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Yamaha YFM700RA Owner's Manual - Owner’S Manual

Summary of YFM700RA

  • Page 1

    Yfm7ra/yfm7rsea yfm700ra/yfm700rsea owner’s manual manuel du propriÉtaire manual del propietario 1as-28199-61 read this manual carefully! It contains important safety information. Lire attentivement ce manuel! Il comprend d’importantes informations de sécurité. ¡lea este manual atentamente! Contiene...

  • Page 2

    Printed in japan 2010.02-0.5 ×1 cr (e,f,s) printed on recycled paper imprimÉ sur papier recyclÉ impreso en papel reciclado yamaha motor co., ltd. Dic183.

  • Page 3: Owner’S Manual

    Read this manual carefully! It contains important safety information. Owner’s manual yfm7ra/yfm7rsea yfm700ra/yfm700rsea 1as-28199-61-e0 u1as61e0.Book page 1 thursday, february 11, 2010 2:17 pm.

  • Page 4

    Ebu29144 read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. Ansi/svia 1-2007 general manager rv engineering division mc operations 25 december, 2009 yfm700r (yfm7r) (jy4am07w0a0025230–) we, yamaha motor co., ltd. 2500 shingai, iwata, ...

  • Page 5

    Ebu17170 introduction ebu17322 congratulations on your purchase of the yamaha yfm7ra/yfm7rsea/yfm700ra/yfm700rsea. 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...

  • Page 6

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

  • Page 7

    Ebu17350 important notice ebu17372 this atv is designed and manufactured for use on unpaved surfaces only. It is unsafe to operate this atv on any paved surface, paved street, paved road or motorway. Please check your local riding laws and regulations before operating this atv. Ebu17390 yfm7ra/yfm7r...

  • Page 8

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

  • Page 9

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

  • Page 10

    Checking the shift pedal ........................... 8-40 checking and lubricating the brake pedal ...................................................... 8-40 checking the wheel hub bearings ............ 8-40 lubricating the swingarm pivots ............... 8-41 lubricating the rear suspension relay ...

  • Page 11

    1-1 1 ebu29680 location of the warning and specification labels ebu29991 read and understand all of the labels on your atv. These labels contain important information for safe and proper operation. Never remove any labels from your atv. If a label becomes difficult to read or comes off, request a re...

  • Page 12

    1-2 1 4aa-22259-40 1s3-2156a-10 yfm700r 35.0 kw 192 kg 4d3-2816l-20 8ac-2817l-00 yamaha motor co., ltd. 2500 shingai, iwata, japan 2010 1 2 4 3 u1as61e0.Book page 2 thursday, february 11, 2010 2:17 pm.

  • Page 13

    1-3 1 1as-2816p-00 27.5 kpa 0.275 kgf/cm² 4.0 psi 27.5 kpa 0.275 kgf/cm² 4.0 psi 4d3-2816m-m0 43p-28199-01 7 6 5 u1as61e0.Book page 3 thursday, february 11, 2010 2:17 pm.

  • Page 14

    1-4 1 familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the owner’s manual. Always use an approved helmet and protective gear. Never permit children under age 6 to operate this atv. Operation of thi...

  • Page 15

    1-5 1 **.* kpa *.** kgf/cm² *.* psi **.* kpa *.** kgf/cm² *.* psi never use with drugs or alcohol. Never store fuel or flammable liquids. This unit contains high-pressure nitrogen gas. Mishandling can cause an explosion. Do not incinerate, puncture or open. Use unleaded gasoline only. Measure the ti...

  • Page 16

    1-6 1 ****** *** kw *** kg 1 2 3 yamaha motor co., ltd. 2500 shingai, iwata, japan **** 1 this pictogram shows trailer hitch tow weight limit. (combined weight of the trailer and all cargo in the trailer.) overloading can cause loss of control. Loss of control can result in severe injury or death. T...

  • Page 17

    1-7 1 for oceania 4 5 2 3 1 1 u1as61e0.Book page 7 thursday, february 11, 2010 2:17 pm.

  • Page 18

    1-8 1 4aa-22259-40 2 1 u1as61e0.Book page 8 thursday, february 11, 2010 2:17 pm.

  • Page 19

    1-9 1 warning operating tire pressure: set with tires cold • recommended : front : 27.5 kpa, rear : 27.5 kpa, • minimum : front : 24.5 kpa, rear : 24.5 kpa, • never set tire pressure below minimum. It could cause the tire to dislodge from the rim. Loading • maximum weight capacity : 100 kg, (220 lbs...

