Yamaha GRIZZLY 125 YFM125GB, Owner'S Manual

Page 1: ...OPIETARIO 1PY 28199 60 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad DIC183 ...

Page 2: ...PRINTED IN JAPAN 2011 03 0 2 1 CR E F S DIC183 PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ IMPRESO EN PAPEL RECICLADO ...

Page 3: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL YFM125GB 1PY 28199 60 E0 U1PY60E0 book Page 1 Friday March 11 2011 9 30 AM ...

Page 4: ...d or number and date of issue of the other Directives of EEC If applicable YAMAHA MOTOR EUROPE N V Koolhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Shinya Shimada Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the...

Page 5: ...the features and operation of this ATV This manual includes important safety information It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE Read this manual completel...

Page 6: ... safety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key info...

Page 7: ...road or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFM125GB OWNER S MANUAL 2011 by Yamaha Motor Co Ltd 1st edition February 2011 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U1PY60E0 book Page 1 Friday March 11 2011 9 30 AM ...

Page 8: ...g 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 6 Instruments lights and switches 5 6 Battery 5 6 OPERATION 6 1 Starting a cold engine 6 1 Starti...

Page 9: ...ning the engine and V belt case air filter elements 8 17 Cleaning the spark arrester 8 23 V belt case drain screw 8 24 Adjusting the carburetor 8 25 Adjusting the engine idling speed 8 25 Adjusting the throttle lever free play 8 26 Valve clearance 8 27 Brakes 8 27 Checking the front and rear brake shoes 8 27 Adjusting the front brake lever free play 8 28 Adjusting the rear brake lever free play 8 ...

Page 10: ... 47 Removing a wheel 8 47 Installing a wheel 8 48 Troubleshooting 8 49 Troubleshooting chart 8 50 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 U1PY60E0 book Page 3 Friday March 11 2011 9 30 AM ...

Page 11: ...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 1 3 4 2 7 8 5 6 U1PY60E0 book Page 1 Friday March 11 2011 9 30 AM ...

Page 12: ...1 2 1 1 2 3 4 1C5 2817R 00 5 kg 11 Ibs 1C5 2817R 10 10 kg 22 Ibs 1C5 2816M M0 kPa kgf cm2 psi 20 0 0 20 2 9 kPa kgf cm2 psi 25 0 0 25 3 6 1AS 2816P 00 U1PY60E0 book Page 2 Friday March 11 2011 9 30 AM ...

Page 13: ...1 3 1 4D3 2816L 20 43P 2816R 01 YFM125A 6 5kW 152kg 1C5 2156A 20 8AC 2817L 00 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN 2011 5 6 7 8 U1PY60E0 book Page 3 Friday March 11 2011 9 30 AM ...

Page 14: ... children under age 10 to operate this ATV Operation of this ATV by children under the age of 10 increases the risk of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 12 to operate this ATV Operation of this ATV by children under the age of 12 increases the risk of severe injury or death Adult supervision required for children under age 1...

Page 15: ...y or death Turning the ATV in 4WD LOCK DIFF LOCK takes more effort Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control This pictogram shows the loading limits and or maximum load capacity for this ATV Follow all load limits and other loading guidelines in this manual Load may include the driver passenger human protective gear accessories goods luggage a...

Page 16: ...ading can cause loss of control Loss of control can result in severe injury or death This pictogram shows trailer Hitch Tongue weight limit Weight on the trailer tongue Overloading can cause loss of control Loss of control can result in severe injury or death 1 2 3 Model Name Max Power Mass In Running Order 1 Year of construction U1PY60E0 book Page 6 Friday March 11 2011 9 30 AM ...

Page 17: ...child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and paved streets Never operate an ATV on any paved street paved road or motorway Watch carefully for other vehicles when operat ing on unpaved public streets or roads Make sure you know your country s ...

Page 18: ...imbing 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 Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully...

Page 19: ...your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires specified in this manual Always maintain proper tire pressure as de scribed in this manual Never modify an ATV through im...

Page 20: ...r open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or par tially enclosed areas such as barns garages or carports Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors WARNING EWB02591 When transporting the ATV in another vehicle be sure it is kept upright and that the ...

