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Yamaha RAPTOR 50 Owner's Manual

Other manuals for RAPTOR 50: Installation Manual, Owner's Manual, Owner's Manual
Manual is about: TILLER HANDLE STEERING FRICTION

Summary of RAPTOR 50

  • Page 1

    This a owner’s manual lit-11626-21-38 5yf-28199-15 this atv should not be ridden by anyone under 6 years of age. Yfm50rx warning read this manual carefully! It contains important safety information..

  • Page 2

    Ebu17091.

  • Page 3: Introduction

    Ebu17170 introduction ebu17180 congratulations on your purchase of the yamaha yfm50rx. 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: Important Manual Information

    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: Important Notice

    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

    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

    Engine break-in ......................................... 6-5 parking ...................................................... 6-5 parking on a slope .................................... 6-6 accessories and loading ........................... 6-7 riding your atv ...................................... ...

  • Page 9

    Storage ...................................................... 9-2 specifications ...................................... 10-1 consumer information ...................... 11-1 identification numbers ............................. 11-1 noise regulation ...................................... 11-3 mainte...

  • Page 10: Safety Information

    1-1 1 2 3 4 5 6 7 8 9 10 11 ebu17430 safety information safety information ebu17632 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...

  • Page 11

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

  • Page 12: Warning

    1-3 1 2 3 4 5 6 7 8 9 10 11 ● always use proper procedures if you stall or roll backwards when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Apply the front brake or dismount on the uphill side or to a side if pointed straight uph...

  • Page 13

    1-4 1 2 3 4 5 6 7 8 9 10 11 you must make the commitment to your child’s proper use of the atv. Your child must rely upon you to be sure he or she has the development, proper training, and proper equipment, as well as an appropriately sized atv and an appropriate riding area. Be sure your child is r...

  • Page 14

    1-5 1 2 3 4 5 6 7 8 9 10 11 also wear the safety equipment described in the riding your atv section of this manual. Choose an appropriate riding area select an area appropriate for your child to learn to ride. (see page 7-11.) follow the instructions in the riding your atv section of this manual. Ch...

  • Page 15: Warning

    1-6 1 2 3 4 5 6 7 8 9 10 11 ewb00021 warning potential hazard improper handling of gasoline. What can happen gasoline can catch fire and you could be burned. 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...

  • Page 16: Warning

    1-7 1 2 3 4 5 6 7 8 9 10 11 ewb00030 warning potential hazard starting or running the engine in a closed ar- ea. What can happen exhaust fumes are poisonous and may cause loss of consciousness and death with- in a short time. How to avoid the hazard always operate your atv in an area with ad- equate...

  • Page 17

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

  • Page 18

    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 19: Warning

    2-3 1 2 3 4 5 6 7 8 9 10 11 warning under 6 operating this atv if you are under the age of 6 increases your chance of severe injury or death. Never permit children under age 6 to operate this atv. 5yf-21697-00 adult supervision required for children under age 16. Warning improper atv use can result ...

  • Page 20: Warning

    2-4 1 2 3 4 5 6 7 8 9 10 11 q 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 9recommended : front : 20 kpa, {0.20 kgf/cm 2 } 2.9 psi rear : 20 kpa, {0.20 kgf/cm 2 } 2.9 psi 9m...

  • Page 21: Description

    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. Fuse 3. Engine stop switch with cord (lanyard) 4. Footboard 5. Drive select lever 1 3 4 5 2 1. Spark arrester 2. Seat 3. Footboard 1 2 3.

  • Page 22: Controls and Instruments

    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 23: Warning

    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 24: Indicator Light

    4-2 1 2 3 4 5 6 7 8 9 10 11 ebu17781 indicator light ebu17860 neutral indicator light “ ” this indicator light comes on when the transmis- sion is in the neutral position. Ebu18061 handlebar switches ebu18070 engine stop switch “eng. Stop” set this switch to “run” before starting the engine. The eng...

  • Page 25: Caution:

    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. Ebu18260 engine stop switch with lanyard the clip must be attached to the engine stop switch fo...