  • Page 20

    2-1 2 ebu17431 safety information ebu26682 an atv is not a toy and can be hazard- ous to operate. An atv handles differently from other vehicles, in- cluding motorcycles and cars. A collision or roll- over can occur quickly, even during routine maneuvers such as turning and riding on hills or over o...

  • Page 21

    2-2 2 ● always inspect your atv each time you use it to make sure it is in safe operating condition. Al- ways follow the inspection and maintenance procedures and schedules described in this manual. ● always keep both hands on the handlebars and both feet on the footboards of the atv during operatio...

  • Page 22

    2-3 2 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 pointed straight up- hill. Turn the atv around and remount, following the procedure described in this manual. ● always chec...

  • Page 23

    2-4 2 and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in en- closed or poorly ventilated areas. If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and seek medical ...

  • Page 24

    3-1 3 ebu17680 description ebu17690 left view 1. Engine oil tank filler cap 2. Coolant reservoir 3. Idle adjusting screw 4. Fuses 5. Rear shock absorber assembly rebound damping force adjusting screw 6. Rear shock absorber assembly compression damping force adjusting bolt (for fast compression dampi...

  • Page 25

    3-2 3 ebu17700 right view 1. Spark arrester 2. Air filter case 3. Battery 4. Rear brake fluid reservoir 5. Crankcase engine oil filler cap 6. Oil filter element 7. Spark plug 8. Front shock absorber assembly compression damping force adjusting bolt (for fast compression damping) 9. Front shock absor...

  • Page 26

    3-3 3 ebu17712 controls and instruments tip the atv you have purchased may differ slightly from the figures shown in this manual. 1. Clutch lever 2. Parking brake lever 3. Main switch 4. Front brake fluid reservoir 5. Brake lever 6. Throttle lever 7. Reverse knob 8. Fuel tank cap 9. Handlebar switch...

  • Page 27

    4-1 4 ebu17733 instrument and control functions ebu17760 main switch the positions of the main switch are as follows: on all electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed. Off all...

  • Page 28

    4-2 4 ebu26694 indicator lights and warning lights ebu17860 neutral indicator light “ ” this indicator light comes on when the transmis- sion is in the neutral position. Ebu17830 reverse indicator light “ ” this indicator light comes on when the transmis- sion is in the reverse position. Ebu26702 co...

  • Page 29

    4-3 4 ebu29391 fuel level warning light “ ” this warning light comes on when the fuel level drops below approximately 2.6 l (0.69 us gal, 0.57 imp.Gal). When this occurs, refuel as soon as possible. The electrical circuit of the warning light can be checked by setting the engine stop switch to “ ” a...

  • Page 30

    4-4 4 ● two tripmeters (which show the distance trav- eled since they were last set to zero) ● a clock ● an hour meter (which shows the total time the engine has been running) ● a self-diagnosis device odometer and tripmeter modes pushing the “select” button switches the display between the odometer...

  • Page 31

    4-5 4 self-diagnosis device this model is equipped with a self-diagnosis de- vice for various electrical circuits. If a problem is detected in any of those circuits, the engine trouble warning light will come on or flash and the multi-function display will indicate an error code. If the multi-functi...

  • Page 32

    4-6 4 ebu18080 engine stop switch “ / ” set this switch to “ ” before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation. The engine will not start or run when this switch is set to “...

  • Page 33

    4-7 4 before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. Ebu18323 speed limiter your atv is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening,...

  • Page 34

    4-8 4 leased slowly for smooth clutch operation. (see page 6-1 for a description of the ignition circuit cut- off system.) ebu18421 brake lever the brake lever is located on the right handlebar. To apply the front brake, pull the brake lever to- ward the handlebar grip. The brake lever is equipped w...

  • Page 35

    4-9 4 ebu18520 parking brake lever use the parking brake before starting the engine or parking the atv, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a). To release the parking brake, move the parking brake lever in direction (b). 1. Brake pedal 1 1. P...

  • Page 36

    4-10 4 warning ewb00220 ● always set the parking brake before starting the engine. The atv could start moving un- expectedly if the parking brake is not ap- plied. This could cause loss of control or a collision. ● always be sure you have released the park- ing brake before you begin to ride. The br...

