Contents

Yamaha YFA1S C Breeze 2004 Owner's Manual PDF

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Summary of Content for Yamaha YFA1S C Breeze 2004 Owner's Manual PDF

YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN

2003.31.01 !

This ATV should not be ridden by anyone under 16 years of age.

OWNERS MANUAL

5VJ-28199-11

YFA1S(C)

READ THIS MANUAL CAREFULLY! It contains important safety information.

LIT-11626-17-02 (E)

w

Improper ATV use can result in SEVERE INJURY or DEATH.

qWARNING

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR

NEVER USE ON PUBLIC

ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

NEVER operate: 9 without proper training or instruction. 9 at speeds too fast for your skills or the

conditions. 9 on public roads - a collision can occur with

another vehicle. 9 with a passenger - passengers affect

balance and steering and increase risk of losing control.

ALWAYS: 9 use proper riding techniques to avoid

vehicle overturns on hills and rough terrain and in turns.

9 avoid paved surfaces - pavement may seriously affect handling and control.

EBU00438

LOCATE AND READ OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558)

5VJ-9-11 hyoshi 3/12/03 1:49 PM Page 1

5VJ-9-11 hyoshi 3/12/03 1:49 PM Page 2

EBU13290

INTRODUCTION Congratulations on your purchase of the Yamaha YFA1. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader 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 techniques and skills necessary to ride your ATV. It also includes basic maintenance and inspection procedures. If you have any questions regard- ing the operation or maintenance of your ATV, please consult a Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE: 8 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COM-

PLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUC- TIONS.

8 PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV. 8 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 INFOR- MATION.

8 THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.

5VJ-9-11-1 3/12/03 3:20 PM Page 1

EBU00801

IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERI- OUS INJURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations:

Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE- TY IS INVOLVED!

w Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.

cC A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE: A NOTE provides key information to make procedures easier or clearer.

5VJ-9-11-1 3/12/03 3:20 PM Page 2

EBU00011

IMPORTANT NOTICE

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

AFFIX DEALER LABEL HERE

EBU13330 YFA1S (C)

OWNER'S MANUAL 2003 by Yamaha Motor Corporation, U.S.A.

1st edition, March 2003 All rights reserved.

Any reprinting or unauthorized use without the written permission

of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in Japan. P/N LIT-11626-17-02

5VJ-9-11-1 3/12/03 3:20 PM Page 3

LOCATION OF THE WARNING AND SPECIFICATION LABELS.......................1-1

SAFETY INFORMATION.........................2-1

DESCRIPTION AND MACHINE IDENTIFICATION.....................................3-1

Identification number records ...............3-2 Key identification number .....................3-2 Vehicle identification number ...............3-3 Model label ...........................................3-3

CONTROL FUNCTIONS..........................4-1 Main switch ...........................................4-1 Indicator lights ......................................4-2 Handlebar switches ..............................4-2 Throttle lever ........................................4-4 Speed limiter ........................................4-5 Front brake lever ..................................4-6 Rear brake lever ...................................4-6 Parking brake .......................................4-7 Drive select lever ..................................4-8 Fuel tank cap........................................4-8 Fuel cock ..............................................4-9 Starter (choke)....................................4-10 Seat ....................................................4-10

EBU00014

w Indicates a potential hazard that could result in serious injury or death.

CONTENTS

1

2

3

4

5VJ-9-11-1 3/12/03 3:20 PM Page 4

PRE-OPERATION CHECKS ...................5-1 Front and rear brakes ...........................5-2 Fuel ......................................................5-3 Engine and transmission oil .................5-5 Chain ....................................................5-6 Throttle lever ........................................5-6 Fittings and fasteners ...........................5-6 Lights....................................................5-6 Switches ...............................................5-6 Battery ..................................................5-6 Tires .....................................................5-7 How to measure tire pressure ..............5-8 Tire wear limit .......................................5-9

OPERATION............................................6-1 Starting a cold engine...........................6-1 Starting a warm engine ........................6-3 Warming up ..........................................6-3 Drive select lever operation and reverse driving....................................6-4

Engine break-in ....................................6-6

Parking .................................................6-7 Parking on a slope................................6-8 Accessories and loading ......................6-9

Riding Your ATV.......................................7-1 Getting to know your ATV.....................7-3 Ride with care and good judgement...........................................7-4

Be careful where you ride...................7-16 Turning your ATV ...............................7-22 Climbing uphill ....................................7-24 Riding downhill ...................................7-30 Crossing a slope.................................7-32 Crossing through shallow water .........7-34 Riding over rough terrain....................7-36 Sliding and skidding ...........................7-38 What to do if .......................................7-40 What to do ..........................................7-40

5

6

7

5VJ-9-11-1 3/12/03 3:20 PM Page 5

PERIODIC MAINTENANCE AND ADJUSTMENT.........................................8-1

Owners manual and tool kit .................8-1 Periodic maintenance/Lubrication ........8-3 Engine oil..............................................8-5 Transmission oil ...................................8-7 Spark plug inspection ...........................8-9 Engine and V-belt compartment air filter element cleaning .................8-11

Idle speed adjustment ........................8-15 Valve clearance adjustment ...............8-16 Throttle lever adjustment ....................8-17 Front and rear brake shoe inspection .........................................8-18

Front brake lever free play adjustment ........................................8-19

Rear brake adjustment .......................8-23 Drive chain slack check......................8-24 Drive chain slack adjustment..............8-25 Lubricating the drive chain .................8-27 Draining the V-belt compartment........8-28 Cable inspection and lubrication ........8-28

Brake lever lubrication........................8-29 Knuckle shaft, lower arms and steering shaft lubrication ..................8-29

Wheel removal ...................................8-30 Wheel installation ...............................8-30 Battery ................................................8-31 Replenishing the battery fluid .............8-33 Fuse replacement...............................8-34 Replacing the headlight bulb ..............8-35 Tail/brake light bulb replacement .......8-37 Headlight beam adjustment................8-38 Spark arrester cleaning ......................8-38 Troubleshooting..................................8-40 Troubleshooting chart.........................8-41

CLEANING AND STORAGE....................9-1 A. CLEANING .......................................9-1 B. STORAGE .......................................9-3

SPECIFICATIONS .................................10-1

9

10

8

5VJ-9-11-1 3/12/03 3:20 PM Page 6

NOISE REGULATION............................11-1

MAINTENANCE RECORD ....................12-1

ATV LIMITED WARRANTY ...................13-1

YAMAHA EXTENDED SERVICE (Y.E.S.)...................................................14-1

11

12

13

14

5VJ-9-11-1 3/12/03 3:20 PM Page 7

1-1

EBU00464

LOCATION OF THE WARNING AND SPECIFICATION LABELS

ewq r t

5VJ-9-11-1 3/12/03 3:20 PM Page 8

1-2

Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV.

Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.

1

21

5FE-21697-01 3FA-21696-41

5VJ-9-11-1 3/12/03 3:20 PM Page 9

1-3

43

5

3FA-2151E-A0

DRIVE SELECT LEVER

8 Read owners manual carefully before operating. 8 ATV MUST be stopped before shifting select

lever. 8 Shifting into reverse is impossible without

applying rear brake lever.

5FE-21568-01

qWARNING NEVER ride as a

passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.

5FE-2151H-01

5VJ-9-11-1 3/12/03 3:20 PM Page 10

2-1

EBU00925

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper pre- cautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: 8 Read this manual and all labels carefully and follow the operating procedures described. 8 Never operate an ATV without proper training or instruction. Take a Training Course.

Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1-800-887-2887 to find out about the training courses nearest you.

8 Always follow the age recommendation: - A child under 16 years old should never operate an ATV with engine size greater than 90cc.

8 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow con- tinued use of an ATV by a child if he or she does not have the abilities to operate it safely.

8 Never carry a passenger on an ATV.

q SAFETY INFORMATION 2

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2-2

8 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.

8 Never operate an ATV on any public street, road or highway, even a dirt or gravel one. 8 Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You

should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.

8 Never consume alcohol or drugs before or while operating this ATV. 8 Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is prop-

er for the terrain, visibility and operating conditions, and your experience. 8 Never attempt wheelies, jumps, or other stunts. 8 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 this manual. 8 Always keep both hands on the handlebars and both feet on the footboards of the ATV during oper-

ation. 8 Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to

changing terrain conditions when operating the ATV.

5VJ-9-11-1 3/12/03 3:20 PM Page 2-2

2-3

8 Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

8 Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

8 Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

8 Always follow proper procedures for climbing hills as described in this manual. 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. Never go over the top of a hill at high speed.

8 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 vehicle to lean sharply to one side. Go straight down the hill where possible.

8 Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

5VJ-9-11-1 3/12/03 3:20 PM Page 2-3

2-4

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

8 Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

8 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 reduce the chance of skidding or sliding out of control.

8 Never operate an ATV in fast flowing water or in water deeper than that recommended in this manu- al. 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.

8 Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly.

8 Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual.

8 Never modify an ATV through improper installation or use of accessories.

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2-5

8 Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY , call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributors Safety Hotline at 1-800-852-5344.

5VJ-9-11-1 3/12/03 3:20 PM Page 2-5

POTENTIAL HAZARD

Improper handling of gasoline.

WHAT CAN HAPPEN

Gasoline can catch fire and you could be burned.

HOW TO AVOID THE HAZARD

Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling. Never refuel while smoking, or while in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers. When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the OFF position.

2-6

Otherwise, fuel may leak out of the carbu- retor or fuel tank.

WHAT CAN HAPPEN

Gasoline is poisonous and can cause injuries.

HOW TO AVOID THE HAZARD

If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

qWARNING

5VJ-9-11-1 3/12/03 3:20 PM Page 2-6

POTENTIAL HAZARD

Starting or running the engine in a closed area.

WHAT CAN HAPPEN

Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.

HOW TO AVOID THE HAZARD

Always operate your ATV in an area with adequate ventilation.

qWARNING

2-7

5VJ-9-11-1 3/12/03 3:20 PM Page 2-7

3-1

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

10. Spark arrester 20. Handlebar switches

NOTE: The machine you have purchased may differ slightly from those shown in the figures of this manual.

