READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YFM400R
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-16-12
5GW-F8199-13
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EBU00941
1
-
Congratulations on your purchase of the Yamaha YFM400. It represents the result of many years
of Yamaha experience in the production of fine sporting, touring, and pace-setting racing ATVs.
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 techniques and skills necessary to ride your ATV. It also includes basic maintenance
and inspection procedures. If you have any questions regarding the operation or maintenance of
your ATV, please consult a Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
G READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND
COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL
INSTRUCTIONS.
G PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.
G 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 INFORMATION.
G THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE
UNDER 16 YEARS OF AGE.
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EBU00801
1
-
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN
SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe
WARNING
injury or death to the machine operator, a bystander or a person
inspecting or repairing the machine.
A CAUTION indicates special precautions that must be taken to
CAUTION:
avoid damage to the machine.
A NOTE provides key information to make procedures easier or clearer.
NOTE:
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EBU00011
IMPORTANT NOTICE
This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to
operate this machine on any public street, road or highway.
This machine 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 machine.
EBU01067
YFM400R
OWNER’S MANUAL
©2002 by Yamaha Motor Corporation,
AFFIX DEALER
U.S.A.
1st edition, June 2002
All rights reserved. Any reprinting or
LABEL HERE
unauthorized use without the written
permission of
Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11626-16-12
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EBU00014
CONTROL FUNCTIONS...................4-1
Main switch ......................................4-1
Indicator and warning lights.............4-2
Speedometer ...................................4-4
Fuel gauge.......................................4-4
Handlebar switches .........................4-5
Throttle lever....................................4-6
Speed limiter....................................4-7
Front brake lever..............................4-8
Rear brake pedal and lever .............4-8
Parking brake...................................4-9
Shift pedal......................................4-10
Reverse knob.................................4-10
Recoil starter..................................4-11
Fuel tank cap .................................4-12
Fuel cock........................................4-13
Starter (choke) ...............................4-14
Seat................................................4-15
Storage box....................................4-16
Front carrier ...................................4-16
Rear carrier....................................4-16
Front shock absorber
4
WARNING
Indicates a potential hazard that could
result in serious injury or death.
CONTENTS
LOCATION OF THE WARNING
1
AND SPECIFICATION LABELS....... 1-1
SAFETY INFORMATION.................. 2-1
2
DESCRIPTION AND MACHINE
3
IDENTIFICATION ............................. 3-1
Identification number records.......... 3-2
Key identification number................ 3-2
Vehicle identification number .......... 3-3
Model label...................................... 3-3
adjustment ...................................4-17
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Rear shock absorber
adjustment................................... 4-18
Auxiliary DC jack........................... 4-19
OPERATION.....................................6-1
Starting a cold engine......................6-1
Starting a warm engine ...................6-3
Warming up .....................................6-3
Reverse knob operation and
reverse driving...............................6-4
Shifting.............................................6-5
To start out and accelerate..............6-5
To decelerate...................................6-6
Engine break-in ...............................6-7
Parking.............................................6-8
Parking on a slope...........................6-9
Accessories and loading ...............6-10
6
PRE-OPERATION CHECKS ........... 5-1
Front and rear brakes ..................... 5-3
Fuel ................................................. 5-5
Engine oil ........................................ 5-7
Final gear oil.................................... 5-8
Throttle lever ................................... 5-8
Fittings and fasteners...................... 5-8
Lights............................................... 5-9
Switches.......................................... 5-9
Tires ................................................ 5-9
How to measure tire
5
RIDING YOUR ATV..........................7-1
Getting to know your ATV ...............7-3
Ride with care and good
7
pressure ...................................... 5-11
Tire wear limit................................ 5-12
judgement......................................7-4
Be careful where you ride..............7-16
Turning your ATV ..........................7-23
Climbing uphill ...............................7-25
Riding downhill ..............................7-30
Crossing a slope............................7-32
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Crossing through shallow
Brake fluid level check...................8-22
Brake fluid replacement.................8-23
Front brake lever free play.............8-24
Rear brake pedal and lever
adjustment ...................................8-25
Adjusting the rear brake light
water............................................ 7-34
Riding over rough terrain...............7-36
Sliding and skidding ......................7-38
What to do if ..................................7-40
What to do.....................................7-40
switch...........................................8-28
Clutch adjustment..........................8-28
Cable inspection and
lubrication.....................................8-29
Brake and shift pedal/
PERIODIC MAINTENANCE AND
8
ADJUSTMENT.................................. 8-1
Owner’s manual and tool kit............ 8-1
Periodic maintenance/
lubrication ...................................... 8-3
Engine oil......................................... 8-5
Final gear oil.................................... 8-9
Spark plug inspection....................8-12
Air filter element cleaning..............8-13
Spark arrester cleaning.................8-17
Carburetor adjustment...................8-18
Idle speed adjustment...................8-19
Valve clearance adjustment..........8-20
Throttle lever adjustment............... 8-20
Front brake pad check ..................8-21
Rear brake shoe inspection ..........8-21
brake lever lubrication..................8-30
Wheel removal...............................8-30
Wheel installation...........................8-31
Battery............................................8-32
Battery maintenance......................8-33
Fuse replacement..........................8-33
Replacing a headlight bulb ............8-35
Headlight beam adjustment...........8-37
Tail/brake light bulb
replacement .................................8-37
Troubleshooting.............................8-39
Troubleshooting chart....................8-40
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CLEANING AND STORAGE............ 9-1
A. Cleaning...................................... 9-1
B. Storage ....................................... 9-3
9
SPECIFICATIONS.......................... 10-1
NOISE REGULATION.................... 11-1
MAINTENANCE RECORD ............ 12-1
ATV LIMITED WARRANTY ........... 13-1
10
11
12
13
14
YAMAHA EXTENDED SERVICE
(Y.E.S.) .......................................... 14-1
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EBU00464
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1-1
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Read and understand all of the labels on your
machine. They contain important information
for safe and proper operation of your ATV.
2
1
2
3
Never remove any labels from your ATV. If a
label becomes difficult to read or comes off, a
replacement label is available from your
Yamaha dealer.
4
5
6
7
8
9
1
3
10
11
12
13
14
WARNING
Overloading this ATV or carrying cargo improperly can change
handling. stability and braking performance and can lead to an
accident. Never exceed the maximum front cargo limit of
: 40kg (88 lbs)
NEVER sit on the carrier. Refer to instructions in the Owner's
Manual.
5ND-F4877-00
1-2
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4
6
WARNING
Overloading this ATV or carrying cargo improperly can change
handling. stability and braking performance and can lead to an
accident. Never exceed the maximum rear cargo limit of
: 80kg (176 lbs)
NEVER sit on the carrier. Refer to instructions in the Owner's
Manual.
5ND-F4897-00
5
1-3
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7
8
.
MAXIMUM LLOOAADDIINNGG LLIIMMIITT
(
(
)
)
PULLING LOAD:
4020
904 l b f
147
33 l b f
N
4 1 0 k g f
1 5 k g f
TONGUE WEIGHT:
N
5FU-F151K-00
1-4
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EBU00924
SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently
from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even
during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take
proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these
instructions:
G Read this manual and all labels carefully and follow the operating procedures described.
G Never operate an ATV without proper training or instruction. Take a Training Course.
Beginners should receive training from a certified instructor. Contact an authorized ATV dealer
or call 1-800-887-2887 to find out about the training courses nearest you.
G Always follow the age recommendation:
- A child under 16 years old should never operate an ATV with engine size greater than 90cc.
