Yamaha RAPTOR YFM80RW, Owner'S Manual

Page 1: ...OWNER S MANUAL 5TH 28199 16 hould not be ridden by anyone under 12 years of age YFM80RW 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 70 cc SHOULD NOT BE OPERATED BY A CHILD UNDER child r...

Page 4: ...e restrictor available while they learn The limiter screw may be gradually he beginner becomes more familiar with operating the ATV Par for more power as their youngster s riding skills improve Once op speed permitted by adjusting the speed limiter alone the air e removal of this plate will result in a significant increase in pow ust it out in stages as you did before ced he or she should take a t...

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 YFM80RW OWNER S MANUAL 2006 by Yamaha Motor Corporation U S A 1st edition March 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 14 ...

Page 7: ...hoke 4 11 Seat 4 12 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 Engine break in 6 5 ...

Page 8: ...clearance 8 21 Checking the front and rear brake shoes 8 21 Adjusting the front brake lever free play 8 22 Adjusting the rear brake lever and brake pedal free play 8 24 Adjusting the clutch free play 8 27 Checking and lubricating the cables 8 28 Checking and lubricating the front and rear brake levers 8 28 Checking and lubricating the brake and shift pedals 8 29 Checking the wheel bearings 8 29 Lu...

Page 9: ... 8 36 9 1 9 1 9 2 10 1 11 1 11 1 11 3 11 4 11 5 11 7 ...

Page 10: ...d 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 ey...

Page 11: ...igh 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 procedu...

Page 12: ...ough improper installa tion or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow in structions in this manual for carrying cargo or pulling a trailer Allow greater distance for brak ing FOR MORE INFORMATION ABOUT ATV SAFE TY call the Consumer Products Safety Commis sion at 1 800 638 2772 or the ATV...

Page 13: ...1 4 1 2 3 4 5 6 7 8 9 10 11 ling s been or ex vicinity ces of r heat r vehi he fuel se fuel ank e inju or in me gas help r skin spills ...

Page 14: ...1 5 ed ar may h with th ad ...

Page 15: ...2 1 1 2 3 4 5 6 7 8 9 10 11 RNING AND SPECIFICATION LABELS ...

Page 16: ...PROTECTIVE GEAR 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 proper riding techniques to avoid vehicle overturns on hills and rough terrain and it turns avoid paved surfaces pav...

Page 17: ... 5 6 7 8 9 10 11 DINGCAN ERE cold m2 2 9 psi m2 2 9 psi m2 2 5 psi m2 2 5 psi rim ssories WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 5FE 2151H 01 4 ...

Page 18: ...3 1 DESCRIPTION EBU17700 Right view 1 Spark arrester 2 Seat 3 Brake pedal 4 Footrest 2 1 4 3 ...

Page 19: ...3 2 1 2 3 4 5 6 7 8 9 10 11 slightly from the figures shown in this manual 4 ...

Page 20: ...4 1 AND CONTROL FUNCTIONS esult in ows er and t be re be re 1 Main switch OFF ON 1 ...

Page 21: ...is switch to RUN before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run when this switch is set to OFF 1 Engine stop switch ENG STOP 2 Start switch START 1 2 ...

Page 22: ...t is operating smoothly Make sure it returns to the idle position as soon as the lever is released EWB00200 1 Throttle lever 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 1 ...

Page 23: ...again adjust it out in stages as done previously 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 NOTE Adjusting for maximum throttle lever movement without removing the air intake res...

Page 24: ... the brake lever toward the handlebar grip 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 er and d Im t The ent or HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 20 mm 0 8 in 1 Front brake lever 1 ...

Page 25: ...g 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 1 Rear brake lever 1 ...

Page 26: ...ng brake is not applied before start ing the engine This could cause loss of con trol or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine Always be sure you have re...

Page 27: ...4 8 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 28: ...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 29: ...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 30: ...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 31: ... 10 11 off the page 6 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 32: ...4 13 esult in ...

Page 33: ...el if neces leakage Correct if necessary 4 8 5 3 engine and add recommended oil to specified eakage Correct if necessary 5 3 8 10 eakage Correct if necessary 5 3 8 12 and correct if necessary necessary lay and adjust if necessary 5 3 8 21 8 22 and correct if necessary necessary edal free play and adjust if necessary 5 3 8 21 8 24 eration is smooth and check cable free play d lever housing if neces...

Page 34: ...nts 8 29 eration is smooth Lubricate lever pivoting points 8 28 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 30 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 35: ...ay is incorrect ad just it See pages 8 22 and 8 24 Check operation of the brake levers and brake pedal They should move smoothly and there should be a firm feeling when the brakes are ap plied If not have the ATV checked by a Yamaha dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance ...

