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Yamaha YFM90RY Owner's Manual - Yfm90Ry

Other manuals for YFM90RY: Owner's Manual

Summary of YFM90RY

  • Page 1

    This a 43d-f8199-60 yfm90ry manual del propietario manuel du propriÉtaire owner’s manual read this manual carefully! It contains important safety information. Lire attentivement ce manuel! Ii comprend d’importantes informations de s écurité . Lea este manual atentamente! Contiene indicaciones import...

  • Page 2

    Printed in taiwan 2008.07 (e,f,s) yamaha motor co., ltd. Printed on recycled paper imprimÉ sur papier recyclÉ impreso en papel reciclado dic183.

  • Page 3: Yfm90Ry

    Yfm90ry 43d-f8199-60-e0 owner’s manual read this manual carefully! It contains important safety information..

  • Page 4

    Read this manual carefully before operating this vehicle.This manual should stay with this ve- hicle if it is sold. Ec declaration of conformity conforming to directive 98/37/ec we, yamaha motor co.,ltd. 2500 shingai, iwata, japan,declare in sole responsibility, that the product yfm90ry (rk1ab07w080...

  • Page 5

    Introduction congratulations on your purchase of the yamaha yfm90ry. 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 degree of craftsmansh...

  • Page 6

    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 7

    Warning n o t i c e tip this is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Damage to the vehicle or other property. A tip provides key information to make procedures easier...

  • Page 8

    Important notice yfm90ry owner’s manual ©2008 by yamaha motor co., ltd. 1st edition, july 2008 all rights reserved. Any reprinting or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited. Printed in taiwan. Welcome to the yamaha world of motor sports! Thi...

  • Page 9

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

  • Page 10

    Cleaning the spark arrester ...................... 8-19 adjusting the carburetor ........................... 8-20 adjusting the engine idling speed ............ 8-20 checking the throttle cable free play ....... 8-21 timing chain ............................................ 8-22 valve clearance .......

  • Page 11

    Specifications ..................................... 10-1 consumer information ..................... 11-1 identification numbers ............................ 11-1.

  • Page 12

    1-1 1 safety information 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 obstacles, if you f...

  • Page 13

    1-2 1 operating this atv. Never operate at speeds too fast for your skills or the riding conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience. Never attempt wheelies, jumps, or other stunts. Always inspect your atv each time you use i...

  • Page 14

    1-3 1 avoid crossing the side of a steep hill if possible. Always use proper procedures if you stall or roll 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 bra...

  • Page 15

    1-4 1 fire and you could be burned. When transporting the atv in another vehi- cle, be sure it is kept upright and that the fuel cock is in the “off” position. Otherwise, fuel may leak out of the carburetor or fuel tank. Gasoline is poisonous. If you should swal- low some gasoline or inhale a lot of...

  • Page 16

    2-1 location of the warning and specification labels 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 fr...

  • Page 17

    2-2 2 for europe 5 1 3 2 4 i i i i i i i i i i i i i i i i i i i i i i i i i i i 6 l l l l ll ll i.

  • Page 18

    For oceania 2-3 2 for oceania 1 3 2 4 i i i i i.

  • Page 19

    3-1 3 description left view right view 1. Fuel cock 2. Rear wheel 3. Footrest 4. Front wheel 1. Spark arrester 2. Seat 3. Footrest 1 4 3 2 1 2 3.

  • Page 20

    3-2 3 controls and instruments 1. Rear brake lever 2. Parking brake 3. Front brake lever 4. Throttle lever 5. Main switch 6. Fuel tank cap 7. Handlebar switches 8. Choke 1 2 3 8 7 6 5 4 tip the atv you have purchased may differ slightly from the figures shown in this manual..

  • Page 21

    4-1 4 instrument and control functions main switch the positions of the main switch are as follows: on all electrical systems are supplied with power, and the engine can be started. The key cannot be re- moved. Off all electrical systems are off. The key can be re- moved. 1. Main switch o f f o i i ...

  • Page 22

    4-2 4 handlebar switches engine stop switch “eng. Stop” set this switch to “run” 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 ...

  • Page 23

    4-3 4 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 to an idle any time the hand i...

