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  5. Owner's Manual

Yamaha Grizzly 80 YFM80GW Owner's Manual

Summary of Grizzly 80 YFM80GW

  • Page 1

    This a this atv should not be ridden by anyone under 12 years of age. Owner’s manual lit-11626-20-06 2d3-28199-13 yfm80gw warning read this manual carefully! It contains important safety information..

  • Page 2

    Ebu17091.

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    Ebu17170 introduction ebu17240 congratulations on your purchase of the yamaha yfm80gw. 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 deg...

  • Page 4

    In skills, physical abilities and judgment. Some children may not be able to operate an atv safely. Parents should supervise their child’s use of the atv at all times. Parents should permit continued use only if they determine that the child has the ability to operate the atv safely. Your atv was de...

  • Page 5

    Ebu17330 important manual information ebu17341 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 6

    Ebu17350 important notice ebu17360 welcome to the yamaha world of motor sports! This atv is designed and manufactured for off-road use only. It is illegal and unsafe to operate this atv on any public street, road or highway. This atv complies with all applicable off-road noise level and spark arrest...

  • Page 7

    Warning ewb00010 indicates a potential hazard that could result in serious injury or death. Ebu17420 table of contents safety information .............................. 1-1 location of the warning and specification labels ............................ 2-1 description ....................................

  • Page 8

    Starting a warm engine ............................. 6-3 shifting ...................................................... 6-3 engine break-in ......................................... 6-5 parking ...................................................... 6-6 parking on a slope ..............................

  • Page 9

    Removing a wheel ................................... 8-36 installing a wheel ..................................... 8-36 troubleshooting ...................................... 8-37 troubleshooting chart ............................. 8-38 cleaning and storage.......................... 9-1 cleaning ......

  • Page 10

    1-1 1 2 3 4 5 6 7 8 9 10 11 ebu17430 safety information ebu17601 an atv is not a toy and can be hazard- ous to operate. An atv handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding ...

  • Page 11

    1-2 1 2 3 4 5 6 7 8 9 10 11 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 it is in safe operating cond...

  • Page 12

    1-3 1 2 3 4 5 6 7 8 9 10 11 backwards when climbing a hill. To avoid stall- ing, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointe...

  • Page 13

    1-4 1 2 3 4 5 6 7 8 9 10 11 ewb00030 how to avoid the hazard always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or ex- haust pipe/muffler when refueling. Never refuel while smoking, or in the vic...

  • Page 14

    2-1 1 2 3 4 5 6 7 8 9 10 11 ebu17660 location of the warning and specification labels 1 2 3 4 5 6.

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    2-2 1 2 3 4 5 6 7 8 9 10 11 ebu17670 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 replace- ment label from your yamaha d...

  • Page 16

    2-3 1 2 3 4 5 6 7 8 9 10 11 warning improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. Operating tire pressure: set with tires cold recommended : front : 20 kpa, {0.20 kgf/cm 2 } 2.9 psi rear : 20 kpa, {0.20 kgf/cm 2 } 2.9 psi minim...

  • Page 17

    3-1 1 2 3 4 5 6 7 8 9 10 11 ebu17680 description ebu17690 left view ebu17700 right view 1. Fuel cock 2. Rear carrier 3. Rear wheel 4. Footboard 5. Shift pedal 6. Choke 7. Front wheel 1 3 4 5 7 2 6 1. Spark arrester 2. Seat 3. Panel 4. Brake pedal 5. Footboard 1 2 3 4 5.

  • Page 18

    3-2 1 2 3 4 5 6 7 8 9 10 11 ebu17712 controls and instruments note: the atv you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Parking brake 3. Neutral indicator light 4. Front brake lever 5. Throttle lever 6. Main switch 7. Fuel tank cap 8. Handleba...

  • Page 19

    4-1 1 2 3 4 5 6 7 8 9 10 11 ebu17720 instrument and control functions warning ewb00010 indicates a potential hazard that could result in serious injury or death. Ebu17740 main switch the positions of the main switch are as follows: on all electrical systems are supplied with power, and the engine ca...

  • Page 20

    4-2 1 2 3 4 5 6 7 8 9 10 11 ebu17780 indicator light ebu17860 neutral indicator light “ ” this indicator light comes on when the transmis- sion is in the neutral position. Ebu18060 handlebar switches ebu18070 engine stop switch “eng. Stop” set this switch to “run” before starting the engine. The eng...

