Contents

Yamaha YFM25BZ Big Bear 250 2010 Owner's Manual PDF

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Summary of Content for Yamaha YFM25BZ Big Bear 250 2010 Owner's Manual PDF

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

OWNERS MANUAL

1P0-F8199-15LIT-11626-23-45

YFM25BZ

READ THIS MANUAL CAREFULLY! It contains important safety information.

DIC2342

EBU17092

Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold.

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EBU17170

INTRODUCTION EBU17272

Congratulations on your purchase of the Yamaha YFM25BZ. This ATV 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 tech- niques and skills necessary to ride the ATV. It also includes basic maintenance and inspection proce- dures. If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE: Read this manual together with TIPS FOR THE ATV RIDER carefully and completely before operating

your ATV. Make sure you understand all instructions. Pay close attention to the warning and notice labels on the ATV. Never operate an ATV without proper training or instruction. Free training is available to anyone who buys

a new ATV. Call 1-800-887-2887 for more information. This ATV should not be ridden by anyone under 16 years of age.

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IMPORTANT MANUAL INFORMATION EBU17342

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:

* Product and specifications are subject to change without notice.

This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards. Obey all safety messages that follow this sym- bol to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

WARNING

NOTICE

TIP

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IMPORTANT NOTICE EBU17362

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.

EBU17402

YFM25BZ OWNERS MANUAL

2009 by Yamaha Motor Corporation, U.S.A. 1st edition, July 2009 All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

is expressly prohibited. Printed in U.S.A.

P/N LIT-11626-23-45

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WARNING EWB00011

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

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TABLE OF CONTENTS

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

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

DESCRIPTION .............................................. 3-1 Left view ...................................................... 3-1 Right view.................................................... 3-1 Controls and instruments ............................ 3-2

INSTRUMENT AND CONTROL FUNCTIONS .................................................. 4-1

Main switch ................................................ 4-1 Indicator lights ............................................ 4-2 Handlebar switches .................................... 4-2 Throttle lever .............................................. 4-3 Speed limiter .............................................. 4-4

Front brake lever .........................................4-4 Brake pedal and rear brake lever ...............4-5 Parking brake ..............................................4-6 Shift pedal ...................................................4-6 Drive select lever ........................................4-7 Recoil starter ...............................................4-7 Fuel tank cap ..............................................4-7 Fuel .............................................................4-8 Fuel cock ..................................................4-10 Starter (choke) ..........................................4-11 Seat ..........................................................4-11 Storage compartment ...............................4-12 Front carrier ..............................................4-13 Rear carrier ...............................................4-13 Adjusting the rear shock absorber

assembly .................................................4-14

PRE-OPERATION CHECKS ..........................5-1 Fuel .............................................................5-3 Engine oil ....................................................5-3 Final gear oil ...............................................5-3 Front and rear brakes .................................5-3 Throttle lever ...............................................5-4 Tires ............................................................5-4 Chassis fasteners .......................................5-6 Instruments, lights and switches .................5-6 Battery ........................................................5-6

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OPERATION .................................................. 6-1 Starting a cold engine ................................ 6-1 Starting a warm engine .............................. 6-3 Operating the drive select lever and

driving in reverse ...................................... 6-3 Shifting ....................................................... 6-4 Engine break-in .......................................... 6-6 Parking ....................................................... 6-7 Parking on a slope ..................................... 6-7 Accessories and loading ............................ 6-8

RIDING YOUR ATV ...................................... 7-1 GETTING TO KNOW YOUR ATV............... 7-2 RIDE WITH CARE AND GOOD

JUDGMENT .............................................. 7-2 BE CAREFUL WHERE YOU RIDE............. 7-9 TURNING YOUR ATV .............................. 7-12 CLIMBING UPHILL ................................... 7-14 RIDING DOWNHILL.................................. 7-16 CROSSING A SLOPE............................... 7-18 CROSSING THROUGH SHALLOW

WATER ................................................... 7-19 RIDING OVER ROUGH TERRAIN ........... 7-21 SLIDING AND SKIDDING......................... 7-21 WHAT TO DO IF... .................................... 7-22 WHAT TO DO... ........................................ 7-23

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

Owners manual and tool kit .......................8-1 Periodic maintenance chart for

the emission control system .....................8-3 General maintenance and lubrication

chart ..........................................................8-5 Checking the spark plug .............................8-9 Engine oil and oil filter element .................8-11 Final gear oil .............................................8-17 Cleaning the air filter element ...................8-20 Cleaning the spark arrester ......................8-23 Adjusting the carburetor ............................8-25 Adjusting the engine idling speed .............8-25 Adjusting the throttle cable free play .........8-26 Valve clearance ........................................8-27 Adjusting the drive select lever safety

system cable ...........................................8-27 Brakes .......................................................8-27 Checking the front brake pads and rear

brake shoes ............................................8-27 Checking the brake fluid level ...................8-29 Changing the brake fluid ...........................8-29 Checking the front brake lever free play ...8-30 Adjusting the brake pedal position,

free play and the rear brake lever free play ..................................................8-30

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Brake light switches ................................. 8-33 Adjusting the clutch free play ................... 8-34 Checking and lubricating the cables ........ 8-35 Checking and lubricating the front and

rear brake levers .................................... 8-35 Checking the shift pedal ........................... 8-36 Checking and lubricating the brake

pedal ...................................................... 8-36 Checking the wheel hub bearings ............ 8-37 Lubricating the swingarm pivots ............... 8-37 Lubricating the steering shaft ................... 8-37 Battery ...................................................... 8-38 Replacing the fuse ................................... 8-42 Replacing a headlight bulb ....................... 8-42 Adjusting a headlight beam ...................... 8-44 Replacing the tail/brake light bulb ............ 8-45 Removing a wheel .................................... 8-45 Installing a wheel ...................................... 8-46 Troubleshooting ....................................... 8-47 Troubleshooting chart .............................. 8-48

CLEANING AND STORAGE.......................... 9-1 Cleaning ..................................................... 9-1 Storage ....................................................... 9-2

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

CONSUMER INFORMATION.......................11-1 Identification numbers ...............................11-1 Noise regulation ........................................11-4 Maintenance record ..................................11-5 YAMAHA MOTOR CORPORATION,

U.S.A. ATV LIMITED WARRANTY .........11-6 YAMAHA EXTENDED SERVICE

(Y.E.S.) ...................................................11-8

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LOCATION OF THE WARNING AND SPECIFICATION LABELS

10

9 8

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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 replace- ment 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 : 66 lbs (30 kg) NEVER sit on the carr ier. Refer to instructions in the Owner's Manual.

4XE-F4877-50

WARNING

1 2

364 lbs, (165 kg).

4XE-F816M-00

2.9 psi, (20 kPa) 3.6 psi, (25 kPa) 2.5 psi, (17 kPa) 3.2 psi, (22 kPa)

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: 99 lbs (45 kg)

4XE-F4897-50

16 UNDER

16

16.

3 5

6

4

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37S-F817J-20

This ATV complies with applicable provisions of ANSI/SVIA 1-2007 and is subject to an approved ATV action plan submitted by YAMAHA and on file with the U.S. Consumer Product safety Commission.

Certification of Compliance

YAMAHA MOTOR CORPORATION U.S.A. 6555 Katella Avenue, Cypress, California 90630-5101, U.S.A.

7 10

8

9

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SAFETY INFORMATION

EBU17445

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-

low the operating procedures described. Never operate an ATV without proper training or

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

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

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

Never carry a passenger on an ATV. Always avoid operating an ATV on any paved

surfaces, including sidewalks, driveways, park- ing lots and streets.

Never operate an ATV on any public street, road or highway, even a dirt or gravel one.

Never operate an ATV without wearing an ap- proved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or a jacket, and long pants.

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

Never operate at speeds too fast for your skills or the riding conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience.

Never attempt wheelies, jumps, or other stunts.

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Always inspect your ATV each time you use it to make sure it is in safe operating condition. Al- ways follow the inspection and maintenance procedures and schedules described in this manual.

Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation.

Always go slowly and be extra careful when op- erating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

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

Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds and never turn at excessive speeds.

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

Always follow proper procedures for climbing hills as described in this manual. Check the ter- rain carefully before you start up any hill. Never climb hills with excessively slippery or loose sur- faces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ve- hicle to lean sharply to one side. Go straight down the hill where possible.

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

Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stall- ing, use the proper gear and maintain a steady

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speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight up- hill. Turn the ATV around and remount, following the procedure described in this manual.

Always check for obstacles before operating 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 obsta- cles as described in this manual.

Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of con- trol.

Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.

Always 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.

Always use the size and type of tires specified in this manual.

Always maintain proper tire pressure as de- scribed in this manual.

Never modify an ATV through improper installa- tion or use of accessories.

Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow in- structions in this manual for carrying cargo or pulling a trailer. Allow greater distance for brak- ing.

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WARNING EWB00071

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

ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels.

Do not run engine in poorly ventilated or par- tially enclosed areas such as barns, garages, or carports.

Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors.

WARNING EWB02591

When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the OFF position. Otherwise, fuel may leak out of the carburetor or fuel tank.

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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.

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EBU17680

DESCRIPTION EBU17690

Left view EBU17700

Right view

1. Headlights 2. Fuel cock 3. Recoil starter 4. Fuses 5. Battery 6. Tail/brake light 7. Rear shock absorber assembly spring preload adjusting

ring 8. Engine oil drain bolt 9. Shift pedal

9 1. Spark arrester 2. Storage compartment and tool kit 3. Air filter case 4. Engine oil filler cap 5. Brake pedal 6. Clutch adjusting screw 7. Oil filter element 8. Rear brake light switch

5

1 2 3 4

678

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EBU17712

Controls and instruments

TIP The ATV you have purchased may differ slightly from the figures shown in this manual.

1. Rear brake lever 2. Handlebar switches 3. Parking brake lock plate 4. Starter (choke) 5. Drive select lever 6. Main switch 7. Fuel tank cap 8. Brake fluid reservoir 9. Throttle lever 10.Front brake lever

1 6 98 1032 4 5 7

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INSTRUMENT AND CONTROL FUNCTIONS

WARNING EWB00011

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

EBU17760

Main switch The positions of the main switch are as follows:

ON All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.

OFF All electrical systems are off. The key can be re- moved.

1. Main switch

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Indicator lights

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

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

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Handlebar switches

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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 situation. The engine will not start or run when this switch is set to .

1. Neutral indicator light N 2. Reverse indicator light R

1. Light switch / /OFF 2. Engine stop switch / 3. Start switch

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Start switch Push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine.

EBU18152

Light switch / /OFF Set this switch to to turn on the low beams and the taillight. Set the switch to to turn on the high beams and the taillight. Set the switch to OFF to turn off all the lights.

NOTICE ECB00041

Do not use the headlights with the engine turned off for an extended period of time, oth- erwise the battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. See page 8-38 for battery charging information.

