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RCA DRD455RH Satellite TV System User Manual

1. Push the start switch with the transmission in the neutral position l Coolant temperature warning light comes on momentarily Coolant temperature warning light comes on Coolant temperature warning light does not come on Coolant temperature and electrical circuit are OK Go ahead with riding Ask a Yamaha dealer to inspect the electrical circuit 4 3 EBU00053 Handlebar switches 1 Light switch OFF Z0 20 2 Engine stop switch Y O 3 Start switch EBU01204 Light switch OFF ZO0 20 Set the switch to ZO to turn on the low beam and the taillight Set the switch to O to turn on the high beam and the taillight Set the switch to OFF to turn off all the lights 4 4 CAUTION Do not use the headlights with the engine turned off for more than thirty minutes The battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it EBU01205 Engine stop switch Make sure that the engine stop switch is set to Q before starting the engine 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 set to X EBU00607 Start switch The star
2. i AT ES 1 Locknut A Cable length 1 Fully loosen the locknut and the adjusting bolt at the clutch lever Loosen the locknut and the adjusting bolt at the rear brake caliper 2 Adjusting bolt 2 8 30 Turn the adjusting bolt at the clutch lever in direction to increase the cable length or in direction to decrease the cable length 1 Locknut 2 Adjusting bolt NOTE If the cable cannot be adjusted to specifica tion consult a Yamaha dealer 4 Tighten the locknut at the clutch lever 5 Screw in the adjusting bolt at the rear brake caliper by hand until it feels tight then screw it out 1 8 turn Tighten the locknut to the specified torque Tightening torque Locknut 16 Nm 1 6 m kgf 12 ft Ibf CAUTION When tightening the locknut hold the ad justing bolt with a wrench so that the ad justing bolt does not turn together with the locknut 8 31 A WARNING POTENTIAL HAZARD Operating with improperly adjusted brakes WHAT CAN HAPPEN The brakes could malfunction causing reduced braking performance This could increase the chance of a collision or accident HOW TO AVOID THE HAZARD After adjusting the parking brake block the rear of the machine off the ground and spin the rear wheels Check to make sure there is no brake drag If brake drag is noticed perform the adjustment again EBU00833 Adjusting the rear brake light switch The rear brake l
3. 4 If the engine oil is below the minimum level mark add sufficient oil of the recom mended type to raise it to the correct lev el NOTE When adding oil be careful not to overfill the engine oil tank the oil level rises faster start ing from the half level portion on the dipstick 5 Insert the dipstick into the oil filler hole and then tighten the oil filler cap CAUTION Make sure that the oil filler cap is securely tightened otherwise oil may seep out when the engine is running 8 7 To change the engine oil with or without oil filter cartridge replacement 1 Engine guard 1 Remove the engine guard by removing the bolts 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to col lect the used oil 2 Bolt x 6 4 Remove the crankcase engine oil drain bolt 1 Engine oil tank drain bolt 5 Remove the engine oil tank filler cap and 1 Crankcase engine oil drain bolt the oil tank drain bolt 6 Check the washers for damage and re place if necessary 8 8 NOTE Skip steps 7 8 if the oil filter cartridge is not being replaced 7 Remove the oil filter cartridge with an oil filter wrench 2 Oil filter wrench 1 Oil filter cartridge NOTE An oil filter wrench is available at a nearby Yamaha dealer 1 O ring 8 Apply a thin coat of engine oil to the O ring of the new oil filt
4. A WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the 1 Unlock 2 Element retaining plate ir filt l t 5 Wash the air filter element gently but pan cetera ai thoroughly in solvent 6 Squeeze the excess solvent out of the air filter element and let it dry CAUTION Do not twist the air filter element when squeezing it 7 Inspect the air filter element and replace it if damaged 1 Frame 2 Air filter element 3 Element retaining plate 8 19 8 Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter el ement If foam air filter oil is not available engine oil may be used NOTE The air filter element should be wet but not dripping 9 Pull the air filter element over its frame 10 Install the air filter element 1 Hose 11 Install the air filter case cover and be sure to connect the hose 8 20 12 Install the seat NOTE The air filter element should be cleaned every 20 40 hours It should be cleaned and lubri cated more often if the machine is operated in extremely dusty areas Each time air filter ele ment maintenance is performed check the air inlet to the air filter case for obstructions Check the air filter element rubber joint to the carburet
5. Do not incinerate puncture or open 4AA 22259 80 EBU00924 AX SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE An ATV handles differently from other vehicles including motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers such as turning and riding on hills or over obstacles if you fail to take proper precautions SEVERE INJURY OR DEATH can result if you do not follow these instructions e Read this manual and all labels carefully and follow the operating procedures described e Never operate an ATV without proper training or instruction Take a Training Course Beginners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you e Always follow the age recommendation Achild under 16 years old should never operate an ATV with engine size greater than 90cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely e Never carry passenger on an ATV 2 1 Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and streets Never operate an ATV on any public street road or highway even a dirt or gravel one Never operate an ATV without wearing an approved motorcycle h
6. in this chapter Refer to this section each time the panel has To install to be removed or installed Place the panel in the original position and then install the bolts 8 5 EBU01238 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter cartridge replaced at the inter vals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the ATV on a level surface 2 Start the engine warm it up until the en gine oil has reached a normal tempera ture of 60 C 141 F let it continue to idle for twenty to thirty seconds During this period rev the engine two or three times to approximately 3 000 r min and then turn the engine off NOTE To achieve the proper engine oil temperature for an accurate oil level reading the engine must have first completely cooled down and then warmed up again for several minutes to normal operating temperature 8 6 3 Wait afew minutes until the oil settles re move the engine oil tank filler cap wipe the dipstick clean with a clean rag insert it back into the filler hole without screw ing it in and then remove it again to check the oil level 1 Engine oil tank 4 Maximum level mark NOTE The engine oil should be between the mini mum and maximum level marks 2 Engine oil tank filler cap 3 Dipstick 5 Minimum level mark
7. pro rated You don t have any out of pocket expenses for covered repairs 14 1 e In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period e Y E S coverage is honored at any authorized Yamaha dealer nationwide e Y E S coverage is transferable to a new owner if you sell or trade in That can make your Yamaha much more valuable This excellent Y E S plan coverage is only available to Yamaha owners like you and only while your Yamaha is still within the Yamaha Limited Warranty period So visit your authorized Yamaha dealer to get all the facts He can show you how easy it is to protect your investment with Yamaha Extended Service We urge you to act now You ll get the excellent benefits of TRIP coverage right away and you ll rest easy knowing you ll have strong factory backed protection even after your Yamaha Limited Warranty expires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note YAMA
8. 1 Headlight bulb holder cover 8 47 7 Push the headlight bulb holder inward turn it counterclockwise and remove the defective bulb 1 Headlight bulb holder 8 48 A WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flamma ble HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it 8 Put a new headlight bulb into position and secure it in place with the bulb hold er 10 Align the projections on the headlight unit with the holders install the headlight unit into the case and then install the screw 1 Headlight bulb 2 Headlight bulb holder 9 Install the headlight bulb holder cover CAUTION Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated against the reflector 8 49 1 Headlight unit 2 Headlight case 11 12 13 14 Place the headlight cover in the original position and then install the screw Connect the headlight coupler Place the headlight assembly in the orig inal position and then install the bolts Have a Yamaha dealer adjust the head light beam if necessary EBU01217 Tail brake light bulb replacement 1 Remove the lens by removing the screws 1 Bulb 3 Install a new bulb by pushi
9. Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always fol low proper procedures when operating over obstacles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by prac ticing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of con trol Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly 2 4 Always use the size and type tires specified in this manual e Always maintain proper tire pressure as described in this manual e Never modify an ATV through improper installation or use of accessories e 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 Safet
10. The carburetor is a vital part of the engine and requires very sophisticated adjustment Most adjusting should be left to a Yamaha dealer who has the professional knowledge and ex perience to do so However the idling speed may be performed by the owner as a part of the usual maintenance routine CAUTION The carburetor was set at the Yamaha fac tory after many tests If the settings are disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result EBU01143 Idle speed adjustment NOTE 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 Connect the tachometer to the spark plug lead and then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in direction to increase the engine speed and in direc tion to decrease the engine speed Specified idle speed 1 450 1 550 r min 8 23 1 Throttle stop screw EBU00303 EBU00307 Valve clearance adjustment Throttle lever adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clear ance must be adjusted regularly This adjust ment however should be left to a profession
11. speed release the throttle and at the same time quickly pull in the clutch lever Shift into second gear be careful not to shift into neutral Open the throttle part way and gradually release the clutch lever 8 Follow the same procedure when shifting to the next higher gear A WARNING POTENTIAL HAZARD Opening the throttle abruptly or releas ing the clutch lever too quickly WHAT CAN HAPPEN The machine could wheelie This would increase the chance of an accident in cluding overturn HOW TO AVOID THE HAZARD Open the throttle gradually Release the clutch lever gradually 6 8 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 Improp er use of the brakes or shifting can cause the tires to lose traction reducing control and in creasing the possibility of an accident A WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating This could cause loss of control an accident and injury It could also cause engine or drive train damage HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear EBU00209 Engine break in There is never a more important period in the life of your ma