Page 36: ...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 KT586 Size AT18 x 7 7 Type Tubeless ...

Page 37: ...ssure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 17 kPa 2 5 psi 0 17 kgf cm2 Rear 17 kPa 2 5 psi 0 17 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 inflation...

Page 38: ...eplace the tire when the tire groove decreases to 3 mm 0 12 in Recommended pressure Front 20 kPa 2 9 psi 0 20 kgf cm2 Rear 20 kPa 2 9 psi 0 20 kgf cm2 Minimum Front 17 kPa 2 5 psi 0 17 kgf cm2 Rear 17 kPa 2 5 psi 0 17 kgf cm2 Maximum Front 23 kPa 3 3 psi 0 23 kgf cm2 Rear 23 kPa 3 3 psi 0 23 kgf cm2 ...

Page 39: ...5 7 1 2 3 4 5 6 7 8 9 10 11 re prop ches are distilled ...

Page 40: ... 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 41: ... 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 42: ...ard transmission with a centrifugal automatic clutch The transmission allows you to control the amount of power you have available at a given speed or for starting ac celerating climbing etc To shift into neutral return the throttle lever to the closed position and repeatedly depress the shift pedal until it stops 1 Shift pedal 2 Neutral position 3 2 1 1 N 2 ...

Page 43: ...es to lose traction reducing con trol and increasing the possibility of an accident EWB00650 ng the crease over HOW TO AVOID THE HAZARD Release the shift pedal before opening the throttle Open the throttle gradually WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating and lose trac tion This could cause loss of control an a...

Page 44: ... 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine through the gears freely but do not use full throttle at any time 20 hours and beyond The ATV can now be operated normally CAUTION ECB00220 If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the ATV EBU20721 Parking When parking the ATV stop the engine shift into first gea...

Page 45: ... Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the ATV trans versely across the incline shift into first gear stop the engine apply the parking brake and then block the front and rear wheels with rocks or other objects Do ...

Page 46: ...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 EBU20930 Loading As originally equipped this ...

Page 47: ...n Choose terrain carefully Added weight affects the stability and handling of the ATV EWB00750 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 atta...

Page 48: ...6 9 esult in ...

Page 49: ...7 1 1 2 3 4 5 6 7 8 9 10 11 DING YOUR ATV ...

Page 50: ...me familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until you are totally familiar with the ATV s handling and performance characteristics EWB01280 WARNING POTENTIAL HAZARD Operating this ATV without proper instruc tion WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how ...

Page 51: ...2 years This ATV is designed to carry operator only passengers prohibited erators course n regu course bed in mation autho 7 ations ecom e inju HOW TO AVOID THE HAZARD A child under 12 should never operate an ATV with engine size greater than 70 cc ...

Page 52: ...7 4 Apparel EWB00920 e and ident ssen t is to eeded g pas WARNING POTENTIAL HAZARD Operating this ATV without wearing an ap proved motorcycle helmet eye protection and protective clothing ...

Page 53: ...e after consuming alcohol or drugs The operator s performance capability is reduced by the influence of alcohol or drugs rcycle severe n acci result nces of dent ng in in the helmet ld 1 Protective clothing 2 Goggles 3 Gloves 4 Boots 5 Helmet ...

Page 54: ...ing Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and mainte nance procedures and schedules described in the Owner s Manual WARNING POTENTIAL HAZARD Operating this ATV with improper ...

Page 55: ...air intake restrictor plate to limit the amount of engine power available Yamaha recommends that all beginning riders start off with the speed limiter turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn The limiter may be gradually adjusted to increase maximum speed as the beginner becomes more familiar with oper ating the ATV Parents sho...

Page 56: ...r cargo The ATV s handling may be adversely affected Re duce your speed when adding additional loads EWB00970 MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and tongue 95 0 kg 209 lb 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 ...

Page 57: ...7 9 1 2 3 4 5 6 7 8 9 10 11 uring op he rear ity for nd se or pull r brak r Own lling a ...

Page 58: ...duce cause of the board t with ou or ebars r ATV other WHAT CAN HAPPEN Increases the chance of an accident includ ing an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off ...

Page 59: ...or other combustible ma terial accumulated around the engine area could catch fire Someone touching the exhaust system dur ing or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exhaust system Do not park the ATV in a pla...

Page 60: ... on any public road street or highway Riding on public roads can result in collisions with other vehicles only han cause HOW TO AVOID THE HAZARD Always avoid paved surfaces including side walks driveways parking lots and streets ...

Page 61: ...et one In TVs on WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operat ing on unfamiliar terrain Always be alert to changing terrain condit...

