Yamaha YFS200N manual

w This ATV should not be ridden by anyone under 16 years of age. OWNER’S MANUAL 5KJ-28199-11 YFS200N READ THIS MANUAL CAREFULLY! It contains important safety information. LIT-11626-14-09[...]

EBU00007 INTR ODUCTION Congratulations on your purchase of the Yamaha YFS200. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a lead[...]

EBU00010 IMPOR T ANT MANU AL 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 SAFETY IS INVOLVED! w Failure to follow WARNING instru[...]

EBU00011 IMPOR T ANT NO TICE 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[...]

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-[...]

Seat ....................................................4-12 Front shock absorber adjustment ........................................4-14 Rear shock absorber adjustment ........................................4-15 PRE-OPERATION CHECKS ...................5-1 Front and rear brakes ...........................5-2 Fuel .................................[...]

Crossing through shallow water .........7-34 Riding over rough terrain ....................7-36 Sliding and skidding ...........................7-38 What to do if... ...................................7-40 What to do... ......................................7-40 PERIODIC MAINTENANCE AND ADJUSTMENT .........................................8-1 Owner?[...]

CLEANING AND STORAGE....................9-1 A. Cleaning ...........................................9-1 B. Storage ............................................9-3 SPECIFICATIONS .................................10-1 NOISE REGULATION............................11-1 MAINTENANCE RECORD ....................12-1 ATV LIMITED WARRANTY ...................13[...]

1-1 EBU00464 LOCA TION OF THE W ARNING AND SPECIFICA TION LABELS w e r t q[...]

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 replace- ment label is available from your Yamaha dealer. 1 q w e 5FE-21697-01 q W ARNING NEVER ride as a passenger . P a[...]

1-3 r t 4AA-22259-80 q WARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion. 8 Read owner’s manual for instructions. 8 Do not incinerate, puncture or open. 5FE-21568-01[...]

2-1 EBU00026 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, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, fol- low the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn th[...]

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

2-6 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 [...]

2-7 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 machine in an area with adequate ventilation. q W ARNING[...]

3-1 1. Spark arrester 11. Rear shock absorber 2. Seat 12. Rear wheel 3. Fuel tank cap 13. Shift pedal 4. Headlight 14. Clutch lever 5. Brake pedal 15. Main switch 6. Kick starter 16. Parking brake 7. Front shock absorber 17. Front brake lever 8. Front wheel 18. Throttle lever 9. Fuel cock 19. Handlebar switch 10. Starter (choke) NO TE: The machine [...]

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[...]

3-3 EBU00036 Vehicle identification number The vehicle identification number is stamped into the frame. 1. Vehicle identification number NO TE: The vehicle identification number is used to identify your machine. EBU00038 Model label The model label is affixed to the frame. Record the information on this label in the space provid- ed. This informati[...]

EBU00039 CONTR OL 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.[...]

EBU00757 Oil level warning light checking method 4-2 Start the engine. Wait a few seconds. Engine oil level and electrical circuit are OK. Supply engine oil. Oil level warning light does not come on (see NOTE). Ask a Yamaha dealer to inspect the electrical circuit. NO TE: If the main switch is turned off after the oil level warning light goes off a[...]

EBU00053 Handlebar switches EBU00054 Engine stop switch “ENG. STOP” Make sure that the engine stop switch is in the “RUN” position. The engine stop switch controls ignition and can be used at all times to stop the engine, especially in an emergency. The engine will not start or run when the engine stop switch is turned to “OFF”. EBU0073[...]

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 [...]

EBU00064 Throttle OverRide System If during operation, the carburetor or the throttle cable should malfunction and will not close fully, take your thumb off the throttle lever.The throttle override system immediately cuts off the igni- tion. 4-5 POTENTIAL HAZARD Continuing to ride the ATV after the Throttle OverRide System (T.O.R.S.) has stopped th[...]

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. 4-6 POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle[...]

EBU00068 Clutch lever The clutch lever is located on the left handlebar. Pull the clutch lever to the handlebar to disen- gage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. 1. Clutch lever EBU00070 Front brake lever The front brake lever is located on the [...]

