Yamaha YFM80GV, Owner'S Manual

Page 1: ...OWNER S MANUAL 2D3 28199 20 YFM80GV 2D3 9 20 hyoshi 3 9 05 6 43 PM Page 1 ...

Page 2: ...2D3 9 11 hyoshi 3 9 05 6 02 PM Page 3 ...

Page 3: ... this machine This manual includes important safety infor mation It provides information about special techniques and skills necessary to ride your machine It also includes basic maintenance and inspec tion procedures If you have any questions regarding the operation or maintenance of your machine please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE 8 READ THIS MANUAL COMPLETELY BEFORE OPERA...

Page 4: ...at all begin ners start off with the speed limiter screw turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn The limiter screw may be gradually turned out to increase maximum speed as the beginner becomes more familiar with operating the ATV Parents should decide when to adjust the ATV for more power as their youngster s riding skills imp...

Page 5: ...ndicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer EBU00111 IMPORTANT NOTICE This ATV is designed and manufactured for use on UNPAVED surfaces only It is unsafe to oper ate this ATV on any paved surface paved street paved road or motorway Please check your local riding laws and regula tions befor...

Page 6: ... switches 4 2 Throttle lever 4 3 Speed limiter 4 4 Front brake lever 4 5 Brake pedal and rear brake lever 4 6 Parking brake 4 6 Shift pedal 4 7 Fuel tank cap 4 8 Fuel cock 4 8 Choke lever 4 9 Seat 4 9 Carrier 4 10 PRE OPERATION CHECKS 5 1 Front and rear brakes 5 3 Fuel 5 4 Engine oil 5 5 Final gear oil 5 5 Throttle lever 5 6 Tires 5 6 How to measure tire pressure 5 7 Tire wear limit 5 8 Fittings a...

Page 7: ...wnhill 7 19 Crossing a slope 7 20 Crossing through shallow water 7 21 Riding over rough terrain 7 23 Sliding and skidding 7 23 What to do if 7 25 What to do 7 25 PERIODIC MAINTENANCE AND ADJUSTMENT 8 1 Owner s manual and tool kit 8 1 Periodic maintenance lubrication 8 3 Engine oil 8 5 Final gear oil 8 7 Spark plug inspection 8 9 Cleaning the air filter element 8 10 Air intake restrictor plate remo...

Page 8: ...rake lever lubrication 8 22 Knuckle shaft and steering shaft lubrication 8 22 Wheel removal 8 23 Wheel installation 8 23 Battery 8 24 Replenishing the battery fluid 8 25 Fuse replacement 8 26 Troubleshooting 8 27 Troubleshooting chart 8 28 CLEANING AND STORAGE 9 1 A Cleaning 9 1 B Storage 9 2 SPECIFICATIONS 10 1 Conversion Table 11 1 9 10 11 2D3 9 20 3 3 9 05 7 56 PM Page 6 ...

Page 9: ...e labels on your machine They contain important information for safe and proper operation of your ATV Never remove any labels from your ATV If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 3 4 2 5 6 1 2D3 9 20 3 3 9 05 7 56 PM Page 7 ...

Page 10: ...ELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate 9 without proper training or instruction 9 at speeds too fast for your skills or the conditions 9 on public roads a collision can occur with another vehicle 9 with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS 9 use proper riding techniques to avoid vehicle overturns on hills and rough terrain ...

Page 11: ...INJURYORDEATH OPERATINGTIREPRESSURE Set with tires cold 9Recommended FRONT 20 kPa 0 20 kgf cm2 2 9 psi REAR 20 kPa 0 20 kgf cm2 2 9 psi 9Minimum FRONT 17 kPa 0 17 kgf cm2 2 5 psi REAR 17 kPa 0 17 kgf cm2 2 5 psi 9Never set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING 9Maximum Vehicle Load 95 kg 209 lbs Includes weight of operator cargo and accessories 4EM 21...

Page 12: ...1 4 6 sit here NEVER 3MX 24875 A0 5 5kg 11lbs 3LD 24877 A0 2D3 9 20 3 3 9 05 7 56 PM Page 10 ...

Page 13: ...n 90 cc q SAFETY INFORMATION 2 8 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 8 Never carry a passenger on an ATV 8 Always avoid operating an ATV on any paved surfaces including sidewalks driveways parking lots and paved streets 8 Never operate an ATV on ...

