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Yamaha 5TH-28199-15 Offroad Vehicle User Manual

1. m Ask a Yamaha dealer to inspect Wipe clean with dry Y Attach spark plug cap and ground to Use electric starter Battery good 3 Ignition gt Wet cloth Remove spark plug and check electrodes gt Dry chassis 4 Battery ___ Engine turns over quickly Use electric starter t Fuel cock clogged Clean fuel cock Spark good gt Ignition system normal Spark weak i No spark Adjust spark plug gap or replace spark plug Y Ask a Yamaha dealer to inspect Engine turns over slowly Check fluid recharge check connections 8 32 EBU00419 CLEANING AND STORAGE A CLEANING Frequent thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components 1 Before cleaning the machine a Block off the end of the exhaust pipe to prevent water entry A plastic bag and strong rubber band may be used b Make sure the spark plug and all filler caps are properly installed 2 If the engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to the wheel axles 9 1 3 Rinse the dirt and degreaser off with a gar den hose Use only enough pre
2. 36 15 000 9 600 960 42 17 500 11 200 1 120 48 20 000 12 800 1 280 54 22 500 14 400 1 440 60 25 000 16 000 1 600 12 1 EBU26310 YAMAHA MOTOR CORPORATION U S A Yamaha Motor Corporation U S A hereby warrants that new Yamaha ATV purchased from an authorized Yamaha ATV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein sub ject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha ATV s shall be six 6 months from the date of purchase DURING THE PERIOD OF WARRANTY any authorized Yamaha ATV dealer will free of charge repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corp U S A GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Competition or racing use b Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse Lack of proper maintenance Accident or collision damage Modification to original parts Damage due to improper transportation ananao ATV LIMITED WARRANTY SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine
3. REAR 20 kPa 0 20 kgf cm eMinimum FRONT 17 kPa 0 17 kgf cm REAR 17 kPa 0 17 kgf cm eNever set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING eMaximum Vehicle Load 95 kg 209 Ibs Includes weight of operator cargo and accessories 4EM 21696 11 A WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 5FE 2151H 01 EBU13390 A SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE An ATV handles differently from other vehicles including motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers such as turning and riding on hills or over obstacles if you fail to take proper pre cautions SEVERE INJURY OR DEATH can result if you do not follow these instructions Read this manual and all labels carefully and follow the operating procedures described Never operate an ATV without proper training or instruction Take a Training Course Beginners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you Always follow the age recommendation A child under 12 years old should never operate an ATV with engine size greater than 70cc Achild under 16 years old should never operate an ATV with engine size greater than 90cc Never allow a
4. 1 Key identification number EBU00036 Vehicle identification number The vehicle identification number is stamped into the frame 1 Vehicle identification number NOTE The vehicle identification number is used to identify your machine 3 3 EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this label in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label EBU00039 CONTROL FUNCTIONS Indicates a potential hazard that could result in serious injury or death EBU00042 Main switch Functions of the respective switch positions are as follows ON The engine can be started only at this position OFF All electrical circuits are switched off The key can be removed in this position OFF ON i 4 1 EBU00043 Indicator lights EBU00603 Neutral indicator light N This indicator light comes on when the transmis sion is in neutral a 1 Neutral indicator light N EBU00053 Handlebar switches 1 Engine stop switch ENG STOP 2 Start switch START EBU11580 Engine stop switch ENG STOP Make sure that the engine stop switch is in the RUN position before starting the engine The engine stop switch controls ignition and can be used at all times to stop the engine especially in an emergency The engine will no
5. Dipstick 3 Minimum level mark 2 Maximum level mark Engine oil replacement 1 2 Place the ATV on a level surface Warm up the engine for several minutes and stop it Place a container under the engine Remove the dipstick and drain bolt to drain the oil Inspect the O ring and replace if damaged Recommended oil type YAMALUBE 4 20W40 or SAE 20W40 YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 Recommended oil classification API Service SE SF SG type or higher Oil quantity Periodic oil change 0 8 L 0 70 Imp qt 0 85 US qt 1 Drain bolt CAUTION esis 6 Install the drain bolt and tighten to specifi Be sure no foreign material enters the cation crankcase Tightening torque Drain bolt 20 Nm 2 0 m kgf 14 ft Ibf 8 Warm up the engine for several minutes at idle speed Check for oil leakage while warming up 7 Fill the engine with oil and install the dip CAUTION stick If oil leakage is found stop the engine imme diately and check for the cause 8 7 EBU00869 Final gear oil Final gear oil measurement 1 Place the ATV on a level surface 2 Remove the dipstick and wipe it off with a clean rag Insert the dipstick in the filler hole without screwing it in 3 Remove the dipstick and inspect the oil level 4 The oil level should be between the maxi mum and minimum marks If the level is low add oil to raise it to the proper level CAUTION Be sure no forei
6. possibility of a safety related defect and recall This list is compiled from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your new ATV please advise us of your new address by sending a postcard listing your ATV model name V I N frame number dealer number or dealer s name as it is shown on your warranty card your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 Attention Warranty Department This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law EBU00435 YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty e In addition Travel and Recreation Interruption Protection expires with genuine Yamaha Extended Service Y E S TRIP is included at no extra cost TRIP gives you up to e Y E S is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction You get uninterrupted factory backed coverage for extra peace of mind e Y E S is flexible You choose the plan that s right for you 12 months 24 months or 36 months beyond your warranty period e Y E S is designed and administered by the same Yamaha people who handle your warranty and it shows in the comprehensive coverage benefits There are no mileage l
7. 8 20 A WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smooth ly and that the free play is correct Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures should be performed by Yamaha dealer 8 21 EBU03351 Rear brake lever and brake pedal adjustment Brake lever free play adjustment 1 Loosen the brake cable locknut 2 Turn the adjusting bolt at the brake lever until brake lever free play is 5 8 mm 0 20 0 30 in 3 Tighten the locknut a Free play 1 Locknut 2 Adjusting bolt NOTE If specified free play cannot be obtained tighten the brake cable adjusting nut at the rear wheel hub until brake lever free play is 5 8 mm 0 20 0 30 in 1 Brake cable adjusting nut Brake pedal free play adjustment Turn the brake rod adjusting nut at the rear wheel hub until brake pedal free play is 20 30 mm 0 8 1 2 in a Free play 1 Brake rod adjusting nut 8 23 A WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smooth ly an
8. 8 4 ENGINE Oll resiree reta rasene 8 6 Final gear oil 8 8 Spark plug inspection ee 8 10 Air filter cleaning 8 11 Air intake restrictor plate removal 8 14 Spark arrester cleaning 0c06 8 15 Carburetor adjustment 0ecee 8 17 Idle speed adjustment ee 8 17 Valve clearance adjustment 8 18 Cam chain adjustment cee 8 18 Front and rear brake shoe INSPECTION ricsina nirin 8 18 Front brake lever free play ACjUSTMENL eee ects eeteeeeeeeeteees 8 19 Rear brake lever and pedal adjustment seeen onkii erer na 8 21 Clutch adjustment ceceeeeeeees 8 24 Cable inspection and lubrication 8 25 Brake and shift pedal brake lever IUDICATION eiin aaaea aiiai 8 25 Knuckle shaft and steering shaft UDICATION a eaaa aaen 8 26 Wheel removal cceceeeeeeeeeeeees 8 26 Wheel installation ccceeeecceees 8 26 Battery sci ie notid aea 8 27 Fuse replacement 8 30 Troubleshooting 8 31 Troubleshooting chart 8 32 CLEANING AND STORAGE 9 1 AxCleaNiNg iesnas 9 1 B Storage ree 9 3 10 SPECIFICATIONS osien 10 1 11 NOISE REGULATION 0 ceeeeeees 11 1 12 MAINTENANCE RECORD 12 1 13 ATV LIMITED WARRANTY 0008 13 1 YAMAHA EXTENDED SERVICE CES eee a OI iar on 14 1 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS Read and understand all of the labels on your machine Th
9. 9 L 0 2 Imp gal 0 2 US gal CAUTION 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 reg ular unleaded gasoline with a pump octane number R MI 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Gasohol There are two types of gasohol gasohol con taining ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems 1 Filler tube 2 Fuel level 5 4 A WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and
10. Avoid crossing the side of a steep hill if possible 2 3 Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling use proper gear and maintain a steady speed when climbing a hill If you stall or roll backwards fol low the special procedure for braking described in this manual Dismount on the uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate an ATV in fast flowing water or in water deeper than that recommended in this manu al Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always use the size and type tires specified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper installation or use of access