Page 21: ...er choke 3 Fuel cock 4 Throttle stop screw 5 Tail brake light 6 Rear carrier 7 Spark arrester 8 Footboard 1 2 3 5 6 7 8 4 1 Owner s tool kit 2 Battery 3 Drive select lever 4 Spark plug 5 Headlight 6 Engine oil filler cap 7 Fuse 2 3 5 6 7 1 4 U1PY60E0 book Page 1 Friday March 11 2011 9 30 AM ...

Page 22: ... from the figures shown in this manual 1 Rear brake lever 2 Parking brake lock plate 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 U1PY60E0 book Page 2 Friday March 11 2011 9 30 AM ...

Page 23: ...follows ON All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch OFF ON 1 U1PY60E0 book Page 1 Friday March 11 2011 9 30 AM ...

Page 24: ...r 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 Horn switch 2 Light switch OFF 3 Engine stop sw...

Page 25: ...the starter motor will not operate properly If this should happen remove the battery and recharge it See page 8 41 EBU18170 Horn switch Press the switch to sound the horn EBU18282 Throttle lever Once the engine is running pushing the throttle le ver will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decel...

Page 26: ...n the adjusting screw out more than 12 mm 0 47 in or the throttle cable could be dam aged Always make sure the throttle lever free play is adjusted to 1 0 3 0 mm 0 04 0 12 in See page 8 26 WARNING Improper ad justment of the speed limiter and throttle could cause throttle cable damage or im proper throttle operation You could lose control resulting in an accident EWB00241 3 Tighten the locknut EBU...

Page 27: ...rip EBU18461 Parking brake Use the parking brake before starting the engine or after 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 U1PY60E0 book Page 5 Friday March 11 2011 9 30 AM ...

Page 28: ...e 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 operation...

Page 29: ...itting on the vehicle Nev er refuel while smoking or while in the vicinity of sparks open flames or other sources of ig nition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reach es the bottom of the filler tube Because fuel expands when it heats...

Page 30: ...leaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand Use of un leaded fuel will extend spark plug life and r...

Page 31: ...e 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 U1PY60E0 book Page 9 Friday March 11 2011 9 30 AM ...

Page 32: ... 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 the rear 1 Arrow mark positioned over...

Page 33: ...nt 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 U1PY60E0 book Page 11 Friday March 11 2011 9 30 AM ...

Page 34: ... by a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 7 5 3 Engine oil Check oil level in engine and add recommended oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary 5 3 8 11 Transmission oil Check oil l...

Page 35: ... Check chain condition Lubricate if necessary 5 3 8 34 8 36 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 38 Chassis fasteners Make sure that all nuts bolts and screws are properly tighte...

Page 36: ...ake is applied If not have the ATV checked by a Yamaha dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance check the brake shoes for wear See page 8 27 EBU19761 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when rel...

Page 37: ...itions EWB02541 Set tire pressures to the following specifications The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Recommended tire pressure Front 20 0 kPa 0 200 kgf cm 2 9 psi Rear 25 0 kPa 0 250 kgf cm 3 6 psi Minimum tire pressure Front 17 ...

Page 38: ...tubeless tires with valves WARNING EWB02551 Use of improper tires on this ATV may cause loss of control increasing your risk of an acci dent After extensive tests only the tires listed below have been approved for this model by Yamaha Motor Co Ltd 1 Low pressure tire gauge 1 1 Tire wear limit U1PY60E0 book Page 5 Friday March 11 2011 9 30 AM ...

Page 39: ...ake sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary EBU19860 Battery Check the fluid level in the battery Fill with distilled water if necessary See page 8 41 Front Manufacturer model DUNLOP KT536A Size AT20 x 7 8 Type Tubeless Rear Manufacturer model DUNLOP...

Page 40: ...rking 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 started only when the drive se lect lever is in the neutral position 5 Use the starter choke in ...

Page 41: ... 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 throttle with the starter choke turned off NOTICE ECB00163 For maximum engine life never accelerate hard when the engine is cold ...

Page 42: ... 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 it is safe to proceed go slowly 1 Neutra...

Page 43: ...d with an odometer or hour meter follow the figures given in hours There is never a more important period in the life of your engine than the first 320 km 200 mi or 20 hours of riding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the first 320 km 200 mi or 20 hours The various parts in the engine wear and poli...

Page 44: ...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 Never park the ATV on hills that are too steep to walk up easi...

Page 45: ...ler Aftermarket parts accessories and modifica tions While you may find aftermarket products similar in design and quality to genuine Yamaha Accesso ries recognize that some aftermarket accessories or modifications are not suitable because of poten tial safety hazards to you or others Installing after market products or having other modifications performed to your ATV that change any of the ve hic...