  • Page 26

    4-4 1 2 3 4 5 6 7 8 9 10 11 should the atv be separated from the parent by a distance longer than the lanyard length, the lan- yard will pull out the clip and stop the engine. For further explanation of this switch and the lan- yard, see “teaching your child to oper- ate the atv” in the “safety info...

  • Page 27: Throttle Lever

    4-5 1 2 3 4 5 6 7 8 9 10 11 ebu18270 throttle lever once the engine is running, movement of the throt- tle lever will increase the engine speed. Regulate the speed of the atv by varying the throttle position. Because the throttle is spring- loaded, the atv will decelerate, and the engine will return...

  • Page 28: Front Brake Lever

    4-6 1 2 3 4 5 6 7 8 9 10 11 ally turned out as the beginner becomes more fa- miliar with operating the atv. 1. Loosen the locknut. 2. To increase the maximum engine power avail- able and the maximum speed of the atv, turn the adjusting screw in direction (a). To de- crease the maximum engine power a...

  • Page 29: Rear Brake Lever

    4-7 1 2 3 4 5 6 7 8 9 10 11 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. Ebu18450 parking brake use the parking brake before starting the engine or parking the atv, especially on a slope....

  • Page 30: Drive Select Lever

    4-8 1 2 3 4 5 6 7 8 9 10 11 ewb00170 ebu18630 drive select lever the drive select lever is located on the left side of the engine. Use the drive select lever to shift the transmission into drive or neutral. 1. Parking brake lock plate warning potential hazard improper use of the parking brake. 1 wha...

  • Page 31: Fuel Tank Cap

    4-9 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. Drive select lever 2. Drive position 3. Neutral position 1...

  • Page 32: Caution:

    4-10 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 33: Fuel Cock

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

  • Page 34: Choke

    4-12 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 35: Seat

    4-13 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 36: Warning

    4-14 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. 1. Projection 2. Seat holder 1 2.

  • Page 37: Pre-Operation Checks

    5-1 1 2 3 4 5 6 7 8 9 10 11 ebu19200 pre-operation checks ebu19212 pre-operation check list before operating this atv, be sure to check the items listed in the following table. Ewb00470 note: the maintenance of some items in the table has to be performed by a yamaha dealer. Refer to the periodic mai...

  • Page 38

    5-2 1 2 3 4 5 6 7 8 9 10 11 engine oil ● check oil level in engine, and add recommended oil to specified level if necessary. ● check atv for oil leakage. Correct if necessary. 5-3, 8-10 final gear oil ● check atv for oil leakage. Correct if necessary. 5-3, 8-12 front brake ● check operation, and cor...

  • Page 39: Fuel

    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 4-9.) 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 40: Throttle Lever

    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. Ebu19781 tires ewb00561 warning potential hazard riding with improperly operati...

  • Page 41: Measuring The Tire Pressure

    5-5 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 rear: manufacturer/model: dunlop/kt145 size: at16 x ...

  • Page 42: Tire Wear Limit

    5-6 1 2 3 4 5 6 7 8 9 10 11 dirt in the gauge could cause the first reading to be incorrect. Set the tire pressure when the tires are cold. Set 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). 1. Low-press...

  • Page 43: Chassis Fasteners

    5-7 1 2 3 4 5 6 7 8 9 10 11 ebu19840 chassis fasteners make 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 t...

  • Page 44: Operation

    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 ebu20231 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 45

    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 46: Caution:

    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 47: Caution:

    6-4 1 2 3 4 5 6 7 8 9 10 11 note: before shifting the transmission into drive, be sure to apply the parking brake. The engine will stop if you attempt to shift into drive without applying the parking brake first. 4. Squeeze the rear brake lever to release the parking brake. 5. Gradually open the thr...

  • Page 48: Engine Break-In

    6-5 1 2 3 4 5 6 7 8 9 10 11 quate lubrication may damage the transmission. Ebu20682 engine break-in note: ● for atvs equipped with an odometer or an hour meter, follow the figures given in km (mi) or the figures given in hours. ● for atvs not equipped with an odometer or hour meter, follow the figur...

