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Yamaha RAPTOR 50 Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM50RX
This A
WARNING
This ATV should not be ridden by anyone under 6 years of age.
LIT-11626-21-38
5YF-28199-15
Table of Contents
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Summary of Contents for Yamaha RAPTOR 50

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM50RX This A WARNING This ATV should not be ridden by anyone under 6 years of age. LIT-11626-21-38 5YF-28199-15...
  • Page 2 EBU17091...
  • Page 3 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.
  • Page 4 ATV safely. Your ATV was delivered with an adjustable speed limiter. Yamaha recommends that all beginners start off with the speed limiter screw turned in to limit the amount of speed available while they learn. The speed limiter screw may be gradually turned out to increase maximum speed as the beginner becomes more fa- miliar with operating the ATV.
  • Page 5 EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury WARNING...
  • Page 6 EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

  • Page 7: Table Of Contents

    EWB00010 Speed limiter ..........4-5 WARNING Front brake lever ........4-6 Rear brake lever ........4-7 Indicates a potential hazard that could result in Parking brake ..........4-7 serious injury or death. Drive select lever ........4-8 Fuel tank cap ..........4-9 Fuel ............
  • Page 8 Engine break-in ......... 6-5 Engine oil ..........8-10 Parking ............6-5 Final gear oil ..........8-12 Parking on a slope ........6-6 Cleaning the air filter element ....8-14 Accessories and loading ......6-7 Cleaning the spark arrester ..... 8-17 Adjusting the carburetor ......
  • Page 9 Storage ............9-2 SPECIFICATIONS ........10-1 CONSUMER INFORMATION ...... 11-1 Identification numbers ......11-1 Noise regulation ........11-3 Maintenance record ........ 11-4 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY ..11-5 YAMAHA EXTENDED SERVICE (Y.E.S.) ..........11-7...

  • Page 10: Safety Information

    EBU17430 SAFETY INFORMATION SAFETY INFORMATION EBU17632 an ATV with engine size greater than 50 cc. – A child under 12 years old should never oper- AN ATV IS NOT A TOY AND CAN BE HAZARD- ate an ATV with engine size greater than 70 cc. OUS TO OPERATE.
  • Page 11 Never operate at speeds too fast for your skills Never operate the ATV on hills too steep for the or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills.
  • Page 12 Always use proper procedures if you stall or roll times to let friction dry out the linings. backwards when climbing a hill. If you stall or roll Always use the size and type of tires specified in backwards, follow the special procedure for this manual.
  • Page 13 that decision, the ATV Safety Institute publishes a WHAT CAN HAPPEN readiness checklist. It is printed in the Parents, If the child rides beyond his or her abilities, Youngsters and ATVs booklet that was included or rides in terrain that is too difficult, he or with your ATV when newly purchased.
  • Page 14 also wear the safety equipment described in the 1. Push the clip on the end of the engine stop Riding Your ATV section of this manual. switch cord under the engine shut-off switch (black button). Choose an appropriate riding area 2.
  • Page 15 EWB00021 HOW TO AVOID THE HAZARD WARNING If you should swallow some gasoline or in- POTENTIAL HAZARD hale a lot of gasoline vapor, or get some gas- Improper handling of gasoline. oline in your eyes, seek medical help WHAT CAN HAPPEN immediately.
  • Page 16 EWB00030 WARNING POTENTIAL HAZARD Starting or running the engine in a closed ar- WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death with- in a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad- equate ventilation.

  • Page 17: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 18 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer.
  • Page 19 WARNING WARNING Improper ATV use can result in SEVERE INJURY or DEATH. UNDER ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL Operating this ATV if you are under PROTECTIVE the age of 6 increases your chance GEAR...
  • Page 20 WARNING WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN NEVER ride as a CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE passenger. INJURY OR DEATH. OPERATING TIRE PRESSURE: Set with tires cold Passengers can cause 9Recommended : FRONT : 20 kPa, { 0.20 kgf/cm } 2.9 psi a loss of control, REAR : 20 kPa, { 0.20 kgf/cm...