G 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.
G Never carry passenger on an ATV.
2-1
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G Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, park-
ing lots and streets.
1
G Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
G Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or
jacket, and long pants.
2
3
4
G Never consume alcohol or drugs before or while operating this ATV.
G Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is
proper for the terrain, visibility and operating conditions, and your experience.
G Never attempt wheelies, jumps, or other stunts.
5
6
7
G 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 man-
ual.
8
9
G Always keep both hands on the handlebars and both feet on the footboards of the ATV during
operation.
G Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.
G 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.
10
11
12
13
14
2-2
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G Always follow proper procedures for turning as described in this manual. Practice turning at low
speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
G Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller
hills before attempting larger hills.
G 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
surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear
changes. Never go over the top of a hill at high speed.
G 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 back-
ward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause
the vehicle to lean sharply to one side. Go straight down the hill where possible.
G Always follow proper procedures for crossing the side of a hill as described in this manual.
Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the
ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning
technique described in this manual on level ground. Avoid crossing the side of a steep hill if
possible.
2-3
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G Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stall-
ing, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll back-
wards, follow the special procedure for braking described in this manual. Dismount on the
uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the
procedure described in this manual.
G 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 op-
erating over obstacles as described in this manual.
G Always be careful when skidding or sliding. Learn to safely control skidding or sliding by prac-
ticing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice,
go slowly and be very cautious in order to reduce the chance of skidding or sliding out of
control.
G Never operate an ATV in fast flowing water or in water deeper than that recommended in this
manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several times to let friction dry out the linings.
G Always be sure there are no obstacles or people behind you when you operate in reverse.
When it is safe to proceed in reverse, go slowly.
2-4
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G Always use the size and type tires specified in this manual.
G Always maintain proper tire pressure as described in this manual.
G Never modify an ATV through improper installation or use of accessories.
G Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Com-
mission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.
2-5
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WARNING
When transporting the ATV in another
vehicle, be sure it is kept upright and
that the fuel cock is in the “OFF” posi-
tion. Otherwise, fuel may leak out of the
carburetor or fuel tank.
WHAT CAN HAPPEN
Gasoline is poisonous and can cause
injuries.
POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could
be burned.
HOW TO AVOID THE HAZARD
Always turn off the engine when refuel-
ing. Do not refuel right after the engine
has been running and is still very hot.
Do not spill gasoline on the engine or
exhaust pipe/muffler when refueling.
Never refuel while smoking, or while in
the vicinity of sparks, open flames, or
other sources of ignition such as the pi-
lot lights of water heaters and clothes
dryers.
HOW TO AVOID THE HAZARD
If you should swallow some gasoline or
inhale a lot of gasoline vapor, or get
some gasoline in your eyes, see your
doctor immediately. If gasoline spills on
your skin, wash with soap and water. If
gasoline spills on your clothing, change
your clothes.
2-6
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WARNING
POTENTIAL HAZARD
Starting or running the engine in a
closed area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
HOW TO AVOID THE HAZARD
Always operate your ATV in an area with
adequate ventilation.
2-7
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EBU00032
DESCRIPTION AND MACHINE IDENTIFICATION
1
2
3
4
5
6
7
8
1. Rear carrier
2. Seat
3. Auxiliary DC jack
4. Front carrier
5. Brake pedal
6. Headlight
12. Front wheel
9
13. Rear brake lever
14. Parking brake lock plate
15. Starter (choke)
16. Speedometer
17. Reverse knob
18. Front brake lever
19. Throttle lever
20. Fuel gauge
21. Main switch
22. Handlebar switches
10
11
12
13
14
7. Fuel cock
8. Recoil starter
9. Tail/brake light
10. Rear wheel
11. Shift pedal
NOTE:
The machine you have purchased may differ slightly
from those shown in the figures of this manual.
3-1
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EBU00600
EBU00035
Identification number records
Record the key identification number, vehicle
identification number and model label infor-
mation in the spaces provided for assistance
when ordering spare parts from a Yamaha
dealer or for reference in case the vehicle is
stolen.
Key identification number
The key identification number is stamped on
the key as shown in the following illustration.
This number can be used for ordering a new
key.
1. KEY IDENTIFICATION NUMBER:
2. VEHICLE IDENTIFICATION NUMBER:
3. MODEL LABEL INFORMATION:
1. Key identification number
3-2
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EBU00036
EBU00787
Vehicle identification number
The vehicle identification number is stamped
into the frame.
Model label
The model label is affixed to the location in the
illustration. Record the information on this la-
bel in the space provided. This information will
be needed to order spare parts from your
Yamaha dealer.
1. Vehicle identification number
NOTE:
The vehicle identification number is used to
identify your machine.
1. Model label
3-3
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EBU00039
CONTROL FUNCTIONS
WARNING
Indicates a potential hazard that could
result in serious injury or death.
EBU00942
Main switch
Functions of the respective switch positions
are as follows:
ON:
The engine can be started only at this position
and the headlights and taillight come on when
the light switch is on.
OFF:
All electrical circuits are switched off. The key
can be removed in this position.
4-1
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EBU00802
EBU00732
Indicator and warning lights
Oil temperature warning light “OIL TEMP”
When the oil temperature reaches a specified
level, this light comes on to warn that the en-
gine oil temperature is too hot. If the warning
light comes on during operation, stop the en-
gine as soon as it is safe to do so and allow
the engine to cool down for about 10 minutes.
1
2
3
4
5
6
CAUTION:
G The engine may overheat if the ATV is
overloaded. If this happens, reduce
the load to specification.
G Restart after making sure that the
warning light is out. Continuous use
while the warning light is on may
cause damage to the engine.
7
8
1. Reverse indicator light “REVERSE”
2. Neutral indicator light “NEUTRAL”
3. Oil temperature warning light “OIL TEMP”
9
10
11
12
13
14
EBU00044
Reverse indicator light “REVERSE”
This indicator light comes on when the trans-
mission is in reverse.
EBU00045
Neutral indicator light “NEUTRAL”
This indicator light comes on when the trans-
mission is in neutral.
4-2
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EBU00733
ACB-10E
Oil temperature warning light checking method
Turn the main switch to “ON” and the
engine stop switch to “
”.
Oil temperature warning
light does not come on.
Oil temperature warning
light comes on.
Push start switch with the
transmission in neutral.
Check engine oil temperature.
Oil temperature
warning light comes
on momentarily.
Oil temperature warning
light does not come on.
Oil tempera-
ture is low.
Oil tempera-
ture is high.
Allow to cool.
Engine oil temperature and
electrical circuit are OK. Go
ahead with riding.
Ask a Yamaha dealer to
inspect the electrical circuit.
4-3
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EBU00051
EBU00052
Speedometer
Fuel gauge
The speedometer shows riding speed. This
speedometer is equipped with an odometer
and trip odometer. The trip odometer can be
reset to “0” with the reset knob. Use the trip
odometer to estimate how far you can ride on
a tank of fuel before going to reserve. This in-
formation will enable you to plan fuel stops in
the future.
The fuel gauge indicates the amount of fuel in
the fuel tank. When the needle reaches the
red line, refill the tank at the first opportunity.
1. Fuel gauge
NOTE:
If the machine runs out of fuel, move the fuel
cock lever to the “RES” position. Approxi-
mately 4.0 L (0.9 Imp gal, 1.1 US gal) of fuel
will be remaining in the tank.
