 Shift pedal This ATV is equipped with a constant-mesh 3- speed transmission. The shift pedal is located on the left side of the engine. Neutral is at the bottom position. 1. P arking brake loc k plate W ARNING POTENTIAL HAZARD Improper use of the parking brake. 1 WHAT CAN HAPPEN The ATV could start movi[...]

4-8 1 2 3 4 5 6 7 8 9 10 11 EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. EBU18730 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. 1. Shift pedal 2. Neutral position 1 N 2 3 2 1 1. Fuel tank cap 1[...]

4-9 1 2 3 4 5 6 7 8 9 10 11 CAUTION: ECB00070 Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a[...]

4-10 1 2 3 4 5 6 7 8 9 10 11 EWB00270 EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car- buretor while also filtering it. The fuel cock lever positions are explained as fol- lows and shown in the illustrations. OFF With the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position w[...]

4-11 1 2 3 4 5 6 7 8 9 10 11 ON With the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding. RES This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of[...]

4-12 1 2 3 4 5 6 7 8 9 10 11 Move the choke in direction (b) to turn off the choke. See the “Starting a cold engine” section on page 6- 1 for proper operation. EBU18870 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear. To install the seat Insert the projection on the front of the seat into the seat holder[...]

4-13 1 2 3 4 5 6 7 8 9 10 11 EBU18950 Carrier ● Do not exceed the load limit of 5.0 kg (11 lb) for the carrier. ● Do not exceed the maximum load of 95.0 kg (209 lb) for the ATV. W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. 1. Projection 2. Seat holder 2 1[...]

5-1 1 2 3 4 5 6 7 8 9 10 11 EBU19200 PRE-OPERATION CHECKS EBU19210 Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table. NO TE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determ[...]

5-2 1 2 3 4 5 6 7 8 9 10 11 EWB00470 Wheels and tires ● Check wheel condition, and replace if damaged. ● Check tire condition and tread depth. Replace if necessar y . ● Check air pressure . Correct if necessary . 5-5, 5-6, 5-7 Brake and shift pedals ● Make sure that operation is smooth. Lubricate pedal pivoting points if necessary . 8-31 Br[...]

5-3 1 2 3 4 5 6 7 8 9 10 11 EBU19530 Fuel Make sure that there is sufficient fuel in the tank. (See page 4-8.) EWB00500 EBU19560 Engine oil Make sure that the engine oil is at the specified lev- el. Add oil as necessary. (See page 8-10.) EBU19590 Final gear oil Make sure that the final gear oil is at the specified level. Add oil as necessary. (See [...]

5-4 1 2 3 4 5 6 7 8 9 10 11 EWB00530 EBU19761 Throttle lever Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary. W ARNING POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could le[...]

5-5 1 2 3 4 5 6 7 8 9 10 11 EBU19781 Tires EWB00561 W ARNING 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 opera- tion of this ATV with improper or uneven tire pressure, may cause loss of control, increas- ing your risk of accident. HOW TO AVO[...]

5-6 1 2 3 4 5 6 7 8 9 10 11 EBU19820 Measuring the tire pressure Use the low-pressure tire gauge. NO TE: 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 the tire pressure when the tires[...]

5-7 1 2 3 4 5 6 7 8 9 10 11 the tire pressures to the following specifications: EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm (0.12 in). EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and sw[...]

6-1 1 2 3 4 5 6 7 8 9 10 11 EBU19870 OPERATION W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU19890 EWB00610 EBU20211 Starting a cold engine EWB00620 CAUTION: ECB00150 See the “Engine break-in” section on page 6-5 prior to operating the engine for the first time. 1. Set the parking brake. 2. Turn[...]

6-2 1 2 3 4 5 6 7 8 9 10 11 light does not come on, have a Yamaha deal- er check the electrical circuit. NO TE: This model is equipped with an ignition circuit cut- off system. The engine can be started under the following conditions. ● The transmission is in neutral. ● The rear brake lever is applied with the transmis- sion in any gear. Howeve[...]

