Yamaha Offroad Vehicle 43D F8199 10 User Manual

READ THIS MANUAL CAREFULLY!

It contains important safety information.

OWNER’S MANUAL

YFM90RY

This A

WARNING

This ATV should not be ridden by anyone under 12 years of age.

LIT-11626-22-13

43D-F8199-10

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INTRODUCTION

Congratulations on your purchase of the Yamaha YFM90RY. This ATV represents the result of many years

of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the

purchase of this Yamaha, you can now appreciate the high degree of 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 ATV.

This manual includes important safety information. It provides information about special tech-

niques and skills necessary to ride the ATV. It also includes basic maintenance and inspection proce-

dures. If you have any questions regarding the operation or maintenance of your ATV, please consult a

Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE:

READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE-

LY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

PAY CLOSE ATTENTION TO THE WARNING AND NOTICELABELS ON THE ATV.

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 INFORMA-

TION.

THIS ATV, AND ANY OTHER ATV OVER 70 cc, SHOULD 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

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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 . Yamaha recommends that all beginners start off

to limit the amount of speed available while they learn. The adjusting screw may be gradually turned out

as the beginner becomes more familiar with operating the ATV. Parents should decide when to adjust

the ATV for more power as their youngster’s riding skills improve. Once the ATV rider can operate with

skill at the top speed permitted by adjusting the vehicle speed limiter alone, the engine speed limiter

plate can be removed. Since removal of this limiter will result in a significant increase in power, turn the

vehicle speed limiter adjusting screw completely back in again; adjust it out in stages as done previously.

If your child is a beginner or is inexperienced, he or she should take a training course. See the previous

page for information about the free training available to purchasers of new ATVs.

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IMPORTANT MANUAL INFORMATION

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:

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this

symbol to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

WARNING

A NOTICE indicates special precautions that must be taken to avoid

damage to the vehicle or other property.

NOTICE

A TIP provides key information to make procedures easier or clearer.

* Product and specifications are subject to change without notice.

TIP

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IMPORTANT NOTICE

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.

Please check your local riding laws and regulations before operating this ATV.

YFM90RY

OWNER’S MANUAL

1st edition, July 2008

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in Taiwan.

P/N LIT-11626-22-13

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Rear brake lever ....................................... 4-6

Parking brake ............................................ 4-7

Fuel tank cap ............................................ 4-8

Fuel ........................................................... 4-8

Fuel cock .............................................. 4-10

Choke ..................................................... 4-11

Seat ........................................................ 4-11

Kick starter ............................................. 4-12

WARNING

A WARNING indicates a hazardous situation

which, if not avoided, could result in death

or serious injury.

TABLE OF CONTENTS

PRE-OPERATION CHECKS.........................5-1

Pre-operation check list............................5-1

Fuel ........................................................... 5-3

Engine oil .................................................. 5-3

Final transmission oil ................................ 5-3

Front and rear brakes ............................... 5-3

Throttle lever ............................................. 5-4

Tires .......................................................... 5-4

Measuring the tire pressure ...................... 5-5

Tire wear limit ........................................... 5-6

Chassis fasteners ..................................... 5-7

Instruments and switches ......................... 5-7

SAFETY INFORMATION..............................1-1

LOCATION OF THE WARNING AND

SPECIFICATION LABELS............................2-1

DESCRIPTION ..............................................3-1

Left view.....................................................3-1

Right view...................................................3-1

Controls and instruments...........................3-2

INSTRUMENT AND CONTROL

FUNCTIONS..................................................4-1

Main switch...............................................4-1

Handlebar switches ................................... 4-2

Throttle lever ............................................. 4-3

Speed limiters............................................. 4-3

Vehicle speed limiter ................................. 4-4

Engine speed limiter plate.......................... 4-5

Front brake lever ........................................ 4-6

OPERATION................................................6-1

Starting a cold engine ............................... 6-1

Starting a warm engine ............................. 6-3

Engine break-in ........................................ 6-4

Parking.....................................................6-4

Parking on a slope ................................... 6-5

Accessories and loading .......................... 6-6

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Cleaning the spark arrester ...................... 8-19

Adjusting the carburetor ........................... 8-20

Adjusting the engine idling speed ............ 8-20

Checking the throttle cable free play ....... 8-21

Timing chain ............................................ 8-22

Brakes ..................................................... 8-22

Valve clearance ....................................... 8-22

Checking the front brake shoes................ 8-22

Adjusting the front brake lever free

play ....................................................... 8-23

Checking the rear brake pads ................. 8-25

Checking the brake fluid level ................. 8-25

Changing the rear brake fluid .................. 8-26

Checking the rear brake lever free

RIDING YOUR ATV ...................................... 7-1

GETTING TO KNOW YOUR ATV...............7-2

RIDE WITH CARE AND GOOD

JUDGEMENT............................................ 7-2

BE CAREFUL WHERE YOU RIDE...........7-11

TURNING YOUR ATV..............................7-15

CLIMBING UPHILL....................................7-17

RIDING DOWNHILL..................................7-20

CROSSING A SLOPE................................7-21

CROSSING THROUGH SHALLOW

WATER ................................................... 7-22

RIDING OVER ROUGH TERRAIN...........7-24

SLIDING AND SKIDDING.........................7-25

WHAT TO DO IF.......................................7-26

WHAT TO DO... ........................................ 7-26

play ........................................................8-26

Checking and lubricating the cables........ 8-27

Checking and lubricating the front

PERIODIC MAINTENANCE AND MINOR

and rear brake levers............................... 8-27

Checking the wheel hub bearings ............ 8-28

Battery ..................................................... 8-28

Replacing the fuse ................................... 8-30

Removing a wheel ................................... 8-32

Installing a wheel ..................................... 8-33

Troubleshooting ....................................... 8-34

Troubleshooting chart .............................. 8-35

CLEANING AND STORAGE.........................9-1

REPAIR..........................................................8-1

Owner’s manual and tool kit ...................... 8-1

Periodic maintenance chart for the

emission control system .......................... 8-3

General maintenance and lubrication

chart ........................................................ 8-5

Checking the spark plug ............................. 8-9

Engine oil ................................................. 8-11

Final transmission oil ................................ 8-14

Cleaning the air filter element .................. 8-15

Cleaning ..................................................... 9-1

Storage ...................................................... 9-2

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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

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SAFETY INFORMATION

– A child under 12 years old should never oper-

AN ATV IS NOT A TOY AND CAN BE HAZARD-

OUS TO OPERATE.

ate an ATV with engine size greater than 70 cc.

– A child under 16 years old should never oper-

ate an ATV with engine size greater than 90 cc.

Never allow a child under age 16 to operate an

ATV without adult supervision, and never allow

continued 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.

An ATV handles differently from other vehicles, in-

cluding motorcycles and cars. A collision or roll-

over can occur quickly, even during routine

maneuvers such as turning and riding on hills or

over obstacles, if you fail to take proper precau-

tions.

SEVERE INJURY OR DEATH can result if you do

not follow these instructions:

Always avoid operating an ATV on any paved

surfaces, including sidewalks, driveways, park-

ing 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 ap-

proved motorcycle helmet that fits properly. You

should also wear eye protection (goggles or face

shield), gloves, boots, a long-sleeved shirt or a

jacket, and long pants.

Read this manual and all labels carefully and fol-

low the operating procedures described.

Never operate an ATV without proper training or

instruction.Take a Training Course. Beginners

should receive training from a certified instruc-

tor. 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:

Never consume alcohol or drugs before or while

1-1

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operating this ATV.

speeds and never turn at excessive speeds.

Never operate the ATV on hills too steep for the

ATV or for your abilities. Practice on smaller hills

before attempting larger hills.

Never operate at speeds too fast for your skills

or the riding conditions. Always go at a speed

that is proper for the terrain, visibility, operating

conditions, and your experience.

Never attempt wheelies, jumps, or other stunts.

Always inspect your ATV each time you use it to

make sure it is in safe operating condition. Al-

ways follow the inspection and maintenance

procedures and schedules described in this

manual.

Always keep both hands on the handlebars and

both feet on the footrests of the ATV during op-

eration.

Always go slowly and be extra careful when op-

erating on unfamiliar terrain. Always be alert to

changing terrain conditions when operating the

ATV.

Never operate on excessively rough, slippery or

loose terrain until you have learned and prac-

ticed 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

Always follow proper procedures for climbing

hills as described in this manual. Check the ter-

rain carefully before you start up any hill. Never

climb hills with excessively slippery or loose sur-

faces. 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 ve-

hicle 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 sur-

faces. 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 tech-

nique described in this manual on level ground.

1-2

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Avoid crossing the side of a steep hill if possible.

Always use proper procedures if you stall or roll

backwards when climbing a hill. To avoid stall-

ing, use the proper gear and maintain a steady

speed when climbing a hill. If you stall or roll

backwards, follow the special procedure for

braking described in this manual. Dismount on

the uphill side or to a side if pointed straight up-

hill. Turn the ATV around and remount, following

the procedure described in this manual.

Always 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 obsta-

cles as described in this manual.

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 of tires specified in

this manual.

Always maintain proper tire pressure as de-

scribed in this manual.

Never modify an ATV through improper installa-

tion or use of accessories.

Never exceed the stated load capacity for an

ATV. Cargo should be properly distributed and

securely attached. Reduce speed and follow in-

structions in this manual for carrying cargo or

pulling a trailer. Allow greater distance for brak-

ing.

FOR MORE INFORMATION ABOUT ATV SAFE-

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 re-

duce the chance of skidding or sliding out of con-

trol.

Never operate an ATV in fast flowing water or in

water deeper than that recommended in this

manual. Remember that wet brakes may have

TY,

call the Consumer Products Safety Commis-

sion at 1-800-638-2772, or the ATV Distributor’s

Safety Hotline at 1-800-852-5344.

WARNING

POTENTIAL HAZARD

Improper handling of gasoline.

WHAT CAN HAPPEN

Gasoline can catch fire and you could be

burned.

1-3

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HOW TO AVOID THE HAZARD

Always turn off the engine when refueling.

Do not refuel right after the engine has been

running and is still very hot.

Do not spill gasoline on the engine or ex-

haust pipe/muffler when refueling.

Never refuel while smoking, or in the vicinity

of sparks, open flames, or other sources of

ignition such as the pilot lights of water heat-

ers and clothes dryers.

When transporting the ATV in another vehi-

cle, be sure it is kept upright and that the fuel

cock is in the “OFF” position. Otherwise, fuel

may leak out of the carburetor or fuel tank.

WHAT CAN HAPPEN

Gasoline is poisonous and can cause inju-

ries.

HOW TO AVOID THE HAZARD

If you should swallow some gasoline or in-

hale a lot of gasoline vapor, or get some gas-

oline in your eyes, seek medical help

immediately. If gasoline spills on your skin,

wash with soap and water. If gasoline spills

on your clothing, change your clothes.

WARNING

POTENTIAL HAZARD

Starting or running the engine in a closed ar-

ea.

WHAT CAN HAPPEN

Exhaust fumes are poisonous and may

cause loss of consciousness and death with-

in a short time.

HOW TO AVOID THE HAZARD

Always operate your ATV in an area with ad-

equate ventilation.

1-4

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LOCATION OF THE WARNING AND SPECIFICATION LABELS

Read and understand all of the labels on your ATV. These labels contain important information for safe and

proper operation.

Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace-

ment label from your Yamaha dealer.

2-1

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2-2

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2-3

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DESCRIPTION

Left view

Right view

1. Fuel cock

2. Rear wheel

3. Footrest

1. Spark arrester

2. Seat

3. Footrest

4. Front wheel

3-1

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Controls and instruments

TIP

The ATV you have purchased may differ slightly

from the figures shown in this manual.