  • Page 24

    4-4 4 4 the vehicle speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. The adjusting screw may be gradually turned out as the beginner becomes more familiar with operating the atv. Parents should decide when to adjust the atv for more power as...

  • Page 25

    4-5 4 warning improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation. You could lose control, have an accident or be injured. Do not turn the adjusting screw out more than 5 mm (0.2 in). Engine speed limiter plate tip store the speed li...

  • Page 26

    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. 1. Front brake lever 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...

  • Page 27

    4-7 parking brake use the parking brake before starting the engine or parking the atv, especially on a slope. Apply the front bake lever and push down the lock button to apply the parking brake. Squeeze the front brake lever to release the parking brake. 1. Parking brake lock button 4 1 warning alwa...

  • Page 28

    4-8 fuel tank cap remove the fuel tank cap by turning it counter- clockwise. 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. Fuel tank cap 1. Fuel level 2. Filler tube recommended fuel: unleaded gasoline only fuel tank capaci...

  • Page 29

    4-9 notice 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. 4 warning do not overfill the fuel tank. Fuel expands when it heats up. If the fuel tank is overfilled, fuel cou...

  • Page 30

    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. 1. Lever positioned over “off” res off with the fuel cock lever in this position, fuel will not flow. Always turn ...

  • Page 31

    4-11 choke the choke is used to start a cold engine. Move the choke in direction (a) to turn on the choke. 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. 1. Fully open “on” 2. Half open (warming up position) 3. Closed...

  • Page 32

    4-12 to install the seat insert the projection on the front of the seat into the seat holder and push down on the seat at the rear. Tip make sure that the seat is securely fitted. 4 1. Projection 2. Seat holder 2 1 1. Kickstarter 1 notice a kickstarter lever is located under the seat to use if the b...

  • Page 33

    5-1 pre-operation checks pre-operation check list before operating this atv, be sure to check the items listed in the following table. Tip the maintenance of some items in the table has to be performed by a yamaha dealer. Refer to the "periodic maintenance and lubrication charts" on page 8-3 to dete...

  • Page 34

    9 make sure that operation is smooth, and check cable free play. Lubricate cable and lever housing if necessary. Control cables make sure that operation is smooth. Lubricate if necessary. 8-27 wheels and tires check wheel condition, and replace if damaged. Check tire condition and tread depth. Repla...

  • Page 35

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

  • Page 36

    5-4 tires brake operation test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, check the brakes for wear. (see pages 8-22 and 8-25.) 5 warning throttle lever check the operation of the throttle lever. It mus...

  • Page 37

    5-5 5 measuring the tire pressure use the low-pressure tire gauge. Tip the low-pressure tire gauge is included as stan- dard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Size: at18 x 9-8 typ...

  • Page 38

    5-6 set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: tire wear limit replace the tire when the tire groove decreases to 3 mm (0.12 in). 1. Low-pressure tire gauge recommended pressure: front 25 kpa (3.6 psi) (0.25 kgf/cm 2 ) rear 25 kpa (3.6 psi)...

  • Page 39

    5-7 chassis fasteners make sure that all nuts, bolts and screws are prop- erly tightened. Instruments and switches check that all instruments and switches are working properly. Correct if necessary. 1. Tire wear limit 5.

  • Page 40

    6-1 operation 6 notice see the “engine break-in” section on page 6-4 prior to operating the engine for the first time. 1. Set the parking brake. 2. Turn the fuel cock to “on”. 3. Turn the main switch to “on” and the engine stop switch to “run”. Read the owner’s manual carefully before riding the atv...

  • Page 41

    6-2 ambient temp./choke position 5 . Completely close the throttle lever and start the engine by pushing the start switch. Tip if the engine fails to start, release the start switch, then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to pres...

  • Page 42

    6-3 6 crank the engine more than 10 seconds on each attempt. 6. 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 position to warm up the eng...

  • Page 43

    Engine break-in there is never a more important period in the life of your engine than the first 320 km (200 mi) or 20 hours of riding. For this reason, you should read the following material carefully. Since the engine is brand new, do not put an ex- cessive load on it for the first 320 km (200 mi)...

  • Page 44

    6-5 parking on a slope 1. Bring the atv to a stop by applying the brakes in the drive position. 2. Stop the engine. 3. Apply the parking brake. 1. Parking brake lock button 1. Locked position 6 1 1 warning avoid parking on hills or other inclines. Park- ing on a hill or other incline could cause the...