6-3 1 2 3 4 5 6 7 8 9 10 11 crank the engine more than 10 seconds on each attempt. 7. If the engine is started with the choke in posi- tion (1), the choke should be returned to posi- tion (2) to warm up the engine. If the engine is started with the choke in position (2), keep the choke in this position to warm up the engine. CAUTION: ECB00160 For m[...]

6-4 1 2 3 4 5 6 7 8 9 10 11 EBU20600 To start out and accelerate 1. Release the throttle lever. CAUTION: ECB00200 Always close the throttle before shifting gears, otherwise damage to the engine and drive train may result. 2. Shift into first gear and release the shift pedal. 3. Open the throttle gradually. 4. Once the ATV has attained adequate spee[...]

6-5 1 2 3 4 5 6 7 8 9 10 11 EWB00650 CAUTION: ECB00190 Even with the transmission in the neutral posi- tion, do not coast for long periods of time with the engine off, and do not tow the ATV for long distances. The transmission is properly lubri- cated only when the engine is running. Inade- quate lubrication may damage the transmission. EBU20670 E[...]

6-6 1 2 3 4 5 6 7 8 9 10 11 20 hours and beyond The ATV can now be operated normally. CAUTION: ECB00220 If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV. EBU20721 Parking When parking the ATV, stop the engine, shift into first gear, apply the parking brake, and then turn the fuel c[...]

6-7 1 2 3 4 5 6 7 8 9 10 11 1. Bring the ATV to a stop by applying the brakes in first gear. 2. Stop the engine. 3. With the rear brake lever and brake pedal ap- plied, apply the parking brake and slowly re- lease the brake pedal. EBU20910 Accessories and loading EBU20920 Accessories Accessories can affect the handling and control of your ATV. Keep[...]

6-8 1 2 3 4 5 6 7 8 9 10 11 limits your ability to move around on the seat, or one that limits your view. ● Use extra caution when riding an ATV with ac- cessories. The ATV may handle differently than it does without accessories. EBU21110 Loading As originally equipped, this ATV is not designed to tow a trailer. If you choose to add accessories s[...]

6-9 1 2 3 4 5 6 7 8 9 10 11 handling of the ATV. EWB00750 W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. W ARNING 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 Nev[...]

7-1 1 2 3 4 5 6 7 8 9 10 11 EBU21131 RIDING YOUR ATV[...]

7-2 1 2 3 4 5 6 7 8 9 10 11 W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU21562 GETTING TO KNOW YOUR ATV This ATV is for recreation use. This section, Riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this section, however, are [...]

7-3 1 2 3 4 5 6 7 8 9 10 11 EWB01280 Riding your ATV requires skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers. Not recommended for children under 12 years of age. EWB01210 W ARNING POTENTIAL HAZARD Operating this ATV without proper instruc- tion. WHA[...]

7-4 1 2 3 4 5 6 7 8 9 10 11 This ATV is designed to carry operator and cargo only – passengers prohibited. EWB00910 W ARNING 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 passen- ger. HOW TO AVOID THE HA[...]

7-5 1 2 3 4 5 6 7 8 9 10 11 Apparel EWB00920 W ARNING POTENTIAL HAZARD Operating this ATV without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an acci- dent. Operating without ey[...]

7-6 1 2 3 4 5 6 7 8 9 10 11 Do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear: ● eye protection (goggles or face shield) ● gloves ● boots ● long-sl[...]

7-7 1 2 3 4 5 6 7 8 9 10 11 EWB00930 Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety. EWB00940 EWB00950 W ARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to [...]

7-8 1 2 3 4 5 6 7 8 9 10 11 W ARNING EWB00010 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. EWB00960 Speed limiter For riders less experienced with this model, the throttle lever housing is equipped with a speed lim- iter. The speed limiter keeps the t[...]

7-9 1 2 3 4 5 6 7 8 9 10 11 see page 8-18. Loading and accessories Use extra caution when riding the ATV with addi- tional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Re- duce your speed when adding additional loads. EWB00970 1. Loc knut 2. Adjusting scre w 1 2 MAXIMUM LOADING LIMIT ATV loading limit (total [...]