8 7

1. Rear brake lever

2. Parking brake

3. Front brake lever

4. Throttle lever

5. Main switch

6. Fuel tank cap

7. Handlebar switches

8. Choke

3-2

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INSTRUMENT AND CONTROL FUNCTIONS

WARNING

A WARNING indicates a hazardous situation

which, if not avoided, could result in death

or serious injury.

OFF

Main switch

The positions of the main switch are as follows:

O F F

All electrical systems are supplied with power, and

the engine can be started. The key cannot be re-

moved.

1. Main switch

OFF

All electrical systems are off. The key can be re-

moved.

4-1

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Start switch “START”

Handlebar switches

Push this switch to crank the engine with the start-

er. See the starting instructions onpage 6-1 prior

to starting the engine.

1. Engine stop switch “ENG. STOP”

2. Start switch “START”

Engine stop switch “ENG. STOP”

Set this switch to “RUN” before starting the engine.

The engine stop switch controls the ignition and

stops the engine when it is running. Use this switch

to stop the engine in an emergency situation. The

engine will not start or run when this switch is set

to “OFF”.

4-2

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Throttle lever

Once the engine is running, movement of the throt-

tle lever will increase the engine speed.

WARNING

POTENTIAL HAZARD

Malfunction of throttle.

Regulate the speed of the ATV by varying the

throttle position. Because the throttle is spring-

loaded, the ATV will decelerate, and the engine will

return to an idle any time the hand is removed from

the throttle lever.

WHAT CAN HAPPEN

The throttle could be hard to operate, making

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 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.

Speed limiters

Your ATV was delivered with two speed limiter

devices. A vehicle speed limiter adjusting screw

and a removable engine speed limiter plate.

Yamaha recommends that all beginning riders start

off with the vehicle speed limiter adjusting screw fully

turned in and the engine speed limiter plate installed

to limit the amount of speed available while they learn.

1. Throttle lever

Before starting the engine, check the throttle to be

sure it is operating smoothly. Make sure it returns

to the idle position as soon as the lever is released.

4-3

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The vehicle speed limiter keeps the throttle from fully

opening, even when the throttle lever is pushed to the

maximum. The adjusting screw may be gradually

turned outasthe beginner becomes morefamiliar 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

vehicle speed limiter alone, the engine speed limiter

plate can be removed. Since removal of this limiter

will result in a significant increase in power, turn the

vehicle speed limiter adjusting screw completely back

in again; adjust it out in stages as done previously.

(b)

(a)

1. Locknut

2. Adjusting screw

3. No more than 11 mm (0.4 in)

Vehicle speed limiter

3. Tighten the locknut.

1. Loosen the locknut.

2. To increase the maximum engine power available

and the maximum speed of the ATV, turn the

adjusting screw in direction (a). To decrease

the maximum engine power available and the

maximum speed of the ATV, turn the adjusting

screw in direction (b).

4-4

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4. Tighten the screw.

5. Install the seat.

WARNING

POTENTIAL HAZARD

Improper adjustment of the speed limiter and

throttle.

WHAT CAN HAPPEN

The throttle cable could be damaged. Im-

proper throttle operation could result. The

child could lose control, have an accident or

be injured.

HOW TO AVOID THE HAZARD

Do not turn the adjusting screw out more

than 5 mm (0.2 in).

1. Speed limiter plate

2. Screws

Engine speed limiter plate

With this plate installed, the engine speed is limited

to 4800 r/min. With this plate removed, top engine

speed (8000 r/min) is available.

TIP

Store the speed limiter plate with the owner’s manual

so that it is readily available whenever you want to

reduce the top engine speed.

Remove the plate as follows.

1. Remove the seat. (See page 4-11.)

2. Loosen the screws.

3. Pull the plate out of its case.

4-5

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Rear brake lever

The rear brake lever is located on the left handle-

bar. To apply the rear brake, pull the brake lever to-

ward the handlebar grip.

Front brake lever

The front brake lever is located on the right handle-

bar. To apply the front brake, pull the brake lever

toward the handlebar grip.

1. Rear brake lever

1. Front brake lever

4-6

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Parking brake

WARNING

Use the parking brake before starting the engine or

parking the ATV, especially on a slope. Apply the

front bake lever and push down the lock button to

apply the parking brake. Squeeze the front brake

lever to release the parking brake.

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 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. 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 starting

the engine.

Always be sure you have released the park-

ing brake before you begin to ride.

1. Parking brake lock button

4-7

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Fuel tank cap

Remove the fuel tank cap by turning it counter-

clockwise.

1. Fuel level

2. Filler tube

Recommended fuel:

UNLEADED GASOLINE ONLY

Fuel tank capacity:

4.8 L (1.27 US gal) (1.06 Imp.gal)

1. Fuel tank cap

Fuel reserve amount:

1.0 L (0.26 US gal) (0.22 Imp.gal)

Fuel

Make sure that there is sufficient fuel in the tank.

Fill the fuel tank to the bottom of the filler tube as

shown.

4-8

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NOTICE

WARNING

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.

POTENTIAL HAZARD

Improper care when refueling.

WHAT CAN HAPPEN

Fuel can spill, which can cause a fire and se-

vere injury.

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. Unleaded fuel will give you long-

er spark plug life and reduced maintenance cost.

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 is still very hot.

Gasohol

There are two types of gasohol: gasohol contain-

ing ethanol and that containing methanol. Gasohol

containing ethanol can be used if the ethanol con-

tent does not exceed 10%. Gasohol containing

methanol is not recommended by Yamaha be-

cause it can cause damage to the fuel system or

ATV performance problems.

4-9

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With the fuel cock lever in this position, fuel flows

to the carburetor. Turn the fuel cock lever to this

position when starting the engine and riding.

Fuel cock

The fuel cock supplies fuel from the tank to the car-

buretor while also filtering it.

The fuel cock lever positions are explained as fol-

lows and shown in the illustrations.

RES

OFF

1. Lever positioned over “RES”

FUEL

1.Lever positioned over “OFF”

FUEL

This indicates reserve. With the fuel cock lever in

this position, the fuel reserve is made available.

Turn the fuel cock lever to this position if you run

out of fuel while riding. When this occurs, refuel as

soon as possible and be sure to turn the fuel cock

lever back to “ON”!

With the fuel cock lever in this position, fuel will not

flow. Always turn the fuel cock lever to this position

when the engine is not running.

1. Lever positioned over “ON”

FUEL

4-10

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Choke

Seat

The choke is used to start a cold engine.

Move the choke in direction (a) to turn on the

choke.

To remove the seat

Pull the seat lock lever upward and pull up the seat

at the rear.

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

(a)

(b)

1. Fully open “ON”

2. Half open (warming up position)

3. Closed “OFF”

4. Choke

4-11

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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.

2. Move the kickstarter lever down lightly with your

foot until the gears engage, and then push it

down smoothly but forcefully.

TIP

Make sure that the seat is securely fitted.

1. Kickstarter

NOTICE

1. Projection

Do not use the kickstarter if there is no battery

installed or if the battery leads are disconnected.

2. Seat holder

Kickstarter

A kickstarter lever is located under the seat to use

if the battery is discharged.

1. Install the kickstarter lever.

WARNING

A WARNING indicates a hazardous situation

which, if not avoided, could result in death

or serious injury.

4-12

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PRE-OPERATION CHECKS

Pre-operation check list

Before operating this ATV, be sure to check the items listed in the following table.

WARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

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 it is in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in the Own-

er's Manual.

TIP

The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the "Periodic

maintenance and lubrication charts" on page 8-3 to determine which service should be performed by a

Yamaha dealer.

5-1

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ITEM

ROUTINE

PAGE

Check fuel level in fuel tank, and add recommended fuel if neces-

Fuel

4-8, 5-3

sary.

Check fuel line for leakage. Correct if necessary.

Check oil level in engine, and add recommended oil to specified

level if necessary.

Check ATV for oil leakage. Correct if necessary.

Check operation, and correct if necessary.

Lubricate cable if necessary.

Engine oil

5-3, 8-11

5-3, 8-14

Final transmission oil

Front brake

5-3, 8-22, 8-23

Check lever free play, and adjust if necessary.

Check operation. If soft or spongy, have Yamaha dealer bleed

hydraulic system.

Check brake pads for wear, and replace if necessary.

Check brake fluid level in reservoir, and add recommended brake

fluid to specified level if necessary.

Rear brake

5-3, 8-25, 8-26

Check hydraulic system for leakage. Correct if necessary.

Make sure that operation is smooth, and check cable free play.

Lubricate cable and lever housing if necessary.

Throttle lever

5-4, 8-21

8-27

Make sure that operation is smooth. Lubricate if necessary.

Control cables

Check wheel condition, and replace if damaged.

Check tire condition and tread depth. Replace if necessary.

Check air pressure. Correct if necessary.

Wheels and tires

5-4, 5-5, 5-6

Make sure that operation is smooth. Lubricate lever pivoting points

if necessary.

Brake levers

8-27

Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened.

5-7

Instruments and switches Check operation, and correct if necessary.

5-2

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Final transmission oil

Fuel

Make sure that the final transmission oil is at the

Make sure that there is sufficient fuel in the tank.

(See page 4-8.)

specified level. Add oil as necessary.

(See page 8-14.)

Front and rear brakes

Brake levers

WARNING

POTENTIAL HAZARD

Check for correct free play in the brake levers. If

the free play is incorrect, adjust it. (See pages

8-23 and 8-26.)

Check operation of the levers. They should

move smoothly and there should be a firm feel-

ing when the brakes are applied. If not, have the

ATV checked by a Yamaha dealer.

Improper care when refueling.

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

Brake fluid level

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 is still very hot.

Check the brake fluid level. Add fluid if necessary.

(See page 8-25.)

Recommended brake fluid:

DOT4

Brake fluid leakage

Check to see if any brake fluid is leaking out of the

pipe joint or brake fluid reservoir. Apply the brake

firmly for one minute. If there is any leakage, have a

Yamaha dealer check the brake system.

Engine oil

Make sure that the engine oil is at the specified lev-

el. Add oil as necessary. (See page 8-11.)

5-3

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Brake operation

Tires

Test the brakes at slow speed after starting out to

make sure they are working properly. If the brakes

do not provide proper braking performance, check

the brakes for wear. (See pages 8-22 and 8-25.)

WARNING

POTENTIAL HAZARD

Operating this ATV with improper tires, or

with improper or uneven tire pressure.

WHAT CAN HAPPEN

WARNING

POTENTIAL HAZARD

Use of improper tires on this ATV, or opera-

tion of this ATV with improper or uneven tire

pressure, may cause loss of control, increas-

ing your risk of accident.

HOW TO AVOID THE HAZARD

The tires listed below have been approved

by Yamaha Motor Co., Ltd. for this model.

Other tire combinations are not recom-

mended.

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 prob-

lem with the brakes. If a problem cannot be

corrected by the adjustment procedures pro-

vided in this manual, have the ATV checked

by a Yamaha dealer.

Front:

Manufacturer/model:

MAXXIS/M939

Size:

AT18 x 7-8

Type:

Throttle lever

Check the operation of the throttle lever. It must

open smoothly and spring back to the idle position

when released. Have a Yamaha dealer correct if

necessary.

Tubeless

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Rear:

Manufacturer/model:

MAXXIS/M940

Size:

AT18 x 9-8

Type:

Tire pressure below the minimum speci-

fied could cause the tire to dislodge from

the rim under severe riding conditions.