12. 6 months Valves e Check valve clearance e Adjust if necessary O Cooling system e Check coolant leakage e Repair if necessary e Replace coolant every 24 months O Spark plug e Check condition e Adjust gap and clean e Replace if necessary O O O Air filter element e Clean e Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor e Check starter choke operation e Adjust engine idling speed O O O Crankcase breather system Exhaust system e Check breather hose for cracks or damage e Replace if necessary e Check for leakage e Tighten if necessary e Replace gasket if necessary Spark arrester e Clean Fuel line e Check fuel hose for cracks or damage e Replace if necessary Engine oil Replace Warm engine before draining Engine oil filter cartridge e Replace if necessary Drive chain e Check and adjust slack alignment clean lube Front brake e Check free play operation fluid leakage See NOTE Page 8 4 e Correct if necessary Rear brake e Correct if necessary e Check operation fluid leakage See NOTE Page 8 4 Clutch e Check operation e Adjust if necessary O O O OOO OoOo O O O O O JO JO O JO O JO O O O O00 O JO O Jojo INITIAL EVERY ROUTINE 3 6 6 months months months e Check balance
13. ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and high ways 7 17 Know the terrain where you ride Ride cau tiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and oth er hidden hazards which may cause the ATV to upset A WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when op erating on unfamiliar terrain Always be alert to changing terrain con ditions when operating the ATV 7 18 A WARNING 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 acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain 7 19 When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NO
14. CHECKS Before using this machine check the following points ITEM ROUTINE PAGE e Check operation free play fluid level and fluid leakage 5 3 5 4 Frontbrake e Fill with DOT 4 brake fluid if necessary 8 25 8 28 e Check operation fluid level and fluid leakage 5 3 5 4 Rear brake e Fill with DOT4 brake fluid if necessary 8 25 8 27 8 29 Clutch e Check operation condition and lever free play 8 32 8 33 Parking brake e Check operation condition and cable length 8 30 8 31 e Check fuel level Fuel e Fill with fuel if necessary SAR e Check oil level Engine oil e Fill with oil if necessary Sane e Check coolant level Poplantreservelr e Fill with coolant if necessary SyaT 1cg1S e Check chain slack and condition Drive chain Adjust if necessary 5 8 8 34 8 37 Throttle e Check for proper throttle cable operation and free play 5 8 8 24 5 9 5 11 Wheels and tires Check tire pressure wear and damage 8 41 8 42 Fittings and fasteners Check all fittings and fasteners 5 8 Lights and switches e Check for proper operation 5 8 8 32 8 45 8 50 A WARNING POTENTIAL HAZARD Failure to inspect the ATV before oper ating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op erating
15. E 5 4 Engine oil a eeeeenneeoone eneen cine tee 5 6 07010 f Ta j AAR E E tee 5 7 KON av snan 5 8 Throttle lever ccccccccecessssssneeeeeees 5 8 Fittings and fasteners 5 8 LINS ia e eaa 5 8 SWINE S acin arite xe dida 5 8 TES ea ieee 5 9 How to measure tire pressure 5 10 Tire wear liMit ccccceccceessessteees 5 11 OPERATION reion marenana 6 1 Starting a cold engine 6 1 Starting a warm engine 0 6 4 Warming Up iisSiieaseweausaasece 6 4 Reverse knob operation and reverse Criving ccesseceeeeee 6 5 Shing ee a 6 6 To start out and accelerate 6 7 To decelerate cceeeeeeeeeeeeeeeeees 6 8 Engine break in neeese 6 9 PaKa es ities 6 10 Parking On a SIOPG eeeeeeee 6 11 Accessories and loading 6 12 RIDING YOUR ATV seeen 7 1 Getting to know your ATV 7 3 Ride with care and good JUDGEMENT c cck eens 7 4 Be careful where you ride 7 16 Turning your ATV osses 7 23 Climbing uphill ceeeeeee 7 25 Riding downhill eee 7 30 Crossing a SIOPGC ccceeeeeee 7 32 Crossing through shallow water 7 34 Riding over rough terrain 7 36 Sliding and skidding 00 65 7 38 What to do if sscxectecttertesectgccncees 7 40 What to do ss ut ccceceeitactertn dese 7 40 EI PERIODIC MAINTENANCE AND ADJUSTMENT wcitienci uence nice 8 1 Owner s manu
16. are no obstacles in your way to regain balance If you dis cover that the ATV is going to tip over dis mount on the uphill side See pages 7 32 7 33 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV un til you have regained adequate braking ability See pages 7 34 7 35 A WARNING Indicates a potential hazard that could result in serious injury or death 7 41 EBU00515 PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection adjustment and lubrica tion will keep your machine in the safest and most efficient condition possible Safety is an obligation of the machine owner The most important points of machine inspection ad justment and lubrication are explained on the following pages A WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components shocks or can start fires HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise speci fied can cause 8 1 Have a Yamaha dealer perform service if you are not familiar with machine ser vice EBU01221 Owner s manual and tool kit You are recommended to put this owner s m
17. charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine EBU00390 Fuse replacement 1 The fuse case is located under the seat 2 If the fuse is blown turn off the main switch and install a new fuse of the spec ified amperage Then turn on the switch es If the fuse immediately blows again consult a Yamaha dealer Specified fuse 20 A 2 Spare fuse A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rat ing Never use a material in place of the proper fuse CAUTION To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 8 45 EBU01215 Replacing a headlight bulb If a headlight bulb burns out replace the bulb as follows 1 Remove the headlight assembly by re moving the bolts 1 Headlight assembly 2 Bolt x 2 2 Disconnect the headlight coupler 3 Remove the screw 1 Headlight coupler 1 Screw 4 Remove the headlight cover from the headlight assembly 8 46 5 Remove the screw and pull the headlight NOTE unit out from its case Pull outward on the rear of the headlight unit and then pull outward on the front 6 Remove the headlight bulb holder cover 1 Screw
18. cock to OFF and apply the parking brake 1 Button 2 Lock plate 6 10 EBU01174 Parking on a slope A WARNING POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control in creasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline put the machine in low gear apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easily Bring the machine to a stop by applying the brakes in low gear Stop the engine and release the clutch lever With the rear brake applied apply the parking brake and slowly release the brake pedal 6 11 EBU00221 Accessories and loading EBU00222 Accessories Accessories can affect the handling and con trol of your ATV Keep the following in mind when considering an accessory or operating an ATV which has accessories e Choose only accessories designed for your ATV Your Yamaha dealer has a variety of genuine Yamaha accessories Other ac cessories may also be available on the market However it is not possible for Yamaha to test all non Yamaha accesso ries nor have any control over the quality or Suitability of them Choose a genuine Yamaha accessory or one that is equiva lent in design and quality e Accessories should b
19. condition Always follow the inspection and main tenance procedures and schedules de scribed in the Owner s Manual 5 2 EBU01166 Front and rear brakes Brake lever and brake pedal e Check that there is no free play in the brake lever If there is free play have a Yamaha dealer inspect the brake system e Check for correct brake pedal height See page 8 29 If the pedal height is incorrect have a Yamaha dealer adjust it e Check the operation of the lever and pedal They should move smoothly and there should be a firm feeling when the brakes are applied If not have a Yamaha dealer inspect the brake system Brake fluid level Check the brake fluid level Add fluid if neces sary See pages 8 26 8 27 Recommended brake fluid DOT 4 5 3 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs Apply the brakes firmly for one minute If there is any leakage have a Yamaha dealer inspect the brake system Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking per formance inspect the brake pads for wear See page 8 25 A WARNING POTENTIAL HAZARD improperly Riding with brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ri
20. drive chain The drive chain must be cleaned and lubricat ed at the intervals specified in the periodic maintenance and lubrication chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows a T gt 1 O rings CAUTION The drive chain must be lubricated after washing the ATV or riding in the rain 1 Clean the drive chain with kerosene and a small soft brush CAUTION To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION Do not use engine oil or any other lubri cants for the drive chain as they may con tain substances that could damage the O rings 8 37 EBU00356 Cable inspection and lubrication A WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a Yamaha dealer to replace them Recommended lubricant Yamaha chain and cable lube or SAE 10W3
21. foot operation Suspension Front Double wishbone Rear Swingarm link suspension Shock absorber Front Coil spring oil damper Rear Coil spring gas oil damper 10 4 MODEL YFM660R Wheel travel Front 230 mm 9 06 in Rear 220 mm 8 66 in Electrical Ignition system DC C D I Generator system A C magneto Battery type voltage capacity YTX14 BS 12 V 12 Ah Headlight type Krypton bulb Bulb voltage wattage x quantity Headlight Tail brake light Indicator warning lights 12V 30 W 30 W x 2 12V 5 W 21Wx 1 Neutral 12V 1 7W x1 Reverse 12V 1 7Wx 1 Coolant temperature 12V 1 7Wx 1 Fuse 20A EBU00430 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inop erative by any person other than for purposes of maintenance repair or replacement of any de vice or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Inta
22. in this Owner s Manu al For more information about the training course contact an authorized ATV deal er or call 1 800 887 2887 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 maneu vers Not recommended for children under 16 years of age A WARNING POTENTIAL HAZARD Failure to follow the age recommenda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc 7 5 This ATV is designed to carry operator only passengers prohibited A WARNING POTENTIAL HAZARD Carrying a passenger on this ATV WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers 7 6 Apparel A WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet eye pro tection and protective clothing WHAT CAN HAPPEN Operating without an approved motor cycle helmet in creases your chances of a
23. operate this ATV in fast flowing water or in water deeper than that spec ified in your Owner s Manual Remember that wet brakes may have re duced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings 7 34 Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability 7 35 CAUTION 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 con ditions 1 Check hose 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 7 36 A WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a colli sion Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always fol low proper procedures as describ
24. over backwards Never go over the top of any hill at high speed 7 26 An obstacle a sharp drop or another vehicle or person could be on the other side of the hill If you are climbing a hill and you find that you taiii have not properly judged your ability to make When crossing the side of a hill it to the top you should turn the ATV around Always follow proper procedures as de while you still have forward motion provided scribed in the Owner s Manual you have the room to do so and go down the Avoid hills with excessively slippery or hill loose surfaces Shift your weight to the A WARNING uphill side of the ATV POTENTIAL HAZARD Ha Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible 7 27 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 dis mount the ATV on the uphill side Physically turn the ATV around and then descend the hill If you start to roll backwards DO NOT
25. severe head injury or death in the event of an accident l Operating without eye protection can re sult in an accident and increases your chances of a severe injury in the event of an accident Protective clothing G Helmet 7 7 Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants Do not operate after consuming alcohol or A WARNING drugs Operator s performance capability is reduced by the influence of alcohol or drugs POTENTIAL HAZARD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV 7 8 Pre operation checks Always perform the pre operation checks list ed on page 5 1 before riding for safety and proper care of the ATV WARNING POTENTIAL HAZARD Failure to inspect the ATV before oper ating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always
