Yamaha YFM125GZ, Owner'S Manual

Page 1: ...This A This ATV should not be ridden by anyone under 16 years of age OWNER S MANUAL LIT 11626 23 13 1C5 28199 16 YFM125GZ WARNING READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 2: ...EBU17092 Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if it is sold ...

Page 3: ...nformation 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...

Page 4: ...ithout 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 propert...

Page 5: ...l 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 EBU17382 YFM125GZ OWNER S MANUAL 2009 by Yamaha Motor Corporation U S A 1st edition February 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited P...

Page 6: ...Throttle lever 4 3 Speed limiter 4 3 Front brake lever 4 4 Rear brake lever 4 5 Parking brake 4 5 Drive select lever 4 6 Fuel tank cap 4 7 Fuel 4 7 Fuel cock 4 8 Starter choke 4 10 Seat 4 10 Front carrier 4 11 Rear carrier 4 11 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Transmission oil 5 3 Front and rear brakes 5 3 Throttle lever 5 3 Drive chain 5 3 Tires 5 3 Chassis fasteners 5 5 Instrumen...

Page 7: ... Transmission oil 8 13 Cleaning the engine and V belt case air filter elements 8 15 Cleaning the spark arrester 8 22 V belt case drain plug 8 23 Adjusting the carburetor 8 24 Adjusting the engine idling speed 8 24 Adjusting the throttle cable free play 8 25 Valve clearance 8 26 Brakes 8 26 Checking the front and rear brake shoes 8 26 Adjusting the front brake lever free play 8 27 Adjusting the rea...

Page 8: ... 8 47 Troubleshooting 8 48 Troubleshooting chart 8 49 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 ...

Page 9: ...1 1 1 2 3 4 5 6 7 8 9 10 11 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 2 6 5 4 3 9 8 7 10 ...

Page 10: ...erstand 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 ...

Page 11: ...ere injury or death OPERATING TIRE PRESSURE Set with tires cold LOADING Recommended Front 2 9 psi 20 0 kPa Rear 3 6 psi 25 0 kPa Minimum Front 2 5 psi 17 0 kPa Rear 3 2 psi 22 0 kPa Never set tire pressure below minimum It could cause the tire to dislodge from the rim Maximum weight capacity 231 Ibs 105 kg Includes weight of operator cargo and accessories 1C5 2816M U0 WARNING NEVER ride as a passe...

Page 12: ...ith another vehicle with a passenger passengers affect balance and steering and increase risk of losing control 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 at speeds too fast for your skills or the conditions Operating this ATV if you are under the age of 16 increases your ch...

Page 13: ...ou 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 s...

Page 14: ...er 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 desc...

Page 15: ... 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 inst...

Page 16: ...s 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...

Page 17: ...1 EBU17680 DESCRIPTION EBU17690 Left view EBU17700 Right view 1 Front carrier 2 Starter choke 3 Fuel cock 4 Tail brake light 5 Rear carrier 6 Spark arrester 7 Footboard 1 2 3 4 5 6 7 1 Seat 2 Drive select lever 3 Headlight 1 2 3 ...

Page 18: ...TV you have purchased may differ slightly from the figures shown in this manual 1 Rear brake lever 2 Parking brake 3 Reverse indicator light 4 Neutral indicator light 5 Front brake lever 6 Throttle lever 7 Main switch 8 Fuel tank cap 9 Handlebar switches 1 2 3 4 5 9 8 7 6 ...

Page 19: ... which if not avoided could result in death or serious injury EBU17740 Main switch The positions of the main switch are as follows ON All electrical systems are supplied with power and the engine can be started The key cannot be re moved OFF All electrical systems are off The key can be re moved 1 Main switch OFF ON 1 ...

Page 20: ...is in the neutral position EBU18061 Handlebar switches EBU18080 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 Reverse indicator light R 2 Neutral indicator light N 1 2 1 Lig...

Page 21: ...If this should happen remove the battery and recharge it See page 8 39 for battery charging information EBU18281 Throttle lever Once the engine is running movement of the throt tle lever 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 hand i...

Page 22: ... in or the throttle cable could be dam aged Always make sure the throttle lever free play is adjusted to 1 0 3 0 mm 0 04 0 12 in See page 8 25 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 ...

Page 23: ...the brake lever to ward the handlebar grip EBU18460 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 1 Front brake lever 1 1 Rear brake lever 1 ...