Minimum tire pressure:

Front:

22 kPa (3.2 psi) (0.22 kgf/cm )

Tubeless

Rear:

The tires should be set to the recommend-

ed pressure:

Recommended tire pressure:

Front:

25 kPa (3.6 psi) (0.25 kgf/cm )

Rear:

25 kPa (3.6 psi) (0.25 kgf/cm )

Check and adjust tire pressures when

the tires are cold.

22 kPa (3.2 psi) (0.22 kgf/cm )

Use no more than the following pressures

when seating the tire beads.

Maximum tire seating pressure:

Front:

250 kPa (36 psi) (2.5 kgf/cm )

Rear:

250 kPa (36 psi) (2.5 kgf/cm )

Higher pressures and fast inflation may

cause a tire to burst. Inflate the tires very

slowly and carefully.

Tire pressures must be equal on both

sides.

Measuring the tire pressure

Use the low-pressure tire gauge.

TIP

The low-pressure tire gauge is included as stan-

dard equipment. Make two measurements of the

tire pressure and use the second reading. Dust or

5-5

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dirt in the gauge could cause the first reading to be

incorrect.

Recommended pressure:

Front

25 kPa (3.6 psi) (0.25 kgf/cm )

Rear

25 kPa (3.6 psi) (0.25 kgf/cm )

Minimum:

Front

22 kPa (3.2 psi) (0.22 kgf/cm )

Rear

22 kPa (3.2 psi) (0.22 kgf/cm )

1. Low-pressure tire gauge

Set the tire pressure when the tires are cold. Set

the tire pressures to the following specifications:

Tire wear limit

Replace the tire when the tire groove decreases to

3 mm (0.12 in).

5-6

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1. Tire wear limit

Chassis fasteners

Make sure that all nuts, bolts and screws are prop-

erly tightened.

Instruments and switches

Check that all instruments and switches are

working properly. Correct if necessary.

5-7

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OPERATION

Starting a cold engine

WARNING

A WARNING indicates a hazardous situation

which, if not avoided, could result in death

or serious injury.

WARNING

POTENTIAL HAZARD

Frozen control cables in cold weather.

WHAT CAN HAPPEN

You could be unable to control the ATV,

which could lead to an accident or collision.

HOW TO AVOID THE HAZARD

When riding in cold weather, always make

sure all control cables work smoothly before

you begin riding.

WARNING

POTENTIAL HAZARD

Operating ATV without being familiar with all

controls.

WHAT CAN HAPPEN

Loss of control, which could cause an acci-

dent 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.

NOTICE

See the “Engine break-in” section on page 6-4

prior to operating the engine for the first time.

1. Set the parking brake.

2. Turn the fuel cock to “ON”.

3. Turn the main switch to “ON” and the engine

stop switch to “RUN”.

6-1

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Ambient temp./choke position

TIP

This model is equipped with an ignition circuit cut-

off system. The engine can be started only when

the rear brake lever is applied.

0°

10°

50°

20°

70°

30°

°C

30°

90° °F

4. Use the choke in reference to the figure:

Position (1):

Cold engine start with ambient temperature be-

low 30 °C (90 °F).

Position (2):

Warming up position.

1. Fully open “ON”

2. Half open (warming up position)

3. Closed “OFF”

4. Choke

Position (3):

Cold engine start with ambient temperature

above 25 °C (80 °F).

5. Completely close the throttle lever and start

the engine by pushing the start switch.

TIP

If the engine fails to start, release the start switch,

then push it again. Pause a few seconds before

the next attempt. Each cranking should be as short

as possible to preserve battery energy. Do not

6-2

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crank the engine more than 10 seconds on each

attempt.

To start out and accelerate

1. Squeeze the front brake lever to release the

parking brake.

2. Gradually open the throttle while slowly re-

leasing the rear brake lever.

6. If the engine is started with the choke in posi-

tion (1), the choke should be returned to posi-

tion (2) to warm up the engine. If the engine is

started with the choke in position (2), keep the

choke in this position to warm up the engine.

NOTICE

WARNING

For maximum engine life, always warm the en-

gine up before starting off. Never accelerate

hard when the engine is cold!

POTENTIAL HAZARD

Opening the throttle before releasing the

parking brake.

WHAT CAN HAPPEN

7. Continue warming up the engine until it idles

smoothly, then return the choke to position (3)

before riding.

The ATV could wheelie. This would increase

the chance of an accident, including over-

turn.

TIP

HOW TO AVOID THE HAZARD

Release the parking brake before opening

the throttle. Open the throttle gradually.

The engine is warm when it responds normally to

the throttle with the choke turned off.

To decelerate

Starting a warm engine

When slowing down or stopping, release the throt-

tle and apply the brakes smoothly and evenly. Im-

proper use of the brakes can cause the tires to lose

traction, reducing control and increasing the possi-

bility of an accident.

Follow the same procedure as for starting a cold

engine, with the exception that the choke is not re-

quired when the engine is warm. Instead, start the

engine with the throttle slightly open.

6-3

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0–160 km (0–100 mi) or 0–10 hours

Avoid prolonged operation above 1/2 throttle. Vary

the speed of the ATV regularly. Do not operate it at

one set throttle position.

160–320 km (100–200 mi) or 10–20 hours

Avoid prolonged operation above 3/4 throttle. Rev

the engine freely, but do not use full throttle at any

time.

NOTICE

Do not tow the ATV for long distances. The

transmission is properly lubricated only when

the engine is running. Inadequate lubrication

may damage the transmission.

320 km (200 mi) or 20 hours and beyond

The ATV can now be operated normally.

Engine break-in

There is never a more important period in the life of

your engine than the first 320 km (200 mi) or 20

hours of riding. For this reason, you should read

the following material carefully.

Since the engine is brand new, do not put an ex-

cessive load on it for the first 320 km (200 mi) or 20

hours. The various parts in the engine wear and

polish themselves to the correct operating clear-

ances. During this period, prolonged full-throttle

operation or any condition that might result in en-

gine overheating must be avoided.

NOTICE

If any engine trouble should occur during the

engine break-in period, immediately have a

Yamaha dealer check the ATV.

Parking

When parking the ATV, stop the engine, shift the

drive select lever into the drive position, apply the

parking brake, and then turn the fuel cock to “OFF”.

6-4

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Parking on a slope

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-

versely across the incline, stop the engine, apply

the parking brake, and then 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 easily.

1. Parking brake lock button

1. Bring the ATV to a stop by applying the brakes

in the drive position.

2. Stop the engine.

3. Apply the parking brake.

1. Locked position

6-5

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Yamaha accessories, nor control over their qual-

ity or suitability. Choose a genuine Yamaha ac-

cessory, or one that is equivalent in design and

quality.

Accessories should be rigidly and securely

mounted. An accessory which can shift position

or come off while you are riding could affect your

ability to control the ATV.

Do not mount an accessory where it could inter-

fere with your ability to control the ATV. Exam-

ples include (but are not limited to) a heavy or

bulky object attached to the handlebars 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 ac-

cessories. The ATV may handle differently than

it does without accessories.

Accessories and loading

Accessories

Accessories can affect the handling and control of

your ATV. Keep the following in mind when consid-

ering an accessory or operating an ATV which has

accessories.

Choose only accessories designed for your

ATV. Your Yamaha dealer has a variety of gen-

uine Yamaha accessories. Other accessories

may also be available on the market. However,

it is not possible for Yamaha to test all non-

As originally equipped, this ATV is not designed to

carry cargo or tow a trailer. If you choose to add ac-

cessories so that you can carry cargo or tow a trail-

er, you must use common sense and good

judgment as the stability and handling of an ATV

can be changed. When adding accessories, keep

6-6

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the following points in mind:

speeds.

Never exceed the weight limits shown. An over-

loaded ATV can be unstable.

Avoid hills and rough terrain. Choose terrain

carefully. Added weight affects the stability and

handling of the ATV.

MAXIMUM LOADING LIMIT

ATV loading limit (total weight of rider, cargo,

accessories, and tongue):

70.0 kg (154 lb)

WARNING

POTENTIAL HAZARD

Overloading this ATV or carrying or towing

cargo improperly.

WHAT CAN HAPPEN

Could cause changes in ATV 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 se-

curely attached.

Reduce speed when carrying cargo or pull-

ing a trailer. Allow greater distance for brak-

ing.

If you are carrying cargo and towing a trailer, in-

clude the tongue weight in the maximum ATV

load limit.

Load cargo on the carriers as close to the center

of the ATV as possible. Put cargo at the rear of

the front carrier, at the front of the rear carrier,

and center it.

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 con-

trols 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.

WARNING

Allow more braking distance. A heavier ATV

takes longer to stop.

Avoid making sharp turns unless at very slow

A WARNING indicates a hazardous situation

which, if not avoided, could result in death

or serious injury.

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RIDING YOUR ATV

7-1

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RIDE WITH CARE AND GOOD JUDGEMENT

WARNING

A WARNING indicates a hazardous situation

which, if not avoided, could result in death

or serious injury.

Get training if you are inexperienced.

Beginners should get training from a certified in-

structor.

Become familiar with this ATV at slow speeds first,

even if you are an experienced operator. Do not at-

tempt to operate at maximum performance until

you are totally familiar with the ATV’s handling and

performance characteristics.

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 pe-

riod of time. Take the time to learn the basic tech-

niques well before attempting more difficult

maneuvers.

Riding your new ATV can be a very enjoyable ac-

tivity, providing you with hours of pleasure. But it is

essential to familiarize yourself with the operation

of the ATV to achieve the skill necessary to enjoy

riding safely. Before you begin to ride, be sure you

have read this Owner’s Manual completely and un-

derstand the operation of the controls. Pay partic-

ular attention to the safety information on pages

1-1–1-4. Please also read all notice and warning

labels on your ATV.

7-2

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Not recommended for children under 12 years

of age.

WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruc-

tion.

WARNING

POTENTIAL HAZARD

WHAT CAN HAPPEN

Failure to follow the age recommendations

for this ATV.

WHAT CAN HAPPEN

Use by children of ATVs that are not recom-

mended for their age can lead to severe inju-

ry or death of the child.

The risk of an accident is greatly increased if

the operator does not know how to operate

the ATV properly in different situations and

on different types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators

should complete the certified training course

offered by Yamaha. They should then regu-

larly practice the skills learned in the course

and the operating techniques described in

this Owner’s Manual. For more information

about the training course, contact an autho-

rized ATV dealer or call 1-800-887-2887.

HOW TO AVOID THE HAZARD

A child under 12 should never operate an ATV

with engine size greater than 70 cc.

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.

7-3

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This ATV is designed to carry operator only –

passengers prohibited.

WARNING

POTENTIAL HAZARD

Carrying a passenger on this ATV.

WHAT CAN HAPPEN

Greatly reduces your ability to balance and

control this ATV. Could cause an accident,

resulting in harm to you and/or your passen-

ger.

HOW TO AVOID THE HAZARD

Never 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.

7-4

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Apparel

HOW TO AVOID THE HAZARD

Always wear an approved motorcycle helmet

that fits properly.

You should also wear:

eye protection (goggles or face shield)

gloves

WARNING

POTENTIAL HAZARD

Operating this ATV without wearing an ap-

proved motorcycle helmet, eye protection

and protective clothing.

boots

WHAT CAN HAPPEN

long-sleeved shirt or jacket

long pants

Operating without an approved motorcycle

helmet increases your chances of a severe

head injury or death in the event of an acci-

dent.

Operating without eye protection can result

in an accident and increases your chances of

a severe injury in the event of an accident.

Operating without protective clothing in-

creases your chances of severe injury in the

event of an accident.

1. Protective clothing

2. Goggles

3. Gloves

4. Boots

5. Helmet

7-5

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Do not operate after consuming alcohol or

drugs.

