Yamaha RAPTOR YFM50RW, Owner'S Manual

Page 1: ...OWNER S MANUAL 5YF 28199 14 should not be ridden by anyone under 6 years of age YFM50RW READ THIS MANUAL CAREFULLY It contains important safety information ...

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Page 3: ...ch ATV It also includes basic maintenance and inspection proce g the operation or maintenance of your ATV please consult a H TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS RNING AND CAUTION LABELS ON THE ATV PROPER TRAINING OR INSTRUCTION FREE TRAINING IS A NEW ATV CALL 1 800 887 2887 FOR MORE INFORMA ER 50 cc SHOULD NOT BE OPERATED BY A CHILD UNDER child r...

Page 4: ...e only if they perate the ATV safely speed limiter Yamaha recommends that all beginners start off mit the amount of speed available while they learn The speed o increase maximum speed as the beginner becomes more fa ced he or she should take a training course See the previous available to purchasers of new ATVs ...

Page 5: ...s change without notice Alert Symbol means ATTENTION BECOME ALERT YOUR NVOLVED ollow WARNING instructions could result in severe injury the ATV operator a bystander or a person inspecting or e ATV indicates special precautions that must be taken to avoid he ATV vides key information to make procedures easier or clearer ...

Page 6: ...laws and regulations in gulations before operating this ATV YFM50RW OWNER S MANUAL 2006 by Yamaha Motor Corporation U S A 1st edition April 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 20 27 ...

Page 7: ...uel cock 4 11 Choke 4 12 Seat 4 13 PRE OPERATION CHECKS 5 1 Pre operation check list 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 Measuring the tire pressure 5 5 Tire wear limit 5 6 Chassis fasteners 5 7 Instruments lights and switches 5 7 Battery 5 7 OPERATION 6 1 Starting a cold engine 6 1 Starting a warm engine 6 3 Shifting 6 3 ...

Page 8: ...earance 8 20 Checking the front and rear brake shoes 8 21 Adjusting the front brake lever free play 8 22 Adjusting the rear brake lever free play 8 24 Checking and lubricating the cables 8 25 Checking and lubricating the front and rear brake levers 8 26 Checking the wheel bearings 8 26 Lubricating the knuckle shafts 8 26 Lubricating the steering shaft 8 27 Battery 8 27 Replacing the fuse 8 30 Remo...

Page 9: ... 9 2 10 1 11 1 11 1 11 3 11 3 11 5 11 7 ...

Page 10: ...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 we...

Page 11: ...ver 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...

Page 12: ...l Always maintain proper tire pressure as de scribed in this manual Never modify an ATV through improper installa tion or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow in structions in this manual for carrying cargo or pulling a trailer Allow greater distance for brak ing FOR MORE INFORMATION A...

Page 13: ...let that was included with your ATV when newly purchased You can also review the checklist on the Internet at www atvsafety org Re evaluate your child s readi ness before every use a child who is too tired or distracted should not be allowed to operate the ATV Be sure your child is properly trained Your child should take a certified training course like the ATV RiderCourse offered by the ATV Safet...

Page 14: ...d of the engine stop switch cord under the engine shut off switch black button 2 Put your fingers in the loop at the other end of the cord 3 As your child is riding walk behind the ATV closely watching his or her actions as well as the path ahead 4 If there is a potential hazard ahead or if your child is not riding correctly pull firmly on the cord to stop the engine Because the ATV will continue ...

Page 15: ...ition such as the pilot lights of water heat ers and clothes dryers When transporting the ATV in another vehi cle be sure it is kept upright and that the fuel cock is in the OFF position Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause inju ries HOW TO AVOID THE HAZARD If you should swallow some gasoline or in hale a lot of gasoline vap...

Page 16: ...1 7 ed ar may h with HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad equate ventilation ...

Page 17: ...2 1 1 2 3 4 5 6 7 8 9 10 11 RNING AND SPECIFICATION LABELS ...

Page 18: ...2 2 ur ATV These labels contain important information for safe and a label becomes difficult to read or comes off request a replace ...

Page 19: ...ast 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 ALWA YS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and it turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLL...

Page 20: ... 4 INGCAN RE old 2 2 9 psi 2 2 9 psi 2 2 5 psi 2 2 5 psi m ories q WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 5FE 2151H 01 5FE 2151H 01 4 ...