Page 24: ...de 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 EBU18581 Drive select lever The drive select lever is used to shift your ATV into the forward neutral and reverse positions See the Operating the drive select lever and driving in re verse section on page 6 3 for the drive select lever oper...

Page 25: ... 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...

Page 26: ... 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 maintena...

Page 27: ...er 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 RES ON FUEL OFF 1 1 Arrow mark positioned over ON ON FUEL RES OFF ON 1 ...

Page 28: ...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 EBU18881 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at ...

Page 29: ...seat is securely fitted EBU18962 Front carrier Do not exceed the load limit of 5 0 kg 11 lb for the front carrier Do not exceed the maximum load of 105 0 kg 231 lb for the ATV EBU18972 Rear carrier Do not exceed the load limit of 10 0 kg 22 lb for the rear carrier Do not exceed the maximum load of 105 0 kg 231 lb for the ATV 1 Seat lock lever 1 1 Projection 2 Seat holder 1 2 ...

Page 30: ...4 12 1 2 3 4 5 6 7 8 9 10 11 WARNING EWB00011 Indicates a hazardous situation which if not avoided could result in death or serious injury ...

Page 31: ...his 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 7 5 3 Engine oil Check oil level in engine and add recommended oil to specified level if necessary Check ATV for oil leakage Correct if necessary 5 3 8 10 Transmission oil Check oil level in transmission case and add r...

Page 32: ...f necessary 5 3 8 33 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 3 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 8 36 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 5 5 Instruments lights and swi...

Page 33: ... 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 See page 8 26 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 de...

Page 34: ...e 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 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire Recommended tire pressure Front 20 0 kPa 0 200 kgf cm2 2 9 psi Rear 25 0 kPa 0 250 kgf cm2 3 6 psi Minimum tire pressu...

Page 35: ...or Co Ltd 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 1 Tire wear limit Front Manufacturer model DU...

Page 36: ...19850 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 39 ...

Page 37: ... break in section on page 6 4 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 drive select lever into the neutral po sition The neutral indicator light should come on If the indicator light does not come on have a Yamaha dealer check the electrical cir cuit TIP The engine can be start...

Page 38: ...rter 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 normally to the throttl...

Page 39: ...ng the drive select lever along the shift guide TIP Make sure that the drive select lever is completely shifted into position 3 Open the throttle lever gradually Shifting 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...

Page 40: ... 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...

Page 41: ...void 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 the drive select lever to the for ward position stop the engine apply the park ing brake and then block the front and rear wheels with rocks or other objects Do ...

Page 42: ...rket 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 hicle s design...

Page 43: ...essories so that you can tow a trailer you must use common sense and good judgment as the stability and han dling of an ATV can be changed When adding ac cessories keep the following points in mind Never exceed the weight limits shown An over loaded ATV can be unstable If you are carrying cargo and towing a trailer in clude the tongue weight in the maximum ATV load limit Load cargo on the carriers...

Page 44: ... 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 ...

Page 45: ...7 1 1 2 3 4 5 6 7 8 9 10 11 EBU21132 RIDING YOUR ATV ...

Page 46: ...ve read this Owner s Manual completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 2 1 2 4 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 accid...

Page 47: ...perienced 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 t...

Page 48: ...ty 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...

Page 49: ... 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 er s 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 li...

Page 50: ...c 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...

Page 51: ...en 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 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident includ...

Page 52: ...ark 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 h...

Page 53: ...f 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 WARNING Never operate this ATV on any pub lic street road or highway even a dirt or gravel one You ...

Page 54: ...xtra 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 roug...

Page 55: ...he 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 ...

Page 56: ... directional control Avoid higher speeds until 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 WARNING EWB01771 Always follow proper procedures for tu...

Page 57: ...oose it may help to position more of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt 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 begi...

Page 58: ...ght forward Never open the throttle suddenly 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 Owner s Manual on level ground Be very careful when turning on a...

Page 59: ...p for you to climb or de scend 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...

Page 60: ...n 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 Engine compression will do most of the braking for...

Page 61: ...ersing 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 cor...

Page 62: ...n The ATV can be used to cross slow moving shallow water of up to a maximum of 20 cm 8 in in depth Before entering the water choose your path care fully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slip pery or upset the ATV Drive slowly and carefully Test your brakes after leaving the water If neces sary apply them several times to let friction dry out th...

Page 63: ... bottom of the air filter case Also remove the V belt case drain plug to drain any water that may have accumulated 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 V belt case drain plug 1 1 ...

