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Yamaha GRIZZLY 125 YFM125GB Owner's Manual

Summary of GRIZZLY 125 YFM125GB

  • Page 1

    Yfm125gd owner’s manual manuel du propriÉtaire manual del propietario 1py-28199-61 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 a...

  • Page 2

    Printed in japan 2012.03-0.3 ×1 cr (e,f,s) dic183 printed on recycled paper imprimÉ sur papier recyclÉ impreso en papel reciclado.

  • Page 3: Owner’S Manual

    Read this manual carefully! It contains important safety information. Warning owner’s manual yfm125gd this atv should not be ridden by anyone under 16 years of age. 1py-28199-61-e0 u1py61e0.Book page 1 wednesday, march 14, 2012 5:22 pm.

  • Page 4

    Ebu30002 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. En15997, ansi/svia 1-2010 general manager rv engineering division recreational vehicle business unit business development operations yamaha motor co., ltd. Yfm125a (yfm125g) ...

  • Page 5

    Ebu17170 introduction ebu17292 congratulations on your purchase of the yamaha yfm125gd. This atv represents the result of many years of yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this yamaha, you can now appreciate the high de...

  • Page 6

    Ebu17330 important manual information ebu17342 failure to follow the warnings contained in this manual can result in serious in- jury or death. Particularly important information is distinguished in this manual by the following notations: * product and specifications are subject to change without no...

  • Page 7

    Ebu17350 important notice ebu17372 this atv is designed and manufactured for use on unpaved surfaces only. It is unsafe to operate this atv on any paved surface, paved street, paved road or motorway. Please check your local riding laws and regulations before operating this atv. Ebu17390 yfm125gd own...

  • Page 8

    Ebu17420 table of contents location of the warning and specification labels ............................ 1-1 safety information .............................. 2-1 description .............................................. 3-1 left view ...................................................... 3-1 right...

  • Page 9

    Parking on a slope ..................................... 6-5 accessories and loading ............................ 6-6 riding your atv ...................................... 7-1 getting to know your atv............... 7-2 ride with care and good judgment .................................................

  • Page 10

    Adjusting a headlight beam ...................... 8-47 replacing the tail/brake light bulb ............ 8-47 removing a wheel .................................... 8-48 installing a wheel ...................................... 8-48 troubleshooting ....................................... 8-49 troubles...

  • Page 11

    1-1 1 ebu29680 location of the warning and specification labels ebu29982 read and understand all of the labels on your atv. These labels contain important information for safe and proper operation. Never remove any labels from your atv. If a label becomes difficult to read or comes off, request a re...

  • 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/cm 2 psi 20.0 0.20 2.9 kpa kgf/cm 2 psi 25.0 0.25 3.6 1as-2816p-00 u1py61e0.Book page 2 wednesday, march 14, 2012 5:22 pm.

  • Page 13

    1-3 1 43p-2816r-01 yfm125a 6.5kw 152kg 1c5-2156a-20 8ac-2817l-00 yamaha motor co., ltd. 2500 shingai, iwata, japan 2012 1pd-2811r-00 5 6 7 8 u1py61e0.Book page 3 wednesday, march 14, 2012 5:22 pm.

  • Page 14

    1-4 1 familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the owner’s manual. Always use an approved helmet and protective gear. For atv type 1 category y12, use from 12 years old. Operation of this a...

  • Page 15

    1-5 1 **.* kpa *.** kgf/cm² *.* psi **.* kpa *.** kgf/cm² *.* psi this pictogram shows trailer hitch tow weight limit. (combined weight of the trailer and all cargo in the trailer.) overloading can cause loss of control. Loss of control can result in severe injury or death. This unit contains high-p...

  • Page 16

    1-6 1 ****** *** kw *** kg 1 2 3 yamaha motor co., ltd. 2500 shingai, iwata, japan **** 1 1 2 3 model name max. Power mass in running order 1 year of construction u1py61e0.Book page 6 wednesday, march 14, 2012 5:22 pm.

