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Cisco Systems 7941 IP Phone User Manual

1. wei q i If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill EWB01190 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 tech nique 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 pos sible 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 ATV 7 21 OK lu ke hk ll i ke hil N 1 w 1 ie w u a mi a Heh N ERI If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to lose control If you are unable to continue up the hill dismount the ATV on the up hill side Physically turn the ATV around and then descend the hill If you start to roll backwards DO NOT apply the rear brake to stop or try to put the ATV in gear The ATV c
2. cay iC y uw i XN y NY om _ th 7 RG Y aa ONDES b K eS 1 Fully open ON 2 Half open warming up position 3 Closed OFF 4 Choke EBU18870 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear 4 12 Y uf NS KE Q A a S 1 Seat lock lever To install the seat Insert the projection on the front of the seat into the seat holder and push down on the seat at the rear NOTE gt Make sure that the seat is securely fitted 1 Projection 2 Seat holder EBU18950 Carrier Do not exceed the load limit of 5 0 kg 11 Ib for the carrier Do not exceed the maximum load of 95 0 kg 209 Ib for the ATV EWBO00010 Indicates a potential hazard that could result in serious injury or death 4 13 EBU19200 PRE OPERATION CHECKS EBU19210 Pre operation check list Before operating this ATV be sure to check the items listed in the following table NOTE gt The maintenance of some items in the table has to be performed by a Yamaha dealer Refer to the Periodic maintenance and lubrication chart on page 8 3 to determine which service should be performed by a 5 Yamaha dealer e Check fuel level in fuel tank and add recommended fuel if neces sary 4 8 5 3 e Check fuel line for leakage Correct if necessary e Check oil level in engine and add recommended oil to specified level if necessary 5 3 8
3. Is the warranty transferable to second owners 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 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
4. When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch Do not ride in areas posted no trespassing Do not ride on private property without getting per mission ss 0 WAS i cael a Su Select a large flat area off road to become familiar 4 WARNING with your ATV Make sure that this area is free of POTENTIAL HAZARD obstacles and other riders You should practice Operating in areas where you might not be control of the throttle brakes shifting procedures seen by other off road vehicles and turning techniques in this area before trying WHAT CAN HAPPEN more difficult terrain Always avoid riding on paved You could be in a collision You could be in surfaces the ATV is designed for off road use jured only and handling maneuvers are more difficult to HOW TO AVOID THE HAZARD perform on pavement Always mount a caution flag on the ATV to Set the parking brake and follow the instruction on make you more visible Watch carefully for page 6 1 to start the engine Once it has warmed other vehicles up you are ready to begin riding your ATV As you get on the ATV be sure not to accidentally move 7 16 the shift pedal Remember that the engine and ex haust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these components With the engi
5. NOTE Be sure the battery is fully charged 1 Install the battery Connect the positive lead first and then con nect the negative lead Make sure that the breather hose is properly routed in good condition and not obstructed 1 Battery 2 Negative lead 3 Positive lead 8 34 ECB00610 CAUTION If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the battery the frame could suf fer structural and external damages EBU25232 Replacing the fuse 1 Fuse 2 Spare fuse The fuse holder is located under the seat See page 4 12 8 35 If the fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits ECBO00640 CAUTION To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 2 Remove the blown fuse and then install a new fuse of the specified amperage Specified fuse 5 0 A EWB02151 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 rating Never use a material in place of the proper fuse 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical syst
6. cccccseeees 7 23 CROSSING THROUGH SHALLOW WATER creere 7 24 RIDING OVER ROUGH TERRAIN 7 26 SLIDING AND SKIDDING 0008 7 27 WHAF TO DO F insnet 7 28 WHAFTO DO remeras E 7 28 PERIODIC MAINTENANCE AND MINOR REPAU senenin ge sncetvacitaentrentiaaternnetiass 8 1 Owner s manual and tool Kit 005 8 1 Periodic maintenance chart for the emission control system aisecGuciaoniistassondusecareunsanenainct 8 3 General maintenance and lubrication CR e a secanseceabecassuseeseaceadet anaes 8 5 Checking the spark plug ccseeeeeeeeees 8 8 ENGINE Oll ssrdirorsioissins i 8 10 Final gear oil ss siscesatessscartueonsdineanectdncdsmnenaas 8 13 Cleaning the air filter element 8 14 Removing the air intake restrictor plate 8 18 Cleaning the spark arrester 08 8 18 Adjusting the carburetor ccseceeees 8 20 Adjusting the engine idling speed 8 20 Checking the throttle cable free play 8 21 TIMIN CNAIN ctoatetasncGosscostenteaninaawtegaunncawers 8 22 Valve clearance cccceccceeceeeseeeeneneeees 8 22 Checking the front and rear brake SNOOS serros reren ee EEaren 8 22 Adjusting the front brake lever free play 8 23 Adjusting the rear brake lever and brake pedal free play ccceecceseseeeeeeeeeeeeeees 8 25 Adjusting the clutch free play 8 28 Checking and lubricating the cables 8 29 Ch
7. oughly in solvent EWB01900 POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode 8 17 HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material 6 Squeeze the excess solvent out of the sponge material and let it dry ECB00440 CAUTION Do not twist the sponge material when squeez ing it 7 Check the sponge material and replace it if damaged 8 Apply Yamaha foam air filter oil or other qual ity foam air filter oil to the sponge material NOTE gt 73 CCU The sponge material should be wet but not drip ping 9 Install the sponge material into the air filter el ement 10 Place the air filter element in the original posi tion and then hook the holder 11 Install the air filter case cover by hooking the holders onto the air filter case 12 Place the panel in the original position and then install the quick fasteners NOTE The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions ECB00460 CAUTION Make sure that the air filter element is prop erly seated in the air filter case Never operate the engine with the air fil
8. 2400 mm 94 5 in Weight With oil and fuel 124 0 kg 273 Ib Engine 10 Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 79 0 cm 4 82 cu in Bore x stroke 47 0 x 45 6 mm 1 85 x 1 80 in SPECIFICATIONS Compression ratio 9 60 1 Starting system Electric starter Lubrication system Wet sump Engine oll Type YAMALUBE 4 SAE5W30 or SAE10W30 or SAE20W40 0 10 30 50 70 90 1 ni 130 F YAMALUBE 4 20W40 or SAE 20W40 7 YAMALUBE 4 10W30 or SAE 10W30 SET a E a S 20 10 0 10 20 30 40 50C Recommended engine oil grade API service SE SF SG type or higher 10 1 Engine oil quantity Periodic oil change 0 80 L 0 85 US qt 0 70 Imp qt Final gear oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 12 L 0 13 US qt 0 11 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 6 8 L 1 80 US gal 1 50 Imp gal Fuel reserve amount 0 9 L 0 24 US gal 0 20 Imp gal Carburetor Manufacturer MIKUNI Type x quantity VM16SH x 1 Spark plug s Manufacturer model NGK CR7HSA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet multiple disc automatic Transmission Primary reduction system Spur gear Primary reduction ratio 65 20 3 250 Secondary reduction system Shaft drive Secondary reduction ratio 19 1
9. AND ANY OTHER ATV OVER 70 cc SHOULD NOT BE OPERATED BY A CHILD UNDER 12 YEARS OF AGE AN IMPORTANT NOTE TO PARENTS This ATV is not a toy Before you let your child ride this ATV you should understand the instructions and warnings in this Owner s Manual Then be sure your child understands and will follow them Children differ in skills physical abilities and judgment Some children may not be able to operate an ATV safely Parents should supervise their child s use of the ATV at all times Parents should permit continued use only if they determine that the child has the ability to operate the ATV safely Your ATV was delivered with an adjustable speed limiter and also with an air intake restrictor plate Yamaha recommends that all beginners start off with the speed limiter screw turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn The limiter screw may be gradually turned out to increase maximum speed as the beginner becomes more familiar with operating the ATV Par ents should decide when to adjust the ATV for more power as their youngster s riding skills improve Once the ATV rider can operate with skill at the top soeed permitted by adjusting the speed limiter alone the air intake restrictor plate can be removed Since removal of this plate will result in a significant increase in pow er turn the speed limiter back in again adjust it out in stages as you did before If your c
10. EBU25070 Lubricating the knuckle shafts The knuckle shafts must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart 8 31 Lubricate the knuckle shafts using a grease gun Recommended lubricant Lithium soap based grease 1 Grease nipple EBU25090 Lubricating the steering shaft The steering shaft must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart Lubricate the steering shaft using a grease gun To check the electrolyte level 1 Place the ATV on a level surface Recommended lubricant 2 Check the electrolyte level in the battery Lithium soap based grease SSS 1 Battery 2 Battery breather hose 1 Grease nipple EBU25111 NOTE gt Battery The electrolyte should be between the minimum A poorly maintained battery will corrode and dis and maximum level marks charge quickly The electrolyte level battery lead 3 If the electrolyte is at or below the minimum connections and breather hose routing should be level mark add distilled water to raise it to the checked before each ride and at the intervals maximum level mark specified in the periodic maintenance and lubrica tion chart 8 32 WHAT CAN HAPPEN You could be poisoned You could be severe ly burned by the sulfuric acid in battery elec trolyte Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothin
11. The key can be re moved 4 1 1 Main switch OFF a N ON x 1 EBU17780 EBU18060 Indicator light Handlebar switches NS 1 Neutral indicator light N 1 Engine stop switch ENG STOP 2 Start switch START EBU17860 Neutral indicator light N EBU18070 This indicator light comes on when the transmis Engine stop switch ENG STOP sion is in the neutral position Set this switch to RUN before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run when this switch is set to OFP 4 2 EBU18090 Start switch START Push this switch to crank the engine with the start er ECB00050 CAUTION See the starting instructions on page 6 1 prior to starting the engine EBU18270 Throttle lever Once the engine is running movement of the throt tle lever will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decelerate and the engine will return to an idle any time the hand is removed from the throttle lever 4 3 1 Throttle lever 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 lever is released EWB00200 WARNING POTENT
12. 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 CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL 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 2006 3 0 6x1 A E Dear Yamaha ATV Owner Please 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 and care will provide hours of riding pleasure BEFORE YOU OPERATE YOUR NEW ATV Yamaha recommends these important points READ YOUR OWNER S MANUAL A CHILD UNDER 6 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 50CC OR GREATER A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER 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 y
