Summary of Content for Yamaha YFM09GYXK Grizzly 90 2019 Owner's Manual PDF
Congratulations on your purchase of the Yamaha YFM09GYXK... This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines... With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields... This manual will provide you with a good basic understanding of the features and operation of this ATV... This manual includes important safety information... It provides information about special tech- niques and skills necessary to ride the ATV... It also includes basic maintenance and inspection proce- dures... If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer...
AN IMPORTANT NOTE TO PARENTS: This ATV is not a toy... Before you let your child ride this ATV, you should understand the instructions and warnings in this Owners Manual... Then be sure your child understands and will follow them... Children differ in skills, physical abilities and judgment... Some children may not be able to operate an ATV safely... Parents should supervise their childs use of the ATV at all times... Parents should permit continued use only if they determine that the child has the ability to operate the ATV safely... Your ATV was delivered with an adjustable speed limiter... Yamaha recommends that all beginners start off to limit the amount of speed available while they learn... The adjusting screw may be gradually turned out as the beginner becomes more familiar with operating the ATV... Parents should decide when to adjust the ATV for more power as their youngsters riding skills improve... Once the ATV rider can operate with skill at the top speed permitted by adjusting the vehicle speed limiter alone, the engine speed limiter plate can be removed... Since removal of this limiter will result in a significant increase in power, turn the vehicle speed limiter adjusting screw completely back in again; adjust it out in stages as done previously... If your child is a beginner or is inexperienced, he or she should take a training course... See the previous page for information about the free training available to purchasers of new ATVs...
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH... Particularly important information is distinguished in this manual by the following notations:
This ATV is designed and manufactured for off-road use only... It is illegal and unsafe to operate this ATV on any public street, road or highway... This ATV complies with all applicable off-road noise level and spark arrester laws and regulations in effect at the time of manufacture... Please check your local riding laws and regulations before operating this ATV...
Front brake lever... 4-5 Rear brake lever ... 4-6 Parking brake ... 4-6 Drive select lever ... 4-7 Kickstarter ... 4-7 Fuel tank cap ... 4-9 Fuel ... 4-10 Fuel cock ... 4-11 Starter (choke) ... 4-12 Seat ... 4-13 Front carrier ... 4-14 Rear carrier ... 4-14 Front shock absorbers ... 4-14 Rear shock absorber ... 4-15
maintenance and lubrication ... 8-5 Checking the spark plug... 8-9 Engine oil ... 8-11 Transmission oil... 8-13 Cleaning the air filter element ... 8-15 Cleaning the spark arrester ... 8-18 Adjusting the carburetor ... 8-18 Adjusting the engine idling speed ... 8-19 Adjusting the throttle lever free play... 8-20 Valve clearance... 8-20 Brakes... 8-21 Checking the front and rear brake
Lubricating the front arm pivots... 8-29 Lubricating the front knuckle pivots... 8-30 Lubricating the steering shaft ... 8-30 Battery... 8-31 Replacing the fuse ... 8-34 Removing a wheel... 8-34 Installing a wheel... 8-35 Troubleshooting ... 8-36 Troubleshooting chart ... 8-37
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Read and understand all of the labels on your ATV... These labels contain important information for safe and proper operation... Never remove any labels from your ATV... If a label becomes difficult to read or comes off, request a re- placement label from your Yamaha dealer...
Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident... Never exceed the maximum front cargo limit of : 11 lbs (5 kg) NEVER sit on the carrier... Refer to instructions in the Owner's Manual...
Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident... Never exceed the maximum rear cargo limit of : 11 lbs (5 kg) NEVER sit on the carrier... Refer to instructions in the Owner's Manual...
AN ATV IS NOT A TOY AND CAN BE HAZARD- OUS TO OPERATE... An ATV handles differently from other vehicles, in- cluding motorcycles and cars... A collision or roll- over can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precau- tions... SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and fol-
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...
Always use proper procedures if you stall or roll backwards when climbing a hill... To avoid stall- ing, use the proper gear and maintain a steady speed when climbing a hill... If you stall or roll backwards, follow the special procedure for braking described in this manual... Dismount on the uphill side or to a side if pointed straight up- hill... Turn the ATV around and remount, following the procedure described in this manual...