7-10 1 2 3 4 5 6 7 8 9 10 11 During operation Always keep your feet on the footboards during op- eration, otherwise they may contact the rear wheels. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and se- curely attached. Reduce speed when carrying cargo or pull- ing a trailer. Allow[...]

7-11 1 2 3 4 5 6 7 8 9 10 11 EWB00980 Avoid wheelies and jumping. You may lose control of the ATV or overturn. EWB00990 Modifications EWB01000 W ARNING 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[...]

7-12 1 2 3 4 5 6 7 8 9 10 11 Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. EWB01010 WHAT CAN HAPPEN Improper installation of accessories or mod- ification of this ATV may c[...]

7-13 1 2 3 4 5 6 7 8 9 10 11 BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. EWB01020 Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. EWB01030 W ARNING POTENTIAL HAZARD Operating this ATV on paved surfac[...]

7-14 1 2 3 4 5 6 7 8 9 10 11 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. EWB01040 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 i[...]

7-15 1 2 3 4 5 6 7 8 9 10 11 EWB01050 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. W ARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause[...]

7-16 1 2 3 4 5 6 7 8 9 10 11 EWB01060 Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. 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 proce[...]

7-17 1 2 3 4 5 6 7 8 9 10 11 the shift pedal. Remember that the engine and ex- haust 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, lift the shift pedal to the 1st gear position and then release the parking brake. Apply the throttle slowly and smoothly. Th[...]

7-18 1 2 3 4 5 6 7 8 9 10 11 lowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. EWB01220 As you approach a curve, slow down and begin to turn the handlebars in the desired directio[...]

7-19 1 2 3 4 5 6 7 8 9 10 11 Once you have learned this technique, you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over [...]

7-20 1 2 3 4 5 6 7 8 9 10 11 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. HOW TO AVOID THE HAZARD Always follow proper procedures for climb- ing hills as desc[...]

7-21 1 2 3 4 5 6 7 8 9 10 11 EWB01190 If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the up- hill side. Physically turn the ATV around and then descen[...]

7-22 1 2 3 4 5 6 7 8 9 10 11 immediately on the uphill side. EWB01231 RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as pos- sible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the en- gine compression to do most of the braking for you. Impr[...]

7-23 1 2 3 4 5 6 7 8 9 10 11 to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- stacles which may appear. EWB01130 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 sk[...]

7-24 1 2 3 4 5 6 7 8 9 10 11 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. E[...]

7-25 1 2 3 4 5 6 7 8 9 10 11 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 care- fully. EWB01150 Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. W ARNING POTENTI[...]

7-26 1 2 3 4 5 6 7 8 9 10 11 CAUTION: ECB00240 After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. L[...]

7-27 1 2 3 4 5 6 7 8 9 10 11 EWB01160 SLIDING AND SKIDDING Care should be used when riding on loose or slip- pery surfaces since the ATV may slide. If unex- pected 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 wi[...]

7-28 1 2 3 4 5 6 7 8 9 10 11 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 re- duced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all[...]

7-29 1 2 3 4 5 6 7 8 9 10 11 Lean more into the turn to regain balance. If nec- essary, gradually let off the throttle and/or steer to the outside of the turn. (See page 7-17.) ● If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have cor[...]

8-1 1 2 3 4 5 6 7 8 9 10 11 EBU21640 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21660 Safety is an obligation of the owner. Periodic in- spection, adjustment and lubrication will keep your ATV in the safest and best operating condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages.[...]

8-2 1 2 3 4 5 6 7 8 9 10 11 The service information included in this manual and the tools provided in the owner’s tool kit are in- tended to assist you in the performance of preven- tive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. NO TE: If you do[...]

8-3 1 2 3 4 5 6 7 8 9 10 11 EBU21741 Periodic maintenance chart for the emission control system NO TE: ● 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 inter- vals. However, keep in mind that if the AT[...]

8-4 1 2 3 4 5 6 7 8 9 10 11 6 * Exhaust system ● Check f or leakage and replace gasket(s) if neces- sary . ● Check f or looseness and tighten all screw clamps and joints if necessary . √√√ 7 Spark arrester ● Clean. √√√ NO . ITEM CHECK OR MAINTENANCE JOB INITIAL EVER Y Whichev- er comes first month 1366 1 2 km (mi) 320 (200) 1300 [...]