1. Reset knob
3. Odometer
2. Speedometer
4. Trip odometer
4-4
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EBU00053
EBU00607
Handlebar switches
Start switch “
”
The starter motor cranks the engine when this
switch is pushed.
CAUTION:
See starting instructions prior to starting
the engine. (See page 6-1 for details.)
_
EBU01204
Light switch “
Set the switch to “
and the taillight.
/
/OFF”
” to turn on the low beam
1. Lights switch “
2. Engine stop switch “ ”/“
3. Start switch “
/
/OFF”
”
Set the switch to “
” to turn on the high
”
beam and the taillight.
Set the switch to “OFF” to turn off all the lights.
EBU01205
Engine stop switch “
Make sure that the engine stop switch is set to
” before starting the engine. The engine
stop switch controls ignition and can be used
at all times to stop the engine, especially in an
emergency. The engine will not start or run
when the engine stop switch is set to “ ”.
/
”
CAUTION:
_
Do not use the headlights with the engine
turned off for more than thirty minutes.
The battery may discharge to the point
that the starter motor will not operate
properly. If this should happen, remove
“
the battery and recharge it.
_
4-5
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EBU00062
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 le-
ver is released.
Once the engine is running, movement of the
throttle lever will increase the engine speed.
Regulate the speed of the machine by varying
the throttle position. Because the throttle is
spring-loaded, the machine will decelerate,
and the engine will return to an idle any time
the hand is removed from the throttle lever.
WARNING
POTENTIAL HAZARD
Malfunction of throttle.
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
before 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.
1. Throttle lever
4-6
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EBU01159
Speed limiter
WARNING
The speed limiter keeps the throttle from fully
opening, even when the throttle lever is
pushed to the maximum. Turning in the ad-
justing screw limits the maximum engine pow-
er available and decreases the maximum
speed of the ATV.
POTENTIAL HAZARD
Improper adjustment of the speed limit-
er and throttle.
WHAT CAN HAPPEN
The throttle cable could be damaged.
Improper throttle operation could result.
You could lose control, have an acci-
dent or be injured.
HOW TO AVOID THE HAZARD
Do not turn the adjusting screw out more
than 12 mm (0.47 in). Always make sure
the throttle lever free play is adjusted to
3–5 mm (0.12–0.20 in). See page 8-20.
1. Locknut
2. Adjusting screw
a. 12 mm (0.47 in)
4-7
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EBU00070
Front brake lever
The front brake lever is located on the right
handlebar. Pull it toward the handlebar to ap-
ply the front brake.
1. Rear brake pedal
1. Front brake lever
EBU00073
Rear brake pedal and lever
The brake pedal is located on the right side of
the machine and the brake lever is located on
the left handlebar. Push down on the pedal or
pull the lever toward the handlebar to apply
the rear brake.
1. Rear brake lever
4-8
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EBU00074
Parking brake
WARNING
Use the parking brake when you have to start
the engine or park the machine, especially on
a slope. Apply the rear brake lever and push
down the lock plate to apply the parking
brake. Squeeze the rear brake lever to re-
lease the parking brake.
POTENTIAL HAZARD
Improper use of the parking brake.
WHAT CAN HAPPEN
The ATV could start moving unexpect-
edly if the parking brake is not applied
before starting the engine. This could
cause loss of control or a collision. The
brake could overheat if you ride the ATV
without releasing the parking brake.
You could lose braking performance
which could cause an accident. You
could also wear out the brakes prema-
turely.
HOW TO AVOID THE HAZARD
Always set the parking brake before
starting the engine. Always be sure you
have released the parking brake before
you begin to ride.
1. Lock plate
4-9
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EBU00084
EBU01028*
Shift pedal
Reverse knob
This machine is equipped with a constant-
mesh 5-speed forward and 1-speed reverse
transmission. The shift pedal is located on the
left side of the engine. Reverse is at the bot-
tom position. Neutral is one position above re-
verse.
The reverse knob is used to shift into reverse
gear. Refer to the “Reverse knob operation
and reverse driving” section (page 6-4) before
operating this machine in reverse gear.
1. Reverse knob
1. Shift pedal
4-10
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EBU00590
Recoil starter
WARNING
Firmly grasp the handle and pull slightly until
engagement can be felt. Then pull forcefully,
being careful not to pull the rope all the way
out.
POTENTIAL HAZARD
Starting the engine in gear and/or start-
ing the engine without setting the park-
ing brake.
WHAT CAN HAPPEN
The ATV could start to move unexpect-
edly, which could cause an accident.
HOW TO AVOID THE HAZARD
Put the transmission in neutral and set
the parking brake before starting the en-
gine.
1. Recoil starter
4-11
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EBU00092
Fuel tank cap
Remove the fuel tank cap by turning it coun-
terclockwise.
1. Fuel tank cap
4-12
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EBU00093
Fuel cock
The fuel cock supplies fuel from the fuel tank
to the carburetor.
The fuel cock has three positions.
OFF: With the lever in this position fuel will
not flow. Always turn the lever to this
position when the engine is not running.
ON: With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
RES: This indicates reserve. If you run out of
fuel while riding, turn the lever to this
position. THEN FILL THE FUEL TANK
AT THE FIRST OPPORTUNITY. After
refuelling, return the fuel cock lever to
the “ON” position.
4-13
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EBU00095
Starter (choke) “
”
Starting a cold engine requires a richer air-fuel
mixture. A separate starter circuit supplies this
mixture.
Move in direction a to turn on the starter
(choke).
Move in direction b to turn off the starter
(choke).
Refer to “Starting a cold engine” for proper op-
eration. (See page 6-1.)
4-14
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EBU00567
Seat
To install the seat, insert the projections on
the front of the seat into the seat holders and
push down on the seat at the rear.
To remove the seat, pull the seat lock lever
upward and pull up the seat at the rear.
NOTE:
Make sure that the seat is securely fitted.
1. Seat lock lever
1. Projection (× 2)
2. Seat holder (× 2)
4-15
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EBU00581
EBU00582
Storage box
Front carrier
Maximum load limit: 2 kg (4.4 lb)
Maximum load limit: 40 kg (88 lb)
CAUTION:
EBU00583
To protect from damage, do not put metal
products, like tools or sharply edged prod-
ucts directly in the storage box. If they
must be stored, wrap them in appropriate
cushion material.
Rear carrier
Maximum load limit: 80 kg (176 lb)
4-16
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EBU01104
Front shock absorber adjustment
The spring preload can be adjusted to suit the
rider’s weight and riding conditions.
Adjust the spring preload as follows.
To increase the spring preload, turn the ad-
justing ring in direction a.
Standard position: B
A - Minimum (soft)
E - Maximum (hard)
WARNING
POTENTIAL HAZARD
Improper shock absorber adjustment.
WHAT CAN HAPPEN
Uneven adjustment can cause poor
handling and loss of stability, which
could lead to an accident.
To decrease the spring preload, turn the ad-
justing ring in direction b.
NOTE:
_
A special wrench can be obtained at a
Yamaha dealer to make this adjustment.
_
HOW TO AVOID THE HAZARD
Always adjust the shock absorbers on
the left and right side to the same set-
ting.
1. Spring preload adjusting ring
2. Position indicator
4-17
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EBU01103
Rear shock absorber adjustment
The spring preload can be adjusted to suit the
rider’s weight and riding conditions.
Adjust the spring preload as follows.
To increase the spring preload, turn the ad-
justing ring in direction a.
Standard position: B
A - Minimum (soft)
E - Maximum (hard)
To decrease the spring preload, turn the ad-
justing ring in direction b.