13. 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 dealers 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 EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation USA also warrants to the ultimate purchaser and each subsequent pur chaser of each 2006 and later model Yamaha ATV covered by this warranty that the vehicle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the period listed immediately below Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and or lack of proper maintenance are not covered by this warranty All Models Thirty 30 months from the original purchase date YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED
14. 10 e Check ATV for oil leakage Correct if necessary Final gear oil e Check ATV for oil leakage Correct if necessary 5 3 8 13 e Check operation and correct if necessary Front brake e Lubricate cable if necessary 5 3 8 22 8 23 e Check lever free play and adjust if necessary e Check operation and correct if necessary Rear brake e Lubricate cable if necessary 5 3 8 22 8 25 e Check lever and pedal free play and adjust if necessary e Make sure that operation is smooth and check cable free play a Be TAVOLE EVET e Lubricate cable and lever housing if necessary oes Control cables e Make sure that operation is smooth Lubricate if necessary 5 1 e Check wheel condition and replace if damaged Wheels and tires e Check tire condition and tread depth Replace if necessary 5 5 5 6 5 7 e Check air pressure Correct if necessary e Make sure that operation is smooth Lubricate pedal pivoting points e Make sure that operation is smooth Lubricate lever pivoting points if necessary Chassis fasteners e Make sure that all nuts bolts and screws are properly tightened Instruments and switches Check operation and correct if necessary Battery e Check electrolyte level Fill with distilled water if necessary 5 7 8 32 EWB00470 A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment
15. 12 V 7 0 Ah Bulb voltage wattage x quantity Neutral indicator light 12V 1 7Wx1 Fuses Main fuse 5 0 A 10 4 EBU25981 CONSUMER INFORMATION EBU26011 Identification numbers Record the key identification number vehicle iden tification number and model label information in the spaces provided below for assistance when or dering spare parts from a Yamaha dealer or for ref erence in case the ATV is stolen KEY IDENTIFICATION NUMBER so VEHICLE IDENTIFICATION NUMBER a MODEL LABEL INFORMATION 11 1 EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key 1 Key identification number EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame 1 Vehicle identification number NOTE gt The vehicle identification number is used to identi fy your ATV EBU26050 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha deal er 11 2 1 Model label EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person oth
16. 200 800 1600 1600 3200 Chassis fasteners Shock absorber e Check operation and correct if necessary assemblies e Check for oil leakage and replace if necessary e Lubricate with lithium soap based grease Knuckle shafts e Lubricate with lithium soap based grease p e Check operation and repair or replace if damaged e Check toe in and adjust if necessary e Check ATV for oil leakage and correct if neces sary e Change Final gear oil e Check ATV for oil leakage and correct if neces sary L Moving parts and Lubricate cables L e Check operation and correct if necessary Throttle lever hous e Check throttle cable free play and have a Yamaha ing and cable dealer adjust if necessary e Lubricate throttle lever housing and cable a pP TONI andirear Brake Check operation and correct if necessary V y y y y switches ay oe 8 6 on CHECK on maintenance Whichev month 1 3 6 6 122 JOB ercomes km 320 1300 2500 2500 5000 first mi 200 800 1600 1600 3200 e Check electrolyte level and specific gravity and correct if necessary eatiory e Make sure that the breather hose is properly y y 1 y i routed EBU23060 NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas 8 7 EWB00010 Indicates a potential hazard that could result in serious injury or death EBU23210
17. 6 5 a control or function you do not understand prior to operating the engine for the first time ask your Yamaha dealer a Suaepaanesee a SSS Set the parking brake 2 Turn the fuel cock to ON 3 Turn the main switch to ON and the engine stop switch to RUN 4 Shift the transmission into neutral The neutral indicator light should come on If the indicator 6 1 light does not come on have a Yamaha deal er check the electrical circuit NOTE gt This model is equipped with an ignition circuit cut off system The engine can be started under the following conditions The transmission is in neutral The rear brake lever is applied with the transmis sion in any gear However it is recommended to shift into neutral before starting the engine 6 5 Use the choke in reference to the figure Position 1 Cold engine start with ambient temperature be low 30 C 90 F Position 2 Warming up position Position 3 Cold engine start with ambient temperature above 25 C 80 F 6 2 Ambient temp choke position 0 10 20 30 C 50 1 30 70 1 Fully open ON 2 Half open warming up position 3 Closed OFF 4 Choke 6 Completely close the throttle lever and start the engine by pushing the start switch NOTE gt If the engine fails to start release the start switch then push it again Pause a few seconds before the next atte
18. 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 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 gt O gt O gt O gt O O WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period The customers 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 failu
19. HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear ECB00190 CAUTION Even with the transmission in the neutral posi tion do not coast for long periods of time with the engine off and do not tow the ATV for long distances The transmission is properly lubri cated only when the engine is running Inade quate lubrication may damage _ the transmission 6 5 EBU20670 Engine break in There is never a more important period in the life of your engine than the first 20 hours of riding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the first 20 hours The various parts in the engine wear and polish themselves to the correct operating clearances During this peri od prolonged full throttle operation or any condi tion that might result in engine overheating must be avoided 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine through the gears freely but do not use full throttle at any time 20 hours and beyond The ATV can now be operated normally ECB00220 CAUTION If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the ATV EBU20721 Parking When parking the
20. Yamaha See your dealer today A special note 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 11 8 Y YAMAHA EXTENDED SERVICE Indicates a potential hazard that could result in serious injury or death EBU26132 PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts and Accessories See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual INDEX A Engine idling SPCC wi cisccec cas cevues deutv ess degaedevaeeeeniebvatededens 8 20 Accessories ANC loading 0ccceccceesecsseceescesseeeeseesseeenees 6 7 lg le goa eee ree are eee een teres Tenner Poe ee 5 3 8 10 Air filter element ClEANING cccccececeesseeeeesteeeerees 8 14 Engine starting a warm secastecacotcnintsuotncthtecesulsvetredecetnaanecs 6 3 Air intake restrictor plate reMOVING c cccceeceeeees 8 18 Engine stop SWIC cicnaxdacseasamnanstainchuedaasenassandonaraaneuasiancs 4 2 B F SCC ce ee se eee 5 7 8 32 Final gear Oil sees teeseeeeetesnsneetenaenes 5 3 8 13 Brake and shift pedals checking and lubricating 8 31 FN assent beets ponent ease endos eaecapeneteatensceedh ek 4 8 5 3 Brake lever and brake pedal free play rear eal Bre Cine tear mene nat gt SUN rer ene pnt ES er ey cn ea 4 10 UNS UNG errora arena Ai wntee can
21. allow the operator to shift position as needed during operation It is not for carrying pas sengers Apparel EWB00920 POTENTIAL HAZARD Operating this ATV without wearing an ap proved motorcycle helmet eye protection and protective clothing WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an acci dent Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing in creases your chances of severe injury in the event of an accident 7 5 HOW TO AVOID THE HAZARD Do not operate after consuming alcohol or Always wear an approved motorcycle helmet drugs that fits properly The operators performance capability is reduced You should also wear by the influence of alcohol or drugs eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants Protective clothing Goggles Gloves Boots Helmet ar WND 7 6 EWB00930 A WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and mainte nance procedures and schedules described Could seriously affect
22. cas cesiee aceneteatencescesecessnceane 4 11 E ene ane eee nee ere eee 4 12 RUM E E E E E ates 4 13 PRE OPERATION CHECKS 00cceeees 5 1 Pre operation Check list cccecceseeeeeeees 5 1 FUGI ene e e a e e 5 3 ENONS Ol samora paia 5 3 Final gear OM soctiaacatenaeqersaoueesacumsnaecmeetaouea 5 3 Front and rear brakes cccccseeeseeeeeeees 5 3 Throttle lever cccccecececeseseeeeeeeeseeeseeees 5 4 NIN S E E E AE T A 5 5 Measuring the tire pressure a se 5 6 Tire wear limit nnannnnnnannanennnnnnnnnnennnnnnnnnne 5 7 Chassis fasteners ccccceeeesseeeseeeeseeeees 5 7 Instruments lights and switches 5 7 BARGI crores iN 5 7 OPERATION isore iesi EE 6 1 Starting a cold engine ceeeeeeesseeeeeees 6 1 Starting a warm ENGINE cccceseeeeeee ees 6 3 SAUNG Sa gsagie acca noses asses ordennensodeeceacoesiranteees 6 3 Engine break in cccesceseseceeseeeeseeeneeeens 6 5 P a E E 6 6 Parking on a slope ccc ceseceeseeenseeeneeeens 6 6 Accessories and loading s 6 7 RIDING YOUR ATV ssscesivcsimtincscsiinsnsoumcstnsces 7 1 GETTING TO KNOW YOUR ATV 7 2 RIDE WITH CARE AND GOOD JUDGEMENT sescca nsere Ernan 7 2 BE CAREFUL WHERE YOU RIDE 7 13 TURNING YOUR ATV wsiesiesiercorvnetumcdniceeinens 7 17 CLIMBING UPHILL wwcsisiscidntoniensaxsisuinaraana 7 19 RIDING DOWNHILL 7 22 CROSSING A SLOPE
23. fast flowing water Test your brakes after leaving the water Do not or in water deeper than that specified in your continue to ride your ATV without verifying that you Owner s Manual have regained proper braking ability Remember that wet brakes may have re duced stopping ability Test your brakes af ter leaving water If necessary apply them several times to let friction dry out the lin ings 7 25 ECB00240 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 conditions 7 26 A 1 Air filter case check hose RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau tion Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac cident 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 re sult EWB01160 A WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for ob stacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper pro If the rear
24. for several 8 12 EBU23403 Final gear oil The final gear case must be checked for oil leak age before each ride If any leakage is found have a Yamaha dealer check and repair the ATV In ad dition the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface NOTE The final gear oil level must be checked on a cold engine 2 Remove the final gear oil filler cap wipe the dipstick off with a clean rag insert it back into the oil filler hole without screwing it in and then remove it again to check the oil level NOTE The final gear oil should be between the minimum and maximum level marks 3 Ifthe oil is at or below the minimum level mark add sufficient oil of the recommended type to raise it to the correct level 8 13 1 Dipstick 2 Maximum level mark 3 Minimum level mark 4 Insert the dipstick into the oil filler hole and ES then tighten the oil filler cap To change the final gear oil 1 Place the ATV on a level surface 2 Place an oil pan under the final gear case to collect the used oil 3 Remove the final gear oil filler cap and the fi nal gear oil drain bolt to drain the oil from the final gear case 1 Final gear oil drain bolt 4 Install the drain bolt and then tighten it to the specified torque Tightening torq