The operator’s performance capability is reduced

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or

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.

WARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

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 mainte-

nance procedures and schedules described

in the Owner’s Manual.

WARNING

POTENTIAL HAZARD

Operating this ATV after consuming alcohol

or drugs.

WHAT CAN HAPPEN

Could seriously affect your judgment.

Could cause you to react more slowly.

Could affect your balance and perception.

Could result in an accident.

7-6

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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 accident.

HOW TO AVOID THE HAZARD

Always go at a speed that is proper for the

terrain, visibility and operating conditions,

and your experience.

Operating this ATV with improper tires, or

with improper or uneven tire pressure.

WHAT CAN HAPPEN

Use of improper tires on this ATV, or opera-

tion of this ATV with improper or uneven tire

pressure, may cause loss of control, increas-

ing your risk of an accident.

HOW TO AVOID THE HAZARD

Always use the size and type tires specified

in the Owner’s Manual for this ATV on page

5-4.

Speed limiters

For riders less experienced with this model, the

throttle lever housing is equipped with a vehicle

speed limiter. This speed limiter keeps the throttle

from fully opening, even when the throttle lever is

pushed to the maximum. Turning in the adjusting

screw limits the maximum engine power available

and decreases the maximum speed of the ATV.

Turning in the adjusting screw decreases top speed,

and turning it out increases top speed.

Always maintain proper tire pressure as de-

scribed in the Owner’s Manual on page 5-5.

WARNING

A WARNING indicates a hazardous situation

which, if not avoided, could result in death

or serious injury.

(See pages 4-3 and 4-4.)

This model also has an engine speed limiter plate

to limit the amount of engine power available.

Yamaha recommends that all beginning riders start

off with the vehicle speed limiter turned in and the

Do not operate at speeds too fast for your

skills or the conditions.

7-7

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engine speed limiter plate installed to limit the amount

of speed available while they learn. The vehicle speed

limitermaybegraduallyadjustedtoincreasemaximum

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

vehicle speed limiter alone, the engine speed limiter

plate can be removed. Since removal of this plate will

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. Re-

duce your speed when adding additional loads.

MAXIMUM LOADING LIMIT

ATV loading limit (total weight of cargo, rider,

accessories, and tongue):

70.0 kg (154 lb)

resultinasignificantincreaseinpower, turnthevehicle

speed limiter adjusting screw back in again; adjust it

out in stages as you did before. For engine speed

limiter plate removal instructions, see page 4-4.

WARNING

POTENTIAL HAZARD

Overloading this ATV or carrying or towing

cargo improperly.

WHAT CAN HAPPEN

Could cause changes in ATV handling which

could lead to an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for

this ATV.

1. Locknut

2. Adjusting screw

7-8

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Cargo should be properly distributed and se-

curely attached.

Reduce speed when carrying cargo or pull-

ing a trailer. Allow greater distance for brak-

ing.

Always follow the instructions in your Own-

er’s Manual for carrying cargo or pulling a

trailer.

WARNING

POTENTIAL HAZARD

Removing hands from handlebars or feet

from footboards during operation.

WHAT CAN HAPPEN

Removing even one hand or foot can reduce

your ability to control 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 accident.

During operation

Always keep your feet on the footboards during op-

eration, otherwise they may contact the rear

wheels.

HOW TO AVOID THE HAZARD

Always keep both hands on the handlebars

and both feet on the footboards of your ATV

during operation.

Avoid wheelies and jumping. You may lose control

of the ATV or overturn.

7-9

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Modifications

WARNING

POTENTIAL HAZARD

Attempting wheelies, jumps, and other

stunts.

WHAT CAN HAPPEN

Increases the chance of an accident, includ-

ing an overturn.

HOW TO AVOID THE HAZARD

Never attempt stunts, such as wheelies or

jumps. Don’t try to show off.

Operating this ATV with improper modifica-

tions.

WHAT CAN HAPPEN

Improper installation of accessories or mod-

ification of this ATV may cause changes in

handling which in some situations could lead

to an accident.

HOW TO AVOID THE HAZARD

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.

If you have questions, consult an authorized

ATV dealer.

Exhaust system

The exhaust system on the ATV is very hot during

and following operation. To prevent burns, avoid

touching the exhaust system. Park the ATV in a

place where pedestrians or children are not likely

to touch it.

7-10

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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.

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 control.

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 ATV to go out of control.

7-11

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HOW TO AVOID THE HAZARD

Always avoid paved surfaces, including side-

walks, driveways, parking lots and streets.

WARNING

POTENTIAL HAZARD

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. In

many states it is illegal to operate ATVs on

public streets, roads and highways.

Do not ride on any public road, street, or highway.

Riding on public roads can result in collisions with

other vehicles.

7-12

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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.

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 operat-

ing on unfamiliar terrain. Always be alert to

changing terrain conditions when operating

the ATV.

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 ATV control,

which could result in an accident, including

an overturn.

7-13

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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.

WARNING

POTENTIAL HAZARD

Operating in areas where you might not be

seen by other off-road vehicles.

WHAT CAN HAPPEN

You could be in a collision. You could be in-

jured.

HOW TO AVOID THE HAZARD

Always mount a caution flag on the ATV to

make you more visible. Watch carefully for

other vehicles.

When riding in an area where you might not easily

be seen, such as desert terrain, mount a caution

flag on the ATV. DO NOT use the flag pole bracket

as a trailer hitch.

7-14

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Do not ride in areas posted “no trespassing”.

Do not ride on private property without getting per-

mission.

member 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.

With the engine idling, release the parking brake.

Apply the throttle slowly and smoothly. You will

start to accelerate. If the throttle is applied too

abruptly, 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 operation of your ATV.

When slowing down or stopping, release the throt-

tle and apply the brakes smoothly and evenly. Im-

proper use of the brakes can cause the tires to lose

traction, reducing control and increasing the possi-

bility of an accident.

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, and turning tech-

niques in this area before trying more difficult ter-

rain. Always avoid riding on paved surfaces: the

ATV is designed for off-road use only, and han-

dling maneuvers are more difficult to perform on

pavement.

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. There-

fore, unless the wheel on the inside of the turn is al-

lowed to slip or lose some traction, the ATV will

resist turning. A special turning technique must be

used to allow the ATV to make turns quickly and

easily. It is essential that this skill be learned first at

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. Re-

7-15

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low speed.

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. Do not turn at

speeds too fast for your skills or the condi-

tions.

1. Lean towards inside of turn.

2. Support your weight on the outer footboard.

As you approach a curve, slow down and begin to

turn the handlebars in the desired direction. As you

do so, put your weight on the footboard to the out-

side of the turn (opposite your desired direction)

and lean your upper body into the turn. Use the

throttle to maintain an even speed through the

turn. This maneuver will let the wheel on the inside

of the turn slip slightly, allowing the ATV to make

the turn properly.

This procedure should be practiced at slow speed

many times in a large off-road area with no obsta-

cles. If an incorrect technique is used, your ATV

may continue to go straight. If the ATV doesn’t

turn, come to a stop and then practice the proce-

dure again. If the riding surface is slippery or loose,

it may help to position more of your weight over the

front wheels by moving forward on the seat.

Once you have learned this technique, you should

be able to perform it at higher speeds or in tighter

7-16

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curves.

WHAT CAN HAPPEN

Improper riding procedures such as abrupt throttle

changes, excessive braking, incorrect body move-

ments, or too much speed for the sharpness of the

turn may cause the ATV to tip. If the ATV begins to

tip over to the outside while negotiating a turn, lean

more to the inside. It may also be necessary to

gradually let off on the throttle and steer to the out-

side of the turn to avoid tipping over.

The ATV can overturn more easily on ex-

tremely steep hills than on level surfaces or

small hills.

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 forward and,

on steeper inclines, standing on the footboards

and leaning forward over the handlebars.

Remember: Avoid higher speeds until you are

thoroughly familiar with the operation of your ATV.

CLIMBING UPHILL

Use proper riding techniques to avoid ATV over-

turns on hills. Be sure that you can maneuver your

ATV well on flat ground before attempting any in-

cline and then practice riding first on gentle slopes.

Try more difficult climbs only after you have devel-

oped your skill. In all cases avoid inclines with slip-

pery or loose surfaces, or obstacles that might

cause you to lose control.

WARNING

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV

to overturn.

WARNING

POTENTIAL HAZARD

Operating on excessively steep hills.

7-17

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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. 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 have

not properly judged your ability to make it to the

top, you should turn the ATV around while you still

have forward motion (provided you have the room

to do so) and go down the hill.

7-18

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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. Be very careful when turning

on any hill.

Avoid crossing the side of a steep hill if pos-

sible.

If your ATV has stalled or stopped and you believe

you can continue up the hill, restart carefully to

make sure you do not lift the front wheels which

could cause you to lose control. If you are unable

to continue up the hill, dismount the ATV on the up-

hill side. Physically turn the ATV around and then

descend the hill.

If you start to roll backwards, DO NOT apply the

rear brake to stop or try to put the ATV in gear. The

ATV could easily tip over backwards. Instead, ap-

ply the front brake gradually, or dismount the ATV

immediately on the uphill side.

When crossing the side of a hill:

Always follow proper procedures as de-

scribed in the Owner’s Manual.

Avoid hills with excessively slippery or loose

surfaces.

Shift your weight to the uphill side of the

ATV.

7-19

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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.

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.

RIDING DOWNHILL

When riding your ATV downhill, shift your weight

as far to the rear and uphill side of the ATV as pos-

sible. Move back on the seat and sit with your arms

straight. Allow the engine compression to do most

of the braking for you. Improper braking may cause

a loss of traction.

Use 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 traction.

Whenever possible, ride your ATV straight down-

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 re-

mount, following the procedure described in

the Owner’s Manual.

7-20

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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.

WARNING

POTENTIAL HAZARD

Going 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 Man-

ual.

TIP: a special technique is required when

braking as you go down a hill.

Always check the terrain carefully before you

start down any hill.

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 slip-

pery surfaces or rough terrain that may upset your

balance.

As you travel across a slope, lean your body in the

uphill direction. It may be necessary to correct the

steering when riding on loose surfaces by pointing

the front wheels slightly uphill. When riding on

Shift your weight backward.

Never go down a hill at high speed.

Avoid going down a hill at an angle that

would cause the ATV to lean sharply to one

side. Go straight down the hill where possi-

ble.

7-21

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slopes, be sure not to make sharp turns either up

or down hill.

If your ATV does begin to tip over, gradually steer

in the downhill direction if there are no obstacles in

your path. As you regain proper balance, gradually

steer again in the direction you wish to travel.

When crossing the side of a hill:

Always follow proper procedures as de-

scribed in the Owner’s Manual.

Avoid hills with excessively slippery or loose

surfaces.

Shift your weight to the uphill side of the

ATV.

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. Be very careful when turning

on any hill. Avoid crossing the side of a steep

hill if possible.

CROSSING THROUGH SHALLOW WATER

The ATV can be used to cross slow moving, shal-

low water of up to a maximum of 20 cm (8 in) in

depth. Before entering the water, choose your path

7-22

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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.

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-

dent.

HOW TO AVOID THE HAZARD

Never operate this ATV in fast flowing water

or in water deeper than that specified in your

Owner’s Manual.

Remember that wet brakes may have re-

duced stopping ability. Test your brakes af-

ter leaving water. If necessary, apply them

several times to let friction dry out the lin-

ings.

Test your brakes after leaving the water. Do not

continue to ride your ATV without verifying that you

have regained proper braking ability.

7-23

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1. Air ﬁlter case check hose

RIDING OVER ROUGH TERRAIN

NOTICE

Riding over rough terrain should be done with cau-

tion. Look out for obstacles which could cause

damage to the ATV or could lead to an upset or ac-

cident. 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 re-

sult.