  • Page 17

    2-1 2 ebu17431 safety information ebu17537 an atv is not a toy and can be hazard- ous to operate. An atv handles differently from other vehicles, in- cluding motorcycles and cars. A collision or roll- over can occur quickly, even during routine maneuvers such as turning and riding on hills or over o...

  • Page 18

    2-2 2 ● never operate at speeds too fast for your skills or the riding conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience. ● never attempt wheelies, jumps, or other stunts. ● always inspect your atv each time you use it to make sure...

  • Page 19

    2-3 2 ● always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stall- ing, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the spe- cial procedure for braking described in this man- ual. Dismount on the uphill side or to a side...

  • Page 20

    2-4 2 in the event of an accident 1. If serious injuries are incurred, you may be safer staying next to your vehicle; it may shield you from oncoming riders. Depending on your injuries and position in the trail; you must make a judgment call as to whether you should move to a position off the trail....

  • Page 21

    2-5 2 4. Once immediate safety hazards are con- firmed not to exist, you may remove your hel- met to more closely inspect your vehicle. Check for external signs of wear, broken parts, fluid leaks, cracks in the frame, suspen- sion damage, wheel damage, and so on. Fuel, oil, and coolant usually give ...

  • Page 22

    2-6 2 warning ewb00072 avoid carbon monoxide poisoning all engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nau- sea, confusion, and eventually death. Carbon monoxide is a colorless, odorless, tasteless gas which may be pres...

  • Page 23

    3-1 3 ebu17680 description ebu17690 left view ebu17700 right view 1. Front carrier 2. Starter (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...

  • Page 24

    3-2 3 ebu17712 controls and instruments tip the atv you have purchased may differ slightly 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 c...

  • Page 25

    4-1 4 ebu17734 instrument and control functions ebu17760 main switch the positions of the main switch are as 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...

  • Page 26

    4-2 4 ebu17793 indicator lights ebu17860 neutral indicator light “ ” this indicator light comes on when the transmis- sion is in the neutral position. Ebu17830 reverse indicator light “ ” this indicator light comes on when the transmis- sion is in the reverse position. Ebu18061 handlebar switches eb...

  • Page 27

    4-3 4 ebu18101 start switch “ ” push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine. Ebu18154 light switch “ / /off” set this switch to “ ” to turn on the low beams and the taillight. Set the switch to “ ” to turn on the hig...

  • Page 28

    4-4 4 ebu18323 speed limiter your atv is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power avail- able and the maximum speed of the ...

  • Page 29

    4-5 4 ebu18401 rear brake lever the rear brake lever is located on the left handle- bar. To apply the rear brake, pull the brake lever to- ward the handlebar grip. Ebu18461 parking brake use the parking brake before starting the engine or after parking the atv, especially on a slope. Apply the rear ...

  • Page 30

    4-6 4 warning ewb00220 ● always set the parking brake before starting the engine. The atv could start moving un- expectedly if the parking brake is not ap- plied. This could cause loss of control or a collision. ● always be sure you have released the park- ing brake before you begin to ride. The bra...

  • Page 31

    4-7 4 ebu18720 fuel tank cap remove the fuel tank cap by turning it counter- clockwise. Ebu28943 fuel make sure there is sufficient gasoline in the tank. Warning ewb02521 gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueli...

  • Page 32

    4-8 4 3. Wipe up any spilled fuel immediately. Notice: immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. [ecb00981] 4. Turn the fuel tank cap fully clockwise to make sure it is securely closed. Warning ewb02531 gasoline is ...

  • Page 33

    4-9 4 off with the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running. 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...

  • Page 34

    4-10 4 res this indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to “on”! Ebu18840...

  • Page 35

    4-11 4 to install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. Make sure that the seat is securely fitted. Ebu18962 front carrier ● do not exceed the load limit of 5.0 kg (11 lb) for the front carrier. ● do not exceed the maxim...

  • Page 36

    5-1 5 ebu19201 pre-operation checks ebu19224 inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual. Warning ewb00481 failure to inspect or maintain the v...