8-5 1 2 3 4 5 6 7 8 9 10 11 EBU21862 General maintenance and lubrication chart NO . ITEM CHECK OR MAINTENANCE JOB INITIAL EVER Y Whichev- er comes first month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 * Timing chain ● Check chain tension. ● Adjust if necessary . √ √√√ 2 Air ?[...]

8-6 1 2 3 4 5 6 7 8 9 10 11 10 * Chassis fasteners ● Make sure that all nuts , bolts, and scre ws are properly tightened. √√√√√ 11 * Shock absorber assemblies ● Check operation and correct if necessary . ● Check f or oil leakage and replace if necessary . √√√ 12 * Knuckle shafts ● Lubricate with lithium-soap-based grease. ?[...]

8-7 1 2 3 4 5 6 7 8 9 10 11 EBU23060 NO TE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 20 * Battery ● Check electrolyte le v el and specific gravity , and correct if necessary . ● Make sure that the breather hose is properly routed. √√√√√ NO . ITEM CHECK OR MAINTENANCE JOB INITIAL EV[...]

8-8 1 2 3 4 5 6 7 8 9 10 11 W ARNING EWB00010 Indicates a potential hazard that could result in serious injury or death. EBU23210 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- d[...]

8-9 1 2 3 4 5 6 7 8 9 10 11 To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medi- um-to-light tan (the ideal color when the ATV is ridden normally). NO TE: If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to di- agnose such problems y[...]

8-10 1 2 3 4 5 6 7 8 9 10 11 and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. NO TE: 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 [...]

8-11 1 2 3 4 5 6 7 8 9 10 11 NO TE: The engine oil should be between the minimum and maximum level marks. 6. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type to raise it to the correct level. 7. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap. To change th[...]

8-12 1 2 3 4 5 6 7 8 9 10 11 en it to the specified torque. 7. Add the specified amount of the recommend- ed engine oil, and then install and tighten the engine oil filler cap. CAUTION: ECB00300 ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel[...]

8-13 1 2 3 4 5 6 7 8 9 10 11 EBU23403 Final gear oil The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrica[...]

8-14 1 2 3 4 5 6 7 8 9 10 11 4. Install the drain bolt, and then tighten it to the specified torque. 5. Add the specified amount of the recommend- ed final gear oil, and then check the oil level. CAUTION: ECB00420 Be sure no foreign material enters the final gear case. 6. Install and tighten the oil filler cap. 7. Check the final gear case for oil [...]

8-15 1 2 3 4 5 6 7 8 9 10 11 ter case. 1. Remove the quick fasteners. 2. Remove the panel by sliding it forward and pulling it off as shown. 1. Air filter case check hose 1 1. Quic k f astener 1 1[...]

8-16 1 2 3 4 5 6 7 8 9 10 11 3. Remove the air filter case cover by unhooking the holders. 4. Unhook the holder holding the air filter ele- ment, and then pull out the sponge material from the air filter element. 1. P anel 1 1 1. Air filter case cov er 2. Air filter case holder 1 2 2[...]

8-17 1 2 3 4 5 6 7 8 9 10 11 5. Wash the sponge material gently but thor- oughly in solvent. EWB01900 6. Squeeze the excess solvent out of the sponge material and let it dry. CAUTION: ECB00440 Do not twist the sponge material when squeez- ing it. 7. Check the sponge material and replace it if damaged. 8. Apply Yamaha foam air filter oil or other qu[...]

8-18 1 2 3 4 5 6 7 8 9 10 11 NO TE: The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar- eas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions. CAUTION: ECB00460 ● Make sure t[...]

8-19 1 2 3 4 5 6 7 8 9 10 11 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 4. Insert the tailpipe into the muffler and align the screw holes. 5. Install the screws and ti[...]

8-20 1 2 3 4 5 6 7 8 9 10 11 EWB01910 EBU23940 Adjusting the carburetor The carburetor should be checked and, if neces- sary, adjusted at the intervals specified in the peri- odic maintenance and lubrication chart. The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments sh[...]