Page 62: ...TV DO NOT use the flag pole bracket as a trailer hitch ng on rrain ontrol uding HOW TO AVOID THE HAZARD Do not operate on excessively rough slip pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especial ly cautious on these kinds of terrain ...

Page 63: ...ol of the throttle brakes shifting procedures and turning techniques in this area before trying more difficult terrain Always avoid riding on paved surfaces the ATV is designed for off road use only and handling maneuvers are more difficult to perform on pavement Set the parking brake and follow the instruction on page 6 1 to start the engine Once it has warmed up you are ready to begin riding you...

Page 64: ...to lose traction reducing con trol and increasing the possibility of an accident EWB01070 TURNING YOUR ATV To achieve maximum traction while riding off road the two rear wheels are mounted solidly on one axle and turn together at the same speed There fore unless the wheel on the inside of the turn is al WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPE...

Page 65: ...es in a large off road area with no obsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the proce dure again If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on the seat sing a urning Prac mpting urn at condi 1 Lean towards inside of t...

Page 66: ...nd on steeper inclines standing on the footboards and leaning forward over the handlebars EWB01100 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...

Page 67: ...u 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 make ld flip t high nother er side OK ...

Page 68: ... 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 69: ...traight Choose a low gear which will allow the en gine compression to do most of the braking for you Improper braking may cause a loss of trac tion Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of traction rly dis steady ou are rolling brake ake ointed and re bed in...

Page 70: ...ding 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 p...

Page 71: ...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 72: ...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 73: ...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 74: ...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 75: ...ou 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 16 WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On...

Page 76: ...ters 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 23 WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death ...

Page 77: ... 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 78: ... 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 79: ...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 80: ...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 81: ... Every 20 40 hours more often in wet or dusty areas and adjust if necessary and correct if necessary er free play and adjust if neces hoes Whenever worn to the limit and correct if necessary er and pedal free play and adjust 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 grea...

Page 82: ...place if damaged adjust if necessary leakage and correct if neces leakage and correct if neces and correct if necessary ble free play and have a Yamaha cessary 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 83: ...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 84: ...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 85: ... In TV erosion sits and 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 1 Specified spark plug NGK CR7HSA Spark plug gap 0 6 0 7 mm 0 024 0 028 in 1 Spark plug gap ...

Page 86: ... surface 2 Start the engine warm it up for several 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 Dipstick 1 ...

Page 87: ... 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 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 88: ...ach ride If any leakage is found have a Yamaha dealer check and repair the ATV In ad dition the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface NOTE The final gear oil level must be checked on a cold engine 2 Remove the final gear oil...

Page 89: ...l 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 4 Install the drain bolt and then tighten it to the specified torque 5 Add the specified amount of the recommend 1 Final gear oil drain bolt Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 16 6 ft lbf 1 ...

Page 90: ...8 14 level e final ge If oil the in ce and nt more or dusty air filter empty d air fil ter case 1 Remove the panel shown by removing the bolts 1 Air filter case check hose 1 ...

Page 91: ...1 2 3 4 5 6 7 8 9 10 11 hooking 3 Unhook the holder holding the air filter ele ment and then pull out the sponge material from the air filter element 2 1 Air filter case cover 2 Air filter case holder 2 2 1 ...

Page 92: ...am air filter oil to the sponge material NOTE The sponge material should be wet but not drip ping 8 Install the sponge material into the air filter el ement 9 Place the air filter element in the original posi tion and then hook the holder 10 Install the air filter case cover by hooking the holders onto the air filter case 11 Install the panel by installing the bolts ine to e can 2 HOW TO AVOID THE...

Page 93: ...e air intake restrictor plate NOTE Store the air intake restrictor plate with the owner s manual so that it is readily available whenever you want to reduce the top speed 3 Install the air filter element EBU23891 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the screws 1 Air intake restrictor plate 1 ...

Page 94: ...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 95: ...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 96: ...odic 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 EBU24050 Timing chain The timing chain stretches with use resulting in im proper valve timing and engine noise To prevent 1 Throttle lever free play 1 ...

Page 97: ... ensioner he inter and lu ulting in oise To 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 brake shoes as a set Front brake 1 Wear limit line 2 Wear indicator 1 2 ...

Page 98: ... 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 99: ...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 100: ...for wear Adjusting the brake lever free play The brake lever free play should measure 5 0 8 0 mm 0 20 0 31 in as shown If the free play is in correct adjust it as follows 1 Loosen the locknut at the brake lever 2 Turn the brake lever free play adjusting bolt at or ad could oothly quires dures ler 1 Locknut 2 Brake lever free play adjusting bolt 3 Brake lever free play 3 1 2 a b ...