EBU00071 Rear brake pedal The brake pedal is located on the right side of the machine. Push down on the pedal to apply the rear brake. EBU00076 Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the front brake lever while pushing the button, then push down the lock plate to apply[...]

4-9 POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake disc could overheat if you ride the ATV without releasing the parking brake. You could lose braking perfor- mance w[...]

EBU00082 Shift pedal This machine is equipped with a constant-mesh 6-speed transmission. The shift pedal is located on the left side of the engine and is used in com- bination with the clutch when shifting. 1. Shift pedal N. Neutral EBU00089 Kick starter Rotate the kick starter away from the engine. Push the starter down lightly with your foot unti[...]

EBU00092 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. 1. Fuel tank cap 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:[...]

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.) 1. Starter (choke) EBU00567 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. NO TE: Make sure that the seat is securely fitted. 4-13[...]

4-14 EBU00635 Front shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows: To increase the spring preload, turn the adjuster in direction a . To decrease the spring preload, turn the adjuster in direction b . q a b POTENTIAL HAZARD Improper shock absorbe[...]

EBU00636 Rear shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows: 1. Loosen the locknut. 2 . To increase the spring preload, turn the adjuster in direction a . To decrease the spring preload, turn the adjuster in direction b . c C Never attempt to tur[...]

4-16 POTENTIAL HAZARD This shock absorber contains highly pres- surized nitrogen gas. WHAT CAN HAPPEN The shock absorber could explode, caus- ing injury or property damage. Cylinder damage could also result in poor handling which could cause an accident. HOW TO AVOID THE HAZARD 1. Do not tamper with or attempt to open the cylinder assembly. 2. Do n[...]

4-17 EBU00112 w Indicates a potential hazard that could result in serious injury or death.[...]

5-1 PRE-OPERA TION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE Front brake 9 Check operation, condition and free play. 5-2 ~ 5-3, 8-20 ~ 8-22 9 Adjust if necessary. Rear brake 9 Check operation and brake pad. 5-2 ~ 5-3, 8-20 Clutch 9 Check operation, condition and lever free play. 8-24 Parking brake 9 Check opera[...]

EBU00474 Front and rear brakes 1. Brake lever and brake pedal Check for correct free play in the front brake lever. If the free play is incorrect, adjust it.(See pages 8-21~8-22 for details.) Check operation of the lever and pedal. They should move smoothly and there should be a firm feeling when the brake is applied. If not, have the machine inspe[...]

EBU00129 Fuel Make sure there is sufficient gasoline in the tank. Your Yamaha engine has been designed to use premium unleaded gasoline with a pump octane number ([R+M]/2) of 90 or higher, or research octane number of 95 or higher. If knocking or pinging occurs, use a different brand of gaso- line. Unleaded fuel will give you longer spark plug life[...]

5-4 Gasohol There are two types of gasohol; gasohol con- taining ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems. 1. Filler tube 2. Fuel level POTENTIAL[...]

5-5 EBU00448 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. See page 10-2. 1. Oil tank filler cap NO TE: Be sure to push the cap into the filler neck until it is properly seated. EBU00488 Transmission oil Make sure the transmission oil is at the specified level. Add oil as necessary. (See pages 8-5~ 8-7.) q Rec[...]

c C Be sure to use motor oils that do not contain anti-friction modifiers. Passenger car motor oils (often labeled “Energy Conserving”) contain anti-friction additives which will cause clutch and/or starter clutch slippage, resulting in reduced component life and poor engine performance. EBU00498 Chain Check the general condition of the chain a[...]

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[...]

EBU00159 How to measure 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 pressure with tires cold. Set tire pressures to the followi[...]

5-9 EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a a. 3 mm (0.12 in)[...]

EBU00161 OPERA TION w Indicates a potential hazard that could result in serious injury or death. EBU00511 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 transmission into neutral. 5. Use the starter (choke) in reference to [...]