Page 46: ...TV is not designed to tow a trailer If you choose to add accessories 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 wei...

Page 47: ...you should go Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV U1PY60E0 book Page 8 Friday March 11 2011 9 30 AM ...

Page 48: ...7 1 7 EBU21141 RIDING YOUR ATV U1PY60E0 book Page 1 Friday March 11 2011 9 30 AM ...

Page 49: ... 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 accident is greatly increased if the operat...

Page 50: ...390 A child under 16 should never operate an ATV with engine size greater than 90 cc Use by chil dren of ATVs that are not recommended for their age can lead to severe injury or death of the child This ATV is designed to carry the operator and cargo only passengers prohibited The long seat is to allow the operator to shift posi tion as needed during operation It is not for carry ing passengers WAR...

Page 51: ...G Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01411 Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating wi...

Page 52: ...ach 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 limiter For r...

Page 53: ...he risk of an accident Do not exceed the maximum loading limits for the vehicle see MAXIMUM LOADING LIMIT in this section or vehicle 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 tr...

Page 54: ...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 including an overturn Never attempt stunts...

Page 55: ...te idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust system dur ing or after operation could be burned Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it The muffler and other engine parts become ex tremely hot during operation ...

Page 56: ...es only WARNING Paved surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets EWB01511 While riding on unpaved public streets or roads may be legal in your area such operation can in crease the risk of collision with other vehicles U1PY60E0 book Page 9 Friday March 11...

Page 57: ... other hidden hazards which may cause the ATV to upset WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Al ways be alert to changing terrain conditions when operating the ATV EWB01531 Do not operate on rough slippery or loose terrain until you have learned and practice...

Page 58: ...on flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if operating in areas where you cannot easily be seen Mount a caution flag on the ATV to make you more visible Watch carefully for other vehicles EWB01551 Do not ride in areas posted no trespassing Do not ride on private property without getting per mission U1PY60E0 book Page 11 Fr...

Page 59: ...eeds 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 turning as described in this Owner s M...

Page 60: ...again If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body move ments or too much speed for the sharpness of the t...

Page 61: ...ly slippery or loose surfaces Shift your weight 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 le...

Page 62: ... on the other side there could be another person an obstacle or a sharp drop off Use common sense and remember that some hills are too steep for you to climb or de scend 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 hi...

Page 63: ...ls as de scribed in this Owner s Manual Always check the terrain carefully before you start down any hill Never operate the ATV on hills too steep for the ATV or for your abilities The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills Shift your weight backward and to the up side of the hill Never go down a hill at high speed Avoid going down a hill at an ...

Page 64: ...n Gradual ly apply only the rear brake Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear CROSSING A SLOPE WARNING EWB01632 Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to overturn ...

Page 65: ...t may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel CR...

Page 66: ...o not continue to ride your ATV with out verifying that you have regained proper braking ability WARNING Wet brakes may have re duced stopping ability which could cause loss of control EWB02621 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 Also remove the V belt case drain screw to drain any water that may have acc...

Page 67: ...in should be done with cau tion Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult SLIDING AND SKIDDING WARNING EWB01662 Skidding or sliding improperly may cause you to lose control of this ATV You may also...

Page 68: ...tioning your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide side ways control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide With practice over a period of time skill at con trolled sliding can be developed The terrai...

Page 69: ...l you are trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 14 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned t...

Page 70: ...rn off the engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 3 for more information about carbon monoxide WARNING EWB02690 B...

Page 71: ...nd the tools provided in the owner s tool kit are in tended to assist you in the performance of preven tive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Owner s manual 2 Low pressure t...

Page 72: ...ire special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust ...

Page 73: ...ess 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 U1PY60E0 book Page 4 Friday March 11 2011 9 30 AM ...

Page 74: ...ols 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 Engine and V belt case air filter ele ment Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Front brake Check operation and correct if necessary Check brake lever free p...

Page 75: ...y Clean and lubricate 9 V belt Check for wear cracks or other damage and re place if necessary 10 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 11 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 12 Front knuckle piv ots Lubricate with lithium soap based grease 13 Steering shaft Lubricate with lit...

Page 76: ...ver free play and adjust if neces sary Lubricate cable and lever housing 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 rout ed NO ITEM CHECK OR MAINTENANCE JOB...