EBU18282

Throttle lever Once the engine is running, pushing the throttle le- ver will increase the engine speed.

Regulate the speed of the ATV by varying the throttle position. Because the throttle is spring- loaded, the ATV will decelerate, and the engine will return to an idle any time the throttle lever is re- leased.

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.

1. Throttle lever

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EBU18323

Speed limiter Your ATV is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum.

1. Loosen the locknut. 2. To increase the maximum engine power avail-

able and the maximum speed of the ATV, turn the adjusting screw in direction (a). To de- crease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b). Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttle cable could be dam- aged. Always make sure the throttle lever free play is adjusted to 3.05.0 mm (0.120.20 in). (See page 8-26.) WARNING! Improper ad- justment of the speed limiter and throttle could cause throttle cable damage or im- proper throttle operation. You could lose control, resulting in an accident. [EWB00241]

3. Tighten the locknut.

EBU18391

Front brake lever The front brake lever is located on the right handle- bar. To apply the front brake, pull the brake lever toward the handlebar grip.

1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in)

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EBU18442

Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip.

1. Front brake lever 1. Brake pedal

1. Rear brake lever

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Parking brake Use the parking brake before starting the engine or parking the ATV, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake.

WARNING EWB00220

Always set the parking brake before starting the engine. The ATV could start moving un- expectedly if the parking brake is not ap- plied. This could cause loss of control or a collision.

Always be sure you have released the park- ing brake before you begin to ride. The brake could overheat if you ride the ATV without re- leasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely.

EBU18550

Shift pedal This ATV is equipped with a constant-mesh 5- speed transmission. The shift pedal is located on the left side of the engine. Neutral is at the bottom position.

1. Parking brake lock plate

1. Shift pedal

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Drive select lever The drive select lever is used for driving the ATV either forward or in reverse. See the Operating the drive select lever and driving in reverse section on page 6-3 for the drive select lever operation.

EBU27610

Recoil starter Firmly grasp the handle and pull slightly until en- gagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out.

WARNING EWB02370

Shift the transmission into the neutral position and apply the parking brake before starting the engine, otherwise the ATV could start to move unexpectedly, which could cause an accident.

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

1. Drive select lever

1. Recoil starter

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EBU18731

Fuel Make sure there is sufficient gasoline in the tank.

WARNING EWB02521

Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, fol- low these instructions.

1. Before refueling, turn off the engine and be sure that no one is sitting on the vehicle. Nev- er refuel while smoking, or while in the vicinity

of sparks, open flames, or other sources of ig- nition such as the pilot lights of water heaters and clothes dryers.

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 reach- es the bottom of the filler tube. Because fuel expands when it heats up, heat from the en- gine or the sun can cause fuel to spill out of the fuel tank.

1. Fuel tank cap

1. Fuel tank filler tube 2. Maximum fuel level

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4 3. Wipe up any spilled fuel immediately. NOTICE: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. [ECB00981]

4. Turn the fuel tank cap fully clockwise to make sure it is securely closed.

WARNING EWB02531

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.

NOTICE ECB00070

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.

Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research oc- tane number of 91 or higher. If knocking (or ping- ing) occurs, use a gasoline of a different brand. Use of unleaded fuel will extend spark plug life and reduce maintenance costs.

Gasohol There are two types of gasohol: gasohol contain- ing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol con- tent does not exceed 10% (E10). Gasohol contain- ing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems.

Recommended fuel: UNLEADED GASOLINE ONLY

Fuel tank capacity: 12.0 L (3.17 US gal, 2.64 Imp.gal)

Fuel reserve amount: 1.6 L (0.42 US gal, 0.35 Imp.gal)

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EBU18820

Fuel cock The fuel cock supplies fuel from the tank to the car- buretor while also filtering it. The fuel cock lever positions are explained as fol- lows and shown in the illustrations.

OFF

With the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running.

ON

With the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding.

1. Arrow mark positioned over OFF

1. Arrow mark positioned over ON

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RES

This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to ON!

EBU18850

Starter (choke) Starting a cold engine requires a richer air-fuel mix- ture, which is supplied by the starter (choke). Move the starter (choke) in direction (a) to turn on the starter (choke).

Move the starter (choke) in direction (b) to turn off the starter (choke). See the Starting a cold engine section on page 6-1 for proper operation.

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Seat

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

1. Arrow mark positioned over RES

1. Starter (choke)

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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. Make sure that the seat is securely fitted.

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Storage compartment

NOTICE ECB00130

Do not store metal or sharply edged objects, like tools, in the storage compartment. If they must be stored, wrap them in appropriate cushion material to prevent damaging the stor- age compartment.

The storage compartment is located under the seat. (See page 4-11.)

1. Seat 2. Seat lock lever

1. Projection 2. Seat holder

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When storing any documents in the storage com- partment, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartment.

TIP There is a check hose at the bottom of the storage compartment. If any water collects in this hose, re- move the hose, empty it, and then install it.

EBU18962

Front carrier Do not exceed the load limit of 30.0 kg (66 lb) for

the front carrier. Do not exceed the maximum load of 165.0 kg

(364 lb) for the ATV.

EBU18972

Rear carrier Do not exceed the load limit of 45.0 kg (99 lb) for

the rear carrier. Do not exceed the maximum load of 165.0 kg

(364 lb) for the ATV.

1. Storage compartment

1. Storage compartment check hose

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EBU19023

Adjusting the rear shock absorber as- sembly The spring preload can be adjusted to suit the rid- ers weight and the riding conditions.

NOTICE ECB01090

Never turn the adjusting mechanism beyond the minimum and maximum settings.

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.

TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment.

1. Spring preload adjusting ring 2. Position indicator

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WARNING EWB00011

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

1. Special wrench

Spring preload setting: Minimum (soft):

1 Standard:

2 Maximum (hard):

5

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EBU19201

PRE-OPERATION CHECKS EBU19224

Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owners Manual.

WARNING EWB00481

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.

Before using this vehicle, check the following points:

ITEM ROUTINE PAGE

Fuel Check fuel level in fuel tank, and add recommended fuel if neces-

sary. Check fuel line for leakage. Correct if necessary.

4-8, 5-3

Engine oil Check oil level in engine, and add recommended oil to specified lev-

el if necessary. Check ATV for oil leakage. Correct if necessary.

5-3, 8-11

Final gear oil Check ATV for oil leakage. Correct if necessary. 5-3, 8-17

Front brake

Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system.

Check brake pads for wear, and replace if necessary. Check brake fluid level in reservoir, and add recommended brake

fluid to specified level if necessary. Check hydraulic system for leakage. Correct if necessary.

5-3, 8-27, 8-29, 8-30

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Rear brake Check operation, and correct if necessary. Lubricate cable if necessary. Check lever and pedal free play, and adjust if necessary.

5-3, 8-27, 8-30

Throttle lever Make sure that operation is smooth. Lubricate cable and lever hous-

ing if necessary. Check cable free play, and adjust if necessary.

5-4, 8-26

Control cables Make sure that operation is smooth. Lubricate if necessary. 8-35

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.

5-4

Shift pedal Make sure that operation is smooth. Correct if necessary. 8-36

Brake pedal Make sure that operation is smooth. Lubricate pedal pivoting point if necessary. 8-36

Brake levers Make sure that operation is smooth. Lubricate lever pivoting points if necessary. 8-35

Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened. 5-6

Instruments, lights and switches Check operation, and correct if necessary. 5-6

Battery Check electrolyte level. Fill with distilled water if necessary. 5-6, 8-38

ITEM ROUTINE PAGE

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EBU19541

Fuel Make sure that there is sufficient fuel in the tank. (See page 4-8.)

EBU19560

Engine oil Make sure that the engine oil is at the specified lev- el. Add oil as necessary. (See page 8-11.)

EBU19590

Final gear oil Make sure that the final gear oil is at the specified level. Add oil as necessary. (See page 8-17.)

EBU27671

Front and rear brakes

Brake levers and brake pedal Check that there is no free play in the front brake

lever. If there is free play, have a Yamaha dealer check the brake system.

Check for correct free play in the rear brake lever and brake pedal. If the free play is incorrect, ad- just it. (See page 8-30.)

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

Brake fluid level (front brake) Check the brake fluid level. Add fluid if necessary. (See page 8-29.)

Brake fluid leakage (front brake) Check to see if any brake fluid is leaking out of the hose, joint or brake fluid reservoir of the front brake. Apply the brake firmly for one minute. If the lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake system should be checked by a Yamaha dealer.

Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, check the brake pads and shoes for wear. (See page 8-27.)

Recommended brake fluid: DOT 4

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EBU19761

Throttle lever Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary.

EBU19814

Tires Check tire pressure regularly to make sure it is at the recommended specifications. Also check for wear and damage.

Tire pressure Use the low-pressure tire gauge to check and ad- just tire pressures when the tires are cold. Tire pressures must be equal on both sides. WARNING! Operation of this vehicle with im- proper tire pressure may cause severe injury or death from loss of control or rollover. Tire pressure below the minimum specified could also cause the tire to dislodge from the rim un- der severe riding conditions. [EWB02541] Set tire pressures to the following specifications:

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.

Recommended tire pressure: Front

20.0 kPa (0.200 kgf/cm, 2.9 psi) Rear

25.0 kPa (0.250 kgf/cm, 3.6 psi) Minimum tire pressure:

Front 17.0 kPa (0.170 kgf/cm, 2.5 psi)

Rear 22.0 kPa (0.220 kgf/cm, 3.2 psi)

Maximum tire seating pressure: Front

250 kPa (2.5 kgf/cm, 36 psi) Rear

250 kPa (2.5 kgf/cm, 36 psi)

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

Tire information This ATV is equipped with tubeless tires with valves.

WARNING EWB02551

Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent.

After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Manufacturing Corporation of America.

1. Low-pressure tire gauge 1. Tire wear limit

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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.

EBU19840

Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened.

EBU19850

Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.

EBU19860

Battery Check the fluid level in the battery. Fill with distilled water if necessary. (See page 8-38.)

Front: Manufacturer/model:

MAXXIS/M905 Size:

AT22 x 7.00-10 Type:

Tubeless Rear:

Manufacturer/model: MAXXIS/M906

Size: AT22 x 10.00-10

Type: Tubeless

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EBU19872

OPERATION

WARNING EWB00011

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

EBU19901

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

WARNING EWB00631

Read the Owners Manual carefully to become familiar with all controls in order to help pre- vent any loss of control, which could cause an accident or injury.

EBU19993

Starting a cold engine

NOTICE ECB00150

See the Engine break-in section on page 6-6 prior to operating the engine for the first time.

1. Set the parking brake. 2. Turn the fuel cock to ON. 3. Turn the key to ON and the engine stop

switch to . 4. Shift the transmission into neutral. The neutral

indicator light should come on. If the indicator light does not come on, have a Yamaha deal- er check the electrical circuit.

TIP The engine can be started under the following con- ditions: The transmission is in neutral. The rear brake lever is applied with the transmis-

sion in any gear. However, it is recommended to shift into neutral before starting the engine.