EBU00032

DESCRIPTION AND MACHINE IDENTIFICATION wq e r

!3 !4 !5

!9 !8 !7

!6!2

@0

!1

iuyt !0o

5VJ-9-11-1 3/12/03 3:20 PM Page 3-2

EBU00600

Identification number records Record the key identification number, vehicle identification number and model label informa- tion in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen.

1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATION NUMBER:

3. MODEL LABEL INFORMATION:

EBU00035

Key identification number The key identification number is stamped on the key as shown in the following illustration. This number can be used for ordering a new key.

3-2

1

6

q

3

1. Key identification number

5VJ-9-11-1 3/12/03 3:20 PM Page 3-3

EBU00036

Vehicle identification number The vehicle identification number is stamped into the frame.

NOTE: The vehicle identification number is used to identify your machine.

EBU00787

Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer.

3-3

q

q

1. Vehicle identification number

1. Model label

5VJ-9-11-1 3/12/03 3:20 PM Page 3-4

EBU00039

CONTROL FUNCTIONS

w Indicates a potential hazard that could result in serious injury or death.

EBU00041

Main switch Functions of the respective switch positions are as follows:

ON: Engine can be started only at this position and the headlight and taillight come on when the light switch is on.

OFF: All electrical circuits are switched off. The key can be removed in this position.

4-1

4

OFF ON

5VJ-9-11-1 3/12/03 3:20 PM Page 4-1

EBU00043

Indicator lights

EBU00044

Reverse indicator light REVERSE This indicator light comes on when the transmis- sion is in reverse.

EBU00045

Neutral indicator light NEUTRAL This indicator light comes on when the transmis- sion is in neutral.

EBU00053

Handlebar switches

EBU11580

Engine stop switch ENG. STOP Make sure that the engine stop switch is in the RUN position before starting the engine. The engine stop switch controls ignition and can be used at all times to stop the engine, especially in an emergency. The engine will not start or run when the engine stop switch is turned to OFF.

4-2

w

q

e

w q e

1. Main switch 2. Reverse indicator light REVERSE 3. Neutral lindicator light NEUTRAL

1. Engine stop switch ENG. STOP 2. Light switch LIGHTS 3. Start switch START

5VJ-9-11-1 3/12/03 3:20 PM Page 4-2

EBU00056

Start switch START The starter motor cranks the engine when this switch is pushed.

cC See starting instructions prior to starting engine (see page 6-1 for details).

NOTE: If the starter switch is pushed with the main switch ON and the engine stop switch OFF, the starter motor will be activated but the engine will not start. To start the engine, be sure to position the engine stop switch at RUN.

EBU12860

Light switch LIGHTS Set the switch to the LO position to switch on the low beam and the taillight. Set the switch to the HI position to switch on the high beam and the taillight. Set the switch to the OFF position to switch off all the lights.

NOTE: The headlight and the taillight can be turned on only when the engine is started.

4-3

5VJ-9-11-1 3/12/03 3:20 PM Page 4-3

EBU00062

Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.

Before 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.

4-4

POTENTIAL HAZARD

Malfunction of throttle.

WHAT CAN HAPPEN

The throttle could be hard to operate, mak- ing it difficult to speed up or slow down when you need to. This could cause an accident.

HOW TO AVOID THE HAZARD

Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can't find or solve the problem yourself.

qWARNING

q

1. Throttle lever

5VJ-9-11-1 3/12/03 3:20 PM Page 4-4

EBU11590

Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV.

4-5

a q

w

POTENTIAL HAZARD

Improper adjustment of the speed limiter and throttle.

WHAT CAN HAPPEN

The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured.

HOW TO AVOID THE HAZARD

Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3.05.0 mm (0.120.20 in). See page 8-17.

qWARNING

1. Adjusting screw 2. Locknut a. No more than 12 mm (0.47 in)

5VJ-9-11-1 3/12/03 3:20 PM Page 4-5

EBU00070

Front brake lever The front brake lever is located on the right han- dlebar. Pull it toward the handlebar to apply the front brake.

EBU00072

Rear brake lever The rear brake lever is located on the left han- dlebar. Pull it toward the handlebar to apply the rear brake.

4-6

q

q

1. Front brake lever 1. Rear brake lever

5VJ-9-11-1 3/12/03 3:20 PM Page 4-6

EBU00074

Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake.

4-7

q

POTENTIAL HAZARD

Improper use of the parking brake.

WHAT CAN HAPPEN

The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake 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 start- ing the engine. Always be sure you have released the parking brake before you begin to ride.

qWARNING

1. Lock plate

5VJ-9-11-1 3/12/03 3:20 PM Page 4-7

4-8

EBU11060

Drive select lever The drive select lever is used to shift your machine into the forward, neutral and reverse positions. (Refer to page 6-4 for the drive select lever operation.)

EBU00092

Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise.

q

we

a

q

a. Drive select lever 1. Neutral 2. Forward 3. Reverse

1. Fuel tank cap

5VJ-9-11-1 3/12/03 3:20 PM Page 4-8

4-9

RES

OFF

ON

EBU00093

Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not

flow. Always turn the lever to this position when the engine is not running.

ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.

RES: This indicates reserve. If you run out of fuel while riding, turn the lever to this position. THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY. After refuelling, return the fuel cock lever to the ON position.

5VJ-9-11-1 3/12/03 3:20 PM Page 4-9

EBU00094

Starter (choke) Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to Starting a cold engine for proper oper- ation. (See page 6-1.)

EBU00567

Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear.

4-10

q

w e

a

b

A q

1. Fully open 2. Half open 3. Closed A. Starter (choke)

1. Seat lock lever

5VJ-9-11-1 3/12/03 3:20 PM Page 4-10

To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear.

NOTE: Make sure that the seat is securely fitted.

4-11

EBU00112

w Indicates a potential hazard that could result in serious injury or death.

5VJ-9-11-1 3/12/03 3:20 PM Page 4-11

5-1

PRE-OPERATION CHECKS Before using this machine, check the following points:

ITEM ROUTINE PAGE

Brakes Check operation, condition and free play. 5-25-3, 8-188-23

Adjust if necessary.

Fuel Check fuel level. Fill with fuel if necessary.

5-35-4

Engine oil and Check oil level. 5-5, 8-58-9transmission oil Fill with oil if necessary.

Drive chain Check chain slack and condition.

5-6, 8-248-26 Adjust if necessary.

Throttle Check for proper throttle cable operation. 5-6

Wheels and tires Check tire pressure, wear and damage. 5-75-9, 8-30

Fittings and fasteners Check all fitting and fasteners. 5-6

Battery Check fluid level. Fill with distilled water if necessary.

5-6, 8-318-33

Lights and switches Check for proper operation. 5-6, 8-348-38

5VJ-9-11-1 3/12/03 3:20 PM Page 5-2

5-2

EBU00472

Front and rear brakes 1. Brake levers

Check for correct free play in the brake levers. If the free play is incorrect, adjust it. (See pages 8-198-23.)

Check operation of the levers. They should move smoothly and there should be a firm feeling when the brake is applied. If not, have the machine inspected by a Yamaha dealer.

2. 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, inspect the brakes for wear. (See page 8-18.)

POTENTIAL HAZARD

Failure to inspect the ATV before operat- ing. Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Increases the possibility of an accident or equipment damage.

HOW TO AVOID THE HAZARD

Always 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 in the Owners Manual.

qWARNING

5

5VJ-9-11-1 3/12/03 3:20 PM Page 5-3

EBU13410

Fuel Make sure there is sufficient gasoline in the tank.

5-3

POTENTIAL HAZARD

Riding with improperly operating brakes.

WHAT CAN HAPPEN

You could lose braking ability, which could lead to an accident.

HOW TO AVOID THE HAZARD

Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have the ATV inspected by a Yamaha dealer.

qWARNING

Recommended fuel: UNLEADED GASOLINE ONLY

Fuel tank capacity: Total: 7L (1.54 Imp gal, 1.8 US gal) Reserve: 1.3L (0.29 Imp gal, 0.34 US gal)

1. Filler tube 2. Fuel level

5VJ-9-11-1 3/12/03 3:20 PM Page 5-4

cC Use only unleaded gasoline. The use of lead- ed gasoline will cause severe damage to inter- nal engine parts, such as the valves and pis- ton rings, as well as to the exhaust system.

Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost.

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

POTENTIAL HAZARD

Improper care when refueling.

WHAT CAN HAPPEN

Fuel can spill, which can cause a fire and severe 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.

qWARNING

5VJ-9-11-1 3/12/03 3:20 PM Page 5-5

EBU01116

Engine and transmission oil Make sure the engine and transmission oil is at the specified level. Add oil as necessary. (See page 8-5.)

cC Be sure to use motor oils that do not contain anti-friction modifiers. Passenger car motor oils (often labeled ENERGY CONSERVING II) contain anti-friction additives which will cause clutch and/or starter clutch slippage, resulting in reduced component life and poor engine per- formance.

5-5

Engine oil quantity: Periodic oil change:

1.25 L (1.10 Imp qt, 1.32 US qt) Total amount:

1.45 L (1.28 Imp qt, 1.53 US qt)

Transmission oil quantity: Total amount:

0.6 L (0.53 Imp qt, 0.63 US qt)

Recommended oil:

Recommended engine/transmission oil clas- sification:

API Service SE, SF, SG type or higher

100 30 50 70 90 110

SAE 5W30

20 10 0 10 20 30 40

YAMALUBE 4 (20W40) or SAE20W40

YAMALUBE 4 (10W30) or SAE10W30

130F

50C

5VJ-9-11-1 3/12/03 3:20 PM Page 5-6

EBU00498

Chain Check the general condition of the chain and check the chain slack before every ride. Lubricate and adjust the chain as necessary. (See pages 8-228-25 for details.)

EBU01083

Throttle lever Check to see that the throttle lever operates cor- rectly. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer repair as necessary for proper operation.