Page 77: ...8 8 8 EBU23061 TIP Some maintenance items need more frequent service if you are riding in unusually wet dusty sandy or muddy areas or at full throttle U1PY60E0 book Page 8 Friday March 11 2011 9 30 AM ...

Page 78: ...dition 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 owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden norm...

Page 79: ...necessary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification To install the spark plug 1 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 2 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Specified spark plug NGK CR7HSA 1 Spa...

Page 80: ... check the engine oil level 1 Place the ATV on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil set tles for an accurate reading 3 Remove the engine oil filler cap and then wipe the engine oil dipstick off with a clean rag 4 Insert the...

Page 81: ...he 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 oil from the crankcase NOTICE When remov ing the engine oil drain bolt the compres sion spri...

Page 82: ... and then install and tight en the engine oil filler cap TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down NOTICE 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 1 Engin...

Page 83: ...ust 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 oi...

Page 84: ...the transmission 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 transmission to col lect the used oil 4 Remove the transmission oil filler bolt the transmission oil drain bolt and their gasket to drain the oil from the transmission case 1 Transmission oil filler bolt 2 Gasket Tightening torque Transmission...

Page 85: ... Make sure that no oil gets on the tires or wheels 9 Start the engine and then let it idle for several minutes while checking the transmission for oil leakage If oil is leaking immediately turn off the engine and check for the cause 10 Turn the engine off and then check the oil lev el and correct it if necessary 1 Transmission oil drain bolt 2 Gasket Tightening torque Transmission oil drain bolt 2...

Page 86: ...se empty the hose and clean the air filter element and air fil ter case 1 Place the ATV on a level surface 2 Remove the seat See page 4 10 3 Remove the breather hose by pulling it out and then loosen the air filter joint screw 4 Remove the air filter case cover by removing its screws then disconnecting the air filter case cover from the air filter joint 1 Air filter case check hose 1 1 Breather ho...

Page 87: ...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 1 Air filter case cover 2 Screw 1 2 2 2 2 1 Screw 2 Washer 3 Sponge material 4 Air filter element frame 5 Air filter case cover 3 4 2 1 5 U1PY60E0 book Page 18 Friday March 11 2011 9 30 AM ...

Page 88: ...r and screw NOTICE Be sure to install the washer with its curved side facing outward as shown ECB00453 12 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 possibl...

Page 89: ...ement maintenance 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 car...

Page 90: ...ler shown 5 Remove the air filter case cover by removing the screw 6 Remove the air filter element 1 Panel 2 Quick fastener 1 Coupler 1 2 2 1 1 1 Air filter case cover 2 Screw 1 2 U1PY60E0 book Page 21 Friday March 11 2011 9 30 AM ...

Page 91: ...into the air filter case 10 Install the air filter case cover by installing the screw 11 Connect the coupler and then install the pan el by installing the quick fasteners 12 Install the front carrier by installing the bolts and then tighten them to the specified torque 1 Air filter element 1 1 Air filter element Tightening torque Front carrier bolt 7 Nm 0 7 m kgf 5 1 ft lbf 1 U1PY60E0 book Page 22...

Page 92: ...n deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 4 Insert the tailpipe into the muffler and align the screw holes 5 Check the gaskets for damage and replace them if necessary 6 Install the screws and their gasket and then tighten the screws to the specified torque 1 Tailpipe screw 1 1 Tailpipe screw 2 Gasket 3 Tailpipe 4 Spark arrester Tightening torque...

Page 93: ...ew to drain the water from the case TIP If water drains from the V belt case after removing the screw have a Yamaha dealer check the ATV as the water may affect other engine parts To drain the water from the V belt case 1 Place the ATV on a level surface 2 Place a container under the V belt case and then remove the V belt case drain screw and its gasket to drain the water from the V belt case 3 In...

Page 94: ...chnical knowl edge may result in poor performance of or damage to the engine EBU24000 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica tion chart TIP A diagnostic tachometer is needed to make this adjustment 1 Start the engine and warm it up TIP The engine is warm when i...

Page 95: ...04 0 12 in as shown Periodically check the throttle lever free play and if necessary adjust it as follows TIP The engine idling speed must be checked and ad justed if necessary before adjusting the throttle le ver free play 1 Slide the rubber cover back 2 Loosen the locknut 3 To increase the throttle lever free play turn the throttle lever free play adjusting bolt in di rection a To decrease the t...