26. the seat at the rear NOTE Make sure that the seat is securely fitted 1 Projection x 2 2 Seat holder x 2 4 15 EBU01104 Front shock absorber adjustment The spring preload can be adjusted to suit the rider s weight and riding conditions Adjust the spring preload as follows To increase the spring preload turn the ad justing ring in direction To decrease the spring preload turn the ad justing ring in direction 1 Spring preload adjusting ring 2 Position indicator NOTE A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Special wrench Standard position C A Minimum soft E Maximum hard 4 16 A WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set ting 4 17 EBU01207 Rear shock absorber adjustment Adjust the spring preload as follows The spring preload rebound damping and 1 Loosen the locknut compression damping forces of the rear 2 Turn the adjusting nut in direction to shock absorber can be adjusted to suit the rid increase the spring preload and in direc er s weight and the riding conditions A WARNING POTENTIAL HAZARD This shock absorber contains highly pressurized
27. use the rear brake to stop or try to put the ATV in gear The ATV could easily tip over backwards In stead dismount the ATV immediately on the uphill side 7 28 A WARNING POTENTIAL HAZARD Stalling rolling backwards or improper ly dismounting while climbing a hill WHAT CAN HAPPEN Could result in the ATV overturning HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking brake after you are stopped If you begin rolling backwards Keep weight uphill Never apply the rear brake while roll ing backwards Apply the front brake When fully stopped apply the rear brake as well and then lock the park ing brake Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the pro cedure described in the Owner s Manu 7 29 RIDING DOWNHILL When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as possible Move back on the seat and sit with your arms straight Choose a low gear which will allow the engine compression to do most of the braking for you Improper braking may cause a loss of traction Use caution while descending a hill with loose or slippery surfaces Braking ability and trac tion may be adversely affected by these sur faces Improper braking may also cause a loss of traction W
28. where pedestrians or children are not likely to touch it A WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en gine area could catch fire Someone touching the exhaust system during or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it 7 15 BE CAREFUL WHERE YOU RIDE This ATV is designed for off road use only Riding on paved surfaces can cause loss of control amp WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of con trol HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets 7 16 Do not ride on any public road street or high way Riding on public roads can result in colli sions with other vehicles A WARNING 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
29. with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher 1 9 L 1 67 Imp qt 2 01 US qt 1 95 L 1 72 Imp qt 2 06 US qt 2 3 L 2 02 Imp qt 2 43 US qt 10 2 MODEL YFM660R Radiator capacity including all routes 1 3 L 1 14 Imp qt 1 37 US qt Air filter Wet element Fuel Type UNLEADED GASOLINE ONLY Tank capacity 12 L 2 64 Imp gal 3 17 US gal Reserve amount 2 6 L 0 57 Imp gal 0 69 US gal Carburetor Type x quantity BSR33 x 1 Manufacturer MIKUNI Spark plug Type manufacturer DPR8EA 9 NGK Gap 0 8 0 9 mm 0 03 0 04 in Clutch Type Wet multiple disc Operation Left hand operation Transmission Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Transmission type Operation Spur gear 71 34 2 088 Chain drive 40 13 3 076 Constant mesh 5 speed forward 1 speed reverse Left foot operation MODEL YFM660R Gear ratio 1st 31 12 2 583 2nd 30 18 1 667 3rd 27 21 1 286 4th 22 21 1 047 5th 19 21 0 904 Reverse 33 25 x 25 18 1 833 Chassis Frame type Steel tube Caster angle F Trail 47 mm 1 85 in Tire Type Tubeless Size Front AT21x7 10 Size Rear AT20 x 10 9 Brake Front brake type Dual disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right
30. 0 motor oil EBU00737 Brake and shift pedal brake and clutch lever lubrication Lubricate the pivoting parts of each lever and pedal Recommended lubricant Lithium soap based grease all purpose grease 8 38 EBU01018 Front upper and lower arm pivot lubrication Lubricate the upper and lower arm pivots Recommended lubricant Lithium soap based grease 1 Upper grease nipple 2 Lower grease nipple x 2 1 Upper grease nipple 2 Lower grease nipple x 2 8 39 EBU00987 Rear arm pivot lubrication Lubricate the rear arm pivots Recommended lubricant Lithium soap based grease 1 Grease nipple 1 Grease nipple 8 40 EBU01112 Wheel removal 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut x 4 8 41 EBU00782 Wheel installation When installing a wheel reverse the removal procedure NOTE When installing a front wheel the arrow mark 4 on the tire must point toward the rotating direction of the wheel e When installing a rear wheel the wording on the tire SIDE FACING OUTWARDS must be facing outwards 1 SIDE FACING OUTWARDS Tighten the wheel nuts to the specified torque Wheel nut torque Front 45 Nm 4 5 m kgf 33 ft lbf Rear 45 Nm 4 5 m kgf 33 ft Ibf 1 Arrow mark 8 42 EBU00380 Battery This machine is equipped wit
31. 2 BAW GLY ena ai 8 43 Battery maintenance 008 8 44 Fuse replacement ceeee 8 44 Replacing a headlight bulb 8 45 Tail brake light bulb replacement ccssecceeeeeeees 8 50 Troubleshooting eee eeeeeeeeeeeeeee 8 51 Troubleshooting charts 0 8 52 gt 29 N _ CLEANING AND STORAGE 9 1 A CIGAning satanic ues 9 1 B SIOK AG serrr eeni 9 3 SPEGIFIGATIONS iis istiisoieiieiivedvs 10 1 NOISE REGULATION 006 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE VES ete eter 14 1 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS Read and understand all of the labels on your machine They contain important information for safe and proper operation of your ATV Never remove any labels from your ATV If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer O A WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 5FE 21697 01 A WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate e without proper tra
32. 4 5 kPa 0 245 kgf cm2 3 5 psi Rear 24 5 kPa 0 245 kgf cm2 3 5 psi Set pressure with tires cold 4 Use no more than the following P Set tire pressures to the following specifica pressures when seating the tire tions beads Front 250 kPa 2 5 kgf cm2 36 psi Recommended ie 2 i Minimum Maximum Rear 250 kPa 2 5 kgf cm 36 psi pressu Higher pressures may cause the 3 tet al ee allio ee ront 0 275 kgf cm 0 245 kgf cm gf cm tire to burst Inflate the tires very 4 0 psi 3 5 psi 4 4 psi slowly and carefully Fast inflation 576 Pa Bh Pa 30 5 kPa could cause the tire to burst Rear 0 275 kgf cm 0 245 kgf cm 0 305 kgf cm2 4 0 psi 3 5 psi 4 4 psi EBU00159 How to measure tire pressure Use the low pressure tire gauge NOTE The low pressure tire gauge is included as standard equipment Make two measure ments of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect 1 Low pressure tire gauge 5 10 EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a 3mm 0 12 in 5 11 EBU00161 OPERATION A WARNING Indicates a potential hazard that could result in serious injury or death A WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause a
33. E HAZARD POTENTIAL HAZARD Wait for the engine to cool before re Removing the radiator cap when the en moving the radiator cap Always use a gine and radiator are still hot thick rag over the cap Allow any re WHAT CAN HAPPEN maining pressure to escape before You could be burned by hot fluid and completely removing the cap steam blown out under pressure Ask a Yamaha dealer to inspect rm Leakage i and repair the cooling system Level is low check the cooling system for leakage No Wait until the Check the coolant level in the leakage Add cool nt S e NOTE engine has cooled reservoir tank and or radiator P Restart the engine If the engine overheats again ask a Level is OK a Yamaha dealer to inspect and or repair the cooling system NOTE If it is difficult to get the recommended coolant tap water can be temporarily used provided that it is changed to the recommended coolant as soon as possible 8 53 EBU00417 CLEANING AND STORAGE A CLEANING Frequent thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components 1 Before cleaning the machine a Block off the end of the exhaust pipe to prevent water entry A plastic bag and strong rubber band may be used b Make sure the spark plug and all filler caps are properly installed 2 If th
34. HA EXTENDED SERVICE If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 14 2 EBU00436 A WARNING Indicates a potential hazard that could result in serious injury or death EBU00437 PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual EBU00438 AWARNING Improper ATV use can result in SEVERE INJURY or DEATH NEVER USE ON PUBLIC ROADS ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions eon public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control NEVER USE WITH DRUGS OR ALCOHOL NEVER CARRY PASSENGERS ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For replacement manual call 1 800 532 1558 YAMAHA YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2002 04 5 1x1 CR E Dear Yamaha ATV Owner Ple
35. IED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION U S A AND EXCLUDED FROM THIS WARRANTY 13 1 SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 Po Pe p Po bo gt Oo PF P WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision damages and oil oil filters air filters spark plugs and brake shoes What are some examples of abnormal strain neglect or abuse These terms are general and overlap each other in areas Specific examples include Running the machine out of oil sustained high rpm full throttle operating the machine with a broken or damaged part which causes another part to fail damage or fai
36. NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE e THIS ATV IS A HIGH PERFORMANCE ATV FOR OFF ROAD USE ONLY FOR SPORT TYPE RECREATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING Failure to follow WARNING instructions could result in severe in jury or death to the machine operator a bystander or a person in specting or repairing the machine CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures easier or clearer EBU00011 IMPORTANT NOTICE This machine is designed and manufactured for OFF ROAD use only It is illegal and unsafe to operate this machine on any public street road or highway This machine complies with all applicable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine EBU00981 YFM660RR OWNER S MANUAL 2002 by Yamaha Motor Corporation U S A 1st edition March 2002 All rights reserved AFFIX DEALER LABEL HERE Any reprinting or unauthor
37. S from this warranty shall include any failures caused by a Competition or racing use b Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse Lack of proper maintenance Accident or collision damage Modification to original parts Damage due to improper transportation Toma p ATV LIMITED WARRANTY SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance such as spark plugs oil oil filter air filter and brake shoes THE CUSTOMER S RESPONSIBILITY under this war ranty shall be to 1 Operate and maintain the ATV as specified in the appropriate owner s manual 2 Give notice to an authorized Yamaha ATV dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPL
38. T use the flag pole bracket as a trailer hitch A WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles 7 20 WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch care fully for other vehicles Do not ride in areas posted no trespassing Do not ride on private property without getting permission Select a large flat area off road to become fa miliar 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 Al ways avoid riding on paved surfaces the ATV is designed for off road use only and han dling maneuvers are more difficult to perform on pavement Set the parking brake and follow the instruc tions on page 6 1 to start the engine Once it has warmed up you are ready to begin riding your ATV As you get on the ATV be sure not to accidentally move the shift pedal Remem ber that the engine and exhaust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these components 7 21 With the engine idling pull the clutch lever to disengage the clutch and shift into 1st gear and then release the parking brake Open the thr
39. TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings EBU00525 B STORAGE Long term storage 60 days or more of your machine will require some preventive proce dures to guard against deterioration After thoroughly cleaning the machine prepare for storage as follows 1 Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equiva lent product Specified amount 1 oz of stabilizer to each gallon of fuel or 7 5 cc of stabilizer to each liter of fuel NOTE Use of fuel stabilizer and conditioner elimi nates the need to drain the fuel system Con sult a Yamaha dealer if the fuel system needs to be drained instead 9 3 Remove the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine over seve ral times to coat the cylinder wall with oil Clean the drive chain thoroughly and lu bricate it See page 8 36 Lubricate all control cables Block up the frame to raise all wheels off the ground Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering If storing in a humid or salt air atmo sphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat cover 8 R
40. YAMAHA EBU00776 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 EBU01200 INTRODUCTION Congratulations on your purchase of the Yamaha YFM660R 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 crafts manship and reliability that have made Yamaha a leader in these fields This manual will provide you with a good basic understanding of the features and operation of this ATV This manual in cludes important safety information It provides information about special techniques and skills necessary to ride your ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE e READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS e PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV e NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV CALL 1 800 887 2887 FOR MORE INFORMATION e THIS ATV AND ANY OTHER ATV OVER 90cc SHOULD
41. al 1 Loosen the locknut Yamaha service technician 2 Turn the adjusting bolt until the throttle le ver free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut NOTE Adjust the engine idling speed before adjust ing the throttle lever free play 1 Locknut 2 Adjusting bolt a Throttle lever free play 8 24 EBU01027 Front and rear brake pad inspection Each brake pad is provided with a wear indi cator groove The indicators allow checking of brake pad wear without disassembling the brake Apply the brake and inspect the wear indicator grooves If the pad is worn to the point that the wear indicator grooves are al most in contact with the disc plate ask a Yamaha dealer to replace the pads 1 Wear indicator groove 8 25 EBU01214 Brake fluid level inspection Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indi cate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage 1 Minimum level mark 1 Minimum level mark NOTE To access the rear brake fluid reservoir re move the reservoir cover by removing the bolts 1 Brake fluid reservoir cover 2 Bolt x 2 Obser
42. al and tool kit 8 1 Periodic maintenance lubrication ssgeces lo tec doa ee eect otras 8 3 Panel removal and installation 8 5 Engine oil and oil filter cartridge 8 6 Cooling SYSteM cceeeeeeeeees 8 11 Changing the coolant 006 8 12 Spark plug inspection 06 8 15 Air filter element cleaning 8 18 Spark arrester cleaning 8 21 Carburetor adjustment 8 22 Idle speed adjustment 2 8 23 Valve clearance adjustment 8 24 Throttle lever adjustment 8 24 Front and rear brake pad INSPECTION lt 2t sccsecmusete ise see 8 25 Brake fluid level inspection 8 26 Brake fluid replacement 8 27 Front brake lever free play 8 28 Brake pedal height adjustment 8 29 Parking brake adjustment 8 30 Adjusting the rear brake light SWIC raige eis eecaets 8 32 Clutch lever free play adjustment 8 32 Drive chain slack check 8 34 Drive chain slack adjustment 8 35 Lubricating the drive chain 8 36 Cable inspection and lubrication 8 37 Brake and shift pedal brake and clutch lever lubrication 8 38 Front upper and lower arm pivot LUD TICA OM esos cost ceric peenacerrenlnct 8 39 Rear arm pivot lubrication 8 40 Wheel removal ceeeeeceeeees 8 41 Wheel installation ceee 8 4
43. anual and low pressure tire gauge in the vi nyl bag and always carry them along with the owner s tool kit under the seat 2 Owner s tool kit 1 Owner s manual 3 Low pressure tire gauge The service information included in this man ual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor re pairs 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 NOTE If you do not have a torque wrench available during a service operation requiring one take your machine to a Yamaha dealer to check the torque settings and adjust them as neces sary 8 2 A WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an autho rized Yamaha ATV dealer EBU00261 PERIODIC MAINTENANCE LUBRICATION ROUTINE INITIAL 3 months
44. ase Review this IMPORTANT SAFETY CARD before operating your ATV If card is not attached call 1 800 344 6418 Dear New Yamaha ATV Owner CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV You have purchased a quality Yamaha product that with proper use ant care will provide hours of riding pleasure BEFORE YOU OPERATE YOUR NEW ATV Yamaha recommends these important points READ YOUR OWNER S MANUAL e A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER e A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER THAN 90CC TAKE THE FREE HANDS ON TRAINING COURSE OFFERED BY YAMAHA ASK YOUR DEALER FOR DETAILS OR CALL 1 800 887 2887 If you have any questions about these points or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership please fill out the information below and mail this card to Yamaha today ATV Model Purchase Date READ CAREFULLY BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 4 CYPRESS CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U S A P O BOX 6555 CYPRESS CALIFORNIA 90630 9989 ATTN SALES ADMINISTRATION NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES
45. chine 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 the various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle oper ation or any condition which might result in ex cessive engine heating must be avoided However momentary 2 3 seconds maxi mum full throttle operation under load does not harm the engine 6 9 Each full throttle acceleration sequence should be followed with a substantial rest pe riod for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this peri od consult a Yamaha dealer 1 0 10 hours Avoid continuous operation above half throttle Allow a cooling off period of five to ten minutes after every hour of opera tion Vary the speed of the machine from time to time Do not operate it at one set throttle position 2 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the machine freely through the gears but do not use full throttle at any time 3 After break in Avoid prolonged full throttle operation Vary speeds occasionally EBU00211 Parking When parking stop the engine and shift into neutral Turn the fuel
46. d lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing e Make sure the brakes operate smoothly and that the free play is correct e Make sure the brakes do not drag e Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re quires professional knowledge These procedures should be performed by a Yamaha dealer EBU01191 Brake pedal height adjustment The top of the brake pedal should be posi tioned 4mm 0 16 in below the top of the footrest If not have a Yamaha dealer adjust it a Brake pedal position 8 29 A WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing e Make sure the brakes operate smoothly and that the brake pedal position is correct e Make sure the brakes do not drag e Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re quires professional knowledge These procedures should be performed by a Yamaha dealer EBU01193 Parking brake adjustment Parking brake adjustment may be required if the parking brake does not hold properly The cable length should be adjusted to 64 68 mm 2 52 2 68 in IES Wins ree Z 9 one a a IAN x Ly
47. damage runout Mies e Replace if necessary e Check bearing assemblies for looseness damage e Replace if damaged e Check operation e Repair if damaged e Check toe in e Adjust if necessary Front and rear e Check operation suspension e Correct if necessary Upper and lower arm piv ot and steering shaft Rear arm pivot e Lubricate every 6 months e Check all chassis fittings and fasteners e Correct if necessary e Check operation e Adjust headlight beam It is recommended that these items be serviced by a Yamaha dealer Lithium soap based grease NOTE Recommended brake fluid DOT4 Brake fluid replacement e When disassembling the master cylinders or calipers re place the brake fluid Normally check the brake fluid level and add fluid as re quired e On the inner parts of the master cylinders and calipers re place the oil seals every two years A WARNING a brake hoses every four years or if cracked or Indicates a potential hazard that could result in serious injury or death Wheel bearings Steering system e Lubricate every 6 months Fittings and fasteners Lights and switches kk 8 4 EBU00807 EBU01013 Panel removal and installation Panel A 1 PanelA 1 PanelA 2 Bolt x 2 The panel illustrated needs to be removed to To remove perform some of the maintenance described Remove the bolts and then take the panel off
48. de the ATV if you find any problem with the brakes If a problem cannot be corrected by the ad justment procedures provided in this manual have a Yamaha dealer check for the cause operating EBU01085 Fuel Make sure there is sufficient gasoline in the tank Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity Total 12 L 2 64 Imp gal 3 17 US gal Reserve 2 6 L 0 57 Imp gal 0 69 US gal CAUTION 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 research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug 5 4 life and reduced maintenance cost 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 Gaso hol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems 1 Fuel tank filler tube 2 Fuel level 5 5 A WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe inj
49. 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 7 32 A WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the 7 33 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 wa ter choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or up set the ATV Drive slowly and carefully A WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Never
50. ds to the throttle normally with the starter choke turned off NOTE When the parking brake is used engine speed is limited to 2 300 r min Be sure the parking brake is released before moving the throttle lever Otherwise the engine will mis fire preventing normal operation 6 4 EBU01209 Reverse knob operation and reverse driving CAUTION Before shifting stop the machine and re turn the throttle lever to its closed posi tion otherwise the transmission may be damaged 1 Bring the machine to a complete stop re turn the throttle lever to the closed posi tion apply the clutch lever and shift the transmission into first gear 2 While applying the brake pedal turn the reverse knob clockwise with your right hand 3 Shift the transmission into reverse by pressing down on the shift pedal 6 5 1 Reverse knob REV 2 Shift pedal NOTE When in reverse the reverse indicator light should be on If the light does not come on ask a Yamaha dealer to inspect the machine 4 Check behind you for people or obsta cles and then release the brake pedal 5 Open the throttle lever gradually and con tinue to watch to the rear while backing A WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person be hind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacl
51. e engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to the chain sprock ets or wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job 9 1 CAUTION Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car wash ers 4 Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bottle brush is handy for hard to get at places 5 Rinse the machine off immediately with clean water and dry all surfaces with a chamois clean towel or soft absorbent cloth 6 Dry the chain and lubricate it to prevent rust 7 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 8 Automotive type wax may be applied to all painted and chrome plated surfaces Avoid combination cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it idle for several minutes 9 2 A WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW
52. e rigidly and securely mounted An accessory which can shift po sition or come off while you are riding could affect your ability to control the ATV 6 12 e Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object attached to the han dlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when riding an ATV with accessories The ATV may handle differ ently than it does without accessories EBU00584 Loading As originally equipped this ATV is not de signed 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 e Never exceed the weight limits shown An overloaded ATV can be unstable MAXIMUM LOADING LIMIT Vehicle loading limit total weight of cargo rider and accessories 100 kg 220 Ib Load cargo on the carriers as close to the center of the vehicle as possible Put cargo at the rear of the front carrier and at the front of the rear carrier Center the load from side to side 6 13 Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an acci dent Make sure the load does not interfere with controls
53. ea with adequate ventilation EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION his manual 3 1 EBU00600 EBU00035 Identification number records Key identification number Record the key identification number vehicle The key identification number is stamped on identification number and model label infor the key as shown in the following illustration mation in the spaces provided for assistance This number can be used for ordering a new when ordering spare parts from a Yamaha key EZ dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER O 2 VEHICLE IDENTIFICATION NUMBER Ce 1 Key identification number 3 MODEL LABEL INFORMATION 3 2 EBU00036 EBU00787 Vehicle identification number Model label The vehicle identification number is stamped The model label is affixed to the location in the into the frame illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Vehicle identification number NOTE The vehicle identification number is used to identify your machine 1 Model label 3 3 EBU00039 CONTROL FUNCTIONS A WARNING Indicates a potential hazard that could result in serious injury or death EBU00942 Main switch Functions of the respective switch positions are as follows ON The engine can be started only at this po
54. ed in the Owner s Manual 7 37 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 position ing your weight over the front wheels will sometimes help 7 38 If the rear wheels of your ATV start to slide sideways control can usually be regained if there is room to do so by steering in the direc tion of the slide Applying the brakes or accel erating is not recommended until you have corrected the slide With practice over a period of time skill at controlled sliding can be developed The ter rain should be chosen carefully before at tempting such maneuvers since both stability and control are reduced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost 7 39 A WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or slid ing by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out o
55. elmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this ATV Never operate at speeds too fast for your skills or the conditions Always go at a speed that is proper for the terrain visibility and 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 maintenance procedures and schedules described in this man ual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Never operate on excessively rough slippery or loose terrain until you have learned and prac ticed the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain 2 2 Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hi
56. emove the battery and charge it Store it in a dry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the machine 9 4 EBU00428 SPECIFICATIONS MODEL YFM660R Dimension Overall length 1 830 mm 72 in Overall width 1 100 mm 43 3 in Overall height 1 150 mm 45 3 in Seat height 860 mm 33 9 in Wheel base 1 245mm 49in Ground clearance 265 mm 10 4 in Minimum turning radius 3 300 mm 129 9 in Basic weight With oil and full fuel tank 193 kg 426 Ib Engine Type Liquid cooled 4 stroke SOHC Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system Forward inclined single cylinder 660 cm 100x 84 mm 3 94 x 3 31 in 9 2 1 Electric starter Dry sump YFM660R Engine oil Type Recommended engine oil classification Quantity Periodic oil change With oil filter replacement Total amount 50 70 90 110 130 F oe mrs YAMALUBE 4 20W40 or SAE 20W40 a i i i ae YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 i 20 40 0 10 20 30 40 API Service SE SF SG type or higher CAUTION o O SS O In order to prevent clutch slippage since the en gine oil also lubricates the clutch do not mix any chemical additives Do not use oils
57. engine performance 1 Fuel Check if there is fuel in the fuel tank 2 Compression Use the electric starter to see if there is compression Turn the fuel cock There is compression Compression normal 3 Ignition iy Remove the spark plug and check the electrodes a 4 Battery No compression Ask a Yamaha dealer to inspect Wet Wipe clean with dry cloth y lever to ON r Turn the fuel cock Remove the fuel hose Check the Fuel cock is There is fusl lever to OFF from the fuel cock fuel flow No f el clogged Some fuel c Turn the fuel cock t Restart the engine a lever to RES Clean the i fuel cock No fuel Supply fuel gt Spark is good Ignition system is normal Dry Attach spark plug cap and ground to chassis Use the electric starter H Spark is weak Engine turns over y Use the electric starter 2 quickly Battery is good y Check the connections Engine turns over slowly 8 52 No spark n Adjust the spark plug gap or replace the spark plug inspect Ask a Yamaha dealer to Engine overheating WARNING HOW TO AVOID TH
58. er cartridge NOTE Make sure that the O ring is properly seated 9 Install a new oil filter cartridge and tighten it to the specified torque with a torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft Ibf 10 Install the crankcase engine oil drain bolt and the engine oil tank drain bolt and then tighten them to the specified torques Tightening torques Crankcase engine oil drain bolt 30 Nm 3 0 m kgf 22 ft lbf 11 12 13 Engine oil tank drain bolt 25 Nm 2 5 m kgf 18 ft lbf Pour only 1 75 L 1 54 Imp qt 1 88 US qt of the specified amount of recommended engine oil through the engine oil tank filler hole insert the dipstick and then tighten the oil tank filler cap Start the engine rev it several times and then turn it off Remove the engine oil tank filler cap and then gradually fill the oil tank with the re maining oil quantity while regularly checking the oil level on the dipstick 8 10 Recommended engine oil See page 10 2 Oil quantity Periodic oil change 1 9 L 1 67 Imp qt 2 01 US qt With oil filter cartridge replacement 1 95 L 1 72 Imp qt 2 06 US qt Total amount 2 3 L 2 02 Imp qt 2 43 US qt CAUTION 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 specification of CD or oils of a high er quality than specif
59. es or people behind you When it is safe to proceed go slow ly 6 6 EBU01173 Shifting This model has a 5 speed forward and 1 speed reverse transmission The transmission allows you to control the amount of power you have available at a given speed or for starting accel erating climbing hills etc To shift into neutral return the throttle lever to the closed position apply the clutch and repeatedly depress the shift pedal until it stops When it stops it will be in first gear Raise the pedal slightly to neutral 1 Shift pedal N Neutral position R Reverse CAUTION e Do not coast for long periods with the engine off and do not tow the ma chine a long distance Even in neutral position the transmission is only properly lubricated when the engine is running Inadequate lubrication may cause damage Always use the clutch when changing gears The engine transmission and drive train are not designed to with stand the shock of forced shifting and can be damaged by shifting without the clutch 6 7 EBU00203 To start out and accelerate 1 Release the throttle lever CAUTION Always close the throttle while shifting gears Otherwise damage to the engine and drive train may result 2 3 4 Pull the clutch lever to disengage the clutch Shift into first gear Open the throttle gradually and at the same time release the clutch lever slow ly Once the machine has attained adequate
60. ess of chassis fittings and fasteners before a ride Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque 5 8 EBU01003 Lights Check the headlights and tail orake light to make sure they are in working condition Re pair as necessary for proper operation EBU01170 Switches Check the operation of all switches Have a Yamaha dealer repair as necessary for proper operation EBU00157 Tires amp WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of acci dent HOW TO AVOID THE HAZARD 1 The tires listed below have been ap proved by Yamaha Motor Co Ltd for this model Other tire combina tions are not recommended Manufacturer Size DUNLOP AT21 x 7 10 DUNLOP AT20 x 10 9 5 9 2 The tires should be set to the rec ommended pressure e Recommended tire pressure Front 27 5 kPa 0 275 kgf cm2 4 0 psi Rear 27 5 kPa 0 275 kgf cm2 4 0 psi e Check and adjust tire pressures when the tires are cold e Tire pressures must be equal on both sides 3 Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions The following are minimums Front 2
61. f control 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 e If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight over the front wheels for better control See pages 7 23 7 24 e If your ATV begins to tip while turning Lean more into the turn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See pag es 7 23 7 24 7 40 e If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide See pages 7 38 7 39 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have for ward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the uphill side See pages 7 25 7 29 e If your ATV is traversing a sloping surface Be sure to ride with your weight positioned towards the uphill side of the ATV to main tain proper balance If the ATV starts to tip steer down the hill if there
62. f of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operation Avoid wheelies and jumping You may lose control of the ATV or overturn A WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off 7 13 Modifications A WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an autho rized ATV dealer 7 14 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
63. h a sealed type battery Therefore it is not necessary to check the electrolyte or add distilled water in the bat tery If the battery seems to have discharged HOW TO AVOID THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren consult a Yamaha dealer Kadete CAUTION EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magne sia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes Do not try to remove the sealing caps of the battery cells You may damage the bat tery WARNING and get prompt medical attention Keep POTENTIAL HAZARD batteries away from sparks flames cig Failure to handle batteries or battery arettes or other sources of ignition Ven electrolyte carefully tilate when charging or using in a closed WHAT CAN HAPPEN space You could be poisoned You could be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases 8 43 EBU00385 Battery maintenance 1 When the machine is not used for a month or longer remove the battery and store it in a cool dark place Completely recharge the battery before reinstallation CAUTION A special battery charger constant volt age ampere or constant voltage is re quired for recharging a sealed type battery Using a conventional battery