11. U S A is expressly prohibited Printed in Japan P N LIT 11626 19 64 EBU00014 AWARNING Indicates a potential hazard that could result in serious injury or death CONTENTS LOCATION OF THE WARNING AND Speed limiter ccceeeeceesssteeeeeeee 4 4 SPECIFICATION LABELS 0008 1 1 Front brake lever cc0cccceeeeeeeeeees 4 5 Brake pedal and rear brake lever 4 5 SAFETY INFORMATION 0000ce0e 2 1 3 2 Parking Drake eeeeeeeeeeeneeeeeeeenees 4 6 Shift pedal ec ceeeeeseeeeeseeeteneees 4 8 DESCRIPTION AND MACHINE Fuel tank Cap cccccccceceeeeeeseeeeseeeeeeees 4 8 IDENTIFICATION cc0ccsecceeeeeeeeeees 3 1 FUEI COCK meiate reei heiii 4 9 Identification number records 3 2 Choke levarsi enara a nn 4 10 Key identification number 00 3 2 Setran ieee tee gett 4 10 Vehicle identification number 3 3 Model label cc cccceeeeeeeeeeseeeeeeeeeees 3 3 PRE OPERATION CHECKG 00 5 1 Front and rear brakes ccccceeeeeeees 5 2 CONTROL FUNCTIONS 4 1 PUG meane ieee a BoM dh 5 3 Main SWitCh eee eeceeeeeeeeeteeeeeeeenneeeeeteee 4 1 Engine Oilearan aae 5 5 Indicator lights encrena 4 1 Final gear Oil cceeeeeseeeeeeesteeeeeeenaees 5 5 Handlebar switches cccccceeeeeees 4 2 Throttle levet waves ecoeeetedtweteeorteusbeee sees 5 6 Throttle levet oo c
12. air filter element and let it dry CAUTION Do not twist the air filter element when squeezing it 6 Inspect the air filter element If damaged replace it 7 Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter ele ment NOTE a The air filter element should be wet but not drip ping 8 Install the air filter element 9 Install the air filter case cover by hooking the fasteners onto the air filter case 10 Install the front cover by installing the bolts NOTE SSS The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the machine is operated in extremely dusty areas Each time air filter ele ment maintenance is performed check the air inlet of the air filter case for obstructions Check the air cleaner rubber joint to the carburetor and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfil tered air entering the engine CAUTION Never operate the engine with the air filter element removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Additionally operation without the filter ele ment will affect carburetor jetting with sub sequent poor performance and possible engine overheating EBU01035 Air intake restrictor plate removal To obtain full engine performance capability removing the air intake restrict
13. and loading EBU00222 Accessories Accessories can affect the handling and control of your ATV Keep the following in mind when considering an accessory or operating an ATV which has accessories e Choose only accessories designed for your ATV Your Yamaha dealer has a variety of genuine Yamaha accessories Other acces sories may also be available on the market However it is not possible for Yamaha to test all non Yamaha accessories nor have any control over the quality or suitability of them Choose a genuine Yamaha accessory or one that is equivalent in design and quality 6 9 Accessories should be rigidly and securely mounted An accessory which can shift posi tion or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object attached to the handle bars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when riding an ATV with accessories The ATV may handle differently than it does without accessories EBU00584 Loading As originally equipped this ATV is not designed to carry cargo or tow a trailer If you choose to add accessories so that you can carry cargo or tow a trailer you must use common sense and good judgment Keep the follow
14. at a Yamaha dealership have the tools experience and know how to properly service your machine Use only gen uine Yamaha parts on your machine Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills 8 31 A WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys tem Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces EBU00440 Troubleshooting chart 1 Fuel fuel in the fuel tank Check if there is 2 Compression Remove the fuel hose from the fuel cock Water or dirt mixed in fuel Clean the fuel filter and the fuel tank Turn the fuel cock to ON Check fuel flow Y y No fuel Restart engine There is fuel gt Turn the fuel cock to OFF Some fuel Turn the fuel cock to RES No fuel gt Supply fuel to see if there is compression Use electric starter A gt There is compresson Compression normal gt No compression
15. child under age 16 to operate an ATV without adult supervision and never allow con tinued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV 2 1 Always avoid operating an ATV on any paved surfaces including sidewalks driveways parking lots and streets Never operate an ATV on any public street road or highway even a dirt or gravel one Never operate an ATV without wearing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this ATV Never operate at speeds too fast for your skills or the conditions Always go at a speed that is prop er for the terrain visibility and 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 condition Always follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footrests of the ATV during opera tion Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV 2 2 Never operate on excessively rough slippery or loose terrain until you have learned and
16. control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For replacement manual call 1 800 532 1558 YAMAHA YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2005 7 2 7x1 A E Dear Yamaha ATV Owner Please Review this IMPORTANT SAFETY CARD before operating your ATV If card is not attached call 1 800 344 6418 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 READ YOUR OWNER S MANUAL A CHILD UNDER 6 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 50CC OR GREATER A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER THAN 90CC TAKE THE FREE HANDS ON TRAINING COURSE OFFERED BY YAMAHA ASK YOUR DEALER FOR DETAILS OR CALL 1 800 887 2887 If you have any questions about these points or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership please fill out the information below and mail this card to yamaha today Name ATV Model Purchase Date l J MO DAY YR Address Primary I D Engine Number Lo i o Dealer Name amp Addr
17. 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 preserve battery ener gy Do not crank the engine more than 10 sec onds on each attempt 7 If the engine is started with the starter choke in position the choke lever should be returned to position to warm up the engine If the engine is started with the starter choke in position keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the choke lever to posi tion before riding 6 3 CAUTION See the Engine break in section prior to Operating engine for the first time EBU00181 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The choke lever should not be used The throttle should be opened slightly EBU00184 Warming up To get maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine To see whether or not the engine is warm check if it responds to the throttle normally with the choke lever turned off EBU00200 Shifting This model has a 3 speed forward transmission with centrifugal automatic clutch The transmis sion allows you to control the amount of power you have available at a given speed or for start ing accelerating climbing etc To shift into neu tral
18. is still very hot EBU10842 EBU00493 Engine oil Final gear oil Make sure the engine oil is at the specified level Make sure the final gear oil is at the specified Add oil as necessary See page 8 6 level Add oil as necessary See pages 8 8 8 9 CAUTION for details In order to prevent clutch slippage since Peesmmended oil the engine oil also lubricates the clutch SAE80API GL 4 Hypoid gear oil do not mix any chemical additives Do not use oils with a diesel specification of CD f desired an SAE 80W90 hypoid gear oil may or oils of a higher quality than specified In be used for all conditions addition do not use oils labeled ENERGY NOTE __ SSS CONSERVING II or higher GL 4 is a quality and additive rating GL 5 or e Make sure that no foreign material enters GL 6 rated hypoid gear oils may also be used the crankcase Ta eee a aa Recommended engine oil type and quantity See page 10 2 5 5 EBU01083 Throttle lever Check to see that the throttle lever operates cor rectly It must open smoothly and spring back to the idle position when released Have a Yamaha dealer repair as necessary for proper operation 5 6 EBU00157 Tires A WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or oper ation of this ATV with improper or uneven tire pressure may cause
19. loss of control increasing your risk of accident HOW TO AVOID THE HAZARD 1 The tires listed below have been approved by Yamaha Motor Co Ltd for this model Other tire combinations are not recommended nee Manufacturer Size Type DUNLOP AT18 x 7 7 KT586 DUNLOP AT18 x 8 7 KT587 2 The tires should be set to the recom mended pressure Recommended tire pressure Front 20 kPa 0 20 kgf cm 2 9 psi Rear 20 kPa 0 20 kgf cm 2 9 psi e Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pressure below the minimum specified could cause the tire to dis lodge from the rim under severe riding conditions The following are mini mums Front 17 kPa 0 17 kgf cm 2 5 psi Rear 17 kPa 0 17 kgf cm 2 5 psi 5 7 4 Use no more than the following pres sures when seating the tire beads Front 230 kPa 2 3 kgf cm 33 psi Rear 230 kPa 2 3 kgf cm 33 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst EBU00159 How to measure tire pressure Use the low pressure tire gauge NOTE The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect EBU00160 Set pressure with