25. property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys tem Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces EBU25791 Troubleshooting chart 1 Fuel There is enough fuel Check the compression The engine does not start Th fuel ener Auppiy isl Check the compression There is compression Check the ignition Check the fuel level in the fuel tank 2 Compression Operate the electric starter Have a Yamaha dealer check the ATV Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV There is no compression 3 Ignition Open the throttle halfway and operate the electric starter The engine does not start Check the battery The engine turns over quickly The engine does not start Operate the electric starter Have a Yamaha dealer The engine turns over Check the electrolyte level recharge the check the ATV slowly battery and check the lead connections Remove the spark plug and check the electrodes 4 Battery The battery is good 8 38 EBU25860 CLEANING AND STORAGE EBU25870 Cleaning Frequent thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many componenis 1 Before cleaning the ATV a Blo
26. stages as done previously 1 Loosen the locknut 2 Toincrease the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction a To de crease the maximum engine power available and the maximum speed of the ATV turn the adjusting screw in direction b NOTE Adjusting for maximum throttle lever movement without removing the air intake restrictor plate will cause the engine to run roughly at higher speeds See page 8 18 1 Locknut 2 Adjusting screw 3 No more than 20 mm 0 8 in 3 Tighten the locknut EWB00180 POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Im proper throttle operation could result The child could lose control have an accident or be injured 4 5 HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 20 mm 0 8 in EBU18391 Front brake lever The front brake lever is located on the right handle bar To apply the front brake pull the brake lever fa toward the handlebar grip 1 Front brake lever EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar To apply the rear brake push down on the brake pedal or pull the brake lever toward the handlebar grip _ 7 a lt N EW FAS i oe ot oe ae 1 Rear brake lever S
27. system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust components haust system EBU23940 Adjusting the carburetor The carburetor should be checked and if neces sary adjusted at the intervals specified in the peri odic maintenance and lubrication chart The carburetor is an important part of the engine and requires very sophisticated adjustment Therefore most carburetor adjustments should be left to a 8 20 Yamaha dealer who has the necessary profes sional knowledge and experience The adjustment described in the following section however may be performed by the owner as part of routine main tenance ECB00480 CAUTION The carburetor has been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor performance of or damage to the engine EBU24000 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica tion chart NOTE gt A diagnostic tachometer is needed to make this adjustment 1 Start the engine and warm it up NOTE gt The engine is warm when it qui
28. your judgment in the Owner s Manual Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV EWB00950 A WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or opera tion of this ATV with improper or uneven tire pressure may cause loss of control increas ing your risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual for this ATV on page 5 5 Always maintain proper tire pressure as de scribed in the Owner s Manual on page 5 6 Pre operation checks Always perform the pre operation checks listed on page 5 1 before riding for proper care of the ATV and to ensure safety EWBO00940 POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage 7 7 EWBO00010 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 EWB00960 a WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of lo
29. 8 x 34 10 3 588 Transmission type Constant mesh 3 speed Operation Left foot operation 1st 39 11 3 545 2nd 35 17 2 059 3rd 31 22 1 409 Chassis Frame type Steel tube frame Caster angle 1 0 Trail 3 8 mm 0 15 in Front tire Type Tubeless Size AT18 x 7 7 10 2 Manufacturer model DUNLOP KT586 Rear tire Type Tubeless Size AT18 x 8 7 Manufacturer model DUNLOP KT587 Loading Maximum load 95 0 kg 209 Ib Total weight of rider cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 20 kPa 2 9 psi 0 20 kgf cm Rear 20 kPa 2 9 psi 0 20 kgf cm Minimum Front 17 kPa 2 5 psi 0 17 kgf cm Rear 17 kPa 2 5 psi 0 17 kgf cm Maximum Front 23 kPa 3 3 psi 0 23 kgf cm Rear 23 kPa 3 3 psi 0 23 kgf cm 10 3 Front wheel Wheel type Panel wheel Rim size 7X5 5AT Rear wheel Wheel type Panel wheel Rim size 7X6 5AT Front brake Type Drum brake Operation Right hand operation Rear brake Type Drum brake Operation Left hand and right foot operation Front suspension Type Leading arm Spring shock absorber type Coil spring oil damper Wheel travel 57 0 mm 2 24 in Rear suspension Type Swingarm Spring shock absorber type Coil spring oil damper Wheel travel 56 0 mm 2 20 in Electrical system Ignition system CDI Charging system AC magneto Battery Model 12N7D 3B Voltage capacity
30. ATV stop the engine shift into 6 first gear apply the parking brake and then turn the fuel cock to OFF 1 Locked position EBU20830 Parking on a slope EWB00790 POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control increasing the chance of an accident 1 Parking brake lock plate 6 6 Avoid parking on hills or other inclines If you Accessories and loading must park on an incline place the ATV trans auipesee versely across the incline shift into first Accessories gear stop the engine apply the parking Accessories can affect the handling and control of brake and then block the front and rear your ATV Keep the following in mind when consid wheels with rocks or other objects ering an accessory or operating an ATV which has Do not park the ATV at all on hills that are so accessories steep you could not walk up them easily Choose only accessories designed for your ATV Your Yamaha dealer has a variety of gen uine Yamaha accessories Other accessories may also be available on the market However it is not possible for Yamaha to test all non Yamaha accessories nor control over their qual ity or suitability Choose a genuine Yamaha ac cessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding could affect your abil
31. Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accor dance with the periodic maintenance and lubrica tion chart In addition the condition of the spark 1 Spark plug cap plug can reveal the condition of the engine 2 Remove the spark plug as shown with the To remove the spark plug spark plug wrench included in the owner s tool 1 Remove the spark plug cap kit 8 8 1 Spark plug wrench To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally NOTE gt If the spark plug shows a distinctly different color the engine could be defective Do not attempt to di agnose such problems yourself Instead have a Yamaha dealer check the ATV 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and 8 9 replace it if necessary Specified spark plug NGK CR7HSA To install the spark plug 1 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification Spark plug gap 0 6 0 7 mm 0 024 0 028 in 1 Spark plug gap 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads
32. IAL 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 be fore 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 EBU18331 Speed limiter and air intake restrictor plate Your ATV was delivered with an adjustable speed limiter and an air intake restrictor plate Yamaha recommends that all beginning riders start off with the speed limiter adjusting screw fully turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn The speed limiter keeps the throttle from fully 4 4 opening even when the throttle lever is pushed to the maximum The adjusting screw may be gradu ally turned out as the beginner becomes more fa miliar with operating the ATV Parents should decide when to adjust the ATV for more power as their youngsters riding skills improve Once the ATV rider can operate with skill at the top speed permitted by adjusting the speed limiter alone the air intake restrictor plate can be removed Since re moval of this plate will result in a significant in crease in power turn the adjusting screw completely back in again adjust it out in
33. IOSS OT CONTrOl E R 20 kPa 0 20 kgf cm Tan eMinimum FRONT 17 kPa 0 17 kgf cm resulting in SEVERE REAR 17 eo Siem INJURY or DEATH eNever set tire pressure below minimum It could cause the tire to dislodge from the rim 5FE 2151H 01 LOADING eMaximum Vehicle Load 95 kg 209 lbs l Includes weight of operator cargo and accessories 4EM 21696 11 9 9 5 5 psi psi psi psi A WARNING NEVER sit here 3MX 24875 A0 2 3 EBU17680 EBU17690 Left view Fuel cock Rear carrier Rear wheel Footboard Shift pedal Choke Front wheel NOoR OD DESCRIPTION EBU17700 Right view Spark arrester Seat Panel Brake pedal Footboard oROND EBU17712 from the figures shown in this manual Controls and instruments 1 2 3 __S N EN ERNIA Kr e we oE L i 7 6 1 Rear brake lever 2 Parking brake 3 Neutral indicator light 4 Front brake lever 5 Throttle lever 6 Main switch 7 Fuel tank cap 8 Handlebar switches NOTE gt The ATV you have purchased may differ slightly 3 2 EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WANS Ne Indicates a potential hazard that could result in serious injury or death EBU17740 Main switch The positions of the main switch are as follows ON All electrical systems are supplied with power and the engine can be started The key cannot be re moved OFF All electrical systems are off
34. Install the spark plug with the spark plug wrench and then tighten it to the specified torque Tightening torque Spark plug 12 5 Nm 1 3 m kgf 9 0 ft lbf NOTE gt y If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 4 Install the spark plug cap EBU23251 Engine oil The engine oil level should be checked before each ride In addition the oil must be changed at the intervals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the ATV on a level surface 8 10 Start the engine warm it up for several min utes and then turn it off Wait a few minutes until the oil settles before checking Remove the engine oil filler cap and then wipe the dipstick off with a clean rag S weg uy CORA DLO SAS o 1 Dipstick 5 Insert the dipstick into the filler hole without screwing it in and then remove it again to check the oil level 2 Start the engine warm it up for several min utes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase 1 Dipstick 2 Maximum level mark 3 Minimum level mark NOTE ee The eng
35. Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag 3 Gua Replacement of brake components requires 3 Bolt professional knowledge These procedures should be performed by a Yamaha dealer 1 Footboard 2 Remove the rubber cap 3 Loosen the locknut alee 4 Slowly turn the adjusting bolt clockwise until Adjusting the clutch free play resistance is felt and then turn it 1 8 counter The clutch free play must be adjusted periodically clockwise Adjust the free play as follows 1 Remove the left footboard by removing the screws and bolts 8 28 gt 1 Rubber cap 2 Locknut 3 Adjusting bolt NOTE Turning the adjusting bolt in decreases clutch free play and turning it out increases clutch free play 5 Tighten the locknut to the specified torque Tightening torque Locknut 8 Nm 0 8 m kof 5 8 ft lbf NOTE When tightening the locknut hold the adjusting 8 29 bolt with a screwdriver so that the adjusting bolt does not turn together with the locknut 6 T Install the rubber cap securely Install the left footboard by installing the screws and bolts and then tighten the bolts to the specified torque Tightening torque Footboard bolt 10 Nm 1 0 m kof 7 2 ft lbf EBU24890 Checking and lubricating the cables The operation and the condition of all control ca bles should be checked before each ride and the cable