  • Page 49: Parking On A Slope

    6-6 1 2 3 4 5 6 7 8 9 10 11 ebu20790 parking on a slope ewb00810 1. Bring the atv to a stop by applying the brakes in the drive position. 2. Stop the engine. 3. With the rear brake lever applied, apply the parking brake, and then slowly release the brake lever. 1. Parking brake lock plate 1. Locked ...

  • Page 50: Accessories and Loading

    6-7 1 2 3 4 5 6 7 8 9 10 11 ebu20910 accessories and loading ebu20920 accessories accessories can affect the handling and control of your atv. Keep the following in mind when consid- ering an accessory or operating an atv which has accessories. ● choose only accessories designed for your atv. Your y...

  • Page 51: Warning

    6-8 1 2 3 4 5 6 7 8 9 10 11 the following points in mind: ● never exceed the weight limits shown. An over- loaded atv can be unstable. ● if you are carrying cargo and towing a trailer, in- clude the tongue weight in the maximum atv load limit. ● load cargo on the carriers as close to the center of t...

  • Page 52: Riding Your Atv

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

  • Page 53: Warning

    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. Ebu21502 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 54: Warning

    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 6 years of age. Ewb01290 warning potential hazard oper...

  • Page 55: Warning

    7-4 1 2 3 4 5 6 7 8 9 10 11 this atv is designed to carry operator 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 you and/or ...

  • Page 56: Warning

    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 57: Warning

    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. 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...

  • Page 58: Warning

    7-7 1 2 3 4 5 6 7 8 9 10 11 ewb00950 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 equi...

  • Page 59: Warning

    7-8 1 2 3 4 5 6 7 8 9 10 11 start off with the speed limiter turned in to limit the amount of speed available while they learn. The limiter may be gradually adjusted to increase max- imum speed as the beginner becomes more famil- iar with operating the atv. Loading and accessories use extra caution ...

  • Page 60: Warning

    7-9 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. Ewb00980 avoid wheelies and jumping. You may lose control of the atv or overturn. Ewb00990 warning potential hazard removing hands from handlebars or f...

  • Page 61: Warning

    7-10 1 2 3 4 5 6 7 8 9 10 11 modifications ewb01000 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. Warning potential hazard...

  • Page 62: Warning

    7-11 1 2 3 4 5 6 7 8 9 10 11 ewb01010 be careful where you ride this atv is designed for off-road use only. Riding on paved surfaces can cause loss of control. Ewb01020 warning potential hazard hot exhaust system. What can happen dry grass or brush or other combustible ma- terial accumulated around ...

  • Page 63: Warning

    7-12 1 2 3 4 5 6 7 8 9 10 11 do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. Ewb01030 how to avoid the hazard always avoid paved surfaces, including side- walks, driveways, parking lots and streets. Warning potential hazard ope...

  • Page 64: Warning

    7-13 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 ewb01050 warning potential hazard failure to use extra care when operating this...

  • Page 65: Warning

    7-14 1 2 3 4 5 6 7 8 9 10 11 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. Ewb01060 how to avoid the hazard do not operate on excessively rough, slip- pery or loose terrain unti...

  • Page 66

    7-15 1 2 3 4 5 6 7 8 9 10 11 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 control of...

  • Page 67: Warning

    7-16 1 2 3 4 5 6 7 8 9 10 11 low speed. Ewb01220 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...

  • Page 68: Warning

    7-17 1 2 3 4 5 6 7 8 9 10 11 curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the atv to tip. If the atv begins to tip over to the outside while negotiating a turn, lean more t...

  • Page 69

    7-18 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 70: Warning

    7-19 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 71: Warning

    7-20 1 2 3 4 5 6 7 8 9 10 11 ewb01301 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. Allow the engine compression to do most of the braking for you. Improper braking ...

  • Page 72: Warning

    7-21 1 2 3 4 5 6 7 8 9 10 11 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. Ewb01130 crossing a slope traversing a sloping surface on your atv requires you to proper...

  • Page 73: Warning

    7-22 1 2 3 4 5 6 7 8 9 10 11 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. ...