EBU01162

Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque.

EBU00803

Lights Check the headlight and tail/brake light to make sure they are in working condition. Repair as necessary for proper operation.

EBU11700

Switches Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation.

EBU00499

Battery Check fluid level and fill if necessary. Use only distilled water if refilling is necessary. (See pages 8-318-33.)

5-6

5VJ-9-11-1 3/12/03 3:20 PM Page 5-7

EBU00157

Tires

5-7

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or uneven tire pressure.

WHAT CAN HAPPEN

Use of improper tires on this ATV, or oper- ation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident.

HOW TO AVOID THE HAZARD

1. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. Other tire combinations are not recommended.

qWARNING 2. The tires should be set to the recom-

mended pressure: 8 Recommended tire pressure

Front 20 kPa (0.20 kgf/cm2, 2.9 psi) Rear 25 kPa (0.25 kgf/cm2, 3.6 psi) 8 Check and adjust tire pressures when

the tires are cold. 8 Tire pressures must be equal on both

sides. 3. Tire pressure below the minimum

specified could cause the tire to dis- lodge from the rim under severe riding conditions. The following are minimums: Front 17 kPa (0.17 kgf/cm2, 2.5 psi) Rear 22 kPa (0.22 kgf/cm2, 3.2 psi)

Manufacturer Size Type

Front DUNLOP AT20 7 - 8 KT536A

Rear DUNLOP AT22 10 - 8 KT537A

5VJ-9-11-1 3/12/03 3:20 PM Page 5-8

5-8

EBU00159

How to measure tire pressure Use the low-pressure tire gauge.

NOTE: The low-pressure tire gauge is included as stan- dard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.

Set pressure with tires cold. Set tire pressures to the following specifications:

q

20 kPa (0.20 kgf/cm2,

2.9 psi)

17 kPa (0.17 kgf/cm2,

2.5 psi)

23 kPa (0.23 kgf/cm2,

3.2 psi)

25 kPa (0.25 kgf/cm2,

3.6 psi)

22 kPa (0.22 kgf/cm2,

3.2 psi)

28 kPa (0.28 kgf/cm2,

4.0 psi)

Front

Rear

Recommended pressure

Minimum Maximum

4. Use no more than the following pres- sures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst.

1. Low-pressure tire gauge

5VJ-9-11-1 3/12/03 3:20 PM Page 5-9

EBU00160

Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire.

5-9

a

a. Tire wear limit

5VJ-9-11-1 3/12/03 3:20 PM Page 5-10

EBU00161

OPERATION

w Indicates a potential hazard that could result in serious injury or death.

EBU00509

Starting a cold engine

1. Set the parking brake. 2. Turn the fuel cock to ON. 3. Turn the main switch to ON and the engine

stop switch to RUN. 4. Shift the drive select lever to neutral.

6-1

POTENTIAL HAZARD

Operating ATV without being familiar with all controls.

WHAT CAN HAPPEN

Loss of control, which could cause an accident or injury.

HOW TO AVOID THE HAZARD

Read the Owners Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer.

qWARNING 6

POTENTIAL HAZARD

Freezing control cables in cold weather.

WHAT CAN HAPPEN

You could be unable to control the ATV, which could lead to an accident or colli- sion.

HOW TO AVOID THE HAZARD

When riding in cold weather, always make sure all control cables work smoothly before you begin riding.

qWARNING

5VJ-9-11-1 3/12/03 3:20 PM Page 6-1

NOTE: 8 The engine can be started only when the

drive select lever is in neutral. 8 When the drive select lever is in neutral, the

neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it.

5. Use the starter (choke) in reference to the figure:

Position 1: Cold engine start- ambient temperature below 5C (40F).

Position 2: Cold engine start- ambient temperature at 0C (30F)30C (90F) and warming up position.

Position 3: Cold engine start- ambient temperature above 25C (80F) and warm engine start posi- tion.

6. Completely close the throttle lever and start the engine by pushing the start switch.

6-2

1. Fully open 2. Half open 3. Closed a. Starter (choke)

AMBIENT TEMP./STARTER (CHOKE) POSITION

5VJ-9-11-1 3/12/03 3:20 PM Page 6-2

NOTE: If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to pre- serve battery energy. Do not crank the engine more than 10 seconds on each attempt.

7. If the engine is started with the starter (choke) in position 1, the starter (choke) should be returned to position 2 to warm up the engine. If the engine is started with the starter (choke) in position 2 , keep the starter (choke) in this position to warm up the engine.

8. Continue warming up the engine until it idles smoothly and return the starter (choke) to position 3 before riding.

cC See the Engine break-in section prior to operating engine for the first time.

EBU00180

Starting a warm engine To start a warm engine, refer to the Starting a cold engine section. The starter (choke) should not be used. The throttle should be opened slightly.

EBU00182

Warming up To get maximum engine life, always warm up the engine before starting off. Never accelerate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally with the starter (choke) turned off.

6-3

5VJ-9-11-1 3/12/03 3:20 PM Page 6-3

EBU12250

Drive select lever operation and reverse dri- ving

cC Before shifting, you must stop the machine and return the throttle lever to its closed position. Otherwise, the transmission may be damaged.

Shifting: forward 1. Bring the machine to a complete stop and

return the throttle lever to the closed posi- tion.

2. Shift the gear from neutral to forward and vice versa by moving the drive select lever along the shift guide.

NOTE: Make sure that the drive select lever is com- pletely shifted into position.

3. Open the throttle lever gradually.

Shifting: reverse 1. Bring the machine to a complete stop and

return the throttle lever to the closed posi- tion.

2. Apply the parking brake. 3. Shift the gear from neutral to reverse and

vice versa by moving the drive select lever along the shift guide.

6-4

q

we

a

a. Drive select lever 1. Neutral N 2. Forward F 3. Reverse R

5VJ-9-11-1 3/12/03 3:20 PM Page 6-4

NOTE: When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect the ATV.

4. Check behind for people or obstacles, then release the parking brake.

5. Open the throttle lever gradually and contin- ue to watch to the rear while backing.

NOTE: If the drive select lever is shifted into reverse while the engine is running, the engine will stop unless the rear brake lever or parking brake is applied.

6-5

POTENTIAL HAZARD

Improper operation in reverse.

WHAT CAN HAPPEN

You could hit an obstacle or person behind you, resulting in serious injury.

HOW TO AVOID THE HAZARD

When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.

qWARNING

5VJ-9-11-1 3/12/03 3:20 PM Page 6-5

EBU02091

Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct oper- ating clearances. During this period, prolonged full throttle opera- tion or any condition which might result in exces- sive engine heating must be avoided. However, momentary (23 seconds maximum) full throttle operation under load does not harm the engine.

Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r/min so the engine can rid itself of the temporary build up of heat. If any abnormality is noticed during this period, consult a Yamaha dealer.

010 hours: 8 Avoid continuous operation above half throt-

tle. Allow a cooling off period of five to ten minutes after every hour of operation. Vary the speed of the machine from time to time. Do not operate it at one set throttle position.

6-6

5VJ-9-11-1 3/12/03 3:20 PM Page 6-6

EBU00211

Parking When parking, stop the engine and shift into neutral. Turn the fuel cock to OFF and apply the parking brake.

6-7

1

1. Locked position

1020 hours: 8 Avoid prolonged operation above 3/4 throttle.

Rev the machine freely through the gears but do not use full throttle at any time.

After break-in: 8 Avoid prolonged full throttle operation. Vary

speeds occasionally.

5VJ-9-11-1 3/12/03 3:20 PM Page 6-7

EBU00215

Parking on a slope 1. Bring the machine to a stop by applying the brakes.

2. Stop the engine. 3. With the rear brake applied, apply the park-

ing brake.

6-8

POTENTIAL HAZARD

Parking on a hill or other incline.

WHAT CAN HAPPEN

The ATV could roll out of control, increas- ing the chance of an accident.

HOW TO AVOID THE HAZARD

Avoid parking on hills or other inclines. If you must park on an incline, place the machine transversely across the incline, apply the parking brake, and block the front and rear wheels with rocks or other objects. Do not park the ATV at all on hills that are so steep you could not walk up them easi- ly.

qWARNING

5VJ-9-11-1 3/12/03 3:20 PM Page 6-8

EBU00221

Accessories and loading

EBU00222

Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. 8 Choose only accessories designed for your

ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other acces- sories may also be available on the market. However, it is not possible for Yamaha to test all non-Yamaha accessories, nor have any control over the quality or suitability of them. Choose a genuine Yamaha accessory, or one that is equivalent in design and quality.

8 Accessories should be rigidly and securely mounted. An accessory which can shift posi- tion or come off while you are riding could affect your ability to control the ATV.

8 Do not mount an accessory where it could interfere with your ability to control the ATV. Examples include (but are not limited to) a heavy or bulky object attached to the handle- bars which could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view.

8 Use extra caution when riding an ATV with accessories. The ATV may handle differently than it does without accessories.

6-9

5VJ-9-11-1 3/12/03 3:20 PM Page 6-9

EBU00585

Loading As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. Keep the following points in mind: 8 Never exceed the weight limits shown. An

overloaded ATV can be unstable.

8 Load cargo on the carriers as close to the center of the vehicle as possible. Put cargo at the rear of the front carrier and at the front of the rear carrier. Center the load from side to side.

8 Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident.

8 Make sure the load does not interfere with controls or your ability to see where you are going.

8 Ride more slowly than you would without a load. The more weight you carry, the slower you should go.

8 Allow more braking distance. A heavier vehi- cle takes longer to stop.

8 Avoid making sharp turns unless at very slow speeds.

8 Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV.

6-10

MAXIMUM LOADING LIMIT Vehicle loading limit (total weight of cargo, rider and accessories):

100 kg (220 lb)

5VJ-9-11-1 3/12/03 3:20 PM Page 6-10

6-11

POTENTIAL HAZARD

Overloading this ATV or carrying or tow- ing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in vehicle handling which could lead to an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.

qWARNING

5VJ-9-11-1 3/12/03 3:20 PM Page 6-11

6-12

EBU13520

w Indicates a potential hazard that could result in serious injury or death.