36. There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs e n 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 your ATV 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
37. WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each section on riding tech niques completely WHAT TO DO f 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 page 7 17 f your ATV begins to tip while turning Lean more into the turn to regain balance If nec essary gradually let off the throttle and or steer to the outside of the turn See page 7 17 e f 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 page 7 27 f your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have forward 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 Instead apply the front brake or dis mount the ATV on the uphill side See page 7 19 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if there are no obstac
38. YAMAHA wal ae EBU17091 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 EBU17170 INTRODUCTION EBU17240 Congratulations on your purchase of the Yamaha YFM80GW This ATV represents the result of many years of Yamaha experience in the production of fine sporting touring and pacesetting racing machines With the purchase of this Yamaha you can now appreciate the high degree of craftsmanship and reliability that have 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 includes important safety information It provides information about special tech niques and skills necessary to ride the 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 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE LY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV 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 INFORMA TION THIS ATV
39. YOUR ATV This ATV is for recreation use This section Riding your ATV provides general ATV riding instructions for recreational riding The skills and techniques described in this section however are appropriate for all types of riding Riding your ATV requires special skills acquired through practice over a pe riod of time Take the time to learn the basic tech niques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable ac tivity 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 Owner s Manual completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 1 1 1 4 Please also read all caution and warning labels on your ATV 7 2 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified in structor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until you are totally familiar with the ATV s handling and performance characteristics EWB01280 A WARNING POTENTIAL HAZARD Operating this ATV without proper instruc tion WHAT CAN HAPPEN The risk of an accident is greatly increased if the oper
40. a to increase the free play and in direction b to decrease it 8 24 1 Upper locknut 2 Upper adjusting bolt 3 Lower locknut 4 Lower adjusting bolt 4 Tighten the lower locknut 5 While applying the front brake turn out the up per adjusting bolt until the upper and lower ca ble lengths are equal The cable joint will become vertical 1 Cable joint 6 Tighten the upper locknut EWB02020 POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident 8 25 HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer EBU24462 Adjusting the rear brake lever and brake pedal free play The brake lever and brake pedal free play must be checked and if necessary adjusted at the inter vals specified in the periodic maintenance and lu brication chart NOTE Always perform this maintenance completely in the following order whenever adjusting the rear brake Before adjusting the brake lever and brake pedal free play check the rear brake shoes for wear Adjusting the brake lever free play The brake lever free play should measure 5 0 8 0 mm 0 20 0 31 in as shown If t
41. ator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regu larly practice the skills learned in the course and the operating techniques described in this Owner s Manual For more information about the training course contact an autho rized ATV dealer 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 maneuvers Not recommended for children under 12 years 7 3 of age EWB01210 A WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not recom mended for their age can lead to severe inju ry or death of the child HOW TO AVOID THE HAZARD A child under 12 should never operate an ATV with engine size greater than 70 cc This ATV is designed to carry operator and cargo only passengers prohibited EWBO00910 POTENTIAL HAZARD Carrying a passenger on this ATV WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passen ger 7 4 HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to
42. ccceeeeeeeeeeees 8 5 Engine break in selene reentrant a diepeaseeeehetcasde ses 6 5 Maintenance chart emission control System 00 8 3 Engine cold start cde smetsictinsecwtoct en oanetuietictendwatwiinnatudeBotooncass 6 1 MAINTENANCE FOCOPL coco coco ccccccccccccceccncencccccceccccccccccceccece 11 4 Model label ccccccecececececececececeeeceeaeeecececueeseeavaeaeaeees 11 2 TS cetera rector eeeneec oe rere eee eeewttcnecneeueateteas 5 5 N Wie wear NIN easten 5 7 Neutral indicator light cccccccsecssscesseeseseeeseeeseeess 4 2 Hlige 0 lt 1 a 0 9 a c amerer pee ter eoiecen peceen eer te tne erat reer tae ener 8 37 Noise regulation ccccccsccssscccsseeesseeeesseeeseeeesseeesaees 11 3 TROUDISSMOOUNG CNA Eesges 8 38 O V Owners Manual AN tool Kit 5 occcccccccccccccceccccccccccececece 8 1 Valve clearance eee eecececcececcececeeeececeeceseeeeceseeaeeeeaeaes 8 22 P Vehicle identification NUMDET cesseeeeeesseeeeeeeeees 11 1 E E ER eee ene en nen eer en ee eee ee 6 6 W Parking Oe Sa csecp ctecez cca ccetapcuacupnvatecesccaescapesaustenreaeiasaaecs 4 6 Waranty EXICNIOEG sscintssnccassadssicinanseitatandienthiaediastes hls Parking on a SlOp cacecceinsscnnspcevsnienciosnisudsnentorianienchisiotsuecte 6 6 Warranty ag cle nnee 11 5 Part locations 22 ccceieeiosssssaiorasesessadenssseveesecessaeaeasevsanneneesns 3 1 Wheel bearings CheCking ccccscccceeeessssteeee
43. ck 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 Ifthe engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job ECB00710 CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed from improper high pressure detergent 9 1 applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach places 5 Rinse the ATV off immediately with clean wa ter and dry all surfaces with a chamois clean towel or soft absorbing cloth 6 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 7 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 protec tive finish When finished cleaning start the engine and let it idle for several minutes EWB02300 A WARNING POTENTIAL HAZARD Operation with wet brakes aft
44. ckly responds to the throttle 2 Attach the tachometer to the spark plug lead 3 Check the engine idling speed and if neces sary adjust it to specification by turning the throttle stop screw at the carburetor To in crease the engine idling speed turn the throt tle stop screw in direction a w to decrease it turn the screw in direction b lt 1 Throttle stop screw Engine idling speed 1750 1850 r min 8 21 NOTE gt If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EBU27070 Checking the throttle cable free play The throttle cable free play should be checked at the intervals specified in the periodic maintenance and lubrication chart The throttle cable free play can be checked by measuring the throttle lever free play 1 0 3 0 mm 0 04 0 12 in as shown Periodically check the throttle cable free play and if necessary have a Yamaha dealer adjust it 1 Throttle lever free play EBU24050 Timing chain The timing chain stretches with use resulting in im proper valve timing and engine noise To prevent this from occurring the timing chain tensioner must be adjusted by a Yamaha dealer at the inter vals specified in the periodic maintenance and lu brication chart EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To 8 22 prevent this from occurr
45. cm Minimum Front 17 kPa 2 5 psi 0 17 kgf cm Rear 17 kPa 2 5 psi 0 17 kgf cm Maximum Front 23 kPa 3 3 psi 0 23 kgf cm Rear 23 kPa 3 3 psi 0 23 kgf cm EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm 0 12 in 1 Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary EBU19860 Battery Check the fluid level in the battery Fill with distilled water if necessary See page 8 32 EBU19870 OPERATION EWBO00010 EBU20211 A WARNING Starting a cold engine Indicates a potential hazard that could result in meen serious injury or death EBU19890 EWB00610 A WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls WHAT CAN HAPPEN WARNING POTENTIAL HAZARD Frozen control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding Loss of control which could cause an acci ECBO00150 dent or injury HOW TO AVOID THE HAZARD CAUTION Read the Owner s Manual carefully If there is See the Engine break in section on page
46. d 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 ATVs 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 EXCLUSIONS 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 Q 4 0 AO 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
47. d stop rotating This could cause loss of control an accident and injury It could also cause engine or drive train dam age 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 There fore unless the wheel on the inside of the turn is al lowed to slip or lose some traction the ATV will resist turning A special turning technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed EWB01220 a WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN The ATV could go out of control causing a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner s Manual Prac tice turning at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the condi tions As you approach a curve slow down and begin to turn the handlebars in the desired direction As you do so put your weight on the footboard to the out 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 maneuver will let the wheel on the inside 7 18 of the turn
48. damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual 5 2 EBU19530 Fuel Make sure that there is sufficient fuel in the tank See page 4 8 EWBO00500 A WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and se vere injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and is still very hot EBU19560 Engine oil Make sure that the engine oil is at the specified lev el Add oil as necessary See page 8 10 5 3 EBU19590 Final gear oil Make sure that the final gear oil is at the specified level Add oil as necessary See page 8 13 EBU19660 Front and rear brakes Brake levers and brake pedal Check for correct free play in the brake levers and brake pedal If the free play is incorrect ad just it See pages 8 23 and 8 25 Check operation of the brake levers and brake pedal They should move smoothly and there
49. 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 EWBO01141 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 tech nique 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 24 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 ATV CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving shal low water of up to a maximum of 20 cm 8 in in depth Before entering the water choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or upset the ATV Drive slowly and care fully EWB01150 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 acci dent HOW TO AVOID THE HAZARD Never operate this ATV in