After riding your ATV in water, be sure to drain

the trapped water by removing the check hose

at the bottom of the air filter case. Wash the

ATV in fresh water if it has been operated in

salt water or muddy conditions.

7-24

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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. When you

go over obstacles, always follow proper pro-

cedures as described in the Owner’s Manual.

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.

SLIDING AND SKIDDING

Care should be used when riding on loose or slip-

pery surfaces since the ATV may slide. If unex-

pected and uncorrected, sliding could lead to an

accident.

To reduce the tendency for the front wheels to slide

in loose or slippery conditions, positioning your

weight over the front wheels will sometimes help.

7-25

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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 re-

duce the chance of skidding or sliding out of

control.

WHAT TO DO IF...

With practice, over a period of time, skill at con-

trolled sliding can be developed. The terrain

should be chosen carefully before attempting such

maneuvers, since both stability and control are re-

duced. Bear in mind that sliding maneuvers should

always be avoided on extremely slippery surfaces

such as ice, since all control may be lost.

This section is designed to be a reference guide

only. Be sure to read each section on riding tech-

niques completely.

WHAT TO DO...

If your ATV doesn’t turn when you want it to:

Bring the ATV to a stop and practice the turning

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 page 7-15.)

WARNING

POTENTIAL HAZARD

Skidding or sliding improperly.

If your ATV begins to tip while turning:

7-26

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Lean more into the turn to regain balance. If nec-

essary, gradually let off the throttle and/or steer

to the outside of the turn. (See page 7-15.)

If your ATV starts to slide sideways:

Steer in the direction of the slide if you have the

room. Applying the brakes or accelerating is not

recommended until you have corrected the

slide. (See page 7-25.)

If your ATV encounters shallow water:

Ride slowly and carefully through slow moving

water, watching for obstacles. Be sure to let wa-

ter drain from the ATV and CHECK YOUR

BRAKES FOR PROPER OPERATION when

you come out of the water. Do not continue to

ride your ATV until you have regained adequate

braking ability. (See page 7-22.)

If your ATV can’t make it up a hill you are trying

to climb:

WARNING

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 dis-

mount the ATV on the uphill side. (See

page 7-17.)

A WARNING indicates a hazardous situation

which, if not avoided, could result in death

or serious injury.

If your ATV is traversing a sloping surface:

Be sure to ride with your weight positioned to-

wards the uphill side of the ATV to maintain

proper balance. If the ATV starts to tip, steer

down the hill (if there are no obstacles in your

way) to regain balance. If you discover that the

ATV is going to tip over, dismount on the uphill

side. (See page 7-21.)

7-27

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PERIODIC MAINTENANCE AND MINOR REPAIR

HOW TO AVOID THE HAZARD

Turn off the engine when performing mainte-

Safety is an obligation of the owner. Periodic in-

spection, adjustment and lubrication will keep your

ATV in the safest and best operating condition

possible. The most important points of inspection,

adjustment, and lubrication are explained on the

following pages.

nance unless otherwise specified. Have a

Yamaha dealer perform the service if you are

not familiar with maintenance work.

Owner’s manual and tool kit

The intervals given in the periodic maintenance

and lubrication chart should be considered as a

general guide under normal riding conditions.

However, DEPENDING ON THE WEATHER,

TERRAIN, GEOGRAPHICAL LOCATION, AND

INDIVIDUAL USE, THE MAINTENANCE INTER-

VALS MAY NEED TO BE SHORTENED.

Be sure to put this owner’s manual in the plastic

bag and to always carry it as well as the owner’s

tool kit and the low-pressure tire gauge in their re-

spective compartments under the seat.

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

start fires.

8-1

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TIP

If you do not have the tools or experience required

for a particular job, have a Yamaha dealer perform

it for you.

WARNING

POTENTIAL HAZARD

It cont

DimTpH

ISrtaM

NsUafAeLtyCinARorEmFaUtion.

ARNING

1626-21-3

This

LLY!

ATV

should

Operating this ATV with improper modifica-

tions.

not

OWNER'S MANUAL

ridden

anyone

YFM90R

under

years

5TH-28199-66

age.

WHAT CAN HAPPEN

Improper installation of accessories or mod-

ification of this ATV may cause changes in

handling which in some situations could lead

to an accident.

1. Owner’s manual

HOW TO AVOID THE HAZARD

2. Low-pressure tire gauge

3. Owner’s tool kit

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.

If you have questions, consult an authorized

Yamaha ATV dealer.

The service information included in this manual

and the tools provided in the owner’s tool kit are in-

tended to assist you in the performance of preven-

tive maintenance and minor repairs. However,

additional tools such as a torque wrench may be

necessary to perform certain maintenance work

correctly.

8-2

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Periodic maintenance chart for the emission control system

TIP

For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.

For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-

vals. However, keep 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.

INITIAL

EVERY

month

Whichev-

er comes

ﬁrst

CHECK OR MAINTENANCE

JOB

NO.

ITEM

(mi)

320

(200)

1300

2500

5000

(800) (1600) (1600) (3200)

hours

160

320

Check fuel hoses for cracks or other damage, and

replace if necessary.

Fuel line

√

Check condition and clean, regap, or replace if

necessary.

Check valve clearance and adjust if necessary.

Check choke operation and correct if necessary.

Check engine idling speed and adjust if neces-

sary.

Check breather hose for cracks or other damage,

and replace if necessary.

Spark plug

Valves

√

Carburetor

Crankcase breather

system

√

8-3

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INITIAL

EVERY

month

Whichev-

er comes

ﬁrst

CHECK OR MAINTENANCE

JOB

NO.

ITEM

(mi)

320

(200)

1300

2500

5000

(800) (1600) (1600) (3200)

hours

160

320

Check for leakage and replace gasket(s) if neces-

sary.

Check for looseness and tighten all screw clamps

and joints if necessary.

Exhaust system

Spark arrester

√

Clean.

8-4

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General maintenance and lubrication chart

INITIAL

EVERY

month

Whichev-

er comes

ﬁrst

CHECK OR MAINTENANCE

JOB

NO.

ITEM

(mi)

320

(200)

1300

2500

5000

(800) (1600) (1600) (3200)

hours

160

320

Check chain tension.

Adjust if necessary.

Timing chain

√

Every 20–40 hours (more often in wet or

dusty areas)

Air ﬁlter element

Clutch

Clean and replace if necessary.

Check operation.

√

Check operation and correct if necessary.

Check brake lever free play and adjust if neces-

sary.

√

Front brake

Rear brake

Replace brake shoes.

Whenever worn to the limit

Check operation and correct if necessary.

Check ﬂuid level and ATV for ﬂuid leakage, and

correct if necessary.

Replace brake pads.

Check for cracks or other damage, and replace if

necessary.

√

Whenever worn to the limit

√

Brake hoses

Wheels

Replace.

Every 4 years

Check runout and for damage, and replace if nec-

essary.

Check tread depth and for damage, and replace if

necessary.

Check air pressure and balance, and correct if

necessary.

√

Tires

√

8-5

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INITIAL

EVERY

month

Whichev-

er comes

ﬁrst

CHECK OR MAINTENANCE

JOB

NO.

ITEM

(mi)

320

(200)

1300

2500

5000

(800) (1600) (1600)

(3200)

hours

160

320

Check for looseness or damage, and replace if

necessary.

Make sure that all nuts, bolts, and screws are

properly tightened.

Check operation and correct if necessary.

Check for oil leakage and replace if necessary.

Wheel hub bearings

Chassis fasteners

√

Shock absorber

assemblies

Front knuckle piv-

ots

Lubricate with lithium-soap-based grease.

√

Steering shaft

Check operation and repair or replace if damaged.

Check toe-in and adjust if necessary.

Steering system

√

Change.

Engine oil

Check ATV for oil leakage, and correct if neces-

sary.

Clean.

√

Engine oil strainer

Change.

Check ATV for oil leakage, and correct if neces-

sary.

√

Final transmission oil

Moving parts and

cables

Lubricate.

√

8-6

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INITIAL

EVERY

month

Whichev-

er comes

first

CHECK OR MAINTENANCE

JOB

NO.

ITEM

(mi)

320

1300

2500

5000

(200) (800) (1600) (1600) (3200)

hours

160

320

Drive select lever

safety system cable

• Check operation and adjust or replace if neces-

sary.

• Check operation and correct if necessary.

√

Throttle lever hous- • Check throttle cable free play and adjust if neces-

ing and cable

√

sary.

• Lubricate throttle lever housing and cable.

Front and rear brake

switches

• Check operation and correct if necessary.

√

• Check operation and correct if necessary.

• Adjust headlight beams.

Check operation

Check for wear, cracks or other damage, and replace

if necessary.

Lights and switches

√

V-belt

8-7

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TIP

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinder and caliper, and

change the brake fluid.

Replace the brake hoses every four years and if cracked or damaged.

8-8

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WARNING

A WARNING indicates a hazardous situation

which, if not avoided, could result in death

or serious injury.

Checking the spark plug

The spark plug is an important engine component,

which is easy to check. Since heat and deposits

will cause any spark plug to slowly erode, the spark

plug should be removed and checked in accor-

dance with the periodic maintenance and lubrica-

tion chart. In addition, the condition of the spark

plug can reveal the condition of the engine.

1. Spark plug cap

2. Remove the spark plug as shown, with the

spark plug wrench included in the owner’s tool

kit.

To remove the spark plug

1. Remove the spark plug cap.

8-9

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replace it if necessary.

Specified spark plug:

NGK/CR7HSA

To install the spark plug

1. Measure the spark plug gap with a wire thick-

ness gauge and, if necessary, adjust the gap

to specification.

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

1. Spark plug wrench

To check the spark plug

1. Check that the porcelain insulator around the

center electrode of the spark plug is a medi-

um-to-light tan (the ideal color when the ATV

is ridden normally).

TIP

If the spark plug shows a distinctly different color,

the engine could be operating improperly. Do not

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

and excessive carbon or other deposits, and

8-10

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2. Clean the surface of the spark plug gasket

and its mating surface, and then wipe off any

grime from the spark plug threads.

To check the engine oil level

1. Place the ATV on a level surface.

2. Check the engine oil level on a cold engine.

3. Install the spark plug with the spark plug

wrench, and then tighten it to the specified

torque.

TIP

If the engine was started before checking the oil

level, be sure to warm up the engine sufficiently,

and then wait at least ten minutes until the oil set-

tles for an accurate reading.

Tightening torque:

Spark plug:

12.0 Nm (1.20 m·kgf, 8.9 ft·lbf)

3. Remove the engine oil filler cap, and then

wipe the dipstick off with a clean rag.

TIP

If a torque wrench is not available when installing

a spark plug, a good estimate of the correct torque

is 1/4–1/2 turn past finger tight. However, the spark

plug should be tightened to the specified torque as

soon as possible.

4. Install the spark plug cap.

Engine oil

The engine oil level should be checked before

each ride. In addition, the oil must be changed at

the intervals specified in the periodic maintenance

and lubrication chart.

1. Engine oil ﬁller cap

2. Dipstick

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4. Insert the dipstick into the filler hole (without

screwing it in), and then remove it again to

check the oil level.

To change the engine oil

1. Place the ATV on a level surface.

2. Start the engine, warm it up for several min-

utes, and then turn it off.

3. Place an oil pan under the engine to collect

the used oil.

4. Remove the engine oil filler cap, and then

remove the engine oil drain bolt to drain the

oil from the crankcase.

1. Maximum level mark

2. Minimum level mark

TIP

1. Engine oil drain bolt

The engine oil should be between the minimum

and maximum level marks.