  • Page 21: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Spark arrester 1. Fuel cock 2. Seat 2. Fuse 3. Footboard 3. Engine stop switch with cord (lanyard) 4. Footboard 5. Drive select lever...

  • Page 22: Controls And Instruments

    EBU17712 from the figures shown in this manual. Controls and instruments 1. Rear brake lever 2. Parking brake 3. Neutral indicator light 4. Front brake lever 5. Throttle lever 6. Main switch 7. Fuel tank cap 8. Handlebar switches NOTE: The ATV you have purchased may differ slightly...

  • Page 23: Instrument And Control Functions

    EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17740 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power, and the engine can be started. The key cannot be re- moved.

  • Page 24: Indicator Light

    EBU17781 EBU18061 Indicator light Handlebar switches 1. Neutral indicator light “N” 1. Engine stop switch “ENG. STOP” 2. Start switch “START” EBU17860 Neutral indicator light “ ” EBU18070 Engine stop switch “ENG. STOP” This indicator light comes on when the transmis- Set this switch to “RUN”...

  • Page 25: Engine Stop Switch With Lanyard

    EBU18090 Start switch “START” Push this switch to crank the engine with the start- ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. EBU18260 Engine stop switch with lanyard The clip must be attached to the engine stop 1.
  • Page 26 1. Lanyard 1. Lanyard For further explanation of this switch and the lan- Should the ATV be separated from the parent by a yard, see “TEACHING YOUR CHILD TO OPER- distance longer than the lanyard length, the lan- ATE THE ATV” in the “SAFETY INFORMATION” yard will pull out the clip and stop the engine.

  • Page 27: Throttle Lever

    Check the operation of the throttle lever be- fore you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can’t find or solve the problem yourself. EBU18351 Speed limiter Your ATV was delivered with an adjustable speed limiter.

  • Page 28: Front Brake Lever

    ally turned out as the beginner becomes more fa- EWB00180 WARNING miliar with operating the ATV. 1. Loosen the locknut. POTENTIAL HAZARD 2. To increase the maximum engine power avail- Improper adjustment of the speed limiter and able and the maximum speed of the ATV, turn throttle.

  • Page 29: Rear Brake Lever

    1. Front brake lever 1. Rear brake lever EBU18401 EBU18450 Rear brake lever Parking brake The rear brake lever is located on the left handle- Use the parking brake before starting the engine or bar. To apply the rear brake, pull the brake lever to- parking the ATV, especially on a slope.

  • Page 30: Drive Select Lever

    WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before start- ing the engine. This could cause loss of con- trol or a collision. The brake could overheat if you ride the ATV without releasing the parking brake.

  • Page 31: Fuel Tank Cap

    1. Drive select lever 1. Fuel tank cap 2. Drive position 3. Neutral position EBU18730 Fuel EBU18720 Make sure that there is sufficient fuel in the tank. Fuel tank cap Fill the fuel tank to the bottom of the filler tube as Remove the fuel tank cap by turning it counter- shown.
  • Page 32 Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research oc- tane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premi- um unleaded fuel.

  • Page 33: Fuel Cock

    WHAT CAN HAPPEN Fuel can spill, which can cause a fire and se- vere 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.

  • Page 34: Choke

    FUEL FUEL 1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES” With the fuel cock lever in this position, fuel flows This indicates reserve. With the fuel cock lever in to the carburetor. Turn the fuel cock lever to this this position, the fuel reserve is made available.

  • Page 35: Seat

    Move the choke in direction (b) to turn off the choke. See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Seat lock lever 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.
  • Page 36 1. Projection 2. Seat holder EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 4-14...

  • Page 37: Pre-Operation Checks

    Manual. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer. ITEM...
  • Page 38 ITEM ROUTINE PAGE Check oil level in engine, and add recommended oil to specified Engine oil level if necessary. 5-3, 8-10 Check ATV for oil leakage. Correct if necessary. Final gear oil Check ATV for oil leakage. Correct if necessary. 5-3, 8-12 Check operation, and correct if necessary.