Page 101: ... the rear brake does not operate correctly have a Yamaha dealer check the internal rear brake mechanism When adjusting the rear brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move Adjusting the brake pedal free play The brake pedal free play should measure 20 0 30 0 mm 0 79 1 18 in as shown If the free play is incorrect adjust it as follows ...

Page 102: ...o to de EWB02020 1 1 Brake pedal free play adjusting nut 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 1 a b ...

Page 103: ...ecreases clutch free play and turning it out increases clutch free play 4 Tighten the locknut to the specified torque NOTE When tightening the locknut hold the adjusting oothly quires edures aler 1 Rubber cap 2 Locknut 3 Adjusting bolt Tightening torque Locknut 8 Nm 0 8 m kgf 5 8 ft lbf 1 2 3 ...

Page 104: ... The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if necessary Front brake lever eaths so be estrict n acci HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Recommended lubricant Lithium soap based grease all purpose grease ...

Page 105: ...a wheel hub or if 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 ose Recommended lubricant Lithium soap based grease 1 Grease nipple 1 ...

Page 106: ...he 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 NOTE The electrolyte should be between the minimum and maximum level marks 3 If the electrolyte is at or below the minimum level mark add distilled water to raise it to the maximum level mark ...

Page 107: ... elec trolyte Batteries 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 ...

Page 108: ...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 1 Battery 2 Battery breather hose 1 2 ...

Page 109: ...a fuse 2 Remove the blown fuse and then install a new fuse of the specified amperage EWB02151 3 Turn the key to ON and turn on the electrical Specified fuse 5 0 A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rating Never use a material ...

Page 110: ...and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel EBU25660 Installing a wheel 1 Install the wheel and the nuts 2 Lower the ATV to the ground 3 Tighten the wheel nuts to the specified 1 Wheel nut 1 ...

Page 111: ...RNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe in jury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys tem Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces ...

Page 112: ...dry cloth and correct the rk 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 ver ver 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 113: ...oap 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 con...

Page 114: ...ent 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...

Page 115: ...11 g on the des are g during mes with der wall he spark lug and pivoting tire air so that ernative in order egraded c bag to it Store once a n exces 0 C 30 ore infor e 8 30 NOTE Make any necessary repairs before storing the ATV ...

Page 116: ...er 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 117: ...Secondary reduction system Shaft drive Secondary reduction ratio 19 18 34 10 3 588 Transmission type Constant mesh 3 speed Operation Left foot operation 1st 39 11 3 545 2nd 35 17 2 059 3rd 31 22 1 409 Chassis Frame type Steel tube frame Caster angle 1 0 Trail 3 8 mm 0 15 in Front tire Type Tubeless Size AT18 x 7 7 ...

Page 118: ...wheel Rim size 7 x 6 5AT Front brake Type Drum brake Operation Right hand operation Rear brake Type Drum brake Operation Left hand and right foot operation Front suspension Type Leading arm Spring shock absorber type Coil spring oil damper Wheel travel 57 mm 2 3 in Rear suspension Type Swingarm ...

Page 119: ...10 4 1 2 3 4 5 6 7 8 9 10 11 ...

Page 120: ...n 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 121: ...11 2 1 2 3 4 5 6 7 8 9 10 11 o identi n the il label in e need ha deal 1 Model label 1 ...

Page 122: ... element of de the purpose of noise control prior to its sale or delivery to the 2 the use of the vehicle after such device or element of design by any person CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW wing systems i e modification removal etc haust system ffler haust pipe encer ke system cleaner case cleaner element ake duct ...

Page 123: ...9 10 11 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 MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS ...

Page 124: ... of manufacture and that it is 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 from the original purchase date...

Page 125: ...TIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model V I N frame number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a s...

Page 126: ... 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 pl...

Page 127: ...11 8 1 2 3 4 5 6 7 8 9 10 11 benefits of y knowing after your also save after you maha with We ll be d Indicates a potential hazard that could result in serious injury or death WARNING ...

Page 128: ...11 9 ...

Page 129: ...el 4 8 5 3 Fuel cock 4 10 Fuel tank cap 4 8 Fuse replacing 8 33 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 29 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 4 Model label ...

Page 130: ...8 30 9 2 8 20 4 3 5 4 8 20 5 5 5 4 Tire wear limit 5 6 Troubleshooting 8 35 Troubleshooting chart 8 36 V Valve clearance 8 21 Vehicle identification number 11 1 W Warranty extended 11 7 Warranty limited 11 5 Wheel bearings checking 8 29 Wheel installing 8 34 Wheel removing 8 34 ...

Page 131: ...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 132: ...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 133: ...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 ...