2. O-ring

3. Spring

4. Oil filter element

5. If the engine oil is at or below the minimum

level mark, add sufficient oil of the recom-

mended type to raise it to the correct level.

6. Insert the dipstick into the oil filler hole, and

then tighten the engine oil filler cap.

5. Check the washer for damage and replace it if

necessary.

6. Install the engine oil drain bolt, and then tighten

it to the specified torque.

8-12

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minutes while checking it for oil leakage. If oil

is leaking, immediately turn the engine off and

check for the cause.

Tightening torque:

Engine oil drain bolt:

8 Nm (0.8m·kgf, 5.8 ft·lbf)

9. Turn the engine off, wait at least ten minutes,

and then check the oil level and correct it if

necessary.

7. Add the specified amount of the recommend-

ed engine oil, and then install and tighten the

engine oil filler cap.

Recommended oil:

See page 10-1.

Oil quantity:

0.8 L (0.84 US qt) (0.70 Imp.qt)

NOTICE

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 CONSERVING II" or

higher.

Make sure that no foreign material enters

the crankcase.

8. Start the engine, and then let it idle for several

8-13

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Final transmission oil

The final transmission case must be checked for

oil leakage before each ride. If any leakage is

found, have a Yamaha dealer check and repair the

ATV. In addition, the final transmission oil must be

changed at the intervals specified in the periodic

maintenance and lubrication chart.

To change the final transmission oil

1. Place the ATV on a level surface.

2. Place an oil pan under the final transmission.

3. Remove the final transmission oil filler cap and

the drain bolt to drain the oil from the final

transmission oil case.

1. Final transmission oil ﬁller cap

4. Install the drain bolt, and then tighten it to the

specified torque.

1. Final transmission oil drain bolt

8-14

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Tightening torque:

Cleaning the air filter element

Final transmission oil drain bolt:

15 Nm (1.5 m·kgf, 10.8 ft·lbf)

The air filter element should be cleaned at the in-

tervals specified in the periodic maintenance and

lubrication chart. Clean the air filter element more

frequently if you are riding in unusually wet or dusty

areas.

5. Add the specified amount of the recommend-

ed final transmission oil, and then check the

oil level.

TIP

Recommended final transmission oil:

See page 10-1.

Oil quantity:

There are check hoses at the bottom of the air filter

case. If dust or water collects in these hoses, empty

them and clean the air filter element and air filter

case.

0.30 L (0.32 US qt) (0.27 Imp.qt)

NOTICE

Be sure no foreign material enters the final

transmission case.

6. Install and tighten the oil filler cap.

7. Check the final transmission case for oil leakage.

If oil is leaking, check for the cause.

1. Air filter case check hose (left)

8-15

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1. Air filter case check hose (right)

1. Air filter case cover (right)

2. Bolts

1. Remove the air filter case cover by remov-

ing the bolts.

1. Air filter case cover (left)

2. Bolts

8-16

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2. Remove the air filter element by removing the

screw, and then pull off the sponge material

WHAT CAN HAPPEN

Low-flash-point solvents or gasoline can

catch fire or explode.

from the air filter element holder.

HOW TO AVOID THE HAZARD

Use parts cleaning solvent to clean the

sponge material.

4. Squeeze the excess solvent out of the sponge

material and let it dry.

NOTICE

Do not twist the sponge material when squeez-

ing it.

1. Air filter element holder

2. Sponge material

3. Wash the sponge material gently but thor-

oughly in solvent.

WARNING

POTENTIAL HAZARD

Using low-flash-point solvents or gasoline to

clean the sponge material.

5. Check the sponge material and replace it if

damaged.

8-17

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ement removed. This will allow unfiltered air

to enter the engine, causing rapid engine

wear and possible engine damage. Addition-

ally, operation without the air filter element

will affect carburetor jetting with subsequent

poor performance and possible engine over-

heating.

6. Apply Yamaha foam air filter oil or other qual-

ity foam air filter oil to the sponge material.

TIP

The sponge material should be wet but not drip-

ping.

7. Install the sponge material onto the air filter

element holder.

8. Place the air filter element in the original position,

and then install the screw.

9. Install the air filter case cover by installing the

bolts.

TIP

The air filter element should be cleaned every 20–

40 hours. It should be cleaned and lubricated more

often if the ATV is operated in extremely dusty ar-

eas. Each time the air filter element maintenance

is performed, check the air inlet of the air filter case

for obstructions.

NOTICE

Make sure that the air filter element is prop-

erly seated in the air filter case.

Never operate the engine with the air filter el-

8-18

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2. Remove the spark arrester by pulling it out

of the muffler.

3. Tap the spark arrester lightly, and then use

a wire brush to remove any carbon deposits.

4. Insert the spark arrester into the muffler and

align the screw holes.

Cleaning the spark arrester

Be sure the exhaust pipe and muffler are cool be-

fore cleaning the spark arrester.

1. Remove the screw and nut.

5. Install the screw and nut, and then tighten the

nut.

1. Spark arrester

2. Screw

3. Nut

8-19

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Adjusting the carburetor

WARNING

The carburetor should be checked and, if neces-

sary, adjusted at the intervals specified in the peri-

odic maintenance and lubrication chart. The

carburetor is an important part of the engine and

requires very sophisticated adjustment. Therefore,

most carburetor adjustments should be left to a

Yamaha dealer, who has the necessary profes-

sional knowledge and experience. The adjustment

described in the following section, however, may

be performed by the owner as part of routine main-

tenance.

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 ex-

haust system.

NOTICE

The carburetor has been set and extensively

tested at the Yamaha factory. Changing these

settings without sufficient technical knowl-

edge may result in poor performance of or

damage to the engine.

Adjusting the engine idling speed

The engine idling speed must be checked and, if

necessary, adjusted as follows at the intervals

specified in the periodic maintenance and lubrica-

8-20

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tion chart.

TIP

A diagnostic tachometer is needed to make this

adjustment.

(b)

(a)

1. Start the engine and warm it up.

TIP

The engine is warm when it quickly responds to the

throttle.

2. Attach the tachometer to the spark plug lead.

3. Check the engine idling speed and, if neces-

sary, adjust it to specification by turning the

throttle stop screw at the carburetor. To in-

crease the engine idling speed, turn the throt-

tle stop screw in direction (a), and to decrease

it, turn the screw in direction (b).

1. Throttle stop screw

Engine idling speed:

1600–1800 r/min

TIP

If the specified idling speed cannot be obtained as

described above, have a Yamaha dealer make the

adjustment.

Checking the throttle cable free play

The throttle cable free play should be checked at

the intervals specified in the periodic maintenance

and lubrication chart.

8-21

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The throttle cable free play should measure 1.0–

3.0 mm (0.04–0.12 in) at the throttle lever. Period-

ically check the throttle cable free play and, if nec-

essary, have a Yamaha dealer adjust it.

Valve clearance

The valve clearance changes with use, resulting in

improper air-fuel mixture and/or engine noise. To

prevent this from occurring, the valve clearance

must be adjusted by a Yamaha dealer at the inter-

vals specified in the periodic maintenance and lu-

brication chart.

Brakes

Replacement of brake components requires

professional knowledge.Brake service should be

performed by a Yamaha dealer.

WARNING

1. Throttle lever free play

Operating with improperly serviced or adjusted

brakes could lead to a loss in braking ability

and an accident.

Timing chain

The timing chain stretches with use, resulting in im-

proper valve timing and engine noise. To prevent

this from occurring, the timing chain tensioner

must be adjusted by a Yamaha dealer at the inter-

vals specified in the periodic maintenance and lu-

brication chart.

Checking the front brake shoes

The front brake shoes must be checked for wear at

the intervals specified in the periodic maintenance

and lubrication chart. Front brake is provided with a

wear indicator on front brake lever, which allows you

8-22

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to check the brake shoe wear without having to

disassemble the brake. To check the brake shoe

wear, there are two adjusting bolts to indicate brake

shoe wear. If the positions of adjusting bolts reach to

12mm (0.47in), the brake shoes should be replaced

as a set by Yamaha dealer.

TIP

Before adjusting the brake lever free play, check

the front brake shoes for wear.

The brake lever free play should measure 4.0–

6.0 mm (0.16–0.24 in) as shown. If the free play

is incorrect, adjust it as follows.

1. Upper adjusting bolt

2. Lower adjusting bolt

1. Brake lever free play

3. No more than 12 mm (0.47 in)

1. Loosen the upper locknut and fully turn in the

upper adjusting bolt.

2. Loosen the lower locknut.

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.

3. Turn the lower adjusting bolt in direction (a) to

increase the free play, and in direction (b) to

decrease it.

8-23

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(a)

(b)

1. Cable joint

1. Upper locknut

2. Upper adjusting bolt

3. Lower locknut

4. Lower adjusting bolt

6. Tighten the upper locknut.

WARNING

4. Tighten the lower locknut.

POTENTIAL HAZARD

Operating with improperly serviced or ad-

justed brakes.

WHAT CAN HAPPEN

You could lose braking ability, which could

lead to an accident.

5. While applying the front brake, turn out the up-

per adjusting bolt until the upper and lower ca-

ble lengths are equal. The cable joint will

become vertical.

8-24

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HOW TO AVOID THE HAZARD

After servicing:

Make sure the brakes operate smoothly

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 a Yamaha dealer.

1. Wear indicator groove

Checking the rear brake pads

The rear brake pads must be checked for wear at the

intervals specified in the periodic maintenance and

lubrication chart. Each brake pad is provided with

wear indicator grooves, which allow you to check the

brake pad wear without having to disassemble the

brake. If a brake pad has worn to the point that the

wear indicator grooves have almost disappeared,

have a Yamaha dealer replace the brake pads as a

set.

Checking the brake fluid level

Insufficient brake fluid may allow air to enter the brake

system, possibly causing it to become ineffective.

Before riding, check that the brake fluid is above the

minimum level mark and replenish if necessary.

A low brake fluid level may indicate worn brake pads

and/or brake system leakage. If the brake fluid level

is low, be sure to check the brake pads for wear and

the brake system for leakage.

8-25

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Checking the rear brake lever free play

The brake lever free play must be checked at the

intervals specified in the periodic maintenance and

lubrication chart. The brake lever free play should

measure 0 –1.5 mm (0 –0.06 in) as shown. If

the free play is incorrect, have a Yamaha dealer

check the brake system.

1. Minimum level mark

Changing the rear brake fluid

Have a Yamaha dealer change the rear brake fluid

at the intervals specified in the TIP after the periodic

maintenance and lubrication chart. In addition,

have the oil seals of the master cylinders and

calipers as well as the brake hoses replaced at the

intervals listed below or whenever they are damaged

or leaking.

Oil seals: Replace every two years.

Brake hoses: Replace every four years.

1. Brake lever free play

Recommended brake fluid:

DOT4

8-26

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WARNING

POTENTIAL HAZARD

Operating with improperly serviced or ad-

justed brakes.

WHAT CAN HAPPEN

You could lose braking ability, which could

lead to an accident.

Recommended lubricant:

Engine oil

WARNING

POTENTIAL HAZARD

Damaged control cables.

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Corrosion can result when the cable sheaths

become damaged, and cables can also be-

come frayed or kinked, which could restrict

the operation of controls and lead to an acci-

dent or injury.

After servicing:

Make sure the brakes operate smoothly

and that the free play is correct.

Make sure the brakes do not drag.

Make sure the brakes are not spongy. All

air must be bled from the brake system.

Replacement of brake components requires

professional knowledge. These procedures

should be performed by a Yamaha dealer.

HOW TO AVOID THE HAZARD

Inspect cables frequently. Replace damaged

cables.