8-21 1 2 3 4 5 6 7 8 9 10 11 NO TE: The engine is warm when it quickly responds to the throttle. 2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if neces- sary, adjust it to specification by turning the throttle stop screw at the carburetor. To in- crease the engine idling speed, turn the throt- tle stop screw[...]

8-22 1 2 3 4 5 6 7 8 9 10 11 EBU24050 Timing chain The timing chain stretches with use, resulting in im- proper valve timing and engine noise. To prevent this from occurring, the timing chain tensioner must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart. EBU24060 Valve clearance The v[...]

8-23 1 2 3 4 5 6 7 8 9 10 11 Front brake Rear brake EBU24320 Adjusting the front brake lever free play The brake lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. NO TE: Before adjusting the brake lever free play, check the front brake shoes for wear. The brake [...]

8-24 1 2 3 4 5 6 7 8 9 10 11 12.0 mm (0.39–0.47 in) as shown. If the free play is incorrect, adjust it as follows. 1. Loosen the upper locknut and fully turn in the upper adjusting bolt. 2. Loosen the lower locknut. 3. Turn the lower adjusting bolt in direction (a) to increase the free play, and in direction (b) to decrease it. 4. Tighten the low[...]

8-25 1 2 3 4 5 6 7 8 9 10 11 6. Tighten the upper locknut. EWB02020 EBU24462 Adjusting the rear brake lever and brake pedal free play The brake lever and brake pedal free play must be checked and, if necessary, adjusted at the inter- vals specified in the periodic maintenance and lu- brication chart. NO TE: ● Always perform this maintenance compl[...]

8-26 1 2 3 4 5 6 7 8 9 10 11 mm (0.20–0.31 in) as shown. If the free play is in- correct, adjust it as follows. 1. Loosen the locknut at the brake lever. 2. Turn the brake lever free play adjusting bolt at the brake lever in direction (a) to increase the free play, and in direction (b) to decrease it. 3. Tighten the locknut at the brake lever. NO[...]

8-27 1 2 3 4 5 6 7 8 9 10 11 Turn the brake pedal free play adjusting nut on the brake rod at the rear wheel hub in direction (a) to increase the free play, and in direction (b) to de- crease it. 1. Brake pedal free pla y 1 1. Brake pedal free pla y adjusting nut 1 (a) (b)[...]

8-28 1 2 3 4 5 6 7 8 9 10 11 EWB02020 EBU24791 Adjusting the clutch free play The clutch free play must be adjusted periodically. Adjust the free play as follows. 1. Remove the left footboard by removing the screws and bolts. 2. Remove the rubber cap. 3. Loosen the locknut. 4. Slowly turn the adjusting bolt clockwise until resistance is felt, and t[...]

8-29 1 2 3 4 5 6 7 8 9 10 11 NO TE: Turning the adjusting bolt in decreases clutch free play and turning it out increases clutch free play. 5. Tighten the locknut to the specified torque. NO TE: When tightening the locknut, hold the adjusting bolt with a screwdriver so that the adjusting bolt does not turn together with the locknut. 6. Install the [...]

8-30 1 2 3 4 5 6 7 8 9 10 11 EWB02120 EBU24911 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Front brake lever Rear brake lever W ARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corr[...]

8-31 1 2 3 4 5 6 7 8 9 10 11 EBU24930 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. EBU24961 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the per[...]

8-32 1 2 3 4 5 6 7 8 9 10 11 Lubricate the steering shaft using a grease gun. EBU25111 Battery A poorly maintained battery will corrode and dis- charge quickly. The electrolyte level, battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrica- tion cha[...]

8-33 1 2 3 4 5 6 7 8 9 10 11 CAUTION: ECB00590 Use only distilled water, as tap water contains minerals that are harmful to the battery. EWB02140 4. Check and, if necessary, tighten the battery lead connections and correct the breather hose routing. To store the battery If the ATV will not be used for more than one month, the battery will need to b[...]