6-2 Position 1 : Cold engine start- ambient temperature below 5°C (40°F). Position 2 : Cold engine start- ambient temperature at 0°C (30°F) ~ 30°C (90°F) and warming up position. Position 3 : Cold engine start- ambient temperature above 25°C (80°F) and warm engine start posi- tion. 1. Fully open 2. Half open 3. Closed a. Starter (choke) 6. [...]

EBU00180 Starting a warm engine To start a warm engine, refer to the “Starting a cold engine” section. The starter (choke) should not be used. The throttle should be opened slightly. EBU00182 Warming up To get maximum engine life, always warm up the engine before starting off. Never accelerate hard with a cold engine! To see whether or not the [...]

EBU00198 Shifting This model has a 6-speed forward transmission. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, return the throttle lever to its original position, apply the clutch and repeatedly depress the shift pedal until i[...]

EBU00203 To start out and accelerate: 1. Release the throttle lever. c C Always close the throttle while shifting gears. Otherwise, damage to the engine and drive train may result. 2. Pull the clutch lever to disengage the clutch. 3. Shift into first gear. 4. Open the throttle gradually and at the same time, release the clutch lever slowly. 5. Once[...]

EBU00207 To decelerate: When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the [...]

6-7 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[...]

EBU00212 Parking When parking, stop the engine and shift into low gear. Turn the fuel cock to “OFF” and apply the parking brake. 1. Button 2. Lock plate 6-8 q w[...]

EBU00213 Parking on a slope 1. Bring the machine to a stop by applying the brakes in low gear. 2 . Stop the engine and release the clutch lever. 3. With the front and rear brakes applied, apply the parking brake and slowly release the rear brake pedal. 6-9 POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out o[...]

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[...]

EBU00584 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[...]

6-12 EBU00558 w Indicates a potential hazard that could result in serious injury or death. 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 b[...]

7-1 Riding Y our AT V 7[...]

7-2[...]

GETTING TO KNOW YOUR ATV This ATV is intended for recreational use by experienced operators only. Even though you are an experienced operator of all other all terrain vehicles or motorcycles, rid- ing the ATV requires special skills acquired through practice. Take your time to fully learn techniques before attempting more difficult maneuvers. Ridin[...]

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 machine’s handling and perfo[...]

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 machine 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 [...]

Apparel Operating without protective clothing increases your chances of severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved motorcycle hel- met that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants 7-7 POTENTIAL HAZARD Operating t[...]

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. Could [...]

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 machine. 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 Alway[...]

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 machine. Turning [...]

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

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 machine 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[...]

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 machine is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the machine in a place where pedestrians or children are not likely to touch it. 7-15 POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Someone touching the exhaust system during or after operatio[...]

7-16 BE CAREFUL WHERE YOU RIDE This machine 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 ou[...]

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[...]

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

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 machine. 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 s[...]

7-21 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 o[...]

7-22 c C Do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or [...]

7-23 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[...]

7-24 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 weig[...]

7-25 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[...]

7-26 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 slippery or l[...]

7-27 If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control [...]

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 rear brake as well, and then lock 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.[...]

7-30 RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the engine compression to do most of the braking for you. Improper braking may cause a loss of traction. Use caution while descendi[...]

7-31 OK[...]

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 travel [...]

7-33 Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. OK[...]

7-34 CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and carefully. POTENTIAL [...]

7-35 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 [...]

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 HAZARD I[...]

7-37[...]

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 wheels[...]

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 lost. PO[...]

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 of the tu[...]

7-41 8 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See p[...]

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 [...]

8-2 The service information included in this manual is intended to provide you, the owner, with the nec- essary information for completing your own pre- ventive maintenance and minor repairs. The tools provided in the Owner’s tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts[...]

8-3 EBU00261 PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY ITEM ROUTINE 1 3 6 6 1 month months months months year Transmission 9 Replace oil. 2 222 9 Check condition. Spark plug 9 Adjust gap and clean. 22222 9 Replace if necessary. Air filter 9 Clean. Every 20 ~ 40 hours. 9 Replace if necessary. (More often in wet or dusty areas) * Carburetor 9 Ch[...]