  • Page 37

    4-11 4 ebu18720 fuel tank cap remove the fuel tank cap by turning it counter- clockwise. Ebu18754 fuel make sure there is sufficient gasoline in the tank. Warning ewb02521 gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refuel...

  • Page 38

    4-12 4 of sparks, open flames, or other sources of ig- nition such as the pilot lights of water heaters and clothes dryers. 2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole. Stop filling when the fuel reach- es the bottom of the fille...

  • Page 39

    4-13 4 doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. Notice ecb00070 use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston ring...

  • Page 40

    4-14 4 ebu30050 adjusting the front shock absorber as- semblies these shock absorber assemblies are equipped with a spring preload adjusting nut, a rebound damping force adjusting screw, with a compres- sion damping force adjusting bolt (for fast com- pression damping), and a compression damping for...

  • Page 41

    4-15 4 would be advisable to check the number of clicks or turns of each damping force adjusting mecha- nism and to modify the specifications as neces- sary. Spring preload 1. Loosen the locknut. 2. Turn the spring preload adjusting nut in direc- tion (a) to increase the spring preload and thereby h...

  • Page 42

    4-16 4 3. Tighten the locknut to the specified torque. Notice: always tighten the locknut against the adjusting nut, and then tighten it to the specified torque. [ecb00081] rebound damping force turn the rebound damping force adjusting screw in direction (a) to increase the rebound damping force and...

  • Page 43

    4-17 4 compression damping force compression damping force (for fast compression damping) to increase the compression damping force and thereby harden the compression damping, turn the compression damping force adjusting bolt in direc- tion (a). To decrease the compression damping force and thereby ...

  • Page 44

    4-18 4 compression damping force (for slow compres- sion damping) to increase the compression damping force and thereby harden the compression damping, turn the compression damping force adjusting screw in di- rection (a). To decrease the compression damping force and thereby soften the compression ...

  • Page 45

    4-19 4 ● do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a yamaha deal- er for any service. Ebu30041 adjusting the rear shock absorber as- sembly this shock absorber assembly is equipped with a spring preload adjusting nut, a rebound damp...

  • Page 46

    4-20 4 tip ● a special wrench can be obtained at a yamaha dealer to make this adjustment. ● the spring preload setting is determined by measuring distance a, shown in the illustration. The shorter distance a is, the higher the spring preload; the longer distance a is, the lower the spring preload. W...

  • Page 47

    4-21 4 rebound damping force turn the rebound damping force adjusting screw in direction (a) to increase the rebound damping force and thereby harden the damping, and in di- rection (b) to decrease the rebound damping force and thereby soften the damping. Compression damping force compression dampin...

  • Page 48

    4-22 4 compression damping force (for slow compres- sion damping) to increase the compression damping force and thereby harden the compression damping, turn the compression damping force adjusting screw in di- rection (a). To decrease the compression damping force and thereby soften the compression ...

  • Page 49

    4-23 4 warning ewb00430 this shock absorber assembly contains highly pressurized nitrogen gas. Read and under- stand the following information before han- dling the shock absorber assembly. ● do not tamper with or attempt to open the cylinder assembly. ● do not subject the shock absorber assembly to...

  • Page 50

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

  • Page 51

    5-2 5 front brake • check operation. If soft or spongy, have yamaha dealer bleed hy- draulic system. • check brake pads for wear, and replace if necessary. • check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary. • check hydraulic system for leakage. C...

  • Page 52

    5-3 5 brake and clutch levers • make sure that operation is smooth. Lubricate lever pivoting points if necessary. 8-40 chassis fasteners • make sure that all nuts, bolts and screws are properly tightened. 5-7 instruments, lights and switches • check operation, and correct if necessary. 5-7 item rout...

  • Page 53

    5-4 5 ebu19541 fuel make sure that there is sufficient fuel in the tank. (see page 4-11.) ebu19560 engine oil make sure that the engine oil is at the specified lev- el. Add oil as necessary. (see page 8-12.) ebu19631 coolant make sure that the coolant is at the specified level. Add coolant as necess...

  • Page 54

    5-5 5 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. Ebu19770 drive chain check the condition of the drive chain and check the drive chain slack. Lubricate and adj...

  • Page 55

    5-6 5 tire wear limit when the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. Tire information this atv is equipped with tubeless tires with valves. Warning ewb02551 use of improper tires on this atv may cause loss of control, increasing your risk of an acci- dent. After exte...