50. e f EBU18450 Parking brake Use the parking brake before starting the engine or parking the ATV especially on a slope Apply the rear brake lever and push down the lock plate to apply the parking brake Squeeze the rear brake lever to release the parking brake 1 Brake pedal 4 6 1 p J ry A 1 Parking brake lock plate EWB00170 POTENTIAL HAZARD Improper use of the parking brake WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before start ing the engine This could cause loss of con trol or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine Always be sure you have released the park ing brake before you begin to ride EBU18550 Shift pedal This ATV is equipped with a constant mesh 3 speed transmission The shift pedal is located on the left side of the engine Neutral is at the bottom position 1 Shift pedal 2 Neutral position EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise 4 8 Q X N D O NZ Fm ae 1 Fuel tank cap EBU18730 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tub
51. e as shown rings as well as to the exhaust system Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or a research oc tane number of 91 or higher If Knocking or pinging occurs use a different brand of gasoline or premi um unleaded fuel Unleaded fuel will give you long er spark plug life and reduced maintenance cost a Gasohol There are two types of gasohol gasohol contain 1 Filler tube ing ethanol and that containing methanol Gasohol 2 Fuel level containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing Recommended fuel methanol is not recommended by Yamaha be UNLEADED GASOLINE ONLY cause it can cause damage to the fuel system or Fuel tank capacity ATV performance problems 6 8 L 1 80 US gal 1 50 Imp gal Fuel reserve amount 0 9 L 0 24 US gal 0 20 Imp gal ECB00070 CAUTION Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston 4 9 EWB00270 A WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and se vere injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especiall
52. e engine area could catch fire Someone touching the exhaust system dur ing 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 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 ina place where pedestrians or children are not likely to touch it EWB01010 POTENTIAL HAZARD Hot exhaust system 7 12 BE CAREFUL WHERE YOU RIDE This ATV is designed for off road use only Riding on paved surfaces can cause loss of control EWB01020 A 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 han dling and control of the ATV and may cause the ATV to go out of control HOW TO AVOID THE HAZARD Always avoid paved surfaces including side walks driveways parking lots and streets Do not ride on any public road street or highway Riding on public roads can result in collisions with other vehicles EWB01030 POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with anoth
53. e oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparking during the next step d Turn the engine over several times with the starter This will coat the cylinder wall with oil e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap Lubricate all control cables and the pivoting points of all levers and pedals Check and if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative ly turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot Cover the muffler outlet with a plastic bag to prevent moisture from entering it Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an excessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more information on storing the battery see page 8 32 9 3 NOTE Make any necessary repairs before storing the ATV EBU25960 EBU25974 Dimensions Overall length 1550 mm 61 0 in Overall width 855 mm 33 7 in Overall height 930 mm 36 6 in Seat height 665 mm 26 2 in Wheelbase 1030 mm 40 6 in Ground clearance 100 mm 3 94 in Minimum turning radius
54. ecking and lubricating the front and rear brake levers assnsessssssesesrsesrssenes 8 30 Checking and lubricating the brake and shift pedals sicivesinandaverstuinenueosindvensetsewweass 8 31 Checking the wheel bearings 5 8 31 Lubricating the knuckle shafts 8 31 Lubricating the steering shaft 8 31 DONOIY spenne et tales sumectaieesc 8 32 Replacing the fuse ceeeceseeseeeeeeeeees 8 35 REMOVING a wheel ccccsesecesesseeseeteeens 8 36 Installing a wheel ee ceceeeeseeeeneeeenees 8 36 Troubleshooting cceceeceseeeeteeeeneneenens 8 37 Troubleshooting chart c cscceeeeeeeee 8 38 CLEANING AND STORAGE c0eeees 9 1 Cleaning ins ssuendssonsiencunmiacinaneianseiaandemiseacdacehs 9 1 RO ACG EEE E E E E 9 2 SPECIFICATIONS cicesimnesseaidmensitiubesunccedunosics 10 1 CONSUMER INFORMATION onssas 11 1 Identification numbers s ssesessseenesennneen 11 1 Noise regulation cccsccseseeseseeeeseeeneees 11 3 Maintenance record ccccccseseeeeseeeneees 11 4 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY 11 5 YAMAHA EXTENDED SERVICE Y E S soacsiinrinaiiri aa anini iiz EBU17430 4d SAFETY INFORMATION EBU17601 AN ATV IS NOT A TOY AND CAN BE HAZARD OUS TO OPERATE An ATV handles differently from other vehicles including motorcycles and cars A collision or rollover can occur quickly
55. eeeeees 8 31 Pre operation Check list sneren 5 1 Wheel IAS PANG se srcacauncsaraweatenepnaucumteniseisariavemnamuhecesvene 8 36 R Wheel removing eheseeaneenccoh teats ctdeteocenteecenteeiesentdences 8 36 Riding YOUN A TV iterate ce te cerecn ape sewtdact eseeneaieutet ceediensce 7 1 Safety information oisececttecasnsxechansbsredenetenddereuundineVeswedetiodnge 1 1 E AE EA E AA A EAE E E RE 4 12 aae E E EE E E EE E 6 3 LIM pedal arenan EEE 4 7 Spark arrester ClOANING csccceeeeeeeeeeeeaeteeeeeeeeeees 8 18 Spark plug CHECKING csdeecsssenrincwtintsncadeneemauderehuedetiervertact 8 8 SDSCINGCANONS esera aA EE 10 1 Speed limiter and air intake restrictor plate 0 4 4 EIU SWIG wre cocnce caste e a a 4 3 Steering shaft lubricating eee eee cece eee eeeeeeeeeeeeees 8 31 2 0 2 Sener ae ee E ere ree eee er ee ee 9 2 T Throttle cable free play checking eesseeeeeeeeeees 8 21 Throttle Jever ccuntecnecudsatcedneimbasesssecenteastedetaaedeertseiaassan 4 3 5 4 TMA GA cece cadens tee doeetaeecheesenttanteceitacaesmieteeeessa cess 8 22 Tire pressure measuring ccceeeeeeeeceeeeeeeeeeeeeeneeees 5 6 EBU26141 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
56. ely slippery or loose sur faces 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 backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ve hicle 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 sur faces 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 tech nique described in this manual on level ground Avoid crossing the side of a steep hill if possible Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stall ing use the proper gear and maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Dismount on the uphill side or to a side if pointed straight up hill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating ina new area Never attempt to operate over lar
57. em EBU25650 Removing a wheel 1 Loosen the wheel nuts Front 1 Wheel nut Rear 1 Wheel nut 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel EBU25660 Installing a wheel 1 Install the wheel and the nuts 2 Lower the ATV to the ground 3 Tighten the wheel nuts to the specified torques 8 36 Tightening torques Front wheel nut 28 Nm 2 8 m kof 20 3 ft lbf Rear wheel nut 28 Nm 2 8 m kof 20 3 ft lbf EBU25710 Troubleshooting Although Yamaha ATVs receive a thorough in spection before shipment from the factory trouble may occur during operation Any problem in the fu el compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself However should your ATV re quire any repair take it toa Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills 8 37 EWB02260 A WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe in jury or
58. er than for purposes of maintenance repair or replacement of any device or element of de sign 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 Exhaust system e Muffler e Exhaust pipe e Silencer Intake system e Air cleaner case e Air cleaner element e Intake duct 11 3 EBU26080 Maintenance record Copies of work orders and or receipts for parts you purchase and install will be required to document main tenance done in accordance with the warranty The chart below is printed only as a reminder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF ERCE SERVICING DEALER km o km mi SERVICE NAME AND ADDRESS ea a 5500 88 E a e aoo eo OO S S m2 swg e S SSS S N O E E A E 10000 6400 12500 a 15000 9600 960 e o p20 a S 20002800 280 J 5420500 14400 4440 iT 6025000 16000 1600 o EBU26501 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY Yamaha Motor Corporation U S A hereby warrants that new Yamaha ATVs purchase
59. er vehicle 7 13 HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways 2 fy IN bay YA aad N k W N ME X ity Ay A Ay Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden hazards 7 14 which may cause the ATV to upset EWB01040 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 operat ing on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Ss Lerma EWB01050 POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Could cause loss of traction or ATV control which could result in an accident including an overturn 7 15 HOW TO AVOID THE HAZARD Do not operate on excessively rough slip pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especial ly cautious on these kinds of terrain
60. er washing WHAT CAN HAPPEN Wet brakes may have reduced stopping abil ity increasing the chance of an accident HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings EBU25932 Storage Short term Always store your ATV in a cool dry place and if necessary protect it against dust with a porous cover ECB00720 CAUTION Storing the ATV in a poorly ventilated room or covering it with a tarp while it is still wet will allow water and humidity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammo 9 2 nia and areas where strong chemicals are stored Long term Before storing your ATV for several months 1 Follow all the instructions in the Cleaning section of this chapter 2 Turn the fuel cock lever to OFP 3 Drain the carburetor float chamber by loosen ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing Specified amount 7 5 ml of stabilizer to each liter of fuel or 1 oz of stabilizer to each gallon of fuel 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engin
61. es sary 4 N J e Check for looseness and tighten all screw clamps and joints if necessary 7 Sparkarrester Clean aa 8 4 EBU21862 General maintenance and lubrication chart INITIAL EVERY CHECK OR MAINTENANCE Whichev month 1 3 6 6 12 JOB ercomes km 320 1300 2500 2500 5000 first 200 800 1600 1600 cs Timina chain e Check chain tension 9 e Adjust if necessary Every 20 40 hours more often in wet or dusty areas M aaas e Check operation and adjust if necessary oo e Check operation and correct if necessary e Check brake lever free play and adjust if neces Front brake sary e Replace brake shoes s sidY e Replace brake shoes s sidY brake shoes Whenever worn to the limit e Check operation and correct if necessary eae acai e Check brake lever and pedal free play and adjust V V y y y SAK DLAKE if necessary e Replace brake shoes Whenever worn to the limit e Check runout and for damage and replace if nec J r J d essary e Check tread depth and for damage and replace if necessary TUES e Check air pressure and balance and correct if y y y y necessary e Check for looseness or damage and replace if p Se eater fp sal joint 8 5 ai Air filter element element e Clean and replace if necessary INITIAL EVERY vey CHECK OR MAINTENANCE Whichev month 1 3 6 6 12 JOB ercomes km 320 1300 2500 2500 5000 first mi