8-4 * It is recommended that these items be serviced by a Yamaha dealer. ** Lithium soap base grease INITIAL EVERY ITEM ROUTINE 1 3 6 6 1 month months months months year Drive chain 9 Lubricate, check free play and alignment. 22 2 2 9 Replace if necessary. * Drive chain guard 9 Check wear and replace if necessary. 222 and rollers * Steering system [...]

EBU00597 Transmission oil 1. Transmission oil measurement a. Place the machine on a level place. b. Warm up the engine for several minutes, and stop it. c. Check the oil level through the level win- dow located at the right side crankcase cover. NO TE: Wait a few minutes until the oil level settles before checking. d. The oil level should be betwee[...]

c C 8 Be sure to use motor oils that do not con- tain anti-friction modifiers. Passenger car motor oils (often labeled “Energy Conserving”) contain anti-friction additives which will cause clutch and/or starter clutch slippage, resulting in reduced component life and poor engine performance. 8 Be sure no foreign material enters the crankcase. 1[...]

8-7 h. Check the oil level. EBU00286 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 [...]

a. Spark plug gap When installing the spark plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads and tighten to the specified torque. EBU00288 Air filter cleaning NO TE There is a check hose at the bottom of the air fil- ter case. If dust or water collects in this hose, empty the hose and clean the air fil[...]

8-9 1. Air filter case cover 3. Remove the air filter element, and sepa- rate it from the guide. 4. Wash the element gently but thoroughly in solvent. 5. Squeeze the excess solvent out of the filter and let it dry. c C Do not twist the filter element when squeez- ing it. q w POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the a[...]

6. Inspect the element. If damaged, replace it. 7. Apply Yamaha foam air filter oil or other quality foam air filter oil to the element. If foam air filter oil is not available, motor oil may be used. NO TE: The element should be wet but not dripping. 8. Reinstall the element to the element guide. 9. Reinstall the element assembly and parts removed[...]

8-11 EBU00458 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the screw. 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 . Make sure the gas[...]

8-12 POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust compo[...]

EBU00297 Carburetor settings In extremely cold weather, it is necessary to change the carburetor settings to maintain opti- mum engine performance and to prevent engine damage. 8-13 POTENTIAL HAZARD Improperly servicing or adjusting the car- buretor. WHAT CAN HAPPEN The carburetor could malfunction. This could cause improper operation with the poss[...]

8-14 Carburetor setting chart Changing the carburetor settings Disassembly 1. Turn the fuel cock to the “OFF” position. 2. Turn out the carburetor drain screw and drain the fuel. q 1st groove 2nd ( Standard ) 3rd 4th 5th Jet needle clip position q 1. Main jet number Temperature Main jet Jet needle Pilot air screw 0°C (32°F) above #230 2nd gro[...]

8-15 3. Disconnect the fuel hose and oil delivery hose. 4. Remove the securing plate. 5. Loosen the joint screws of the carburetor and remove the carburetor. 6. Remove the carburetor cap. q w q w w 1. Carburetor cap securing 2. Joint screw ( × 3) plate 1. Fuel hose 2. Oil delivery hose[...]

7. Remove the throttle cable from the throttle valve and then remove the holder. 1. Carburetor cap 2. Throttle cable 3. Throttle valve 4. Holder 8. Remove the float chamber. 1. Float chamber 9. Remove the float and needle valve. 10. Change the main jet and the jet needle clip position. (See page 8-14.) 1. Float 2. Needle valve 3. Main jet e w r q q[...]

8-17 NO TE: Optional main jet can be obtained at a Yamaha dealer. Assembly 1 . Reassemble the needle valve, float and float chamber. 2. Reassemble the throttle valve. 3 . Install the carburetor cap and tighten it securely to the specified torque. 4. Install the carburetor and tighten the joint screws. 5. Install the securing plate. Match one of the[...]

8-18 EBU00301 Idle speed adjustment NO TE: A diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Connect the tachometer and set the idle t[...]