  • Page 56

    5-7 5 aftermarket tires and rims the tires and rims that came with your atv were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Ebu19840 chassis fasteners make su...

  • Page 57

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

  • Page 58

    6-2 6 4. Completely close the throttle lever and start the engine by pushing the start switch. Notice: for maximum engine life, never accelerate hard when the engine is cold! [ecb00162] tip if the engine fails to start, release the start switch, then push it again. Pause a few seconds before the nex...

  • Page 59

    6-3 6 3. Shift into first gear, and then release the brake. 4. Open the throttle gradually and at the same time, release the clutch lever slowly. Warning! Opening the throttle abruptly or releasing the clutch lever too quickly could make the atv wheelie, which would increase the chance of an acciden...

  • Page 60

    6-4 6 ● always use the clutch when changing gears. The engine, transmission and drive train are not designed to withstand the shock of forced shifting and can be damaged by shift- ing without using the clutch. Ebu20501 operating the reverse knob and driving in reverse warning ewb00720 improper opera...

  • Page 61

    6-5 6 5. Open the throttle lever gradually and release the clutch lever slowly. Continue to watch to the rear while backing. Ebu20672 engine break-in tip ● 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 ...

  • Page 62

    6-6 6 ebu20904 parking on a slope warning ewb00851 avoid parking on hills or other inclines. Park- ing on a hill or other incline could cause the atv to roll out of control, increasing the chance of an accident. If you must park on an incline, place the atv transversely across the incline, shift int...

  • Page 63

    6-7 6 ebu20910 accessories and loading ebu20921 genuine yamaha accessories choosing accessories for your atv is an important decision. Genuine yamaha accessories, which are available only from a yamaha dealer, have been designed, tested, and approved by yamaha for use on your atv. Many companies wit...

  • Page 64

    6-8 6 ebu20941 loading warning ewb00820 never exceed the stated load capacity for this atv. Overloading this atv or carrying or tow- ing cargo improperly could cause changes in atv handling which could lead to an accident. Cargo should be properly distributed and se- curely attached. Reduce speed wh...

  • Page 65

    7-1 7 ebu21141 riding your atv u1as61e0.Book page 1 thursday, february 11, 2010 2:17 pm.

  • Page 66

    7-2 7 ebu21616 getting to know your atv this atv is intended for recreational use by expe- rienced operators only. This section, riding your atv, provides general atv riding instructions for recreational riding. The skills and techniques de- scribed in this section, however, are appropriate for all ...

  • Page 67

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

  • Page 68

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

  • Page 69

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

  • Page 70

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

  • Page 71

    7-7 7 during operation always keep your feet on the footrests during op- eration; otherwise, they may contact the rear wheels. Warning! Removing even one hand or foot can reduce your ability to control the atv or could cause you to lose your balance and fall off of the atv. If you remove a foot from...

  • Page 72

    7-8 7 warning! Operating this atv with improper modifications may cause changes in handling which in some situations could lead to an acci- dent. [ewb01491] exhaust system warning ewb01501 ● dry grass or brush or other combustible ma- terial accumulated around the engine area could catch fire. Do no...

  • Page 73

    7-9 7 be careful where you ride this atv is designed for use on unpaved surfaces only. Warning! Paved surfaces may seriously affect handling and control of the atv, and may cause the atv to go out of control. Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets. [ewb...

  • Page 74

    7-10 7 have enough time to react to hidden rocks, bumps, or holes. Go slowly and be extra care- ful when operating on unfamiliar terrain. Al- ways be alert to changing terrain conditions when operating the atv. [ewb01531] do not operate on rough, slippery, or loose terrain until you have learned and...

  • Page 75

    7-11 7 do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. Select a large, flat, unpaved area to become famil- iar with your atv. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brake...

  • Page 76

    7-12 7 trol. [ewb02631] notice: do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. [ecb01071] use this same procedure as you move into the higher gears. Be sure to coordinate the use of the throttle and shift pedal properly. Avoid higher speeds until yo...

  • Page 77

    7-13 7 this procedure should be practiced at slow speed many times in a large unpaved area with no obsta- cles. If an incorrect technique is used, your atv may continue to go straight. If the atv doesn’t turn, come to a stop and then practice the proce- dure again. If the riding surface is slippery ...

  • Page 78

    7-14 7 ● shift your weight forward. ● never open the throttle suddenly or make sudden gear changes. The atv could flip over backwards. ● never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. ● never attempt to...