5. Use the starter (choke) in reference to the fig- ure: 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).

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Position (3): Cold engine start with ambient temperature above 25 C (80 F).

Ambient temp./starter (choke) position

6. Completely close the throttle lever and start the engine by pushing the start switch. NOTICE: For maximum engine life, never accelerate hard when the engine is cold! [ECB00162]

TIP If the engine fails to start, release the start

switch, then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery ener- gy. Do not crank the engine more than 10 sec- onds on each attempt.

If the battery is discharged, pull the recoil starter to start the engine.

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, then return the starter (choke) to position (3) before riding.

TIP The engine is warm when it responds quickly to the throttle with the starter (choke) turned off.

1. Fully open 2. Half open 3. Closed 4. Starter (choke)

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EBU20291

Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open.

EBU20321

Operating the drive select lever and driving in reverse

NOTICE ECB00170

Before shifting, stop the ATV, otherwise the transmission may be damaged.

Shifting: Reverse to Forward 1. Bring the ATV to a complete stop. 2. Apply the brake pedal. 3. Move the drive select lever forward until it

completely stops.

4. Release the brake pedal, and then open the throttle lever gradually.

Shifting: Forward to Reverse

WARNING EWB00720

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.

1. Drive select lever 2. Forward F 3. Reverse R

F

R

2

3

1

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TIP To shift into reverse, the transmission must be in first gear.

1. Bring the ATV to a complete stop. 2. Apply the brake pedal. 3. Shift the transmission into first gear. 4. Move the drive select lever to the rear until it

completely stops.

TIP When in reverse, the reverse indicator light should be on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit.

5. Check behind you for people or obstacles, and then release the brake pedal.

6. Open the throttle lever gradually and continue to watch to the rear while backing.

EBU20551

Shifting This ATV has a 5-speed forward transmission with a centrifugal, automatic clutch. The transmission allows you to control the amount of power you have available at a given speed or for starting ac- celerating, climbing, etc. To shift into neutral, release the throttle lever and repeatedly depress the shift pedal until it stops.

1. Drive select lever 2. Forward F 3. Reverse R

F

R

2

3

1

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EBU20611

To start out and accelerate 1. Release the throttle lever.

NOTICE ECB00200

Always close the throttle before shifting gears, otherwise damage to the engine and drive train may result.

2. Shift into first gear and release the shift pedal.

3. Open the throttle gradually. WARNING! Al- ways open the throttle gradually. Opening the throttle abruptly would increase the chance of an accident. It could make the ATV wheelie or overturn. [EWB00741]

4. Once the ATV has attained adequate speed, release the throttle lever.

5. Shift into second gear and release the shift pedal.

6. Open the throttle gradually. 7. Follow the same procedure when shifting to

the next higher gear.

EBU20650

To decelerate When slowing down or stopping, release the throt- tle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing con- trol and increasing the possibility of an accident.

1. Shift pedal 2. Neutral position

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WARNING EWB00710

Make sure the engine has sufficiently slowed before shifting to a lower gear. Engaging a low- er gear when the engine speed is too high could make the wheels stop rotating and lose traction. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage.

NOTICE ECB00190

Even with the transmission in the neutral posi- tion, do not coast for long periods of time with the engine off, and do not tow the ATV for long distances. The transmission is properly lubri- cated only when the engine is running. Inade- quate lubrication may damage the transmission.

EBU20672

Engine break-in

TIP For ATVs equipped with an odometer or an hour

meter, follow the figures given in km (mi) or the figures given in hours.

For ATVs not equipped with an odometer or hour meter, follow the figures given in hours.

There is never a more important period in the life of your engine than the first 320 km (200 mi) or 20 hours of riding. For this reason, you should read the following material carefully. Since the engine is brand new, do not put an ex- cessive load on it for the first 320 km (200 mi) or 20 hours. The various parts in the engine wear and polish themselves to the correct operating clear- ances. During this period, prolonged full-throttle operation or any condition that might result in en- gine overheating must be avoided.

0160 km (0100 mi) or 010 hours Avoid prolonged operation above 1/2 throttle. Vary the speed of the ATV regularly. Do not operate it at one set throttle position.

160320 km (100200 mi) or 1020 hours Avoid prolonged operation above 3/4 throttle. Rev the engine through the gears freely, but do not use full throttle at any time.

320 km (200 mi) or 20 hours and beyond The ATV can now be operated normally.

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NOTICE ECB00220

If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV.

EBU20722

Parking When parking the ATV, shift into first gear, stop the engine, apply the parking brake, and then turn the fuel cock to OFF.

EBU20843

Parking on a slope

WARNING EWB00851

Avoid parking on hills or other inclines. Park- ing 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 into first gear, stop the engine, ap- ply 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.

1. With the transmission in first gear, bring the ATV to a stop by applying the brakes.

2. Stop the engine. 3. With the rear brake lever and brake pedal ap-

plied, apply the parking brake and slowly re- lease the brake pedal.

4. Turn the fuel cock to OFF.

1. Parking brake lock plate

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Accessories and loading

EBU20921

Genuine Yamaha Accessories Choosing accessories for your ATV is an important decision. Genuine Yamaha Accessories, which are available only from a Yamaha dealer, have been designed, tested, and approved by Yamaha for use on your ATV. Many companies with no con- nection to Yamaha manufacture parts and acces- sories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket companies pro- duce. Therefore, Yamaha can neither endorse nor recommend the use of accessories not sold by

Yamaha or modifications not specifically recom- mended by Yamaha, even if sold and installed by a Yamaha dealer.

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 poten- tial safety hazards to you or others. Installing after- market products or having other modifications performed to your ATV that change any of the ve- hicles design or operation characteristics can put you and others at greater risk of serious injury or death. You are responsible for injuries related 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

mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV.

Do not mount an accessory where it could inter- fere with your ability to control the ATV. Exam- ples include (but are not limited to) a heavy or

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bulky object attached to the handlebars which could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view.

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

EBU21101

Loading

WARNING EWB00820

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.

Cargo or a trailer can change the stability and han- dling of an ATV. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind:

Never exceed the weight limits shown. An over- loaded ATV can be unstable.

Do not exceed the maximum tongue weight. You can measure tongue weight with a bath- room scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height. Ad- just the load in the trailer, if necessary, to reduce the weight on the hitch. If you are carrying cargo and towing a trailer, include the tongue weight in the maximum ATV load limit.

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

165.0 kg (364 lb) Front carrier:

30.0 kg (66 lb) Rear carrier:

45.0 kg (99 lb) Trailer hitch:

Pulling load (total weight of trailer and car- go):

3230 N (330 kgf, 727 lbf) Tongue weight (vertical weight on trailer hitch point):

147 N (15 kgf, 33 lbf)

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6

Load cargo on the carriers as close to the center of the ATV as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, and center it.

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

Make sure the load does not interfere with con- trols or your ability to see where you are going.

Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trail- er.

Allow more braking distance. A heavier ATV takes longer to stop.

Avoid making sharp turns unless at very slow speeds.

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

WARNING EWB00011

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

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EBU21132

RIDING YOUR ATV

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WARNING EWB00011

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

EBU21325

GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use. This sec- tion, 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 ba- sic techniques well before attempting more difficult maneuvers. Riding your new ATV can be a very enjoyable ac- tivity, providing you with hours of pleasure. But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely. Before you begin to ride, be sure you have read this Owners Manual completely and un- derstand the operation of the controls. Pay partic-

ular attention to the safety information on pages 2-12-5. Also read all warning and notice labels on your ATV.

RIDE WITH CARE AND GOOD JUDGMENT

Get training if you are inexperienced.

WARNING EWB01381

Do not operate this ATV or allow anyone else to operate it without proper instruction. The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.

Do not operate this ATV at speeds too fast for your skills or the conditions, as this in- creases your chances of losing control of the ATV and an accident. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experi- ence.

Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating tech-

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niques described in this Owners Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887.

Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATVs handling and performance characteristics. Take the time to learn the basic techniques well before attempting more difficult maneuvers. Become fa- miliar with this ATV at slow speeds first, even if you are an experienced operator.

Not recommended for children under 16 years of age.

WARNING EWB01390

A child under 16 should never operate an ATV with engine size greater than 90 cc. Use by chil- dren of ATVs that are not recommended for their age can lead to severe injury or death of the child.

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. [EWB01401]

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Apparel Always wear the following to reduce risk of injury in an accident: Approved motorcycle helmet that fits properly Eye protection (goggles, helmet face shield, or

protective eyewear) Over-the-ankle boots, gloves, long-sleeved 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. [EWB01411]

Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury. Eye protection, such as a face shield or goggles, may reduce the risk of foreign material getting in your eyes and help prevent loss of vision. WARNING! Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. [EWB02611]

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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 al- cohol 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. [EWB01421]

Pre-operation checks Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance procedures and schedules described in the Own- ers Manual. WARNING! Failure to inspect the ATV before operating it and to maintain it prop- erly increases the possibility of an accident or equipment damage. [EWB01431]

Speed limiter For riders less experienced with this model, the throttle lever housing is equipped with a speed lim- iter. The speed limiter keeps the throttle from fully

1. Protective clothing 2. Goggles 3. Gloves 4. Boots 5. Helmet

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opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and de- creases the maximum speed of the ATV. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (See page 4-4.)

Loading and accessories

WARNING EWB01461

Improper loading or towing can increase the risk of loss of control, an overturn, or other ac- cident. To reduce the risk of an accident:

Do not exceed the maximum loading limits for the vehicle (see box in this section or ve- hicle labeling).

Keep weight on racks centered side to side, and as low as possible. Be sure cargo is se- cured a loose load could change handling unexpectedly.

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

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

Reduce speed and allow more room to stop. A heavier vehicle takes longer to stop.

Avoid hills and rough terrain. Choose terrain carefully. Use extreme caution when towing or carrying a load on inclines.

Turn gradually and go slowly.

Take extra precautions when driving with a load or trailer. Follow these instructions and always use common sense and good judgment when carrying cargo or towing a trailer.

1. Adjusting screw

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Drive more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice to drive slowly (shift into first gear or low drive if avail- able on this model) whenever you are carrying heavier loads or when towing a trailer.

During operation Always keep your feet on the footboards during op- eration; 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 contact with the rear wheels, which could injure you or cause an accident. [EWB01471]

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

165.0 kg (364 lb) Front carrier:

30.0 kg (66 lb) Rear carrier:

45.0 kg (99 lb) Trailer hitch:

Pulling load (total weight of trailer and car- go):

3230 N (330 kgf, 727 lbf) Tongue weight (vertical weight on trailer hitch point):

147 N (15 kgf, 33 lbf)

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Avoid wheelies and jumping. WARNING! At- tempting wheelies, jumps, and other stunts in- creases the chance of an accident, including an overturn. Never attempt stunts, such as wheelies or jumps. Dont try to show off. [EWB01481]

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 de- signed for use on this ATV and should be installed 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. [EWB01491]

Exhaust system

WARNING EWB01501

Dry grass or brush or other combustible ma- terial accumulated around the engine area could catch fire. Do not operate, idle, or park the ATV in dry grass or other dry ground cov- er. Keep the engine area free of dry grass, brush, or other combustible material.