  • Page 39: Fuel

    If not, have the HOW TO AVOID THE HAZARD ATV checked by a Yamaha dealer. Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust Brake operation pipe.

  • Page 40: Throttle Lever

    HOW TO AVOID THE HAZARD vided in this manual, have the ATV checked The tires listed below have been approved by a Yamaha dealer. by Yamaha Motor Co., Ltd. for this model. Other tire combinations are not recom- EBU19761 Throttle lever mended.

  • Page 41: Measuring The Tire Pressure

    Rear: Tire pressure below the minimum speci- Manufacturer/model: fied could cause the tire to dislodge from DUNLOP/KT145 the rim under severe riding conditions. Size: Minimum tire pressure: AT16 x 8-7 Front: Type: 17 kPa (2.5 psi) (0.17 kgf/cm Tubeless Rear: The tires should be set to the recommend- 17 kPa (2.5 psi) (0.17 kgf/cm ed pressure:...

  • Page 42: Tire Wear Limit

    dirt in the gauge could cause the first reading to be incorrect. Recommended pressure: Front 20 kPa (2.9 psi) (0.20 kgf/cm Rear 20 kPa (2.9 psi) (0.20 kgf/cm Minimum: Front 17 kPa (2.5 psi) (0.17 kgf/cm Rear 17 kPa (2.5 psi) (0.17 kgf/cm Maximum: Front 23 kPa (3.3 psi) (0.23 kgf/cm...

  • Page 43: Chassis Fasteners

    1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary. EBU19860 Battery Check the fluid level in the battery. Fill with distilled water if necessary.

  • Page 44: Operation

    See the “Engine break-in” section on page 6-5 a control or function you do not understand, prior to operating the engine for the first time. ask your Yamaha dealer. 1. Set the parking brake. 2. Turn the fuel cock to “ON”.
  • Page 45 Yamaha deal- Ambient temp./choke position er check the electrical circuit. °C 0° 10° 20° 30° NOTE: This model is equipped with an ignition circuit cut- °F 30° 50° 70° 90° off system. The engine can be started under the following conditions.

  • Page 46: Starting A Warm Engine

    crank the engine more than 10 seconds on each EBU27880 Shifting attempt. This ATV has an automatic, centrifugal clutch. 7. If the engine is started with the choke in posi- To shift into the drive position, release the throttle tion (1), the choke should be returned to posi- lever and apply the parking brake.
  • Page 47 EWB00700 WARNING POTENTIAL HAZARD Opening the throttle before releasing the parking brake. WHAT CAN HAPPEN The ATV could wheelie. This would increase the chance of an accident, including over- turn. HOW TO AVOID THE HAZARD Release the parking brake before opening the throttle.

  • Page 48: Engine Break-In

    For this reason, you should read engine break-in period, immediately have a the following material carefully. Yamaha dealer check the ATV. Since the engine is brand new, do not put an ex- cessive load on it for the first 320 km (200 mi) or 20 EBU26770 hours.

  • Page 49: Parking On A Slope

    EBU20790 Parking on a slope EWB00810 WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the ATV trans- 1.

  • Page 50: Accessories And Loading

    Yamaha accessories, nor control over their qual-2 12 0 4 EBU20910 Accessories and loading EBU20920 Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when consid- ering an accessory or operating an ATV which has accessories.
  • Page 51 the following points in mind: speeds. Never exceed the weight limits shown. An over- Avoid hills and rough terrain. Choose terrain loaded ATV can be unstable. carefully. Added weight affects the stability and handling of the ATV. MAXIMUM LOADING LIMIT EWB00750 ATV loading limit (total weight of rider, cargo, WARNING...

  • Page 52: Riding Your Atv

    EBU21131 RIDING YOUR ATV...