64. h in the lock plate to apply the parking brake Squeeze the clutch lever to release the parking brake NOTE When the parking brake is used engine speed is limited to 2 300 r min Be sure the parking brake is released before moving the throttle lever Otherwise the engine will mis fire preventing normal operation 4 10 1 Locked position A WARNING POTENTIAL HAZARD Improper use of the parking brake WHAT CAN HAPPEN The ATV could start moving unexpect edly 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 park ing brake You could lose braking per formance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine Always be sure you have released the parking brake before you begin to ride 4 11 EBU00788 Shift pedal This machine is equipped with a constant mesh 5 speed forward and 1 speed reverse transmission The shift pedal is located on the left side of the engine and is used in combina tion with the clutch when shifting 1 Shift pedal EBU01028 Reverse knob REV The reverse knob is used to shift into reverse gear Refer to the Reverse knob operation and re verse driving section page 6 5 before oper ating this machine in re
65. hen the engine is cold The coolant lev el will vary with engine temperature The coolant level is satisfactory if it is between the upper and lower level marks on the coolant reservoir If the coolant level is at or below the lower level mark add tap water soft water to bring the level up to upper level mark Change the coolant every two years See pages 8 11 8 15 for details CAUTION Hard water or salt water is harmful to the engine You may use distilled water if you cannot get soft water Coolant reservoir capacity 0 29 L 0 26 Imp qt 0 31 US qt 5 7 A WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before re moving the radiator cap Always use a thick rag over the cap Allow any re maining pressure to escape before completely removing the cap EBU00498 Chain Check the general condition of the chain and check the chain slack before every ride Lubri cate and adjust the chain as necessary See pages 8 34 8 37 for details EBU01083 Throttle lever Check to see that the throttle lever operates correctly It must open smoothly and spring back to the idle position when released Have a Yamaha dealer repair as necessary for proper operation EBU01162 Fittings and fasteners Always check the tightn
66. henever possible ride your ATV straight downhill Avoid sharp angles which could al low the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear 7 30 A WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for go ing down hills as described in this Own er s Manual Note a special technique is required when braking as you go down a hill Always check the terrain carefully be fore you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible 7 31 CROSSING A SLOPE Traversing a sloping surface on your ATV re quires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slippery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loose sur faces by pointing the front wheels slightly up hill When riding on slopes be sure not to make sharp turns either up or
67. ied In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase 14 15 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause Turn the engine off and then check the oil level and correct it if necessary 8 11 EBU01015 Cooling system 1 Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine tem perature The coolant level should be be tween the maximum and minimum marks 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark 2 If the level is low remove the coolant res ervoir cap and then add coolant or dis tilled water to raise it to the specified level Coolant reservoir capacity 0 29 L 0 26 Imp qt 0 31 US qt CAUTION Hard water or salt water is harmful to the engine You may use soft water if you can t get distilled water NOTE e f water is added have a Yamaha dealer check the antifreeze content of the cool ant as soon as possible e The radiator fan operation is completely automatic It is switched on or off accord ing to the coolant temperature in the radi ator If your ATV overheats see page 8 53 for de tails 8 12 EBU01016 Changing the coolant A WARNING POTENTIAL HAZARD Remov
68. ight switch which is activated by the brake pedal and brake lever is proper ly adjusted when the brake light comes on just before braking takes effect If necessary ad just the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction To make the brake light come on later turn the adjusting nut in direction 1 Rear brake light switch 2 Adjusting nut 8 32 EBU00741 Clutch lever free play adjustment The clutch lever free play should be adjusted to 5 10 mm 0 20 0 39 in 1 Loosen the locknut at the clutch lever 2 Turn the adjusting bolt at the clutch lever in direction to increase the free play or in direction to decrease the free play 3 Tighten the locknut at the clutch lever NOTE If the specified free play cannot be obtained proceed with the following steps 4 Loosen the locknut at the clutch lever 5 Turn the adjusting bolt at the clutch lever in direction to loosen the cable 6 Loosen the locknut at the crankcase side 7 Turn the adjusting nut at the crankcase in direction to increase the free play or in direction to decrease the free play 8 Tighten the locknut at the crankcase and the clutch lever 1 Locknut 2 Adjusting bolt c Clutch lever free play 1 Locknut 2 Adjusting nut 8 33 EBU01144 Drive chain slack check NOTE M
69. ime to fully learn techniques be fore attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Own ers Manual completely and understand the 7 3 operation of the controls Pay particular atten tion to the safety information on pages 2 1 2 7 Please also read all caution and warning labels on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified instructor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not attempt to operate at maximum perfor mance until you are totally familiar with the ATV s handling and performance characteris tics A WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in creased if the operator does not know how to operate the ATV properly in dif ferent situations and on different types of terrain 7 4 HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regularly practice the skills learned in the course and the operating tech niques described
70. imum soft 20 clicks out Standard 10 clicks out Maximum hard 3 clicks out 4 20 Adjust the compression damping force as fol lows Turn the compression damping force adjust ing screw in direction to increase the com pression damping force and in direction to decrease the compression damping force 1 Compression damping force adjusting screw From the fully turned out position Minimum soft 1 click in Standard 7 clicks in Maximum hard 12 clicks in CAUTION Never turn an adjusting mechanism be yond the minimum and maximum settings NOTE Although the total number of clicks of a damp ing force adjusting mechanism may not exact ly match the above specifications due to small differences in production the actual number of clicks always represents the entire adjust ing range To obtain a precise adjustment it would be advisable to check the number of clicks of each damping force adjusting mech anism and to modify the specifications as nec essary 4 21 A WARNING POTENTIAL HAZARD Suspension components become hot during operation WHAT CAN HAPPEN You could be burned HOW TO AVOID THE HAZARD Never touch the compression damping adjuster rebound damping adjuster or oil reservoir with your bare hand or skin until Suspension components have cooled EBU00112 A WARNING Indicates a potential hazard that could result in serious injury or death PRE OPERATION
71. ing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before re moving the radiator cap Always use a thick rag over the cap Allow any re maining pressure to escape before completely removing the cap Place the ATV on a level surface 4 Remove the radiator cap 2 Remove panel A See page 8 5 for pan el removal and installation procedures 3 Place a container under the engine and then remove the coolant drain bolt s 1 Radiator cap 1 Coolant drain bolt 8 13 5 Remove the coolant reservoir cap 6 Disconnect the hose on the coolant res ervoir side and then drain the coolant from the coolant reservoir 1 Coolant reservoir cap 2 Hose 7 After draining the coolant thoroughly flush the cooling system with clean tap water 8 Replace the coolant drain bolt washer if it is damaged and then tighten the coolant drain bolt to the specified torque 8 14 Tightening torque Coolant drain bolt 10 Nm 1 0 m kgf 7 ft lbf Install the coolant reservoir hose 10 Pour the recommended coolant into the radiator until it is full Fill the coolant reservoir with coolant up to the maximum level Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for alumi num engines Antifreeze and
72. ining or instruction e at speeds too fast for your skills or the conditions eon public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For replacement manual call 1 800 532 1558 5FE 21568 01 A WARNING Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH SFE 2151H 01 A WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires cold Recommended FRONT 27 5kPa 0 275kgf cm 4 Opsi Minimum FRONT 24 5kPa 0 245kgf cm 3 5psi REAR 24 5kPa 0 245kgf cm 3 5psi Never set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING Maximum Vehicle Load 100kg 220lbs Includes weight of operator cargo and accessories REAR 27 5kPa 0 275kgf cm 4 0psi ki 5LP 21696 00 1 3 AWARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions
73. inspect your ATV each time you use it to make sure the ATV is in safe op erating condition Always follow the in spection and maintenance procedures and schedules described in the Owner s Manual 7 9 A WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of an acci dent HOW TO AVOID THE HAZARD Always use the size and type tires spec ified in the Owner s Manual for this vehi cle on pages 5 9 5 10 Always maintain proper tire pressure as described in the Owner s Manual on page 5 10 A WARNING 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 amp WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing con trol of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain visibility and operating con ditions and your experience 7 10 Speed limiter For riders inexperienced with this model this model is equipped with a speed limiter in the throttle lever housing The speed limiter limits the powe
74. ized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 16 09 EBU00014 A WARNING Indicates a potential hazard that could result in serious injury or death o D CONTENTS LOCATION OF THE WARNING AND SPECIFICATION LABELG 1 1 SAFETY INFORMATION 04 2 1 DESCRIPTION AND MACHINE IDENTIFICATION ccecce 3 1 Identification number records 3 2 Key identification numbev 3 2 Vehicle identification number 3 3 Model label ccccecessseeeeeeeeeees 3 3 CONTROL FUNCTIONG 24 4 1 Main switch ptensnindtmeiinuineeads 4 1 Indicator and warning lights 4 2 Handlebar switches 4 4 Throttle leVer ccccssscccceeeeesseeeees 4 6 Speed limiter 4 7 Clutch lever ccceeesseeeeesseeeeeeseeees 4 8 Bra ke levt nen ina 4 8 Brake pedal iiiaciciandwaiiieiiiens 4 9 Parking brake ccceccceeeeeeeeees 4 10 Shit POC Altos size er eonun 4 11 Reverse Knob ccccecceeeseceees 4 12 Fuel tank cap s s ets et eine 4 12 FUG COCK nanne aa 4 13 Starter choke ceeeeeeeeeeeeees 4 14 SEA eerste vito SAA oh 4 14 Front shock absorber adjustment axeaseetecs ce atseaticense 4 16 Rear shock absorber adjustment rcice shievccmteneienlted 4 18 PRE OPERATION CHECKS 5 1 Front and rear brakes 000 5 3 FUG EE E
75. ke system Air cleaner element Intake duct 11 1 EBU00431 MAINTENANCE RECORD Copies of work orders and or receipts for parts you purchase and install will be required to docu ment maintenance done in accordance with the warranty The chart below is printed only as a re minder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE DATE OF SERVICING DEALER INTERVAL SERVICE MEARE NAME AND ADDRESS an ee 1 Month 3 Months 6 Months 12 Months 18 Months 24 Months 30 Months 36 Months 42 Months 48 Months 54 Months 60 Months EBU00432 YAMAHA MOTOR CORPORATION U S A Yamaha Motor Corporation U S A hereby warrants that new Yamaha ATV purchased from an authorized Yamaha ATV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein sub ject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha ATV s shall be six 6 months from the date of purchase DURING THE PERIOD OF WARRANTY any authorized Yamaha ATV dealer will free of charge repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corp U S A GENERAL EXCLUSION