Someone touching the exhaust system dur- ing or after operation could be burned. Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it.

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 op-

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erating in areas where combustible materials may have collected. Do not idle or park the vehicle in long dry grass or other dry ground cover. To prevent burns, avoid touching the exhaust sys- tem. Park the ATV in a place where pedestrians or children are not likely to touch it.

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. [EWB01511]

Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. In many states it is illegal to operate ATVs on public streets, roads and highways.

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7

WARNING! Never operate this ATV on any pub- lic street, road or highway, even a dirt or gravel one. You could collide with another vehicle. [EWB01031]

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. [EWB01531]

Do not operate on rough, slippery, or loose terrain until you have learned and practiced the skills nec- essary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. WARNING! Failure to use extra care when op- erating on excessively rough, slippery, or loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. [EWB01541]

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7-11

7When 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. WARNING! You could collide with another vehicle if operating in off-road ar- eas where you cannot easily be seen. Mount a caution flag on the ATV to make you more vis- ible. Watch carefully for other vehicles. [EWB01061]

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

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7

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. 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. As you get on the ATV, be sure not to accidentally move the shift pedal. With the engine idling, lift the shift pedal to the 1st gear position and then release the parking brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. Once the ATV has at- tained adequate speed, release the throttle and lift the shift pedal to the 2nd gear position. Release the shift pedal and apply the throttle smoothly. WARNING! If the throttle is applied too abruptly or if the throttle is not released during shifting, or if the shift pedal is not released before ap- plying the throttle, the front wheels may lift off the ground, resulting in a loss of directional control. [EWB02631] NOTICE: Do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. [ECB01071]

Use this same procedure as you move into the higher gears. Be sure to coordinate the use of the throttle and shift pedal properly. Avoid higher speeds until you are thoroughly famil- iar with the operation of your ATV. When slowing down or stopping, release the throt- tle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing con- trol and increasing the possibility of an accident.

TURNING YOUR ATV

WARNING EWB01771

Always follow proper procedures for turning 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. ATV could go out of control, causing a collision or overturn.

To achieve maximum traction while riding off-road, the two rear wheels turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction,

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7

the ATV will resist turning. A special turning tech- nique 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 out- side of the turn (opposite your desired direction) and lean your upper body into the turn. Use the throttle to maintain an even speed through the turn. This maneuver will let the wheel on the inside 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.

1. Lean towards inside of turn. 2. Support your weight on the outer footboard.

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7

Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be necessary to gradually let off on the throttle and steer to the out- side of the turn to avoid tipping over. Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your ATV.

CLIMBING UPHILL

WARNING EWB01591

Climbing hills improperly can cause overturns or loss of control. Use proper riding tech- niques described in this Owners Manual. Never operate the ATV on hills too steep for

the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills.

Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward.

Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backwards.

Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

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.

Avoid crossing the side of a steep hill if pos- sible. When crossing the side of a hill, shift your weight to the uphill side of the ATV.

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7

Do not attempt to climb hills until you have mas- tered basic maneuvers on flat ground. Always check the terrain carefully before attempting any hill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control. To climb a hill, you need traction, momentum, and steady throttle. Travel fast enough to maintain mo- mentum, but not so fast that you cannot react to changes in the terrain as you climb. It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars. Whenev- er 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 remember that some hills are too steep for you to climb or de- scend.

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7

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 up- hill side. Physically turn the ATV around and then descend the hill. If you start to roll backwards, DO NOT apply the rear brake, and apply the front brake gradually. The ATV could easily tip over backwards. When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount the ATV im- mediately on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owners Manual. WARNING! Stalling, 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. [EWB01802]

RIDING DOWNHILL

WARNING EWB01131

Going down a hill improperly could cause overturns or loss of control. Always follow proper procedures for going down hills as de- scribed in this Owners Manual. Always check the terrain carefully before

you start down any hill. Never operate the ATV on hills too steep for

the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills.

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7

Shift your weight backward and to the up side of the hill.

Never go down a hill at high speed. Avoid going down a hill at an angle that

would cause the ATV to lean sharply to one side. Go straight down the hill where possi- ble.

Improper braking can cause the wheels on the uphill side to come off the ground or cause loss of traction. Gradually apply only the rear brake when going downhill.

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. Choose a low gear which will allow the en- gine compression to 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. Gradual- ly 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.

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7

CROSSING A SLOPE

WARNING EWB01632

Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to overturn. Always follow proper procedures as de-

scribed in the Owners Manual. Avoid hills with excessively slippery or loose

surfaces. Avoid crossing the side of a steep hill. Shift your weight to the uphill side of the

ATV. Never attempt to turn the ATV around on any

hill until you have mastered the turning tech- nique as described in the Owners Manual on level ground. Be very careful when turning on any hill.

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 slip- pery surfaces or rough terrain that may upset your balance.

As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the steering when riding on loose 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, gradually steer again in the direction you wish to travel.

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7

CROSSING THROUGH SHALLOW WATER

WARNING EWB01641

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.

The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and care- fully.

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 with- out verifying that you have regained proper braking ability. WARNING! Wet brakes may have re- duced stopping ability, which could cause loss of control. [EWB02621]

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7 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, the drive select lever box check hose, and the storage compartment check hose. NOTICE: Undrained water can cause damage or improper operation. [ECB00841]

Wash the ATV in fresh water if it has been operat- ed in salt water or muddy conditions.

1. Air filter case check hose

1. Drive select lever box check hose

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7-21

7RIDING OVER ROUGH TERRAIN

WARNING EWB01651

Riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt 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.

Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac-

cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may re- sult.

SLIDING AND SKIDDING

WARNING EWB01662

Skidding or sliding improperly may cause you to lose control of this ATV. You may also re- gain traction unexpectedly, which may cause the ATV to overturn. Learn to safely control skidding or sliding by

practicing at low speeds and on level, smooth terrain.

On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of control.

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

1. Storage compartment check hose

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7

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.

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

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

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7

WHAT TO DO... If your ATV doesnt turn when you want it to:

Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See page 7-12.)

If your ATV begins to tip while turning: Lean more into the turn to regain balance. If nec- essary, gradually let off the throttle and/or steer to the outside of the turn. (See page 7-12.)

If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See page 7-21.)

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 7-14.)

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 7-18.)

If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let wa- ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See page 7-19.)

WARNING EWB00011

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

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8

EBU2164A

PERIODIC MAINTENANCE AND ADJUSTMENT EBU21671

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/operator. The most important points of vehicle inspection, adjustment, and lubri- cation are explained on the following pages.

WARNING EWB01841

Failure to properly maintain the vehicle or per- forming maintenance activities incorrectly may increase your risk of injury or death during ser- vice or while using the vehicle. If you are not fa- miliar with vehicle service, have a Yamaha dealer perform the service.

WARNING EWB02561

Turn off the engine when performing mainte- nance unless otherwise specified. A running engine has moving parts that can

catch on body parts or clothing and electri- cal parts that can cause shocks or fires.

Running the engine while servicing can lead to eye injury, burns, fire, or carbon monoxide poisoning - possibly leading to death. See page 2-1 for more information about carbon monoxide.

The intervals given in the periodic maintenance and lubrication chart should be considered as a general guide under normal riding conditions. However, DEPENDING ON THE WEATHER, TERRAIN, GEOGRAPHICAL LOCATION, AND INDIVIDUAL USE, THE MAINTENANCE INTER- VALS MAY NEED TO BE SHORTENED.

EBU21731

Owners manual and tool kit Be sure to put this owners manual in the plastic bag and always carry it on the bottom of the seat as shown. Put the owners tool kit and low-pres- sure tire gauge under the seat.

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8-2

8 The service information included in this manual and the tools provided in the owners tool kit are in- tended to assist you in the performance of preven- tive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.

TIP If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

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

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8

EBU21743

Periodic maintenance chart for the emission control system

TIP For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-

vals. However, keep in mind that if the ATV isnt used for a long period of time, the month maintenance intervals should be followed.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

first

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

1 * Fuel line Check fuel hoses for cracks or other damage, and replace if necessary.

2 Spark plug Check condition and clean, regap, or replace if necessary.

3 * Valves Check valve clearance and adjust if necessary.

4 * Carburetor

Check starter (choke) operation and correct if nec- essary.

Check engine idling speed and adjust if neces- sary.

5 * Crankcase breather system

Check breather hose for cracks or other damage, and replace if necessary.

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8

6 * Exhaust system

Check for leakage and replace gasket(s) if neces- sary.

Check for looseness and tighten all screw clamps and joints if necessary.

7 Spark arrester Clean.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

first

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

U1P015E0.book Page 4 Friday, July 31, 2009 9:40 AM

8-5

8

EBU21865

General maintenance and lubrication chart

TIP For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-

vals. However, keep in mind that if the ATV isnt used for a long period of time, the month maintenance intervals should be followed.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

first

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

1 Air filter element Clean and replace if necessary. Every 2040 hours (more often in wet or dusty areas)

2 * Clutch Check operation and adjust if necessary.

3 * Front brake

Check operation and correct if necessary. Check fluid level and ATV for fluid leakage, and

correct if necessary.

Replace brake pads. Whenever worn to the limit

4 * Rear brake

Check operation and correct if necessary. Check brake lever and pedal free play, and adjust

if necessary.

Replace brake shoes. Whenever worn to the limit

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8

5 * Brake hoses Check for cracks or other damage, and replace if

necessary.

Replace. Every 4 years

6 * Wheels Check runout and for damage, and replace if nec- essary.

7 * Tires

Check tread depth and for damage, and replace if necessary.

Check air pressure and balance, and correct if necessary.

8 * Wheel hub bearings Check for looseness or damage, and replace if necessary.

9 * Swingarm pivots Check operation and for excessive play, and re-

place bearings if necessary. Lubricate with lithium-soap-based grease.

10 * Chassis fasteners Make sure that all nuts, bolts, and screws are properly tightened.

11 * Shock absorber as- semblies

Check operation and correct if necessary. Check for oil leakage and replace if necessary.

12 * Steering shaft Lubricate with lithium-soap-based grease.

13 * Steering system Check operation and repair or replace if damaged. Check toe-in and adjust if necessary.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

first

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

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8-7

8

14 Engine oil Change. Check ATV for oil leakage, and correct if neces-

sary.

15 Engine oil filter ele- ment Clean or replace if necessary.

16 Engine oil strainer Clean.

17 Final gear oil Change. Check ATV for oil leakage, and correct if neces-

sary.

18 * Moving parts and cables Lubricate.

19 * Drive select lever safety system cable

Check operation and adjust or replace if neces- sary.