Page 21: ...3 1 1 2 3 4 5 6 7 8 9 10 11 DESCRIPTION EBU17700 Right view 1 Spark arrester 2 Seat 3 Footboard 1 2 3 ...

Page 22: ...3 2 slightly from the figures shown in this manual 4 ...

Page 23: ...4 1 1 2 3 4 5 6 7 8 9 10 11 AND CONTROL FUNCTIONS esult in lows wer and ot be re n be re 1 Main switch OFF ON 1 ...

Page 24: ... RUN before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run when this switch is set to OFF 1 Engine stop switch ENG STOP 2 Start switch START 1 2 ...

Page 25: ...4 3 1 2 3 4 5 6 7 8 9 10 11 he start 1 prior ne stop The lanyard should be held by putting your fingers in the loop as shown 1 Engine stop switch 2 Clip 3 Lanyard 3 1 2 ...

Page 26: ...SAFETY INFORMATION section NOTE The engine cannot be started with the clip re moved When your child has developed sufficient skill to no longer need you to follow with the lanyard the lanyard can be stowed under the seat of the ATV However you must still closely supervise your child at all times during ATV operation 1 1 Lanyard 1 ...

Page 27: ...ps the throttle from fully opening even when the throttle lever is pushed to the maximum The adjusting screw may be gradu WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever be fore you start ...

Page 28: ...ake pull the brake lever toward the handlebar grip WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Im proper throttle operation could result The child could lose control have an accident or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in ...

Page 29: ...ng brake Use the parking brake before starting the engine or parking the ATV especially on a slope Apply the rear brake lever and push down the lock plate to apply the parking brake Squeeze the rear brake lever to release the parking brake 1 Rear brake lever 1 ...

Page 30: ...rake is not applied before start ing the engine This could cause loss of con trol or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine Always be sure you have releas...

Page 31: ...4 9 1 2 3 4 5 6 7 8 9 10 11 counter EBU18730 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Fuel tank cap 1 ...

Page 32: ...soline or premi um unleaded fuel Unleaded fuel will give you long er spark plug life and reduced maintenance cost 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 Gasohol containing methanol is not recommended by Yamaha be cause it can cause damage to the fuel system or ...

Page 33: ...F 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 nd se he fuel due to not to xhaust diately curely s been 1 Arrow mark positioned over OFF RES ON FUEL OFF 1 ...

Page 34: ...rn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18860 Choke The choke is used to start a cold engine Move the choke in direction a to turn on the choke 1 Arrow mark positioned over RES OFF ON FUEL RES RES 1 ...

Page 35: ...10 11 off the on page the seat To install the seat Insert the projection on the front of the seat into the seat holder and push down on the seat at the rear NOTE Make sure that the seat is securely fitted 1 Seat lock lever 1 ...

Page 36: ...4 14 esult in ...

Page 37: ... fuel if neces leakage Correct if necessary 4 9 5 3 engine and add recommended oil to specified eakage Correct if necessary 5 3 8 10 eakage Correct if necessary 5 3 8 13 and correct if necessary necessary lay and adjust if necessary 5 3 8 21 8 22 and correct if necessary necessary lay and adjust if necessary 5 3 8 21 8 24 eration is smooth Lubricate cable and lever hous play and adjust if necessar...

Page 38: ...ubricate lever pivoting points 8 26 nuts bolts and screws are properly tightened 5 7 nd correct if necessary 5 7 evel Fill with distilled water if necessary 5 7 8 27 WARNING ating t or equipment damage u use it to make sure it is in safe operating condition tenance procedures and schedules described in the Own ROUTINE PAGE ...

Page 39: ...ay is incorrect adjust it See pages 8 22 and 8 24 Check operation of the levers They should move smoothly and there should be a firm feel ing when the brake is applied If not have the ATV checked by a Yamaha dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance check the brakes for wear...

Page 40: ...sure WHAT CAN HAPPEN Use of improper tires on this ATV or opera tion of this ATV with improper or uneven tire pressure may cause loss of control increas ing your risk of accident HOW TO AVOID THE HAZARD The tires listed below have been approved by Yamaha Motor Co Ltd for this model Other tire combinations are not recom mended Front Manufacturer model DUNLOP KT145 Size AT16 x 7 7 Type Tubeless ...