62. 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 Read this manual and all labels carefully and fol low the operating procedures described Never operate an ATV without proper training or instruction Take a Training Course Beginners should receive training from a certified instruc tor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you Always follow the age recommendation Achild under 12 years old should never oper ate an ATV with engine size greater than 70 cc Achild under 16 years old should never oper ate an ATV with engine size greater than 90 cc 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 Never carry a passenger on an ATV 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 ap proved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots a long sleeved shirt or a jacket and long pants Never con
63. ever ECB00200 CAUTION Always close the throttle before shifting gears otherwise damage to the engine and drive train may result 2 Shift into first gear and release the shift pedal 3 Open the throttle gradually 4 Once the ATV has attained adequate speed release the throttle lever 5 Shift into second gear and release the shift pedal 6 Open the throttle gradually 7 Follow the same procedure when shifting to the next higher gear EWBO00690 POTENTIAL HAZARD Opening the throttle before releasing the shift pedal WHAT CAN HAPPEN The ATV could wheelie This would increase the chance of an accident including over turn 6 4 HOW TO AVOID THE HAZARD Release the shift pedal before opening the throttle Open the throttle gradually EBU20640 To decelerate When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly As you slow down shift to a lower gear Be sure that the engine has sufficiently slowed before engaging a lower gear Improper use of the brakes or shifting can cause the tires to lose traction reducing con trol and increasing the possibility of an accident EWBO00650 A WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating and lose trac tion This could cause loss of control an ac cident and injury It could also cause engine or drive train damage HOW TO AVOID THE
64. g Al ways shield eyes when working near batter ies Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten 1 Maximum level mark egg or vegetable oil Get prompt medical at 2 Minimum level mark tention EYES Flush with water for 15 minutes and ECB00590 get prompt medical attention Keep batteries CAUTION away from sparks flames cigarettes or other Use only distilled water as tap water contains sources of ignition Ventilate when charging minerals that are harmful to the battery or using in a closed space EWB02140 4 Check and if necessary tighten the battery lead connections and correct the breather POTENTIAL HAZARD hose routing Failure to handle batteries or battery electro lyte carefully To store the battery If the ATV will not be used for more than one month the battery will need to be removed and 8 33 stored as follows 1 Disconnect the negative lead first and then the positive lead 1 Battery 2 Negative lead 3 Positive lead 2 Remove the battery fully charge it and then place it in a cool dry place ECBO0600 CAUTION Do not leave or store the battery on its side 3 If the battery will be stored for more than two months check the specific gravity of the elec trolyte at least once a month and fully charge the battery whenever necessary To install the battery
65. g hands from handlebars or feet HOW TO AVOID THE HAZARD from footboards during operation Never attempt stunts such as wheelies or WHAT CAN HAPPEN jumps Don t try to show off Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation Avoid wheelies and jumping You may lose control of the ATV or overturn Modifications EWB01000 EWBO00990 POTENTIAL HAZARD POTENTIAL HAZARD Attempting wheelies jumps and other Operating this ATV with improper modifica stunts tions 7 11 WHAT CAN HAPPEN Improper installation of accessories or mod ification of this ATV may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV dealer WHAT CAN HAPPEN Dry grass or brush or other combustible ma terial accumulated around th
66. ge obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obsta cles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to re duce 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 use the size and type of tires specified in this manual Always maintain proper tire pressure as de scribed in this manual Never modify an ATV through improper installa tion or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow in structions in this manual for carrying cargo or pulling a trailer Allow greater distance for brak ing FOR MORE INFORMATION ABOUT ATV SAFE TY call the Consumer Products Safety Commis sion at 1 800 638 2772 or the ATV Distributor s Safety Hotline at 1 800 852 5344 EWBO00021 POTENTIAL HAZARD Improper handling of gasoline WHAT CAN HAPPEN Gasoline can catch fi
67. have purchased your new ATV please advise us of your new address by sending a postcard listing your ATV model name V I N frame number dealer number or dealers 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 EBU26122 YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service Y E S e YE 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
68. he free play is in correct adjust it as follows 1 Locknut 2 Brake lever free play adjusting bolt 3 Brake lever free play 1 Loosen the locknut at the brake lever 2 Turn the brake lever free play adjusting bolt at the brake lever in direction a to increase the free play and in direction b to decrease it 3 Tighten the locknut at the brake lever NOTE gt If the specified free play cannot be obtained turn the brake lever free play adjusting nut on the brake 8 26 cable at the rear wheel hub until the brake lever free play measures 5 0 8 0 mm 0 20 0 31 in E hE J iy 1 Brake lever free play adjusting nut NOTE When adjusting the rear brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move Adjusting the brake pedal free play The brake pedal free play should measure 20 0 30 0 mm 0 79 1 18 in as shown If the free play is incorrect adjust it as follows 1 Brake pedal free play Turn the brake pedal free play adjusting nut on the brake rod at the rear wheel hub in direction a to increase the free play and in direction b to de crease it 8 27 1 Brake pedal free play adjusting nut EWB02020 A WARNING POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing
69. hild is a beginner or is inexperienced he or she should take a training course See the previous page for information about the free training available to purchasers of new ATVs EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN JURY OR DEATH Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury WARNING or death to the ATV operator a bystander or a person inspecting or repairing the ATV A CAUTION indicates special precautions that must be taken to avoid CAUTION damage to the ATV NOTE A NOTE provides key information to make procedures easier or clearer Product and specifications are subject to change without notice EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports This ATV is designed and manufactured for OFF ROAD use only It is illegal and unsafe to operate this ATV on any public street road or highway This ATV complies with all applicable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17381 YFM80GW OWNER S MANUAL 2006 by Yamaha Motor Corporation U S A 1st ed
70. ier and center it Tie down cargo securely to the carrier Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load does not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower 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 trail er Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV EWBO00750 A WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death 6 9 EBU21131 RIDING YOUR ATV gt O 7 1 EWBO00010 A WARNING Indicates a potential hazard that could result in serious injury or death EBU21562 GETTING TO KNOW
71. ine oil should be between the minimum and maximum level marks Go oe ee i ee 1 Engine oil drain bolt 6 If the engine oil is at or below the minimum i Eee TAT 200 Suniel OL eT te TECO 5 Check the O ring for damage and replace it if mended type to raise it to the correct level 7 Insert the dipstick into the oil filler hole and E ae i 6 Install the engine oil drain bolt and then tight then tighten the engine oil filler cap To change the engine oil 1 Place the ATV on a level surface 8 11 en it to the specified torque minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and Tightening torque check for the cause Engine oil drain bolt 9 Turn the engine off and then check the oil lev 20 Nm 2 0 m kgf 14 5 ft lbf el and correct it if necessary 7 Add the specified amount of the recommend ed engine oil and then install and tighten the engine oil filler cap Recommended oil See page 10 1 Oil quantity 0 80 L 0 85 US qt 0 70 Imp qt ECB00300 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 higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher Make sure that no foreign material enters the crankcase 8 Start the engine and then let it idle
72. ing the valve clearance must be adjusted by a Yamaha dealer at the inter vals specified in the periodic maintenance and lu brication chart EBU24090 Checking the front and rear brake shoes The front and rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart Each brake is provided with a wear indicator which allows you to check the brake shoe wear without having to dis assemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit line or mark have a Yamaha dealer replace the brake shoes as a set Front brake Rear brake WW I 7 1 Wear limit line 1 Wear limit mark 2 Wear indicator 2 Wear indicator EBU24320 Adjusting the front brake lever free e play The brake lever free play must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart NOTE gt Before adjusting the brake lever free play check the front brake shoes for wear The brake lever free play should measure 10 0 8 23 12 0 mm 0 39 0 47 in as shown If the free play is incorrect adjust it as follows 1 Brake lever free play ES 2 3 Loosen the upper locknut and fully turn in the upper adjusting bolt Loosen the lower locknut Turn the lower adjusting bolt in direction
73. ing mainte nance unless otherwise specified Have a Yamaha dealer perform the service if you are not familiar with maintenance work EBU27100 Owner s manual and tool kit Be sure to put this owners manual in the plastic bag and to always carry it as well as the owner s tool kit and the low pressure tire gauge in their re spective compartments under the seat it for you EWB01830 4 i A WARNING LUS Operating this ATV with improper modifica tions o E 1 WHAT CAN HAPPEN AN Improper installation of accessories or mod BS ification of this ATV may cause changes in handling which in some situations could lead to an accident 1 Owner s manual HOW TO AVOID THE HAZARD 2 Low pressure tire gauge Never modify this ATV through improper in 3 Owner s tool kit stallation or use of accessories All parts and accessories added to this ATV should be The service information included in this manual genuine Yamaha or equivalent components and the tools provided in the owner s tool kit are in designed for use on this ATV and should be tended to assist you in the performance of preven installed and used according to instructions tive maintenance and minor repairs However If you have questions consult an authorized additional tools such as a torque wrench may be Yamaha ATV dealer necessary to perform certain maintenance work correctly NOTE SSS If you do not have the tools or experience required for a particular job ha