8-19 EBU00307 Throttle lever adjustment NO TE: 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 4~6 mm (0.16~0.24 in). 3. Tighten the locknut. 1. Adjusting bolt 2. Locknut a. 4 ~ 6 mm (0.16 ~ 0.24 in) q w a[...]

EBU00310 Front brake shoe inspection A wear indicator is provided on the front brake. This indicator allows checking of brake shoe wear without disassembling the brake. Apply the front 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. 1. Wear limit 2. Wear[...]

EBU00523 Front brake lever free play adjustment NO TE Before adjusting the brake, inspect the front brake shoes. The front brake lever free play should be adjust- ed to 3~5 mm (0.12~0.20 in) at the brake lever pivot. If the free play is incorrect, adjust as fol- lows: 1 . Loosen the locknut and fully turn in the adjusting bolt at the front brake le[...]

8-22 1. Adjusting nut 3. Turn the adjusting bolt at the brake lever until specified free play is obtained. 1. Adjusting bolt 2. Locknut a. 3 ~ 5 mm (0.12 ~ 0.20 in) 4. Tighten the locknut. q a w q POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. [...]

EBU00601 Parking brake adjustment Parking brake adjustment may be required if the parking brake does not hold properly. 1. Loosen the locknut of the parking brake cable. 1. Adjusting bolt 2. Locknut 2. Turn the adjusting bolt until there is little or no free play. 3. Tighten the locknut. 8-23 w q POTENTIAL HAZARD Operating with improperly adjusted [...]

EBU00539 Clutch adjustment The clutch lever free play should be 2~3 mm (0.08~0.12 in). If the free play is incorrect, adjust as follows. 1. Loosen the locknut. 2. Turn the adjusting bolt so that clutch lever free play is 2~3 mm (0.08~0.12in). 3. Tighten the locknut. 1. Adjusting bolt 2. Locknut a. 2 ~ 3 mm (0.08 ~ 0.12 in) EBU00349 Autolube pump ad[...]

8-25 EBU00350 Drive chain slack check Inspect the drive chain while all tires are touch- ing the ground. Check the slack at the position shown in the figure. The normal vertical deflec- tion is approximately 30~40 mm (1.2~1.6 in). If the deflection exceeds 40 mm (1.6 in), adjust the chain slack. a. 30 ~ 40 mm (1.2 ~ 1.6 in) EBU00351 Drive chain sla[...]

1. Locknut 2. Chain adjuster 3. Alignment marks 3. After adjusting, be sure to tighten the lock- nuts and the wheel hub bolts. EBU00354 Drive chain cleaning and lubrication The drive chain is equipped with rubber O-rings between the chain plates. Steam cleaning, high- pressure washes, and certain solvents can dam- age these O-rings. Use only kerose[...]

EBU00356 Cable inspection and lubrication Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. EBU00737 Brake and shift pedal/brake and clutch lever lubrication Lubricate the pivoting parts of each lever and pedal. EBU00368 Upper arm and lower arm pivot lubrication Lubricate the [...]

EBU00370 Steering shaft lubrication Lubricate the pivot points. Use a grease gun. 8-28 Recommended lubricant: Lithium soap base grease[...]

EBU00373 Wheel removal 1 . Elevate the wheel by placing a suitable stand under the frame. 2. Remove the nuts from the wheel. 3. Remove the wheel assembly. EBU00740 Wheel installation When installing the wheel, reverse the removal procedure. Tighten the wheel nuts to the specified torque. 8-29 Tightening torque: Wheel nut: Front: 45 Nm (4.5 m•kg, [...]

EBU00645 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 bulb holder cover, turn the bulb holder counterclockwise and remove the defective bulb. 8-30 q 1. Screw ( × 2)[...]

3. Put a new bulb into position and secure it in place with the bulb holder. 4. Install the 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. Adjust the headlight beam if necessary. POTENTIAL HAZARD The headlight bulb is hot when i[...]