Checking and lubricating the front and

rear brake levers

Checking and lubricating the cables

The operation and the condition of all control ca-

bles should be checked before each ride, and the

cables and cable ends should be lubricated if nec-

essary. If a cable is damaged or does not move

smoothly, have a Yamaha dealer check or replace

it.

The operation of the front and rear brake levers

should be checked before each ride, and the lever

pivots should be lubricated if necessary.

8-27

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Battery

Recommended lubricant:

Front brake lever:

This model is equipped with a VRLA (Valve

Regulated Lead Acid) battery. There is no need to

check the electrolyte or to add distilled water.

However, the battery lead connections need to be

checked and, if necessary, tightened.

Lithium-soap-based grease

Rear brake lever:

Silicone grease

NOTICE

Never attempt to remove the battery cell seals,

as this would permanently damage the battery.

WARNING

POTENTIAL HAZARD

Failure to handle batteries or battery electro-

lyte carefully.

1. Lever pivot

WHAT CAN HAPPEN

Checking the wheel hub bearings

You could be poisoned. You could be severe-

ly burned by the sulfuric acid in battery elec-

trolyte. Batteries produce explosive gases.

HOW TO AVOID THE HAZARD

The front and rear wheel hub bearings must be

checked at the intervals specified in the periodic

maintenance and lubrication chart. If there is play

in a wheel hub or if a wheel does not turn smoothly,

have a Yamaha dealer check the wheel hub bearings.

8-28

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To store the battery

Avoid contact with skin, eyes or clothing. Al-

ways shield eyes when working near batter-

ies. Keep out of reach of children.

Antidote:

1. If the ATV will not be used for more than one

month, remove the battery, fully charge it, and

then place it in a cool, dry place.

2. If the battery will be stored for more than two

months, check it at least once a month and fully

charge it if necessary.

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 at-

tention.

EYES: Flush with water for 15 minutes and

get prompt medical attention. Keep batteries

away from sparks, flames, cigarettes or other

sources of ignition. Ventilate when charging

or using in a closed space.

To install the battery

TIP

Be sure the battery is fully charged.

1. Place the battery in its compartment.

2. Make sure to properly connect the battery

leads to the battery terminals.

To charge the battery

Have a Yamaha dealer charge the battery as soon

as possible if it seems to have discharged. Keep in

mind that the battery tends to discharge more quickly

if the ATV is equipped with optional electrical

accessories.

1. Battery

2. Negative lead

3. Positive lead

8-29

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(See page 4-11.)

If the fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn off all electrical

circuits.

NOTICE

Always keep the battery charged. Storing a

discharged battery can cause permanent

battery damage.

To charge a VRLA (Valve Regulated Lead Acid)

battery, a special (constant-voltage) battery

charger is required. Using a conventional

battery charger will damage the battery. If you

do not have access to a constant-voltage

battery charger, have a Yamaha dealer charge

your battery.

NOTICE

To prevent accidental short-circuiting, turn off

the main switch when checking or replacing a

fuse.

2. Remove the blown fuse, and then install a

new fuse of the specified amperage.

Specified fuse:

10 A

Replacing the fuse

WARNING

POTENTIAL HAZARD

Using an improper fuse.

WHAT CAN HAPPEN

An improper fuse can cause damage to the

electrical system, which could lead to a fire.

HOW TO AVOID THE HAZARD

Always use a fuse of the specified rating.

Never use a material in place of the proper

fuse.

1. Fuse

2. Spare fuse

The fuse holder is located under the seat.

8-30

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3. Turn the key to “ON” and turn on the electrical

circuits to check if the devices operate.

4. If the fuse immediately blows again, have a

Yamaha dealer check the electrical system.

8-31

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Removing a wheel

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.

1. Wheel nuts

8-32

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Installing a wheel

2. Lower the ATV to the ground.

3. Tighten the wheel nuts to the specified

torques.

1. Install the wheel and the nuts.

TIP

When installing the wheel, make sure its arrow

Tightening torques:

Front wheel nut:

mark

points toward the rotating direction of the

45 Nm (4.5 m·kgf, 33 ft·lbf)

Rear wheel nut:

45 Nm (4.5 m·kgf, 33 ft·lbf)

wheel.

Front

1. Arrow mark

8-33

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HOW TO AVOID THE HAZARD

Troubleshooting

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.

Although Yamaha ATVs receive a thorough in-

spection before shipment from the factory, trouble

may occur during operation. Any problem in the fu-

el, compression, or ignition systems, for example,

can cause poor starting and loss of power.

The following troubleshooting chart represents a

quick and easy procedure for checking these vital

systems yourself. 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.

Use only genuine Yamaha replacement parts. Im-

itation parts may look like Yamaha parts, but they

are often inferior, have a shorter service life and

can lead to expensive repair bills.

WARNING

POTENTIAL HAZARD

Checking the fuel system while smoking or

near an open flame.

WHAT CAN HAPPEN

Fuel can ignite or explode, causing severe in-

jury or property damage.

8-34

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Troubleshooting chart

1. Fuel

There is enough fuel.

There is no fuel.

Check the compression.

Check the fuel level in

the fuel tank.

The engine does not start.

Check the compression.

Supply fuel.

2. Compression

There is compression.

Check the ignition.

Operate the electric starter.

Have a Yamaha dealer

check the ATV.

There is no compression.

3. Ignition

Open the throttle halfway and operate

the electric starter.

Wipe off with a dry cloth and correct the

spark plug gap, or replace the spark plug.

Wet

Dry

Remove the spark plug

and check the electrodes.

The engine does not start.

Check the battery.

Have a Yamaha dealer check the ATV.

4. Battery

The engine turns over

quickly.

The battery is good.

The engine does not start.

Have a Yamaha dealer

Operate the electric starter.

check the ATV.

The engine turns over

slowly.

Check the battery lead connections, and

charge the battery if necessary.

8-35

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CLEANING AND STORAGE

applications such as those available in coin-

operated car washers.

Cleaning

Frequent, thorough cleaning of your ATV will not

only enhance its appearance but will improve its

general performance and extend the useful life of

many components.

4. Once most of the dirt has been hosed off,

wash all surfaces with warm water and mild,

detergent-type soap. An old toothbrush or bot-

tle brush is handy for hard-to-reach places.

5. Rinse the ATV off immediately with clean wa-

ter and dry all surfaces with a chamois, clean

towel or soft absorbing cloth.

1. Before cleaning the ATV:

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.

6. Clean the seat with a vinyl upholstery cleaner

to keep the cover pliable and glossy.

7. Automotive type wax may be applied to all

painted and chrome plated surfaces. Avoid

combination cleaner-waxes. Many contain

abrasives which may mar the paint or protec-

tive finish. When finished cleaning, start the

engine and let it idle for several minutes.

2. If the engine case is excessively greasy, apply

degreaser with a paint brush. Do not apply de-

greaser to the wheel axles.

3. Rinse the dirt and degreaser off with a garden

hose. Use only enough pressure to do the job.

NOTICE

Excessive water pressure may cause water

seepage and deterioration of wheel bearings,

brakes, transmission seals and electrical de-

vices. Many expensive repair bills have result-

ed from improper high-pressure detergent

9-1

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nia) and areas where strong chemicals are

stored.

WARNING

POTENTIAL HAZARD

Operation with wet brakes after washing.

WHAT CAN HAPPEN

Wet brakes may have reduced stopping abil-

ity, increasing the chance of an accident.

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.

Long-term

Before storing your ATV for several months:

1. Follow all the instructions in the “Cleaning”

section of this chapter.

2. Turn the fuel cock lever to “OFF”.

3. Drain the carburetor float chamber by loosen-

ing the drain bolt; this will prevent fuel deposits

from building up. Pour the drained fuel into the

fuel tank.

4. Fill up the fuel tank and add fuel stabilizer (if

available) to prevent the fuel from deteriorat-

ing.

Storage

Short-term

Always store your ATV in a cool, dry place and, if

necessary, protect it against dust with a porous

cover.

Specified amount:

7.5 ml of stabilizer to each liter of fuel (or 1 oz

of stabilizer to each gallon of fuel)

NOTICE

5. Perform the following steps to protect the cyl-

inder, piston rings, etc. from corrosion.

a. Remove the spark plug cap and spark

plug.

Storing the ATV in a poorly ventilated room

or covering it with a tarp while it is still wet,

will allow water and humidity to seep in and

cause rust.

To prevent corrosion, avoid damp cellars,

stables (because of the presence of ammo-

b. Pour a teaspoonful of engine oil into the

spark plug bore.

c. Install the spark plug cap onto the spark

9-2

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plug, and then place the spark plug on the

cylinder head so that the electrodes are

grounded. (This will limit sparking during

the next step.)

TIP

Make any necessary repairs before storing the

ATV.

d. Turn the engine over several times with

the starter. (This will coat the cylinder wall

with oil.)

e. Remove the spark plug cap from the spark

plug, and then install the spark plug and

the spark plug cap.

6. Lubricate all control cables and the pivoting

points of all levers and pedals.

7. Check and, if necessary, correct the tire air

pressure, and then block up the ATV so that

all of its wheels are off the ground. Alternative-

ly, turn the wheels a little every month in order

to prevent the tires from becoming degraded

in one spot.

8. Cover the muffler outlet with a plastic bag to

prevent moisture from entering it.

9. Remove the battery and fully charge it. Store

it in a cool, dry place and charge it once a

month. Do not store the battery in an exces-

sively cold or warm place [less than 0 °C (30

°F) or more than 30 °C (90 °F)]. For more infor-

mation on storing the battery, see page 8-28.

9-3

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SPECIFICATIONS

Compression ratio:

Dimensions:

Overall length:

10.2 : 1

Starting system:

1490 mm (58.7 in)

Electric starter & kickstarter

Lubrication system:

Wet sump

Overall width:

885 mm (34.8 in)

Overall height:

910 mm (35.8 in)

Seat height:

654 mm (25.7 in)

Wheelbase:

Engine oil:

Type:

YAMALUBE 4, SAE5W-30 or SAE10W-40 or SAE20W-50

1010 mm (39.8 in)

Ground clearance:

100 mm (3.9 in)

Minimum turning radius:

2900 mm (114 in)

110 130 F

Weight:

With oil and fuel:

120.0 kg (264 lb)

Engine:

YAMALUBE 4 (20W-50) or SAE 20W-50

YAMALUBE 4 (10W-40) or SAE 10W-40

SAE 5W-30

Engine type:

Forced air cooled 4-stroke

Cylinder arrangement:

Single cylinder

-20

50 C

-10

Displacement:

88 cm³(5.37 cu. in)

Bore × stroke:

47.0 × 51.0 mm (1.85 x 2.0 in)

Recommended engine oil grade:

API service SG type or higher, JASO standard MA

10-1

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Transmission:

Primary reduction system:

Engine oil quantity:

Periodic oil change:

0.8 L (0.84 US qt) (0.70 Imp.qt)

V-belt

Primary reduction ratio:

2.47-0.61:1

Final transmission oil:

Type:

Secondary reduction system:

Spur

SAE80 API GL-4 Hypoid gear oil

Quantity:

Secondary reduction ratio:

41/15 × 45/13 (9.462)

Third reduction system:

Chain drive

Third reduction ratio:

28/13(2.154)

0.30 L (0.32 US qt) (0.27 Imp.qt)

Air filter:

Air filter element:

Wet element

Fuel:

Recommended fuel:

Unleaded gasoline only

Fuel tank capacity:

4.8 L (1.27 US gal) (1.06 lmp.gal)

Fuel reserve amount:

1.0l(0.26 US gal) (0.22 Imp.gal)