20. maintenance such as spark plugs oil oil filter air filter and brake shoes THE CUSTOMER S RESPONSIBILITY under this war ranty shall be to 1 Operate and maintain the ATV as specified in the appropriate owner s manual 2 Give notice to an authorized Yamaha ATV dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation USA also warrants to the ultimate purchaser and each subsequent pur chaser of each 2006 and later model Yamaha ATV covered by this warranty that the vehicle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards 13 1 within the period listed immediately below Failures other than those resulting from defects in materi
21. return the throttle lever to its original posi tion and repeatedly depress the shift pedal until it stops 1 Shift pedal N Neutral position CAUTION Do not coast for long periods with the engine off and do not tow the machine a long dis tance Even with gears in neutral the trans mission is only properly lubricated when the engine is running Inadequate lubrication may damage the transmission EBU00205 To start out and accelerate 1 Release the throttle lever CAUTION Always close the throttle while 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 gradually 4 Once the machine has attained adequate speed release the throttle lever 5 Shift into second gear and release the shift pedal 6 Open the throttle gradually 7 Follow the same procedure when shifting to the next higher gear A WARNING POTENTIAL HAZARD Opening the throttle before releasing the shift pedal WHAT CAN HAPPEN The machine could wheelie This would increase the chance of an accident including overturn HOW TO AVOID THE HAZARD Release the shift pedal before opening the throttle Open the throttle gradually 6 5 EBU00207 To decelerate When slowing down or stopping release the throttle and apply the brakes smoothly and evenly As you slow down shift to a lower gear Be sure that the engine has suf
22. seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV 7 8 Pre operation checks Always perform the pre operation checks listed on page 5 1 before riding for safety and proper care of the ATV A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operat ing Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual A WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or oper ation of this ATV with improper or uneven tire pressure may cause loss of control increasing your risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires speci fied in the Owner s Manual for this vehicle on pages 5 6 5 7 Always maintain proper tire pressure as described in the Owner s Manual on page 5 8 AWARNING Indicates a potential hazard that could result in serious injury or death
23. sophisticated adjustment Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so However the idling speed may be per formed by the owner as a part of the usual main tenance routine CAUTION The carburetor was set at the Yamaha facto ry after many tests If the settings are dis turbed by someone without sufficient techni cal knowledge poor engine performance and damage may result EBU13020 Idle speed adjustment NOTE ee A diagnostic tachometer must be used for this procedure 1 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Connect the tachometer to the spark plug lead and then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in direction to increase the engine speed and in direction 6 to decrease the engine speed Specified idle speed 1 750 1 850 r min 1 Throttle stop screw 8 18 EBU00303 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a professional Yamaha service technician EBU00304 Cam chain adjustment The cam chain becomes loose wi
24. spark plug CR7HSA NGK Before installing the spark plug measure the electrode gap with a wire thickness gauge and adjust it to specification Spark plug gap 0 6 0 7 mm 0 024 0 028 in a Spark plug gap When installing the spark plug always clean the gasket surface and its mating surface Wipe off any grime from the threads and tighten it to the specified torque Tightening torque Spark plug 12 5 Nm 1 25 m kgf 9 1 ft Ibf EBU10343 Air filter cleaning NOTE There is a check hose at the bottom of the air fil ter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case 8 11 1 Front cover 1 Check hose 1 Remove the front cover by removing the bolts 2 Bolt x2 1 Air filter case cover 2 Fastener x4 2 Remove the air filter case cover by 3 unhooking the fasteners 4 1 Fastener 2 Air filter element Remove the air filter element by unhooking the fastener Wash the air filter element gently but thor oughly in solvent A WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element 5 Squeeze the excess solvent out of the
25. this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways 7 17 Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden haz ards which may cause the ATV to upset A WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when oper ating on unfamiliar terrain Always be alert to changing terrain condi tions when operating the ATV 7 18 A WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Could cause loss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slip pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terr
26. tires cold Tire wear limit Set tire pressures to the following specifications When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire Recommended pressure 20 kPa 17 kPa 23 kPa 0 20 kgf cm 0 17 kgf cm 0 23 kgf cm 2 9 psi 2 5 psi 3 3 psi Minimum Maximum 20 kPa 17 kPa 23 kPa 0 20 kgf cm 0 17 kgf cm 0 23 kgf cm 3 3 psi a Tire wear limit 1 Low pressure tire gauge 5 8 EBU11620 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque EBU11700 Switches Check the operation of all switches Have a Yamaha dealer repair as necessary for proper operation EBU00499 Battery Check fluid level and fill if necessary Use only distilled water if refilling is necessary See pages 8 27 8 29 5 9 EBU00161 OPERATION AWARNING Indicates a potential hazard that could result in serious injury or death A WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer 6 1 EBU00579 Starting a cold engine A WARNING POTENTIAL HAZARD Fre
27. ATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Intake system Air cleaner element Intake duct 11 1 EBU13653 MAINTENANCE RECORD Copies of work orders and or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty The chart below is printed only as a reminder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENACE DATE OF SERVICING DEALER n aa nour SERVICE MILEAGE NAME AND ADDRESS REMARKS 1 320 200 20 3 1 300 800 80 6 2 500 1 600 160 12 5 000 3 200 320 18 7 500 4 800 480 24 10 000 6 400 640 30 12 500 8 000 800
28. D GASOLINE ONLY 6 8 L 1 5 Imp gal 1 8 US gal 0 9 L 0 2 Imp gal 0 2 US gal Carburetor Type manufacturer VM16SH MIKUNI Spark plug Type manufacturer Gap CR7HSA NGK 0 6 0 7 mm 0 024 0 028 in Clutch type Wet multiple disc automatic Model YFM80R Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio ist 2nd 3rd Spur gear 65 20 3 250 Shaft drive 19 18 x 34 10 3 588 Constant mesh 3 speed Left foot operation 39 11 3 545 35 17 2 059 31 22 1 409 Chassis Frame type Caster angle Trail Steel tube 1 3 8 mm 0 15 in Tire Type Size Front Rear Manufacturer type Front Rear Tubeless AT18 x 7 7 AT18 x 8 7 DUNLOP KT586 DUNLOP KT587 YFM80R Brake Front brake type Operation Rear brake type Operation Drum brake Right hand operation Drum brake Left hand and right foot operation Suspension Front Rear Leading arm Swingarm Shock Absorber Front Rear Coil spring Oil damper Coil spring Oil damper Wheel travel Front Rear 57 mm 2 24 in 56 mm 2 2 in Electrical Ignition system Charging system Battery type voltage capacity C D I A C magneto 12N7D 3B 12V 7Ah Indicator light voltage wattage x quantity Neutral 12V 1 7W x 1 Fuse EBU13640 NOISE REGUL
29. Do not operate at speeds too fast for your skills or the conditions A WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can result in an acci dent HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain visibility and operating conditions and your experience Speed limiter For riders inexperienced with this model this model is equipped with a speed limiter in the throt tle lever housing The speed limiter limits the power and top speed of the ATV Turning the screw in decreases top speed and turning it out increases top speed This model also has an intake restrictor plate to limit the amount of engine power available Yamaha recommends that all beginning riders start off with the speed limiter turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn The limiter may be gradually adjusted to increase maximum speed as the beginner becomes more familiar with oper ating the ATV Parents should decide when to adjust the ATV for more power as their youngster s riding skills improve Once the ATV rider can oper 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 t
30. L HAZARD Carrying a passenger on this ATV WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an acci dent resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for car rying passengers 7 6 Apparel Operating without protective clothing A WARNING increases your chances of severe injury in POTENTIAL HAZARD the event of an accident Operating this ATV without wearing an HOW TO AVOID THE HAZARD approved motorcycle helmet eye protec Always wear an approved motorcycle hel tion and protective clothing met that fits properly WHAT CAN HAPPEN You should also wear o ti Peau eye protection Deere ee eee goggles or face shield approved motorcycle gloves helmet increases Protective our chances of a ae ae y ea long sleeved shirt or jacket sever injury or everenee jury o long pants death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Helmet 7 7 Do not operate after consuming alcohol or A WARNING drugs Operator s performance capability is reduced by POTENTIAL HAZARD the influence of alcohol or drugs Operating this ATV after consuming alco hol or drugs WHAT CAN HAPPEN Could