  • Page 37

    5-2 5 rear brake • check operation, and correct if necessary. • lubricate cable if necessary. • check lever free play, and adjust if necessary. 5-3, 8-28, 8-33 throttle lever • make sure that operation is smooth. Lubricate cable and lever hous- ing if necessary. • check lever free play, and adjust i...

  • Page 38

    5-3 5 ebu19541 fuel make sure that there is sufficient fuel in the tank. (see page 4-7.) ebu19560 engine oil make sure that the engine oil is at the specified lev- el. Add oil as necessary. (see page 8-11.) ebu19580 transmission oil make sure that the transmission oil is at the speci- fied level. Ad...

  • Page 39

    5-4 5 tire pressure use the low-pressure tire gauge to check and ad- just tire pressures when the tires are cold. Tire pressures must be equal on both sides. Warning! Operation of this vehicle with im- proper tire pressure may cause severe injury or death from loss of control or rollover. Tire press...

  • Page 40

    5-5 5 tire wear limit when the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. Tire information this atv is equipped with 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 exte...

  • Page 41

    5-6 5 aftermarket tires and rims the tires and rims that came with your atv were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Ebu19840 chassis fasteners make su...

  • Page 42

    6-1 6 ebu19881 operation ebu19901 read the owner’s manual carefully before riding the atv. If there is a control or function you do not understand, ask your yamaha dealer. Warning ewb00631 read the owner’s manual carefully to become familiar with all controls in order to help pre- vent any loss of c...

  • Page 43

    6-2 6 position (3): cold engine start with ambient temperature above 25 °c (80 °f). Ambient temp./starter (choke) position 6. Completely close the throttle lever and start the engine by pushing the start switch. Tip ● if the engine fails to start, release the start switch, then push it again. Pause ...

  • Page 44

    6-3 6 ebu20291 starting a warm engine follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. Ebu20361 operating the drive select lever and driving in reve...

  • Page 45

    6-4 6 1. Bring the atv to a complete stop. 2. Apply the parking brake. 3. Shift from neutral to reverse and vice versa by moving the drive select lever along the shift guide. Tip when in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a yamaha deale...

  • Page 46

    6-5 6 notice ecb00220 if any engine trouble should occur during the engine break-in period, immediately have a yamaha dealer check the atv. Ebu30020 parking when parking the atv, apply the rear brake lever, shift the drive select lever into the forward position, stop the engine, apply the parking br...

  • Page 47

    6-6 6 ebu20910 accessories and loading ebu20921 genuine yamaha accessories choosing accessories for your atv is an important decision. Genuine yamaha accessories, which are available only from a yamaha dealer, have been designed, tested, and approved by yamaha for use on your atv. Many companies wit...

  • Page 48

    6-7 6 ● do not mount an accessory where it could inter- fere with your ability to control the atv. Exam- ples include (but are not limited to) a heavy or bulky object attached to the handlebars which could make steering difficult, an accessory that limits your ability to move around on the seat, or ...

  • Page 49

    6-8 6 ● ride more slowly than you would without a load. The more weight you carry, the slower 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 weig...

  • Page 50

    7-1 7 ebu21141 riding your atv u1py61e0.Book page 1 wednesday, march 14, 2012 5:22 pm.

  • Page 51

    7-2 7 ebu21316 getting to know your atv this atv is for recreation and utility use. This sec- tion, 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 at...

  • Page 52

    7-3 7 riding your atv requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the atv’s handling and performance characteristics. Take the time to learn the basic techniques well before attempting more di...

  • Page 53

    7-4 7 apparel always wear the following to reduce risk of injury in an accident: ● approved motorcycle helmet that fits properly ● eye protection (goggles, helmet face shield, or protective eyewear) ● over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants an approved helmet and o...

  • Page 54

    7-5 7 do not operate after or while consuming alco- hol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. Consuming al- cohol or drugs could seriously affect your judg- ment, cause you to react more slowly, and affect your balance and perception. Warnin...

  • Page 55

    7-6 7 opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and de- creases the maximum speed of the atv. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (see page 4-4.) loa...

  • Page 56

    7-7 7 drive 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 to drive slowly (shift into first gear or low drive if avail- able on this model) whenever you are carrying heavier loads or when towing a trailer...