Page 14: ...rate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain 8 Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed 8 Never operate the ...

Page 15: ...s use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling use proper gear and maintain a steady speed when climbing a hill If you stall or roll backwards follow the special proce dure for braking described in this manual Dismount on the uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in this m...

Page 16: ...8 Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and fol low instructions in this manual for carrying cargo or pulling a trailer Allow greater dis tance for braking w 8 Always turn off the engine when refueling 8 Do not refuel right after the engine has been running and is still very hot 8 Do not spill gasoline on the engine...

Page 17: ... or inhale a lot of gaso line vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes w Always operate your ATV in an area with adequate ventilation Never start or run the engine in a closed area Exhaust fumes are poisonous and may cause loss of con sciousness and death with...

Page 18: ...t 4 Brake pedal 13 Front brake lever 5 Fuel cock 14 Throttle lever 6 Rear wheel 15 Main switch 7 Footboard 16 Fuel tank cap 8 Shift pedal 17 Handlebar switches 9 Front wheel NOTE The machine you have purchased may differ slightly from those shown in the figures of this manual 1 2 3 4 7 0 q w e r y t u 5 6 8 9 7 2D3 9 20 3 3 9 05 7 56 PM Page 16 ...

Page 19: ...rts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION 1 6 3 EBU00035 Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key q 1 Key identification number 2D3 9 20 3 3 9 05 7 56 PM Page 17...

Page 20: ...is used to identify your machine 1 1 Vehicle identification number 3 3 EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this label in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 1 Model label 2D3 9 20 3 3 9 05 7 56 PM Page 18 ...

Page 21: ...gine can be started only at this position OFF All electrical circuits are switched off The key can be removed in this position OFF ON q EBU00043 Indicator lights EBU00603 Neutral indicator light N This indicator light comes on when the transmis sion is in neutral 1 Neutral indicator light N 2D3 9 20 3 3 9 05 7 56 PM Page 19 ...

Page 22: ...ne stop switch is turned to OFF 1 1 Engine stop switch ENG STOP 1 1 Start switch START EBU00056 Start switch START The starter motor cranks the engine when this switch is pushed cC See starting instructions prior to starting engine see page 6 1 for details NOTE If the starter switch is pushed with the main switch ON and the engine stop switch OFF the starter motor will be activated but the engine ...

Page 23: ...Before starting the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released w Malfunction of the throttle could make it diffi cult to speed up or slow down when you need to This could cause an accident Check the operation of the throttle lever before you start the engine If the throttle does not work smoothly check fo...

Page 24: ...maximum speed as the beginner becomes more familiar with operating the ATV Parents should decide when to adjust the ATV for more power as their youngster s riding skills improve Once the ATV rider can operate with skill at the top speed permitted by adjusting the speed limiter alone the air intake restrictor plate can be removed q w a 1 Locknut 2 Adjuster a No more than 20 mm Since removal of this...

Page 25: ...dlebar to apply the front brake w Improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation You could lose control have an accident or be injured Do not turn the speed adjuster out more than 20 mm or the throttle cable could be dam aged 2D3 9 20 4 5 3 10 05 7 25 PM Page 4 ...

Page 26: ... down on the pedal or pull the lever toward the handlebar to apply the rear brake 4 6 EBU00075 Parking brake Use the parking brake when you have to start the engine or park the machine 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 q 1 Lock plate 2D3 9 20 4 5 3 10 05 7 25 PM Page 5 ...

Page 27: ...parking brake before you begin to ride 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 1 1 Locked position EBU00083 Shift pedal This machine is equipped with a constant mesh 3 speed transmission The shift pedal is located on the left side of the engine Ne...

Page 28: ...fuel will not flow Always turn the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling return the fuel cock lever to th...

Page 29: ...ing up position 1 Fully open ON 3 Closed OFF EBU00566 Seat To remove the seat pull the seat lock lever upward and pull up the seat at the rear 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 q 1 Seat lock lever 2D3 9 20 4 5 3 10 05 7 25 PM Page 8 ...

Page 30: ...4 10 q w 1 Projection 2 Seat holder Maximum load limit 5 kg EBU15680 Carrier 2D3 9 20 4 5 3 10 05 7 25 PM Page 9 ...