76. knut 2 Adjustingscrew a 12mm 0 47 in 4 7 A WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an acci dent or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjust ed to 3 5 mm 0 12 0 20 in See page 8 24 EBU00069 Clutch lever The clutch lever is located on the left handle bar and the ignition circuit cut off system is in corporated in the clutch lever holder Pull the clutch lever to the handlebar to disengage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch operation Refer to Starting a cold engine for a de scription of the ignition circuit cut off system 1 Clutch lever EBU00988 Brake lever The brake lever is located on the right handle bar Pull it toward the handlebar to apply the front brake EBU00989 Brake pedal The brake pedal is located on the right side of the machine Push down on the pedal to apply the rear brake 1 Brake pedal 4 9 EBU00080 Parking brake Use the parking brake when you have to start the engine or park the machine especially on a slope Squeeze the clutch lever while push ing the button then pus
77. lls as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight back ward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if possible 2 3 Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stall ing use proper gear and maintain a steady speed when climbing a hill If you stall or roll back wards follow the special procedure for braking described in this manual Dismount on the uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual
78. lure due to improper or careless transportation and or tie down If you have any specific questions on operation or maintenance please contact your dealer for advice Does the warranty cover incidental costs such as towing or transportation due to a failure No The warranty is limited to repair of the machine itself May I perform any or all of the recommended maintenance shown in the Owner s Manual instead of having the dealer do them Yes if you are a qualified mechanic and follow the procedures specified in the Owner s and Service Manual We do recommend however that items requiring special tools or equipment be done by Yamaha ATV dealer Will the warranty be void or cancelled if do not operate or maintain my new ATV exactly as specified in the Owner s Manual No The warranty on a new ATV cannot be voided or cancelled However if a particular failure is caused by operation or maintenance other than as shown in the Owner s Manual that failure may not be covered under warranty What responsibility does my dealer have under this warranty Each Yamaha ATV dealer is expected to 1 Completely set up every new machine before sale 2 Explain the operation maintenance and warranty requirements to your satis faction at the time of sale and upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Is the warranty transferable to second owner
79. move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes ex cessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug Specified spark plug DPR8EA 9 NGK Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust Spark plug Tightening torque NOTE If a torque wrench is not available when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possible Spark plug gap 0 8 0 9 mm 0 03 0 04 in 4 Install the spark plug cap a Spark plug gap 2 Clean the gasket surface Wipe off any grime from the threads 3 Install the spark plug and tighten it to the specified torque 8 17 EBU01211 Air filter element cleaning NOTE There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case 1 Check hose 1 Remove the seat See page 4 14 for seat removal and installation proce dures 8 18 1 Air filter case cover 2 Holder x 6 2 3 4 Remove the air filter case cover by un hooking the holders Remove the air filter element Remove the air filter element from its frame
80. n accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer 6 1 EBU00789 Starting a cold engine A WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or colli sion HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding 1 Set the parking brake 2 Turn the fuel cock to ON 3 Turn the main switch to ON and the en gine stop switch to O 4 Shift the transmission into neutral NOTE This model is equipped with an ignition circuit cut off system The engine can be started un der the following conditions e When the transmission is in neutral The neutral indicator light should come on If the light does not come on ask a Yamaha dealer to inspect it e When the clutch is disengaged with the transmission in any position However it is recommended to shift into neutral be fore starting the engine 5 Use the starter choke in reference to the figure Position Cold engine start ambient temperature below 5 C 40 F Position Cold engine start ambient temperature at 0 C 30 F 30 C 90 F and warm ing up position Position Cold engine start ambient temperat
81. ng it inward and turning it clockwise 4 Install the lens by installing the screws 1 Lens 2 Screw x 2 2 Remove the defective bulb by pushing it CAUTION inward and turning it counterclockwise Do not overtighten the screws as the lens may break 8 50 EBU00412 Troubleshooting Although Yamaha machines receive a rigid in spection before shipment from the factory trouble may occur during operation Any prob lem in the fuel compression or ignition sys tems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your machine requires any repair take it to a Yamaha dealer The skilled technicians at a Yamaha dealer ship have the tools experience and know how to properly service your machine Use only genuine Yamaha parts on your machine Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to ex pensive repair bills 8 51 A WARNING POTENTIAL HAZARD Checking the fuel system while smok ing or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing se vere injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnac es EBU00806 Troubleshooting charts Starting problems or poor
82. nitrogen gas WHAT CAN HAPPEN The shock absorber could explode causing injury or property damage Cylinder damage could also result in poor handling which could cause an accident HOW TO AVOID THE HAZARD e Do not tamper with or attempt to open tion to decrease the spring preload 1 Spring preload adjusting nut 2 Locknut the cylinder assembly Senay e Do not subject the shock absorber to an open flame or other high heat e Do not deform or damage the cylinder in any way e Do not dispose of a damaged or worn out shock absorber yourself Take the unit to a Yamaha dealer NOTE A special wrench can be obtained at a Yamaha dealer to make this adjustment 3 The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjusting nut Measurement Installed length Minimum hard 232 mm 9 1 in Standard 240 mm 9 4 in Maximum soft 247 mm 9 7 in A Spring length 4 19 4 Tighten the locknut to the specified torque Tightening torque 42 Nm 4 2 m kgf 30 ft lbf CAUTION Always tighten the locknut against the ad justing nut and tighten it to the specified torque Adjust the rebound damping force as follows Turn the rebound damping force adjusting screw in direction to increase the rebound damping force and in direction to decrease the rebound damping force 1 Rebound damping force adjusting screw From the fully turned in position Min
83. or and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine CAUTION Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally op eration without the air filter element will af fect carburetor jetting with subsequent poor performance and possible engine overheating EBU00780 Spark arrester cleaning 2 Remove the tailpipe by pulling it out of Be sure the exhaust pipe and muffler are cool the muffler before cleaning the spark arrester 3 Tap the tailpipe lightly then use a wire 1 Remove the bolt brush to remove any carbon deposits from the spark arrester portion of the tailpipe 1 Bolt 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the bolt and tighten it 8 21 A WARNING 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 poison ing possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool pri or to touching exhaust components Do not start the engine when cleaning the exhaust system 8 22 EBU00296 Carburetor adjustment
84. or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slow er you should go Although conditions vary it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trailer Allow more braking distance A heavier ve hicle takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose ter rain carefully Added weight affects the sta bility and handling of the ATV amp WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking 6 14 EBU01176 A WARNING Indicates a potential hazard that could result in serious injury or death 6 16 7 2 A WARNING Indicates a potential hazard that could result in serious injury or death GETTING TO KNOW YOUR ATV This ATV is intended for recreational use by experienced operators only Even though you are an experienced operator of all other all terrain vehicles or motorcycles riding the ATV requires special skills acquired through practice Take your t
85. ottle gradually and at the same time re lease the clutch lever slowly Once the ATV has attained adequate speed release the throttle lever and at the same time quickly pull in the clutch lever and shift into 2nd gear Open the throttle part way and gradually re lease the clutch Use this same procedure as you move into the higher gears Be sure to co ordinate the use of the throttle and shift pedal properly If the throttle is applied too abruptly or if the throttle is not released during shifting or if the shift pedal is not released before ap plying the throttle the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds until you are thoroughly familiar with the operation of your ATV 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 Improp er use of the brakes or shifting can cause the tires to lose traction reducing control and in creasing the possibility of an accident A WARNING A WARNING POTENTIAL HAZARD Opening the throttle abruptly or releas ing the clutch lever to quickly WHAT CAN HAPPEN The ATV could wheelie This would in crease the chance of an accident in cluding overturn HOW TO AVOID THE HAZARD Open the throttle gradually Release the clutch lever gradually CAUTION Do not shif
86. ove the ATV back and forth and find the tightest position of the drive chain Check and or adjust the chain slack while it is in this tight est position To check the drive chain slack all tires must be touching the ground and there should be no weight on it Check the drive chain slack at the position shown in the illustration Normal slack is approximately 27 37 mm 1 1 1 5 in If the slack exceeds 37 mm 1 5 in adjust it to specification 8 34 a Drive chain slack EBU01194 Drive chain slack adjustment 1 Loosen the rear wheel hub upper and lower nuts 2 Lower wheel hub nut 1 Upper wheel hub nut 2 Loosen the locknuts on each side of the swingarm To tighten the drive chain turn the adjusting bolts in direction To loosen the drive chain turn the adjusting bolts in direction and push the wheels forward Turn each adjusting bolt exactly the same amount to maintain correct axle alignment 8 35 NOTE There are alignment marks on each side of the swingarm and on the hub Use them to check for proper wheel axle alignment 1 Locknut x 2 3 Alignment marks 3 After adjusting tighten the locknuts and the wheel hub nuts to the specified torques 2 Adjusting bolt x 2 Tightening torques Locknut 16 Nm 1 6 m kgf 12 ft lbf Upper wheel hub nut 90 Nm 9 0 m kgf 65 ft lbf Lower wheel hub nut 90 Nm 9 0 m kgf 65 ft lbf 8 36 EBU00805 Lubricating the