  • Page 79

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

  • Page 80

    7-16 7 if you start to roll backwards, do not apply the rear brake, and apply the front brake gradually. The atv could easily tip over backwards. When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount the atv im- mediately on the uphill side or to a side if point...

  • Page 81

    7-17 7 ● never operate the atv on hills too steep for the atv or for your abilities. The atv can overturn more easily on extremely steep hills than on level surfaces or small hills. ● shift your weight backward and to the up side of the hill. ● never go down a hill at high speed. ● avoid going down ...

  • Page 82

    7-18 7 crossing a slope warning ewb01632 improperly crossing hills or turning on hills could cause loss of control or cause the atv to overturn. ● always follow proper procedures as de- scribed in the owner’s manual. ● avoid hills with excessively slippery or loose surfaces. ● avoid crossing the sid...

  • Page 83

    7-19 7 crossing through shallow water warning ewb01641 operating this vehicle through deep or fast- flowing water can lead to loss of control or an overturn. To reduce your risk of drowning or other injuries, use care when crossing through water. Never operate this atv water deeper than the depth sp...

  • Page 84

    7-20 7 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. Notice: undrained water can cause damage or improper opera- tion. [ecb00841] wash the atv in fresh water if it has been operat- ed in salt water or muddy conditi...

  • Page 85

    7-21 7 cident. Be sure to keep your feet firmly mounted on the footrests at all times. Avoid jumping the atv as loss of control and damage to the atv may result. Sliding and skidding warning ewb01662 skidding or sliding improperly may cause you to lose control of this atv. You may also re- gain trac...

  • Page 86

    7-22 7 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 extremely slippery sur...

  • Page 87

    7-23 7 ● if your atv is traversing a sloping surface: be sure to ride with your weight positioned to- wards the uphill side of the atv to maintain proper balance. If the atv starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the atv is ...

  • Page 88

    8-1 8 ebu28783 periodic maintenance and adjustment ebu21672 periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most effi- cient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection, adjustmen...

  • Page 89

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

  • Page 90

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

  • Page 91

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

  • Page 92

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

  • Page 93

    8-6 8 5 * brake hoses • check for cracks or other damage, and replace if necessary. √ √ √ √ • replace. Every 4 years 6 * parking brake • check operation and adjust if necessary. √ √ √ √ √ 7 * wheels • check runout and for damage, and replace if nec- essary. √ √ √ √ 8 * tires • check tread depth and ...

  • Page 94

    8-7 8 14 * chassis fasteners • make sure that all nuts, bolts, and screws are properly tightened. √ √ √ √ √ 15 * shock absorber as- semblies • check operation and correct if necessary. • check for oil leakage and replace if necessary. √ √ √ 16 * rear suspension re- lay arm and con- necting arm pivot...

  • Page 95

    8-8 8 ebu23071 tip ● some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. ● hydraulic brake service • regularly check and, if necessary, correct the brake fluid level. • every two years replace the internal components...

  • Page 96

    8-9 8 ebu23080 removing and installing the panel the panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. Ebu23101 panel a to remove the panel remove the bolts, and then take th...

  • Page 97

    8-10 8 to remove the spark plug 1. Remove the spark plug cap. 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medi- um-to-light tan (the id...

  • Page 98

    8-11 8 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. 3. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification. To install the spark plug 1. Clean the surface of the spark plug g...

  • Page 99

    8-12 8 ebu26786 engine oil and oil filter element the engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element replaced at the intervals spec- ified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place t...

  • Page 100

    8-13 8 be sure the engine oil is at the correct lev- el, otherwise engine damage may result. [ecb00851] tip when adding oil, be careful not to overfill the en- gine oil tank; the oil level rises faster starting from the half-level-portion on the dipstick. 6. Insert the dipstick into the engine oil t...

  • Page 101

    8-14 8 5. Remove the engine oil tank filler cap, and then remove the engine oil tank drain bolt and its gasket. Tip skip steps 6–9 if the oil filter element is not being replaced. 6. Remove the oil filter element cover by remov- ing the bolts. 7. Remove the oil filter element and the o-rings. 1. Eng...

  • Page 102

    8-15 8 8. Install a new oil filter element and new o- rings. Tip make sure that the o-rings are properly seated. 9. Install the oil filter element cover by installing the bolts, and then tighten them to the speci- fied torque. 10. Install the crankcase engine oil drain bolt, the engine oil tank drai...