31. N 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 a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an acci dent HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operation Avoid wheelies and jumping You may lose con trol of the ATV or overturn AWARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off 7 13 Modifications A WARNING POTENTIAL HAZARD Operating this ATV with improper modifi cations WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situa tions could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used accord ing to instructions If you have questions consult an authorized ATV dealer Exhaust system The exhaust syste
32. NOT BE OPERATED BY A CHILD UNDER 12 YEARS OF AGE AN IMPORTANT NOTE TO PARENTS This ATV is not a toy Before you let your child ride this ATV you should understand the instructions and warnings in this Owner s Manual Then be sure your child understands and will follow them Children differ 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 delivered with an adjustable speed limiter and also with an air intake restrictor plate Yamaha recommends that all beginners start off with the speed limiter screw turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn The limiter screw may be gradually turned out to increase maximum speed as the beginner becomes more familiar with operating the ATV Parents should decide when to adjust the ATV for more power as their youngster s riding skills improve Once the ATV rider can operate with skill at the top speed permitted by adjusting 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 stages as you did before If your child is a beginner or is inexperienced h
33. Overall width 841 mm 33 1 in Overall height 940 mm 37 0 in Seat height 669 mm 26 3 in Wheel base 1 030 mm 40 6 in Ground clearance 100 mm Minimum turning radius 2 400 mm 94 5in Basic weight With oil and full fuel tank 116 kg 256 Ib Engine Type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder Forward inclined Displacement 79 cm 4 82 cu in Bore x Stroke 47 0 x 45 6 mm 1 85 x 1 80 in Compression ratio 9 6 1 Starting system Electric starter Lubrication system Wet sump 10 1 YFM80R Engine oil Type YAMALUBE 4 20W40 or SAE20W40 1 1 i i 1 gt YAMALUBE 4 10W30 or SAE10W30 ii T 30 50 70 90 110 130 F saESw30 O 20 10 0 10 20 30 40 50 C Recommended engine oil classification API Service SE SF SG type or higher CAUTION In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher Quantity Periodic oil change 0 80 L 0 70 Imp qt 0 85 US qt 10 2 YFM80R Final gear oil Type Quantity Total amount SAE80API GL 4 Hypoid gear oil 0 12 L 0 11 Imp qt 0 13 US qt Air filter Wet type element Fuel Type Tank capacity Reserve amount UNLEADE
34. V to make the turn properly Support your weight on the outer footrest This procedure should be practiced at slow speed many times in a large off road area with no obstacles 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 procedure again If the riding surface is slip pery or loose it may help to position more of your weight over the front wheels by moving for ward on the seat 7 24 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 throt tle changes excessive braking incorrect body movements or too much speed for the sharp ness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while nego tiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills Be sure that you can maneu ver your ATV well on flat ground before attempt ing any incline and then practice riding first on gentle slopes Try more difficult climbs only after you have developed your skill In all cases avoid inclines with slippery or loose surfaces or obst
35. YAMAHA A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 INTRODUCTION Congratulations on your purchase of the Yamaha YFM8OR It 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 craftsmanship and reliability that have made Yamaha a leader in these fields This manual will provide you with a good basic understanding of the features and operation of this machine This manual includes important safety information It provides information about special tech niques and skills necessary to ride your machine It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your machine please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COM PLETELY BEFORE OPERATING YOUR MACHINE MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MACHINE e NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV CALL 1 800 887 2887 FOR MORE INFOR MATION e THIS ATV AND ANY OTHER ATV OVER 70cc SHOULD
36. a cles that might cause you to lose control A WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small hills 7 25 HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by leaning for ward and on steeper inclines standing on the footboards and leaning forward over the handle bars AWARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces 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 If you are climbing a hill and you find that you When crossing the side of a hill have not properly judged your ability t
37. a No more than 20 mm 0 8 in A WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an accident or be injured HOW TO AVOID THE HAZARD Do not turn the speed adjuster out more than 20 mm 0 8 in 4 5 EBU00070 Front brake lever The front brake lever is located on the right han dlebar Pull it toward the handlebar to apply the front brake 1 Front brake lever EBU00732 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar Push down on the pedal or pull the lever toward the handlebar to apply the rear brake 1 Rear brake lever 4 6 EBU00074 Parking brake Use the parking brake when you have to start the engine or park the machine especially on a slope Apply the rear brake lever and push down the lock plate to apply the parking brake Squeeze the rear brake lever to release the parking brake 1 Lock plate 1 Locked position 4 7 A WARNING POTENTIAL HAZARD Improper use of the parking brake WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine This could cause loss of control or a collision The brake could overheat if you ride the ATV without r
38. a Yamaha dealer if you can t find or solve the problem yourself 4 3 EBU15650 Speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV Your ATV was delivered with an adjustable speed limiter and also with an air intake restric tor plate Yamaha recommends that all begin ning riders start off with the speed limiter screw turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn The limiter screw may be grad ually turned out to increase maximum speed as the beginner becomes more familiar with operat ing the ATV Parents should decide when to adjust the ATV for more power as their young ster s riding skills improve Once the ATV rider can operate with skill at the top speed permitted by adjusting the speed limiter alone the air intake restrictor plate can be removed Since 4 4 removal of this plate will result in a significant increase in power turn the speed limiter com pletely back in again adjust it out in stages as you did before Adjusting for maximum throttle lever movement without removing the air intake restrictor plate will cause the engine to run roughly at higher speeds For air intake restrictor plate removal instruc tions see page 8 14 1 Locknut 2 Adjuster
39. a hill WHAT CAN HAPPEN Could result in the ATV overturning HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking brake after you are stopped If you begin rolling backwards Keep weight uphill Never apply the rear brake while rolling backwards Apply the front brake When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the proce dure described in the Owner s Manual RIDING DOWNHILL When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as possible Move back on the seat and sit with your arms straight Choose a low gear which will allow the engine compression to do most of the braking for you Improper braking may cause a loss of traction Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of trac tion Whenever possible ride your ATV straight downhill 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 obstacles which may appear 7 30 A WARNING POTENTIAL HAZARD Going
40. ain 7 19 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 AWARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles 7 20 WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch carefully for other vehicles 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 shifting procedures and turning techniques in this area before trying more difficult terrain Always avoid riding on paved surfaces the ATV is designed for off road use only and handling maneuvers are more difficult to perform on pavement Set the parking brake and follow the instruction on page 6 1 to start the engine Once it has warmed up you are ready to begin riding your ATV As you get on the ATV be sure not to accidentally move the shift pedal Remember that the engine and exhaust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these compo nents 7 21 With the en
41. al or workmanship which arise solely as a result of owner abuse and or lack of proper maintenance are not covered by this warranty All Models Thirty 30 months from the original purchase date YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION U S A AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 Po po p gt P gt P Rk P WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision damages and oil oil filters air filters spark plugs and brake shoes What are some examples of abnormal st
42. ation maintenance and warranty requirements to your satis faction at the time of sale and upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain effective 13 2 CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha ATV dealer within the continental United States Be sure to bring your warranty registration card or other valid proof of the original date of purchase If a question or problem arises regarding warranty first contact the owner of the dealership Since all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model V I N frame number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the