Page 96: ... 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 brake To check the brake shoe wear ...

Page 97: ...cked 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 U1PY60E0 book Page 28 Friday March 11 2011 9 30 AM ...

Page 98: ...ay is in correct adjust it as follows 1 Remove the front carrier by removing the bolts 2 Remove the panel by removing the quick fas teners and then pulling it upward as shown 1 Brake lever free play 1 1 Front carrier 2 Front carrier bolt 1 2 2 2 U1PY60E0 book Page 29 Friday March 11 2011 9 30 AM ...

Page 99: ...ment cover by removing the screw 5 Loosen the locknut and fully turn in the brake lever free play adjusting bolt at the brake le ver 1 Panel 2 Quick fastener 1 Coupler 1 2 2 1 1 1 V belt air filter element cover 2 Screw 1 2 U1PY60E0 book Page 30 Friday March 11 2011 9 30 AM ...

Page 100: ...t isn t straight loosen the locknuts and then turn the adjusting nuts on the front brake cables until the cable joint becomes straight 1 Locknut 2 Brake lever free play adjusting bolt 1 2 1 Brake equalizer 2 Cable joint 1 Locknut 2 Adjusting nut a a a a 1 2 2 1 1 2 U1PY60E0 book Page 31 Friday March 11 2011 9 30 AM ...

Page 101: ...ghten them to the specified torque EBU30440 Adjusting the rear brake lever free play The 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 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 p...

Page 102: ...rn the adjusting bolt fully in direction a and then adjust the free play us ing the brake lever free play adjusting nut on the rear wheel hub 4 Turn the brake lever free play adjusting nut on the rear wheel hub in direction a to increase the free play and in direction b to decrease it 1 Brake lever free play 1 1 Locknut 2 Brake lever free play adjusting bolt a b 2 1 U1PY60E0 book Page 33 Friday Ma...

Page 103: ...in slack 1 Place the ATV on a level surface TIP When checking and adjusting the drive chain slack there should 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 1 Brake lever free play adjusting ...

Page 104: ... 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 slip page or breakage To prevent this from oc curring keep the drive chain slack within the specified limits ECB00542 5 Tighten the drive chain slack adjusting bolt locknut and the axle holding bolts to the spec ified torques 1 Hub stopper bolt 2 Hub stoppe...

Page 105: ...hain as follows NOTICE ECB00561 The drive chain must be lubricated after wash ing the ATV or riding in the rain or wet areas 1 Clean the drive chain with kerosene and a small soft brush NOTICE To prevent dam aging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents ECB00571 Tightening torques Drive chain slack adjusting bolt locknut 16 Nm 1 ...

Page 106: ...able is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWB02581 Inspect cables frequently and replace if dam aged Corrosion can result when the cable sheaths become damaged and cables can also become frayed or kinked which could restrict the operation of controls and lead to an accident or injury Always make sure all control cables work smoothly before you begin...

Page 107: ...brake lever Rear brake lever EBU24963 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bear ings Recommended lubricant Lithium soap based grease U1PY60E0 book Page 38 Friday Ma...

Page 108: ...he in tervals specified in the periodic maintenance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun Left side Right side Recommended lubricant Lithium soap based grease 1 Grease nipple 1 Grease nipple 1 1 1 1 U1PY60E0 book Page 39 Friday March 11 2011 9 30 AM ...

Page 109: ...rease gun EBU25092 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun Recommended lubricant Lithium soap based grease 1 Grease nipple 1 Recommended lubricant Lithium soap based grease 1 Grease nipple 1 U1PY60E0 book Page 40 F...

Page 110: ...orking near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ig nition away Ventilate when charging or using in an e...

Page 111: ...ttery 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 To store the battery If the ATV will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 1 Battery 2 Battery breat...

Page 112: ...ry 2 Connect the positive lead first and then con nect the negative lead NOTICE When in stalling the battery the main switch must be off and the positive lead must be con nected before the negative lead ECB01110 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 ...

Page 113: ...NING Always use a fuse of the spec ified rating and never use a substitute ob ject in place of the proper fuse An improper fuse or a substitute object can cause damage to the electrical system which could lead to a fire EWB02172 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical sy...

Page 114: ...e 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 Headli...