  • Page 53: Getting To Know Your Atv

    EWB00010 RIDE WITH CARE AND GOOD JUDGEMENT WARNING Get training if you are inexperienced. Indicates a potential hazard that could result in Beginners should get training from a certified in- serious injury or death. structor. Become familiar with this ATV at slow speeds first, EBU21502 even if you are an experienced operator.
  • Page 54 HOW TO AVOID THE HAZARD should complete the certified training course A child under 6 should never operate an ATV offered by Yamaha. They should then regu- with engine size greater than 50 cc. larly practice the skills learned in the course and the operating techniques described in this Owner’s Manual.
  • Page 55 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 carrying pas- sengers. This ATV is designed to carry operator only – passengers prohibited.
  • Page 56 Apparel HOW TO AVOID THE HAZARD EWB00920 Always wear an approved motorcycle helmet WARNING that fits properly. POTENTIAL HAZARD You should also wear: Operating this ATV without wearing an ap- eye protection (goggles or face shield) proved motorcycle helmet, eye protection gloves and protective clothing.
  • Page 57 Do not operate after consuming alcohol or HOW TO AVOID THE HAZARD drugs. Never consume alcohol or drugs before or The operator’s performance capability is reduced while driving this ATV. by the influence of alcohol or drugs. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety.
  • Page 58 Turning in the adjusting screw limits the maximum engine power available and de- creases the maximum speed of the ATV. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (See page 4-5.) Yamaha recommends that all beginning riders...
  • Page 59 start off with the speed limiter turned in to limit the amount of speed available while they learn. The MAXIMUM LOADING LIMIT limiter may be gradually adjusted to increase max- ATV loading limit (total weight of cargo, rider, imum speed as the beginner becomes more famil- accessories, and tongue): iar with operating the ATV.
  • Page 60 During operation WHAT CAN HAPPEN Always keep your feet on the footboards during op- Removing even one hand or foot can reduce eration, otherwise they may contact the rear your ability to control the ATV or could cause wheels. you to lose your balance and fall off of the ATV.
  • Page 61 Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions.

  • Page 62: Be Careful Where You Ride

    EWB01010 WARNING POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible ma- terial accumulated around the engine area could catch fire. Someone touching the exhaust system dur- ing or after operation could be burned. HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV in dry grass or other dry ground cover.
  • Page 63 EWB01030 HOW TO AVOID THE HAZARD WARNING Always avoid paved surfaces, including side- POTENTIAL HAZARD walks, driveways, parking lots and streets. Operating 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.
  • Page 64 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. EWB01040 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 65 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 especial- ly cautious on these kinds of terrain. EWB01060 WARNING POTENTIAL HAZARD...

  • Page 66: Turning Your Atv

    Do not ride in areas posted “no trespassing”. hot when riding and afterwards; do not allow skin Do not ride on private property without getting per- or clothing to come in contact with these compo- mission. nents. With the engine idling, shift the transmission into the drive position and then release the parking brake.
  • Page 67 low speed. EWB01220 WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN The ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner’s Manual. Prac- tice turning at low speeds before attempting to turn at faster speeds.

  • Page 68: Climbing Uphill

    curves. WHAT CAN HAPPEN Improper riding procedures such as abrupt throttle The ATV can overturn more easily on ex- changes, excessive braking, incorrect body move- tremely steep hills than on level surfaces or ments, or too much speed for the sharpness of the small hills.
  • Page 69 HOW TO AVOID THE HAZARD Always follow proper procedures for climb- ing 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.
  • Page 70 EWB01190 WARNING 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 turning tech- nique as described in the Owner’s Manual on level ground.

  • Page 71: Riding Downhill

    EWB01301 WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dis- mounting while climbing a hill. WHAT CAN HAPPEN Could result in the ATV overturning. HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.

  • Page 72: Crossing A Slope

    hill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- stacles which may appear. EWB01130 WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.

  • Page 73: Crossing Through Shallow Water

    slopes, be sure not to make sharp turns either up When crossing the side of a hill: or down hill. Always follow proper procedures as de- If your ATV does begin to tip over, gradually steer scribed in the Owner’s Manual. in the downhill direction if there are no obstacles in Avoid hills with excessively slippery or loose your path.
  • Page 74 carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and care- fully. EWB01150 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 acci-...