43. ceecccessssssseseeeeeees 4 3 TIrES ecccih ssctevtitect lecaieei ieee laiii 5 6 How to measure tire pressure 5 7 Tire wear limit eener 5 8 Fittings and fasteners 0 0 00 5 9 SWItCNES iien ne airiai 5 9 Battery E AE E E E E 5 9 OPERATION siari ias eead d aaa 6 1 Starting a cold engine 6 1 Starting a warm engine sasen 6 3 Warming Up sseeeieeeseeeeeeereeerereserensses 6 3 SHIMING inae aiaa 6 4 To start out and accelerate 6 4 To decelerate eecccesseereereeseeeeeees 6 5 Engine break in neseser 6 6 Parkin E EE ir aeh era eens 6 7 Parking On a SlOp seee 6 8 Accessories and loading 008 6 9 r Riding Your ATV ssssssssssseseseerereerrrrereenense 7 1 Getting to know your ATV 7 3 Ride with care and good JUAGOMENE csc cee esteecesseeeestieenseene 7 4 Be careful where you ride 7 16 Turning your ATV osasse 7 23 Climbing uphill 0 cc eeeeeeeeeeees 7 25 Riding downhill aeee 7 30 Crossing a SlOpe n 7 32 Crossing through shallow water 7 34 Riding over rough terrain 06 7 36 Sliding and skidding ceeee 7 38 What to do ocase cciurieonaidare 7 40 Whit lodo cernentes a 7 40 PERIODIC MAINTENANCE AND ADJUSTMENT cccecesseeceesssteeeeeeeaes 8 1 Owner s manual and tool kit 8 1 Periodic maintenance chart for the emission control system eee 8 3 General maintenance and lubrication CNAME oeae iia aee aE cea estate
44. could cause loss of control an accident and injury It could also cause engine or drive train damage HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear TURNING YOUR ATV To achieve maximum traction while riding off road the two rear wheels are mounted solidly on one axle and turn together at the same speed Therefore unless the wheel on the inside of the turn is allowed 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 A WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN The ATV could go out of control causing a collision or overturn 7 23 HOW TO AVOID THE HAZARD Always follow proper procedures for turn ing as described in this Owner s Manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions 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 outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the AT
45. d pull up the seat at the rear See page 6 1 1 Seat lock lever a Choke lever 1 Fully open ON 2 Half open warming up position 3 Closed OFF 4 10 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 1 Projection 2 Seat holder NOTE Make sure that the seat is securely fitted 4 11 EBU00112 AWARNING Indicates a potential hazard that could result in serious injury or death 4 12 PRE OPERATION CHECKS Before using this machine check the following points ROUTINE PAGE Check operation condition and free play Brakes Adjust if necessary 5 2 5 3 8 18 8 23 Check fuel level 5 3 5 4 Fuel Fill with fuel if necessary Check oil level 5 5 8 6 8 7 Fill with oil if necessary Final gear oil Check for leakage 5 5 8 8 8 9 Throttle Check for proper throttle cable operation 5 6 Wheels and tires Check tire pressure wear and damage 5 6 5 8 8 26 Fittings and fasteners Check all fittings and fasteners 5 9 Switches Check operation 5 9 Check fluid level Battery Fill with distilled water if necessary 5 9 8 27 8 29 Engine oil 5 1 A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operat ing Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect
46. d that the free play is correct Make sure the brakes do not drag Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer EBU00872 Clutch adjustment 1 Remove the rubber cap 2 Loosen the locknut 3 Slowly turn the adjusting bolt clockwise until resistance is felt Then turn it 1 8 counterclockwise 1 Rubber cap 2 Locknut 3 Adjusting bolt 4 Tighten the locknut to the specified torque Tightening torque 8 Nm 0 8 m kgf 5 8 ft Ibf 8 24 NOTE Ss et Turn the adjusting bolt clockwise to decrease the clutch free play and turn it counterclockwise to increase the free play 5 Install the rubber cap securely EBU00356 Cable inspection and lubrication AWARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer cov ering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables 8 25 Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a Yamaha dealer to replace them Recommended lubricant Yamaha chain and cable lube or SAE 10W30 motor oil EBU00727 Brake and shift pedal brake lever lubrication Lubricate the pivoting parts of each l
47. d the operating techniques described in this Owner s Manual For more information about the training course contact an authorized ATV dealer or call 1 800 887 2887 Get training if you are inexperienced Beginners should get training from a certified instructor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not attempt to operate at maximum perfor mance until you are totally familiar with the ATV s handling and performance characteristics AWARNING POTENTIAL HAZARD 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 Operating this ATV without proper instruc tion WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in differ ent situations and on different types of ter rain 7 4 Not recommended for children under 12 years of age A WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to severe injury or death of the child HOW TO AVOID THE HAZARD A child under 12 should never operate an ATV with engine size greater than 70cc 7 5 This ATV is designed to carry operator only passengers prohibited AWARNING POTENTIA
48. down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owner s Manual Note a special technique is required when braking as you go down a hill Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible 7 31 CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slippery surfaces or rough ter rain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to cor rect the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper bal ance gradually steer again in the direction you wish to travel 7 32 A WARNING POTENTIAL HAZARD Improperly crossin
49. e or she should take a training course See the previ ous page for information about the free training available to purchasers of new ATVs EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED AUAA e Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures easier or clearer EBU15000 IMPORTANT NOTICE 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 arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU13330 YFM80RV OWNER S MANUAL 2005 by Yamaha Motor Corporation U S A AFFIX DEALER 1st edition June 2005 LABEL HERE All rights reserved Any reprinting or unauthorized use without the written permission _ of Yamaha Motor Corporation
50. eleasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before start ing the engine Always be sure you have released the parking brake before you begin to ride EBU00083 EBU00092 Shift pedal Fuel tank cap This machine is equipped with a constant mesh Remove the fuel tank cap by turning it counter 3 speed transmission The shift pedal is located clockwise on the left side of the engine Neutral is at the bottom position 1 Fuel tank cap 1 Shift pedal N Neutral position 4 8 EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor The fuel cock has three positions OFF With the lever in this position fuel will not flow Always turn the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling return the fuel cock lever to the ON position 4 9 EBU00096 EBU00566 Choke lever Seat The choke is used to start a cold engine Refer To remove the seat pull the seat lock lever to Starting a cold engine for proper operation upward an
51. er Ride slowly and carefully through slow mov ing water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not con tinue to ride your ATV until you have regained adequate braking ability See pages 7 34 7 35 Indicates a potential hazard that could result in serious injury or death 7 41 EBU00515 PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection adjustment and lubrication will keep your machine in the safest and most efficient condition possible Safety is an obliga tion of the machine owner The most important points of machine inspection adjustment and lubrication are explained on the following pages A WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified Have a Yamaha dealer perform service if you are not familiar with machine service EBU01221 Owner s manual and tool kit You are recommended to put this owner s man ual and low pressure tire gauge in the vinyl bag and always carry them along with the owner s tool kit under the seat 1 Owners manual 2 Low pressure tire gauge 8 1 3 Owner s tool kit The service informa
52. ess Telephone CAREFULLY READ BUSINESS REPLY MAIL 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 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES
53. ever and pedal Recommended lubricant Lithium soap based grease all purpose grease EBU01220 Knuckle shaft and steering shaft lubrication Lubricate the pivot points using a grease gun Recommended lubricant Lithium soap based grease all purpose grease 1 Grease nipple EBU01112 Wheel removal 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 8 26 1 Wheel nut x4 2 Wheel nut x3 EBU00871 Wheel installation When installing the wheel reverse the removal procedure Tighten the wheel nuts to the specified torques Tightening torque Wheel nut Front 28 Nm 2 8 m kgf 20 ft Ibf Rear 28 Nm 2 8 m kgf 20 ft Ibf EBU00378 Battery Check the level of the battery fluid and see if the terminals are tight Add distilled water if the fluid level is low CAUTION Do not leave or store the battery on its side When inspecting the battery be sure the breather hose is routed correctly If it touch es the frame or exists in such a way as to cause battery electrolyte or gas to exit onto the frame structural and cosmetic damage to the machine can occur 8 27 1 Battery 2 Battery breather hose A WARNING POTENTIAL HAZARD Failure to handle batteries or battery elec trolyte carefully WHAT CAN HAPPEN You could be poisoned You could be severely bu