Page 64: ...f 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 c...

Page 65: ...t 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 66: ...r that the ATV is going to tip over dismount on the uphill side See page 7 17 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 18...

Page 67: ...f 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 ...

Page 68: ...he 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 Owner s manual 2 Low pressure tire gauge 3 Owner s tool kit 1 2 3 ...

Page 69: ...rmed 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 Valv...

Page 70: ...ket 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 ...

Page 71: ...correct if necessary Check brake lever free play and adjust if neces sary Replace brake shoes Whenever worn to the limit 3 Rear brake Check operation and correct if necessary Check brake lever free play and adjust if neces sary Replace brake shoes Whenever worn to the limit 4 Wheels Check runout and for damage and replace if nec essary 5 Tires Check tread depth and for damage and replace if necess...

Page 72: ... necessary 12 Front knuckle piv ots Lubricate with lithium soap based grease 13 Steering shaft Lubricate with lithium soap based grease 14 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 15 Engine oil Change Check ATV for oil leakage and correct if neces sary 16 Engine oil strainer Clean 17 Transmission oil Change Check ATV for oil leakage and ...

Page 73: ...ary Lubricate throttle lever housing and cable 20 Front and rear brake switches Check operation and correct if necessary 21 Lights and switches Check operation and correct if necessary Adjust headlight beams 22 Battery Check electrolyte level and specific gravity and correct if necessary Make sure that the breather hose is properly routed NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er c...

Page 74: ...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 ...

Page 75: ...ould 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 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 Spark plug wrench 1 Specified ...

Page 76: ... spark plug cap EBU23266 Engine oil The engine oil level should be checked before each ride In addition the oil must be changed at the intervals specified 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 e...

Page 77: ... 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 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...

Page 78: ...n 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 ECB00330 Do not use oils with a diesel specification of CD or oils of a higher quality than speci fied In addition do not use oils labeled EN ERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase 9 Start the engine and then let it i...

Page 79: ...t be changed at the intervals specified in the periodic maintenance and lubrication chart To check the transmission oil level 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 Wait a few minutes until the oil settles and then loosen the transmission oil check screw located at the right side of the crankcase until oil flows out 4 If no oil ...

Page 80: ...ace 2 Start the engine warm it up for several min utes and then turn it off 3 Place an oil pan under the transmission to col lect the used oil 4 Remove the transmission oil filler bolt and the transmission oil drain bolt to drain the oil from the transmission case 5 Install the drain bolt and then tighten it to the specified torque 1 Transmission oil filler bolt Tightening torque Transmission oil ...

Page 81: ... 8 Turn the engine off and then check the oil lev el and correct it if necessary EBU23843 Cleaning the engine and V belt case air filter elements Both air filter elements should be cleaned at the specified intervals in the periodic maintenance chart Engine air filter element 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 cle...

Page 82: ... Place the ATV on a level surface 2 Remove the seat See page 4 10 3 Remove the breather hose and then loosen the clamp screw 4 Remove the air filter case cover by removing the screws 1 Check hose 1 1 Breather hose 2 Clamp screw 1 2 ...

Page 83: ... WARNING Always use parts cleaning solvent to clean the sponge material Never use low flash point sol vents or gasoline to clean the sponge ma terial because the engine could catch fire or explode EWB01941 8 Squeeze the excess solvent out of the sponge material and let it dry NOTICE Do not twist the sponge material when squeezing it ECB00441 1 Air filter case cover 2 Screw 1 2 2 2 2 1 Bolt 2 Washe...

Page 84: ...edge facing outward as shown ECB00452 13 Install the air filter element into the air filter case 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 removed This will allow un filtered air to enter the engine causing rap id engine wear and possible engine damage Additionally operation without the air filter ele...

Page 85: ...intenance is performed 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 manifold fittings for an air tight seal Tighten all fit tings securely to avoid the possibility of unfiltered air entering the engine V belt case air filter element 1 Place the ATV on a level surface 2 Remove the front carrier by ...

Page 86: ...8 20 1 2 3 4 5 6 7 8 9 10 11 4 Disconnect the coupler shown 5 Remove the air filter case cover by removing the screw 1 Panel 2 Quick fastener 1 2 2 1 1 Panel 2 Coupler 1 2 ...

Page 87: ...0 11 6 Remove the air filter element 7 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 1 Air filter case cover 2 Screw 1 2 1 Air filter element 1 ...