Page 41: ...ssure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 17 0 kPa 2 5 psi 0 170 kgf cm2 Rear 17 0 kPa 2 5 psi 0 170 kgf cm2 Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 36 psi 2 5 kgf cm2 Rear 250 kPa 36 psi 2 5 kgf cm2 Higher pressures and fast inf...

Page 42: ...e tire when the tire groove decreases to 3 mm 0 12 in Recommended pressure Front 20 0 kPa 2 9 psi 0 200 kgf cm2 Rear 20 0 kPa 2 9 psi 0 200 kgf cm2 Minimum Front 17 0 kPa 2 5 psi 0 170 kgf cm2 Rear 17 0 kPa 2 5 psi 0 170 kgf cm2 Maximum Front 23 0 kPa 3 3 psi 0 230 kgf cm2 Rear 23 0 kPa 3 3 psi 0 230 kgf cm2 ...

Page 43: ...5 7 1 2 3 4 5 6 7 8 9 10 11 re prop ches are distilled ...

Page 44: ... ON and the engine stop switch to RUN 4 Shift the transmission into neutral The neutral indicator light should come on If the indicator with all acci here is stand WARNING POTENTIAL HAZARD Frozen control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all ...

Page 45: ...r and start the engine by pushing the start switch NOTE 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 energy Do not 1 Fully open ON 2 Half open warming up position 3 Closed OFF 4 Choke ON O F F 0 30 10 20 30 50 70 90 F C 4 1 1 3 3 2 ...

Page 46: ... lever and apply the parking brake To shift into neutral stop the ATV by releasing the throttle lever and applying the brakes smoothly and evenly EBU20620 To start out and accelerate 1 Release the throttle lever CAUTION ECB00210 Always close the throttle before shifting the transmission into drive otherwise damage to the engine and drive train may result 2 Apply the parking brake See page 6 5 3 Sh...

Page 47: ...ON 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 WARNING POTENTIAL HAZARD Opening the throttle before releasing the parking brake WHAT CAN HAPPEN The ATV could wheelie This would increase the chance of an a...

Page 48: ... be operated normally CAUTION ECB00220 If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the ATV EBU26770 Parking When parking the ATV stop the engine shift the drive select lever into the drive position apply the parking brake and then turn the fuel cock to OFF 1 Parking brake lock plate 1 ...

Page 49: ...e brake lever easing HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the ATV trans versely across the incline shift the shift lever to the drive position stop the engine apply the parking brake and then block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them ea...

Page 50: ...ntrol the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that 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 EBU20950 Loading As originally equipped this ...

Page 51: ...WB00010 Indicates a potential hazard that could result in serious injury or death cargo WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce s...

Page 52: ...7 1 DING YOUR ATV ...

Page 53: ...ing labels on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified in structor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until you are totally familiar with the ATV s handling and performance characteristics ...

Page 54: ...ed in mation autho WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not recom mended for their age can lead to severe inju ry or death of the child HOW TO AVOID THE HAZARD A child under 6 should never operate an ATV with engine size greater than 50 cc ...

Page 55: ...4 5 6 7 8 9 10 11 r only ce and cident assen HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying pas sengers ...

Page 56: ...in the HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants 1 Protective clothing 2 Goggles 3 Gloves 4 Boots 5 Helmet ...

Page 57: ...ol or drugs before or while driving this ATV WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and mainte nance proce...

Page 58: ...urning in the adjusting screw decreases top speed and turning it out increases top speed See page 4 5 Yamaha recommends that all beginning riders start off with the speed limiter turned in to limit the es or opera en tire creas cified page as de 5 5 WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing cont...

Page 59: ... carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own er s Manua...

Page 60: ...from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident includ ing an overturn HOW TO AVO...

Page 61: ...ians or children are not likely to touch it difica r mod ges in ld lead HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV...

Page 62: ...an cause loss of control EWB01020 e ma e area m dur in dry grass others WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect han dling and control of the ATV and may cause the ATV to go out of control ...

Page 63: ...rating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways ...

Page 64: ... out of perat lert to rating WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Could cause loss of traction or ATV control which could result in an accident including an overturn ...

Page 65: ...ial WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be in jured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch carefully for other vehicles ...