NOTE:
_
A special wrench can be obtained at a
Yamaha dealer to make this adjustment.
_
1. Spring preload adjusting ring
2. Position indicator
4-18
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EBU01002
Auxiliary DC jack
The auxiliary DC jack is located at the front
right side of the ATV. The auxiliary DC jack
can be used for suitable work lights, radios,
etc. The auxiliary DC jack should only be used
when the engine is running.
1. Set the light switch to “OFF”.
2. Start the engine. (See pages 6-1–6-3.)
3. Open the auxiliary DC jack cap, and then
insert the accessory power plug into the
jack.
1. Auxiliary DC jack
2. Cap
Maximum rated capacity for the auxiliary
DC jack:
DC 12 V, 120 W (10 A)
4. When the auxiliary DC jack is not being
used, cover it with the cap.
4-19
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CAUTION:
_
G Do not use accessories requiring
more than the above maximum capac-
ity. This may overload the circuit and
cause the fuse to blow.
G If accessories are used without the
engine running or with the headlights
turned on, the battery will lose its
charge and engine starting may be-
come difficult.
G Do not use an automotive cigarette
lighter or other accessories with a
plug that gets hot because the jack
can be damaged.
_
EBU00112
WARNING
Indicates a potential hazard that could
result in serious injury or death.
4-20
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PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM
ROUTINE
PAGE
• Check operation, free play, fluid level and fluid leakage.
• Fill with DOT 4 brake fluid if necessary.
Front brake
5-3–5-4,
8-21–8-28
Rear brake
Fuel
• Check operation, lever/pedal free play and pedal height.
• Check fuel level.
• Fill with fuel if necessary.
5-5–5-6
• Check oil level.
• Fill with oil if necessary.
Engine oil
5-7, 8-5–8-9
Final gear oil
Throttle
• Check for leakage.
5-8, 8-9–8-11
• Check for proper throttle cable operation and free play.
5-8, 8-19
5-9–5-12,
8-30–8-31
Wheels and tires
• Check tire pressure, wear and damage.
Fittings and fasteners
Lights
• Check all fittings and fasteners.
• Check for proper operation.
5-8
5-9, 8-35–8-38
5-1
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WARNING
1
POTENTIAL HAZARD
Failure to inspect the ATV before oper-
2
ating.
3
Failure to properly maintain the ATV.
4
WHAT CAN HAPPEN
Increases the possibility of an accident
5
6
or equipment damage.
HOW TO AVOID THE HAZARD
7
Always inspect your ATV each time you
use it to make sure the ATV is in safe op-
erating condition.
8
9
Always follow the inspection and main-
tenance procedures and schedules de-
scribed in the Owner’s Manual.
10
11
12
13
14
5-2
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EBU01252
Front and rear brakes
Brake fluid leakage (front brake)
Brake levers and brake pedal
Check to see if any brake fluid is leaking out of
the hose, joint or brake fluid reservoir of the
front brake. Apply the brake firmly for one
minute. If the lever moves slowly inward,
there may be a leak in the brake system. If
there is any leakage, the brake system should
be inspected by a Yamaha dealer.
Check for correct free play in the front brake
lever. If the free play is incorrect, have a
Yamaha dealer adjust it.
Check for correct free play in the rear brake
lever and brake pedal. If the free play is incor-
rect, adjust it. (See pages 8-24–8-27.)
Check operation of the levers and pedal. They
should move smoothly and there should be a
firm feeling when the brake is applied. If not,
have a Yamaha dealer inspect them.
Brake operation
Test the brakes at slow speed after starting
out to make sure they are working properly. If
the brakes do not provide proper braking per-
formance, inspect the brake pads and shoes
for wear. (See page 8-21.)
Brake fluid level (front brake)
Check the brake fluid level. Add fluid if neces-
sary. (See pages 8-22–8-23.)
Recommended brake fluid: DOT 4
5-3
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WARNING
POTENTIAL HAZARD
Riding with improperly operating
brakes.
WHAT CAN HAPPEN
You could lose braking ability, which
could lead to an accident.
HOW TO AVOID THE HAZARD
Always check the brakes at the start of
every ride. Do not ride the ATV if you
find any problem with the brakes. If a
problem cannot be corrected by the ad-
justment procedures provided in this
manual, have a Yamaha dealer check for
the cause.
5-4
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EBU01085
Fuel
Your Yamaha engine has been designed to
use regular unleaded gasoline with a pump
octane number ([R+M]/2) of 86 or higher, or
research octane number of 91 or higher. If
knocking or pinging occurs, use a different
brand of gasoline or premium unleaded fuel.
Unleaded fuel will give you longer spark plug
life and reduced maintenance cost.
Make sure there is sufficient gasoline in the
tank.
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
Total:
15 L (3.3 Imp gal, 4.0 US gal)
Reserve:
4.0 L (0.9 Imp gal, 1.1 US gal)
CAUTION:
_
Use only unleaded gasoline. The use of
leaded gasoline will cause severe damage
to internal engine parts, such as the valves
and piston rings, as well as to the exhaust
system.
_
5-5
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Gasohol
WARNING
There are two types of gasohol; gasohol con-
taining ethanol and that containing methanol.
Gasohol containing ethanol can be used if
ethanol content does not exceed 10%. Gaso-
hol containing methanol is not recommended
by Yamaha because it may cause fuel system
damage or vehicle performance problems.
POTENTIAL HAZARD
Improper care when refueling.
WHAT CAN HAPPEN
Fuel can spill, which can cause a fire
and severe injury.
Fuel expands when it heats up. If the
fuel tank is overfilled, fuel could spill out
due to heat from the engine or the sun.
HOW TO AVOID THE HAZARD
Do not overfill the fuel tank. Be careful
not to spill fuel, especially on the engine
or exhaust pipe. Wipe up any spilled fuel
immediately. Be sure the fuel tank cap is
closed securely.
Do not refuel right after the engine has
been running and is still very hot.
1. Fuel level
2. Fuel tank filler tube
5-6
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EBU01084
Engine oil
CAUTION:
_
Make sure the engine oil is at the specified
level. Add oil as necessary. (See pages 8-5–
8-9.)
G In order to prevent clutch slippage
(since the engine oil also lubricates
the clutch), do not mix any chemical
additives. Do not use oils with a diesel
specification of “CD” or oils of a high-
er quality than specified. In addition,
do not use oils labeled “ENERGY
CONSERVING II” or higher.
Recommended oil:
0˚
90˚
110˚ 130˚F
10˚
30˚
70˚
50˚
YAMALUBE 4 (20W40) or SAE 20W40
YAMALUBE 4 (10W30) or SAE 10W30
SAE 5W30
G Make sure that no foreign material en-
ters the crankcase.
_
-20˚
30˚
40˚ 50˚C
-10˚
0˚
20˚
10˚
Oil quantity:
Periodic oil change:
Recommended engine oil classification:
API Service SE, SF, SG type or higher
2.9 L (2.6 Imp qt, 3.1 US qt)
With oil filter replacement:
3.0 L (2.6 Imp qt, 3.2 US qt)
Total amount:
3.5 L (3.1 Imp qt, 3.7 US qt)
5-7
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EBU00493
EBU01083
Final gear oil
Throttle lever
Make sure the final gear oil is at the specified
level. Add oil as necessary. (See pages 8-9–
8-11 for details.)
Check to see that the throttle lever operates
correctly. It must open smoothly and spring
back to the idle position when released. Have
a Yamaha dealer repair as necessary for
proper operation.