20 * Throttle lever hous- ing and cable

Check operation and correct if necessary. Check throttle cable free play and adjust if neces-

sary. Lubricate throttle lever housing and cable.

21 * Front and rear brake switches Check operation and correct if necessary.

22 * Lights and switches Check operation and correct if necessary. Adjust headlight beams.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

first

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

U1P015E0.book Page 7 Friday, July 31, 2009 9:40 AM

8-8

8

EBU28391

TIP Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or

muddy areas, or at full-throttle. Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinder and calipers, and change

the brake fluid. Replace the brake hoses every four years and if cracked or damaged.

23 * Battery

Check electrolyte level and specific gravity, and correct if necessary.

Make sure that the breather hose is properly rout- ed.

NO. ITEM CHECK OR MAINTENANCE JOB

INITIAL EVERY

Whichev- er comes

first

month 1 3 6 6 12

km (mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

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8

WARNING EWB00011

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

EBU23213

Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- tion chart. In addition, the condition of the spark plug can reveal the condition of the engine.

To remove the spark plug 1. Remove the spark plug cap.

2. Remove the spark plug as shown, with the spark plug wrench included in the owners tool kit.

1. Spark plug cap

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8

To check the spark plug 1. Check that the porcelain insulator around the

center electrode of the spark plug is a medi- um-to-light tan (the ideal color when the ATV is ridden normally).

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.

2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

3. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.

1. Spark plug wrench

Specified spark plug: NGK/DR7EA

1. Spark plug gap

Spark plug gap: 0.60.7 mm (0.0240.028 in)

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8-11

8

To install the spark plug 1. Clean the surface of the spark plug gasket

and its mating surface, and then wipe off any grime from the spark plug threads.

2. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque.

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 specified torque as soon as possible.

3. Install the spark plug cap.

EBU2329F

Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element cleaned at the intervals speci- fied in the periodic maintenance and lubrication chart.

To check the engine oil level 1. Place the ATV on a level surface. 2. Check the engine oil level on a cold engine.

TIP If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading.

3. Remove the engine oil filler cap, and then wipe the engine oil dipstick off with a clean rag.

4. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level.

Tightening torque: Spark plug:

17.5 Nm (1.75 mkgf, 12.7 ftlbf)

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8-12

8

TIP The engine oil should be between the minimum and maximum level marks.

5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type to raise it to the correct level. NOTICE: Be sure the engine oil is at the correct level, otherwise engine damage may result. [ECB00851]

6. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap.

To change the engine oil (with or without oil fil- ter element cleaning)

1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min-

utes, and then turn it off. 3. Place an oil pan under the engine to collect

the used oil. 4. Remove the engine oil filler cap, and then re-

move the engine oil drain bolt to drain the oil from the crankcase. NOTICE: When remov- ing the engine oil drain bolt, the compres- sion spring, oil strainer and O-ring will fall out. Take care not to lose these parts. [ECB00311]

1. Engine oil filler cap 2. Engine oil dipstick 3. Maximum level mark 4. Minimum level mark

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8-13

8 TIP Skip steps 511, 16, and 17 if the oil filter element is not being cleaned.

5. Remove the footboard by removing the bolts.

6. Fully loosen the brake pedal free play adjust- ing nut, and push the brake pedal downward.

1. Engine oil drain bolt 2. O-ring 3. Compression spring 4. Oil strainer

1. Footboard 2. Bolt

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8-14

8

7. Move the drive select lever safety system ca- ble away from the oil filter element cover. 8. Remove the oil filter element cover by remov-

ing the bolts, and then remove the oil filter el- ement and the O-ring. NOTICE: Do not loosen the adjusting nuts shown when re- moving the oil filter element cover or oil fil- ter element. [ECB00341]

1. Brake pedal free play adjusting nut 1. Drive select lever safety system cable 2. Oil filter element cover

1

2

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8 9. Clean the oil strainer and oil filter element with

solvent.

10. Install the oil filter element and a new O-ring.

TIP Make sure that the O-ring is properly seated.

11. Install the oil filter element cover by installing the bolts, and then tighten them to the speci- fied torque.

1. Adjusting nut 2. Oil filter element cover 3. Bolt

1

2

3

3 1. Oil filter element 2. O-ring

Tightening torque: Oil filter element cover bolt:

10 Nm (1.0 mkgf, 7.2 ftlbf)

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8

12. Install the oil strainer, the compression spring, a new O-ring and the engine oil drain bolt, and then tighten the engine oil drain bolt to the specified torque. NOTICE: Before installing the engine oil drain bolt, be sure to install the O-ring, compression spring and oil strainer. [ECB00321]

13. Refill with the specified amount of the recom- mended engine oil, and then install and tight- en the engine oil filler cap.

TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down.

NOTICE ECB00300

In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of CD or oils of a higher quality than specified. In addition, do not use oils labeled ENERGY CONSERV- ING II or higher.

Make sure that no foreign material enters the crankcase.

14. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause.

15. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary.

16. Install the footboard by installing the bolts, and then tighten them to the specified torques.

Tightening torque: Engine oil drain bolt:

43 Nm (4.3 mkgf, 31 ftlbf)

Recommended oil: See page 10-1.

Oil quantity: Without oil filter element removal:

1.50 L (1.59 US qt, 1.32 Imp.qt) With oil filter element removal:

1.60 L (1.69 US qt, 1.41 Imp.qt)

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8

17. Adjust the brake pedal free play. (See page 8-30.)

EBU23386

Final gear oil The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart.

To check the final gear oil level 1. Place the ATV on a level surface. 2. Remove the final gear oil filler bolt and its gas-

ket, and then check the oil level in the final gear case. The oil level should be at the brim of the filler hole.

1. Footboard bolt A 2. Footboard bolt B

Tightening torques: Footboard bolt A:

4 Nm (0.4 mkgf, 2.9 ftlbf) Footboard bolt B:

7 Nm (0.7 mkgf, 5.1 ftlbf)

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83. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level.

4. Check the gasket for damage, and replace it if necessary.

5. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.

To change the final gear oil 1. Place the ATV on a level surface. 2. Remove the final gear case guard by remov-

ing the bolts.

3. Place an oil pan under the final gear case to collect the used oil.

4. Remove the final gear oil filler bolt, the final gear oil drain bolt, and their gasket to drain the oil from the final gear case.

1. Final gear oil filler bolt 2. Gasket 3. Final gear oil 4. Correct oil level

Tightening torque: Final gear oil filler bolt:

23 Nm (2.3 mkgf, 17 ftlbf)

12 4

3

1. Final gear case guard 2. Bolt

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5. Install the drain bolt and its new gasket, and then tighten the bolt to the specified torque.

6. Refill with the recommended final gear oil to the brim of the filler hole as shown. NOTICE: Be sure no foreign material enters the final gear case. [ECB00421]

7. Check the oil filler bolt gasket for damage, and replace it if necessary.

8. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.

1. Final gear oil drain bolt 2. Gasket

Tightening torque: Final gear oil drain bolt:

23 Nm (2.3 mkgf, 17 ftlbf)

1 1

2

1. Final gear oil filler bolt 2. Gasket 3. Final gear oil 4. Correct oil level

Recommended final gear oil: See page 10-1.

Tightening torque: Final gear oil filler bolt:

23 Nm (2.3 mkgf, 17 ftlbf)

12 4

3

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9. Check the final gear case for oil leakage. If oil is leaking, check for the cause.

10. Install the final gear case guard by installing the bolts and tightening them to the specified torque.

EBU23686

Cleaning the air filter element The air filter element should be cleaned at the in- tervals specified in the periodic maintenance and lubrication chart. Clean or, if necessary, replace the air filter element more frequently if you are riding in unusually wet or dusty areas.

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

1. Place the ATV on a level surface. 2. Remove the seat. (See page 4-11.) 3. Remove the air filter case cover by unhooking

the holders.

Tightening torque: Final gear case guard bolt:

17 Nm (1.7 mkgf, 12 ftlbf)

1. Air filter case check hose

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4. Pull the air filter element assembly out of the air filter case.

5. Remove the sponge material from the air filter element.

1. Air filter case cover 2. Air filter case cover holder

1. Air filter element assembly

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6. Clean the sponge material with water or sol- vent. WARNING! When using solvent to clean the sponge material, always use parts cleaning solvent or water. Never use low-flash-point solvents or gasoline to clean the sponge material because the en- gine could catch fire or explode. [EWB01951]

7. Squeeze the excess water or solvent out of the sponge material and let it dry. NOTICE: Do not twist the sponge material when squeezing it. Do not apply oil to the sponge material. [ECB00471]

8. Check the sponge material and replace it if damaged.

9. Tap the air filter element lightly to remove most of the dust and dirt. Blow out the remain- ing dirt with compressed air as shown. If the air filter element is damaged, replace it.

1. Air filter element 2. Sponge material

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8

10. Pull the sponge material over the air filter ele- ment.

11. Insert the air filter element assembly into the air filter case, and then install the air filter case cover by hooking the holders. NOTICE: Make sure that the air filter element is properly seated in the air filter case. Never operate the engine with the air filter element re- moved. This will allow unfiltered air to en- ter the engine, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating. [ECB00461]

12. Install the seat.

TIP The air filter element should be cleaned every 20 40 hours. It should be cleaned more often if the ATV is operated in extremely dusty areas. Each time the air filter element maintenance is per- formed, check the air inlet of the air filter case for obstructions. Check the air filter case rubber joint to the carburetor fittings and the rubber joint mani- fold fittings for an air-tight seal. Tighten all fittings securely to avoid the possibility of unfiltered air en- tering the engine.

EBU27081

Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be- fore cleaning the spark arrester.

1. Remove the bolts.

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

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

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

5. Install the bolts and tighten them to the speci- fied torque.

1. Bolt 2. Tailpipe

1. Tailpipe 2. Spark arrester

Tightening torque: Tailpipe bolt:

10 Nm (1.0 mkgf, 7.2 ftlbf)

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WARNING EWB02340

Do not start the engine when cleaning the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poison- ing, possibly leading to death, and start a fire. Always let the exhaust system cool prior to touching exhaust components.

EBU23940

Adjusting the carburetor The carburetor should be checked and, if neces- sary, adjusted at the intervals specified in the peri- odic maintenance and lubrication chart. The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary profes- sional knowledge and experience. The adjustment described in the following section, however, may be performed by the owner as part of routine main- tenance.

NOTICE ECB00480

The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowl- edge may result in poor performance of or damage to the engine.

EBU24000

Adjusting the engine idling speed The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrica- tion chart.

TIP A diagnostic tachometer is needed to make this adjustment.

1. Start the engine and warm it up.

TIP The engine is warm when it quickly responds to the throttle.

2. Attach the tachometer to the spark plug lead.

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3. Check the engine idling speed and, if neces- sary, adjust it to specification by turning the throttle stop screw at the carburetor. To in- crease the engine idling speed, turn the throt- tle stop screw in direction (a), and to decrease it, turn the screw in direction (b).