Page 88: ...ng the quick fasteners 12 Install the front carrier by installing the bolts EBU27630 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester 1 Remove the screws 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...

Page 89: ...sibly leading to death and start a fire Always let the exhaust system cool prior to touching exhaust components EBU23930 V belt case drain plug After riding in water deep enough to allow it to en ter the V belt case remove this plug to drain the water from the case TIP If water drains from the V belt case after removing the plug have a Yamaha dealer check the ATV as the water may affect other engi...

Page 90: ...ed 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 adju...

Page 91: ... 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 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 adju...

Page 92: ...roperly serviced or adjust ed brakes could lead to a loss in braking ability and an accident EBU24090 Checking the front and rear brake shoes The front and rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart Each brake is provided with a wear indicator which allows you to check the brake shoe wear without having to dis assemble the...

Page 93: ...he brake lever free play must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart TIP Before adjusting the brake lever free play check the front brake shoes for wear 1 Wear limit line 2 Wear indicator 1 2 1 Wear limit line 2 Wear indicator 1 2 ...

Page 94: ... 0 mm 0 20 0 31 in as shown If the free play is in correct adjust it as follows 1 Remove the front carrier by removing the bolts 2 Remove the panel shown by removing the quick fasteners then disconnect the coupler shown 1 Brake lever free play 1 1 Front carrier 2 Bolt 1 2 2 2 ...

Page 95: ...8 29 1 2 3 4 5 6 7 8 9 10 11 3 Remove the V belt air filter element cover by removing the screw 1 Panel 2 Quick fastener 1 2 2 1 1 Panel 2 Coupler 1 2 ...

Page 96: ...brake cable joint in the equaliz er is straight when the brake is applied If the cable joint isn t straight loosen the locknuts and then turn the adjusting nuts on the front brake cables until the cable joint becomes straight 1 V belt air filter element cover 2 Screw 1 2 1 Locknut 2 Brake lever free play adjusting bolt 1 2 ...

Page 97: ... 11 6 Tighten the locknut on each brake cable 7 Turn the adjusting bolt in direction a to in crease the free play and in direction b to de crease it 1 Brake equalizer 2 Cable joint a a a a 1 2 1 Locknut 2 Adjusting nut 1 2 2 1 ...

Page 98: ... intervals specified in the periodic maintenance and lubrication chart TIP Before adjusting the brake lever free play check the rear brake shoes for wear 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 Turn the brake lever free play adjusting nut on the rear wheel hub in direction a to increase the free play and in direc...

Page 99: ...ld be no weight on the ATV and all tires must be touching the ground 2 Move the ATV back and forth to locate the tightest portion of the drive chain and then measure the drive chain slack as shown 3 If the drive chain slack is incorrect adjust it as follows To adjust the drive chain slack 1 Place the ATV on a level surface 2 Loosen the hub stopper bolt locknut and then 1 Brake lever free play adju...

Page 100: ...wheels forward NOTICE Improper drive chain slack will overload the engine as well as other vital parts of the ATV and can lead to drive chain slippage or break age To prevent this from occurring keep the drive chain slack within the specified limits ECB00542 5 Tighten the locknut and the axle holding bolts to the specified torques 1 Hub stopper bolt 2 Locknut 3 Axle holding bolt lower 4 Axle holdi...

Page 101: ...chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows Tightening torques Chain adjusting bolt locknut 15 5 Nm 1 6 m kgf 11 2 ft lbf Axle holding bolt upper 85 Nm 8 5 m kgf 61 5 ft lbf Axle holding bolt lower 6...

Page 102: ...ked 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...

Page 103: ...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 EBU25032 Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte nance and lubrication chart Lubricate the pivoting points using a grease gun Recommended lubricant Lithium soap based grease Recomm...

Page 104: ...nt knuckle pivots The front knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricate the front knuckle pivots using a grease gun 1 Grease nipple 1 1 1 Grease nipple Recommended lubricant Lithium soap based grease 1 1 ...

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

Page 106: ...to the battery ECB00591 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 im...

Page 107: ...month the battery will need to be removed and stored as follows 1 Disconnect the negative lead first and then the positive lead NOTICE When removing the battery the main switch must be off and the negative lead must be disconnected before the positive lead ECB01001 2 Remove the battery fully charge it and then place it in a cool dry place NOTICE Do not leave or store the battery on its side ECB006...