5VJ-9-11-1 3/12/03 3:20 PM Page 6-12

7

7-1

Riding Your ATV

5VJ-9-11-2 3/12/03 1:53 PM Page 7-1

7-2

5VJ-9-11-2 3/12/03 1:53 PM Page 7-2

this Owners Manual completely and understand the operation of the controls. Pay particular attention to the safety information on pages 2-12-7. Please also read all caution and warn- ing labels on your ATV.

w Indicates a potential hazard that could result in serious injury or death.

GETTING TO KNOW YOUR ATV This ATV is for recreation and utility 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 period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers.

Riding your new ATV can be a very enjoyable activity, providing you with hours of pleasure. But it is essential to familiarize yourself with the operation of the ATV to achieve the skill neces- sary to enjoy riding safely. Before you begin to ride, be sure you have read

7-3

5VJ-9-11-2 3/12/03 1:53 PM Page 7-3

7-4

RIDE WITH CARE AND GOOD JUDGEMENT

Get training if you are inexperienced. Beginners should get training from a certified instructor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV's handling and performance characteristics.

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.

POTENTIAL HAZARD

Operating this ATV without proper instruc- tion.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator does not know how to oper- ate 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 regularly practice the skills learned in the course and the operating techniques described in this Owners Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-4

7-5

Not recommended for children under 16 years of age.

POTENTIAL HAZARD

Failure to follow the age recommendations for this ATV.

WHAT CAN HAPPEN

Use by children of ATVs that are not rec- ommended for their age can lead to severe injury or death of the child.

HOW TO AVOID THE HAZARD

A child under 16 should never operate an ATV with engine size greater than 90cc.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-5

7-6

This ATV is designed to carry operator only - passengers prohibited.

POTENTIAL HAZARD

Carrying a passenger on this ATV.

WHAT CAN HAPPEN

Greatly reduces your ability to balance and control this ATV. Could cause an acci- dent, resulting in harm to you and/or your passenger.

HOW TO AVOID THE HAZARD

Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for car- rying passengers.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-6

Apparel

POTENTIAL HAZARD

Operating this ATV without wearing an approved motorcycle helmet, eye protec- tion and protective clothing.

WHAT CAN HAPPEN

Operating without an approved motorcy- cle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.

7-7

Operating without protective clothing increases your chances of severe injury in the event of an accident.

HOW TO AVOID THE HAZARD

Always wear an approved motorcycle hel- met that fits properly. You should also wear:

eye protection(goggles or face shield) gloves boots long-sleeved shirt or jacket long pants

qWARNING

Gloves

Goggles

Boots

Helmet

Protective clothing

5VJ-9-11-2 3/12/03 1:53 PM Page 7-7

7-8

Do not operate after consuming alcohol or drugs. Operators performance capability is reduced by the influence of alcohol or drugs.

POTENTIAL HAZARD

Operating this ATV after consuming alco- hol or drugs.

WHAT CAN HAPPEN

Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident.

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or while driving this ATV.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-8

7-9

Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the ATV.

POTENTIAL HAZARD

Failure to inspect the ATV before operat- ing. Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Increases the possibility of an accident or equipment damage.

HOW TO AVOID THE HAZARD

Always 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 in the Owners Manual.

qWARNING

POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure.

WHAT CAN HAPPEN

Use of improper tires on this ATV, or oper- ation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident.

HOW TO AVOID THE HAZARD

Always use the size and type tires speci- fied in the Owners Manual for this vehicle on pages 5-75-8. Always maintain proper tire pressure as described in the Owners Manual on page 5-8.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-9

w Indicates a potential hazard that could result in serious injury or death.

Do not operate at speeds too fast for your skills or the conditions

Speed limiter For riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits the power and top speed of the ATV. Turning the screw in decreases top speed, and turning it out increases top speed.

7-10

POTENTIAL HAZARD

Operating this ATV at speeds too fast for your skills or the conditions.

WHAT CAN HAPPEN

Increases your chances of losing control of the ATV, which can result in an acci- dent.

HOW TO AVOID THE HAZARD

Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience.

qWARNING

q

w

1. Adjusting screw 2. Locknut

5VJ-9-11-2 3/12/03 1:53 PM Page 7-10

7-11

Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATVs handling may be adversely affected. Reduce your speed when adding additional loads.

MAXIMUM LOADING LIMIT Vehicle loading limit (total weight of cargo, rider and accessories):

100 kg (220 lb)

POTENTIAL HAZARD

Overloading this ATV or carrying or tow- ing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in vehicle handling which could lead to an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in your Owners Manual for carrying cargo or pulling a trailer.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-11

7-12

During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels.

POTENTIAL HAZARD

Removing hands from handlebars or feet from footboards during operation.

WHAT CAN HAPPEN

Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance 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 acci- dent.

HOW TO AVOID THE HAZARD

Always keep both hands on the handle- bars and both feet on the footboards of your ATV during operation.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-12

7-13

Avoid wheelies and jumping. You may lose con- trol of the ATV or overturn.

POTENTIAL HAZARD

Attempting wheelies, jumps, and other stunts.

WHAT CAN HAPPEN

Increases the chance of an accident, including an overturn.

HOW TO AVOID THE HAZARD

Never attempt stunts, such as wheelies or jumps. Dont try to show off.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-13

7-14

Modifications

POTENTIAL HAZARD

Operating this ATV with improper modifi- cations.

WHAT CAN HAPPEN

Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situa- tions could lead to an accident.

HOW TO AVOID THE HAZARD

Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used accord- ing to instructions. If you have questions, consult an authorized ATV dealer.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-14

Exhaust system The exhaust system on the ATV is very hot dur- ing and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it.

7-15

POTENTIAL HAZARD

Hot exhaust system.

WHAT CAN HAPPEN

Dry grass or brush or other combustible material accumulated around the engine area could catch fire. Someone touching the exhaust system during or after operation could be burned.

qWARNING

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.

5VJ-9-11-2 3/12/03 1:53 PM Page 7-15

BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of con- trol.

POTENTIAL HAZARD

Operating this ATV on paved surfaces.

WHAT CAN HAPPEN

ATVs are designed for off-road use only. Paved surfaces may seriously affect han- dling and control of the ATV, and may cause the vehicle to go out of control.

HOW TO AVOID THE HAZARD

Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.

7-16

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-16

7-17

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

POTENTIAL HAZARD

Operating this ATV on public streets, roads or highways.

WHAT CAN HAPPEN

You can collide with another vehicle.

HOW TO AVOID THE HAZARD

Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-17

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

7-18

POTENTIAL HAZARD

Failure to use extra care when operating this ATV on unfamiliar terrain.

WHAT CAN HAPPEN

You can come upon hidden rocks, bumps, or holes, 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 oper- ating on unfamiliar terrain. Always be alert to changing terrain condi- tions when operating the ATV.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-18

7-19

POTENTIAL HAZARD

Failure to use extra care when operating on excessively rough, slippery or loose terrain.

WHAT CAN HAPPEN

Could cause loss of traction or vehicle control, which could result in an accident, including an overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-19

7-20

When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch.

Do not ride in areas posted no trespassing. Do not ride on private property without getting per- mission.

POTENTIAL HAZARD

Operating in areas where you might not be seen by other off-road vehicles.

qWARNING

WHAT CAN HAPPEN

You could be in a collision. You could be injured.

HOW TO AVOID THE HAZARD

Always mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles.

5VJ-9-11-2 3/12/03 1:53 PM Page 7-20

Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Always avoid riding on paved surfaces: the ATV is designed for off-road use only, and handling maneuvers are more difficult to perform on pavement.

Set the parking brake and follow the instruction on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your ATV. Remember that the engine and exhaust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components.

With the engine idling, return the starter knob to the closed position and shift the drive select lever into the forward position. Then release the parking brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is applied too abruptly, the front wheels may lift off the ground resulting in a loss of directional con- trol. Avoid higher speeds until you are thorough- ly familiar with the operation of your ATV.

When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. Improper use of the brakes can cause the tires to lose traction, reducing control and increasing the possibility of an accident.

7-21

5VJ-9-11-2 3/12/03 1:53 PM Page 7-21

7-22

TURNING YOUR ATV To achieve maximum traction while riding off- road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. 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 outside 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 of the turn slip slightly, allowing the ATV to make the turn properly.

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

ATV could go out of control, causing a collision or overturn.

qWARNING

HOW TO AVOID THE HAZARD

Always follow proper procedures for turn- ing as described in this Owners Manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions.

5VJ-9-11-2 3/12/03 1:53 PM Page 7-22

This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesn't turn, come to a stop and then practice the procedure again. If the riding surface is slip- pery or loose, it may help to position more of your weight over the front wheels by moving for- ward 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 throt- tle changes, excessive braking, incorrect body movements, or too much speed for the sharp- ness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while nego- tiating a turn, lean more to the inside. It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over. Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your ATV.

7-23

Lean towards inside of turn. Support your

weight on the outer footboard

5VJ-9-11-2 3/12/03 1:53 PM Page 7-23

7-24

CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneu- ver your ATV well on flat ground before attempt- ing any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obsta- cles that might cause you to lose control.

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 for- ward and, on steeper inclines, standing on the footboards and leaning forward over the handle- bars.

POTENTIAL HAZARD

Operating on excessively steep hills.

WHAT CAN HAPPEN

The vehicle can overturn more easily on extremely steep hills than on level sur- faces or small hills.

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.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-24

7-25

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for climbing hills as described in this Owner's Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards. Never go over the top of any hill at high speed.

qWARNING An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

OK

5VJ-9-11-2 3/12/03 1:53 PM Page 7-25

7-26

If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill.

POTENTIAL HAZARD

Improperly crossing hills or turning on hills.