TIP If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment.

EBU24045

Adjusting the throttle cable free play The throttle cable free play should be checked and, if necessary, adjusted at the intervals speci- fied in the periodic maintenance and lubrication chart. The throttle cable free play should measure 3.0 5.0 mm (0.120.20 in) at the throttle lever. Period- ically check the throttle cable free play and, if nec- essary, adjust it as follows.

TIP The engine idling speed must be checked, and ad- justed if necessary, before adjusting the throttle ca- ble free play.

1. Slide the rubber cover back. 2. Loosen the locknut. 3. To increase the throttle cable free play, turn

the throttle cable free play adjusting bolt in di- rection (a). To decrease the throttle cable free play, turn the adjusting bolt in direction (b).

1. Throttle stop screw

Engine idling speed: 14001500 r/min

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8 4. Tighten the locknut. 5. Slide the rubber cover to its original position.

EBU24060

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.

EBU24071

Adjusting the drive select lever safety system cable The drive select lever safety system cable stretch- es with use, which can result in improper function. Therefore, the safety system cable should be checked and adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.

EBU29601

Brakes Replacement of brake components requires pro- fessional knowledge. Brake service should be per- formed by a Yamaha dealer.

WARNING EWB02571

Operating with improperly serviced or adjust- ed brakes could lead to a loss in braking ability and an accident.

EBU24120

Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.

1. Rubber cover 2. Locknut 3. Throttle cable free play adjusting bolt 4. Throttle cable free play

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EBU24171

Front brake pads Check each front brake pad for damage and mea- sure the lining thickness. If a brake pad is dam- aged or if the lining thickness is less than 1.0 mm (0.04 in), have a Yamaha dealer replace the brake pads as a set.

TIP The wheels need to be removed to check the brake pads. (See page 8-45.)

EBU24180

Rear brake shoes The rear brake is provided with a wear indicator, which allows you to check the brake shoe wear without having to disassemble the brake. To check the brake shoe wear, check the position of the wear indicator while applying the brake. If a brake shoe has worn to the point that the wear indicator reaches the wear limit line or mark, have a Yamaha dealer replace the brake shoes as a set.

1. Brake pad 2. Lining thickness

1. Wear indicator 2. Wear limit line

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EBU29840

Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.

Observe these precautions: When checking the fluid level, make sure that

the top of the brake fluid reservoir is level.

Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance.

Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance.

Be careful that water does not enter the brake fluid reservoir when refilling. Water will signifi- cantly lower the boiling point of the fluid and may result in vapor lock.

Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid imme- diately.

As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.

EBU24281

Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart. In addition,

1. Minimum level mark

Recommended brake fluid: DOT 4

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have the oil seals of the brake master cylinder and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are dam- aged or leaking. Oil seals: Replace every two years. Brake hoses: Replace every four years.

EBU24394

Checking the front brake lever free play The brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart. The brake lever should have no free play as shown. If there is free play, have a Yamaha dealer check the brake system.

EBU24574

Adjusting the brake pedal position, free play and the rear brake lever free play The brake pedal position and free play and the brake lever free play must be checked and, if nec- essary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.

TIP Always perform this maintenance completely in

the following order whenever adjusting the rear brake.

Before adjusting the brake lever free play and the brake pedal free play and position, check the rear brake shoes for wear.

1. Adjusting the brake pedal position The top of the brake pedal should be posi- tioned 43.053.0 mm (1.692.09 in) above the top of the footboard bracket. If the position is incorrect, adjust it as follows.

1. No brake lever free play

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8 a. Remove the footboard. (See Engine oil

on page 8-11 for removal and installation procedures.)

b. Loosen the locknuts at the brake pedal. c. Turn the brake pedal position adjusting

bolt at the brake pedal in direction (a) to raise the brake pedal, and in direction (b) to lower it.

d. Tighten the locknuts at the brake pedal. 2. Adjusting the brake pedal free play

The brake pedal free play should measure 20.030.0 mm (0.791.18 in) as shown. If the free play is incorrect, adjust it as follows.

a. Fully loosen the brake lever free play ad- justing nut on the brake cable at the rear wheel hub.

b. Turn the brake pedal free play adjusting nut on the brake rod at the rear wheel hub in direction (a) to increase the free play, and in direction (b) to decrease it.

1. Locknut 2. Brake pedal position adjusting bolt 3. Brake pedal position

1. Brake pedal free play

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3. Adjusting the brake lever free play The brake lever free play should measure 5.07.0 mm (0.200.28 in) as shown. If the free play is incorrect, adjust it as follows.

a. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjust- ing bolt.

b. Turn the brake lever free play adjusting nut on the brake cable at the rear wheel hub so that the distance between the brake cam- shaft lever and the pin, gap A, measures 01 mm (00.04 in).

1. Brake lever free play adjusting nut 2. Brake pedal free play adjusting nut

1. Brake lever free play 2. Locknut 3. Brake lever free play adjusting bolt

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8 c. Turn the brake lever free play adjusting bolt at the brake lever in direction (a) to in- crease the free play, and in direction (b) to decrease it.

d. Tighten the locknut at the brake lever. e. Install the footboard.

TIP When adjusting the rear brake lever free play: Be sure not to step on the brake pedal. Make sure the brake pedal does not move.

EBU24762

Brake light switches The brake light, which is activated by the brake pedal and brake levers, should come on just be- fore braking takes effect.

1. Brake lever free play adjusting nut 2. Brake camshaft lever 3. Pin 4. Gap A

23

1

4

1. Locknut 2. Brake lever free play adjusting bolt

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The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer.

1. Remove the footboard. (See Engine oil on page 8-11 for removal and installation proce- dures.)

2. Turn the adjusting nut while holding the brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direc- tion (a). To make the brake light come on lat- er, turn the adjusting nut in direction (b).

3. Install the footboard.

EBU24803

Adjusting the clutch free play The clutch free play must be adjusted periodically. Adjust the free play as follows.

1. Remove the footboard. (See Engine oil on page 8-11 for removal and installation proce- dures.)

2. Loosen the locknut. 3. Slowly turn the clutch adjusting screw in direc-

tion (a) until resistance is felt, and then turn it 1/8 turn in direction (b).

1. Brake light switch 2. Brake light switch adjusting nut

1. Locknut 2. Clutch adjusting screw

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8

TIP Turning the clutch adjusting screw in direction (a) decreases clutch free play and turning it in direc- tion (b) increases clutch free play.

4. Tighten the locknut to the specified torque.

TIP When tightening the locknut, hold the clutch ad- justing screw with a screwdriver so that it does not turn together with the locknut.

5. Install the footboard.

EBU24901

Checking and lubricating the cables The operation and the condition of all control ca- bles should be checked before each ride, and the cables and cable ends should be lubricated if nec- essary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.

WARNING EWB02581

Inspect cables frequently and replace if dam- aged. Corrosion can result when the cable 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.

Always make sure all control cables work smoothly before you begin riding in cold weather. If the control cables are frozen or do not work smoothly, you could be unable to control the ATV, which could lead to an acci- dent or collision.

EBU28711

Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride, and the lever pivots should be lubricated if necessary.

Tightening torque: Locknut:

15 Nm (1.5 mkgf, 11 ftlbf)

Recommended lubricant: Engine oil

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Front brake lever

Rear brake lever

EBUM0170

Checking the shift pedal The operation of the shift pedal should be checked before each ride. If operation is not smooth, have a Yamaha dealer check the vehicle.

EBU28871

Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary.

Recommended lubricants: Front brake lever:

Silicone grease Rear brake lever:

Lithium-soap-based grease

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8 EBU24963

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 smoothly, have a Yamaha dealer check the wheel hub bear- ings.

EBU24995

Lubricating the swingarm pivots The swingarm pivots must be lubricated by a Yamaha dealer at the intervals specified in the pe- riodic maintenance and lubrication chart.

EBU25091

Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. Lubricate the steering shaft using a grease gun.

Recommended lubricant: Lithium-soap-based grease

Recommended lubricant: Lithium-soap-based grease

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8 EBU29872

Battery A poorly maintained battery will corrode and dis- charge quickly. The electrolyte level, battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrica- tion chart.

WARNING EWB02160

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 ig- nition away. Ventilate when charging or using in an enclosed space. KEEP OUT OF REACH OF CHILDREN.

To check the electrolyte level 1. Place the ATV on a level surface. 2. Remove the battery cover by pulling it upward.

Recommended lubricant: Lithium-soap-based grease

1. Grease nipple

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3. Check the electrolyte level in the battery.

TIP The electrolyte should be between the minimum and maximum level marks.

4. If the electrolyte is at or below the minimum level mark, add distilled water to raise it to the maximum level mark. NOTICE: Use only dis- tilled water, as tap water contains minerals that are harmful to the battery. [ECB00591]

1. Battery cover 1. Battery 2. Maximum level mark 3. Minimum level mark

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5. Check and, if necessary, tighten the battery lead connections and correct the breather hose routing as explained in step 5 of To in- stall the battery.

6. Install the battery cover.

To remove the battery 1. Remove the battery cover by pulling it upward. 2. Disconnect the negative battery lead.

NOTICE: When removing the battery, the main switch must be off, and the negative lead must be disconnected before the pos- itive lead. [ECB01001]

3. Remove the battery holding plate by removing the bolts.

4. Disconnect the positive battery lead.

5. Remove the battery.

To store the battery If the ATV will not be used for more than one

month, remove the battery, fully charge it, and then place it in a cool, dry place.

If the battery will be stored for more than two months, check the specific gravity of the electro- lyte at least once a month and fully charge the battery whenever necessary.

1. Battery 2. Battery holding plate 3. Bolt 4. Positive battery lead (red) 5. Negative battery lead (black)

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8

NOTICE ECB01100

Always keep the battery charged. Storing a discharged battery can cause permanent battery damage.

Do not leave or store the battery on its side.

To install the battery

TIP Be sure the battery is fully charged.

1. Install the battery. 2. Connect the positive battery lead. 3. Install the holding plate by installing the bolts. 4. Connect the negative battery lead. 5. Make sure that the breather hose is properly

routed, in good condition, and not obstructed. The breather hose end should measure 50.0 60.0 mm (1.972.36 in) past the bottom hose clamp.NOTICE: If the breather hose is posi- tioned in such a way that the frame is ex- posed to electrolyte or gas expelled from the battery, the frame could suffer struc- tural and external damages. [ECB00611]

6. Install the battery cover.

1. Battery 2. Battery breather hose 3. Hose clamp 4. Breather hose end

4

1 2 3

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EBU25243

Replacing the fuse

The fuse holder is located under the seat. (See page 4-11.) If the fuse is blown, replace it as follows.

1. Turn the key to OFF and turn off all electrical circuits.

NOTICE ECB00640

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

2. Remove the blown fuse, and then install a new fuse of the specified amperage. 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. [EWB02172]

3. Turn the key to ON and turn on the electrical circuits to check if the devices operate.

4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.