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
EBU01162
If desired, an SAE 80W90 hypoid gear oil may
be used for all conditions.
Fittings and fasteners
Always check the tightness of chassis fittings
and fasteners before a ride. Take the machine
to a Yamaha dealer or refer to the Service
Manual for correct tightening torque.
NOTE:
GL-4 is a quality and additive rating, GL-5 or
GL-6 rated hypoid gear oils may also be used.
5-8
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EBU01003
EBU00157
Lights
Tires
Check the headlights and tail/brake light to
make sure they are in working condition. Re-
pair as necessary for proper operation.
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires, or
with improper or uneven tire pressure.
EBU01170
WHAT CAN HAPPEN
Switches
Use of improper tires on this ATV, or op-
eration of this ATV with improper or un-
even tire pressure, may cause loss of
control, increasing your risk of accident.
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper
operation.
HOW TO AVOID THE HAZARD
1. The tires listed below have been ap-
proved by Yamaha Motor Co., Ltd. for
this model. Other tire combinations
are not recommended.
Manufacturer
Size
Type
KT121
KT125
Front
Rear
DUNLOP
AT25 x 8-12
AT25 x 11-10
DUNLOP
Manufacturer
CHENG SHIN
CHENG SHIN
Size
Type
M907
Front
Rear
AT25 x 8-12
AT25 x 11-10
M908
5-9
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2. The tires should be set to the recom-
mended pressure:
4. Use no more than the following pres-
sures when seating the tire beads.
Front 250 kPa (2.5 kgf/cm2, 36 psi)
Rear 250 kPa (2.5 kgf/cm2, 36 psi)
Higher pressures may cause the tire
to burst. Inflate the tires very slowly
and carefully. Fast inflation could
cause the tire to burst.
G Recommended tire pressure
Front 25 kPa (0.25 kgf/cm2, 3.6 psi)
Rear 25 kPa (0.25 kgf/cm2, 3.6 psi)
G Check and adjust tire pressures when
the tires are cold.
G Tire pressures must be equal on both
sides.
3. Tire pressure below the minimum
specified could cause the tire to dis-
lodge from the rim under severe
riding conditions.
The following are minimums:
Front 22 kPa (0.22 kgf/cm2, 3.2 psi)
Rear 22 kPa (0.22 kgf/cm2, 3.2 psi)
5-10
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EBU00159
How to measure tire pressure
Use the low-pressure tire gauge.
NOTE:
The low-pressure tire gauge is included as
standard equipment. Make two measure-
ments of the tire pressure and use the second
reading. Dust or dirt in the gauge could cause
the first reading to be incorrect.
Set pressure with tires cold. Set tire pressures
to the following specifications:
1. Low-pressure tire gauge
Recommended
Minimum
22 kPa
Maximum
28 kPa
pressure
25 kPa
Front
Rear
(0.25 kgf/cm2, (0.22 kgf/cm2, (0.28 kgf/cm2,
3.6 psi)
3.2 psi)
4.0 psi)
25 kPa
22 kPa
28 kPa
(0.25 kgf/cm2, (0.22 kgf/cm2, (0.28 kgf/cm2,
3.6 psi)
3.2 psi)
4.0 psi)
5-11
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EBU00160
Tire wear limit
When the tire groove decreases to 3 mm
(0.12 in) due to wear, replace the tire.
a. 3 mm (0.12 in)
5-12
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EBU00161
EBU00749
Starting a cold engine
OPERATION
WARNING
WARNING
Indicates a potential hazard that could
result in serious injury or death.
POTENTIAL HAZARD
Freezing control cables in cold weather.
WHAT CAN HAPPEN
You could be unable to control the ATV,
which could lead to an accident or colli-
sion.
WARNING
POTENTIAL HAZARD
Operating ATV without being familiar
with all controls.
HOW TO AVOID THE HAZARD
When riding in cold weather, always
make sure all control cables work
smoothly before you begin riding.
WHAT CAN HAPPEN
Loss of control, which could cause an
accident or injury.
HOW TO AVOID THE HAZARD
1. Set the parking brake.
Read the Owner’s Manual carefully. If
there is a control or function you do not
understand, ask your Yamaha dealer.
2. Turn the fuel cock to “ON”.
3. Turn the main switch to “ON” and the en-
gine stop switch to “ ”.
4. Shift the transmission into neutral.
6-1
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Position 3: Cold engine start-
ambient temperature above
NOTE:
G When the transmission is in neutral, the
1
neutral indicator light should come on. If
the light does not come on, ask a
Yamaha dealer to inspect it.
25 °C (80 °F) and warm engine
start position.
2
3
G The engine can be started in any gear if
the rear brake lever is applied. However,
it is recommended to shift into neutral be-
4
5
6
fore starting the engine.
_
7
5. Use the starter (choke) in reference to
the figure:
8
Position 1: Cold engine start-
ambient temperature below 5 °C
(40 °F).
Position 2: Cold engine start-
ambient temperature at 0 °C
(30 °F)–30 °C (90°F) and warm-
ing up position.
9
10
11
12
13
14
a. Starter (choke) lever
2. Half open
1. Fully open
3. Closed
6. Completely close the throttle lever and
start the engine by pushing the start
switch.
6-2
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NOTE:
_
CAUTION:
See the “Engine break-in” section prior to
operating the engine for the first time.
_
G If the engine fails to start, release the
start switch, then push the start switch
again. Pause a few seconds before the
next attempt. Each cranking should be as
short as possible to preserve battery en-
ergy. Do not crank the engine more than
10 seconds on each attempt.
_
EBU00180
Starting a warm engine
To start a warm engine, refer to the “Starting a
cold engine” section. The starter (choke)
should not be used. The throttle should be
opened slightly.
G If the battery is discharged, pull the recoil
starter to start the engine.
_
7. If the engine is started with the starter
(choke) in position 1, the starter (choke)
should be returned to position 2 to warm
up the engine. If the engine is started with
the starter (choke) in position 2, keep
the starter (choke) in this position to
warm up the engine.
8. Continue warming up the engine until it
idles smoothly and return the starter
(choke) to position 3 before riding.
EBU00182
Warming up
To get maximum engine life, always warm up
the engine before starting off. Never acceler-
ate hard with a cold engine! To see whether or
not the engine is warm, check if it responds to
the throttle normally with the starter (choke)
turned off.
6-3
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EBU00195
NOTE:
Reverse knob operation and reverse
driving
When in reverse, the reverse indicator light
should be on. If the light does not come on, ask
a Yamaha dealer to inspect the machine.
CAUTION:
Before shifting, stop the machine and re-
turn the throttle lever to its closed posi-
tion. Otherwise the transmission may be
damaged.
4. Check behind you for people or obsta-
cles, then release the rear brake lever.
5. Open the throttle lever gradually and con-
tinue to watch to the rear while backing.
1. Bring the machine to a complete stop
and return the throttle lever to the closed
position with the transmission in neutral.
2. While applying the rear brake lever, turn
the reverse knob clockwise with your
right hand.
WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or person be-
hind you, resulting in serious injury.
3. Shift the transmission into reverse by
pressing down on the shift pedal.
HOW TO AVOID THE HAZARD
When you shift into reverse, make sure
there are no obstacles or people behind
you. When it is safe to proceed, go slow-
ly.