87. r and top speed of the ATV Turning the adjusting screw in decreases the top speed and turning it out increases the top speed See page 4 7 for details 1 Locknut 2 Adjusting screw Loading and accessories Use extra caution when riding the ATV with additional loads such as accessories or car go The ATV s handling may be adversely af fected Reduce your speed when adding additional loads MAXIMUM LOADING LIMIT Vehicle loading limit total weight of rider cargo and accessories 100 kg 220 Ib 7 11 A WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in your Owner s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the footboards dur ing operation Otherwise your feet may con tact the rear wheels 7 12 A WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation WHAT CAN HAPPEN Removing even one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall of
88. s Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain effective 13 2 CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha ATV dealer within the continental United States Be sure to bring your warranty registration card or other valid proof of the original date of purchase If a question or problem arises regarding warranty first contact the owner of the dealership Since all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model V I N frame number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and recall This list is compiled from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your new ATV please advise u
89. s of your new address by sending a postcard listing your ATV model name V I N frame number dealer number or dealer s name as it is shown on your warranty card your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 Attention Warranty Department This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law EBU00435 YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service Y E S e Y E S is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction You get uninterrupted factory backed coverage for extra peace of mind Y E S is flexible You choose the plan that s right for you 12 months 24 months or 36 months beyond your warranty period Y E S is designed and administered by the same Yamaha people who handle your warranty and it shows in the comprehensive coverage benefits There are no mileage limitations Coverage isn t limited to moving parts or the drive train like many other plans And Y E S covers manufacturing defects just like the warranty See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be You don t have to pay anything for covered repairs There s no deductible to pay and repairs aren t
90. side of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneu ver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly Lean towards ao inside of turn l Support your weight on the outer footboard 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 sur face is slippery or loose it may help to posi tion more of your weight over the front wheels by moving forward on the seat 7 24 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 movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the in side It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL Use proper riding techniques to avoid vehicle o
91. sition and the headlights and taillight come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position 4 1 ON EBU00802 Indicator and warning lights 1 Reverse indicator light R 2 Neutral indicator light N 3 Coolant temperature warning light EBU00602 Reverse indicator light R This indicator light comes on when the trans mission is in reverse EBU00603 Neutral indicator light N This indicator light comes on when the trans mission is in neutral i EBU00713 Coolant temperature warning light When the coolant temperature reaches a specified level this light comes on to warn that the coolant temperature is too hot If the light comes on during operation stop the en gine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes The coolant temperature warning light circuit can be checked according to the procedure on page 4 3 CAUTION e The engine may overheat if the ATV is overloaded If this happens reduce the load to specification e Restart after making sure that the light is out Continuous use while the light is on may cause damage to the en gine EBU00714 Coolant temperature warning light checking method Turn the main switch to ON and the engine stop switch to O Coolant temperature warning light does not come on
92. t gears without releasing the throttle Damage to the engine or drive train may occur 7 22 POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating This could cause loss of control an accident and injury It could also cause engine or drive train damage HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear 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 in side of the turn is allowed to slip or lose some traction the ATV will resist turning A special turning technique must be used to allow the ATV to make turns quickly and easily It is es sential that this skill be learned first at low speed A WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN The ATV could go out of control caus ing a collision or overturn 7 23 HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner s Manual Practice turning at low speeds before at tempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions As you approach a curve slow down and be gin to turn the handlebars in the desired direc tion AS you do so put your weight on the footboard to the out
93. ter motor cranks the engine when this switch is pushed CAUTION See starting instructions prior to starting the engine See page 6 1 for details 4 5 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 1 Throttle lever 4 6 Before starting the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the le ver is released amp WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine If it does not work smoothly check for the cause Correct the problem before riding the ATV Consult a Yamaha dealer if you can t find or solve the problem yourself EBU01159 Speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum Turning in the ad justing screw limits the maximum engine pow er available and decreases the maximum speed of the ATV 1 Loc
94. ure above 25 C 80 F and warm engine start position AMBIENT TEMP STARTER CHOKE POSITION 30 C 0 10 20 30 50 70 90 F 1 Fully open 3 Closed 6 Completely close the throttle lever and start the engine by pushing the start switch 2 Half open NOTE If the engine fails to start release the start switch then push it again Pause a few sec onds before the next attempt Each cranking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt 7 If the engine is started with the starter choke in position the starter choke should be returned to position to warm up the engine If the engine is started with the starter choke in position keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter choke to position before riding 6 3 CAUTION See the Engine break in section prior to operating engine for the first time 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 EBU00538 Warming up To get maximum engine life always warm up the engine before starting off Never acceler ate hard with a cold engine To see whether or not the engine is warm check if it respon
95. ury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and is still very hot EBU01084 Engine oil Make sure the engine oil is at the specified level Add oil as necessary See page 8 6 Recommended oil 30 50 i 90 110 130 F i i 2 YAMALUBE 4 owa or SAE 20W40 YAMALUBE 4 Gowen or SAE 10W30 SAE 5W30 l 20 10 0 10 20 30 40 50C Recommended engine oil classification API Service SE SF SG type or higher 5 6 CAUTION e 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 specification of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher e Make sure that no foreign material en ters the crankcase Oil quantity Periodic oil change 1 9 L 1 67 Imp qt 2 01 US qt With oil filter replacement 1 95 L 1 72 Imp qt 2 06 US qt Total amount 2 3 L 2 02 Imp qt 2 43 US qt EBU01127 Coolant Check the coolant level in the coolant reser voir w
96. ve these precautions e When checking the brake fluid level make sure the top of the brake fluid reservoir is level e Use only the designated quality brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Recommended brake fluid DOT 4 8 27 Refill with the same type of brake fluid Mix ing fluids may result in a harmful chemical reaction and lead to poor brake perfor mance Be careful that water does not enter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfac es or plastic parts Always clean up spilled fluid immediately Have a Yamaha dealer check the cause if the brake fluid level goes down EBU01186 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking e Replace the oil seals every two years e Replace the brake hoses every four years EBU01187 Front brake lever free play The front brake lever should have a free play of zero mm zero in at the lever end If not have a Yamaha dealer check the brake sys tem a Brake lever free play 8 28 A WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You coul
97. verse gear 1 Reverse knob REV EBU00092 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 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 With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling return the fuel cock lever to the ON position 4 13 EBU00095 Starter choke lt N Starting a cold engine requires a richer air fuel mixture A separate starter circuit supplies this mixture Move in direction to turn on the starter choke Move in direction to turn off the starter choke Refer to Starting a cold engine for proper op eration See page 6 1 1 Starter choke 4 N 4 14 EBU01010 Seat To remove the seat insert your hand between the rear of the seat and the rear fender pull the seat lock lever upward and pull up the seat at the rear 1 Seat lock lever To install the seat insert the projections on the front of the seat into the seat holders and push down on
98. verturns on hills Be sure that you can ma neuver your ATV well on flat ground before at tempting 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 sur faces or obstacles that might cause you to lose control WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small hills 7 25 HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempt ing large hills It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by lean ing forward and on steeper inclines standing on the footboards and leaning forward over the handlebars A WARNING 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 Own er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV could flip
99. water mixing ratio 1 1 Total amount 1 3 L 1 14 Imp qt 1 37 US qt Coolant reservoir capacity 0 29 L 0 26 Imp qt 0 31 US qt CAUTION Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water 12 13 14 15 NOTE Install the radiator cap and the coolant reservoir cap Start the engine and let it idle for several minutes Stop the engine and then check the coolant level in the radiator If it is low add more coolant until it reaches the top of the radiator Check the coolant level in the reservoir If it is low add coolant to the maximum lev el mark Start the engine and then check for cool ant leakage If any leakage is found have a Yamaha deal er check the cooling system 16 Install the panel 8 15 EBU00680 Spark plug inspection Removal 1 Remove the spark plug cap 1 Spark plug cap 2 Use the spark plug wrench in the tool kit to remove the spark plug as shown 1 Spark plug wrench 8 16 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 The ideal color on the white insulator around the center electrode is a medium to light tan color for a ATV that is being ridden normally Do not attempt to diagnose such problems yourself Instead take the ATV to a Yamaha dealer You should periodically re
100. y Com mission at 1 800 638 2772 or the ATV Distributor s Safety Hotline at 1 800 852 5344 2 5 A WARNING 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 refuel ing 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 while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pi lot lights of water heaters and clothes dryers 2 6 When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF posi tion Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes 2 7 A WARNING POTENTIAL HAZARD Starting or running the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an ar

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