54. ey contain important information for safe and proper operation of your ATV Never remove any labels from your ATV If a label becomes difficult to read or comes off a replace ment label is available from your Yamaha dealer 4 WARNING Operating this ATV if you are under the age of 12 increases your chance of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 12 to operate this ATV 4EM 21697 31 1 2 A WARNING Improper ATV use can result in SEVERE INJURY or DEATH 2 ALWAYS USE NEVERUSE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMETAND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction e at speeds too fast for your skills or the conditions e on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and it turns e avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 5FE 21568 11 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
55. ezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or colli sion HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding 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 4 Shift the transmission into neutral NOTE Position Warming up position This model is equipped with an ignition circuit Position Cold engine start cut off system ambient temperature above 25 C The engine can be started under the following 80 F and warm engine start posi conditions tion a When the transmission is in neutral At this time the neutral indicator light should come on If the light does not come on ask a Yamaha dealer to inspect it b When the transmission is in gear and the rear brake lever is applied However it is recommended to shift into neutral before starting the engine AMBIENT TEMP CHOKE LEVER POSITION 10 20 30 C 5 Use the choke lever in reference to the fig ure a Choke lever 1 Fully open ON 2 Half open warming up position Position Q Cold engine start 3 Closed OFF ambient temperature below 30 C 90 F 6 2 6 Completely close the throttle lever and start the engine by pushing the start switch NOTE If the engine
56. ficiently slowed before engaging a lower gear Improper use of the brakes or shifting can cause the tires to lose traction reducing control and increasing the possibility of an accident A WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating This could cause loss of control an accident and injury It could also cause engine or drive train damage HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear EBU02092 Engine break in There is never a more important period in the life of your machine than the period between zero and 20 hours For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an excessive load on it for the first several hours of running During the first 20 hours the various parts in the engine wear and polish themselves to the correct oper ating clearances During this period prolonged full throttle opera tion or any condition which might result in exces sive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat 6 6 If any abnor
57. g hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turn ing technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as described in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV 7 33 CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving shallow water of up to a maximum of 20 cm 7 9 inches in depth Before entering the water choose your path 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 carefully A WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that speci fied in your Owner s Manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out t
58. g the ATV to a stop and practice the turn ing maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight over the front wheels for better control See pages 7 23 7 24 e If your ATV begins to tip while turning Lean more into the turn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See pages 7 23 7 24 7 40 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 rec ommended until you have corrected the slide See pages 7 38 7 39 If your ATV can t make it up a hill you are try ing to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Instead apply the front brake or dismount the ATV on the uphill side See pages 7 25 7 29 e If your ATV is traversing a sloping surface Be sure to ride with your weight positioned towards 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 going to tip over dismount on the uphill side See pages 7 32 7 33 If your ATV encounters shallow wat
59. gine idling lift the shift pedal to the 1st gear position and then release the parking brake Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate Once the ATV has attained adequate speed release the throttle and lift the shift pedal to the 2nd gear position Release the shift pedal and apply the throttle smoothly Use this same procedure as you move into the high er gears Be sure to coordinate the use of the throttle and shift pedal properly If the throttle is applied too abruptly or if the throttle is not released during shifting or if the shift pedal is not released before applying the throttle the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds until you are thoroughly familiar with the opera tion of your ATV CAUTION Do not shift gears without releasing the throttle Damage to the engine or drive train may occur When slowing down or stopping release the throttle and apply the brakes smoothly and evenly As you slow down shift to a lower gear Be sure that the engine has sufficiently slowed before engaging a lower gear Improper use of the brakes or shifting can cause the tires to lose traction reducing control and increasing the possibility of an accident 7 22 A WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating This
60. gn material enters the final gear case 5 Install the dipstick 8 8 1 Dipstick 2 Maximum level mark 3 Minimum level mark Final gear oil replacement 1 2 Place the ATV on a level place Place a container under the final gear case Remove the dipstick and drain bolt to drain the oil 5 Fill the final gear case with oil Recommended oil SAE80API GL 4 Hypoid gear oil Oil quantity 0 12L 0 11 Imp qt 0 13 US qt CAUTION Be sure no foreign material enters the final gear case 1 Drain bolt 4 Install the drain bolt and tighten to specifi 6 Install the dipstick canon 7 Check for oil leakage If oil leakage is found check for the cause Tightening torque Drain bolt 23 Nm 2 3 m kgf 17 ft Ibf 8 9 EBU11820 Spark plug inspection The spark plug is an important engine compo nent and is easy to inspect The condition of the spark plug can indicate the condition of the engine For example a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder Do not attempt to diagnose such problems yourself Instead take the ATV to a Yamaha dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive you should replace the spark plug with one of the proper type Standard
61. he linings 7 34 Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability 7 35 CAUTION 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 condi tions 1 Check hose RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may result 7 36 A WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide If unexpected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose o
62. if the ATV isn t used for a long period of time the month maintenance intervals should be followed INITIAL Whichever 3 ROUTINE comes first 1300 gt 800 80 e Check valve clearance e Adjust if necessary e Check chain tension e Adjust if necessary e Check condition Spark plug e Adjust gap and clean e Replace if necessary e Check idle speed choke lever operation e Adjust if necessary Valves Cam chain Carburetor Crankcase breather e Check breather hose for cracks or damage system e Replace if necessary e Check for leakage Exhaust system e Tighten if necessary e Replace gasket if necessary Spark arrester e Clean e Check fuel hose for cracks or damage e Replace if necessary Fuel line 8 3 General maintenance and lubrication chart INITIAL EVERY Whichever 3 6 6 12 comes first o gt ROUTINE 1300 800 2500 1600 2500 1600 5000 3200 80 160 160 320 Air filter element e Clean e Replace if necessary Every 20 40 hours more often in wet or dusty areas Engine oil Final gear oil e Replace warm engine before draining e Check oil level oil leakage e Replace every 12 months Brakes e Check operation e Adjust if necessary Clutch e Check operation e Adjust if necessary Wheels Wheel bearings e Check bala
63. ight away and you ll rest easy knowing you ll have strong factory backed protection even after your Yamaha Limited Warranty expires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note YAMAHA EXTENDED SERVICE If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 14 2 EBU00436 AWARNING Indicates a potential hazard that could result in serious injury or death PROTECT YOUR INVESTMENT Use Genuine YAMAHA parts And Accessories See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual EBU00438 AWARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions e on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and
64. imitations Coverage isn t limited to moving parts or the drive train like many other plans And Y E S covers manufacturing defects just like the warranty See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be e You don t have to pay anything for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs 14 1 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period e Y E S coverage is honored at any authorized Yamaha dealer nationwide e Y E S coverage is transferable to a new owner if you sell or trade in That can make your Yamaha much more valuable This excellent Y E S plan coverage is only available to Yamaha owners like you and only while your Yamaha is still within the Yamaha Limited Warranty period So visit your authorized Yamaha dealer to get all the facts He can show you how easy it is to protect your investment with Yamaha Extended Service We urge you to act now You ll get the excellent benefits of TRIP coverage r