8-34 1 2 3 4 5 6 7 8 9 10 11 stored as follows. 1. Disconnect the negative lead first and then the positive lead. 2. Remove the battery, fully charge it, and then place it in a cool, dry place. CAUTION: ECB00600 Do not leave or store the battery on its side. 3. If the battery will be stored for more than two months, check the specific gravity of th[...]

8-35 1 2 3 4 5 6 7 8 9 10 11 CAUTION: ECB00610 If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the battery, the frame could suf- fer structural and external damages. EBU25232 Replacing the fuse The fuse holder is located under the seat. (See page 4-12.) If the fuse is blown, replace it [...]

8-36 1 2 3 4 5 6 7 8 9 10 11 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU25650 Removing a wheel 1. Loosen the wheel nuts. Front Rear 2. Elevate the ATV and place a suitable stand under the frame. 3. Remov[...]

8-37 1 2 3 4 5 6 7 8 9 10 11 EBU25710 Troubleshooting Although Yamaha ATVs receive a thorough in- spection before shipment from the factory, trouble may occur during operation. Any problem in the fu- el, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting chart represents a quick a[...]

8-38 1 2 3 4 5 6 7 8 9 10 11 EBU25791 Troubleshooting chart Check the fuel level in the fuel tank. 1. Fuel There is enough fuel. There is no fuel. Check the compression. Supply fuel. The engine does not start. Check the compression. Operate the electric starter. 2. Compression There is compression. There is no compression. Check the ignition. Have [...]

9-1 1 2 3 4 5 6 7 8 9 10 11 EBU25860 CLEANING AND STORAGE EBU25870 Cleaning Frequent, thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the ATV: a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag an[...]

9-2 1 2 3 4 5 6 7 8 9 10 11 EWB02300 EBU25932 Storage Short-term Always store your ATV in a cool, dry place and, if necessary, protect it against dust with a porous cover. CAUTION: ECB00720 ● Storing the ATV in a poorly ventilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust. ● T[...]

9-3 1 2 3 4 5 6 7 8 9 10 11 plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with 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 p[...]

10-1 1 2 3 4 5 6 7 8 9 10 11 EBU25960 SPECIFICATIONS EBU25974 Dimensions: Overall length: 1550 mm (61.0 in) Overall width: 855 mm (33.7 in) Overall height: 930 mm (36.6 in) Seat height: 665 mm (26.2 in) Wheelbase: 1030 mm (40.6 in) Ground clearance: 100 mm (3.94 in) Minimum turning radius: 2400 mm (94.5 in) Weight: With oil and fuel: 124.0 kg (273 [...]

10-2 1 2 3 4 5 6 7 8 9 10 11 Engine oil quantity: Periodic oil change: 0.80 L (0.85 US qt) (0.70 Imp.qt) Final gear oil: Type: SAE80 API GL-4 Hypoid gear oil Quantity: 0.12 L (0.13 US qt) (0.11 Imp.qt) Air filter: Air filter element: Wet element Fuel: Recommended fuel: Unleaded gasoline only Fuel tank capacity: 6.8 L (1.80 US gal) (1.50 Imp.gal) Fu[...]

10-3 1 2 3 4 5 6 7 8 9 10 11 Manufacturer/model: DUNLOP/KT586 Rear tire: Type: Tubeless Size: AT18 x 8-7 Manufacturer/model: DUNLOP/KT587 Loading: Maximum load: 95.0 kg (209 lb) (Total weight of rider, cargo, accessories, and tongue) Tire air pressure (measured on cold tires): Recommended: Front: 20 kPa (2.9 psi) (0.20 kgf/cm 2 ) Rear: 20 kPa (2.9 [...]

10-4 1 2 3 4 5 6 7 8 9 10 11 Spring/shock absorber type: Coil spring/oil damper Wheel travel: 56.0 mm (2.20 in) Electrical system: Ignition system: CDI Charging system: AC magneto Battery: Model: 12N7D-3B Voltage, capacity: 12 V, 7.0 Ah Bulb voltage, wattage x quantity: Neutral indicator light: 12 V, 1.7 W × 1 Fuses: Main fuse: 5.0 A[...]