  • Page 45

    6-6 accessories and loading 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 yamaha dealer has a variety of gen- uine yama...

  • Page 46

    6-7 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 the atv as possible. Put cargo ...

  • Page 47

    7-1 riding your atv 7.

  • Page 48

    7-2 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 techniques described in this section, however, are appropriate for all types of riding. Riding your atv requires special skills...

  • Page 49

    7-3 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. 7 warning never operate this atv without proper instruc- tion. Beginni...

  • Page 50

    This atv is designed to carry operator only – passengers prohibited. 7 7-4 warning never carry a passenger. The long seat is to al- low the operator to shift position as needed during operation. It is not for carrying passen- gers. Carrying a passenger on this atv greatly reduces your ability to bal...

  • Page 51

    7-5 1. Protective clothing 2. Goggles 3. Gloves 4. Boots 5. Helmet 7 warning never operate this atv without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. Operating without an ap- proved motorcycle helmet increases your chances of a severe head injury or death in th...

  • Page 52

    7-6 do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. 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. 7 warning never c...

  • Page 53

    7-7 do not operate at speeds too fast for your skills or the conditions. Speed limiters for riders less experienced with this model, the throttle lever housing is equipped with a vehicle speed limiter. This speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed t...

  • Page 54

    7-8 result in a significant increase in power, turn the vehicle speed limiter adjusting screw back in again; adjust it out in stages as you did before. For engine speed limiter plate removal instructions, see page 4-4. Loading and accessories use extra caution when riding the atv with addi- tional l...

  • Page 55

    7-9 avoid wheelies and jumping. You may lose control of the atv or overturn. 7 during operation always keep your feet on the footboards during op- eration, otherwise they may contact the rear wheels. Warning always keep both hands on the handlebars and both feet on the footboards of your atv during ...

  • Page 56

    7-10 modifications 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. 7 warning never attempt stunts, such as wheelies or jumps...

  • Page 57

    7-11 be careful where you ride this atv is designed for off-road use only. Riding on paved surfaces can cause loss of control. 7 warning do not touch the hot exhaust system. Do not park the atv during or after operation in a place where others might be likely to touch it. Do not operate, idle, or pa...

  • Page 58

    7-12 7 while riding on unpaved public streets or roads may be legal in your area, such operation can in- crease the risk of collision with other vehicles. Watch carefully for other vehicles. Make sure you know your country’s laws and regulations before you ride on unpaved public streets or roads. Do...

  • Page 59

    7-13 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. 7 warning go slowly and be extra careful when operating on a paved paved road or motorway. You can collide with ...

  • Page 60

    7-14 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. 7 warning always mount a caution flag on the atv to make you more visible when operating in areas where you might not be seen ...

  • Page 61

    7-15 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 the throttle, brakes, a...

  • Page 62

    7-16 low speed. As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the footboard to the out- side of the turn (opposite your desired direction) and lean your upper body into the turn. Use the throttle to maintain an even spe...

  • Page 63

    7-17 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 to the inside. It may als...

  • Page 64

    7-18 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. Ok 7.

  • Page 65

    7-19 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 side. Physically turn the atv aroun...

  • Page 66

    7-20 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 may cause a loss of traction. Use...

  • Page 67

    7-21 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. Crossing a slope traversing a sloping surface on your atv requires you to properly position your weight to mainta...

  • Page 68

    7-22 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. Crossing through shallow...

  • Page 69

    7-23 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. Test your brakes after leaving the water. Do not continue to ride your atv without verifying that you have regained proper braking ability....

  • Page 70

    7-24 notice 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 over rough terrain should be done wi...

  • Page 71

    7-25 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, positioning your weight over th...

  • Page 72

    7-26 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 surfa...

  • Page 73

    7-27 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 accelerating is not recommen...

  • Page 74

    8-1 periodic maintenance and minor repair 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 lubrication are explained on the followin...

  • Page 75

    8-2 it for you. 1. Owner ’s manual 2. Low-pressure tire gauge 3. Owner ’s tool kit 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 s...

  • Page 76

    8-3 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- intervals should be followed. Items ...