  • Page 21

    4-3 1 2 3 4 5 6 7 8 9 10 11 ebu18090 start switch “start” push this switch to crank the engine with the start- er. Caution: ecb00050 see the starting instructions on page 6-1 prior to starting the engine. Ebu18270 throttle lever once the engine is running, movement of the throt- tle lever will incre...

  • Page 22

    4-4 1 2 3 4 5 6 7 8 9 10 11 ewb00200 ebu18331 speed limiter and air intake restrictor plate your atv was delivered with an adjustable speed limiter and an air intake restrictor plate. Yamaha recommends that all beginning riders start off with the speed limiter adjusting screw fully turned in and the...

  • Page 23

    4-5 1 2 3 4 5 6 7 8 9 10 11 3. Tighten the locknut. Ewb00180 ebu18391 front brake lever the front brake lever is located on the right handle- bar. To apply the front brake, pull the brake lever toward the handlebar grip. Ebu18442 brake pedal and rear brake lever the brake pedal is located on the rig...

  • Page 24

    4-6 1 2 3 4 5 6 7 8 9 10 11 handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip. Ebu18450 parking brake use the parking brake before starting the engine or parking the atv, especially on a slope. Apply the rear brake lever and push down ...

  • Page 25

    4-7 1 2 3 4 5 6 7 8 9 10 11 ewb00170 ebu18550 shift pedal this atv is equipped with a constant-mesh 3- speed transmission. The shift pedal is located on the left side of the engine. Neutral is at the bottom position. 1. Parking brake lock plate warning potential hazard improper use of the parking br...

  • Page 26

    4-8 1 2 3 4 5 6 7 8 9 10 11 ebu18720 fuel tank cap remove the fuel tank cap by turning it counter- clockwise. Ebu18730 fuel make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. 1. Shift pedal 2. Neutral position 1 n 2 3 2 1 1. Fuel tank c...

  • Page 27

    4-9 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00070 use only unleaded 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 ...

  • Page 28

    4-10 1 2 3 4 5 6 7 8 9 10 11 ewb00270 ebu18820 fuel cock the fuel cock supplies fuel from the tank to the car- buretor while also filtering it. The fuel cock lever positions are explained as fol- lows and shown in the illustrations. Off with the fuel cock lever in this position, fuel will not flow. ...

  • Page 29

    4-11 1 2 3 4 5 6 7 8 9 10 11 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. Res this indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the ...

  • Page 30

    4-12 1 2 3 4 5 6 7 8 9 10 11 move the choke in direction (b) to turn off the choke. See the “starting a cold engine” section on page 6- 1 for proper operation. Ebu18870 seat to remove the seat pull the seat lock lever upward and pull up the seat at the rear. To install the seat insert the projection...

  • Page 31

    4-13 1 2 3 4 5 6 7 8 9 10 11 ebu18950 carrier ● do not exceed the load limit of 5.0 kg (11 lb) for the carrier. ● do not exceed the maximum load of 95.0 kg (209 lb) for the atv. Warning ewb00010 indicates a potential hazard that could result in serious injury or death. 1. Projection 2. Seat holder 2...

  • Page 32

    5-1 1 2 3 4 5 6 7 8 9 10 11 ebu19200 pre-operation checks ebu19210 pre-operation check list before operating this atv, be sure to check the items listed in the following table. Note: the maintenance of some items in the table has to be performed by a yamaha dealer. Refer to the “periodic maintenance...

  • Page 33

    5-2 1 2 3 4 5 6 7 8 9 10 11 ewb00470 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. 5-5, 5-6, 5-7 brake and shift pedals ● make sure that operation is smooth. Lubricate pedal ...

  • Page 34

    5-3 1 2 3 4 5 6 7 8 9 10 11 ebu19530 fuel make sure that there is sufficient fuel in the tank. (see page 4-8.) ewb00500 ebu19560 engine oil make sure that the engine oil is at the specified lev- el. Add oil as necessary. (see page 8-10.) ebu19590 final gear oil make sure that the final gear oil is a...

  • Page 35

    5-4 1 2 3 4 5 6 7 8 9 10 11 ewb00530 ebu19761 throttle lever check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a yamaha dealer correct if necessary. Warning potential hazard riding with improperly operating brakes. What can happ...