WHAT CAN HAPPEN

Could cause loss of 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 turn- ing technique as described in the Owners Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.

qWARNING

When crossing the side of a hill:

Always follow proper procedures as described in the Owners Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

OK

5VJ-9-11-2 3/12/03 1:53 PM Page 7-26

7-27

5VJ-9-11-2 3/12/03 1:53 PM Page 7-27

7-28

If your ATV has stalled or stopped and you believe you can continue up the hill, restart care- fully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then descend the hill.

If you start to roll backwards, DO NOT use the rear brake to stop. The ATV could easily tip over backwards. Instead, dismount the ATV immedi- ately on the uphill side.

POTENTIAL HAZARD

Stalling, rolling backwards or improperly dismounting while climbing a hill.

WHAT CAN HAPPEN

Could result in ATV overturning.

HOW TO AVOID THE HAZARD

Maintain steady speed when climbing a hill.

If you lose all forward speed:

Keep weight uphill. Apply the brakes. Lock the parking brake, after you are stopped.

If you begin rolling backwards:

Keep weight uphill. Never apply the rear brake while rolling backwards. Apply the front brake.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-28

7-29

When fully stopped, apply the rear brake as well, and then lock the parking brake.

Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the proce- dure described in the Owners Manual.

5VJ-9-11-2 3/12/03 1:53 PM Page 7-29

7-30

RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of trac- tion. Whenever possible, ride your ATV straight downhill. 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 obstacles which may appear.

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 Owners Manual. Note: a special technique is required when braking as you go down a hill. Always 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 vehicle to lean sharply to one side. Go straight down the hill where possible.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-30

7-31

OK

5VJ-9-11-2 3/12/03 1:53 PM Page 7-31

7-32

CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough ter- rain that may upset your balance.

As you travel across a slope, lean your body in the uphill direction. It may be necessary to cor- rect the steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes be sure not to make sharp turns either up or down hill.

If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path. As you regain proper bal- ance, gradually steer again in the direction you wish to travel.

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 turn- ing technique as described in the Owner's Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible.

When crossing the side of a hill:

Always follow proper procedures as described in the Owners Manual. Avoid hills with excessively slippery or loose surfaces.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-32

7-33

Shift your weight to the uphill side of the ATV.

OK

5VJ-9-11-2 3/12/03 1:53 PM Page 7-33

7-34

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

POTENTIAL HAZARD

Operating this ATV through deep or fast flowing water.

WHAT CAN HAPPEN

Tires may float, causing loss of traction and loss of control, which could lead to an accident.

HOW TO AVOID THE HAZARD

Never operate this ATV in fast flowing water or in water deeper than that speci- fied in your Owners Manual.

qWARNING

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.

5VJ-9-11-2 3/12/03 1:53 PM Page 7-34

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

cC 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 condi- tions.

7-35

q

1. Check hose

5VJ-9-11-2 3/12/03 1:53 PM Page 7-35

7-36

RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result.

POTENTIAL HAZARD

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 obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owners Manual.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-36

7-37

5VJ-9-11-2 3/12/03 1:53 PM Page 7-37

7-38

SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help.

If the rear wheels of your ATV start to slide side- ways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide.

5VJ-9-11-2 3/12/03 1:53 PM Page 7-38

7-39

With practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneu- vers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost.

POTENTIAL HAZARD

Skidding or sliding improperly.

WHAT CAN HAPPEN

You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Learn to safely control skidding or 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 reduce the chance of skidding or sliding out of control.

qWARNING

5VJ-9-11-2 3/12/03 1:53 PM Page 7-39

7-40

WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely.

WHAT TO DO ...

8 If your ATV doesnt turn when you want it to: Bring the ATV to a stop and practice the turn- ing maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See pages 7-22 7-23.)

8 If your ATV begins to tip while turning: Lean more into the turn to regain balance. If necessary, gradually let off the throttle and/or steer to the outside of the turn. (See pages 7-227-23.)

8 If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not rec- ommended until you have corrected the slide. (See pages 7-387-39.)

8 If your ATV cant make it up a hill you are try- ing 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. Dismount the ATV on the uphill side. (See pages 7-247-29.)

5VJ-9-11-2 3/12/03 1:53 PM Page 7-40

8 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 7-327-33.)

8 If your ATV encounters shallow water: Ride slowly and carefully through slow mov- ing water, watching for obstacles. Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not con- tinue to ride your ATV until you have regained adequate braking ability. (See pages 7-34 7-35.)

7-41

w Indicates a potential hazard that could result in serious injury or death.

5VJ-9-11-2 3/12/03 1:53 PM Page 7-41

EBU00515

PERIODIC MAINTENANCE AND ADJUSTMENT

Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obliga- tion of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages.

EBU12210

Owners manual and tool kit You are recommended to put this owners man- ual and low-pressure tire gauge in the vinyl bag and always carry them along with the owners tool kit under the seat.

8-1

e

q

w

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 can start fires.

HOW TO AVOID THE HAZARD

Turn off the engine when performing maintenance unless otherwise specified.

qWARNING

Have a Yamaha dealer perform service if you are not familiar with machine service.

1. Owners manual 2. Low-pressure tire gauge 3. Owners tool kit

5VJ-9-11-3 3/13/03 3:01 PM Page 8-2

The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the owners tool kit are suffi- cient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts.

NOTE: If you do not have a torque wrench available during a service operation requiring one, take your machine to a Yamaha dealer to check the torque settings and adjust them as necessary.

8-2

POTENTIAL HAZARD

Operating this ATV with improper modifi- cations.

WHAT CAN HAPPEN

Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situa- tions could lead to an accident.

HOW TO AVOID THE HAZARD

Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used accord- ing to instructions. If you have questions, consult an authorized Yamaha ATV dealer.

qWARNING

8

5VJ-9-11-3 3/13/03 3:01 PM Page 8-3

8-3

EBU00261

PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY

ITEM ROUTINE 1 3 6 6 1 month months months months year

Valves* Check valve clearance. 1 1 1 1 Adjust if necessary.

Check condition. Spark plug Adjust gap and clean. 1 1 1 1 1

Replace if necessary.

Air filter element Clean. Every 20 40 hours(for engine and V-belt Replace if necessary. (more often in wet or dusty areas)compartment)

Carburetor* Check idle speed/starter operation. 1 1 1 1 Adjust if necessary.

Cylinder head cover Check breather hose for cracks or damage. 1 1 1breather system* Replace if necessary.

Check leakage. Exhaust system* Retighten if necessary. 1 1 1

Replace gasket if necessary.

Spark arrester Clean. 1 1 1

Fuel line* Check fuel hose for cracks or damage. 1 1 1 Replace if necessary.

Engine oil Replace (warm engine before draining). 1 1 1 1

Oil strainer* Clean. 1 1 1 Replace if necessary.

Drive chain Check and adjust slack/alignment/clean/lube. 1 1 1 1 1

Transmission oil Check oil level/oil leakage. 1 1 Replace every 12 months.

5VJ-9-11-3 3/13/03 3:01 PM Page 8-4

8-4

INITIAL EVERY ITEM ROUTINE 1 3 6 6 1

month months months months year

Brakes* Check operation. 1 1 1 1 1 Adjust if necessary.

V-belt* Check operation Replace if damage or excessive wear. 1 1

Wheels* Check balance/damage/runout. 1 1 1 1 Replace if necessary.

Wheel bearings* Check bearing assembly for looseness/damage. 1 1 1 1 Replace if damaged.

Check operation.

Steering system* Replace if damaged. 1 1 1 1 1 Check toe-in.

Adjust if necessary.

Knuckle shafts/ Lubricate every 6 months.** 1 1 1steering shaft*

Fittings and fasteners* Check all chassis fittings and fasteners. 1 1 1 1 1 Correct if necessary.

Check specific gravity. Battery* Check breather hose for correct routing. 1 1 1 1 1

Correct if necessary.

w Indicates a potential hazard that could result in serious injury or death.

* It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease.

5VJ-9-11-3 3/13/03 3:01 PM Page 8-5

EBU00896

Engine oil Engine oil level measurement 1. Place the machine on a level surface. 2. Warm up the engine for several minutes and

stop it. 3. Remove the dipstick and wipe it off with a

clean rag. Insert the dipstick in the filler hole without screwing it in.

NOTE: Wait a few minutes until the oil level settles before checking.

4. Remove the dipstick and inspect the oil level. 5. The oil level should be between the maximum

and minimum marks. If the level is low, add oil to raise it to the proper level.

cC Be sure no foreign material enters the crankcase.

Engine oil replacement and oil filter cleaning 1. Place the machine on a level surface. 2. Warm up the engine for several minutes and

stop it. 3. Place a container under the engine to collect

the used oil. 8-5

q w

e

1. Dipstick 2. Maximum level mark 3. Minimum level mark

5VJ-9-11-3 3/13/03 3:01 PM Page 8-6

4. Remove the dipstick and drain bolt to drain the oil.

cC When removing the drain bolt, the compres- sion spring, oil strainer and O-ring will fall out. Take care not to lose these parts.

5. Clean the oil strainer with solvent. 6. Inspect the O-ring and replace it if damaged. 7. Install the O-ring, oil strainer, compression

spring and drain bolt. Tighten the drain bolt to specification.

cC Before installing the drain bolt, be sure to install the O-ring, compression spring and oil strainer.

8-6

Tightening torque: Drain bolt (engine):

32 Nm (3.2 m0kgf, 23 ft0lbf)

q

r

e w q

1. Drain bolt 2. O-ring 3. Compression spring 4. Oil strainer

5VJ-9-11-3 3/13/03 3:01 PM Page 8-7

EBU00891

Transmission oil Transmission oil measurement 1. Place the machine on a level surface. 2. Remove the screw and check the oil level. It

should be up to the brim of the hole. If the level is low, remove the oil filler bolt and add oil to raise it to the proper level.

8. Fill the engine with oil and install the dipstick.

cC Be sure no foreign material enters the crankcase.

9. Warm up the engine for several minutes at idle speed. Check for oil leakage while warm- ing up.

cC If oil leakage is found, stop the engine imme- diately and check for the cause.

8-7

w e

q

Recommended oil: See page 10-2.