6-4
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EBU01295
Shifting
CAUTION:
_
This model has a 5-speed forward and
1-speed reverse transmission with centrifugal
automatic clutch. The transmission allows you
to control the amount of power you have avail-
able at a given speed or for starting, acceler-
ating, climbing hills, etc. To shift into neutral,
return the throttle lever to the closed position
and repeatedly depress the shift pedal until it
stops. When it stops, it will be in reverse gear.
Raise the pedal slightly to neutral.
Do not coast for long periods with the en-
gine off, and do not tow the ATV a long dis-
tance. Even in the neutral position, the
transmission is only properly lubricated
when the engine is running. Inadequate lu-
brication may cause damage.
_
EBU00205
To start out and accelerate
1. Release the throttle lever.
CAUTION:
Always close the throttle while shifting
gears. Otherwise, damage to the engine
and drive train may result.
2. Shift into first gear and release the shift
pedal.
3. Open the throttle gradually.
1. Shift pedal
N. Neutral position
R. Reverse position
6-5
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EBU00207
4. Once the machine has attained adequate
speed, release the throttle lever.
5. Shift into second gear and release the
shift pedal.
6. Open the throttle gradually.
7. Follow the same procedure when shifting
to the next higher gear.
To decelerate
When slowing down or stopping, release the
throttle and apply the brakes smoothly and
evenly. As you slow down, shift to a lower
gear. Be sure that the engine has sufficiently
slowed before engaging a lower gear. Improp-
er use of the brakes or shifting can cause the
tires to lose traction, reducing control and in-
creasing the possibility of an accident.
WARNING
POTENTIAL HAZARD
Opening the throttle before releasing
the shift pedal.
WARNING
POTENTIAL HAZARD
Engaging a lower gear when the engine
speed is too high.
WHAT CAN HAPPEN
The machine could wheelie. This would
increase the chance of an accident, in-
cluding overturn.
WHAT CAN HAPPEN
The wheels could stop rotating. This
could cause loss of control, an accident
and injury. It could also cause engine or
drive train damage.
HOW TO AVOID THE HAZARD
Release the shift pedal before opening
the throttle. Open the throttle gradually.
HOW TO AVOID THE HAZARD
Make sure the engine has sufficiently
slowed before shifting to a lower gear.
6-6
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EBU00209
Engine break-in
Each full throttle acceleration sequence
should be followed with a substantial rest pe-
riod for the engine by cruising at lower r/min
so the engine can rid itself of the temporary
build up of heat.
If any abnormality is noticed during this peri-
od, consult a Yamaha dealer.
1. 0–10 hours:
There is never a more important period in the
life of your machine than the period between
zero and 20 hours.
For this reason, we ask that you carefully read
the following material. Because the engine is
brand new, you must not put an excessive
load on it for the first several hours of running.
During the first 20 hours, the various parts in
the engine wear and polish themselves to the
correct operating clearances.
During this period, prolonged full throttle oper-
ation or any condition which might result in ex-
cessive engine heating must be avoided.
However, momentary (2–3 seconds maxi-
mum) full throttle operation under load does
not harm the engine.
Avoid continuous operation above half
throttle. Allow a cooling off period of five
to ten minutes after every hour of opera-
tion. Vary the speed of the machine from
time to time. Do not operate it at one set
throttle position.
6-7
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EBU00211
2. 10–20 hours:
Parking
Avoid prolonged operation above 3/4
throttle. Rev the machine freely through
the gears but do not use full throttle at
any time.
When parking, stop the engine and shift into
neutral. Turn the fuel cock to “OFF” and apply
the parking brake.
3. After break-in:
Avoid prolonged full throttle operation.
Vary speeds occasionally.
1. Lock plate
6-8
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EBU01296
Parking on a slope
1. Bring the ATV to a stop by applying the
brakes in low gear.
2. Stop the engine.
3. With the rear brake lever and pedal ap-
plied, apply the parking brake and slowly
release the brake pedal.
WARNING
POTENTIAL HAZARD
Parking on a hill or other incline.
WHAT CAN HAPPEN
The ATV could roll out of control, in-
creasing the chance of an accident.
HOW TO AVOID THE HAZARD
Avoid parking on hills or other inclines.
If you must park on an incline, put the
ATV in low gear, apply the parking
brake, and block the front and rear
wheels with rocks or other objects. Do
not park the ATV at all on hills that are
so steep you could not walk up them
easily.
6-9
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EBU00221
Accessories and loading
G Accessories should be rigidly and securely
mounted. An accessory which can shift po-
sition or come off while you are riding could
affect your ability to control the ATV.
EBU00222
Accessories
Accessories can affect the handling and con-
trol of your ATV. Keep the following in mind
when considering an accessory or operating
an ATV which has accessories.
G Do not mount an accessory where it could
interfere with your ability to control the ATV.
Examples include (but are not limited to) a
heavy or bulky object attached to the han-
dlebars which could make steering difficult,
an accessory that limits your ability to move
around on the seat, or one that limits your
view.
G Choose only accessories designed for your
ATV. Your Yamaha dealer has a variety of
genuine Yamaha accessories. Other ac-
cessories may also be available on the
market. However, it is not possible for
Yamaha to test all non-Yamaha accesso-
ries, nor have any control over the quality or
suitability of them. Choose a genuine
Yamaha accessory, or one that is equiva-
lent in design and quality.
G Use extra caution when riding an ATV with
accessories. The ATV may handle differ-
ently than it does without accessories.
6-10
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EBU00588
Loading
G Do not exceed the maximum tongue
weight. You can measure tongue weight
with a bathroom scale. Put the tongue of
the loaded trailer on the scale with the
tongue at hitch height. Adjust the load in the
trailer, if necessary, to reduce the weight on
hitch.
G If you are carrying cargo and towing a trail-
er, include the tongue weight in the maxi-
mum vehicle load limit.
G Load cargo on the carrier as close to the
center of the vehicle as possible. Put cargo
at the front of the rear carrier. Center the
load from side to side.
G Tie down cargo securely to the carriers.
Make sure cargo in the trailer cannot move
around. A shifting load can cause an acci-
dent.
Cargo or a trailer can change the stability and
handling of an ATV.
You must use common sense and good judg-
ment when carrying cargo or towing a trailer.
Keep the following points in mind:
G Never exceed the weight limits shown. An
overloaded ATV can be unstable.
MAXIMUM LOADING LIMIT
G Vehicle loading limit (total weight of car-
go, rider and accessories, and tongue
weight): 210 kg (463 lb)
G Front carrier: 40 kg (88 lb)
G Rear carrier: 80 kg (176 lb)
G Storage box: 2 kg (4.4 lb)
G Trailer hitch:
Pulling load (total weight of trailer and
cargo): 410 kgf (904 lbf)
Tongue weight (vertical weight on trailer
hitch point): 15 kgf (33 lbf)
G Make sure the load does not interfere with
controls or your ability to see where you are
going.
6-11
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G Ride more slowly than you would without a
load. The more weight you carry, the slow-
er you should go. Although conditions vary,
it is good practice not to exceed 2nd gear
whenever you are carrying heavier loads or
when towing a trailer.
G Allow more braking distance. A heavier ve-
hicle takes longer to stop.
G Avoid making sharp turns unless at very
slow speeds.
WARNING
POTENTIAL HAZARD
Overloading this ATV or carrying or tow-
ing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle han-
dling which could lead to an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity
for this ATV.
G Avoid hills and rough terrain. Choose ter-
rain carefully. Added weight affects the sta-
bility and handling of the ATV.
Cargo should be properly distributed
and securely attached. Reduce speed
when carrying cargo or pulling a trailer.