  • Page 74: Warning

    7-23 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 75: Caution:

    7-24 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 76: Warning

    7-25 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 77: Warning

    7-26 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 78: Warning

    7-27 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 7-15.) ● 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 79: Warning

    8-1 1 2 3 4 5 6 7 8 9 10 11 ebu21647 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 80: Warning

    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 81

    8-3 1 2 3 4 5 6 7 8 9 10 11 ebu21742 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 82

    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 83

    8-5 1 2 3 4 5 6 7 8 9 10 11 ebu21864 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 84

    8-6 1 2 3 4 5 6 7 8 9 10 11 9 * shock absorber assemblies ● check operation and correct if necessary. ● check for oil leakage and replace if necessary. √ √ √ 10 * front knuckle piv- ots ● lubricate with lithium-soap-based grease. √ √ √ 11 * steering shaft ● lubricate with lithium-soap-based grease. ...

  • Page 85

    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..

  • Page 86: Warning

    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. Ebu23211 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 87

    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 operat...

  • Page 88: Engine Oil

    8-10 1 2 3 4 5 6 7 8 9 10 11 2. Clean the surface of the spark plug gasket 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 whe...

  • Page 89

    8-11 1 2 3 4 5 6 7 8 9 10 11 4. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level. Note: 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 o...

  • Page 90: Caution:

    8-12 1 2 3 4 5 6 7 8 9 10 11 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 chemical additives. Do not use o...

  • Page 91

    8-13 1 2 3 4 5 6 7 8 9 10 11 note: the final gear oil should be between the minimum and maximum level marks. 3. If the oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. 4. Insert the dipstick into the oil filler hole, and then tig...

  • Page 92: Caution:

    8-14 1 2 3 4 5 6 7 8 9 10 11 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 filler cap. 7. Check the final gear case for oil leakage. If oil is lea...

  • Page 93

    8-15 1 2 3 4 5 6 7 8 9 10 11 2. Remove the air filter case cover by unhooking the holders. 1. Panel 2. Bolt 1 2 2 1. Air filter case cover 2. Air filter case holder 2 2 1.

  • Page 94: Caution:

    8-16 1 2 3 4 5 6 7 8 9 10 11 3. Unhook the holder holding the air filter ele- ment, and then pull out the sponge material from the air filter element. 4. Wash the sponge material gently but thor- oughly in solvent. Ewb01900 5. Squeeze the excess solvent out of the sponge material and let it dry. Cau...

  • Page 95: Caution:

    8-17 1 2 3 4 5 6 7 8 9 10 11 7. Apply yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material. Note: the sponge material should be wet but not drip- ping. 8. Install the sponge material into the air filter el- ement. 9. Place the air filter element in the original po...

  • Page 96: Adjusting The Carburetor

    8-18 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 97: Caution:

    8-19 1 2 3 4 5 6 7 8 9 10 11 yamaha dealer, who has the necessary profes- sional knowledge and experience. The adjustment described in the following section, however, may be performed by the owner as part of routine main- tenance. Caution: ecb00480 the carburetor has been set and extensively tested ...

  • Page 98: Valve Clearance

    8-20 1 2 3 4 5 6 7 8 9 10 11 note: if the specified idling speed cannot be obtained as described above, have a yamaha dealer make the adjustment. Ebu27071 checking the throttle cable free play the throttle cable free play should be checked at the intervals specified in the periodic maintenance and l...

  • Page 99: Play

    8-21 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

    8-22 1 2 3 4 5 6 7 8 9 10 11 the brake lever free play should measure 10.0– 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 d...

  • Page 101: Warning

    8-23 1 2 3 4 5 6 7 8 9 10 11 6. Tighten the upper locknut. Ewb02020 ebu24441 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. Note: before adjusting the brake l...

  • Page 102

    8-24 1 2 3 4 5 6 7 8 9 10 11 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 it. 3. Tighten the locknut at the brake lever. If the specified free play cannot be ...

