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  4. RAPTOR YFM80RW
  5. Owner's Manual

Yamaha RAPTOR YFM80RW Owner's Manual

Summary of RAPTOR YFM80RW

  • Page 1

    This a owner’s manual lit-11626-20-14 5th-28199-16 this atv should not be ridden by anyone under 12 years of age. Yfm80rw warning read this manual carefully! It contains important safety information..

  • Page 2

    Ebu17091.

  • Page 3: Introduction

    Ebu17170 introduction ebu17240 congratulations on your purchase of the yamaha yfm80rw. 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

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

  • Page 9

    Troubleshooting chart ............................. 8-36 cleaning and storage.......................... 9-1 cleaning .................................................... 9-1 storage ...................................................... 9-2 specifications ...................................... 10-1 ...

  • Page 10: Safety Information

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

  • 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: Warning

    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 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 vicinity of ...

  • Page 14: Warning

    1-5 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 15

    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.

  • Page 16: Warning

    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 17: Warning

    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 18: Description

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

  • Page 19: 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 20: 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 21: Indicator Light

    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 22: 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. Ebu18270 throttle lever once the engine is running, movement of the throt- tle lever will incre...

  • Page 23: Plate

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

  • Page 24: Front Brake Lever

    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 25: Parking Brake

    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 26: Shift Pedal

    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 27: Fuel Tank Cap

    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 3 2 1 1 n 2 1. Fuel tank c...

  • Page 28: Caution:

    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 29: Fuel Cock

    4-10 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 30: Choke

    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 31: Seat

    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 32: Warning

    4-13 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 33: Pre-Operation Checks

    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 34: Warning

    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. 5-4, 5-5, 5-6 brake and shift pedals ● make sure that operation is smooth. Lubricate pedal ...

  • Page 35: 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 4-8.) 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 36: 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 37: 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/kt587 size: at18 x ...

  • Page 38: 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 39: 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 40: 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 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 41

    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 42: 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 43: Caution:

    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 44: Caution:

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

  • Page 45: Parking On A Slope

    6-6 1 2 3 4 5 6 7 8 9 10 11 ebu20830 parking on a slope ewb00790 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. 1. Parking brake lock plate 1. L...

  • Page 46: 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 47: 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 48: Warning

    6-9 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..

  • Page 49: Riding Your Atv

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

  • Page 50: 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. Ebu21532 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 51: Warning

    7-3 1 2 3 4 5 6 7 8 9 10 11 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 this atv is designed to carry operato...

  • Page 52: Warning

    7-4 1 2 3 4 5 6 7 8 9 10 11 ewb00910 apparel ewb00920 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 your passen- ger. How to avoid the hazard never carr...

  • Page 53

    7-5 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. What can happen operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of ...

  • Page 54: Warning

    7-6 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: Warning

    7-7 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: Warning

    7-8 1 2 3 4 5 6 7 8 9 10 11 ate with skill at the top speed permitted by adjust- ing the speed limiter alone, the air intake restrictor plate can be removed. Since removal of this plate will result in a significant increase in power, turn the speed limiter back in again; adjust it out in stag- es as...

  • Page 57

    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. 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: Warning

    7-10 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 warning potential hazard removing hands from handlebars or feet from footboards during operation. What can happen removing even one hand or foot can reduce your ability to control ...

  • Page 59: Warning

    7-11 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. Ewb01010 warning potenti...

  • Page 60: Warning

    7-12 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. Warning potential h...

  • Page 61: Warning

    7-13 1 2 3 4 5 6 7 8 9 10 11 ewb01030 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 warning potential hazard operating this atv on public streets, roads o...

  • Page 62: Warning

    7-14 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: Warning

    7-15 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: Caution:

    7-16 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: Warning

    7-17 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: Warning

    7-18 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

    7-19 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: Warning

    7-20 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: Warning

    7-21 1 2 3 4 5 6 7 8 9 10 11 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 compression to do most of the bra...

  • Page 70: Warning

    7-22 1 2 3 4 5 6 7 8 9 10 11 whenever possible, ride your atv straight down- hill. Avoid sharp angles which could allow the atv to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- stacles which may appear. Ewb01130 crossing a slope traversing a sl...

  • Page 71: Warning

    7-23 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 72: Warning

    7-24 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: Caution:

    7-25 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: Warning

    7-26 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: Warning

    7-27 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: Warning

    7-28 1 2 3 4 5 6 7 8 9 10 11 ● if your atv begins to tip while turning: 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 7-16.) ● if your atv starts to slide sideways: steer in the direction of the slide if y...

  • Page 77: Warning

    8-1 1 2 3 4 5 6 7 8 9 10 11 ebu21641 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: 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 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: 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 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 operat...

  • Page 86: 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 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: Caution:

    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 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 90: Caution:

    8-14 1 2 3 4 5 6 7 8 9 10 11 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 leaking, check for the cause. Ebu23791 cleaning t...