Allow greater distance for braking.
6-12
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EBU01297
WARNING
_
Indicates a potential hazard that could
result in serious injury or death.
6-13
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Riding
Your
ATV
7
7-1
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WARNING
_
Indicates a potential hazard that could
result in serious injury or death.
GETTING TO KNOW YOUR ATV
begin to ride, be sure you have read this
Owner’s Manual completely and understand
the operation of the controls. Pay particular
attention to the safety information on pages
2-1–2-7. Please also read all caution and
warning labels on your ATV.
This ATV is mainly for utility use, but may also
be used for recreation. This section, Riding
your ATV, provides general ATV riding in-
structions for recreational riding. The skills
and techniques described in this section,
however, are appropriate for all types of
riding. Riding your ATV requires special skills
acquired through practice over a period of
time. Take the time to learn the basic tech-
niques well before attempting more difficult
maneuvers.
Riding your new ATV can be a very enjoyable
activity, providing you with hours of pleasure.
But it is essential to familiarize yourself with
the operation of the ATV to achieve the skill
necessary to enjoy riding safely. Before you
7-3
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RIDE WITH CARE AND GOOD
JUDGEMENT
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators
should complete the certified training
course offered by Yamaha. They should
then regularly practice the skills learned
in the course and the operating tech-
niques described in this Owner’s Manu-
al.
For more information about the training
course, contact an authorized ATV deal-
er or call 1-800-887-2887.
Get training if you are inexperienced.
Beginners should get training from a certified
instructor.
Become familiar with this ATV at slow speeds
first, even if you are an experienced operator.
Do not attempt to operate at maximum perfor-
mance until you are totally familiar with the
ATV’s handling and performance characteris-
tics.
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 maneu-
vers.
WARNING
POTENTIAL HAZARD
Operating this ATV without proper in-
struction.
WHAT CAN HAPPEN
The risk of an accident is greatly in-
creased if the operator does not know
how to operate the ATV properly in dif-
ferent situations and on different types
of terrain.
7-4
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Not recommended for children under
16 years of age.
WARNING
POTENTIAL HAZARD
Failure to follow the age recommenda-
tions for this ATV.
WHAT CAN HAPPEN
Use by children of ATVs that are not rec-
ommended for their age can lead to se-
vere injury or death of the child.
HOW TO AVOID THE HAZARD
A child under 16 should never operate
an ATV with engine size greater than
90cc.
7-5
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This ATV is designed to carry operator and
cargo 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 passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The long seat
is to allow the operator to shift position
as needed during operation. It is not for
carrying passengers.
7-6
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Apparel
Operating without protective clothing
increases your chances of severe injury
in the event of an accident.
HOW TO AVOID THE HAZARD
Always wear an approved motorcycle
helmet that fits properly.
You should also wear:
eye protection
WARNING
POTENTIAL HAZARD
Operating this ATV without wearing an
approved motorcycle helmet, eye pro-
tection and protective clothing.
WHAT CAN HAPPEN
Operating without an
approved
cycle helmet increas-
es your chances of a
severe head injury or
death in the event of
(goggles or face shield)
gloves
boots
long-sleeved shirt or jacket
long pants
motor-
an accident.
Operating without
eye protection can
result in an accident and increases your
chances of a severe injury in the event
of an accident.
7-7
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Do not operate after consuming alcohol or
drugs.
Operator’s performance capability is reduced
by the influence of alcohol or drugs.
WARNING
POTENTIAL HAZARD
Operating this ATV after consuming al-
cohol or drugs.
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and percep-
tion.
Could result in an accident.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before
or while driving this ATV.
7-8
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Pre-operation checks
WARNING
Always perform the pre-operation checks list-
ed on page 5-1 before riding for safety and
proper care of the ATV.
POTENTIAL HAZARD
Operating this ATV with improper tires,
or with improper or uneven tire pres-
sure.
WARNING
POTENTIAL HAZARD
WHAT CAN HAPPEN
Failure to inspect the ATV before oper-
ating. 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 op-
erating condition. Always follow the in-
spection and maintenance procedures
and schedules described in the Owner’s
Manual.
Use of improper tires on this ATV, or op-
eration of this ATV with improper or un-
even tire pressure, may cause loss of
control, increasing your risk of an acci-
dent.
HOW TO AVOID THE HAZARD
Always use the size and type tires spec-
ified in the Owner’s Manual for this vehi-
cle on pages 5-9–5-10.
Always maintain proper tire pressure as
described in the Owner’s Manual on
page 5-11.
7-9
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Speed limiter
WARNING
_
For riders inexperienced with this model, this
model is equipped with a speed limiter in the
throttle lever housing. The speed limiter limits
the power and top speed of the ATV. Turning
the adjusting screw in decreases top speed,
and turning it out increases top speed. (See
page 4-7 for details.)
Indicates a potential hazard that could
result in serious injury or death.
Do not operate at speeds too fast for your
skills or the conditions.
WARNING
POTENTIAL HAZARD
Operating this ATV at speeds too fast
for your skills or the conditions.
WHAT CAN HAPPEN
Increases your chances of losing con-
trol 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 con-
ditions, and your experience.
1. Locknut
2. Adjusting screw
7-10
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Loading and accessories
WARNING
Use extra caution when riding the ATV with
additional loads, such as accessories or car-
go. The ATV’s handling may be adversely af-
fected. Reduce your speed when adding
additional loads.
POTENTIAL HAZARD
Overloading this ATV or carrying or tow-
ing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle han-
dling which could lead to an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity
for this ATV.
Cargo should be properly distributed
and securely attached.
Reduce speed when carrying cargo or
pulling a trailer. Allow greater distance
for braking.
MAXIMUM LOADING LIMIT
G Vehicle loading limit (total weight of
cargo, rider and accessories, and
tongue weight): 210 kg (463 lb)
G Front carrier: 40 kg (88 lb)
G Rear carrier: 80 kg (17 lb)
G Storage box: 2 kg (4.4 lb)
G Trailer hitch:
Pulling load (total weight of trailer
and cargo): 410 kgf (904 lbf)
Tongue weight (vertical weight on
trailer hitch point): 15 kgf (33 lbf)
Always follow the instructions in your
Owner’s Manual for carrying cargo or
pulling a trailer.
7-11
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During operation
WARNING
Always keep your feet on the footboards dur-
ing operation. Otherwise your feet may con-
tact the rear wheels.
POTENTIAL HAZARD
Removing hands from handlebars or
feet from footboards during operation.
WHAT CAN HAPPEN
Removing even one hand or foot can re-
duce 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.
HOW TO AVOID THE HAZARD
Always keep both hands on the handle-
bars and both feet on the footboards of
your ATV during operation.
7-12
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Avoid wheelies and jumping. You may lose
control of the ATV or overturn.
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps, and other
stunts.
WHAT CAN HAPPEN
Increases the chance of an accident, in-
cluding an overturn.
HOW TO AVOID THE HAZARD
Never attempt stunts, such as wheelies
or jumps. Don’t try to show off.
7-13
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Modifications
WARNING
POTENTIAL HAZARD
Operating this ATV with improper modi-
fications.
WHAT CAN HAPPEN
Improper installation of accessories or
modification of this vehicle may cause
changes in handling which in some situ-
ations could lead to an accident.
HOW TO AVOID THE HAZARD
Never modify this ATV through improp-
er installation or use of accessories. All
parts and accessories added to this ve-
hicle 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 autho-
rized ATV dealer.
7-14
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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.