  • Page 75: Riding Over Rough Terrain

    1. Air filter case check hose ECB00240 RIDING OVER ROUGH TERRAIN CAUTION: Riding over rough terrain should be done with cau- After riding your ATV in water, be sure to drain tion. Look out for obstacles which could cause the trapped water by removing the check hose damage to the ATV or could lead to an upset or ac- at the bottom of the air filter case.

  • Page 76: Sliding And Skidding

    EWB01160 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 ob- stacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees.

  • Page 77: What To Do If

    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.
  • Page 78 Lean more into the turn to regain balance. If nec- If your ATV encounters shallow water: essary, gradually let off the throttle and/or steer Ride slowly and carefully through slow moving to the outside of the turn. (See page 7-15.) water, watching for obstacles.

  • Page 79: Periodic Maintenance And Minor Repair

    Safety is an obligation of the owner. Periodic in- nance unless otherwise specified. Have a spection, adjustment and lubrication will keep your Yamaha dealer perform the service if you are ATV in the safest and best operating condition not familiar with maintenance work.
  • Page 80 If you have questions, consult an authorized additional tools such as a torque wrench may be Yamaha ATV dealer. necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform...

  • Page 81: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 82 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 83: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check chain tension. √ √ √ √ Timing chain Adjust if necessary. Every 20–40 hours (more often in wet or Air filter element Clean and replace if necessary.
  • Page 84 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Shock absorber Check operation and correct if necessary. √ √ √ assemblies Check for oil leakage and replace if necessary. Front knuckle piv- √...
  • Page 85 EBU23060 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 86: Checking The Spark Plug

    EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU23211 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- 1.
  • Page 87 If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 1. Spark plug gap 2. Check the spark plug for electrode erosion...

  • Page 88: Engine Oil

    2. Clean the surface of the spark plug gasket To check the engine oil level and its mating surface, and then wipe off any 1. Place the ATV on a level surface. grime from the spark plug threads. 2. Check the engine oil level on a cold engine. 3.
  • Page 89 4. Insert the dipstick into the filler hole (without To change the engine oil screwing it in), and then remove it again to 1. Place the ATV on a level surface. check the oil level. 2. Start the engine, warm it up for several min- utes, and then turn it off.

  • Page 90: Final Gear Oil

    Recommended oil: age before each ride. If any leakage is found, have See page 10-1. a Yamaha dealer check and repair the ATV. In ad- Oil quantity: dition, the final gear oil level must be checked and 0.80 L (0.85 US qt) (0.70 Imp.qt) the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 91 To change the final gear oil NOTE: 1. Place the ATV on a level surface. The final gear oil should be between the minimum 2. Place an oil pan under the final gear case to and maximum level marks. collect the used oil. 3.

  • Page 92: Cleaning The Air Filter Element

    5. Add the specified amount of the recommend- the hose and clean the air filter element and air fil- ed final gear oil, and then check the oil level. ter case. Recommended final gear oil: See page 10-1. Oil quantity: 0.12 L (0.13 US qt) (0.11 Imp.qt) ECB00420 CAUTION:...
  • Page 93 1. Panel 1. Air filter case cover 2. Bolt 2. Air filter case holder 2. Remove the air filter case cover by unhooking the holders. 8-15...
  • Page 94 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 sponge material. 5. Squeeze the excess solvent out of the sponge material and let it dry. ECB00440 CAUTION: Do not twist the sponge material when squeez-...

  • Page 95: Cleaning The Spark Arrester

    7. Apply Yamaha foam air filter oil or other qual- ement removed. This will allow unfiltered air ity foam air filter oil to the sponge material. to enter the engine, causing rapid engine wear and possible engine damage. Addition- NOTE:...

  • Page 96: Adjusting The Carburetor

    2. Remove the tailpipe by pulling it out of the EWB01910 WARNING muffler. 3. Tap the tailpipe lightly, and then use a wire POTENTIAL HAZARD brush to remove any carbon deposits from the Improper cleaning of the spark arrester. spark arrester portion of the tailpipe and inside Hot exhaust system.