Page 108: ...negative lead 3 Make sure that the breather hose is properly routed in good condition and not obstructed NOTICE If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the bat tery the frame could suffer structural and external damages ECB00611 1 Battery 2 Negative battery lead black 3 Positive battery lead red 1 2 3 ...

Page 109: ... 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 electrica...

Page 110: ...o 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 1 He...

Page 111: ...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 EBU25611 Replacing the tail brake light bulb If the tail brake light bulb burns o...

Page 112: ...rning 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 1 Tail brake light bulb 2 Tail brake light bulb holder 1 2 ...

Page 113: ...heel 1 Place the ATV on a level surface 2 Elevate the ATV and place a suitable stand under the frame 3 Install the wheel and the nuts TIP Tapered nuts are used for both the front and rear wheels Install the nuts with their tapered side to wards the wheel 4 Lower the ATV to the ground 5 Tighten the wheel nuts to the specified torques 1 Wheel nut 1 1 1 Tapered nut 1 ...

Page 114: ...t 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...

Page 115: ...eck 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 batte...

Page 116: ...eds to let friction dry out the lin ings EWB02311 NOTICE Excessive water pres sure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car washers ECB00711 4 Once most of the dirt has been hosed off wash all s...

Page 117: ... 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...

Page 118: ... 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 information on storing the battery see page 8 39 TIP Make any necessary repairs before storing the ATV ...

Page 119: ...linder arrangement Forward inclined single cylinder Displacement 124 cm3 Bore stroke 49 0 66 0 mm 1 93 2 60 in Compression ratio 9 00 1 Starting system Electric 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 Engine oil quantity Periodic oil cha...

Page 120: ...mm 0 024 0 028 in Clutch Clutch type Dry centrifugal automatic Transmission Primary reduction system Helical gear spur gear Primary reduction ratio 43 14 40 17 7 226 Secondary reduction system Chain drive Secondary reduction ratio 32 12 2 666 Transmission type V belt automatic Operation Centrifugal automatic type Reverse gear 49 14 49 15 40 17 26 902 Chassis Frame type Steel tube frame Caster angl...

Page 121: ...heel type Panel wheel Rim size 8 x 5 5AT Rear wheel Wheel type Panel wheel Rim size 8 x 8 0AT Front brake Type Drum brake Operation Right hand operation Rear brake Type Drum brake Operation Left hand operation Front suspension Type Swing axle Spring shock absorber type Coil spring oil damper Wheel travel 70 mm 2 8 in Rear suspension Type Swingarm Spring shock absorber type Coil spring oil damper W...

Page 122: ...10 11 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 Fuses Main fuse 15 0 A ...

Page 123: ...arts 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 numbe...

Page 124: ...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 numb...

Page 125: ...11 3 1 2 3 4 5 6 7 8 9 10 11 1 Vehicle Emission Control Information label 1 ...

Page 126: ...ted into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modifi...

Page 127: ...nted 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 mont h 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 2250...

Page 128: ...rom 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 ...

Page 129: ...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 e...

Page 130: ...overed repairs There s no deductible to pay and repairs aren 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 to...

Page 131: ...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 isn t convenient contact Yamaha with your Primary ID number your frame number We ll 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 ...

Page 132: ...11 10 1 2 3 4 5 6 7 8 9 10 11 EBU26132 ...

Page 133: ...r 4 11 Chassis fasteners 5 5 Cleaning 9 1 D Drive chain 5 3 Drive chain lubricating 8 35 Drive chain slack 8 33 Drive select lever 4 6 Drive select lever and driving in reverse 6 3 E Engine break in 6 4 Engine cold start 6 1 Engine idling speed 8 24 Engine oil 5 3 8 10 Engine starting a warm 6 2 Engine stop switch 4 2 F Front knuckle pivots lubricating 8 38 Fuel 4 7 5 3 Fuel cock 4 8 Fuel tank cap...

Page 134: ...hecking 8 8 Specifications 10 1 Speed limiter 4 3 Starter choke 4 10 Start switch 4 3 Steering shaft lubricating 8 39 Storage 9 2 Suspension lubricating the upper and lower arm pivots 8 37 T Tail brake light bulb replacing 8 45 Throttle cable free play adjusting 8 25 Throttle lever 4 3 5 3 Tires 5 3 Transmission oil 5 3 8 13 Troubleshooting 8 48 Troubleshooting chart 8 49 V Valve clearance 8 26 V ...

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Page 136: ...es 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 P...

Page 137: ... 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 138: ...D 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 08 12 2 10 24 AM Page 2 ...