  • Page 103: Rear Brake Levers

    8-25 1 2 3 4 5 6 7 8 9 10 11 ewb02020 ebu24890 checking and lubricating the cables the operation and the condition of all control ca- bles should be checked before each ride, and the cables and cable ends should be lubricated if nec- essary. If a cable is damaged or does not move smoothly, have a ya...

  • Page 104: Battery

    8-26 1 2 3 4 5 6 7 8 9 10 11 ebu24962 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 t...

  • Page 105: Caution:

    8-27 1 2 3 4 5 6 7 8 9 10 11 charge quickly. The electrolyte level, battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrica- tion chart. To check the electrolyte level 1. Place the atv on a level sur...

  • Page 106: Warning

    8-28 1 2 3 4 5 6 7 8 9 10 11 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 for more than one month, the battery will need to be removed and stored as follows. 1. Disconnect the negativ...

  • Page 107: Caution:

    8-29 1 2 3 4 5 6 7 8 9 10 11 caution: ecb00600 do not leave or store the battery on its side. 3. If the battery will be stored for more than two months, check the specific gravity of the elec- trolyte at least once a month and fully charge the battery whenever necessary. To install the battery note:...

  • Page 108: Replacing The Fuse

    8-30 1 2 3 4 5 6 7 8 9 10 11 ebu25232 replacing the fuse the fuse holder is located under the seat. (see page 4-13.) if the fuse is blown, replace it as follows. 1. Turn the key to “off” and turn off all electrical circuits. Caution: ecb00640 to prevent accidental short-circuiting, turn off the main...

  • Page 109: Installing A Wheel

    8-31 1 2 3 4 5 6 7 8 9 10 11 front rear 2. Elevate the atv and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Ebu27480 installing a wheel 1. Install the wheel and the nuts. Note: when installing the wheel, make sure its arrow mark points toward the ro...

  • Page 110

    8-32 1 2 3 4 5 6 7 8 9 10 11 wheel. Front rear 2. Lower the atv to the ground. 3. Tighten the wheel nuts to the specified torques. 1. Arrow mark 1 1. Arrow mark tightening torques: front wheel nut: 28 nm (2.8 m·kgf, 20 ft·lbf) rear wheel nut: 28 nm (2.8 m·kgf, 20 ft·lbf) 1.

  • Page 111: Troubleshooting

    8-33 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 112: Troubleshooting Chart

    8-34 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 113: Cleaning and Storage

    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 114: Storage

    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 115

    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 116: Specifications

    10-1 1 2 3 4 5 6 7 8 9 10 11 ebu25960 specifications ebu2597a dimensions: overall length: 1537 mm (60.5 in) overall width: 825 mm (32.5 in) overall height: 915 mm (36.0 in) seat height: 618 mm (24.3 in) wheelbase: 1030 mm (40.6 in) ground clearance: 75 mm (3.0 in) minimum turning radius: 2300 mm (91...

  • Page 117

    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 118

    10-3 1 2 3 4 5 6 7 8 9 10 11 rear tire: type: tubeless size: at16 x 8-7 manufacturer/model: dunlop/kt145 loading: maximum loading limit: 40.0 kg (88 lb) (total weight of rider, cargo, accessories, and tongue) tire air pressure (measured on cold tires): recommended: front: 20 kpa (2.9 psi) (0.20 kgf/...

  • Page 119

    10-4 1 2 3 4 5 6 7 8 9 10 11 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, 1.7 w × 1 fuses: main fuse: 5.0 a.

  • Page 120: Consumer Information

    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 121

    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 122: Noise Regulation

    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 123: Maintenance Record

    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 124

    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 125

    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 126

    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 127

    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 128

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

  • Page 129: Index

    Index a accessories and loading ................................................ 6-7 air filter element, cleaning............................................ 8-14 b battery.................................................................. 5-7 , 8-26 brake lever free play, adjusting the front...........

  • Page 130

    N neutral indicator light ..................................................... 4-2 noise regulation ........................................................... 11-3 o owner’s manual and tool kit........................................... 8-1 p parking ..................................................

  • Page 132: Warning

    Printed in japan 2007.06-1.0x1 ! (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 terrai...

  • Page 133: 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 manual ...

  • Page 134

    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.