  • Page 57

    7-8 7 modifications and accessories never modify this atv through improper installa- tion or use of accessories or other modification. All parts and accessories added to this atv should be genuine yamaha or equivalent components de- signed for use on this atv and should be installed and used accordi...

  • Page 58

    7-9 7 to prevent burns, avoid touching the exhaust sys- tem. Park the atv in a place where pedestrians or children are not likely to touch it. Be careful where you ride this atv is designed for use on unpaved surfaces only. Warning! Paved surfaces may seriously affect handling and control of the atv...

  • Page 59

    7-10 7 watch carefully for other vehicles. Make sure you know your country’s laws and regulations before you ride on unpaved public streets or roads. Do not ride on any paved public street, road or motorway. Warning! Never operate this atv on any paved street, paved road or motorway. You can collide...

  • Page 60

    7-11 7 loose terrain could cause loss of traction or atv control, which could result in an accident, including an overturn. [ewb01541] 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 hit...

  • Page 61

    7-12 7 select a large, flat, unpaved area to become famil- iar with your atv. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Set the pa...

  • Page 62

    7-13 7 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 out- side of the turn (opposite your desired direction) and lean your upper body into the turn. Use the throttle to maintain an even speed throug...

  • Page 63

    7-14 7 climbing uphill warning ewb01671 climbing hills improperly can cause overturns or loss of control. Use proper riding tech- niques described in this owner’s manual. ● never operate the atv on hills too steep for the atv or for your abilities. The atv can overturn more easily on extremely steep...

  • Page 64

    7-15 7 do not attempt to climb hills until you have mas- tered basic maneuvers on flat ground. Always check the terrain carefully before attempting any hill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control. To climb a hill, you need trac...

  • Page 65

    7-16 7 mediately on the uphill side or to a side if pointed straight uphill. Turn the atv around and remount, following the procedure described in the owner’s manual. Warning! Stalling, rolling backwards or improperly dismounting while climbing a hill could result in atv overturning. If you cannot c...

  • Page 66

    7-17 7 when riding your atv downhill, shift your weight as far to the rear and uphill side of the atv as pos- sible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you. Use caution while descending a hill with loose or slippery surfaces. Bra...

  • Page 67

    7-18 7 ● shift your weight to the uphill side of the atv. ● never attempt to turn the atv around on any hill until you have mastered the turning tech- nique as described in the owner’s manual on level ground. Be very careful when turning on any hill. Traversing a sloping surface on your atv requires...

  • Page 68

    7-19 7 the atv can be used to cross slow moving, shal- low water of up to a maximum of 20 cm (8 in) 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 car...

  • Page 69

    7-20 7 riding over rough terrain warning ewb01651 riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always fo...

  • Page 70

    7-21 7 ● learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. ● on extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- duce the chance of skidding or sliding out of control. Care should be used when riding on loose...

  • Page 71

    7-22 7 what to do if... This section is designed to be a reference guide only. Be sure to read each section on riding tech- niques completely. What to do... ● if your atv doesn’t turn when you want it to: bring the atv to a stop and practice the turning maneuvers again. Be sure you are putting your ...

  • Page 72

    8-1 8 ebu28783 periodic maintenance and adjustment ebu21674 periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most effi- cient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection, adjustmen...

  • Page 73

    8-2 8 ebu27111 owner’s manual and tool kit be sure to put this owner’s manual in the plastic bag and to always carry it as well as the owner’s tool kit and the low-pressure tire gauge in their re- spective compartments under the seat. The service information included in this manual and the tools pro...

  • Page 74

    8-3 8 ebu21743 periodic maintenance chart for the emission control system tip ● for atvs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● for atvs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter- vals. However, keep i...

  • Page 75

    8-4 8 6 * exhaust system • check for leakage and replace gasket(s) if neces- sary. • check for looseness and tighten all screw clamps and joints if necessary. √ √ √ 7 spark arrester • clean. √ √ √ no. Item check or maintenance job initial every whichev- er comes first month 1 3 6 6 12 km (mi) 320 (2...