Page 66: ... control Avoid higher speeds un til you are thoroughly familiar with the operation of your ATV When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly Im proper use of the brakes can cause the tires to lose traction reducing control and increasing the possi bility of an accident TURNING YOUR ATV To achieve maximum traction while riding off road the two rear whe...

Page 67: ...ue to go straight If the ATV doesn t turn come to a stop and then practice the proce dure again If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter sing a urning Prac mpting urn at condi 1 Lean towards inside of ...

Page 68: ...teeper inclines standing on the footboards and leaning forward over the handlebars EWB01180 WHAT CAN HAPPEN The ATV can overturn more easily on ex tremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills WARNING POTENTIAL HAZARD Climbing hills ...

Page 69: ... 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 climb anual re you pery or e ATV t high nother er side OK ...

Page 70: ... continue up the hill dismount the ATV on the up hill side Physically turn the ATV around and then descend the hill If you start to roll backwards DO NOT apply the rear brake to stop or try to put the ATV in gear The ATV could easily tip over backwards Instead ap ply the front brake gradually or dismount the ATV immediately on the uphill side hills e ATV n any tech ual on urning f pos s de loose o...

Page 71: ...llow the engine compression to do most of the braking for you Improper braking may cause a loss of traction Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of traction Whenever possible ride your ATV straight down rly dis g a hill ou are rolling brake ake ointed and r...

Page 72: ...ng 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 e ATV going s Man when re you e that o one pos...

Page 73: ...w water of up to a maximum of 20 cm 8 in in depth Before entering the water choose your path n hills he ATV on any g tech ual on urning a steep When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV OK ...

Page 74: ...off may be d care Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability r fast n and acci water n your ve re es af them he lin ...

Page 75: ...rrain 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 1 Air filter case check hose 1 ...

Page 76: ...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 on or ob acles n you r pro anual ...

Page 77: ...weight on the footboard to the outside of the turn Position your weight over the front wheels for better control See page 7 15 If your ATV begins to tip while turning WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on lev...

Page 78: ...ow 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 22 WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death ...

Page 79: ... to put this owner s manual in the plastic bag and to always carry it as well as the owner s tool kit and the low pressure tire gauge in their re spective compartments under the seat arts of cks or HOW TO AVOID THE HAZARD Turn off the engine when performing mainte nance unless otherwise specified Have a Yamaha dealer perform the service if you are not familiar with maintenance work ...

Page 80: ... this ATV may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consul...

Page 81: ...e month maintenance e performed by a Yamaha dealer as they require special tools TENANCE 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 s for cracks or other damage and ary and clean regap or replace if rance and adjust if necessary eration and correct if necessary ing speed and adjust if neces hose for cracks or o...

Page 82: ...and replace gasket s if neces ess and tighten all screw clamps ssary TENANCE 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 ...

Page 83: ... if necessary Every 20 40 hours more often in wet or dusty areas and correct if necessary er free play and adjust if neces hoes Whenever worn to the limit and correct if necessary er free play and adjust if neces hoes Whenever worn to the limit d for damage and replace if nec h and for damage and replace if re and balance and correct if ess or damage and replace if hium soap based grease ...

Page 84: ... replace if damaged adjust if necessary leakage and correct if neces leakage and correct if neces and correct if necessary ble free play and adjust if neces lever housing and cable and correct if necessary TENANCE 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 ...

Page 85: ...ding in unusually wet or dusty areas e level and specific gravity and ary he breather hose is properly TENANCE 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 ...

Page 86: ...8 8 esult in ponent eposits e spark accor ubrica e spark 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit 1 Spark plug cap 1 ...

Page 87: ... replace it if necessary To install the spark plug 1 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification 2 Clean the surface of the spark plug gasket 1 Specified spark plug NGK CR7HSA Spark plug gap 0 6 0 7 mm 0 024 0 028 in 1 Spark plug gap ...

Page 88: ...l min utes and then turn it off 3 Wait a few minutes until the oil settles before checking 4 Remove the engine oil filler cap and then wipe the dipstick off with a clean rag 5 Insert the dipstick into the filler hole without screwing it in and then remove it again to check the oil level 1 Engine oil filler cap 2 Dipstick 1 2 ...

Page 89: ...e 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 5 Check the O ring for damage and replace it if necessary 6 Install the engine oil drain bolt and then tight 1 2 1 Engine oil drain bolt 1 ...