8-32 EBU00411 Headlight beam adjustment c C It is advisable to have a Yamaha dealer make this adjustment. Vertical adjustment: Loosen the headlight assembly mounting bolts and adjust the vertical beam by moving the headlight up or down. 1. Mounting bolt ( × 2) EBU00412 Troubleshooting Although Yamaha machines receive a rigid inspection before ship[...]

8-33 POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe injury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys- tem. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnace[...]

8-34 EBU00440 Troubleshooting chart Check fuel flow 1. Fuel Check if there is fuel in the fuel tank 2. Compression Kick the kick lever to see if there is compression 3. Ignition Remove plug and check electrode Wet Wipe clean with dry cloth Dry Attach plug cap and ground to chassis Kick the kick starter strongly Spark weak Spark good Ignition system[...]

EBU00414 No spark Throttle override system (T.O.R.S.) is incorpo- rated in the ignition circuit, and if the system should fail, the spark plug will not spark. POTENTIAL HAZARD Testing for an ignition system problem by disconnecting the Throttle OverRide System (T.O.R.S.). WHAT CAN HAPPEN With T.O.R.S. disconnected, the engine will not stop if the t[...]

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EBU00417 CLEANING AND ST ORA GE 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[...]

9-2 4 . Once the majority of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bottle brush is handy for hard-to-get-at places. 5 . Rinse the machine off immediately with clean water and dry all surfaces with a chamois, clean towel or soft absorbent cloth. 6. Dry the chain and lubrica[...]

9-3 EBU00527 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[...]

10-1 EBU00428 SPECIFICA TIONS Model YFS200 Dimension: Overall length 1,735 mm (68.3 in) Overall width 1,035 mm (40.7 in) Overall height 1,040 mm (40.9 in) Seat height 740 mm (29.1 in) Wheel base 1,100 mm (43.3 in) Minimum ground clearance 120 mm ( 4.7 in) Minimum turning radius 3,000 mm (118 in) Basic weight: With oil and full fuel tank 153 kg (337[...]

10-2 Model YFS200 Engine oil (2-cycle): Type Yamalube 2-cycle oil or air cooled 2-stroke engine oil Quantity 1.3 L (1.14 Imp qt, 1.37 US qt) Transmission oil: Type Yamalube 4 (10W30) or SAE 10W30 type SE motor oil Recommended transmission oil API Service SE, SF, SG type or higher classification Quantity Periodic oil change 0.65 L (0.57 Imp qt, 0.69[...]

10-3 Model YFS200 Carburetor: Type/manufacturer VM26SS/MIKUNI Spark plug: Type/manufacturer BR8ES (NGK) Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) Clutch: Type Wet, multi-disk Operation Left hand operation Transmission: Primary reduction system Helical gear Primary reduction ratio 71/22 (3.227) Secondary reduction system Chain drive Secondary reduction ra[...]

10-4 Model YFS200 Chassis: Frame type Steel Tube Frame Caster angle 9.0° Trail 40 mm (1.57 in) Tire: Type Tubeless Size – Front AT21 × 7 - 10 Rear AT21 × 10 - 8 Brake: Front brake type Drum brake Operation Right hand operation Rear brake type Single, Disk brake Operation Right foot operation Suspension: Front Double wishbone Rear Swingarm (mon[...]

10-5 Model YFS200 Wheel travel: Front 180 mm (7.09 in) Rear 180 mm (7.09 in) Electrical: Ignition system C.D.I. Generator system C.D.I. Magneto Headlight Type: Bulb type Bulb voltage, wattage × quantity Headlight 12V, 45W/45W × 1 Taillight 12V, 3.8W × 1 Indicator light: Oil level 12V, 1.7W × 1[...]

11-1 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 [...]

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. 1 Month 3 Months 6 Months 12 M[...]

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14-3 EBU00436 w Indicates a potential hazard that could result in serious injury or death.[...]

EBU00437 PR O TECT Y OUR INVESTMENT[...]

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000·4–3.0 × 1 ! (E) Y AMAHA MOT OR CO. , L TD. Improper ATV use can result in SEVERE INJURY or DEATH. q W ARNING ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: 9 without proper training or instruction. 9[...]