  • Page 36

    5-5 1 2 3 4 5 6 7 8 9 10 11 ebu19781 tires ewb00561 warning potential hazard operating this atv with improper tires, or with improper or uneven tire pressure. What can happen use of improper tires on this atv, or opera- tion of this atv with improper or uneven tire pressure, may cause loss of contro...

  • Page 37

    5-6 1 2 3 4 5 6 7 8 9 10 11 ebu19820 measuring the tire pressure use the low-pressure tire gauge. Note: 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 b...

  • Page 38

    5-7 1 2 3 4 5 6 7 8 9 10 11 the tire pressures to the following specifications: ebu19830 tire wear limit replace the tire when the tire groove decreases to 3 mm (0.12 in). Ebu19840 chassis fasteners make sure that all nuts, bolts and screws are prop- erly tightened. Ebu19850 instruments, lights and ...

  • Page 39

    6-1 1 2 3 4 5 6 7 8 9 10 11 ebu19870 operation warning ewb00010 indicates a potential hazard that could result in serious injury or death. Ebu19890 ewb00610 ebu20211 starting a cold engine ewb00620 caution: ecb00150 see the “engine break-in” section on page 6-5 prior to operating the engine for the ...

  • Page 40

    6-2 1 2 3 4 5 6 7 8 9 10 11 light does not come on, have a yamaha deal- er check the electrical circuit. Note: this model is equipped with an ignition circuit cut- off system. The engine can be started under the following conditions. ● the transmission is in neutral. ● the rear brake lever is applie...

  • Page 41

    6-3 1 2 3 4 5 6 7 8 9 10 11 crank the engine more than 10 seconds on each attempt. 7. If the engine is started with the choke in posi- tion (1), the choke should be returned to posi- tion (2) to warm up the engine. If the engine is started with the choke in position (2), keep the choke in this posit...

  • Page 42

    6-4 1 2 3 4 5 6 7 8 9 10 11 ebu20600 to start out and accelerate 1. Release the throttle lever. Caution: ecb00200 always close the throttle before shifting gears, otherwise damage to the engine and drive train may result. 2. Shift into first gear and release the shift pedal. 3. Open the throttle gra...

  • Page 43

    6-5 1 2 3 4 5 6 7 8 9 10 11 ewb00650 caution: ecb00190 even with the transmission in the neutral posi- tion, do not coast for long periods of time with the engine off, and do not tow the atv for long distances. The transmission is properly lubri- cated only when the engine is running. Inade- quate l...

  • Page 44

    6-6 1 2 3 4 5 6 7 8 9 10 11 20 hours and beyond the atv can now be operated normally. Caution: ecb00220 if any engine trouble should occur during the engine break-in period, immediately have a yamaha dealer check the atv. Ebu20721 parking when parking the atv, stop the engine, shift into first gear,...

  • Page 45

    6-7 1 2 3 4 5 6 7 8 9 10 11 1. Bring the atv to a stop by applying the brakes in first gear. 2. Stop the engine. 3. With the rear brake lever and brake pedal ap- plied, apply the parking brake and slowly re- lease the brake pedal. Ebu20910 accessories and loading ebu20920 accessories accessories can...

  • Page 46

    6-8 1 2 3 4 5 6 7 8 9 10 11 limits your ability to move around on the seat, or one that limits your view. ● use extra caution when riding an atv with ac- cessories. The atv may handle differently than it does without accessories. Ebu21110 loading as originally equipped, this atv is not designed to t...

  • Page 47

    6-9 1 2 3 4 5 6 7 8 9 10 11 handling of the atv. Ewb00750 warning ewb00010 indicates a potential hazard that could result in serious injury or death. Warning potential hazard overloading this atv or carrying or towing cargo improperly. What can happen could cause changes in atv handling which could ...

  • Page 48

    7-1 1 2 3 4 5 6 7 8 9 10 11 ebu21131 riding your atv.

  • Page 49

    7-2 1 2 3 4 5 6 7 8 9 10 11 warning ewb00010 indicates a potential hazard that could result in serious injury or death. Ebu21562 getting to know your atv this atv is for recreation use. This section, riding your atv, provides general atv riding instructions for recreational riding. The skills and te...