Page 31: ...ine oil 9 Check oil level 9 Fill with oil if necessary 5 5 8 5 8 6 Final gear oil 9 Check for leakage 5 5 8 7 8 8 Throttle 9 Check for proper throttle cable operation 5 6 Wheels and tires 9 Check tire pressure wear and damage 5 6 5 8 8 23 Fittings and fasteners 9 Check all fittings and fasteners 5 8 Switches 9 Check operation 5 9 Battery 9 Check fluid level 5 9 8 24 8 25 9 Fill with distilled wate...

Page 32: ...re the ATV is in safe operating condi tion Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual Failure to inspect increases the possibility of an accident or equipment dam age 2D3 9 20 4 5 3 10 05 7 25 PM Page 11 ...

Page 33: ...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 perfor mance inspect the brake linings for wear See page 8 16 w Always check the brakes at the start of every ride Do not ride the ATV if you find any problem with the brakes or you could lose braking ability which could lead to an acci d...

Page 34: ...iston rings as well as to the exhaust system w 8 Do not overfill the fuel tank Fuel expands when it heats up If the fuel tank is over filled fuel could spill out due to heat from the engine or the sun 8 Be careful not to spill fuel especially on the engine or exhaust pipe which can cause a fire and severe injury Wipe up any spilled fuel immediately 8 Do not refuel right after the engine has been r...

Page 35: ... not use oils labeled ENERGY CONSERVING II or higher 8 Make sure that no foreign material enters the crankcase Recommended engine oil type and quantity See page 10 2 EBU00493 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 7 8 8 for details If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additi...

Page 36: ... ATV with improper or uneven tire pressure may cause loss of control increas ing your risk of accident Pay attention to the following 1 The tires listed below have been approved by Yamaha Motor Co Ltd for this model Other tire combinations are not recommended 2 The tires should be set to the recom mended pressure 8 Recommended tire pressure Front 20 kPa 0 20 kgf cm2 0 20 bar Rear 20 kPa 0 20 kgf c...

Page 37: ...g pres sures when seating the tire beads Front 230 kPa 2 3 kgf cm2 2 3 bar Rear 230 kPa 2 3 kgf cm2 2 3 bar Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst EBU14450 How to measure tire pressure Use the low pressure tire gauge NOTE The low pressure tire gauge is included as stan dard equipment Make two measurement...

Page 38: ... cm2 0 20 bar 17 kPa 0 17 kgf cm2 0 17 bar 23 kPa 0 23 kgf cm2 0 23 bar Front Rear q 1 Low pressure tire gauge EBU00160 Tire wear limit When the tire groove decreases to 3 mm due to wear replace the tire EBU11620 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening...

Page 39: ... of all switches Have a Yamaha dealer repair as necessary for proper operation EBU00499 Battery Check fluid level and fill if necessary Use only distilled water if refilling is necessary See pages 8 24 8 25 2D3 9 20 4 5 3 10 05 7 25 PM Page 18 ...

Page 40: ... Yamaha dealer EBU00580 Starting a cold engine w Always make sure all control cables work smoothly before you begin riding in cold weather If the control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead to an accident or collision 1 Set the parking brake 2 Turn the fuel cock to ON 3 Turn the main switch to ON and the engine stop switch to RUN 4 Shif...

Page 41: ...C Position 2 Warming up position Position 3 Cold engine start ambient temperature above 25 C and warm engine start position CHOKE ON O F F 0 10 20 30 C a 3 1 1 2 3 1 Fully open ON 2 Half open warming up position 3 Closed OFF a Choke lever AMBIENT TEMP CHOKE LEVER POSITION POSITION DE LEVIER DE STARTER TEMP AMBIANTE POSICION DEL MANDO DEL STARTER TEMP AMBIENTE 6 6 Completely close the throttle leve...

Page 42: ...before riding cC See the Engine break in section prior to operating engine for the first time 6 3 EBU00181 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The choke lever should not be used The throttle should be opened slightly EBU00184 Warming up To get maximum engine life always warm up the engine before starting off Never accelerate hard with a cold en...

Page 43: ...ng accelerating climbing etc To shift into neu tral return the throttle lever to its original posi tion and repeatedly depress the shift pedal until it stops 6 4 cC Do not coast for long periods with the engine off and do not tow the machine a long dis tance Even with gears in neutral the trans mission is only properly lubricated when the engine is running Inadequate lubrication may damage the tra...