65. ing points in mind Never exceed the weight limits shown An overloaded ATV can be unstable MAXIMUM LOADING LIMIT Vehicle loading limit total weight of cargo rider and accessories 95 kg 209 Ib Load cargo on the carriers as close to the center of the vehicle as possible Put cargo at the rear of the front carrier and at the front of the rear carrier Center the load from side to side Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load does not interfere with controls or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed 2nd gear when ever you are carrying heavier loads or when towing a trailer Allow more braking distance A heavier vehi cle takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV A WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely at
66. line spills on your clothing change your clothes 2 7 A WARNING POTENTIAL HAZARD Starting or running the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1 Spark arrester 10 Rear brake lever 2 Seat 11 Parking brake 3 Front cover 12 Neutral indicator light 4 Brake pedal 13 Front brake lever 5 Fuel cock 14 Throttle lever 6 Rear wheel 15 Main switch 7 Footrest 16 Fuel tank cap 8 Shift pedal 17 Handlebar switches 9 Front wheel NOTE The machine you have purchased may differ slightly from those shown in the figures of this manual 3 1 EBU00600 Identification number records Record the key identification number vehicle identification number and model label informa tion in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION O 3 2 EBU00035 Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key
67. m on the ATV is very hot dur ing 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 A WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire Someone touching the exhaust system during or after opera tion could be burned 7 15 HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it BE CAREFUL WHERE YOU RIDE This ATV is designed for off road use only Riding on paved surfaces can cause loss of con trol A WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect han dling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets 7 16 Do not ride on any public road street or high way Riding on public roads can result in colli sions with other vehicles A WARNING POTENTIAL HAZARD Operating
68. mality is noticed during this period consult a Yamaha dealer 0 10 hours Avoid continuous operation above half throttle Allow a cooling off period of five to ten minutes after every hour of operation Vary the speed of the machine from time to time Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the machine freely through the gears but do not use full throttle at any time After break in Avoid prolonged full throttle operation Vary speeds occasionally EBU02111 Parking When parking stop the engine and shift into first gear Turn the fuel cock to OFF and apply the parking brake 1 Lock plate 6 7 1 Locked position EBU12960 Parking on a slope A WARNING POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control increas ing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline put the ATV in low gear apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easi ly Bring the ATV to a stop by applying the brakes in low gear Stop the engine With the rear brake lever and pedal applied apply the parking brake and slowly release the brake pedal 6 8 EBU00221 Accessories
69. nce damage runout e Replace if necessary e Check brearing assemblies for looseness damage e Replace if damaged Steering system e Check operation e Replace if damaged e Check toe in e Adjust if necessary Knuckle shafts steering shaft e Lubricate every 6 months with Lithium soap based grease Fittings and fasteners e Check all chassis fittings and fasteners e Correct if necessary 8 4 ROUTINE Whichever comes first o gt INITIAL 3 e Check specific gravity Battery e Check breather hose for correct routing e Correct if necessary Since these items require special tools data and technical skills have a Yamaha dealer perform the service 8 5 AWARNING Indicates a potential hazard that could result in serious injury or death EBU08682 Engine oil Engine oil level measurement 1 Place the ATV on a level surface 2 Warm up the engine for several minutes and stop it 3 Remove the dipstick and wipe it off with a clean rag Insert the dipstick in the filler hole without screwing it in NOTE Wait a few minutes until the oil level settles before checking 4 Remove the dipstick and inspect the oil level 5 The oil level should be between the maxi mum and minimum marks If the level is low add oil to raise it to the specified level CAUTION Be sure no foreign material enters the crankcase 8 6 1
70. o 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 Always follow proper procedures as described in the Owner s Manual Avoid hills with excessively slippery or loose surfaces A WARNING Shift your weight to the uphill side of the ATV POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turn ing technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible 7 27 If your ATV has stalled or stopped and you believe you can continue up the hill restart care fully 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 uphill side Physically turn the ATV around and then descend the hill If you start to roll backwards DO NOT use the rear brake to stop or try to put the ATV in gear The ATV could easily tip over backwards Instead apply the front brake gradually or dis mount the ATV immediately on the uphill side 7 28 A WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing
71. or plate is required 1 Remove the air filter element See page 8 11 for removal and installation procedures 2 Remove the air intake restrictor plate 1 Air intake restrictor plate NOTE Store the air intake restrictor plate with the owner s manual so that you can install it when ever you want to reduce the top speed available 3 Install the air filter element 8 15 EBU13600 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester 1 Remove the screws 1 Screw x2 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe 1 Tailpipe 2 Spark arrester 3 Screw x2 4 Insert the tailpipe into the muffler and align the screw holes 5 Install the screws and tighten them 8 16 A WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system EBU00296 Carburetor adjustment The carburetor is a vital part of the engine and requires very
72. oration After thor oughly cleaning the machine prepare for stor age as follows 1 Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equivalent product Specified amount 1 oz of stabilizer to each gallon of fuel or 7 5 cc of stabilizer to each liter of fuel NOTE Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system Consult a Yamaha dealer if the fuel system needs to be drained instead 2 Remove the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe out let to prevent moisture from entering 6 If storing in a humid or salt air atmosphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat cover 7 Remove the battery and charge it Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the machine EBU00428 SPECIFICATIONS YFM80R Dimension Overall length 1 537 mm 60 5 in
73. ories 2 4 e Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Products Safety Commission at 1 800 638 2772 or the ATV Distributor s Safety Hotline at 1 800 852 5344 2 5 A WARNING POTENTIAL HAZARD Improper handling of gasoline WHAT CAN HAPPEN Gasoline can catch fire and you could be burned HOW TO AVOID THE HAZARD Always turn off the engine when refueling Do not refuel right after the engine has been running and is still very hot Do not spill gasoline on the engine or exhaust pipe muffler when refueling Never refuel while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers 2 6 When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF position Otherwise fuel may leak out of the carbu retor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gaso
74. practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground
75. r a longer period than the above check the specific gravity at least once a month and recharge the battery when it is too low Always make sure the connections are cor rect when putting the battery back in the machine Make sure the breather hose is properly connected and is not damaged or obstructed EBU00390 Fuse replacement A WARNING 1 The fuse case is located under the seat 2 Ifthe fuse is blown turn off the main switch POTENTIAL HAZARD and install a new fuse of the specified Using an improper fuse amperage Then turn on the switches If WHAT CAN HAPPEN the fuse immediately blows again consult An improper fuse can cause damage to a Yamaha dealer the electrical system which could lead to a fire Specified fuse 5 A HOW TO AVOID THE HAZARD Always use a fuse of the specified rating Never use a material in place of the proper fuse CAUTION To prevent accidental short circuiting turn off the main switch when checking or replac ing a fuse 1 Fuse 2 Spare fuse 8 30 EBU00412 Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory trouble may occur during operation Any prob lem in the fuel compression or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your machine requires any repair take it to a Yamaha dealer The skilled technicians
76. r slippery conditions positioning your weight over the front wheels will sometimes help L d esd Sa j l altan mee WH Tr CA i r If the rear wheels of your ATV start to slide side ways control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide 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 reduced Bear in mind that sliding maneu vers should always be avoided on extremely slippery surfaces such as ice since all control may be lost 7 39 A WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each section on riding techniques completely WHAT TO DO e f your ATV doesn t turn when you want it to Brin