3... If your injuries are light, when safe to do so, move your vehicle off the trail to avoid colli- sions with oncoming riders... Check for injuries and apply first aid as necessary... If you can physically operate your vehicle, inspect your vehicle... If the vehicle is in safe operating con- dition and you can safely operate it, restart it and ride gently back to camp or other known location where you can receive medical at-
Aftermarket Parts, Accessories, and Modifica- tions While you may find aftermarket products similar in design and quality to genuine Yamaha accesso- ries, recognize that some aftermarket accessories or modifications are not suitable because of po- tential safety hazards to you or others... Installing aftermarket products or having other modifica- tions performed to your vehicle that change any of the vehicles design or operation characteristics can put you and others at greater risk of serious injury or death... You are responsible for injuries re- lated to changes in the vehicle... Keep the following guidelines in mind, as well as those found in the
Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, a deadly gas... Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nau- sea, confusion, and eventually death... Carbon Monoxide is a colorless, odorless, tasteless gas which may be present even if you do not see or smell any engine exhaust... Deadly levels of carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself... Also, deadly levels of carbon monoxide can linger for hours or days in en- closed or poorly ventilated areas... If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT... Do not run engine indoors... Even if you try to
FOR MORE INFORMATION ABOUT ATV SAFE- TY, call the Consumer Products Safety Commis- sion at 1-800-638-2772, or the ATV Distributors Safety Hotline at 1-800-852-5344...
1... Fuel tank cap 2... Fuel cock 3... Air filter 4... Fuse 5... Battery 6... Rear shock absorber 7... Kickstarter lever cap 8... Front shock absorber
1... Rear brake lever 2... Handlebar switches 3... Parking brake lock plate 4... Starter (choke) lever 5... Main switch 6... Throttle lever 7... Front brake lever 8... Drive select lever
ON All electrical systems are supplied with power, and the engine can be started... The key cannot be re- moved...
Engine stop switch / Set this switch to before starting the engine... The engine stop switch controls the ignition and stops the engine when it is running... Use this switch to stop the engine in an emergency situa- tion... The engine will not start or run when this switch is set to ...
Speed limiter Your ATV was delivered with two speed limiter de- vices... A vehicle speed limiter adjusting screw and a removable engine speed limiter plate... Yamaha recommends that all beginning riders start off with the vehicle speed limiter adjusting screw fully turned in and the engine speed limiter plate in- stalled to limit the amount of speed available while they learn... The vehicle speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum... The adjusting screw may be gradually turned out as the beginner becomes more familiar with operating the ATV... Parents should decide when to adjust the ATV for more power as their youngsters riding skills improve... Once the ATV rider can operate with skill at the top speed permitted by adjusting the vehicle speed limiter alone, the engine speed limiter plate can be removed... Since removal of this plate will result in a significant increase in power, turn the vehicle speed limiter adjusting screw completely back in again and adjust it out in stages as done previous- ly...
available and the maximum speed of the ATV, turn the adjusting screw in direction (a)... To decrease the maximum engine power avail- able and the maximum speed of the ATV, turn the adjusting screw in direction (b)... Do not turn the adjusting screw out more than 14... 5 mm (0... 57 in) or the throttle cable could be damaged... Always make sure the throttle lever free play is adjusted to 1... 54... 0 mm (0... 06 0... 16 in)... (See page 8-20... ) WARNING! Im- proper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation... You could lose control, resulting in an accident... [EWB00242]
TIP Store the engine speed limiter plate with the Own- ers Manual so that it is readily available whenever you want to reduce top engine speed...
Parking brake Use the parking brake before starting the engine or after parking the ATV, especially on a slope... Ap- ply 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...
The drive select lever is used to shift the transmis- sion into the forward, neutral and reverse posi- tions... See page 6-3 for drive select lever operation...
Do not use the kickstarter if the battery is not installed or if the battery leads are not connect- ed...
2... Do not overfill the fuel tank... When refueling, be sure to insert the pump nozzle into the fuel tank filler hole... Stop filling when the fuel reaches the bottom of the filler tube... Because fuel expands when it heats up, heat from the engine or the sun can cause fuel to spill out of the fuel tank...
Gasoline is poisonous and can cause injury or death... Handle gasoline with care... Never siphon gasoline by mouth... 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...