Page 44: ...n the throttle gradually 4 Once the machine has attained adequate speed release the throttle lever 5 Shift into second gear and release the shift pedal 6 Open the throttle gradually 7 Follow the same procedure when shifting to the next higher gear w Always open the throttle gradually Opening the throttle abruptly would increase the chance of an accident It could make the machine wheelie or overtur...

Page 45: ...There is never a more important period in the life of your machine than the period between zero and 20 hours For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an excessive load on it for the first several hours of running During the first 20 hours the various parts in the engine wear and polish themselves to the correct oper atin...

Page 46: ...not operate it at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the machine freely through the gears but do not use full throttle at any time After break in Avoid prolonged full throttle operation Vary speeds occasionally EBU15690 Parking When parking stop the engine and shift into the forward position Turn the fuel cock to OFF and apply the parking brake q...

Page 47: ...t the ATV in low gear apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easily 1 Bring the machine to a stop by applying the brakes in low gear 2 Stop the engine 3 With the rear brake lever and pedal applied apply the parking brake and slowly release the rear brake pedal 2D3 9 20 ...

Page 48: ...Choose a genuine Yamaha accessory or one that is equivalent in design and quality 8 Accessories should be rigidly and securely mounted An accessory which can shift posi tion or come off while you are riding could affect your ability to control the ATV 8 Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky o...

Page 49: ...d can cause an accident MAXIMUM LOADING LIMIT 8 Vehicle loading limit total weight of rider cargo and accessories 95 kg 8 Carrier 5 kg 8 Make sure the load does not interfere with controls or your ability to see where you are going 8 Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed 2nd gear ...

Page 50: ...ying or towing cargo improperly could cause changes in vehicle handling which could lead to an accident Cargo should be properly distributed and securely attached Reduce speed when car rying cargo or pulling a trailer Allow greater distance for braking 2D3 9 20 6 3 11 05 10 29 AM Page 10 ...

Page 51: ...Riding Your ATV 7 7 1 2D3 9 20 7 3 10 05 7 27 PM Page 144 ...

Page 52: ...ING TO KNOW YOUR ATV This ATV is for recreation use This section Riding your ATV provides general ATV riding instructions for recreational riding The skills and techniques described in this section however are appropriate for all types of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting...

Page 53: ... of ATVs that are not recommend ed 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 w Never carry a passenger The long seat is to allow the operator to shift position as need ed during operation It is not for carrying passengers Carrying a passenger on this ATV greatly reduces your ability to balance and c...

Page 54: ... eye protection and protective clothing Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your chances of severe injury in the event of a...

Page 55: ...gs Operator s performance capability is reduced by the influence of alcohol or drugs w Never consume alcohol or drugs before or while driving this ATV Pre operation checks Always perform the pre operation checks listed on page 5 1 before riding for safety and proper care of the ATV 2D3 9 20 7 3 10 05 7 27 PM Page 148 ...

Page 56: ...n pages 5 6 5 7 Always maintain proper tire pressure as described in the Owner s Manual on page 5 8 Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pressure may cause loss of con trol increasing your risk of an accident 7 6 Do not operate at speeds too fast for your skills or the conditions w Always go at a speed that is proper for the terrain visibility and...

Page 57: ...d to increase maximum speed as the beginner becomes more familiar with oper ating the ATV Parents should decide when to adjust the ATV for more power as their young ster s riding skills improve Once the ATV rider can operate with skill at the top speed permitted by adjusting the speed limiter alone the air intake restrictor plate can be removed Since removal of this plate will result in a signific...

Page 58: ...ing cargo or pulling a trailer MAXIMUM LOADING LIMIT 8 Vehicle loading limit total weight of cargo rider and accessories 95 kg 8 Carrier 5 kg During operation Always keep your feet on the footboards during operation Otherwise your feet may contact the rear wheels w Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation Removing even one hand or foot c...

Page 59: ...ries All parts and accessories added to this vehicle should be genuine Yamaha or equivalent compo nents designed for use on this ATV and should be installed and used according to instructions Improper installation of acces sories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident If you have questions consult an authorized ATV dealer 2D...