Page 115: ...r and seated properly ECB00671 8 Adjust the headlight beam if necessary EBU25551 Adjusting a headlight beam NOTICE ECB00690 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the headlight beam adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b 1 Headlight bulb 1 1 Headlight beam adjusting screw 1 a b U1PY60E0 b...

Page 116: ...y pushing it in and turning it counterclockwise 3 Insert a new bulb into the bulb holder push it in and then turn it clockwise until it stops 4 Install the bulb holder together with the bulb by turning it clockwise EBU25651 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 1 Tail brake light bulb holder 1 1 Tail brake light bulb 2 Tail brake light bulb holder 1 2 U1PY60E0...

Page 117: ...ace 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 U1PY60E0 book Page 48 Friday March 11 2011 9 30 AM ...

Page 118: ... technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02280 Do not smoke when checking the fuel system Fuel can ignite or explode causing severe inju ry or property damage...

Page 119: ... check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is good Check the electrolyte leve...

Page 120: ...gs EWB02311 NOTICE Excessive water pressure may cause water seepage and deteriora tion of wheel bearings brakes transmis sion seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applica tions such as those available in coin oper ated car washers ECB00711 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild de...

Page 121: ...zer if available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit s...

Page 122: ...rom entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation on storing the battery see page 8 41 TIP Make any necessary repairs before storing the ATV U1PY60E0 book Page 3 Friday March 11 2011 9 30 AM ...

Page 123: ...vibration level Noise level 77 311 EEC 78 0 dB A 3500 r min Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s Vibration on handlebar EN1032 ISO5008 Will not exceed 2 5 m s Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 124 cm Bore stroke 49 0 66 0 mm 1 93 2 60 in Compression ratio 9 00 1 Starting system Electric starter Lubrica...

Page 124: ... Fuel reserve amount 1 3 L 0 34 US gal 0 29 Imp gal Carburetor Type quantity VM18SH x 1 Spark plug s Manufacturer model NGK CR7HSA Spark plug gap 0 6 0 7 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 Tra...

Page 125: ... cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 20 0 kPa 0 200 kgf cm 2 9 psi Rear 25 0 kPa 0 250 kgf cm 3 6 psi Minimum Front 17 0 kPa 0 170 kgf cm 2 5 psi Rear 22 0 kPa 0 220 kgf cm 3 2 psi Front wheel Wheel type Panel wheel Rim size 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 R...

Page 126: ...0 For EUR only The figures quoted are emission levels and are not necessarily safe working levels Whilst there is a correlation between the emission and exposure levels this cannot be used reliably to determine whether or not further precautions are required Factors that influence the actual level of exposure of work force include the characteristics of the work room the other sources of noise etc...

Page 127: ...parts from a Yamaha dealer or for reference in case the ATV is stolen VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26041 Vehicle identification number The vehicle identification number is stamped into the frame The year of manufacture is listed in the vehicle identification number as shown in the illustration 1 Vehicle identification number 1 U1PY60E0 book Page 1 Friday March 11 2011 9...

Page 128: ...on in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha deal er 1 Vehicle identification number 2 Year of manufacture 0 0 8 2008 9 2009 A 2010 B 2011 I O Q U Z not used 1 2 1 Model label 1 U1PY60E0 book Page 2 Friday March 11 2011 9 30 AM ...

Page 129: ...icating 8 36 Drive chain slack 8 34 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 25 Engine oil 5 3 8 11 Engine starting a warm 6 2 Engine stop switch 4 2 F Front knuckle pivots lubricating 8 40 Fuel 4 7 5 3 Fuel cock 4 8 Fuel tank cap 4 7 Fuse replacing 8 44 H Handlebar switches 4 2 Headlight beam adjusting 8...

Page 130: ...r choke 4 10 Start switch 4 3 Steering shaft lubricating 8 40 Storage 9 2 Suspension lubricating the lower arm pivots 8 39 T Tail brake light bulb replacing 8 47 Throttle lever 4 3 5 3 Throttle lever free play adjusting 8 26 Tires 5 3 Transmission oil 5 3 8 14 Troubleshooting 8 49 Troubleshooting chart 8 50 V Valve clearance 8 27 V belt case drain screw 8 24 Vehicle identification number 11 1 W Wh...

Page 131: ...U1PY60E0 book Page 3 Friday March 11 2011 9 30 AM ...

Page 132: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2011 03 0 2 1 CR E U1PY60E0 book Page 1 Friday March 11 2011 9 30 AM ...