  • Page 76

    8-5 8 ebu21865 general maintenance and lubrication chart tip ● for atvs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● for atvs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter- vals. However, keep in mind that if th...

  • Page 77

    8-6 8 4 * wheels • check runout and for damage, and replace if nec- essary. √ √ √ √ 5 * tires • check tread depth and for damage, and replace if necessary. • check air pressure and balance, and correct if necessary. √ √ √ √ 6 * wheel hub bearings • check for looseness or damage, and replace if neces...

  • Page 78

    8-7 8 14 * steering shaft • lubricate with lithium-soap-based grease. √ √ √ 15 * steering system • check operation and repair or replace if damaged. • check toe-in and adjust if necessary. √ √ √ √ √ 16 engine oil • change. • check atv for oil leakage, and correct if neces- sary. √ √ √ √ 17 engine oi...

  • Page 79

    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. 23 * battery • check electrolyte level and specific gravity, and correct if necessary. • make sure that the breather hose is properly rout- ed. √...

  • Page 80

    8-9 8 ebu23213 checking the spark plug the spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- tion chart. In ad...

  • Page 81

    8-10 8 tip if the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a yamaha dealer check the atv. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and repla...

  • Page 82

    8-11 8 tip if a torque wrench is not available when installing the spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 3. Install the spark plug cap. Ebu23268 engine oil the engi...

  • Page 83

    8-12 8 tip the engine oil should be between the minimum and maximum level marks. 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended type to raise it to the correct level. Notice: be sure the engine oil is at the correct level, otherwise engine damage ...

  • Page 84

    8-13 8 5. Clean the oil strainer with solvent. 6. Apply a thin coat of clean engine oil to a new o-ring. 7. Install the oil strainer, the compression spring, the new o-ring and the engine oil drain bolt. Tighten the engine oil drain bolt to the speci- fied torque. Notice: before installing the engin...

  • Page 85

    8-14 8 9. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 10. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary. Ebu27026 t...

  • Page 86

    8-15 8 5. Pour the recommended type of oil in the trans- mission oil filler hole until it flows out of the check screw hole. 6. Tighten the oil check screw to the specified torque. 7. Check the oil filler bolt gasket for damage, and replace it if necessary. 8. Install the transmission oil filler bol...

  • Page 87

    8-16 8 5. Install the drain bolt and its new gasket, and then tighten the bolt to the specified torque. 6. Refill with the specified amount of the recom- mended transmission oil. Notice: make sure that no foreign material enters the transmission case. [ecb00791] 7. Check the oil filler bolt gasket f...

  • Page 88

    8-17 8 ebu2384c cleaning the engine and v-belt case air filter elements both air filter elements should be cleaned at the specified intervals in the periodic maintenance chart. Engine air filter element tip there is a check hose at the bottom of the air filter case. If dust or water collects in this...

  • Page 89

    8-18 8 5. Remove the screw and washer shown, and then pull the sponge material off from the air filter element frame. 6. Wash the sponge material gently but thor- oughly in solvent. Warning! Always use parts cleaning solvent to clean the sponge material. Never use low-flash-point sol- vents or gasol...

  • Page 90

    8-19 8 7. Squeeze the excess solvent out of the sponge material and let it dry. Notice: do not twist the sponge material when squeezing it. [ecb00441] 8. Check the sponge material and replace it if damaged. 9. Apply yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge mate...

  • Page 91

    8-20 8 13. Install the air filter element into the air filter case. Notice: make sure that the air filter element is properly seated in the air filter case. Never operate the engine with the air filter element removed. This will allow un- filtered air to enter the engine, causing rap- id engine wear...

  • Page 92

    8-21 8 3. Remove the panel by removing the quick fas- teners, and then pulling it upward as shown. 4. Disconnect the coupler shown. 1. Front carrier bolt 2. Front carrier 2 1 1 1 1. Panel 2. Quick fastener 1. Coupler 1 2 2 1 1 u1py61e0.Book page 21 wednesday, march 14, 2012 5:22 pm.