Page 60: ... ATV during or after operation in a place where others might be likely to touch it BE CAREFUL WHERE YOU RIDE This ATV is designed for off road use only Riding on paved surfaces can cause loss of con trol w Always avoid paved surfaces including side walks driveways parking lots and streets ATVs are designed for off road use only Paved surfaces may seriously affect han dling and control of the ATV a...

Page 61: ... Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle In many areas it is ille gal to operate ATVs on public streets roads and highways Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden hazards which may cause the ATV to upset w Go slowly and be extra careful when...

Page 62: ...in an accident including an overturn When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch w Always mount a caution flag on the ATV to make you more visible when operating in areas where you might not be seen by other off road vehicles Watch carefully for other vehicles Do not ride in are...

Page 63: ...are ready to begin riding your ATV As you get on the ATV be sure not to accidentally move the shift pedal Remember that the engine and exhaust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these compo nents With the engine idling lift the shift pedal to the 1st gear position and then release the parking brake Apply the throttle slowly and smoothl...

Page 64: ...hout releasing the throttle Damage to the engine or drive train may occur When slowing down or stopping release the throttle and apply the brakes smoothly and evenly As you slow down shift to a lower gear Be sure that the engine has sufficiently slowed before engaging a lower gear Improper use of the brakes or shifting can cause the tires to lose traction reducing control and increasing the possib...

Page 65: ...bed in this Owner s Manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions 1 Lean towards inside of turn 2 Support your weight on the outer footrest 1 2 As you approach a curve slow down and begin to turn the handlebars in the desired direction As you do so put your weight on the footboard to the outside of ...

Page 66: ...r to the outside of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills Be sure that you can maneu ver your ATV well on flat ground before attempt ing any incline and then practice riding first on gentle slopes Try more difficult climbs only afte...

Page 67: ...limbing 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 w 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 o...

Page 68: ...ad apply the front brake gradually or dis mount the ATV immediately on the uphill side w Use proper gear and maintain steady speed when climbing a hill If you lose all forward speed 8 Keep weight uphill 8 Apply the brakes 8 Lock the parking brake after you are stopped If you begin rolling backwards 8 Keep weight uphill 8 Never apply the rear brake while rolling backwards Apply the front brake When...

Page 69: ...aking may cause a loss of traction Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of trac tion Whenever possible ride your ATV straight downhill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you wi...

Page 70: ... 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 slippery surfaces or rough ter rain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to cor rect the steering when riding on loose surfaces by pointing the front whee...

Page 71: ... moving shallow water of up to a maximum of 20 cm in depth Before entering the water choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or upset the ATV Drive slowly and carefully w Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember that wet brakes may have reduc...

Page 72: ...fying that you have regained proper braking ability cC After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case Wash the ATV in fresh water if it has been operated in salt water or muddy condi tions 2D3 9 20 7 3 10 05 7 27 PM Page 165 ...

Page 73: ... area check for obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper pro cedures as described in the Owner s Manual SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide If unexpected and uncorrected sliding could lead to an accident To reduce the tendency for th...

Page 74: ...d The terrain should be chosen carefully before attempting such maneuvers since both stability and control are reduced Bear in mind that sliding maneu vers should always be avoided on extremely slippery surfaces such as ice since all control may be lost w Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice g...

Page 75: ...radually let off the throttle and or steer to the outside of the turn See pages 7 15 7 16 8 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not rec ommended until you have corrected the slide See pages 7 23 7 24 8 If your ATV can t make it up a hill you are try ing to climb Turn the ATV around if you still have fo...

Page 76: ...you discover that the ATV is going to tip over dismount on the uphill side See pages 7 20 7 21 8 If your ATV encounters shallow water Ride slowly and carefully through slow mov ing water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not con tinue to ride your ATV until you have regained adequate braking a...

Page 77: ... parts can catch clothing or parts of the body causing injury Electrical compo nents can cause shocks or can start fires Turn off the engine when performing mainte nance unless otherwise specified Have a Yamaha dealer perform service if you are not familiar with machine service 8 EBU01222 Owner s manual and tool kit You are recommended to put this owner s man ual and low pressure tire gauge in the...

Page 78: ... requiring one take your machine to a Yamaha dealer to check the torque settings and adjust them as necessary w Never modify this ATV through improper installation or use of accessories Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident All parts and accessories added to this vehicle should be genuin...