  • Page 50

    7-3 1 2 3 4 5 6 7 8 9 10 11 ewb01280 riding your atv requires skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers. Not recommended for children under 12 years of age. Ewb01210 warning potential hazard ope...

  • Page 51

    7-4 1 2 3 4 5 6 7 8 9 10 11 this atv is designed to carry operator and cargo only – passengers prohibited. Ewb00910 warning potential hazard carrying a passenger on this atv. What can happen greatly reduces your ability to balance and control this atv. Could cause an accident, resulting in harm to y...

  • Page 52

    7-5 1 2 3 4 5 6 7 8 9 10 11 apparel ewb00920 warning potential hazard operating this atv without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. What can happen operating without an approved motorcycle helmet increases your chances of a severe head injury or death in...

  • Page 53

    7-6 1 2 3 4 5 6 7 8 9 10 11 do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. How to avoid the hazard always wear an approved motorcycle helmet that fits properly. You should also wear: ● eye protection (goggles or...

  • Page 54

    7-7 1 2 3 4 5 6 7 8 9 10 11 ewb00930 pre-operation checks always perform the pre-operation checks listed on page 5-1 before riding for proper care of the atv and to ensure safety. Ewb00940 ewb00950 warning potential hazard operating this atv after consuming alcohol or drugs. What can happen could se...

  • Page 55

    7-8 1 2 3 4 5 6 7 8 9 10 11 warning ewb00010 indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. Ewb00960 speed limiter for riders less experienced with this model, the throttle lever housing is equipped with...

  • Page 56

    7-9 1 2 3 4 5 6 7 8 9 10 11 see page 8-18. Loading and accessories use extra caution when riding the atv with addi- tional loads, such as accessories or cargo. The atv’s handling may be adversely affected. Re- duce your speed when adding additional loads. Ewb00970 1. Locknut 2. Adjusting screw 1 2 m...

  • Page 57

    7-10 1 2 3 4 5 6 7 8 9 10 11 during operation always keep your feet on the footboards during op- eration, otherwise they may contact the rear wheels. How to avoid the hazard never exceed the stated load capacity for this atv. Cargo should be properly distributed and se- curely attached. Reduce speed...

  • Page 58

    7-11 1 2 3 4 5 6 7 8 9 10 11 ewb00980 avoid wheelies and jumping. You may lose control of the atv or overturn. Ewb00990 modifications ewb01000 warning potential hazard removing hands from handlebars or feet from footboards during operation. What can happen removing even one hand or foot can reduce y...

  • Page 59

    7-12 1 2 3 4 5 6 7 8 9 10 11 exhaust system the exhaust system on the atv is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the atv in a place where pedestrians or children are not likely to touch it. Ewb01010 what can happen improper installation ...

  • Page 60

    7-13 1 2 3 4 5 6 7 8 9 10 11 be careful where you ride this atv is designed for off-road use only. Riding on paved surfaces can cause loss of control. Ewb01020 do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. Ewb01030 warning po...

  • Page 61

    7-14 1 2 3 4 5 6 7 8 9 10 11 know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the atv to upset. Ewb01040 how to avoid the hazard never operate this atv on any public street, road or hi...

  • Page 62

    7-15 1 2 3 4 5 6 7 8 9 10 11 ewb01050 when riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the atv. Do not use the flag pole bracket as a trailer hitch. Warning potential hazard failure to use extra care when operating on excessively rough, slipp...

  • Page 63

    7-16 1 2 3 4 5 6 7 8 9 10 11 ewb01060 do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. Select a large, flat area off-road to become familiar with your atv. Make sure that this area is free of obstacles and other riders. You should practice c...

  • Page 64

    7-17 1 2 3 4 5 6 7 8 9 10 11 the shift pedal. Remember that the engine and ex- haust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components. With the engine idling, lift the shift pedal to the 1st gear position and then release the parking...

  • Page 65

    7-18 1 2 3 4 5 6 7 8 9 10 11 lowed to slip or lose some traction, the atv will resist turning. A special turning technique must be used to allow the atv to make turns quickly and easily. It is essential that this skill be learned first at low speed. Ewb01220 as you approach a curve, slow down and be...

  • Page 66

    7-19 1 2 3 4 5 6 7 8 9 10 11 once you have learned this technique, you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may ca...