Fuel cock The fuel cock supplies fuel from the tank to the carburetor while also filtering it... The fuel cock lever positions are explained as fol- lows and shown in the illustrations...
This indicates reserve... With the fuel cock lever in this position, the fuel reserve is made available... Turn the fuel cock lever to this position if you run out of fuel while riding... When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to ON!
To use the starter (choke) and enrich the air-fuel ratio, move the starter (choke) lever in direction (a)... To decrease the starter (choke) or turn it off, move the starter (choke) lever in direction (b)...
Always adjust the shock absorber assemblies on the left and right side to the same setting... Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident...
Turn the spring preload adjusting ring in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to de- crease the spring preload and thereby soften the suspension... Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber...
Adjust the spring preload as follows... Turn the spring preload adjusting ring in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to de- crease the spring preload and thereby soften the suspension...
Indicates a hazardous situation which, if not avoided, could result in death or serious injury...
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equip- ment damage... Do not operate the vehicle if you find any problem... If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer...
Wheels and tires Check wheel condition, and replace if damaged... Check tire condition and tread depth... Replace if necessary... Check air pressure... Correct if necessary...
Brake operation Test the brakes at slow speed after starting out to make sure they are working properly... If the brakes do not provide proper braking performance, check the brake shoes for wear... (See page 8-21... )
A low-pressure tire gauge is included as standard 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 in- correct... Tire pressure must be checked and set when the tires are cold... The tire pressure should be the same on both sides, and must be adjusted ac- cording to vehicle loading conditions... Set the tire pressure as specified below... WARNING! Opera- tion of this vehicle with improper tire pressure may cause severe injury or death from loss of
When the tire tread depth has worn to 3 mm (0... 12 in) replace the tire... If the tire has a nail or glass fragments in it, or if the sidewall is cracked, re- place the tire...
Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort... Other tires, rims, sizes, and combinations may not be appropriate...
5... Position the starter (choke) lever according to the ambient temperature... Position (1): Cold engine start with ambient temperature below 5 C (40 F)... Position (2): Cold engine start with ambient temperature between 0 C (30 F) and 30 C (90 F)... Position (3): Cold engine start with ambient temperature above 25 C (80 F)...
7... If the engine is started with the starter (choke) lever in position (1), move the lever to position (2) to warm up the engine... If the engine is started with the starter (choke) lever in posi- tion (2), keep the lever in this position to warm up the engine...
Improper operation in reverse could make you hit an obstacle or even a person behind you, resulting in serious injury... When you shift into reverse, make sure there are no people or ob- stacles behind you... When it is safe to proceed, go slowly...
Engine break-in There is never a more important period in the life of your engine than the first 320 km (200 mi) or 20 hours of operation... For this reason, you should fol- low the engine break-in instructions carefully... Since the engine is brand new, do not put an ex- cessive load on it for the first 320 km (200 mi) or 20 hours... During this period the various parts in the engine wear and polish themselves to the cor- rect operating clearances... Avoid prolonged full- throttle operation or any condition that might re- sult in engine overheating...
Avoid parking on hills or other inclines... Parking on a hill or other incline could cause the ATV to roll out of control, increasing the chance of an accident... If you must park on an incline, place the ATV transversely across the incline, shift the drive select lever to the forward position, stop the engine, apply the parking brake, and then block the front and rear wheels with rocks or other objects... Never park the ATV on hills that are too steep to walk up easily...
Aftermarket parts, accessories, and modifica- tions While you may find aftermarket products similar in design and quality to genuine Yamaha Accesso- ries, recognize that some aftermarket accessories or modifications are not suitable because of po- tential safety hazards to you or others... Installing aftermarket products or having other modifica- tions performed to your ATV that change any of the vehicles design or operation characteristics can put you and others at greater risk of serious injury or death... You are responsible for injuries re- lated to changes in the vehicle... Keep the following in mind when considering an accessory or operating an ATV which has acces- sories... Accessories should be rigidly and securely
Never exceed the stated load capacity for this ATV... Overloading this ATV or carrying or tow- ing cargo improperly could cause changes in ATV handling which could lead to an accident... Cargo should be properly distributed and se- curely attached... Reduce speed when carrying cargo or pulling a trailer... Allow greater dis- tance for braking...