  • Page 93

    8-22 8 5. Remove the air filter case cover by removing the screw. 6. Remove the air filter element. 7. Tap the air filter element lightly to remove most of the dust and dirt. Blow out the remain- ing dirt with compressed air as shown. 1. Air filter case cover 2. Screw 1 2 1. Air filter element 1 u1p...

  • Page 94

    8-23 8 8. Check the air filter element and replace it if damaged. 9. Install the air filter element 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 ...

  • Page 95

    8-24 8 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. Warning ewb02340 do not start the engine when cleaning the spark arre...

  • Page 96

    8-25 8 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. Install the v-belt case drain screw and its new gasket, and then tigh...

  • Page 97

    8-26 8 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...

  • Page 98

    8-27 8 the throttle lever free play should measure 1.0– 3.0 mm (0.04–0.12 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. ...

  • Page 99

    8-28 8 ebu29601 brakes replacement of brake components requires pro- fessional knowledge. Brake service should be per- formed by a yamaha dealer. Warning ewb02571 operating with improperly serviced or adjust- ed brakes could lead to a loss in braking ability and an accident. Ebu24090 checking the fr...

  • Page 100

    8-29 8 rear brake ebu24374 adjusting the front 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 front brake shoes for wea...

  • Page 101

    8-30 8 2. Remove the panel by removing the quick fas- teners, and then pulling it upward as shown. 3. Disconnect the coupler shown. 1. Front carrier 2. Front carrier bolt 1 2 2 2 1. Panel 2. Quick fastener 1. Coupler 1 2 2 1 1 u1py61e0.Book page 30 wednesday, march 14, 2012 5:22 pm.

  • Page 102

    8-31 8 4. Remove the v-belt air filter element 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. 6. Make sure the brake cable joint in the equaliz- er is straight when the brake is applied. If the cable joint isn’t str...

  • Page 103

    8-32 8 7. Tighten the locknut on each brake cable. 8. Turn the brake lever free play adjusting bolt in direction (a) to increase the free play, and in direction (b) to decrease it. 9. Tighten the locknut at the brake lever. 10. Install the v-belt air filter element cover by in- stalling the screw. 1...

  • Page 104

    8-33 8 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 ...

  • Page 105

    8-34 8 3. If the correct free play cannot be obtained as described above, turn 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 dire...

  • Page 106

    8-35 8 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...

  • Page 107

    8-36 8 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...

  • Page 108

    8-37 8 6. Tighten the hub stopper bolt and hub stopper bolt locknut to the specified torques. Ebu24882 lubricating the drive chain the drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especial...

  • Page 109

    8-38 8 essary. If a cable is damaged or does not move smoothly, have a yamaha dealer check or replace it. Warning ewb02581 ● inspect cables frequently and replace if dam- aged. Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could restri...

  • Page 110

    8-39 8 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 wh...

  • Page 111

    8-40 8 left side right side ebu28823 lubricating the front knuckle pivots the front knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Tip for parts equipped with a grease nipple, use a grease gun. 1. Grease nipple 1. Grease nipple 1 1 1 1...

  • Page 112

    8-41 8 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. Ebu2512a battery the battery is located under the seat....

  • Page 113

    8-42 8 batteries produce explosive gases. Keep sparks, flame, cigarettes or other sources of ig- nition away. Ventilate when charging or using in an enclosed space. Keep out of reach of children. To check the electrolyte level 1. Place the atv on a level surface. 2. Check the electrolyte level in th...

  • Page 114

    8-43 8 2. 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] 3. Remove the battery. To store the battery ● if the atv will not be used for more ...

  • Page 115

    8-44 8 3. Make sure that the breather hose is properly routed, in good condition, and not obstructed. Notice: if the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the bat- tery, the frame could suffer structural and external damages. [ecb0061...

  • Page 116

    8-45 8 notice ecb00640 to prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Warning! Always use a fuse of the spec- ified rating, and never use a substitute ob- ject in pla...

  • Page 117

    8-46 8 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. 4. Remove the burnt-out bulb by pulling it out. 5. Insert a new headlight bulb into the bulb hold- er by pushing it in. Notice: do not touch the glass part of the headlight bulb to keep it free from oil, oth...