77. rain neglect or abuse These terms are general and overlap each other in areas Specific examples include Running the machine out of oil sustained high rpm full throttie operating the machine with a broken or damaged part which causes another part to fail damage or failure due to improper or careless transportation and or tie down If you have any specific questions on operation or maintenance please contact your dealer for advice Does the warranty cover incidental costs such as towing or transportation due to a failure No The warranty is limited to repair of the machine itself May perform any or all of the recommended maintenance shown in the Owner s Manual instead of having the dealer do them Yes if you are a qualified mechanic and follow the procedures specified in the Owner s and Service Manual We do recommend however that items requiring special tools or equipment be done by Yamaha ATV dealer Will the warranty be void or cancelled if do not operate or maintain my new ATV exactly as specified in the Owner s Manual No The warranty on a new ATV cannot be voided or cancelled However if a particular failure is caused by operation or maintenance other than as shown in the Owner s Manual that failure may not be covered under warranty What responsibility does my dealer have under this warranty Each Yamaha ATV dealer is expected to 1 Completely set up every new machine before sale 2 Explain the oper
78. rned by the sulfuric acid in bat tery electrolyte Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Always shield eyes when working near batteries Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention 8 28 EYES Flush with water for 15 minutes and get prompt medical attention Keep batter ies away from sparks flames cigarettes or other sources of ignition Ventilate when charging or using in a closed space EBU11950 Replenishing the battery fluid A poorly maintained battery will corrode and dis charge quickly The battery fluid should be checked at least once a month 1 The level should be between the maximum and minimum level marks Use only dis tilled water if refilling is necessary 2 Minimum level mark 4 Positive lead 1 Maximum level mark 3 Negative lead 2 Disconnect the negative lead 3 Disconnect the positive lead and then remove the battery 8 29 CAUTION Normal tap water contains minerals which are harmful to a battery Therefore refill only with distilled water When the machine is not to be used for a month or longer remove the battery and store it in a cool dark place Completely recharge the battery before using If the battery is to be stored fo
79. ssure to do the job CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure deter gent applications such as those available in coin operated car washers 4 Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bottle brush is handy for hard to get at places 5 Rinse the machine off immediately with A WARNING clean water and dry all surfaces with a chamois clean towel or soft absorbent POTENTIAL HAZARD cloth Operation with wet brakes after washing 6 Clean the seat with a vinyl upholstery WHAT CAN HAPPEN cleaner to keep the cover pliable and Wet brakes may have reduced stopping glossy ability increasing the chance of an acci 7 Automotive type wax may be applied to all dent painted and chrome plated surfaces Avoid combination cleaner waxes Many contain abrasives which may mar the paint or pro tective finish When finished start the engine and let it idle for several minutes HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings 9 2 EBU00530 B STORAGE Long term storage 60 days or more of your machine will require some preventive proce dures to guard against deteri
80. t start or run when the engine stop switch is turned to OFF 4 2 EBU00056 Start switch START The starter motor cranks the engine when this switch is pushed CAUTION See starting instructions prior to starting engine see page 6 1 for details NOTE ee If the starter switch is pushed with the main switch ON and the engine stop switch OFF the starter motor will be activated but the engine will not start To start the engine be sure to position the engine stop switch at RUN EBU00062 Throttle lever Before starting the engine check the throttle to Once the engine is running movement of the be sure it is operating smoothly Make sure it throttle lever will increase the engine speed returns to the idle position as soon as the lever Regulate the speed of the machine by varying is released the throttle position Because the throttle is spring loaded the machine will decelerate and A WARNING the engine will return to an idle any time the POTENTIAL HAZARD hand is removed from the throttle lever Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate mak ing it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine If it does not work smoothly check for the cause 1 Throttle lever Correct the problem before riding the ATV Consult
81. tached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking EBU13541 AWARNING Indicates a potential hazard that could result in serious injury or death 6 13 AWARNING Indicates a potential hazard that could result in serious injury or death 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 acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill neces sary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual completely and understand the operation of the controls Pay particular attention to the safety information on pages 2 1 2 7 Please also read all caution and warning labels on your ATV RIDE WITH CARE AND GOOD JUDGEMENT HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regularly practice the skills learned in the course an
82. th use result ing in improper valve timing and engine noise To prevent this the cam chain tensioner must be adjusted regularly This adjustment should be left to a Yamaha service technician EBU01218 Front and rear brake shoe inspection A wear indicator is provided on each brake The indicators allows checking of brake shoe wear without disassembling the brake Apply the brake and check the position of the indicator If the indi cator reaches the wear limit line or mark ask a Yamaha dealer to replace the shoes as a set EBU00323 Front brake lever free play adjustment NOTE Before adjusting the brake inspect the front brake shoes The front brake lever free play should be adjust ed to 10 12 mm 0 4 0 5 in at the brake lever pivot If the free play is incorrect adjust as fol lows 1 Wear limit line 2 Wear indicator 1 Wear limit mark 2 Wear indicator 1 Loosen the upper locknut and fully turn in 5 While applying the front brake turn out the the adjusting bolt upper adjusting bolt until the upper and 2 Loosen the lower locknut lower cable lengths are equal The cable 3 Turn the lower adjusting bolt until specified joint will become vertical free play is obtained 1 Cable joint 1 Upper locknut 2 Upper adjusting bolt f 3 Lower locknut 4 Lower adjusting bolt 6 Tighten the upper locknut Specified free play 10 12 mm 0 4 0 5 in 4 Tighten the lower locknut
83. tion included in this manual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor repairs The tools provided in the owner s tool kit are suffi cient for this purpose except that a torque wrench is also necessary to properly tighten nuts and bolts NOTE If you do not have a torque wrench available during a service operation requiring one take your machine to a Yamaha dealer to check the torque settings and adjust them as necessary 8 2 A WARNING POTENTIAL HAZARD Operating this ATV with improper modifi cations WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situa tions could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used accord ing to instructions If you have questions consult an authorized Yamaha ATV dealer EBU02611 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 intervals However keep in mind that
84. urn the speed limiter back in again adjust it out in stages as you did before Adjusting for maximum throttle lever movement without removing the air intake restrictor plate will cause the engine to run roughly at higher speeds For air intake restrictor plate removal instruc tions see page 8 14 1 Locknut 2 Adjuster Loading and accessories Use extra caution when riding the ATV with addi tional loads such as accessories or cargo The ATV s handling may be adversely affected Reduce your speed when adding additional loads 7 11 MAXIMUM LOADING LIMIT Vehicle loading limit total weight of cargo rider and accessories 95 kg 209 Ib A WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in your Owner s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the footboards during operation Otherwise your feet may contact the rear wheels 7 12 A WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation WHAT CAN HAPPE
85. your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and mainte nance procedures and schedules described in the Owner s Manual 5 2 EBU04762 Front and rear brakes Brake levers and brake pedal Check for correct free play in the brake levers and brake pedal If the free play is incorrect adjust it See pages 8 19 8 23 Check operation of the brake levers and brake pedal They should move smoothly and there should be a firm feeling when the brakes are applied If not have the ATV inspected by a Yamaha dealer 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 perfor mance inspect the brake linings for wear See page 8 18 8 19 A WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any problem with the brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have the ATV inspected by a Yamaha dealer 5 3 EBU13410 Fuel Make sure there is sufficient gasoline in the tank Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity Total 6 8 L 1 5 Imp gal 1 8 US gal Reserve 0

Yamaha 5TH-28199-15 Offroad Vehicle User Manual

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