  • Page 67

    7-20 1 2 3 4 5 6 7 8 9 10 11 if you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the atv around while you still have forward motion (provided you have the room to do so) and go down the hill. How to avoid the hazard always fol...

  • Page 68

    7-21 1 2 3 4 5 6 7 8 9 10 11 ewb01190 if your atv has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the atv on the up- hill si...

  • Page 69

    7-22 1 2 3 4 5 6 7 8 9 10 11 immediately on the uphill side. Ewb01231 riding downhill when riding your atv downhill, shift your weight as far to the rear and uphill side of the atv as pos- sible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the en- gine c...

  • Page 70

    7-23 1 2 3 4 5 6 7 8 9 10 11 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. Ewb01130 crossing a slope traversing a sloping surface on your atv requires you to properly position your weight to maintain proper balance....

  • Page 71

    7-24 1 2 3 4 5 6 7 8 9 10 11 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 ...

  • Page 72

    7-25 1 2 3 4 5 6 7 8 9 10 11 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 care- fully. Ewb01150 test your brakes after leaving the water. Do not continue to ride your atv without verifying that you have...

  • Page 73

    7-26 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00240 after riding your atv in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the atv in fresh water if it has been operated in salt water or muddy conditions. Riding over rough terrain riding o...

  • Page 74

    7-27 1 2 3 4 5 6 7 8 9 10 11 ewb01160 sliding and skidding care should be used when riding on loose or slip- pery surfaces since the atv may slide. If unex- pected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions...

  • Page 75

    7-28 1 2 3 4 5 6 7 8 9 10 11 with practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are re- duced. Bear in mind that sliding maneuvers should always be avoided on ...

  • Page 76

    7-29 1 2 3 4 5 6 7 8 9 10 11 lean more into the turn to regain balance. If nec- essary, gradually let off the throttle and/or steer to the outside of the turn. (see page 7-17.) ● if your atv starts to slide sideways: steer in the direction of the slide if you have the room. Applying the brakes or ac...

  • Page 77

    8-1 1 2 3 4 5 6 7 8 9 10 11 ebu21640 periodic maintenance and minor repair ebu21660 safety is an obligation of the owner. Periodic in- spection, adjustment and lubrication will keep your atv in the safest and best operating condition possible. The most important points of inspection, adjustment, and...

  • Page 78

    8-2 1 2 3 4 5 6 7 8 9 10 11 the service information included in this manual and 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 cert...

  • Page 79

    8-3 1 2 3 4 5 6 7 8 9 10 11 ebu21741 periodic maintenance chart for the emission control system note: ● 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 inte...

  • Page 80

    8-4 1 2 3 4 5 6 7 8 9 10 11 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...

  • Page 81

    8-5 1 2 3 4 5 6 7 8 9 10 11 ebu21862 general maintenance and lubrication chart 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 * timing chain ● check chain tension. ● a...

  • Page 82

    8-6 1 2 3 4 5 6 7 8 9 10 11 10 * chassis fasteners ● make sure that all nuts, bolts, and screws are properly tightened. √ √ √ √ √ 11 * shock absorber assemblies ● check operation and correct if necessary. ● check for oil leakage and replace if necessary. √ √ √ 12 * knuckle shafts ● lubricate with li...

  • Page 83

    8-7 1 2 3 4 5 6 7 8 9 10 11 ebu23060 note: the air filter needs more frequent service if you are riding in unusually wet or dusty areas. 20 * battery ● check electrolyte level and specific gravity, and correct if necessary. ● make sure that the breather hose is properly routed. √ √ √ √ √ no. Item ch...

  • Page 84

    8-8 1 2 3 4 5 6 7 8 9 10 11 warning ewb00010 indicates a potential hazard that could result in serious injury or death. Ebu23210 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 spa...

  • Page 85

    8-9 1 2 3 4 5 6 7 8 9 10 11 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 normally). Note: if the spark plug shows a distinctly different color, the engine could be defect...

  • Page 86

    8-10 1 2 3 4 5 6 7 8 9 10 11 and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. Note: if a torque wrench is not available when installing a spark plug, a good estimate of ...

  • Page 87

    8-11 1 2 3 4 5 6 7 8 9 10 11 note: the engine oil should be between the minimum and maximum level marks. 6. 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. 7. Insert the dipstick into the oil filler hole, and the...