Page 90: ... oils oils of ddition SERV ers the several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 9 Turn the engine off and then check the oil lev el and correct it if necessary ...

Page 91: ...ller hole and then tighten the oil filler cap To change the final gear oil 1 Place the ATV on a level surface 2 Place an oil pan under the final gear case to collect the used oil 3 Remove the final gear oil filler cap and the fi nal gear oil drain bolt to drain the oil from the final gear case 1 Final gear oil filler cap 2 Dipstick 3 Maximum level mark 4 Minimum level mark 2 3 4 1 ...

Page 92: ...he air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean the air filter element more frequently if you are riding in unusually wet or dusty areas NOTE There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air fil R...

Page 93: ...8 15 1 2 3 4 5 6 7 8 9 10 11 ving the 1 Panel 2 Bolt 1 2 2 ...

Page 94: ...pull out the sponge material from the air filter element 4 Wash the sponge material gently but thor oughly in solvent EWB01900 2 1 Air filter element holder 2 Sponge material WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material 1 2 ...

Page 95: ... is performed check the air inlet of the air filter case for obstructions CAUTION ECB00460 Make sure that the air filter element is prop erly seated in the air filter case Never operate the engine with the air filter el ement removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Addition ally operation without the air filter element will af...

Page 96: ...4 Insert the tailpipe into the muffler and align the screw holes 5 Install the screws and tighten them EWB01910 1 Tailpipe 2 Spark arrester 3 Screw WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system 2 1 3 ...

Page 97: ...EBU24000 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica tion chart NOTE A diagnostic tachometer is needed to make this adjustment 1 Start the engine and warm it up NOTE The engine is warm when it quickly responds to the throttle 2 Attach the tachometer to the spark plu...

Page 98: ...dic maintenance and lubrication chart The throttle cable free play should measure 1 0 3 0 mm 0 04 0 12 in at the throttle lever Period ically check the throttle cable free play and if nec essary have a Yamaha dealer adjust it EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To 1 Throttle lever free play 1 ...

Page 99: ...8 21 1 2 3 4 5 6 7 8 9 10 11 earance he inter and lu e checked periodic brake is s you to g to dis ke shoe or while rn to the ear limit ace the Front brake 1 Wear limit line 2 Wear indicator 1 2 ...

Page 100: ... the free play is incorrect adjust it as follows 1 Loosen the upper locknut and fully turn in the upper adjusting bolt 2 Loosen the lower locknut 3 Turn the lower adjusting bolt in direction a to increase the free play and in direction b to decrease it 1 Brake lever free play 1 ...

Page 101: ...8 23 1 2 3 4 5 6 7 8 9 10 11 t the up ower ca oint will 6 Tighten the upper locknut a a 1 Cable joint 1 ...

Page 102: ... the brake lever free play adjusting bolt at the brake lever in direction a to increase the free play and in direction b to decrease it 3 Tighten the locknut at the brake lever If the specified free play cannot be obtained proceed with the following steps 4 Loosen the locknut at the brake lever or ad could oothly quires dures ler 1 Brake lever free play 2 Locknut 3 Brake lever free play adjusting ...

Page 103: ...essary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag ...

Page 104: ... a wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EBU25070 Lubricating the knuckle shafts The knuckle shafts must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart Lubricate the knuckle shafts using a grease gun eaths so be estrict n acci maged Recommended lubricant Lithium soap based grease all purpose grease Recommended lubri...

Page 105: ...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 To check the electrolyte level 1 Place the ATV on a level surface 2 Check the electrolyte level in the battery 1 Grease nipple 1 ...

Page 106: ...ries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Al ways shield eyes when working near batter ies Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical at tention EYES Flush with water for 15 minutes and get prompt medi...

Page 107: ...o months check the specific gravity of the elec trolyte at least once a month and fully charge the battery whenever necessary To install the battery NOTE Be sure the battery is fully charged 1 Install the battery 2 Connect the positive lead first and then con nect the negative lead 3 Make sure that the breather hose is properly routed in good condition and not obstructed 3 ...

Page 108: ...located under the seat See page 4 13 If the fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical circuits CAUTION ECB00640 To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 1 Fuse 2 Spare fuse 1 2 ...

Page 109: ...8 31 1 2 3 4 5 6 7 8 9 10 11 nstall a lectrical e have a ystem Front to the a fire rating proper 1 Wheel nut 1 1 ...