Page 79: ...150 300 Valves 9 Check valve clearance 9 Adjust if necessary 2 2 2 2 Cam chain 9 Check chain tension 9 Adjust if necessary 2 2 2 2 9 Check condition Spark plug 9 Adjust gap and clean 2 2 2 2 2 9 Replace if necessary Air filter element 9 Clean Every 20 40 hours 9 Replace if necessary more often in wet or dusty areas Carburetor 9 Check idle speed choke lever operation 2 2 2 2 9 Adjust if necessary C...

Page 80: ...tch 9 Check operation 2 2 2 2 9 Adjust if necessary Wheels 9 Check balance damage runout 2 2 2 2 9 Replace if necessary 9 Check bearing assemblies for looseness Wheel bearings damage 2 2 2 2 9 Replace if damaged 9 Check operation Steering system 9 Replace if damage 2 2 2 2 2 9 Check toe in 9 Adjust if necessary Knuckle shafts 9 Lubricate every 6 months with lithium soap based 2 2 2 steering shaft ...

Page 81: ...er hole without screwing it in NOTE Wait a few minutes until the oil level settles before checking 4 Remove the dipstick and inspect the oil level 5 The oil level should be between the mini mum and maximum marks If the level is low add oil to raise it to the specified level cC Be sure no foreign material enters the crankcase 2 3 1 1 Dipstick 2 Maximum level mark 3 Minimum level mark 8 5 2D3 9 20 8...

Page 82: ... 7 Fill the engine with oil and install the dip stick cC Be sure no foreign material enters the crankcase 8 Warm up the engine for several minutes at idle speed Check for oil leakage while warming up cC If oil leakage is found stop the engine imme diately and check for the cause Recommended oil type 20W50 20W40 15W40 10W40 10W30 5W30 Recommended oil classification API Service SE SF SG type or high...

Page 83: ...er hole without screwing it in 3 Remove the dipstick and inspect the oil level 4 The oil level should be between the maxi mum and minimum marks If the level is low add oil to raise it to the proper level cC Be sure no foreign material enters the final gear case 5 Install the dipstick w e q 1 Dipstick 2 Maximum level mark 3 Minimum level mark 2D3 9 20 8 3 11 05 10 31 AM Page 6 ...

Page 84: ...Install the drain bolt and tighten to specifi cation Tightening torque Drain bolt 23 Nm 2 3 m0kgf Recommended oil SAE80API GL 4 Hypoid gear oil Oil quantity 0 12 L 5 Fill the final gear case with oil cC Be sure no foreign material enters the final gear case 6 Install the dipstick 7 Check for oil leakage If oil leakage is found check for the cause 2D3 9 20 8 3 11 05 10 31 AM Page 7 ...

Page 85: ...ose such problems yourself Instead take the ATV to a Yamaha dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive you should replace the spark plug with one of the proper type Before installing the spark plug measure the electrode gap with a wire thickness gauge and ...

Page 86: ...e specified torque 1 Spark plug wrench Tightening torque Spark plug 12 5 Nm 1 25 m0kgf 1 1 Check hose EBU15621 Cleaning the air filter element NOTE There is a check hose at the bottom of the air fil ter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case 2D3 9 20 8 3 11 05 10 31 AM Page 9 ...

Page 87: ...eners 2 Remove the front cover by sliding it down ward and pulling it off as shown 8 11 2 2 1 1 Air filter case cover 2 Fastener 4 3 Remove the air filter case cover by unhooking the fasteners 1 2 1 Fastener 2 Air filter element 2D3 9 20 8 3 11 05 10 31 AM Page 10 ...

Page 88: ...E The air filter element should be wet but not drip ping 9 Install the air filter element 10 Install the air filter case cover by hooking the fasteners onto the air filter case 11 Place the front cover in the original posi tion and then install the quick fasteners NOTE The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the machine is operat...

Page 89: ...ating EBU01035 Air intake restrictor plate removal To obtain full engine performance capability removing the air intake restrictor plate is required 1 Remove the air filter element See page 8 11 for removal and installation procedures 2 Remove the air intake restrictor plate 1 1 Air intake restrictor plate NOTE Store the air intake restrictor plate with the owner s manual so you can install it whe...