Carburetor:

Transmission type:

V-belt automatic

Chassis:

Frame type:

Steel tube frame

Caster angle:

4.0 °

Manufacturer:

Type x quantity:

SVR 22-1G x 1

Trail:

16 mm (0.63 in)

Front tire:

Type:

Tubeless

Size:

AT18 x 7-8

Manufacturer/model:

MAXXIS/M939

Spark plug (s):

Manufacturer/model:

NGK/CR7HSA

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Clutch:

Clutch type:

Dry, centrifugal automatic

10-2

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Front wheel:

Rear tire:

Type:

Wheel type:

Panel wheel

Rim size:

8 x 5.5AT

Rear wheel:

Wheel type:

Panel wheel

Rim size:

8 x 7AT

Front brake:

Type:

Drum brake

Operation:

Right hand operation

Rear brake:

Type:

Single disc brake

Operation:

Left hand operation

Recommended fluid:

DOT4

Tubeless

Size:

AT18 x 9-8

Manufacturer/model:

MAXXIS/M940

Loading:

Maximum loading limit:

70.0 kg (154 lb)

(Total weight of rider, cargo, accessories, and tongue)

Tire air pressure (measured on cold tires):

Recommended:

Front:

25 kPa (3.6 psi) (0.25 kgf/cm )

Rear:

25 kPa (3.6 psi) (0.25 kgf/cm )

Minimum:

Front:

22 kPa (3.2 psi) (0.22 kgf/cm )

Rear:

22 kPa (3.2 psi) (0.22 kgf/cm )

Front suspension:

Type:

Double wishbone

Spring/shock absorber type:

Coil spring/oil damper

10-3

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Wheel travel:

111 mm (4.4 in)

Rear suspension:

Type:

Swingarm

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

83 mm (3.3 in)

Electrical system:

Ignition system:

CDI

Charging system:

AC magneto

Battery:

Model:

GTX5L-BS

Voltage, capacity:

12 V, 4.0 AH

Fuses:

Main fuse:

10 A

10-4

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CONSUMER INFORMATION

Key identification number

Identification numbers

The key identification number is stamped into the

key. Record this number in the space provided and

use it for reference when ordering a new key.

Record the key identification number, vehicle iden-

tification number and model label information in

the spaces provided below for assistance when or-

dering spare parts from a Yamaha dealer or for ref-

erence in case the ATV is stolen.

KEY IDENTIFICATION NUMBER:

VEHICLE IDENTIFICATION NUMBER:

MODEL LABEL INFORMATION:

1. Key identification number

Vehicle identification number

The vehicle identification number is stamped into

the frame.

11-1

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1. Vehicle identification number

1. Model label

TIP

The vehicle identification number is used to identi-

fy your ATV.

Model label

The model label is affixed at the location in the il-

lustration. Record the information on this label in

the space provided. This information will be need-

ed when ordering spare parts from a Yamaha deal-

er.

11-2

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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.

“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.

Exhaust system

Muffler

Exhaust pipe

Silencer

Intake system

Air cleaner case

Air cleaner element

Intake duct

11-3

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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. It is not acceptable proof of maintenance work.

MAINTENANCE INTERVAL

DATE OF

SERVICE

SERVICING DEALER

NAME AND ADDRESS

MILEAGE

REMARKS

month

km (mi)

hours

320 (200)

1300 (800)

2500 (1600)

5000 (3200)

7500 (4800)

10000 (6400)

12500 (8000)

15000 (9600)

17500 (11200)

20000 (12800)

22500 (14400)

25000 (16000)

160

320

480

640

800

960

1120

1280

1440

1600

11-4

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YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY

Yamaha Motor Corporation, U.S.A. hereby warrants

that new Yamaha ATVs purchased from an

authorized Yamaha ATV dealer in the continental

United States will be free from defects in material and

workmanship for the period of time stated herein, sub-

ject to certain stated limitations.

SPECIFIC EXCLUSIONS from this warranty shall

include parts replaced due to normal wear or routine

maintenance, such as spark plugs, oil, oil filter, air filter,

and brake shoes.

within the period listed immediately below. Failures

other than those resulting from defects in material or

workmanship which arise solely as a result of owner

abuse and/or lack of proper maintenance are not

covered by this warranty.

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.

All Models

Thirty (30) months from the original purchase date

THE PERIOD OF WARRANTY for Yamaha ATVs

shall be six (6) months from the date of purchase.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO

OTHER WARRANTY OF ANY KIND, EXPRESSED OR

IMPLIED. ALL IMPLIED WARRANTIES OF

DURINGTHE PERIOD OFWARRANTY 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.

MERCHANTABILITY AND FITNESS FOR

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.

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.

SOME STATES DO NOT ALLOW LIMITATIONS ON

HOW LONG AN IMPLIEDWARRANTY LASTS, SOTHE

ABOVE LIMITATION MAY NOT APPLYTOYOU. 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 APPLYTOYOU.

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.

c. Abnormal strain, neglect, or abuse.

d. Lack of proper maintenance.

EMISSION CONTROL SYSTEM WARRANTY

e. Accident or collision damage.

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

f. Modification to original parts.

g. Damage due to improper transportation.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL

RIGHTS, ANDYOU MAY ALSO HAVE OTHER RIGHTS

WHICHVARY FROM STATETO STATE.

YAMAHA MOTOR CORPORATION, U.S.A.

P.O. Box 6555

Cypress, California 90630

11-5

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WARRANTY QUESTIONS AND ANSWERS

CUSTOMER SERVICE

Q. What costs are my responsibility during the warranty period?

A. The customer’s responsibility includes all costs of normal maintenance services,

non-warranty repairs, accident and collision damages, and oil, oil filters, air filters,

spark plugs, and brake shoes.

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:

Q. What are some examples of “abnormal” strain, neglect, or abuse?

A. These terms are general and overlap each other in areas. Specific examples include:

Running the machine out of oil, sustained high rpm, full-throttle, 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.

YAMAHA MOTOR CORPORATION U.S.A.

CUSTOMER RELATIONS DEPARTMENT

P.O. Box 6555

Cypress, California 90630

Q. Does the warranty cover incidental costs such as towing or transportation due to

a failure?

A. No. The warranty is limited to repair of the machine itself.

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.

Q. May I perform any or all of the recommended maintenance shown in the Owner’s

Manual instead of having the dealer do them?

A. 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 a Yamaha ATV dealer.

CHANGE OF ADDRESS

The federal government requires each manufacturer of a motor vehicle to

maintain

complete, up-to-date list of all first purchasers against the

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.

Q. Will the warranty be void or cancelled if I do not operate or maintain my new ATV

exactly as specified in the Owner’s Manual?

A. 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 described

in the Owner’s Manual, that failure may not be covered under warranty.

If you should move after you have purchased your new ATV, please advise

us of your new address by sending

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:

Q. What responsibility does my dealer have under this warranty?

A. Each Yamaha ATV dealer is expected to:

1. Completely set up every new machine before sale.

2. Explain the operation, 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.

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.

Q. Is the warranty transferable to second owners?

A. 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.

11-6

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YAMAHA EXTENDED SERVICE (Y.E.S.)

Keep your Yamaha protected even after your warranty

expires with genuine Yamaha Extended Service (Y.E.S.).

In addition, Travel and Recreation Interruption Protection

(TRIP) is included at no extra cost. TRIP gives you up to

$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.

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.

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.

Y.E.S. coverage is honored at any authorized Yamaha

dealer nationwide.

Y.E.S. is designed and administered by the same

Yamaha people who handle your warranty

–

and it

Y.E.S. coverage is transferable to a new owner if you

sell or trade in your ATV. That can make your Yamaha

much more valuable!

shows in the comprehensive coverage benefits. There

are no mileage limitations. 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.

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.

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.

11-7

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We urge you to act now. You’ll get the excellent benefits of

TRIP coverage right 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:

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

WARNING

A WARNING indicates a hazardous situation

which, if not avoided, could result in death

or serious injury.

11-8

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11-9

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INDEX

Engine oil............................................................5-3, 8-11

Accessories and loading ................................................ 6-6

Air filter element, cleaning............................................ 8-15

Engine, starting a warm................................................6-3

Engine stop switch.......................................................4-2

Engine speed limiter plate............................................ 4-5

Battery...........................................................................8-28

Brake lever, front.............................................................4-6

Brake lever, rear............................................................4-6

Brake lever free play, checking the rear........................8-26

Brake lever free play, adjusting the front......................8-23

Brake levers, checking and lubricating ........................8-27

Brakes, front and rear....................................................5-3

Brake shoes, checking the front .................................. 8-22

Brake pads, checking the rear.......................................8-25

Brake fluid level, checking the rear...............................8-25

Brake fluid level, changing the rear..............................8-26

Final transmission oil ........................................... 5-3, 8-14

Fuel........................................................................4-8, 5-3

Fuel cock......................................................................4-10

Fuel tank cap..................................................................4-8

Fuse, replacing.............................................................8-30

Handlebar switches........................................................ 4-2

Identification numbers.................................................. 11-1

Instruments and switches.............................................5-7

Cables, checking and lubricating ................................. 8-27

Carburetor, adjusting.................................................... 8-20

Chassis fasteners........................................................... 5-7

Choke ............................................................................ 4-11

Cleaning..........................................................................9-1

Key identification number............................................. 11-1

Kick starter ................................................................. 4-12

Label locations...............................................................2-1

Engine break-in.............................................................. 6-4

Engine, cold start...........................................................6-1

Engine idling speed...................................................... 8-20

Main switch .................................................................... 4-1

Maintenance and lubrication chart.................................8-5

Maintenance chart, emission control system.................8-3

Model label...................................................................11-2

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Valve clearance............................................................ 8-22

Owner’s manual and tool kit........................................... 8-1

Vehicle identification number ....................................... 11-1

Vehicle speed limiter ...................................................... 4-4

Parking........................................................................... 6-4

Parking brake................................................................. 4-7

Parking on a slope ......................................................... 6-5

Part locations ................................................................. 3-1

Pre-operation check list.................................................. 5-1

Wheel hub bearings, checking..................................... 8-28

Wheel, installing........................................................... 8-33

Wheel, removing .......................................................... 8-32

Riding your ATV............................................................. 7-1

Safety information .......................................................... 1-1

Seat .............................................................................. 4-11

Spark arrester, cleaning............................................... 8-19

Spark plug, checking...................................................... 8-9

Specifications.................................................................. 10-1

Speed limiters.................................................................. 4-3

Start switch..................................................................... 4-2

Storage........................................................................... 9-2

Throttle cable free play, checking................................8-21

Throttle lever..........................................................4-3, 5-4

Timing chain.................................................................8-22

Tire pressure, measuring ............................................... 5-5

Tires ............................................................................... 5-4

Tire wear limit................................................................. 5-6

Troubleshooting...........................................................8-34

Troubleshooting chart..................................................8-35

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WARNING

Improper ATV use can result in SEVERE INJURY or DEATH.

ALWAYS USE

AN APPROVED

HELMET AND

NEVER USE

ON PUBLIC

ROADS

NEVER CARRY

PASSENGERS

NEVER USE

WITH DRUGS

OR ALCOHOL

PROTECTIVE GEAR

NEVER operate:

ALWAYS:

without proper training or instruction.

at speeds too fast for your skills or the

conditions.

use proper riding techniques to avoid

vehicle overturns on hills and rough

terrain and in turns.

on public roads-a collision can occur with

another vehicle.

with a passenger-passengers affect

balance and steering and increase risk

of losing control.

avoid paved surfaces-pavement may

seriously affect handling and control.

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 TAIWAN

PRINTED ON RECYCLED PAPER

2008.07

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(E)

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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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