  • Page 97: Adjusting The Engine Idling Speed

    Yamaha dealer, who has the necessary profes- NOTE: sional knowledge and experience. The adjustment The engine is warm when it quickly responds to the described in the following section, however, may throttle. be performed by the owner as part of routine main- 2.

  • Page 98: Checking The Throttle Cable Free Play

    To adjustment. prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- EBU27071 vals specified in the periodic maintenance and lu- Checking the throttle cable free play brication chart.

  • Page 99: Adjusting The Front Brake Lever Free Play

    Front brake Rear brake 1. Wear limit line 1. Wear limit mark 2. Wear indicator 2. Wear indicator EBU24320 Adjusting the front brake lever free play The brake lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 100 The brake lever free play should measure 10.0– 12.0 mm (0.39–0.47 in) as shown. If the free play is incorrect, adjust it as follows. 1. Upper locknut 2. Upper adjusting bolt 3. Lower locknut 4. Lower adjusting bolt 1. Brake lever free play 4.

  • Page 101: Adjusting The Rear Brake Lever Free Play

    Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24441 Adjusting the rear brake lever free play The brake lever free play must be checked and, if 1.
  • Page 102 If the specified free play cannot be obtained, scribed above or if the rear brake does not operate proceed with the following steps. correctly, have a Yamaha dealer check the internal 4. Loosen the locknut at the brake lever. rear brake mechanism.

  • Page 103: Checking And Lubricating The Cables

    The operation of the front and rear brake levers essary. If a cable is damaged or does not move should be checked before each ride, and the lever smoothly, have a Yamaha dealer check or replace pivots should be lubricated if necessary. 8-25...

  • Page 104: Checking The Wheel Hub Bearings

    If there is play in a wheel hub or if a wheel does not turn smoothly, 1. Grease nipple have a Yamaha dealer check the wheel hub bear- ings. EBU25101 Lubricating the steering shaft...
  • Page 105 charge quickly. The electrolyte level, battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrica- tion chart. To check the electrolyte level 1. Place the ATV on a level surface. 2.
  • Page 106 EWB02140 hose routing. WARNING To store the battery POTENTIAL HAZARD If the ATV will not be used for more than one Failure to handle batteries or battery electro- month, the battery will need to be removed and lyte carefully. stored as follows. WHAT CAN HAPPEN 1.
  • Page 107 ECB00600 CAUTION: Do not leave or store the battery on its side. 3. If the battery will be stored for more than two months, check the specific gravity of the elec- trolyte at least once a month and fully charge the battery whenever necessary.

  • Page 108: Replacing The Fuse

    1. Turn the key to “OFF” and turn off all electrical 4. If the fuse immediately blows again, have a circuits. Yamaha dealer check the electrical system. ECB00640 CAUTION: EBU25650 Removing a wheel To prevent accidental short-circuiting, turn off 1.

  • Page 109: Installing A Wheel

    Front Rear 1. Wheel nut 1. Wheel nut 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. EBU27480 Installing a wheel 1. Install the wheel and the nuts. NOTE: When installing the wheel, make sure its arrow mark...
  • Page 110 wheel. Rear Front 1. Arrow mark 2. Lower the ATV to the ground. 1. Arrow mark 3. Tighten the wheel nuts to the specified torques. Tightening torques: Front wheel nut: 28 Nm (2.8 m·kgf, 20 ft·lbf) Rear wheel nut: 28 Nm (2.8 m·kgf, 20 ft·lbf) 8-32...

  • Page 111: Troubleshooting

    However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.

  • Page 112: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.

  • Page 113: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25870 applications such as those available in coin- Cleaning operated car washers. Frequent, thorough cleaning of your ATV will not 4. Once most of the dirt has been hosed off, only enhance its appearance but will improve its wash all surfaces with warm water and mild, general performance and extend the useful life of detergent-type soap.