  • Page 103

    8-16 8 14. Remove the engine oil tank filler cap, and then gradually fill the oil tank with the remaining oil quantity while regularly checking the oil level on the dipstick. 15. Install and tighten the engine oil tank filler cap. Tip be sure to wipe off spilled oil on any parts after the engine and...

  • Page 104

    8-17 8 tip the coolant level must be checked on a cold en- gine since the level varies with engine tempera- ture. 2. Check the coolant level in the coolant reser- voir. Tip the coolant should be between the minimum and maximum level marks. 3. If the coolant is at or below the minimum level mark, rem...

  • Page 105

    8-18 8 tip ● the radiator fan is automatically switched on or off according to the coolant temperature in the radiator. ● if the engine overheats, see page 8-52 for fur- ther instructions. Ebu23543 to change the coolant warning ewb01890 wait for the engine and radiator to cool before removing the ra...

  • Page 106

    8-19 8 4. Remove the radiator cap. 5. Remove the coolant reservoir cap. 6. Disconnect the coolant reservoir hose on the coolant reservoir side, and then drain the cool- ant from the coolant reservoir. 7. After draining the coolant, thoroughly flush the cooling system with clean tap water. 8. Install...

  • Page 107

    8-20 8 9. Connect the coolant reservoir hose. 10. Pour the recommended coolant into the reser- voir to the maximum level mark, and then in- stall the reservoir cap. Notice: mix antifreeze with distilled water only. Howev- er, if distilled water is not available, soft water may be used for refilling....

  • Page 108

    8-21 8 1. Place the atv on a level surface. 2. Remove the seat. (see page 4-13.) 3. Remove the air filter case cover by unhooking the holders. 4. Loosen the wing bolt. 5. Remove the air filter element together with the wing bolt and washer. 1. Air filter case check hose 1 1. Air filter case cover 2....

  • Page 109

    8-22 8 6. Remove the wing bolt and washer from the air filter element. 7. Remove the sponge material from the air filter element frame. 8. Wash the sponge material gently but thor- oughly in solvent. Warning! Always use parts cleaning solvent to clean the sponge material. Never use low-flash-point s...

  • Page 110

    8-23 8 10. Check the sponge material and replace it if damaged. 11. Apply yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material. Tip the sponge material should be wet but not drip- ping. 12. Pull the sponge material over the air filter ele- ment frame. 13. Apply al...

  • Page 111

    8-24 8 15. Insert the air filter element into the air filter case, and then tighten the wing bolt. Notice: make sure that the air filter element is properly seated in the air filter case. Never operate the engine with the air filter ele- ment removed. This will allow unfiltered air to enter the engi...

  • Page 112

    8-25 8 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 align the bolt holes. 5...

  • Page 113

    8-26 8 7. Start the engine and rev it up approximately twenty times while momentarily creating ex- haust system back pressure by blocking the end of the muffler with a shop towel. 8. Stop the engine and allow the exhaust pipe to cool. 9. Check the gasket for damage, and replace it if necessary. 10. ...

  • Page 114

    8-27 8 tip a diagnostic tachometer is needed to make this adjustment. 1. Start the engine and warm it up. 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 idle adjusting screw. To increase the engine idli...

  • Page 115

    8-28 8 3. To increase the throttle cable free play, turn the throttle cable free play adjusting bolt in di- rection (a). To decrease the throttle cable free play, turn the adjusting bolt in direction (b). 4. Tighten the locknut. 5. Slide the rubber cover to its original position. Ebu24060 valve clea...

  • Page 116

    8-29 8 ebu24130 checking the front and rear brake pads the front and rear brake pads must be checked for wear at the intervals specified in the periodic main- tenance and lubrication chart. Ebu29560 front brake pads each brake pad is provided with wear indicator grooves, which allow you to check the...

  • Page 117

    8-30 8 ebu26823 checking the brake fluid level insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary. A low brake fluid level may indicate w...

  • Page 118

    8-31 8 tip to check the rear brake fluid level, remove the seat. (see page 4-13.) to access the rear brake fluid reservoir for replen- ishing: 1. Remove the cowling bolt and quick fastener screw. 2. Pull the cowling slightly outward as shown. 3. After replenishing, place the cowling in the original ...

  • Page 119

    8-32 8 ● refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. ● be careful that water does not enter the brake fluid reservoir when refilling. Water will signifi- cantly lower the boiling point of the fluid and may re...