EBU25481

Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.

1. Remove the cover at the rear of the headlight by pulling it off.

1. Fuse 2. Spare fuse

Specified fuse: 20.0 A

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2. Remove the headlight bulb holder cover by pulling it off.

3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise.

4. Remove the burnt-out bulb by pulling it out. 5. Insert a new headlight bulb into the bulb hold-

er by pushing it in. NOTICE: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and finger- prints on the headlight bulb using a cloth moistened with alcohol or thinner. [ECB00651]

1. Cover at the rear of the headlight

1. Headlight bulb holder cover

1. Headlight bulb holder

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6. Install the bulb holder by pushing it in and turn- ing it clockwise.

7. Install the bulb holder cover and the cover at the rear of the headlight. NOTICE: Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. [ECB00671]

8. Adjust the headlight beam if necessary.

EBU25551

Adjusting a headlight beam

NOTICE ECB00690

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

To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b).

1. Do not touch the glass part of the bulb.

1. Headlight beam adjusting screw

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8

EBU25611

Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as follows.

1. Remove the bulb holder (together with the bulb) by turning it counterclockwise.

2. Remove the burnt-out bulb by pushing it in and turning it counterclockwise.

3. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops.

4. Install the bulb holder (together with the bulb) by turning it clockwise.

EBU25651

Removing a wheel 1. Place the ATV on a level surface. 2. Loosen the wheel nuts.

1. Tail/brake light bulb holder

1. Tail/brake light bulb holder 2. Tail/brake light bulb

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3. Elevate the ATV and place a suitable stand under the frame.

4. Remove the nuts from the wheel. 5. Remove the wheel.

EBU25701

Installing a wheel 1. Place the ATV on a level surface. 2. Install the wheel and the nuts.

TIP The arrow mark on the tire must point toward

the rotating direction of the wheel.

Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel.

1. Wheel nut

1. Arrow mark

1

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3. Lower the ATV to the ground. 4. Tighten the wheel nuts to the specified

torques.

EBU25720

Troubleshooting Although Yamaha ATVs receive a thorough in- spection before shipment from the factory, trouble may occur during operation. Any problem in the fu- el, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly. Use only genuine Yamaha replacement parts. Im- itation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills.

WARNING EWB02280

Do not smoke when checking the fuel system. Fuel can ignite or explode, causing severe inju- ry or property damage. Make sure there are no open flames or sparks in the area, including pi- lot lights from water heaters or furnaces.

1. Tapered nut

Tightening torques: Front wheel nut:

55 Nm (5.5 mkgf, 40 ftlbf) Rear wheel nut:

55 Nm (5.5 mkgf, 40 ftlbf)

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EBU25791

Troubleshooting chart

Check the fuel level in the fuel tank.

1. Fuel There is enough fuel.

There is no fuel.

Check the compression.

Supply fuel. The engine does not start. Check the compression.

Operate the electric starter.

2. Compression There is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealer check the ATV.

Remove the spark plug and check the electrodes.

3. Ignition Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug.

Have a Yamaha dealer check the ATV.

The engine does not start. Have a Yamaha dealer check the ATV.

The engine does not start. Check the battery.

Operate the electric starter.

4. Battery The engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the electrolyte level, recharge the battery and check the lead connections.

Dry

Wet Open the throttle halfway and operate the electric starter.

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EBU25860

CLEANING AND STORAGE EBU25881

Cleaning Frequent, thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many components.

1. Before cleaning the ATV: 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 de- greaser to the wheel axles.

3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure to do the job. WARNING! Wet brakes may have reduced stopping ability, increasing the chance of an accident. Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings. [EWB02311] NOTICE: Excessive water pressure may cause water seepage and deteriora-

tion of wheel bearings, brakes, transmis- sion seals and electrical devices. Many expensive repair bills have resulted from improper high-pressure detergent applica- tions such as those available in coin-oper- ated car washers. [ECB00711]

4. Once most of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bot- tle brush is handy for hard-to-reach places.

5. Rinse the ATV off immediately with clean wa- ter and dry all surfaces with a chamois, clean towel or soft absorbing cloth.

6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.

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

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EBU25933

Storage

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. [ECB00721]

Long-term Before storing your ATV for several months:

1. Follow all the instructions in the Cleaning section of this chapter.

2. Turn the fuel cock lever to OFF. 3. Drain the carburetor float chamber by loosen-

ing the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank.

4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel from deteriorat- ing.

5. Perform the following steps to protect the cyl- inder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark

plug. b. Pour a teaspoonful of engine oil into the

spark plug bore. c. Install the spark plug cap onto the spark

plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.)

d. Turn the engine over several times with the starter. (This will coat the cylinder wall with oil.)

e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap.

6. Lubricate all control cables and the pivoting points of all levers and pedals.

7. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that all of its wheels are off the ground. Alternative-

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

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ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.

8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it.

9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an exces- sively cold or warm place [less than 0 C (30 F) or more than 30 C (90 F)]. For more in- formation on storing the battery, see page 8-38.

TIP Make any necessary repairs before storing the ATV.

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EBU25960

SPECIFICATIONS Dimensions:

Overall length: 1916 mm (75.4 in)

Overall width: 1038 mm (40.9 in)

Overall height: 1118 mm (44.0 in)

Seat height: 772 mm (30.4 in)

Wheelbase: 1170 mm (46.1 in)

Ground clearance: 150 mm (5.9 in)

Minimum turning radius: 2900 mm (114 in)

Weight: With oil and fuel:

216.0 kg (476 lb) Engine:

Engine type: Air cooled 4-stroke, SOHC

Cylinder arrangement: Forward-inclined single cylinder

Displacement: 229 cm

Bore stroke: 71.0 58.0 mm (2.80 2.28 in)

Compression ratio: 8.70 :1

Starting system: Electric and recoil starter

Lubrication system: Wet sump

Engine oil: Recommended brand:

YAMALUBE Type:

SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- 50

Recommended engine oil grade: API service SG type or higher, JASO standard MA

0 10 30 50 70 90 110 130 F

20 10 0 10 20 30 40 50 C

SAE 5W-30

SAE 10W-30

SAE 10W-40

SAE 15W-40

SAE 20W-40

SAE 20W-50

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Engine oil quantity: Without oil filter element removal:

1.50 L (1.59 US qt, 1.32 Imp.qt) With oil filter element removal:

1.60 L (1.69 US qt, 1.41 Imp.qt) Final gear oil:

Type: SAE 80 API GL-4 Hypoid gear oil

Quantity: 0.25 L (0.26 US qt, 0.22 Imp.qt)

Air filter: Air filter element:

Dry element Fuel:

Recommended fuel: Unleaded gasoline only

Fuel tank capacity: 12.0 L (3.17 US gal, 2.64 Imp.gal)

Fuel reserve amount: 1.6 L (0.42 US gal, 0.35 Imp.gal)

Carburetor: Type quantity:

BSR33 x 1 Spark plug (s):

Manufacturer/model: NGK/DR7EA

Spark plug gap: 0.60.7 mm (0.0240.028 in)

Clutch: Clutch type:

Wet, centrifugal automatic

Transmission: Primary reduction system:

Spur gear Primary reduction ratio:

73/22 (3.318) Secondary reduction system:

Shaft drive Secondary reduction ratio:

19/18 46/11 (4.414) Transmission type:

Constant mesh 5-speed.forward, 1-speed.reverse Operation:

Left foot operation Gear ratio:

1st: 34/12 (2.833)

2nd: 34/19 (1.789)

3rd: 29/22 (1.318)

4th: 26/25 (1.040)

5th: 23/28 (0.821)

Reverse gear: 73/22 34/12 19/18 (9.924)

Chassis: Frame type:

Steel tube frame Caster angle:

4.0

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Trail: 20.0 mm (0.79 in)

Front tire: Type:

Tubeless Size:

AT22 x 7.00-10 Manufacturer/model:

MAXXIS/M905 Rear tire:

Type: Tubeless

Size: AT22 x 10.00-10

Manufacturer/model: MAXXIS/M906

Loading: Maximum loading limit:

165.0 kg (364 lb) (Total weight of rider, cargo, accessories, and tongue)

Tire air pressure (measured on cold tires): Recommended:

Front: 20.0 kPa (0.200 kgf/cm, 2.9 psi)

Rear: 25.0 kPa (0.250 kgf/cm, 3.6 psi)

Minimum: Front:

17.0 kPa (0.170 kgf/cm, 2.5 psi) Rear:

22.0 kPa (0.220 kgf/cm, 3.2 psi)

Front wheel: Wheel type:

Panel wheel Rim size:

10 x 6.0AT Rear wheel:

Wheel type: Panel wheel

Rim size: 10 x 8.0AT

Front brake: Type:

Dual disc brake Operation:

Right hand operation Recommended fluid:

DOT 4 Rear brake:

Type: Drum brake

Operation: Left hand and right foot operation

Front suspension: Type:

Strut Spring/shock absorber type:

Coil spring/oil damper Wheel travel:

125 mm (5.0 in)

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Rear suspension: Type:

Swingarm (monocross) Spring/shock absorber type:

Coil spring/oil damper Wheel travel:

135 mm (5.3 in) Electrical system:

Ignition system: DC. CDI

Charging system: AC magneto

Battery: Model:

CB14A-A2 Voltage, capacity:

12 V, 14.0 Ah Headlight:

Bulb type: Krypton bulb

Bulb voltage, wattage quantity: Headlight:

12 V, 30/30 W 2 Tail/brake light:

12 V, 5.0/21.0 W 1 Neutral indicator light:

12 V, 1.7 W 1 Reverse indicator light:

12 V, 1.7 W 1

Fuse: Fuse:

20.0 A

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EBU25981

CONSUMER INFORMATION EBU26012

Identification numbers Record the key identification number, vehicle iden- tification number and model label information in the spaces provided below for assistance when or- dering spare parts from a Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER:

VEHICLE IDENTIFICATION NUMBER:

MODEL LABEL INFORMATION:

EBU26020

Key identification number The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key.

EBU26030

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

1. Key identification number

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TIP The vehicle identification number is used to identify your ATV.

EBU26050

Model label The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- er.

EBU29662

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.

1. Vehicle identification number 1. Model label

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1. Vehicle Emission Control Information label

1

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EBU26060

Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ul- timate 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

Intake system Air cleaner case Air cleaner element Intake duct

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EBU26080

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

MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER

NAME AND ADDRESS REMARKS month km (mi) hours

1 320 (200) 20 3 1300 (800) 80 6 2500 (1600) 160 12 5000 (3200) 320 18 7500 (4800) 480 24 10000 (6400) 640 30 12500 (8000) 800 36 15000 (9600) 960 42 17500 (11200) 1120 48 20000 (12800) 1280 54 22500 (14400) 1440 60 25000 (16000) 1600

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EBU26501

YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY

Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha ATVs purchased from an authorized Yamaha ATV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, sub- ject to certain stated limitations.