  • Page 88

    8-12 1 2 3 4 5 6 7 8 9 10 11 en it to the specified torque. 7. Add the specified amount of the recommend- ed engine oil, and then install and tighten the engine oil filler cap. Caution: ecb00300 ● in order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any c...

  • Page 89

    8-13 1 2 3 4 5 6 7 8 9 10 11 ebu23403 final gear oil the final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a yamaha dealer check and repair the atv. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals...

  • Page 90

    8-14 1 2 3 4 5 6 7 8 9 10 11 4. Install the drain bolt, and then tighten it to the specified torque. 5. Add the specified amount of the recommend- ed final gear oil, and then check the oil level. Caution: ecb00420 be sure no foreign material enters the final gear case. 6. Install and tighten the oil...

  • Page 91

    8-15 1 2 3 4 5 6 7 8 9 10 11 ter case. 1. Remove the quick fasteners. 2. Remove the panel by sliding it forward and pulling it off as shown. 1. Air filter case check hose 1 1. Quick fastener 1 1.

  • Page 92

    8-16 1 2 3 4 5 6 7 8 9 10 11 3. Remove the air filter case cover by unhooking the holders. 4. Unhook the holder holding the air filter ele- ment, and then pull out the sponge material from the air filter element. 1. Panel 1 1 1. Air filter case cover 2. Air filter case holder 1 2 2.

  • Page 93

    8-17 1 2 3 4 5 6 7 8 9 10 11 5. Wash the sponge material gently but thor- oughly in solvent. Ewb01900 6. Squeeze the excess solvent out of the sponge material and let it dry. Caution: ecb00440 do not twist the sponge material when squeez- ing it. 7. Check the sponge material and replace it if damage...

  • Page 94

    8-18 1 2 3 4 5 6 7 8 9 10 11 note: the air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the atv is operated in extremely dusty ar- eas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for ...

  • Page 95

    8-19 1 2 3 4 5 6 7 8 9 10 11 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 4. Insert the tailpipe into the muffler and a...

  • Page 96

    8-20 1 2 3 4 5 6 7 8 9 10 11 ewb01910 ebu23940 adjusting the carburetor the carburetor should be checked and, if neces- sary, adjusted at the intervals specified in the peri- odic maintenance and lubrication chart. The carburetor is an important part of the engine and requires very sophisticated adj...

  • Page 97

    8-21 1 2 3 4 5 6 7 8 9 10 11 note: the engine is warm when it quickly responds to the throttle. 2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if neces- sary, adjust it to specification by turning the throttle stop screw at the carburetor. To in- crease the en...

  • Page 98

    8-22 1 2 3 4 5 6 7 8 9 10 11 ebu24050 timing chain the timing chain stretches with use, resulting in im- proper valve timing and engine noise. To prevent this from occurring, the timing chain tensioner must be adjusted by a yamaha dealer at the inter- vals specified in the periodic maintenance and l...

  • Page 99

    8-23 1 2 3 4 5 6 7 8 9 10 11 front brake rear brake ebu24320 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. Note: before adjusting the brake lever free play,...

  • Page 100

    8-24 1 2 3 4 5 6 7 8 9 10 11 12.0 mm (0.39–0.47 in) as shown. If the free play is incorrect, adjust it as follows. 1. Loosen the upper locknut and fully turn in the upper adjusting bolt. 2. Loosen the lower locknut. 3. Turn the lower adjusting bolt in direction (a) to increase the free play, and in ...

  • Page 101

    8-25 1 2 3 4 5 6 7 8 9 10 11 6. Tighten the upper locknut. Ewb02020 ebu24462 adjusting the rear brake lever and brake pedal free play the brake lever and brake pedal free play must be checked and, if necessary, adjusted at the inter- vals specified in the periodic maintenance and lu- brication chart...

  • Page 102

    8-26 1 2 3 4 5 6 7 8 9 10 11 mm (0.20–0.31 in) as shown. If the free play is in- correct, adjust it as follows. 1. Loosen the locknut at the brake lever. 2. Turn the brake lever free play adjusting bolt at the brake lever in direction (a) to increase the free play, and in direction (b) to decrease i...

  • Page 103

    8-27 1 2 3 4 5 6 7 8 9 10 11 turn the brake pedal free play adjusting nut on the brake rod at the rear wheel hub in direction (a) to increase the free play, and in direction (b) to de- crease it. 1. Brake pedal free play 1 1. Brake pedal free play adjusting nut 1 (a) (b).