Avoid hills and rough terrain... Choose terrain carefully... Added weight affects the stability and handling of the ATV...
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GETTING TO KNOW YOUR ATV This ATV is intended for recreational use by young operators under adult supervision... This section, Riding your ATV, provides general riding instruc- tions which 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 at- tempting more difficult maneuvers... Riding your new ATV can be a very enjoyable ac- tivity, providing you with hours of pleasure... But it is essential to familiarize yourself with the opera- tion of the ATV to achieve the skill necessary to enjoy riding safely... Before you begin to ride, be sure you have read this manual completely and understand how to operate all of the ATVs con- trols... Pay particular attention to the safety infor- mation on pages 2-1 to 2-7 and all notice and warning labels on the vehicle...
This ATV is designed to carry the operator and cargo only passengers prohibited... The long seat is to allow the operator to shift posi- tion as needed during operation... It is not for carry- ing passengers... WARNING! Never carry a passenger... Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV... You could have an accident, resulting in severe injury or death to you and/or your passenger... [EWB01402]
shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident... WARNING! Operating without an ap- proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident... [EWB01412]
Do not operate after or while consuming alco- hol or drugs... The operators performance capability is reduced by the influence of alcohol or drugs... Consuming alcohol or drugs could seriously affect your judg- ment, cause you to react more slowly, and affect your balance and perception... WARNING! Never consume alcohol or drugs before or while driv- ing this ATV... You increase your chance of an accident... [EWB01422]
Speed limiter For beginning riders, riders less experienced with this model, or whenever limited speed is desir- able, the throttle lever housing is equipped with a vehicle 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... Turning in the adjusting screw decreases top speed, and turning it out increases top speed... (See page 4-3... ) This model also has an engine speed limiter plate to limit the amount of engine power available... Yamaha recommends that all beginning riders start off with the engine speed limiter plate in- stalled and the vehicle speed limiter adjusting screw turned in to limit the amount of speed avail- able while they learn... The vehicle speed limiter may be gradually adjusted to increase maximum speed as the beginner becomes more familiar with
During operation Always keep your feet on the footboards during operation; otherwise, they may contact the rear wheels... WARNING! 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 con- tact with the rear wheels, which could injure you or cause an accident... [EWB01472]
Modifications and accessories Never modify this ATV through improper installa- tion or use of accessories or other modification... All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be in- stalled and used according to instructions... If you have questions, consult an authorized ATV dealer... WARNING! Operating this ATV with improper modifications may cause changes in handling which in some situations could lead to an acci- dent... [EWB01492]
The muffler and other engine parts become ex- tremely hot during operation and remain hot after the engine has stopped... To reduce the risk of fire during operation or after leaving the ATV, do not let brush, grass and other materials collect under the vehicle, near the muffler or exhaust pipe, or next to other hot parts... Check under the vehicle after operating in areas where combustible mate- rials may have collected... Do not idle or park the vehicle in long dry grass or other dry ground cov- er...
BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only... WARNING! Paved surfaces may seriously af- fect handling and control of the ATV, and may cause the ATV to go out of control... Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets... [EWB01512]
Know the terrain where you ride... Ride cautiously in unfamiliar areas... Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset... WARNING! The ATV could go out of control if you do not have enough time to react to hidden rocks, bumps, or holes... Go slowly and be extra care- ful when operating on unfamiliar terrain... Al- ways be alert to changing terrain conditions when operating the ATV... [EWB01532]
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, and turning tech- niques in this area before trying more difficult ter- rain... 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... Re- member 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 compo- nents... With the engine idling, release the parking brake... Apply the throttle slowly and smoothly... You will start to accelerate... If the throttle is applied too
ing 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 direc- tion) 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...
This procedure should be practiced at slow speed many times in a large off-road area with no obsta- cles... If an incorrect technique is used, your ATV may continue to go straight... If the ATV doesnt turn, come to a stop and then practice the proce- dure again... If the riding surface is slippery or loose, it may help to position more of your weight over the front wheels by moving forward on the seat... Once you have learned this technique, you should be able to perform it at higher speeds or in tighter curves... Improper riding procedures such as abrupt throt- tle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip... If the ATV be- gins to tip over to the outside while negotiating a turn, lean more to the inside... It may also be nec- essary 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...
Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owners Manual on level ground... Be very careful when turning on any hill...
on steeper inclines, standing on the footboards and leaning forward over the handlebars... When- ever possible, ride straight up hills... Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side there could be another person, an obstacle, or a sharp drop-off... Use common sense and remem- ber that some hills are too steep for you to climb or descend... 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... If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control... If you are unable to continue up the hill, dismount the ATV on the uphill side... Physically turn the ATV around and then descend the hill... If you start to roll backwards, DO NOT apply the brakes abruptly... Apply only the front brake... When fully stopped, apply the rear brake as well, and then lock the parking brake... The ATV could easily tip over backwards so immediately dismount the
ATV on the uphill side or to the left-hand side when the ATV is pointed straight uphill... If possible, get help to turn the ATV around and then remount it when safe and ride downhill carefully as ex- plained in the following section... WARNING! Stall- ing, rolling backwards or improperly dismounting while climbing a hill could result in ATV overturning... If you cannot control the ATV, dismount immediately on the uphill side... [EWB01803]
When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as pos- sible... Move back on the seat and sit with your arms straight... Engine compression will do most of the braking for you... Use caution while descending a hill with loose or slippery surfaces... Braking ability and traction may be adversely affected by these surfaces... Improper braking may also cause a loss of traction... Gradu- ally apply only the rear brake... Whenever possible, ride your ATV straight down- hill... Avoid sharp angles which could allow the ATV to tip or roll over... Carefully choose your path and ride no faster than you will be able to react to ob- stacles which may appear...
As you travel across a slope, lean your body in the uphill direction... It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill... When riding on slopes, be sure not to make sharp turns either up or down hill... If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path... As you regain proper balance, grad- ually steer again in the direction you wish to travel...
Operating this vehicle through deep or fast- flowing water can lead to loss of control or an overturn... To reduce your risk of drowning or other injuries, use care when crossing through water... Never operate this ATV water deeper than the depth specified in your Owners Man- ual, as tires may float, increasing the risk of an overturn...
Test your brakes after leaving the water... If neces- sary, apply them several times to let friction dry out the linings... Do not continue to ride your ATV without verifying that you have regained proper braking ability... WARNING! Wet brakes may have reduced stopping ability, which could cause loss of control... [EWB02622]
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...
If your ATV cant make it up a hill you are trying to climb: Turn the ATV around if you still have forward speed... If not, stop, dismount on the uphill side of the ATV and physically turn the ATV around... If the ATV starts to slip backwards, DO NOT USE THE REAR BRAKE the ATV may tip over on top of you... Dismount the ATV on the uphill side... (See page 7-15... )
If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards the uphill side of the ATV to maintain proper balance... If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance... If you discover that the ATV is going to tip over, dismount on the uphill side... (See page 7-19... )
Periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most effi- cient condition possible... Safety is an obligation of the vehicle owner and operator... The most impor- tant points of vehicle inspection, adjustment, and lubrication are explained on the following pages...
The information included in this manual and the tools provided in the tool kit are intended to assist you in the performance of preventive maintenance and minor repairs... However, additional tools, such as a torque wrench, are necessary to perform cer- tain maintenance work correctly...
ridden for the stated mileage or engine operating hours... Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
Check for looseness and tighten all screw clamps and joints if necessary...
ridden for the stated mileage or engine operating hours... Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
12 * Chassis fasteners Make sure that all nuts, bolts, and screws are properly tightened...
19 Transmission oil Change... Check ATV for oil leakage, and correct if neces-
TIP Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle...
Checking the spark plug The spark plug is an important engine component, which is easy to check... Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in ac- cordance with the periodic maintenance and lubri- cation chart... In addition, the condition of the spark plug can reveal the condition of the engine...
TIP If the spark plug shows a distinctly different color, the engine could be operating improperly... Do not attempt to diagnose such problems yourself... In- stead, have a Yamaha dealer check the ATV...
TIP If a torque wrench is not available when installing the spark plug, a good estimate of the correct torque is 1/41/2 turn past finger tight... However, the spark plug should be tightened to the speci- fied torque as soon as possible...