Oil quantity: Periodic oil change

1.25 L (1.10 Imp qt, 1.32 US qt) Total amount:

1.45 L (1.28 Imp qt, 1.53 US qt)

1. Screw 2. Brim 3. Correct oil level

5VJ-9-11-3 3/13/03 3:01 PM Page 8-8

3 Install the screw and oil filler bolt and tighten to specification.

Transmission oil replacement 1. Place the machine on a level surface. 2. Place a container under the engine.

3. Remove the oil filler bolt and drain bolt to drain the oil.

4. Install the drain bolt and tighten to specifica- tion.

8-8

q

Tightening torque: Screw:

16 Nm (1.6 m0kgf, 11 ft0lbf) Oil filler bolt:

23 Nm (2.3 m0kgf, 17 ft0lbf)

q

Tightening torque Drain bolt:

23 Nm (2.3 m0kgf, 17 ft0lbf)

1. Oil filler bolt

1. Drain bolt

5VJ-9-11-3 3/13/03 3:01 PM Page 8-9

EBU11820

Spark plug inspection The spark plug is an important engine compo- nent and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder. Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, you should replace the spark plug with one of the proper type.

5. Fill the engine with oil and install the oil filler bolt.

cC Be sure no foreign material enters the crankcase.

6. Start the engine and warm up for a few min- utes. While warming up, check for oil leakage. If oil leakage is found, stop the engine imme- diately and check for the cause.

7. Check the oil level.

8-9

Recommended oil: See page 10-2

Oil quantity: Total amount:

0.6 L (0.53 Imp qt, 0.63 US qt)

Standard spark plug: CR7HS (NGK)

5VJ-9-11-3 3/13/03 3:01 PM Page 8-10

Before installing the spark plug, measure the electrode gap with a wire thickness gauge and adjust it to specification.

When installing the spark plug, always clean the gasket surface and its mating surface. Wipe off any grime from the threads and tighten it to the specified torque.

8-10

a

Spark plug gap: 0.60.7 mm (0.020.03 in)

Tightening torque: Spark plug:

12.5 Nm (1.25 m0kgf, 9.1 ft0lbf)

a. Spark plug gap

1. Spark plug wrench

q

5VJ-9-11-3 3/13/03 3:01 PM Page 8-11

8-11

1. Remove the seat. 2. Remove the breather hose, and then loosen

the clamp screw. 3. Remove the air filter case cover.

w

e

q

1. Air filter case cover 2. Breather hose 3. Clamp

EBU01142

Engine and V-belt case air filter element cleaning Both air filter elements should be cleaned at the specified intervals in the periodic maintenance chart. Engine air filter element

NOTE: There is a check hose at the bottom of the air fil- ter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case.

q

1. Check hose

5VJ-9-11-3 3/13/03 3:01 PM Page 8-12

4. Remove the air filter element, and separate it from the frame.

5. Wash the element gently but thoroughly in solvent.

6. Squeeze the excess solvent out of the air fil- ter element and let it dry.

cC Do not twist the air filter element when squeezing it.

8-12

POTENTIAL HAZARD

Using low flash point solvents or gasoline to clean the air filter element.

WHAT CAN HAPPEN

Low flash point solvents or gasoline can catch fire or explode.

HOW TO AVOID THE HAZARD

Use parts cleaning solvent to clean the air filter element.

qWARNING

qw

1. Air filter element 2. Element frame

5VJ-9-11-3 3/13/03 3:01 PM Page 8-13

7. Inspect the air filter element. If damaged, replace it.

8. Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter ele- ment. If foam air filter oil is not available, engine oil may be used.

NOTE: The element should be wet but not dripping.

9. Install the air filter element on the frame. 10. Install the air filter element into the air filter

case, and then install the parts removed for access.

cC Install the washer with the bent edge facing upward as shown.

8-13

q

1. Washer

5VJ-9-11-3 3/13/03 3:01 PM Page 8-14

NOTE: The air filter element should be cleaned every 20 40 hours. It should be cleaned and lubricat- ed more often if the machine is operated in extremely dusty areas. Each time air filter ele- ment maintenance is performed, check the air inlet to the air filter case for obstructions. Check the air cleaner rubber joint to the carburetor and manifold fittings for an airtight seal. Tighten all fittings securely to avoid the possibility of unfil- tered air entering the engine.

cC Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid engine wear and possible engine damage. Additionally, opera- tion without the air filter element will affect carburetor jetting with subsequent poor per- formance and possible engine overheating.

V-belt case air filter element 1. Remove the front cover by removing the

screws and bolts.

8-14

1

2

2

3

3

1. Front cover 2. Screw ( 2) 3. Bolt ( 2)

5VJ-9-11-3 3/13/03 3:01 PM Page 8-15

2. Remove the air filter element cover. 3. Pull out the air filter element.

4. Tap the element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air. If the air filter element is damaged, replace it.

5. Assemble by reversing the removal proce- dure. Be sure the air filter element is seated properly against the case.

EBU13020

Idle speed adjustment

NOTE: A diagnostic tachometer must be used for this procedure.

1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle.

8-15

w

q e

1. Element cover 2. Screw 3. Element

5VJ-9-11-3 3/13/03 3:01 PM Page 8-16

2. Connect the tachometer to the spark plug lead, and then set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw in direction a to increase the engine speed, and in direction b to decrease the engine speed.

EBU00303

Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician.

8-16

Specified idle speed: 1,6501,750 r/min

a b

q

1. Throttle stop screw

5VJ-9-11-3 3/13/03 3:01 PM Page 8-17

EBU00307

Throttle lever adjustment

NOTE: Adjust the engine idling speed before adjusting the throttle lever free play.

1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever

free play is 35 mm (0.120.20 in). 3. Tighten the locknut.

8-17

a

q

w

1. Locknut 2. Adjusting bolt a. Free play

5VJ-9-11-3 3/13/03 3:01 PM Page 8-18

EBU00308

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

8-18

q

w

w

q

Front

Rear

1. Wear limit line 2. Wear indicator

1. Wear limit line 2. Wear indicator

5VJ-9-11-3 3/13/03 3:01 PM Page 8-19

8-19

EBU11492

Front brake lever free play adjustment

NOTE: Before adjusting the brake lever free play, inspect the front brake shoes.

The front brake lever free play should be adjust- ed to 58 mm (0.20.3 in) at the brake lever pivot. If the free play is incorrect, adjust it as fol- lows.

1. Remove the front cover by removing the screws and bolts. (See page 8-14 for removal and installation procedures.)

2. Remove the V-belt air filter element cover. (See page 8-15 for removal and installation procedures.)

3. Remove the front fender by removing the screws and bolts.

1. Front fender 2. Bolt ( 2)

ww

q

a. Free play

a

5VJ-9-11-3 3/13/03 3:01 PM Page 8-20

4. Loosen the locknut and fully turn in the adjusting bolt at the front brake lever.

8-20

w

e

w

e

q

1. Locknut 2. Adjusting bolt

q

w

1. Front fender 2. Bolt ( 2) 3. Screw ( 6)

5VJ-9-11-3 3/13/03 3:01 PM Page 8-21

5. Make sure the brake cable joint in the equal- izer is straight when the brake is applied. If not, loosen the locknut, and then turn the adjusting nuts at the front brake cables until the cable joint becomes straight.

6. Tighten the locknut at the front of each brake cable.

8-21

q

wq

w

1. Locknut ( 2) 2. Adjusting nut ( 2)

q

w

a = a

a a

1. Equalizer 2. Cable joint

5VJ-9-11-3 3/13/03 3:01 PM Page 8-22

7. Turn the adjusting bolt at the brake lever until the specified free play is obtained.

8. Tighten the locknut at the brake lever. 9. Install by reversing the removal procedure.

POTENTIAL HAZARD

Operating with improperly serviced or adjusted brakes.

WHAT CAN HAPPEN

You could lose braking ability, which could lead to an accident.

HOW TO AVOID THE HAZARD

After servicing: 8 Make sure the brakes operate smoothly

and that the free play is correct. 8 Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer.

qWARNING

a

q

w

Specified free play: 58 mm (0.20.3 in)

1. Locknut 2. Adjusting bolt a. Free play

8-22

5VJ-9-11-3 3/13/03 3:01 PM Page 8-23

8-23

EBU00965

Rear brake adjustment Brake lever free play should be 58 mm (0.20.3 in) at the brake lever pivot. If the free play is incorrect, adjust as follows:

Turn the adjusting nut on the brake hub in direc- tion a to decrease play, and in direction b to increase play.

a

ab

q

a. Free play

1. Adjusting nut

5VJ-9-11-3 3/13/03 3:01 PM Page 8-24

POTENTIAL HAZARD

Operating with improperly serviced or adjusted brakes.

WHAT CAN HAPPEN

You could lose braking ability, which could lead to an accident.

HOW TO AVOID THE HAZARD

After servicing: 8 Make sure the brakes operate smoothly

and that the free play is correct. 8 Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer.

qWARNING EBU01144

Drive chain slack check

NOTE: Move the ATV back and forth and find the tight- est position of the drive chain. Check and/or adjust the chain slack while it is in this tightest position.

To check the drive chain slack, all tires must be touching the ground and there should be no weight on it. Check the drive chain slack at the position shown in the illustration Normal slack is approximately 30 mm (1.18 in). If the slack exceeds 30 mm (1.18 in), adjust it to specification.

a

a. Drive chain slack 8-24

5VJ-9-11-3 3/13/03 3:01 PM Page 8-25

8-25

EBU01146

Drive chain slack adjustment 1. Loosen the hub stopper bolt locknut and

then the hub stopper bolt.