  • Page 114: Storage

    EWB02300 nia) and areas where strong chemicals are WARNING stored. POTENTIAL HAZARD Operation with wet brakes after washing. Long-term WHAT CAN HAPPEN Before storing your ATV for several months: Wet brakes may have reduced stopping abil- 1. Follow all the instructions in the “Cleaning” ity, increasing the chance of an accident.
  • Page 115 plug, and then place the spark plug on the 8-26. cylinder head so that the electrodes are NOTE: grounded. (This will limit sparking during Make any necessary repairs before storing the the next step.) ATV. d. Turn the engine over several times with the starter.

  • Page 116: Specifications

    EBU25960 SPECIFICATIONS Bore × stroke: EBU2597A 39.0 × 41.4 mm (1.54 × 1.63 in) Compression ratio: Dimensions: 10.30 :1 Overall length: Starting system: 1537 mm (60.5 in) Electric starter Overall width: Lubrication system: 825 mm (32.5 in) Wet sump Overall height: Engine oil: 915 mm (36.0 in) Type:...
  • Page 117 Engine oil quantity: Transmission: Periodic oil change: Primary reduction system: 0.80 L (0.85 US qt) (0.70 Imp.qt) Spur gear Final gear oil: Primary reduction ratio: Type: 65/20 (3.250) SAE80 API GL-4 Hypoid gear oil Secondary reduction system: Quantity: Shaft drive 0.12 L (0.13 US qt) (0.11 Imp.qt) Secondary reduction ratio: 19/18 ×...
  • Page 118 Rear tire: Rim size: 7 x 5.5AT Type: Rear wheel: Tubeless Size: Wheel type: AT16 x 8-7 Panel wheel Manufacturer/model: Rim size: DUNLOP/KT145 7 x 6.5AT Loading: Front brake: Maximum loading limit: Type: 40.0 kg (88 lb) Drum brake (Total weight of rider, cargo, accessories, and tongue) Operation: Tire air pressure (measured on cold tires): Right hand operation...
  • Page 119 Electrical system: Ignition system: Charging system: AC magneto Battery: Model: 12N7D-3B Voltage, capacity: 12 V, 7.0 Ah Bulb voltage, wattage x quantity: Neutral indicator light: 12 V, 1.7 W × 1 Fuses: Main fuse: 5.0 A 10-4...

  • Page 120: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 121 EBU26050 Model label The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- 11-2...

  • Page 122: Noise Regulation

    EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign 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.

  • Page 123: Maintenance Record

    EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.

  • Page 124: Yamaha Motor Corporation, U.s.a. Atv Limited Warranty

    (6) months from the date of purchase. appropriate owner’s manual; YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 2. Give notice to an authorized Yamaha ATV dealer OTHER WARRANTY OF ANY KIND, EXPRESSED OR of any and all apparent defects within ten (10) days DURING THE PERIOD OF WARRANTY any authorized IMPLIED.
  • Page 125 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

  • Page 126: Yamaha Extended Service (Y.e.s.)

    Yamaha people who handle your warranty – and it Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn’t limited to much more valuable! “moving par ts”...
  • Page 127 Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
  • Page 128 EBU26132 11-9...
  • Page 129 INDEX Engine stop switch ............4-2 Engine stop switch with lanyard ........4-3 Accessories and loading ..........6-7 Air filter element, cleaning..........8-14 Final gear oil............5-3 8-12 Front knuckle pivots, lubricating........8-26 Battery..............5-7 8-26 Fuel ................ 4-9 Brake lever free play, adjusting the front...... 8-21 Fuel cock..............
  • Page 130 Troubleshooting chart ..........8-34 Neutral indicator light ............. 4-2 Noise regulation ............11-3 Valve clearance............8-20 Vehicle identification number ........11-1 Owner’s manual and tool kit........... 8-1 Warranty, extended............11-7 Warranty, limited ............11-5 Parking ................6-5 Wheel hub bearings, checking ........8-26 Parking brake ..............
  • Page 132 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2007.06-1.0x1 !
  • Page 133 8 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.
  • Page 134 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES FIRST CLASS PERMIT NO. 4 CYPRESS, CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U.S.A. P.O. BOX 6555 CYPRESS, CALIFORNIA 90630-9989 ATTN: SALES ADMINISTRATION...

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