Page 90: ... cal knowledge poor engine performance and damage may result EBU13020 Idle speed adjustment NOTE A diagnostic tachometer must be used for this procedure 1 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Connect the tachometer to the spark plug le...

Page 91: ...rance must be adjusted regularly This adjustment however should be left to a professional Yamaha service technician EBU00304 Cam chain adjustment The cam chain becomes loose with use result ing in improper valve timing and engine noise To prevent this the cam chain tensioner must be adjusted regularly This adjustment should be left to a Yamaha service technician 2D3 9 20 8 3 11 05 10 31 AM Page 14...

Page 92: ...rake shoe wear without disassembling the brake Apply the brake and check the position of the indicator If the indicator reaches the wear limit line or mark ask a Yamaha dealer to replace the shoes as a set w q w q 1 Wear limit line 2 Wear indicator 1 Wear limit mark 2 Wear indicator Front Rear 2D3 9 20 8 3 11 05 10 31 AM Page 15 ...

Page 93: ... brake shoes The front brake lever free play should be adjust ed to 10 12 mm at the brake lever pivot If the free play is incorrect adjust as follows a a Free play 1 Loosen the upper locknut and fully turn in the adjusting bolt 2 Loosen the lower locknut 3 Turn the lower adjusting bolt until specified free play is obtained Specified free play 10 12 mm 2D3 9 20 8 3 11 05 10 31 AM Page 16 ...

Page 94: ...the upper locknut w Operating with improperly serviced or adjusted brakes could cause loss of braking ability which could lead to an accident After servicing 8 Make sure the brakes operate smoothly and that the free play is correct 8 Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer 2D3 9 20 8 3 ...

Page 95: ...ver free play adjustment 1 Loosen the brake cable locknut 2 Turn the adjusting bolt at the brake lever until brake lever free play is 5 8 mm 3 Tighten the locknut NOTE If specified free play cannot be obtained tighten the brake cable adjusting nut at the rear wheel hub until brake lever free play is 5 8 mm 2D3 9 20 8 3 11 05 10 31 AM Page 18 ...

Page 96: ... improperly serviced or adjus ted brakes could cause loss of braking abili ty which could lead to an accident After servicing 8 Make sure the brakes operate smoothly and that the free play is correct 8 Make sure the brakes do not drag 8 Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer 2D3 9 20 8 3 11 05 10 31 AM Page 19 ...

Page 97: ...usting bolt clockwise until resistance is felt Then turn it 1 8 counterclockwise 5 Tighten the locknut to the specified torque NOTE Turn the adjusting bolt clockwise to decrease the clutch free play and turn it counterclockwise to increase the free play 6 Install the rubber cap securely q w e 1 Rubber cap 2 Locknut 3 Adjusting bolt Tightening torque 8 Nm 0 8 m0kgf 2D3 9 20 8 3 11 05 10 31 AM Page ...

Page 98: ...t or injury Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a Yamaha dealer to replace them Recommended lubricant Engine oil Tightening torque 10 Nm 1 0 m0kgf 1 EBU00727 Brake and shift pedal brake lever lubrication Lubricate the pivoting parts of each lever and pedal EBU01220 Knuckle shaft and steering shaft lubrication Lubricate the pivot points using a gr...

Page 99: ...cified torque Tightening torque Wheel nut Front 28 Nm 2 8 m0kgf Rear 28 Nm 2 8 m0kgf 1 1 2 Front Rear 1 Wheel nut 4 2 Wheel nut 3 EBU01112 Wheel removal 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 2D3 9 20 8 3 11 05 10 31 AM Page 22 ...

Page 100: ...an occur w Battery electrolyte is poisonous and danger ous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing 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 imme diately EYES Flush with water for 15 minutes and get prompt medical attention Batterie...

Page 101: ...fill only with distilled water 4 When the machine is not to be used for a month or longer remove the battery and store it in a cool dark place Completely recharge the battery before using 5 If the battery is to be stored for a longer period than the above check the specific gravity at least once a month and recharge the battery when it is too low 6 Always make sure the connections are cor rect whe...

Page 102: ...the switches If the fuse immediately blows again consult a Yamaha dealer Specified fuse 5 A w Always use a fuse of the specified rating Never use a material in place of the proper fuse An improper fuse can cause damage to the electrical system which could lead to a fire cC To prevent accidental short circuiting turn off the main switch when checking or replac ing a fuse 2D3 9 20 8 3 11 05 10 31 AM...