2. Loosen the upper and lower axle holding bolts.

3. Loosen the locknut. To tighten the drive chain, turn the adjusting bolt in direction a. To loosen the drive chain, turn the adjusting bolt in direction b, and then push the wheels forward.

cC Too little of drive chain slack will overload the engine and other important parts. Keep the drive chain slack within the specified limit.

q

w

a b

wq

e

e

1. Hub stopper bolt 3. Axle holding bolt ( 4) 2. Locknut

1. Locknut 2. Chain adjusting bolt

5VJ-9-11-3 3/13/03 3:01 PM Page 8-26

4. After adjusting, be sure to tighten the lock- nut and the axle holding bolts.

5. Finger tighten the hub stopper bolt and tight- en the hub stopper bolt locknut.

cC If measurement A of the drive chain adjust- ing bolt is less than 27 mm (1.06 in), ask a Yamaha dealer to replace the drive chain.Tightening torque:

Locknut: 15.5 Nm (1.55 m0kgf, 11.2 ft0lbf)

Axle holding bolts (upper): 85 Nm (8.5 m0kgf, 61 ft0lbf)

Axle holding bolts (lower): 60 Nm (6.0 m0kgf, 43 ft0lbf)

Tightening torque: Locknut:

15.5 Nm (1.55 m0kgf, 11.2 ft0lbf)

A

A. Measurement A

8-26

5VJ-9-11-3 3/13/03 3:01 PM Page 8-27

8-27

2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a

special O-ring chain lubricant.

cC Do not use engine oil or any other lubricants for the drive chain, as they may contain sub- stances that could damage the O-rings.

EBU00805

Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic mainte- nance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.

cC The drive chain must be lubricated after washing the ATV or riding in the rain.

1. Clean the drive chain with kerosene and a small soft brush.

cC To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate sol- vents.

q

1. O-rings

5VJ-9-11-3 3/13/03 3:01 PM Page 8-28

EBU00355

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

EBU00356

Cable inspection and lubrication

Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them.

q

POTENTIAL HAZARD

Damaged control cables.

WHAT CAN HAPPEN

Corrosion can result when the outer cov- ering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury.

HOW TO AVOID THE HAZARD

Inspect cables frequently. Replace dam- aged cables.

qWARNING

Recommended lubricant: Yamaha chain and cable lube or

SAE 10W30 motor oil

1. Drain screw

8-28

5VJ-9-11-3 3/13/03 3:01 PM Page 8-29

8-29

EBU00725

Brake lever lubrication Lubricate the pivoting parts of the brake levers.

EBU00728

Knuckle shaft, lower arms and steering shaft lubrication Lubricate the pivot points using a grease gun.

Recommended lubricant: Lithium-soap-based grease (all-purpose grease)

1 1

1

1

Recommended lubricant: Lithium-soap-based grease

1. Grease nipple (6)

5VJ-9-11-3 3/13/03 3:01 PM Page 8-30

EBU01112

Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand

under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel.

EBU01150

Wheel installation 1. Install the wheel and the nuts.

NOTE: Tapered wheel nuts are used for both front and rear wheels. Install the nut with its tapered side towards the wheel.

2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified

torque.

q

1. Tapered wheel nut

Tightening torque: Front wheel nut:

55 Nm (5.5 m0kgf, 40 ft0lbf) Rear wheel nut:

55 Nm (5.5 m0kgf, 40 ft0lbf)

8-30

5VJ-9-11-3 3/13/03 3:01 PM Page 8-31

8-31

EBU00378

Battery Check the level of the battery fluid and see if the terminals are tight. Add distilled water if the fluid level is low.

cC Do not leave or store the battery on its side. When inspecting the battery, be sure the breather hose is routed correctly. If it touch- es the frame or exists in such a way as to cause battery electrolyte or gas to exit onto the frame, structural and cosmetic damage to the machine can occur.

qw

e

1. Battery 2. Battery breather hose 3. Guide ( 2)

5VJ-9-11-3 3/13/03 3:01 PM Page 8-32

POTENTIAL HAZARD

Failure to handle batteries or battery elec- trolyte carefully.

WHAT CAN HAPPEN

You could be poisoned. You could be severely burned by the sulfuric acid in bat- tery electrolyte. Batteries produce explosive gases.

HOW TO AVOID THE HAZARD

Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Get prompt medical attention.

qWARNING EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batter- ies away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed space.

8-32

5VJ-9-11-3 3/13/03 3:01 PM Page 8-33

8-33

EBU11950

Replenishing the battery fluid A poorly maintained battery will corrode and dis- charge quickly. The battery fluid should be checked at least once a month.

1. The level should be between the maximum and minimum level marks. Use only distilled water if refilling is necessary.

2. Disconnect the negative () lead. 3. Disconnect the positive (+) lead, and then

remove the battery.

cC Normal tap water contains minerals which are harmful to a battery. Therefore, refill only with distilled water.

4. When the machine is not to be used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before using.

5. If the battery is to be stored for a longer period than the above, check the specific gravity at least once a month and recharge the battery when it is too low.

6. Always make sure the connections are cor- rect when putting the battery back in the machine. Make sure the breather hose is properly connected and is not damaged or obstructed.

w

q

e

r

1. Maximum level mark 2. Minimum level mark 3. Negative () lead 4. Positive (+) lead

5VJ-9-11-3 3/13/03 3:01 PM Page 8-34

EBU00388

Fuse replacement 1. The fuse case is located on the right side of

the machine. 2. If the fuse is blown, turn off the main switch

and install a new fuse of the specified amperage. Then turn on the switches, if the fuse immediately blows again, consult a Yamaha dealer.

cC To prevent accidental short-circuiting, turn off the main switch when checking or replac- ing a fuse.

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.

qWARNING

q

w

Specified fuse: 5A

1. Fuse 2. Spare fuse

8-34

5VJ-9-11-3 3/13/03 3:01 PM Page 8-35

8-35

EBU01151

Replacing the headlight bulb If the headlight bulb burns out, replace the bulb as follows.

1. Remove the screws holding the headlight unit assembly to the headlight body.

2. Remove the headlight bulb holder cover, turn the bulb holder counterclockwise and remove the defective bulb.

1 1

1. Screw ( 2)

1. Headlight bulb holder

5VJ-9-11-3 3/13/03 3:01 PM Page 8-36

3. Put a new headlight bulb into position and secure it in place with the bulb holder.

4. Install the headlight bulb holder cover.

cC Make sure the bulb holder cover is securely fitted over the bulb holder and seated against the reflector.

5. Install the headlight unit assembly by installing the screws.

6. Adjust the headlight beam if necessary.POTENTIAL HAZARD

The headlight bulb is hot when it is on and immediately after it is turned off.

WHAT CAN HAPPEN

You can be burned, or a fire could start if the bulb touches something flammable.

HOW TO AVOID THE HAZARD

Wait for the bulb to cool before touching or removing it.

qWARNING

8-36

5VJ-9-11-3 3/13/03 3:01 PM Page 8-37

8-37

EBU00861

Tail/brake light bulb replacement 1. Remove the bulb holder (together with the

bulb) by turning it counterclockwise.

2. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise.

3. Install a new bulb in the bulb holder by push- ing it inward and turning it clockwise.

4. Install the bulb holder (together with the bulb).

q

1. Bulb holder

q w

1. Bulb 2. Bulb holder

5VJ-9-11-3 3/13/03 3:01 PM Page 8-38

EBU13600

Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester.

1. Remove the screws.

1. Screw ( 2)

q

EBU00410

Headlight beam adjustment

cC It is advisable to have a Yamaha dealer make this adjustment.

Vertical adjustment: To raise the beam, loosen the adjusting screw and pull the headlight assembly toward you. To lower the beam, push it away from you. After adjusting, be sure to tighten the screw.

q

1. Adjusting screw 8-38

5VJ-9-11-3 3/13/03 3:01 PM Page 8-39

8-39

2. Remove the tailpipe by pulling it out of the muffler.

3. Tap the tailpipe lightly, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe.

4. Insert the tailpipe into the muffler and align the screw holes.

5. Install the screws and tighten them.

1. Tailpipe 2. Spark arrester

w

q

POTENTIAL HAZARD

Improper cleaning of the spark arrester. Hot exhaust system

WHAT CAN HAPPEN

Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire.

HOW TO AVOID THE HAZARD

When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components. Do not start the engine when cleaning the exhaust system.

qWARNING

5VJ-9-11-3 3/13/03 3:01 PM Page 8-40

EBU00412

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

The skilled technicians at a Yamaha dealership have the tools, experience, and know-how to properly service your machine. Use only gen- uine Yamaha parts on your machine. Imitation parts may look like Yamaha parts, but they are often inferior. Consequently, they have a shorter service life and can lead to expensive repair bills.

POTENTIAL HAZARD

Checking the fuel system while smoking or near an open flame.

WHAT CAN HAPPEN

Fuel can ignite or explode, causing severe injury or property damage.

HOW TO AVOID THE HAZARD

Do not smoke when checking the fuel sys- tem. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces.

qWARNING

8-40

5VJ-9-11-3 3/13/03 3:01 PM Page 8-41

EBU00440

Troubleshooting chart

1. Fuel

Check if there is fuel in the fuel tank.

2. Compression

Use electric starter to see if there is compression.

3. Ignition

Remove plug and check electrodes.

Wet Wipe clean with dry cloth.

Dry Attach plug cap and ground to chassis.

Use electric starter. Spark weak.

Spark good. Ignition system normal.

No spark.

Ask a Yamaha dealer to inspect.

Adjust plug gap or replace plug.

There is compresson. Compression normal.

Ask a Yamaha dealer to inspect.No compression.

There is fuel. Turn the fuel cock to OFF.

Remove the fuel hose from the fuel cock.

Some fuel. Turn the fuel cock to RES. Restart engine.

No fuel. Supply fuel.

4. Battery

Use electric starter.

Engine turns over quickly. Battery good.

Engine turns over slowly.

Check fluid, recharge, check connections.

Check fuel flow.

Water or dirt mixed in fuel.

Turn the fuel cock to ON. No fuel. Fuel cock clogged.

Clean the fuel filter and the fuel tank.

Clean fuel cock.

8-41

5VJ-9-11-3 3/13/03 3:01 PM Page 8-42

EBU00417

CLEANING AND STORAGE A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components.