  • Page 120

    8-33 8 the top of the brake pedal should be positioned 15.3 mm (0.60 in) below the top of the footrest as shown. If the brake pedal is not positioned as spec- ified, have a yamaha dealer adjust it. Ebu26850 adjusting the parking brake free play the parking brake free play must be checked and, if nec...

  • Page 121

    8-34 8 tip if the cable length cannot be adjusted to specifica- tion, consult a yamaha dealer. 4. Tighten the locknut on the brake cable. Warning ewb02090 operating with improperly serviced or adjust- ed brakes could cause the brakes to malfunc- tion, resulting in reduced braking performance. This c...

  • Page 122

    8-35 8 ebu29750 adjusting the clutch lever free play the clutch lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The clutch lever free play should measure 5.0– 10.0 mm (0.20–0.39 in) as shown. If the free play i...

  • Page 123

    8-36 8 7. Fully turn the adjusting bolt at the clutch lever in direction (a) to loosen the clutch cable. 8. Loosen the locknut at the crankcase. 9. To increase the clutch lever free play, turn the adjusting nut at the crankcase in direction (a), and to decrease it, turn the nut in direction (b). 10....

  • Page 124

    8-37 8 3. If the drive chain slack is incorrect, adjust it as follows. To adjust the drive chain slack 1. Place the atv on a level surface. 2. Loosen the rear wheel axle pinch bolts. 3. Insert a rod of a diameter of 8 mm (0.3 in) and a length of 10 cm (4 in) into one of the holes in the drive chain ...

  • Page 125

    8-38 8 vent this from occurring, keep the drive chain slack within the specified limits. [ecb00542] 6. Pull the rod out, and then tighten the rear axle pinch bolts to the specified torque in the order shown. Ebu24882 lubricating the drive chain the drive chain must be cleaned and lubricated at the i...

  • Page 126

    8-39 8 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special o-ring chain lubricant. Notice: do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the o- rings. [ecb00581] ebu24901 checking and lubricating th...

  • Page 127

    8-40 8 ebu24922 checking and lubricating the brake and clutch levers the operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Ebum0170 checking the shift pedal the operation of the shift pedal should be checked before ea...

  • Page 128

    8-41 8 ebu24995 lubricating the swingarm pivots the swingarm pivots must be lubricated by a yamaha dealer at the intervals specified in the pe- riodic maintenance and lubrication chart. Ebu25003 lubricating the rear suspension relay arm and connecting arm pivoting points the rear suspension relay ar...

  • Page 129

    8-42 8 ebu25032 lubricating the upper and lower arm pivots the upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Lubricate the pivoting points using a grease gun. Left side 1. Grease nipple 1. Grease nipple 1 1 recommended l...

  • Page 130

    8-43 8 right side ebu25103 lubricating the steering shaft the steering shaft must be lubricated by a yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. Ebu30030 battery this model is equipped with a vrla (valve regu- lated lead acid) battery. There is no need...

  • Page 131

    8-44 8 batteries produce explosive gases. Keep sparks, flame, cigarettes or other sources of ig- nition away. Ventilate when charging or using in an enclosed space. Keep out of reach of children. To remove the battery 1. Remove the seat. (see page 4-13.) 2. Remove the battery holding plate (together...

  • Page 132

    8-45 8 notice ecb00930 to charge a vrla (valve regulated lead acid) battery, a special (constant-voltage) battery charger is required. Using a conventional bat- tery charger will damage the battery. If you do not have access to a constant-voltage battery charger, have a yamaha dealer charge your bat...

  • Page 133

    8-46 8 4. Install the battery holding plate with the bat- tery cover by installing the bolts and the quick fastener screws. 5. Install the seat. (see page 4-13.) ebu25326 replacing a fuse the main fuse and the fuse box are located under the seat. (see page 4-13.) 1. Battery holding plate 2. Battery ...

  • Page 134

    8-47 8 if a fuse is blown, replace it as follows. 1. Turn the key to “off” and turn off all electrical circuits. Notice ecb00640 to prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified ...

  • Page 135

    8-48 8 ebu29670 replacing a headlight bulb if a headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the bolts. 2. Disconnect the headlight coupler. 3. Remove the headlight bulb holder cover. 4. Remove the headlight bulb holder by pushing it in and turning it cou...

  • Page 136

    8-49 8 5. Place a new headlight bulb into position. Notice: do not touch the glass part of the headlight bulb to keep it free from oil, oth- erwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints ...