7... Install the oil strainer, the compression spring, the new O-ring and the engine oil drain bolt... Tighten the engine oil drain bolt to the specified torque... NOTICE: Before in- stalling the engine oil drain bolt, be sure to install the O-ring, compression spring and oil strainer... [ECB00322]
Transmission oil The transmission case must be checked for oil leakage before each ride... If any leakage is found, have a Yamaha dealer check and repair the ATV... In addition, the transmission oil must be changed at the intervals specified in the periodic mainte- nance and lubrication chart...
6... Refill with the specified amount of the recom- mended oil... NOTICE: Make sure that no foreign material enters the transmission case... [ECB03380]
Cleaning the air filter element The air filter element should be serviced at the in- tervals specified in the periodic maintenance and lubrication chart... Clean or, if necessary, replace the air filter element more frequently if you are rid- ing in unusually wet or dusty areas...
4... Remove the air filter element, and clean it with solvent... WARNING! Always use parts cleaning solvent to clean the air filter ele- ment... Never use low-flash-point solvents or gasoline to clean the air filter element because the engine could catch fire or ex- plode... [EWB03540]
ment removed... This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage... Addi- tionally, operation without the air filter ele- ment will affect carburetor jetting with subsequent poor performance and possi- ble engine overheating... [ECB00462]
Adjusting the carburetor The carburetor should be checked and, if neces- sary, adjusted at the intervals specified in the pe- riodic maintenance and lubrication chart... The carburetor is an important part of the engine and requires very sophisticated adjustment... There- fore, most carburetor adjustments should be left
sary, adjust it to specification by turning the throttle stop screw at the carburetor... To in- crease the engine idling speed, turn the throt- tle stop screw in direction (a), and to decrease it, turn the screw in direction (b)...
Valve clearance The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise... To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart...
Checking the front and rear brake shoes The front and rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart... Without disas- sembling the brake, this can be performed by checking the position of the brake lever free play adjusting bolts or nut...
1... Rear brake lever free play adjusting nut 2... Bolt 3... No more than 18 mm (0... 71 in)
upper adjusting bolt until the upper and lower cable lengths are equal... The cable joint will become vertical...
Periodically check the rear brake lever free play and adjust if necessary... Turn the adjusting nut in direction (a) to increase the brake lever free play, and in direction (b) to de- crease it...
To check the drive chain slack 1... Place the ATV on a level surface... 2... Move the ATV back and forth to locate the
4... To tighten the drive chain, turn the drive chain slack adjusting nut in direction (a)... To loosen the drive chain, turn the adjusting nut in direc- tion (b) and push the rear wheels forward... NOTICE: Improper drive chain slack will overload the engine as well as other vital parts of the ATV and can lead to drive chain slippage or breakage... To prevent this from occurring, keep the drive chain slack within the specified limits... [ECB00543]
Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas... Service the drive chain as follows...
Inspect cables frequently and replace if damaged... Corrosion can result when the ca- ble sheaths become damaged, and cables can also become frayed or kinked, which could restrict the operation of controls and lead to an accident or injury...
Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart... If there is play in a wheel hub or if a wheel does not turn smooth- ly, have a Yamaha dealer check the wheel hub bearings...
Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the pe- riodic maintenance and lubrication chart...
Battery electrolyte is poisonous and danger- ous, as it contains sulfuric acid, which can cause severe burns... Avoid contact with skin, eyes or clothing... Always shield your eyes when working near batteries... Antidote: EXTERNAL: Flush with water... INTERNAL: Drink large quantities of water or milk... Follow with milk of magnesia, beaten egg or vegetable oil... Call a physician immediately... EYES: Flush with water for 15 minutes and get prompt medical attention... Batteries produce explosive gases... Keep sparks, flame, cigarettes or other sources of ignition away... Ventilate when charging or using in an enclosed space... KEEP OUT OF REACH OF CHILDREN...
83... Disconnect the negative battery lead first, then the positive battery lead by removing their bolt... NOTICE: When removing the bat- tery, the main switch must be off, and the negative lead must be disconnected be- fore the positive lead... [ECB01002]
connect the negative battery lead by installing their bolt... NOTICE: When installing the bat- tery, the main switch must be off, and the positive lead must be connected before the negative lead... [ECB01111]
3... Remove the blown fuse, and then install a new fuse of the specified amperage... WARNING! Always use a fuse of the spec- ified rating, and never use a substitute ob- ject in place of the proper fuse... An improper fuse or a substitute object can cause damage to the electrical system, which could lead to a fire... [EWB02173]
in the forward rotating direction of the wheel, and then install the wheel bolts...