  • Page 118

    8-47 8 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). Ebu25613 replacing the t...

  • Page 119

    8-48 8 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. 3. Elevate the atv and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. Ebu25692...

  • Page 120

    8-49 8 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. Ebu25720 troubleshooting although yamaha atvs receive a thorough in- spection before ...

  • Page 121

    8-50 8 warning ewb02280 do not smoke when checking the fuel system. Fuel can ignite or explode, causing severe inju- ry or property damage. Make sure there are no open flames or sparks in the area, including pi- lot lights from water heaters or furnaces. U1py61e0.Book page 50 wednesday, march 14, 20...

  • Page 122

    8-51 8 ebu25791 troubleshooting chart check the fuel level in the fuel tank. 1. Fuel there is enough fuel. There is no fuel. Check the compression. Supply fuel. The engine does not start. Check the compression. Operate the electric starter. 2. Compression there is compression. There is no compressio...

  • Page 123

    9-1 9 ebu25860 cleaning and storage ebu25902 cleaning frequent, thorough cleaning of your atv will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the atv: a. Block off the end of the exhaust pipe to prevent w...

  • Page 124

    9-2 9 ebu30360 storage short-term always store your atv in a cool, dry place and, if necessary, protect it against dust with a porous cover. Notice: storing the atv in a poorly ven- tilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust...

  • Page 125

    9-3 9 ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. D...

  • Page 126

    10-1 10 ebu25961 specifications dimensions: overall length: 1700 mm (66.9 in) overall width: 990 mm (39.0 in) overall height: 980 mm (38.6 in) seat height: 685 mm (27.0 in) wheelbase: 1080 mm (42.5 in) ground clearance: 145 mm (5.7 in) minimum turning radius: 2900 mm (114 in) weight: with oil and fu...

  • Page 127

    10-2 10 type: sae 5w-30, 10w-30, 10w-40, 15w-40, 20w-40 or 20w- 50 recommended engine oil grade: api service sg type or higher, jaso standard ma engine oil quantity: periodic oil change: 1.25 l (1.32 us qt, 1.10 imp.Qt) transmission oil: quantity: 0.6 l (0.63 us qt, 0.53 imp.Qt) air filter: air filt...

  • Page 128

    10-3 10 reverse gear: 49/14 × 49/15 × 40/17 (26.902) chassis: frame type: steel tube frame caster angle: 6.0 ° trail: 15.0 mm (0.59 in) front tire: type: tubeless size: at20 x 7-8 manufacturer/model: duro/di-k635a rear tire: type: tubeless size: at22 x 10-8 manufacturer/model: duro/di-k735a loading:...

  • Page 129

    10-4 10 spring/shock absorber type: coil spring/oil damper wheel travel: 70 mm (2.8 in) rear suspension: type: swingarm spring/shock absorber type: coil spring/oil damper wheel travel: 80 mm (3.1 in) electrical system: ignition system: dc cdi charging system: ac magneto battery: model: 12n12c-4a-2 v...

  • Page 130

    11-1 11 ebu26000 consumer information ebu28201 identification numbers record the vehicle identification number and mod- el label information in the spaces provided below for assistance when ordering spare parts from a yamaha dealer or for reference in case the atv is stolen. Vehicle identification n...

  • Page 131

    11-2 11 1. Model label 1 u1py61e0.Book page 2 wednesday, march 14, 2012 5:22 pm.

  • Page 132

    Index a accessories and loading ................................................ 6-6 air filter elements, engine and v-belt filter cleaning ..... 8-17 b battery ...................................................................5-6, 8-41 brake lever free play, adjusting the front ......................

  • Page 133

    N neutral indicator light ..................................................... 4-2 o owner’s manual and tool kit ........................................... 8-2 p parking ........................................................................... 6-5 parking brake .....................................

  • Page 134

    Ebu26162 warning always : • use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns. • avoid paved surfaces—pavement may seriously affect handling and control. Improper atv use can result in severe injury or death. Never use with drugs or alcohol always use an...