  • Page 137

    8-50 8 to raise a headlight beam, turn the headlight beam adjusting bolt in direction (a). To lower a headlight beam, turn the adjusting bolt in direction (b). Ebu26920 tail/brake light this model is equipped with an led type of tail/brake light. If the tail/brake light does not come on, have a yama...

  • Page 138

    8-51 8 tip when installing the wheel, make sure its arrow mark points toward the rotating direction of the wheel. 3. Lower the atv to the ground. 4. Tighten the wheel nuts to the specified torques. Ebu25740 troubleshooting although yamaha atvs receive a thorough in- spection before shipment from the...

  • Page 139

    8-52 8 ebu27691 troubleshooting charts starting problems or poor engine performance 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. Compressio...

  • Page 140

    8-53 8 engine overheating warning ewb02290 wait for the engine and radiator to cool before removing the radiator cap. You could be burned by hot fluid and steam blown out under pressure. Always put a thick rag over the cap when opening. Allow any remaining pressure to escape before completely removi...

  • Page 141

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

  • Page 142

    9-2 9 ebu27261 storage short-term always store your atv in a cool, dry place and, if necessary, protect it against dust with a porous cover. Notice: storing the atv in a poorly ven- tilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust...

  • Page 143

    9-3 9 6. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 7. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an exces- sively cold or warm place [less than 0 °c (30 °f) or more than 30 °c (...

  • Page 144

    10-1 10 ebu25960 specifications dimensions: overall length: 1845 mm (72.6 in) overall width: 1170 mm (46.1 in) overall height: 1130 mm (44.5 in) seat height: 815 mm (32.1 in) wheelbase: 1280 mm (50.4 in) ground clearance: 240 mm (9.4 in) minimum turning radius: 3500 mm (138 in) weight: with oil and ...

  • Page 145

    10-2 10 type: sae 5w-30, 10w-30, 10w-40, 15w-40, 20w-40 or 20w- 50 recommended engine oil grade: api service sg type or higher, jaso standard ma engine oil quantity: without oil filter element replacement: 1.75 l (1.85 us qt, 1.54 imp.Qt) with oil filter element replacement: 1.85 l (1.96 us qt, 1.63...

  • Page 146

    10-3 10 secondary reduction system: chain drive secondary reduction ratio: 38/14 (2.714) transmission type: constant mesh 5-speed.Forward, 1-speed.Reverse operation: left foot operation gear ratio: 1st: 38/13 (2.923) 2nd: 28/14 (2.000) 3rd: 25/17 (1.471) 4th: 25/22 (1.136) 5th: 22/24 (0.917) reverse...

  • Page 147

    10-4 10 rear wheel: wheel type: panel wheel rim size: 9 x 8.0at front brake: type: dual disc brake operation: right hand operation recommended fluid: dot 4 rear brake: type: single disc brake operation: right foot operation recommended fluid: dot 4 front suspension: type: double wishbone spring/shoc...

  • Page 148

    10-5 10 engine trouble warning light: led fuses: main fuse: 20.0 a fuel injection system fuse: 10.0 a headlight fuse: 15.0 a signaling system fuse: 10.0 a ignition fuse: 10.0 a u1as61e0.Book page 5 thursday, february 11, 2010 2:17 pm.

  • Page 149

    11-1 11 ebu26000 consumer information ebu28200 identification numbers record the vehicle identification number and mod- el label information in the spaces provided below for assistance when ordering spare parts from a yamaha dealer or for reference in case the atv is stolen. Vehicle identification n...

  • Page 150

    11-2 11 tip the vehicle identification number is used to identify 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 spare parts from a yamaha dea...

  • Page 151

    Index a accessories and loading ................................................ 6-7 air filter element, cleaning ............................................ 8-20 b battery .......................................................................... 8-43 brake and clutch levers, checking and lubricat...

  • Page 152

    Maintenance chart, emission control system ................. 8-3 model label ................................................................... 11-2 multi-function display ...................................................... 4-3 n neutral indicator light .............................................

  • Page 153

    U1as61e0.Book page 3 thursday, february 11, 2010 2:17 pm.

  • Page 154

    Yamaha motor co., ltd. Printed on recycled paper printed in japan 2010.02-0.5 ×1 cr (e) u1as61e0.Book page 1 thursday, february 11, 2010 2:17 pm.