  • Page 104

    8-28 1 2 3 4 5 6 7 8 9 10 11 ewb02020 ebu24791 adjusting the clutch free play the clutch free play must be adjusted periodically. Adjust the free play as follows. 1. Remove the left footboard by removing the screws and bolts. 2. Remove the rubber cap. 3. Loosen the locknut. 4. Slowly turn the adjust...

  • Page 105

    8-29 1 2 3 4 5 6 7 8 9 10 11 note: turning the adjusting bolt in decreases clutch free play and turning it out increases clutch free play. 5. Tighten the locknut to the specified torque. Note: when tightening the locknut, hold the adjusting bolt with a screwdriver so that the adjusting bolt does not...

  • Page 106

    8-30 1 2 3 4 5 6 7 8 9 10 11 ewb02120 ebu24911 checking and lubricating the front and rear brake levers the operation of the front and rear brake levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Front brake lever rear brake lever warning potential ha...

  • Page 107

    8-31 1 2 3 4 5 6 7 8 9 10 11 ebu24930 checking and lubricating the brake and shift pedals the operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. Ebu24961 checking the wheel bearings the front and rear wheel bearings mus...

  • Page 108

    8-32 1 2 3 4 5 6 7 8 9 10 11 lubricate the steering shaft using a grease gun. Ebu25111 battery a poorly maintained battery will corrode and dis- charge quickly. The electrolyte level, battery lead connections and breather hose routing should be checked before each ride and at the intervals specified...

  • Page 109

    8-33 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00590 use only distilled water, as tap water contains minerals that are harmful to the battery. Ewb02140 4. Check and, if necessary, tighten the battery lead connections and correct the breather hose routing. To store the battery if the atv will not be used f...

  • Page 110

    8-34 1 2 3 4 5 6 7 8 9 10 11 stored as follows. 1. Disconnect the negative lead first and then the positive lead. 2. Remove the battery, fully charge it, and then place it in a cool, dry place. Caution: ecb00600 do not leave or store the battery on its side. 3. If the battery will be stored for more...

  • Page 111

    8-35 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00610 if the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the battery, the frame could suf- fer structural and external damages. Ebu25232 replacing the fuse the fuse holder is located under the seat. ...

  • Page 112

    8-36 1 2 3 4 5 6 7 8 9 10 11 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 system. Ebu25650 removing a wheel 1. Loosen the wheel nuts. Front rear 2. Elevate the atv and pl...

  • Page 113

    8-37 1 2 3 4 5 6 7 8 9 10 11 ebu25710 troubleshooting although yamaha atvs receive a thorough in- spection before shipment from the factory, trouble may occur during operation. Any problem in the fu- el, compression, or ignition systems, for example, can cause poor starting and loss of power. The fo...

  • Page 114

    8-38 1 2 3 4 5 6 7 8 9 10 11 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. ...

  • Page 115

    9-1 1 2 3 4 5 6 7 8 9 10 11 ebu25860 cleaning and storage ebu25870 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 exh...

  • Page 116

    9-2 1 2 3 4 5 6 7 8 9 10 11 ewb02300 ebu25932 storage short-term always store your atv in a cool, dry place and, if necessary, protect it against dust with a porous cover. Caution: ecb00720 ● storing the atv in a poorly ventilated room or covering it with a tarp while it is still wet, will allow wat...

  • Page 117

    9-3 1 2 3 4 5 6 7 8 9 10 11 plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (this will limit sparking during the next step.) d. Turn the engine over several times with the starter. (this will coat the cylinder wall with oil.) e. Remove the spark plug cap...

  • Page 118

    10-1 1 2 3 4 5 6 7 8 9 10 11 ebu25960 specifications ebu25974 dimensions: overall length: 1550 mm (61.0 in) overall width: 855 mm (33.7 in) overall height: 930 mm (36.6 in) seat height: 665 mm (26.2 in) wheelbase: 1030 mm (40.6 in) ground clearance: 100 mm (3.94 in) minimum turning radius: 2400 mm (...

  • Page 119

    10-2 1 2 3 4 5 6 7 8 9 10 11 engine oil quantity: periodic oil change: 0.80 l (0.85 us qt) (0.70 imp.Qt) final gear oil: type: sae80 api gl-4 hypoid gear oil quantity: 0.12 l (0.13 us qt) (0.11 imp.Qt) air filter: air filter element: wet element fuel: recommended fuel: unleaded gasoline only fuel ta...