11-1 1 2 3 4 5 6 7 8 9 10 11 EBU25981 CONSUMER INFORMATION EBU26011 Identification numbers Record the key identification number, vehicle iden- tification number and model label information in the spaces provided below for assistance when or- dering spare parts from a Yamaha dealer or for ref- erence in case the ATV is stolen. ● KEY IDENTIFICATION[...]

11-2 1 2 3 4 5 6 7 8 9 10 11 NO TE: The vehicle identification number is used to identi- fy your ATV. EBU26050 Model label The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- er. 1. V ehicle ident[...]

11-3 1 2 3 4 5 6 7 8 9 10 11 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 de- sign incorporated into any new v[...]

11-4 1 2 3 4 5 6 7 8 9 10 11 EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance 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.[...]

11-5 1 2 3 4 5 6 7 8 9 10 11 EBU26501 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY Y amaha Motor Cor poration, U.S .A. hereby warr ants that new Y amaha A TVs purchased from an authorized Y amaha A TV dealer in the continental United States will be free from defects in material and wor kmanship for the period of time stated herein, sub- je[...]

11-6 1 2 3 4 5 6 7 8 9 10 11 W ARRANTY QUESTIONS AND ANSWERS Q. What costs are my responsibility during the warranty period? A. The customer’ s responsibility includes all costs of normal maintenance ser vices, non-warranty repairs, accident and collision damages , and oil, oil filters, air filters, spark plugs, and brake shoes . Q. What are some[...]

11-7 1 2 3 4 5 6 7 8 9 10 11 EBU26122 YAMAHA EXTENDED SERVICE (Y.E.S.) K eep your Y amaha protected ev en after your w arranty e xpires with genuine Y amaha Extended Ser vice (Y .E.S.). Y .E.S. is designed and administered by Y amaha Motor Corporation to provide maximum owner satisf action. Y ou get uninterrupted factory-backed co verage f or e xtr[...]

11-8 1 2 3 4 5 6 7 8 9 10 11 We urge you to act now . Y ou’ll get the excellent benefits of TRIP cov erage right awa y , and you’ll rest easy knowing y ou’ll hav e strong factory-back ed protection ev en after your Y amaha Limited Warr anty expires . Y ou can also save money: Y .E.S. costs less within the first 90 days after you b uy your Y a[...]

11-9 1 2 3 4 5 6 7 8 9 10 11 EBU26132[...]

INDEX A Accessories and loading ................................................ 6-7 Air filter element, cleaning ............................................ 8-14 Air intake restrictor plate, removing.............................. 8-18 B Battery .................................................................. 5-7 , 8-32 Brake and shift pedals, c[...]

Model label.................................................................... 11-2 N Neutral indicator light ......................................................4-2 Noise regulation ............................................................ 11-3 O Owner’s manual and tool kit............................................ 8-1 P Parking ........[...]

PRINTED IN JAP AN 2006.3-0.6x1 ! (E) Y AMAHA MOT OR CO. , L TD. PRINTED ON RECYCLED PAPER LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) WARNING ALWAYS : use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns. avoid paved surfaces-pavemen[...]

Dear New Y amaha A TV Owner: CONGRA TULA TIONS ON THE PURCHASE OF YOUR NEW Y AMAHA A TV . Y ou have purchased a quality Y amaha pr oduct that , with proper use and care , will pro vide hours of riding pleasure. BEFORE YOU OPERATE YOUR NEW ATV , Y amaha recommends these impor tant points: 8 READ YOUR OWNER ’ S MANU AL 8 A CHILD UNDER 6 YEARS OLD S[...]

NO POST AGE NECESSARY IF MAILED IN THE UNITED ST A TES FIRST CLASS PERMIT NO . 4 CYPRESS, CA POST AGE WILL BE P AID BY ADDRESSEE Y AMAHA MOTOR CORPORA TION U.S.A. P .O. BOX 6555 CYPRESS, CALIFORNIA 90630-9989 A TTN: SALES ADMINISTRA TION ATV card for US 4/2/03 9:06 AM Page 2[...]