74. ition February 2006 All rights reserved Any reprinting or unauthorized use LABEL HERE without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 20 06 _ o EWB00010 Indicates a potential hazard that could result in serious injury or death EBU17420 TABLE OF CONTENTS SAFETY INFORMATION c cceeeeeeee 1 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS c 0c0ceceee 2 1 DESCRIPTION sssciccsdcaccceetacconcdecnconeseceechecdoass 3 1 Left WICW scccioccsas docednwntannadewanenebeeeecdabeadeeee dimes 3 1 RIONU WIC WY soosis aaa 3 1 Controls and instruments c0cceceeeees 3 2 INSTRUMENT AND CONTROL FUNG TIONS wiesisinsncccicutenccesieterecacviasemenc Vea TaN 4 1 Main switch casictecticccu deca uvesusneuet dentsamavonicacese 4 1 indicator ONU sssrin a 4 2 Handlebar switches cceceeceseeeeceeeeeeeeeees 4 2 Throttle lever oo cece eeeececececeeeseeeeeeseeeeeees 4 3 Speed limiter and air intake restrictor POG a E 4 4 Front brake lever cccceseceeeeeeeeseeeseeees 4 5 Brake pedal and rear brake lever 4 5 Parking OLA cistscomcntenacutmiwneioacaanmianteueentenees 4 6 Shit pedal eee ee ee ene ee eee eer ae 4 7 Fuel tank cap seer ce ees nc teriecs cea eeeerceeeencens 4 8 US pnis bases sees AE S SEAE 4 8 Fuel COCK ade deepee crniiin cet epeedtoeeeenecencene 4 10 ONOKE eho eee a taete
75. ity to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that 1 Bring the ATV toa stop by applying the brakes in first gear 2 Stop the engine 3 With the rear brake lever and brake pedal ap plied apply the parking brake and slowly re lease the brake pedal 6 7 limits your ability to move around on the seat or one that limits your view Use extra caution when riding an ATV with ac cessories The ATV may handle differently than it does without accessories EBU21110 Loading As originally equipped this ATV is not designed to tow a trailer If you choose to add accessories so that you can tow a trailer you must use common sense and good judgment as the stability and han dling of an ATV can be changed When adding ac cessories keep the following points in mind Never exceed the weight limits shown An over loaded ATV can be unstable MAXIMUM LOADING LIMIT ATV loading limit total weight of rider cargo accessories and tongue 95 0 kg 209 Ib Carrier 5 0 kg 11 Ib f you are carrying cargo and towing a trailer in clude the tongue weight in the maximum ATV load limit 6 8 Load cargo on the carrier as close to the center of the ATV as possible Put cargo at the front of the carr
76. l DUNLOP KT586 Size AT18 x 7 7 Type Tubeless 5 5 Rear Manufacturer model DUNLOP KT587 Size AT18 x 8 7 Type Tubeless e The tires should be set to the recommend ed pressure Recommended tire pressure Front 20 kPa 2 9 psi 0 20 kgf cm Rear 20 kPa 2 9 psi 0 20 kgf cm e Check and adjust tire pressures when the tires are cold e Tire pressures must be equal on both sides Tire pressure below the minimum speci dirt in the gauge could cause the first reading to be fied could cause the tire to dislodge from incorrect the rim under severe riding conditions Minimum tire pressure Front 17 kPa 2 5 psi 0 17 kgf cm Rear 17 kPa 2 5 psi 0 17 kgf cm Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 36 psi 2 5 kgf cm Rear 250 kPa 36 psi 2 5 kgf cm 1 Low pressure tire gauge Higher pressures and fast inflation may cause a tire to burst Inflate the tires very Set the tire pressure when the tires are cold Set slowly and carefully EBU19820 Measuring the tire pressure Use the low pressure tire gauge NOTE The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or 5 6 the tire pressures to the following specifications Recommended pressure Front 20 kPa 2 9 psi 0 20 kgf cm Rear 20 kPa 2 9 psi 0 20 kgf
77. les in your way to regain balance If you discover that the ATV is going to tip over dismount on the uphill side See page 7 19 7 29 f your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let wa ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability See page 7 24 EWB00010 Indicates a potential hazard that could result in serious injury or death EBU21640 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21660 Safety is an obligation of the owner Periodic in spection adjustment and lubrication will keep your ATV in the safest and best operating condition possible The most important points of inspection adjustment and lubrication are explained on the following pages The intervals given in the periodic maintenance and lubrication chart should be considered as a general guide under normal riding conditions However DEPENDING ON THE WEATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED EWB01820 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 can cause shocks or start fires HOW TO AVOID THE HAZARD Turn off the engine when perform
78. mpt 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 Ifthe engine is started with the choke in posi tion 1 the choke should be returned to posi tion 2 to warm up the engine If the engine is started with the choke in position 2 keep the choke in this position to warm up the engine ECB00160 CAUTION For maximum engine life always warm the en gine up before starting off Never accelerate hard when the engine is cold 8 Continue warming up the engine until it idles smoothly then return the choke to position 3 before riding NOTE The engine is warm when it responds normally to the throttle with the choke turned off EBU20301 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the choke is not re quired when the engine is warm Instead start the engine with the throttle slightly open 6 3 EBU20550 Shifting This ATV has a 3 speed forward transmission with a centrifugal automatic clutch The transmission allows you to control the amount of power you have available at a given speed or for starting ac celerating climbing etc To shift into neutral return the throttle lever to the closed position and repeatedly depress the shift pedal until it stops 1 Shift pedal 2 Neutral position EBU20600 To start out and accelerate 1 Release the throttle l
79. ne idling lift the shift pedal to the 1st gear position and then release the parking brake Apply the throttle slowly and smoothly The centrif ugal clutch will engage and you will start to accel erate Once the ATV has attained adequate speed release the throttle and lift the shift pedal to the 2nd gear position Release the shift pedal and apply the throttle smoothly Use this same proce dure as you move into the higher gears Be sure to coordinate 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 applying the throttle the front wheels may lift off the ground re sulting in a loss of directional control Avoid higher speeds until you are thoroughly familiar with the operation of your ATV ECB00230 CAUTION Do not shift gears without releasing the throt tle Damage to the engine or drive train may oc cur 7 17 When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly As you slow down shift to a lower gear Be sure that the engine has sufficiently slowed before engaging a lower gear Improper use of the brakes or shifting can cause the tires to lose traction reducing con trol and increasing the possibility of an accident EWB01070 A WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels coul
80. ou 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 Name ATV Model Purchase Date Lo o MO DAY YR Address Primary I D Engine Number E i w J E Tt dI AT t 4 Dealer Name amp Address Telephone CAREFULLY READ 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
81. ould easily tip over backwards Instead ap ply the front brake gradually or dismount the ATV immediately on the uphill side EWB01231 A WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dis mounting while climbing a hill WHAT CAN HAPPEN Could result in the ATV overturning HOW TO AVOID THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking brake after you are stopped If you begin rolling backwards Keep weight uphill Never apply the rear brake while rolling backwards Apply the front brake When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and re mount following the procedure described in the Owner s Manual 7 22 RIDING DOWNHILL When riding your ATV downhill shift your weight fi as far to the rear and uphill side of the ATV as pos sible Move back on the seat and sit with your arms straight Choose a low gear which will allow the en gine compression to do most of the braking for you Improper braking may cause a loss of trac tion Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of traction Wheneve
82. portant information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer 2X WARNING Operating this ATV if you are under the age of 12 increases your chance of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 12 to operate this ATV 4EM 21697 31 A WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYSUSE_ NEVERUSE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMETAND ROADS OR ALCOHOL 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 ris of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and it 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 4 WARNING NEVER ride as a MER PEIRE E TS OR OVERLOADING CAN LOSS OF CONTROL CAN RESULT IN SEVERE passenger INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires cold Kee a eRecommended zE 20 e a a
83. r possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear EWB01130 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 going down hills as described in this Owner s Man ual Note a special technique is required when braking as you go down a hill Always check the terrain carefully before you CROSSING A SLOPE start down any hill Traversing a sloping surface on your ATV requires Shift your weight backward you to properly position your weight to maintain Never go down a hill at high speed proper balance Be sure that you have learned the Avoid going down a hill at an angle that basic riding skills on flat ground before attempting would cause the ATV to lean sharply to one to cross a sloping surface Avoid slopes with slip side Go straight down the hill where possi pery surfaces or rough terrain that may upset your ble 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 surfaces by pointing 7 23 the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV
84. re and you could be burned HOW TO AVOID THE HAZARD Always turn off the engine when refueling Do not refuel right after the engine has been running and is still very hot Do not spill gasoline on the engine or ex haust pipe muffler when refueling Never refuel while smoking or in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heat ers and clothes dryers When transporting the ATV in another vehi cle be sure it is kept upright and that the fuel cock is in the OFF position Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause inju ries HOW TO AVOID THE HAZARD If you should swallow some gasoline or in hale a lot of gasoline vapor or get some gas oline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes ME Nie EWB00030 A WARNING POTENTIAL HAZARD Starting or running the engine in a closed ar ea WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death with in a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad equate ventilation EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 2 1 EBU17670 Read and understand all of the labels on your ATV These labels contain im
85. re 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 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 a 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 A No The warranty on a new ATV cannot be voided or cancelled However PO gt O if a particular failure is caused by operation or maintenance other than as described 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
86. s and cable ends should be lubricated if nec essary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it Recommended lubricant Engine oil EWB02120 A WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged and cables can also be come frayed or kinked which could restrict the operation of controls and lead to an acci dent or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables EBU24911 8 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if necessary Recommended lubricant Lithium soap based grease all purpose grease 8 30 Front brake lever Rear brake lever A EBU24930 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lubricated if necessary Recommended lubricant Lithium soap based grease all purpose grease EBU24961 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel bearings