Page 110: ...8 32 e stand s arrow n of the wheel Front 1 Arrow mark 1 ...

Page 111: ...ss 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 ar...

Page 112: ...8 34 ng or ere in l sys mes or s from ...

Page 113: ...e off with a dry cloth and correct the ark plug gap or replace the spark plug ve 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 over over The battery is good Check the electrolyte level recharge the battery and check the lead connections Open the throttle halfway and operate the electric starter ...

Page 114: ... 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 ti...

Page 115: ...uel 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 ...

Page 116: ...9 3 es with der wall e spark ug and pivoting tire air so that rnative n order graded bag to t Store once a exces C 30 more in e page ing the ATV ...

Page 117: ...lectric starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 SAE5W30 or SAE10W30 or SAE20W40 Recommended engine oil grade API service SE SF SG type or higher 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 ...

Page 118: ...duction system Shaft drive Secondary reduction ratio 19 18 34 10 3 588 Transmission type Constant mesh 1 speed Operation Left hand operation 1st 38 14 2 714 Chassis Frame type Steel tube frame Caster angle 1 0 Trail 3 4 mm 0 13 in Front tire Type Tubeless Size AT16 x 7 7 Manufacturer model DUNLOP KT145 ...

Page 119: ...e Drum brake Operation Right hand operation Rear brake Type Drum brake Operation Left hand operation Front suspension Type Leading arm Spring shock absorber type Coil spring oil damper Wheel travel 57 mm 2 3 in Rear suspension Type Swingarm Spring shock absorber type Coil spring oil damper Wheel travel 56 mm 2 2 in ...

Page 120: ...10 4 ...

Page 121: ... 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 1 ...

Page 122: ...11 2 o identi n the il abel in e need ha deal 1 Model label 1 ...

Page 123: ... to the 2 the use of the vehicle after such device or element of design e by any person CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW owing systems i e modification removal etc arts you purchase and install will be required to document main anty The chart below is printed only as a reminder to you that the eptable proof of maintenance work haust system uffler haust pipe encer ake system r cleaner...

Page 124: ...11 4 MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS ...

Page 125: ...ns standards e at the time of manufacture and that it is m defects in materials and workmanship uld 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 fro...

Page 126: ...55 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model V I N frame number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and re...

Page 127: ...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 Thi...

Page 128: ...11 8 enefits of knowing after your lso save after you maha with We ll be Indicates a potential hazard that could result in serious injury or death WARNING ...

Page 129: ...11 9 1 2 3 4 5 6 7 8 9 10 11 ...

Page 130: ...9 5 3 Fuel cock 4 11 Fuel tank cap 4 9 Fuse replacing 8 30 H Handlebar switches 4 2 I Identification numbers 11 1 Indicator light 4 2 Instruments lights and switches 5 7 K Key identification number 11 1 Knuckle shafts lubricating 8 26 L Label locations 2 1 M Main switch 4 1 Maintenance and lubrication chart 8 5 Maintenance chart emission control system 8 3 Maintenance record 11 3 Model label 11 2 ...

Page 131: ...8 8 10 1 4 5 4 3 8 27 9 2 8 20 4 5 5 4 5 5 5 4 5 6 8 33 Troubleshooting chart 8 35 V Valve clearance 8 20 Vehicle identification number 11 1 W Warranty extended 11 7 Warranty limited 11 5 Wheel bearings checking 8 26 Wheel installing 8 32 Wheel removing 8 31 ...

Page 132: ...558 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 n result in SEVERE INJURY or DEATH on the cur with t risk SE LIC S NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL B E E R B E E R ...

Page 133: ...E AN ATV WITH ENGINE SIZE GREATER THAN 90CC 8 TAKE THE FREE HANDS ON TRAINING COURSE OFFERED BY YAMAHA ASK YOUR DEALER FOR DETAILS OR CALL 1 800 887 2887 If you have any questions about these points or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership please fill out the information below and mail this card...

Page 134: ...ED IN THE UNITED STATES FIRST CLASS PERMIT NO 4 CYPRESS CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U S A P O BOX 6555 CYPRESS CALIFORNIA 90630 9989 ATTN SALES ADMINISTRATION ATV card for US 4 2 03 9 06 AM Page 2 ...