  • Page 120

    10-3 1 2 3 4 5 6 7 8 9 10 11 manufacturer/model: dunlop/kt586 rear tire: type: tubeless size: at18 x 8-7 manufacturer/model: dunlop/kt587 loading: maximum load: 95.0 kg (209 lb) (total weight of rider, cargo, accessories, and tongue) tire air pressure (measured on cold tires): recommended: front: 20...

  • Page 121

    10-4 1 2 3 4 5 6 7 8 9 10 11 spring/shock absorber type: coil spring/oil damper wheel travel: 56.0 mm (2.20 in) electrical system: ignition system: cdi charging system: ac magneto battery: model: 12n7d-3b voltage, capacity: 12 v, 7.0 ah bulb voltage, wattage x quantity: neutral indicator light: 12 v...

  • Page 122

    11-1 1 2 3 4 5 6 7 8 9 10 11 ebu25981 consumer information ebu26011 identification numbers record the key identification number, vehicle iden- tification number and model label information in the spaces provided below for assistance when or- dering spare parts from a yamaha dealer or for ref- erence...

  • Page 123

    11-2 1 2 3 4 5 6 7 8 9 10 11 note: the vehicle identification number is used to identi- fy your atv. Ebu26050 model label the model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spar...

  • Page 124

    11-3 1 2 3 4 5 6 7 8 9 10 11 ebu26060 noise regulation tampering with noise control system prohibited: federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device ...

  • Page 125

    11-4 1 2 3 4 5 6 7 8 9 10 11 ebu26080 maintenance record copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is require...

  • Page 126

    11-5 1 2 3 4 5 6 7 8 9 10 11 ebu26501 yamaha motor corporation, u.S.A. Atv limited warranty yamaha motor corporation, u.S.A. Hereby warrants that new yamaha atvs purchased from an authorized yamaha atv dealer in the continental united states will be free from defects in material and workmanship for ...

  • Page 127

    11-6 1 2 3 4 5 6 7 8 9 10 11 warranty questions and answers q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spa...

  • Page 128

    11-7 1 2 3 4 5 6 7 8 9 10 11 ebu26122 yamaha extended service (y.E.S.) keep your yamaha protected even after your warranty expires with genuine yamaha extended ser vice (y.E.S.). Y.E.S. Is designed and administered by yamaha motor corporation to provide maximum owner satisfaction. You get uninterr u...

  • Page 129

    11-8 1 2 3 4 5 6 7 8 9 10 11 we urge you to act now. You’ll get the excellent benefits of trip coverage r ight away, and you’ll rest easy knowing you’ll have strong factor y-backed protection even after your ya m a h a l i m i t e d wa r ra n t y ex p i r e s. Yo u c a n a l s o s ave money: y.E.S. ...

  • Page 130

    11-9 1 2 3 4 5 6 7 8 9 10 11 ebu26132.

  • Page 131

    Index a accessories and loading ................................................ 6-7 air filter element, cleaning............................................ 8-14 air intake restrictor plate, removing.............................. 8-18 b battery..........................................................

  • Page 132

    Model label....................................................................11-2 n neutral indicator light ......................................................4-2 noise regulation ............................................................11-3 o owner’s manual and tool kit........................

  • Page 133

    Printed in japan 2006.3-0.6x1 ! (e) yamaha motor co., ltd. Printed on recycled paper locate and read owner’s manual. Follow all instructions and warnings. (for replacement manual, call 1-800-532-1558) warning always : use proper riding techniques to avoid vehicle overturns on hills and rough terrain...

  • Page 134: Read    Carefull

    Dear new yamaha atv owner: congratulations on the purchase of your new yamaha atv. You have purchased a quality yamaha product that , with proper use and care , will provide hours of riding pleasure. Before you operate your new atv, yamaha recommends these important points: 8 read your owner ’ s man...

  • Page 135

    No postage necessary if mailed in the united states first class permit no. 4 cypress, ca postage will be paid by addressee yamaha motor corporation u.S.A. P.O. Box 6555 cypress, california 90630-9989 attn: sales administration atv card for us 4/2/03 9:06 am page 2.