Page 103: ...er The skilled technicians at a Yamaha dealership have the tools experience and know how to properly service your machine Use only gen uine Yamaha parts on your machine Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a short er service life and can lead to expensive repair bills w Do not smoke when checking the fuel sys tem Fuel can ignite or explode c...

Page 104: ...park plug gap or replace spark plug There is compresson Compression normal Ask a Yamaha dealer to inspect No compression There is fuel Turn the fuel cock to OFF Remove the fuel hose from the fuel cock Some fuel Turn the fuel cock to RES Restart engine No fuel Supply fuel 4 Battery Use electric starter Engine turns over quickly Battery good Engine turns over slowly Check fluid recharge check connec...

Page 105: ...wheel axles 9 3 Rinse the dirt and degreaser off with a gar den hose Use only enough pressure to do the job cC Excessive water pressure 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 deter gent applications such as those available in coin operated car washers 4 Once t...

Page 106: ...9 2 EBU00427 B STORAGE Long term storage 60 days or more of your machine will require some preventive proce dures to guard against deterioration After thor oughly cleaning the machine prepare for stor age as follows 1 Fill the fuel tank with fresh fuel and add fuel stabilizer if available NOTE Use of fuel stabilizer eliminates the need to drain the fuel system Consult a Yamaha dealer if the fuel s...

Page 107: ...re coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat cover 7 Remove the battery and charge it Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than 0 C or more than 30 C NOTE Make any necessary repairs before storing the machine 2D3 9 20 9 3 7 05 9 39 PM Page 300 ...

Page 108: ...Minimum turning radius 2 400 mm Basic weight With oil and full fuel tank 124 kg Engine Type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder forward inclined Displacement 79 cm3 Bore Stroke 47 0 45 6 mm Compression ratio 9 6 1 Starting system Electric starter Lubrication system Wet sump EBU00428 SPECIFICATIONS 2D3 9 20 9 3 7 05 9 39 PM Page 301 ...

Page 109: ...o prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher 20 10 20 30 40 10W30 10W40 20W40 20W50 50 C 0 10 5W30 15W40 2D3 9 20 9 3 7 05 9 39 PM Page 302 ...

Page 110: ...mount 0 12 L Air filter Wet type element Fuel Type Unleaded gasoline only Tank capacity 6 8 L Reserve amount 0 9 L Carburetor Type manufacturer VM16SH MIKUNI Spark plug Type manufacturer CR7HSA NGK Gap 0 6 0 7 mm Clutch type Wet multiple disc automatic 2D3 9 20 9 3 7 05 9 39 PM Page 303 ...

Page 111: ...tion ratio 19 18 34 10 3 588 Transmission type Constant mesh 3 speed Operation Left foot operation Gear ratio 1st 39 11 3 545 2nd 35 17 2 059 3rd 31 22 1 409 Chassis Frame type Steel tube Caster angle 1 Trail 3 8 mm Tire Type Tubeless Size Front AT18 7 7 Rear AT18 8 7 Manufacturer type Front DUNLOP KT586 Rear DUNLOP KT587 2D3 9 20 9 3 7 05 9 39 PM Page 304 ...

Page 112: ...t Leading arm Rear Swingarm Shock absorber Front Coil spring Oil damper Rear Coil spring Oil damper Wheel travel Front wheel travel 57 mm Rear wheel travel 56 mm Electrical Ignition system C D I Charging system A C magneto Battery type voltage capacity 12N7D 3B 12V 7Ah Indicator light voltage wattage quantity Neutral 12V 1 7W 1 Fuse 5A 2D3 9 20 9 3 7 05 9 39 PM Page 305 ...

Page 113: ... SYSTEM Metric unit Conversion factor Imperial unit Torque m kgf m kgf cm kgf cm kgf 7 233 86 794 0 0723 0 8679 ft lbf in lbf ft lbf in lbf Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg m...

Page 114: ...2D3 9 20 9 3 7 05 9 39 PM Page 307 ...

Page 115: ...2D3 9 11 hyoshi 3 9 05 6 02 PM Page 3 ...

Page 116: ...PRINTED IN JAPAN 2005 3 0 1x1 E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2D3 9 20 hyoshi 3 9 05 6 43 PM Page 2 ...