87. should be a firm feeling when the brakes are ap plied If not have the ATV checked by a Yamaha dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance check the brake linings for wear See page 8 22 EWB00530 A WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any prob lem with the brakes If a problem cannot be corrected by the adjustment procedures pro vided in this manual have the ATV checked by a Yamaha dealer EBU19761 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary 5 4 EBU19781 Tires EWBO00561 POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or opera tion of this ATV with improper or uneven tire pressure may cause loss of control increas ing your risk of accident HOW TO AVOID THE HAZARD The tires listed below have been approved by Yamaha Motor Co Ltd for this model Other tire combinations are not recom mended Front Manufacturer mode
88. sing control 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 conditions and your experience Speed limiter For riders less experienced with this model the throttle lever housing is equipped with a speed lim iter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to 7 8 the maximum Turning in the adjusting screw limits the maximum engine power available and de creases the maximum speed of the ATV Turning in the adjusting screw decreases top speed and turning it out increases top speed See page 4 4 This model also has an air intake restrictor plate to limit the amount of engine power available Yamaha recommends that all beginning riders start off with the speed limiter turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn The limiter may be gradually adjusted to increase maximum speed as the beginner becomes more familiar with oper ating the ATV Parents should decide when to ad just the ATV for more power as their youngsters riding skills improve Once the ATV rider can oper ate with skill at the top speed permitted by adjust ing the speed limiter alone the air intake restrictor plate can be removed Since removal of this plate will result in a significant increase in power turn the speed limiter back in again adj
89. slip slightly allowing the ATV to make the turn properly 1 Lean towards inside of turn 2 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 obsta cles 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 proce dure again If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body move ments or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the out side 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 ATV over turns on hills Be sure that you can maneuver your ATV well on flat ground before attempting any in cline and then practice riding first on gentle slopes Try more difficult climbs only after you have devel oped your skill In all cases a
90. sume alcohol or drugs before or while operating this ATV Never operate at speeds too fast for your skills or the riding conditions Always go at a speed that is proper for the terrain visibility operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe operating condition Al ways follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footrests of the ATV during op eration Always go slowly and be extra careful when op erating 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 Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds and never turn at excessive speeds 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 hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessiv
91. tante 8 25 FS WAV CAP erncsu mo e T 4 8 Brake lever free play adjusting the front 06 8 23 PUSS replat sosote enina i 8 35 Brake lever front 2 2 s s000sss0000ssseseeeeeseseeeeeseseeeeeeees 4 5 H Brake levers checking and lubricating 008 8 30 Handlebar SWHCNES v ccnsenscesncedocevsceruesbenesendocenseysansbersrenic 4 2 Brake pedal and rear brake leVer 00000ceeeeeeeees 4 5 I Brakes FON ANG TEAN asrscravoitnacansimtentasasremaantauninudains 5 3 Identification NUMDbErS seeren 11 1 Brake shoes checking the front and rear 00 8 22 lae WO e a ss secs aon xt E E ct atea ecarcaceatdtantticaeaces 4 2 C Instruments lights and switches ssseeeeseseeeeer reesen 5 7 Cables checking and lubricating cccceesseeeeeees 8 29 K Carburetor AC USUING ss sicsicsascsscenardseddeorectezbseecktertcbieweres 8 20 Key identification NUMDED eceeeceseeeeeeeeeteseeseeeeees 11 1 Carrier vce chestacsteuuicd wad vetdtdauws une aedwceuwidudedwevescwdecswwiuuswadenencs 4 13 Knuckle shafts lubricating cccccccesscesseesseeesseeseeeens 8 31 Chassis TASISNELS iciat sits ceccadsinestncewsisdercsdendarderexatededsenendes 5 7 L GROK Os asst ceettcivcze even aE AEAU AEN RERA 4 11 Label locations o 2 1 a a o E E E EAE E E OAE E EA 9 1 M Clutch free play ADJUSTING eeceesttetetntettee 8 28 AEE altos 0 a Ree Pn a 4 1 E Maintenance and lubrication Chart ccc
92. ter el ement removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Addition ally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine over heating EBU23850 Removing the air intake restrictor plate To obtain full engine performance capability re moving the air intake restrictor plate is required 1 Remove the air filter element See page 8 14 8 18 2 Remove the air intake restrictor plate 1 Air intake restrictor plate NOTE gt Store the air intake restrictor plate with the owner s manual so that it is readily available whenever you want to reduce the top speed 3 Install the air filter element EBU23891 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the screws 1 Screw 1 Tailpipe 2 Spark arrester 2 Remove the tailpipe by pulling it out of the ome muffler 4 Insert the tailpipe into the muffler and align the ZZ screw holes Install the screws and tighten them 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside 9 of the tailpipe housing 8 19 8 Do not start the engine when cleaning the ex EWB01910 A WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust
93. ue Final gear oil drain bolt 23 Nm 2 3 m kgf 16 6 ft lbf 5 Add the specified amount of the recommend 8 14 ed final gear oil and then check the oil level Recommended final gear oil See page 10 1 Oil quantity 0 12 L 0 13 US qt 0 11 Imp qt ECB00420 CAUTION Be sure no foreign material enters the final gear case 6 Install and tighten the oil filler cap 7 Check the final gear case for oil leakage If oil is leaking check for the cause EBU27170 Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean the air filter element more frequently if you are riding in unusually wet or dusty areas 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 fil ter case SO Tan a LD J AS 2 1 Quick fastener 2 Remove the panel by sliding it forward and 1 Remove the quick fasteners PUG OA Ea 1 Air filter case check hose 8 15 1 Panel 1 Air filter case cover 2 Air filter case holder 3 Remove the air filter case cover by unhooking the holders 4 Unhook the holder holding the air filter ele 8 ment and then pull out the sponge material from the air filter element 8 16 1 Unhook 2 Sponge material 5 Wash the sponge material gently but thor
94. ust it out in stag es as you did before Adjusting for maximum throttle lever movement without removing the air intake restrictor plate will cause the engine to run roughly at higher speeds For air intake restrictor plate removal instructions see page 8 18 duce your speed when adding additional loads MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and tongue 95 0 kg 209 Ib Carrier 5 0 kg 11 Ib EWB00970 POTENTIAL HAZARD Overloading this ATV or carrying or towing 1 Locknut cargo improperly 2 Adjusting screw WHAT CAN HAPPEN Could cause changes in ATV handling which Loading and accessories could lead to an accident Use extra caution when riding the ATV with addi tional loads such as accessories or cargo The ATV s handling may be adversely affected Re 7 9 HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull y A aN ing a trailer Allow greater distance for brak pb Ga ing Always follow the instructions in your Own er s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the footboards during op eration otherwise they may contact the rear wheels 7 10 a WHAT CAN HAPPEN WARNING Increases the chance of an accident includ POTENTIAL HAZARD ing an overturn Removin
95. ve a Yamaha dealer perform 8 2 EBU21741 Periodic maintenance chart for the emission control system NOTE For ATVs not equipped with an odometer or an hour meter follow the month maintenance intervals For ATVs equipped with an odometer or an hour meter follow the km mi or hours maintenance inter vals However keep in mind that if the ATV isn t used for a long period of time the month maintenance intervals should be followed Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills INITIAL EVERY sneceonmaennce Meme te JOB nee 320 1300 2500 2500 5000 a 200 800 1600 1600 3200 Eas EES e Check fuel hoses for cracks or other damage and 1 Fuctine rentace it necessary rey pepe e Check condition and clean regap or replace if 2 Spark pis necessary ie RARER EE 3 Valves e Check valve clearance and adjust if necessary e Check choke operation and correct if necessary Carburetor e Check engine idling speed and adjust if neces y y y y sary Crankcase breather e Check breather hose for cracks or other damage J J d system and replace if necessary 8 3 INITIAL EVERY CHECK ORMAINTENANCE Whichev month 1 3 6 6 12 JOB ercomes km 320 1300 2500 2500 5000 first mi 200 800 1600 1600 3200 5 e Check for leakage and replace gasket s if nec
96. void inclines with slip pery or loose surfaces or obstacles that might cause you to lose control EWB01090 POTENTIAL HAZARD Operating on excessively steep hills 7 19 WHAT CAN HAPPEN The ATV can overturn more easily on ex tremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by leaning forward and on steeper inclines standing on the footboards and leaning forward over the handlebars EWB01 100 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 climb ing hills as described in this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 7 20 2 N x Ses ae Wires O pya w Da a Y E A
97. wheels of your ATV start to slide side cedures as described in the Owner s Manual ways control can usually be regained if there is room to do so by steering in the direction of the SLIDING AND SKIDDING slide Applying the brakes or accelerating is not Care should be used when riding on loose or slip recommended until you have corrected the slide pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help 7 27 With practice over a period of time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are re duced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost EWBO01170 POTENTIAL HAZARD Skidding or sliding improperly 7 28 WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to re duce the chance of skidding or sliding out of control
98. y 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 EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations OFF 1 Arrow mark positioned over OFF With the fuel cock lever in this position fuel will not flow Always turn the fuel cock lever to this position when the engine is not running ON OFF FUEL ON 1 Arrow mark positioned over ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding RES RES 1 S OFF FUEL ON 1 Arrow mark positioned over RES This indicates reserve With the fuel cock lever in this position the fuel reserve is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18860 Choke The choke is used to start a cold engine Move the choke in direction a to turn on the choke Move the choke in direction b to turn off the choke See the Starting a cold engine section on page 6 1 for proper operation

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