1. Before cleaning the machine: a. Block off the end of the exhaust pipe to

prevent water entry. A plastic bag and strong rubber band may be used.

b. Make sure the spark plug and all filler caps are properly installed.

2. If the engine case is excessively greasy, apply degreaser with a paint brush. Do not apply degreaser to the chain, sprockets or wheel axles.

3. Rinse the dirt and degreaser off with a gar- den hose. Use only enough pressure to do the job.

cC Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high pressure deter- gent applications such as those available in coin-operated car washers.

4. Once the majority of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old tooth- brush or bottle brush is handy for hard-to- get-at places.

5. Rinse the machine off immediately with clean water and dry all surfaces with a chamois, clean towel or soft absorbent cloth.

6. Dry the chain and lubricate it to prevent rust.

9-1

9

5VJ-9-11-3 3/13/03 3:01 PM Page 9-2

7. Clean the seat with a vinyl upholstery clean- er to keep the cover pliable and glossy.

8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or pro- tective finish. When finished, start the engine and let it idle for several minutes.

9-2

POTENTIAL HAZARD

Operation with wet brakes after washing.

WHAT CAN HAPPEN

Wet brakes may have reduced stopping ability, increasing the chance of an acci- dent.

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.

qWARNING

5VJ-9-11-3 3/13/03 3:01 PM Page 9-3

EBU00525

B. STORAGE Long term storage (60 days or more) of your machine will require some preventive proce- dures to guard against deterioration. After thor- oughly cleaning the machine, prepare for stor- age as follows:

1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equivalent product.

NOTE: Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system. Consult a Yamaha dealer if the fuel system needs to be drained instead.

2. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40

9-3

Specified amount: 1 oz of stabilizer to each gallon of fuel (or 7.5 cc of stabilizer to each liter of fuel)

motor oil in the spark plug hole and reinstall the spark plug. Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil.

3. Clean the drive chain thoroughly and lubri- cate it. (See page 8-25.)

4. Lubricate all control cables. 5. Block up the frame to raise all wheels off the

ground. 6. Tie a plastic bag over the exhaust pipe out-

let to prevent moisture from entering. 7. If storing in a humid or salt-air atmosphere,

coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat cover.

8. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0C (30F) or more than 30C (90F)).

NOTE: Make any necessary repairs before storing the machine.

5VJ-9-11-3 3/13/03 3:01 PM Page 9-4

EBU00428

SPECIFICATIONS

Model YFA1

Dimension: Overall length 1,640 mm (64.6 in) Overall width 965 mm (38.0 in) Overall height 980 mm (38.6 in) Seat height 690 mm (27.2 in) Wheel base 1,080 mm (42.5 in) Minimum ground clearance 145 mm ( 5.7 in) Minimum turning radius 2,900 mm (114.2 in)

Basic weight: With oil and full fuel tank 144 kg (318 lb)

Engine: Type Air cooled, 4-stroke, SOHC Cylinder arrangement: Single cylinder, Forward inclined Displacement 124 cm3

Bore Stroke 49 66 mm (1.93 2.60 in) Compression ratio 9.0 : 1 Starting system Electric starter Lubrication system: Wet sump

10-1

5VJ-9-11-3 3/13/03 3:01 PM Page 10-1

Model YFA1

Engine oil/transmission oil: Type

Recommended engine oil/transmission API Service SE, SF, SG type or higher oil classification:

Quantity Engine oil:

Periodic oil change 1.25 L (1.10 lmp qt, 1.32 US qt) Total amount 1.45 L (1.28 lmp qt, 1.53 US qt)

Transmission oil: 0.6 L (0.53 lmp qt, 0.63 US qt)

cC Be sure to use motor oils that do not contain anti-friction modifiers. Passenger car motor oils (often labeled ENERGY CONSERVING II) contain anti-friction additives which will cause clutch and/or starter clutch slippage, resulting in reduced component life and poor engine performance.

100 30 50 70 90 110

SAE 5W30

20 10 0 10 20 30 40

YAMALUBE 4 (20W40) or SAE20W40

YAMALUBE 4 (10W30) or SAE10W30

130F

50C

10-2

10

5VJ-9-11-3 3/13/03 3:01 PM Page 10-2

Model YFA1

Air filter: for engine Wet type element for V-belt compartment Dry type element

Fuel: Type UNLEADED GASOLINE ONLY Tank capacity 7.0 L (1.54 Imp gal, 1.8 US gal) Reserve amount 1.3 L (0.29 Imp gal, 0.34 US gal)

Carburetor: Type/manufacturer VM18SH/MIKUNI

Spark plug: Type/manufacturer CR7HS/NGK Gap 0.60.7 mm (0.020.03 in)

Clutch: Type Dry, centrifugal automatic

Transmission: Primary reduction system Helical gear/Spur gear Primary reduction ratio 43/14 40/17 (7.226) Secondary reduction system Chain drive Secondary reduction ratio 32/12 (2.666) Transmission type/Reduction ratio V-belt automatic/2.300.82 Reverse (2.300.82) 49/14 49/15 40/17

(61.87422.059)

10-3

5VJ-9-11-3 3/13/03 3:01 PM Page 10-3

Model YFA1

Chassis: Frame type Steel tube Caster angle 6 Trail 15 mm (0.59 in)

Tire: Type Tubeless Size: Front AT20 7 - 8

Rear AT22 10 - 8 Manufacturer/type:

Front DUNLOP/KT536A Rear DUNLOP/KT537A

Brake: Front brake type Drum brake Operation Right hand operation Rear brake type Drum brake Operation Left hand operation

Suspension: Front Swing axle Rear Swingarm

Shock absorber: Front Coil spring/Oil damper Rear Coil spring/Oil damper

10-4

5VJ-9-11-3 3/13/03 3:01 PM Page 10-4

Model YFA1

Wheel travel: Front 70 mm (2.8 in) Rear 80 mm (3.2 in)

Electrical: Ignition system C.D.I. Charging system A.C. Magneto Battery type/voltage, capacity 12N12C-4A-2/12V, 12Ah

Headlight type: Bulb

Bulb voltage, wattage quantity: Headlight 12V, 25 W/25 W 1 Tail/brake light 12V, 5 W/21W 1 Indicator light:

Neutral 12V, 3.4 W 1 Reverse 12V, 3.4 W 1

Fuse: 5A

10-5

5VJ-9-11-3 3/13/03 3:01 PM Page 10-5

EBU13640

NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inopera- tive by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of 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 Muffler Exhaust pipe Silencer

Air cleaner case Air cleaner element Intake duct

Intake system

11-1

11

5VJ-9-11-3 3/13/03 3:01 PM Page 11-1

EBU13651

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

MAINTENACE INTERVAL

1 Month

3 Months

6 Months

12 Months

18 Months

24 Months

30 Months 36 Months

42 Months

48 Months

54 Months

60 Months

DATE OF

SERVICE

SERVICING DEALER NAME AND ADDRESS

REMARKS

12-1

5VJ-9-11-3 3/13/03 3:01 PM Page 12-1

12-2

12

5VJ-9-11-3 3/13/03 3:01 PM Page 12-2

13-1

EBU00432

5VJ-9-11-3 3/13/03 3:01 PM Page 13-2

13-2

13

5VJ-9-11-3 3/13/03 3:01 PM Page 13-3

14-1

EBU00435

5VJ-9-11-3 3/13/03 3:01 PM Page 14-2

14-2

14

5VJ-9-11-3 3/13/03 3:01 PM Page 14-3

EBU00436

w Indicates a potential hazard that could result in serious injury or death.

5VJ-9-11-3 3/13/03 3:01 PM Page 14-4

5VJ-9-11-3 3/13/03 3:01 PM Page 14-5

EBU00437

PROTECT YOUR INVESTMENT

5VJ-9-11-3 3/13/03 3:01 PM Page 14-6

YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN

2003.31.01 !

This ATV should not be ridden by anyone under 16 years of age.

OWNERS MANUAL

5VJ-28199-11

YFA1S(C)

READ THIS MANUAL CAREFULLY! It contains important safety information.

LIT-11626-17-02 (E)

w

Improper ATV use can result in SEVERE INJURY or DEATH.

qWARNING

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR

NEVER USE ON PUBLIC

ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

NEVER operate: 9 without proper training or instruction. 9 at speeds too fast for your skills or the

conditions. 9 on public roads - a collision can occur with

another vehicle. 9 with a passenger - passengers affect

balance and steering and increase risk of losing control.

ALWAYS: 9 use proper riding techniques to avoid

vehicle overturns on hills and rough terrain and in turns.

9 avoid paved surfaces - pavement may seriously affect handling and control.

EBU00438

LOCATE AND READ OWNERS

Manualsnet FAQs

If you want to find out how the YFA1S C Yamaha works, you can view and download the Yamaha YFA1S C Breeze 2004 Owner's Manual on the Manualsnet website.

Yes, we have the Owner's Manual for Yamaha YFA1S C as well as other Yamaha manuals. All you need to do is to use our search bar and find the user manual that you are looking for.

The Owner's Manual should include all the details that are needed to use a Yamaha YFA1S C. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

The best way to navigate the Yamaha YFA1S C Breeze 2004 Owner's Manual is by checking the Table of Contents at the top of the page where available. This allows you to navigate a manual by jumping to the section you are looking for.

This Yamaha YFA1S C Breeze 2004 Owner's Manual consists of sections like Table of Contents, to name a few. For easier navigation, use the Table of Contents in the upper left corner.

You can download Yamaha YFA1S C Breeze 2004 Owner's Manual free of charge simply by clicking the “download” button in the upper right corner of any manuals page. This feature allows you to download any manual in a couple of seconds and is generally in PDF format. You can also save a manual for later by adding it to your saved documents in the user profile.

To be able to print Yamaha YFA1S C Breeze 2004 Owner's Manual, simply download the document to your computer. Once downloaded, open the PDF file and print the Yamaha YFA1S C Breeze 2004 Owner's Manual as you would any other document. This can usually be achieved by clicking on “File” and then “Print” from the menu bar.