THE PERIOD OF WARRANTY for Yamaha ATVs shall be six (6) months from the date of purchase.

DURING THE PERIOD OF WARRANTY any authorized Yamaha ATV dealer will, free of charge, repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the products warranty period. All parts replaced under warranty become property of Yamaha Motor Corp. U.S.A.

GENERAL EXCLUSIONS from this warranty shall include any failures caused by: a. Competition or racing use. b. Installation of parts or accessories that are not

qualitatively equivalent to genuine Yamaha parts. c. Abnormal strain, neglect, or abuse. d. Lack of proper maintenance. e. Accident or collision damage. f. Modification to original parts. g. Damage due to improper transportation.

SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance, such as spark plugs, oil, oil filter, air filter, and brake shoes.

THE CUSTOMERS RESPONSIBILITY under this war- ranty shall be to: 1. Operate and maintain the ATV as specified in the

appropriate owners manual; 2. Give notice to an authorized Yamaha ATV dealer

of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealers place of business.

WARRANTY TRANSFER: To transfer the warranty from the original purchaser to any subsequent pur- chaser(s), it is imperative that the machine be inspected and registered for warranty by an autho- rized Yamaha ATV dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. An inspection and registration fee will be charged for this service.

EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation, USA also warrants to the ultimate purchaser and each subsequent pur- chaser of each 2006 and later model Yamaha ATV covered by this warranty that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards

within the period listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty.

All Models Thirty (30) months from the original purchase date

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

YAMAHA MOTOR CORPORATION, U.S.A. P.O. Box 6555

Cypress, California 90630

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WARRANTY QUESTIONS AND ANSWERS

Q. What costs are my responsibility during the warranty period? A. The customers responsibility includes all costs of normal maintenance services,

non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes.

Q. What are some examples of abnormal strain, neglect, or abuse? A. These terms are general and overlap each other in areas. Specific examples include:

Running the machine out of oil, sustained high rpm, full-throttle, operating the machine with a broken or damaged part which causes another part to fail, damage or failure due to improper or careless transportation and or tie-down. If you have any specific questions on operation or maintenance, please contact your dealer for advice.

Q. Does the warranty cover incidental costs such as towing or transportation due to a failure?

A. No. The warranty is limited to repair of the machine itself.

Q. May I perform any or all of the recommended maintenance shown in the Owners Manual instead of having the dealer do them?

A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owners and Service Manual. We do recommend, however, that items requiring special tools or equipment be done by a Yamaha ATV dealer.

Q. Will the warranty be void or cancelled if I do not operate or maintain my new ATV exactly as specified in the Owners Manual?

A. No. The warranty on a new ATV cannot be voided or cancelled. However, if a particular failure is caused by operation or maintenance other than as described in the Owners Manual, that failure may not be covered under warranty.

Q. What responsibility does my dealer have under this warranty? A. Each Yamaha ATV dealer is expected to:

1. Completely set up every new machine before sale. 2. Explain the operation, maintenance, and warranty requirements to your satis-

faction at the time of sale, and upon your request at any later date. 3. Each Yamaha ATV dealer is held responsible for his setup, service and war-

ranty repair work.

Q. Is the warranty transferable to second owners? A. Yes. The remainder of the existing warranty can be transferred upon request. The

unit has to be inspected and re-registered by an authorized Yamaha ATV dealer for the policy to remain effective.

CUSTOMER SERVICE

If your machine requires warranty service, you must take it to any authorized Yamaha ATV dealer within the continental United States. Be sure to bring your warranty registration card or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write:

YAMAHA MOTOR CORPORATION U.S.A. CUSTOMER RELATIONS DEPARTMENT

P.O. Box 6555 Cypress, California 90630

When contacting Yamaha Motor Corporation, U.S.A. dont forget to include any important information such as names, addresses, model, V.I.N. (frame number), dates, and receipts.

CHANGE OF ADDRESS

The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related defect and recall. This list is compiled from the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase.

If you should move after you have purchased your new ATV, please advise us of your new address by sending a postcard listing your ATV model name, V.I.N. (frame number), dealer number (or dealers name) as it is shown on your warranty card, your name and new mailing address. Mail to:

YAMAHA MOTOR CORPORATION, U.S.A. P.O. Box 6555

Cypress, California 90630 Attention: Warranty Department

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

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EBU26123

YAMAHA EXTENDED SERVICE (Y.E.S.)

Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.).

Y.E.S. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get uninterrupted factory-backed coverage for extra peace of mind.

Y. E. S. is flexible. You choose the plan thats right for you: 12 months, 24 months, or 36 months beyond your warranty period.

Y.E.S. is designed and administered by the same Yamaha people who handle your warranty and i t shows in the comprehensive coverage benefits. There are no mileage l imitat ions. Coverage isn t l imited to moving par ts or the drive train l ike many other plans. And Y.E.S. covers manufacturing defects just l ike the warranty. See the sample contract at your Yamaha dealer to see how comfor t ing uninterrupted factory- backed protection can be.

You don t have to pay anything for covered repairs. There s no deduc t ib le to pay, and repa i rs a ren t pro-rated. You don t have any out-of-pocket expenses for covered repairs.

In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost. TRIP gives you up to $150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb coverage goes into effect when you purchase Y.E.S., so it applies to any warranty repairs as well as covered repairs during your entire Y.E.S. plan period.

Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide.

Y.E.S. coverage is transferable to a new owner if you sell or trade in your ATV. That can make your Yamaha much more valuable!

This excellent Y.E.S. plan coverage is only available to Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha Extended Service.

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We urge you to act now. Youll get the excellent benefits of TRIP coverage r ight away, and you l l rest easy knowing you l l have strong factory-backed protection even after your Yamaha Limited Warranty expires. You can also save money: Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today!

A special note: If visiting your dealer isnt convenient, contact Yamaha with your Pr imary ID number (your frame number). We l l be happy to help you get the Y.E.S. coverage you need.

Yamaha Service Marketing P.O. Box 6555 Cypress, CA 90630

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

WARNING

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EBU26132

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INDEX

A Accessories and loading ................................................ 6-8 Air filter element, cleaning ............................................ 8-20

B Battery ................................................................... 5-6, 8-38 Brake fluid, changing ................................................... 8-29 Brake fluid level, checking ........................................... 8-29 Brake lever free play, checking the front ...................... 8-30 Brake lever, front ............................................................ 4-4 Brake levers, checking and lubricating ........................ 8-35 Brake light switches ..................................................... 8-33 Brake pads and shoes, checking ................................. 8-27 Brake pedal and rear brake lever ................................... 4-5 Brake pedal, checking and lubricating ......................... 8-36 Brake pedal position, free play and

brake lever free play (rear), adjusting ........................ 8-30 Brakes .......................................................................... 8-27 Brakes, front and rear .................................................... 5-3

C Cables, checking and lubricating ................................. 8-35 Carburetor, adjusting ................................................... 8-25 Carrier, front ................................................................. 4-13 Carrier, rear .................................................................. 4-13 Chassis fasteners .......................................................... 5-6 Cleaning ......................................................................... 9-1 Clutch free play, adjusting ............................................ 8-34

D Drive select lever ........................................................... 4-7

Drive select lever and driving in reverse ........................ 6-3 Drive select lever safety system cable, adjusting ........ 8-27

E Engine break-in .............................................................. 6-6 Engine, cold start ........................................................... 6-1 Engine idling speed ..................................................... 8-25 Engine oil ....................................................................... 5-3 Engine oil and oil filter element .................................... 8-11 Engine, starting a warm ................................................. 6-3 Engine stop switch ......................................................... 4-2

F Final gear oil ......................................................... 5-3, 8-17 Fuel ......................................................................... 4-8, 5-3 Fuel cock ..................................................................... 4-10 Fuel tank cap ................................................................. 4-7 Fuse, replacing ............................................................ 8-42

H Handlebar switches ....................................................... 4-2 Headlight beam, adjusting ........................................... 8-44 Headlight bulb, replacing ............................................. 8-42

I Identification numbers .................................................. 11-1 Indicator lights ................................................................ 4-2 Instruments, lights and switches .................................... 5-6

K Key identification number ............................................ 11-1

L Label locations ............................................................... 1-1

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Light switch .................................................................... 4-3 M

Main switch .................................................................... 4-1 Maintenance and lubrication chart ................................. 8-5 Maintenance chart, emission control system ................. 8-3 Maintenance record ..................................................... 11-5 Model label ................................................................... 11-2

N Neutral indicator light .....................................................4-2 Noise regulation ........................................................... 11-4

O Owners manual and tool kit ........................................... 8-1

P Parking ........................................................................... 6-7 Parking brake ................................................................. 4-6 Parking on a slope ......................................................... 6-7 Part locations ................................................................. 3-1

R Recoil starter .................................................................. 4-7 Reverse indicator light .................................................... 4-2 Riding your ATV ............................................................. 7-1

S Safety information .......................................................... 2-1 Seat .............................................................................. 4-11 Shifting ........................................................................... 6-4 Shift pedal ...................................................................... 4-6 Shift pedal, checking .................................................... 8-36 Shock absorber assembly, adjusting the rear .............. 4-14 Spark arrester, cleaning ............................................... 8-23 Spark plug, checking ...................................................... 8-9 Specifications ............................................................... 10-1 Speed limiter .................................................................. 4-4

Starter (choke) ............................................................. 4-11 Start switch ..................................................................... 4-3 Steering shaft, lubricating ............................................. 8-37 Storage ........................................................................... 9-2 Storage compartment ................................................... 4-12 Swingarm pivots, lubricating ........................................ 8-37

T Tail/brake light bulb, replacing ..................................... 8-45 Throttle cable free play, adjusting ................................ 8-26 Throttle lever ...........................................................4-3, 5-4 Tires ............................................................................... 5-4 Troubleshooting ........................................................... 8-47 Troubleshooting chart .................................................. 8-48

V Valve clearance ............................................................ 8-27 Vehicle Emission Control Information label .................. 11-2 Vehicle identification number ....................................... 11-1

W Warranty, extended ...................................................... 11-8 Warranty, limited .......................................................... 11-6 Wheel hub bearings, checking ..................................... 8-37 Wheel, installing ........................................................... 8-46 Wheel, removing .......................................................... 8-45

U1P015E0.book Page 2 Friday, July 31, 2009 9:40 AM

U1P015E0.book Page 3 Friday, July 31, 2009 9:40 AM

YAMAHA MOTOR CO., LTD.

EBU26151

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

WARNING

ALWAYS: use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns. avoid paved surfaces-pavement may seriously affect handling and control.

Improper ATV use can result in SEVERE INJURY or DEATH.

NEVER operate: without proper training or instruction. at speeds too fast for your skills or the conditions. on public roads-a collision can occur with another vehicle. with a passenger-passengers affect balance and steering and increase risk of losing control.

ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR

NEVER USE ON PUBLIC

ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

B EE R

B EE R

PRINTED IN USA 2009.08-0.3

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