  • Page 91

    8-15 1 2 3 4 5 6 7 8 9 10 11 2. Remove the air filter case cover by unhooking the holders. 3. Unhook the holder holding the air filter ele- ment, and then pull out the sponge material from the air filter element. 1. Panel 1 2 2 1. Air filter case cover 2. Air filter case holder 2 2 1.

  • Page 92: Caution:

    8-16 1 2 3 4 5 6 7 8 9 10 11 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. Caution: ecb00440 do not twist the sponge material when squeez- ing it. 6. Check the sponge material and replace it if damage...

  • Page 93: Caution:

    8-17 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 94: Warning

    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 95: Adjusting The Carburetor

    8-19 1 2 3 4 5 6 7 8 9 10 11 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 adjustment. ...

  • Page 96: Timing Chain

    8-20 1 2 3 4 5 6 7 8 9 10 11 throttle stop screw at the carburetor. To in- crease the engine idling speed, turn the throt- tle stop screw in direction (a), and to decrease it, turn the screw in direction (b). Note: if the specified idling speed cannot be obtained as described above, have a yamaha de...

  • Page 97: Valve Clearance

    8-21 1 2 3 4 5 6 7 8 9 10 11 this from occurring, the timing chain tensioner must be adjusted by a yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart. Ebu24060 valve clearance the valve clearance changes with use, resulting in improper air-fuel mixture and...

  • Page 98: Play

    8-22 1 2 3 4 5 6 7 8 9 10 11 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, check the f...

  • Page 99

    8-23 1 2 3 4 5 6 7 8 9 10 11 4. Tighten the lower locknut. 5. While applying the front brake, turn out the up- per adjusting bolt until the upper and lower ca- ble lengths are equal. The cable joint will become vertical. 6. Tighten the upper locknut. 1. Upper locknut 2. Upper adjusting bolt 3. Lower...

  • Page 100: Brake Pedal Free Play

    8-24 1 2 3 4 5 6 7 8 9 10 11 ewb02020 ebu24463 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. Note: ● always perform this ...

  • Page 101

    8-25 1 2 3 4 5 6 7 8 9 10 11 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 obtained, proceed with the following steps. 4. Loosen the locknut at the brake lever. 5. Fully...

  • Page 102: Warning

    8-26 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. Ewb02020 1. Brake pedal free play 1 1. Brake pedal free play adjusting nut warning potential hazard oper...

  • Page 103

    8-27 1 2 3 4 5 6 7 8 9 10 11 ebu24781 adjusting the clutch free play the clutch free play must be adjusted periodically. Adjust the free play as follows. 1. Remove the rubber cap. 2. Loosen the locknut. 3. Slowly turn the adjusting bolt clockwise until resistance is felt, and then turn it 1/8 counte...

  • Page 104: Rear Brake Levers

    8-28 1 2 3 4 5 6 7 8 9 10 11 bolt with a screwdriver so that the adjusting bolt does not turn together with the locknut. 5. Install the rubber cap securely. Ebu24890 checking and lubricating the cables the operation and the condition of all control ca- bles should be checked before each ride, and th...

  • Page 105: Shift Pedals

    8-29 1 2 3 4 5 6 7 8 9 10 11 rear brake lever 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 w...

  • Page 106: Battery

    8-30 1 2 3 4 5 6 7 8 9 10 11 ebu25090 lubricating the steering shaft the steering shaft must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart. Lubricate the steering shaft using a grease gun. Ebu25111 battery a poorly maintained battery will corrode and ...

  • Page 107: Caution:

    8-31 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 108: Caution:

    8-32 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 109: Caution:

    8-33 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 110: Removing A Wheel

    8-34 1 2 3 4 5 6 7 8 9 10 11 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 place a suitable stand under the frame. 3. Remove the...

  • Page 111: Troubleshooting

    8-35 1 2 3 4 5 6 7 8 9 10 11 torques. 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 powe...

  • Page 112: Troubleshooting Chart

    8-36 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 ebu25974 dimensions: overall length: 1537 mm (60.5 in) overall width: 841 mm (33.1 in) overall height: 940 mm (37.0 in) seat height: 669 mm (26.3 in) wheelbase: 1030 mm (40.6 in) ground clearance: 100 mm (3.9 in) minimum turning radius: 2400 mm (9...

  • 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 manufacturer/model: dunlop/kt586 rear tire: type: tubeless size: at18 x 8-7 manufacturer/model: dunlop/kt587 loading: maximum loading limit: 95.0 kg (209 lb) (total weight of rider, cargo, accessories, and tongue) tire air pressure (measured on cold tires): recommended: ...

  • Page 119

    10-4 1 2 3 4 5 6 7 8 9 10 11 spring/shock absorber type: coil spring/oil damper wheel travel: 56 mm (2.2 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, 1...

  • 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 air intake restrictor plate, removing.............................. 8-17 b battery..........................................................

  • Page 130

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

  • Page 131: Warning

    Printed in japan 2006.04-0.9x1 ! (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 132: 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 133

    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.