  • Page 77

    8-4 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 (200) 1300...

  • Page 78

    8-5 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. Adjust if necessary. √ √ √ √ 2 air fil...

  • Page 79

    8-6 11 * shock absorber assemblies check operation and correct if necessary. Check for oil leakage and replace if necessary. √ √ √ 12 * front knuckle piv- ots lubricate with lithium-soap-based grease. √ √ √ 13 * steering shaft lubricate with lithium-soap-based grease. √ √ √ 14 * steering system chec...

  • Page 80

    8-7 8 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 19 * drive select lever safety system cable • check operation and adjust or replace if neces- sary. √ √ √ 20 * throt...

  • Page 81

    8-8 tip 8 the air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinder and caliper, and change the b...

  • Page 82

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

  • Page 83

    8-10 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). Tip if the spark plug shows a distinctly different color, the engine could be operating improperly. Do not at...

  • Page 84

    8-11 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. Tip if a torque wrench is not available when installing a spark plug,...

  • Page 85

    8-12 4. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level. Tip the engine oil should be between the minimum and maximum level marks. 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recom- mended ty...

  • Page 86

    8-13 8 7. Add the specified amount of the recommend- ed engine oil, and then install and tighten the engine oil filler cap. Tightening torque: engine oil drain bolt: 8 nm (0.8m·kgf, 5.8 ft·lbf) recommended oil: see page 10-1. Oil quantity: 0.8 l (0.84 us qt) (0.70 imp.Qt) notice do not mix any chemi...

  • Page 87

    8-14 8 1. Final transmission oil filler cap 1 1 1. Final transmission oil drain bolt 4. Install the drain bolt, and then tighten it to the specified torque. Final transmission oil the final transmission case must be checked for oil leakage before each ride. If any leakage is found, have a yamaha dea...

  • Page 88

    8-15 8 tightening torque: final transmission oil drain bolt: 15 nm (1.5 m·kgf, 10.8 ft·lbf) 5. Add the specified amount of the recommend- ed final transmission oil, and then check the oil level. Notice be sure no foreign material enters the final transmission case. 6. Install and tighten the oil fil...

  • Page 89

    8-16 8 1 2 2 2 1. Remove the air filter case cover by remov- ing the bolts. 1. Air filter case cover (left) 2. Bolts 1. Air filter case check hose (right) 1 1. Air filter case cover (right) 2. Bolts 2 2 2 1.

  • Page 90

    Notice do not twist the sponge material when squeez- ing it. 5. Check the sponge material and replace it if damaged. 1. Air filter element holder 2. Sponge material 1 2 8 8-17 2. Remove the air filter element by removing the 3. Wash the sponge material gently but thor- oughly in solvent. 4. Squeeze ...

  • Page 91

    8-18 6. 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. 7. Install the sponge material onto the air filter element holder. 8. Place the air filter element in the original position, and then inst...

  • Page 92

    8-19 cleaning the spark arrester be sure the exhaust pipe and muffler are cool be- fore cleaning the spark arrester. 1. Remove the screw and nut. 2. Remove the spark arrester by pulling it out of the muffler. 3. Tap the spark arrester lightly, and then use a wire brush to remove any carbon deposits....

  • Page 93

    8-20 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. Therefore, most carburetor adjust...

  • Page 94

    8-21 8 tion chart. Tip a diagnostic tachometer is needed to make this adjustment. 1. Start the engine and warm it up. Tip the engine is warm when it quickly responds to the throttle. 2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if neces- sary, adjust it to s...

  • Page 95

    8-22 the throttle cable free play should measure 1.0– 3.0 mm (0.04–0.12 in) at the throttle lever. Period- ically check the throttle cable free play and, if nec- essary, have a yamaha dealer adjust it. Timing chain the timing chain stretches with use, resulting in im- proper valve timing and engine ...

  • Page 96

    8 8-23 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. 1 the brake lever free play should measure 4.0– 6.0 mm (0.16– 0.24 in) as shown. If the free play is in...

  • Page 97

    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. 1. Upper locknut 2. Upper adjusting bolt 3. Lower locknut 4. Lower adjusting bolt 1 2 4 3 (a) (b) (a) (b) 1 ...

  • Page 98

    8-25 the rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. If a brake pad has worn to the ...