Troubleshooting Although Yamaha ATVs receive a thorough in- spection before shipment from the factory, trouble may occur during operation... Any problem in the fuel, compression, or ignition systems, for exam- ple, can cause poor starting and loss of power... The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself... However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, ex- perience, and know-how to service the ATV prop- erly... Use only genuine Yamaha replacement parts... Im- itation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills...
3... Ignition Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug...
3... Rinse the dirt and degreaser off with a garden hose... Use only enough pressure to do the job... WARNING! Wet brakes may have re- duced stopping ability, increasing the chance of an accident... Test the brakes af- ter washing... Apply the brakes several times at slow speeds to let friction dry out the linings... [EWB02312] NOTICE: Excessive wa-
Short-term Always store your ATV in a cool, dry place and, if necessary, protect it against dust with a porous cover... NOTICE: Storing the ATV in a poorly ven- tilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust... To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemi- cals are stored... [ECB00722]
7... Put the frame on stands or blocks to raise all wheels off the ground... (Alternatively, turn the wheels each month to prevent the tires from degrading in one spot... )
Maximum loading limit: 92... 0 kg (203 lb) (Total weight of rider, cargo, accessories, and tongue)
Recommended engine oil grade: API service SG type or higher, JASO standard MA
Tire air pressure (measured on cold tires): Vehicle load:
UB8W10E0... book Page 4 Wednesday, June 20, 2018 10:49 AM
Identification numbers Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen...
Vehicle Emission Control Information label The Vehicle Emission Control Information label is affixed at the location in the illustration... This label shows specifications related to exhaust emissions as required by federal law, state law and Environ- ment Canada...
UB8W10E0... book Page 3 Wednesday, June 20, 2018 10:49 AM
Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of 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...
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...
EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation, U... S... A... also warrants to the ultimate purchaser and each subsequent purchaser of each applicable model Yamaha ATV covered by this warranty that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U... S... emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the period listed immediately below... Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty...
If your machine requires warranty service, you must take it to any authorized Yamaha ATV dealer within the continental United States... Be sure to bring your warranty registration card or other valid proof of the original date of purchase... If a question or problem arises regarding warranty, first contact the owner of the dealership... Since all warranty matters are handled at the dealer level, this person is in the best position to help you... If you are still not satisfied and require additional assistance, please write:
In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost... TRIP gives you up to $250 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered serv ice: replacement vehicle rental, emergency tow ing, phone calls, even food and lodging when you are away from home... This superb coverage goes into effect when you purchase Y... E... S... , so it applies to any warranty repairs as well as covered repairs dur ing your entire Y... E... S... plan period...
We urge you to act now... Youll get the excellent benefits of TRIP coverage r ight away, and youl l rest easy knowing youll have strong factory-backed protection even after your Yamaha Limited Warranty expires... You can also save money: Y... E... S... costs less within the first 90 days after you buy your Yamaha... See your dealer today!
B Battery ... 8-31 Brake lever free play, adjusting the front ... 8-22 Brake lever free play (rear), adjusting ... 8-24 Brake lever, front ... 4-5 Brake lever, rear ... 4-6 Brake levers, checking and lubricating ... 8-28 Brakes ... 8-21 Brakes, front and rear ... 5-3
S Safety information ... 2-1 Seat ... 4-13 Shock absorber, rear ... 4-15 Shock absorbers, front ... 4-14 Spark arrester, cleaning ... 8-18 Spark plug, checking ... 8-9 Specifications ... 10-1 Speed limiter ... 4-3 Starter (choke) ... 4-12 Start switch ... 4-3 Steering shaft, lubricating ... 8-30 Storage ... 9-2
Genuine Yamaha Parts Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect... Why settle for aftermarket parts that may not provide full confidence and satisfaction?
NEVER operate: without proper training or instruction... at speeds too fast for your skills or the conditions... on public roadsa collision can occur with another vehicle... with a passengerpassengers affect balance and steering and increase risk of losing control...
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