  • Page 99

    Changing the rear brake fluid checking the rear brake lever free play the brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart. The brake lever free play should measure 0 – 1.5 mm (0 – 0.06 in) as shown. If the free play is incorrect, hav...

  • Page 100

    8-27 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 yamaha dealer check or replace it. Checking ...

  • Page 101

    8-28 8 checking the wheel hub bearings the front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a yamaha dealer check the wheel hub bearings. 1. Lever...

  • Page 102

    8-29 to charge the battery have a yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the atv is equipped with optional electrical accessories. To store the battery 1. If the atv will not be used for mo...

  • Page 103

    8-30 1. Turn the key to “off” and turn off all electrical circuits. Notice to prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuse: 10 a the fuse holder is loca...

  • Page 104

    8-31 3. Turn the key to “on” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a yamaha dealer check the electrical system. 8.

  • Page 105

    8-32 2. Elevate the atv and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. 1. Wheel nuts removing a wheel 1. Loosen the wheel nuts. 8 1 1.

  • Page 106

    8-33 2. Lower the atv to the ground. 3. Tighten the wheel nuts to the specified torques. Tightening torques: front wheel nut: 45 nm (4.5 m·kgf, 33 ft·lbf) rear wheel nut: 45 nm (4.5 m·kgf, 33 ft·lbf) wheel. Front 1. Arrow mark installing a wheel 1. Install the wheel and the nuts. Tip when installing...

  • Page 107

    8-34 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 following troubleshooting chart rep...

  • Page 108

    8-35 troubleshooting chart check the fuel level in the fuel tank. 1. Fuel there is enough fuel. There is no fuel. Check the compression. Supply fuel. The engine does not start. Check the compression. Operate the electric starter. 2. Compression there is compression. There is no compression. Check th...

  • Page 109

    9-1 cleaning and storage 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 water entry. A plasti...

  • Page 110

    9-2 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 ventilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust. To prevent c...

  • Page 111

    9-3 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 from the spark plug, an...

  • Page 112

    10-1 10 specifications engine: engine type: forced air cooled 4-stroke cylinder arrangement: single cylinder displacement: 88 cm (5.37 cu.In) 3 bore × stroke: 47.0 × 51.0 mm (1.85 x 2.0 in) compression ratio: starting system: electric starter & kickstarter lubrication system: wet sump 10.2 : 1 engin...

  • Page 113

    10 engine oil quantity: periodic oil change: 0.8 l (0.84 us qt) (0.70 imp.Qt) final transmission oil: type: sae80 api gl-4 hypoid gear oil quantity: 0.30 l (0.32 us qt) (0.27 imp.Qt) air filter: air filter element: wet element fuel: recommended fuel: regular unleaded gasoline only (eur) unleaded gas...

  • Page 114

    10-3 10 rear tire: type: tubeless size: at18 x 9-8 manufacturer/model: maxxis/m940 loading: maximum loading limit: 70.0 kg (154 lb) (total weight of rider, cargo, accessories, and tongue) tire air pressure (measured on cold tires): recommended: front: 25 kpa (3.6 psi) (0.25 kgf/cm 2 ) rear: 25 kpa (...

  • Page 115

    10-4 10 electrical system: ignition system: cdi charging system: ac magneto battery: model: gtx5l-bs voltage, capacity: 12 v,4 .0 ah fuses: main fuse: 10 a noise and vibration level: noise level (77/311/eec): 77.4 db(a) (eur) vibration on seat (en1032, iso5008): will not exceed 0.5 m/s 2 (eur) vibra...

  • Page 116

    11-1 11 consumer information 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 in case the atv is stolen. Key identif...

  • Page 117

    11-2 11 tip the vehicle identification number is used to identi- fy your atv. 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 deal- er. ...

  • Page 118

    Index a accessories and loading ................................................ 6-6 air filter element, cleaning............................................ 8-15 b battery...........................................................................8-28 brake lever, front.................................

  • Page 119

    O owner’s manual and tool kit........................................... 8-1 p parking ........................................................................... 6-4 parking brake ................................................................. 4-7 parking on a slope .................................

  • Page 120

    Yamaha motor co., ltd. Printed on recycled paper printed in taiwan 2008.07 (e).