WARNING
POTENTIAL HAZARD
Hot exhaust system.
WHAT CAN HAPPEN
Dry grass or brush or other combustible
material accumulated around the en-
gine area could catch fire.
Someone touching the exhaust system
during 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.
7-15
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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
handling and control of the ATV, and
may cause the vehicle to go out of con-
trol.
HOW TO AVOID THE HAZARD
Always avoid paved surfaces, including
sidewalks, driveways, parking lots and
streets.
7-16
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Do not ride on any public road, street, or high-
way.
Riding on public roads can result in collisions
with other vehicles.
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 high-
ways.
7-17
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Know the terrain where you ride. Ride cau-
tiously in unfamiliar areas. Stay alert for
holes, rocks, or roots in the terrain, and oth-
er 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 op-
erating on unfamiliar terrain.
Always be alert to changing terrain con-
ditions when operating the ATV.
7-18
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WARNING
POTENTIAL HAZARD
Failure to use extra care when operating
on excessively rough, slippery or loose
terrain.
WHAT CAN HAPPEN
Could cause loss of traction or vehicle
control, which could result in an acci-
dent, including an overturn.
HOW TO AVOID THE HAZARD
Do not operate on excessively rough,
slippery or loose terrain until you have
learned and practiced the skills neces-
sary to control the ATV on such terrain.
Always be especially cautious on these
kinds of terrain.
7-19
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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.
WHAT CAN HAPPEN
You could be in a collision. You could
be injured.
HOW TO AVOID THE HAZARD
Always mount a caution flag on the ATV
to make you more visible. Watch care-
fully for other vehicles.
Do not ride in areas posted “no trespassing”.
Do not ride on private property without getting
permission.
WARNING
POTENTIAL HAZARD
Operating in areas where you might not
be seen by other off-road vehicles.
7-20
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Select a large, flat area off-road to become fa-
miliar with your ATV. Make sure that this area
is free of obstacles and other riders. You
should practice control of the throttle, brakes,
shifting procedures, and turning techniques in
this area before trying more difficult terrain. Al-
ways 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.
With the engine idling, lift the shift pedal to the
1st gear position and then release the parking
brake. Apply the throttle slowly and smoothly.
The centrifugal clutch will engage and you will
start to accelerate. Once the ATV has at-
tained adequate speed, release the throttle
and lift the shift pedal to the 2nd gear position.
Release the shift pedal and apply the throttle
smoothly. Use this same procedure as you
move into the higher gears. Be sure to coordi-
nate the use of the throttle and shift pedal
properly. If the throttle is applied too abruptly
or if the throttle is not released during shifting,
or if the shift pedal is not released before ap-
plying the throttle, the front wheels may lift off
the ground resulting in a loss of directional
control. Avoid higher speeds until you are
thoroughly familiar with the operation of your
ATV.
Set the parking brake and follow the instruc-
tion on page 6-1 to start the engine. Once it
has warmed up you are ready to begin riding
your ATV. As you get on the ATV, be sure not
to accidentally move the shift pedal. Remem-
ber 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
components.
7-21
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CAUTION:
WARNING
_
Do not shift gears without releasing the
throttle. Damage to the engine or drive
POTENTIAL HAZARD
Engaging a lower gear when the engine
speed is too high.
train may occur.
_
WHAT CAN HAPPEN
When slowing down or stopping, release the
throttle and apply the brakes smoothly and
evenly. As you slow down, shift to a lower
gear. Be sure that the engine has sufficiently
slowed before engaging a lower gear. Improp-
er use of the brakes or shifting can cause the
tires to lose traction, reducing control and in-
creasing the possibility of an accident.
The wheels could stop rotating. This
could cause loss of control, an accident
and injury. It could also cause engine or
drive train damage.
HOW TO AVOID THE HAZARD
Make sure the engine has sufficiently
slowed before shifting to a lower gear.
7-22
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TURNING YOUR ATV
HOW TO AVOID THE HAZARD
Always follow proper procedures for
turning as described in this Owner’s
Manual.
Practice turning at low speeds before at-
tempting to turn at faster speeds. Do not
turn at speeds too fast for your skills or
the conditions.
To achieve maximum traction while riding off-
road, the two rear wheels are mounted solidly
on one axle and turn together at the same
speed. Therefore, unless the wheel on the in-
side of the turn is allowed to slip or lose some
traction, the ATV will resist turning. A special
turning technique must be used to allow the
ATV to make turns quickly and easily. It is es-
sential that this skill be learned first at low
speed.
As you approach a curve, slow down and be-
gin to turn the handlebars in the desired direc-
tion. As you do so, put your weight on the
footboard to the outside of the turn (opposite
your desired direction) and lean your upper
body into the turn. Use the throttle to maintain
an even speed through the turn. This maneu-
ver will let the wheel on the inside of the turn
slip slightly, allowing the ATV to make the turn
properly.
WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
ATV could go out of control, causing a
collision or overturn.
7-23
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Once you have learned this technique you
should be able to perform it at higher speeds
or in tighter curves.
Improper riding procedures such as abrupt
throttle changes, excessive braking, incorrect
body movements, 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 in-
side. It may also be necessary to gradually let
off on the throttle and steer to the outside of
the turn to avoid tipping over.
This procedure should be practiced at slow
speed many times in a large off-road area
with no obstacles. If an incorrect technique is
used, your ATV may continue to go straight. If
the ATV doesn’t turn, come to a stop and then
practice the procedure again. If the riding sur-
face is slippery or loose, it may help to posi-
tion more of your weight over the front wheels
by moving forward on the seat.
Remember: Avoid higher speeds until you are
thoroughly familiar with the operation of your
ATV.
7-24
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CLIMBING UPHILL
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 attempt-
ing large hills.
Use proper riding techniques to avoid vehicle
overturns on hills. Be sure that you can ma-
neuver your ATV well on flat ground before at-
tempting any incline and then practice riding
first on gentle slopes. Try more difficult climbs
only after you have developed your skill. In all
cases avoid inclines with slippery or loose sur-
faces, or obstacles that might cause you to
lose control.
It is important when climbing a hill to make
sure that your weight is transferred forward on
the ATV. This can be accomplished by lean-
ing forward and, on steeper inclines, standing
on the footboards and leaning forward over
the handlebars.
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle can overturn more easily on
extremely steep hills than on level sur-
faces or small hills.
7-25
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WARNING
An obstacle, a sharp drop, or another
vehicle or person could be on the other
side of the hill.
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause the
ATV to overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for
climbing hills as described in this Own-
er’s Manual.
Always check the terrain carefully be-
fore you start up any hill.
Never climb hills with excessively slip-
pery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly or
make sudden gear changes.
The ATV could flip over backwards.
Never go over the top of any hill at high
speed.
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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.
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
ATV to overturn.
HOW TO AVOID THE HAZARD
Never attempt to turn the ATV around
on any hill until you have mastered the
turning technique as described in the
Owner’s Manual on level ground. Be
very careful when turning on any hill.
Avoid crossing the side of a steep hill if
possible.
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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, dis-
mount the ATV on the uphill side. Physically
turn the ATV around and then descend the
hill.
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards or improper-
ly dismounting while climbing a hill.
WHAT CAN HAPPEN
Could result in ATV overturning.
HOW TO AVOID THE HAZARD
Use proper gear and maintain steady
speed when climbing a hill.
If you lose all forward speed:
Keep weight uphill.
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 back-
wards. Instead, dismount the ATV immediate-
ly on the uphill side.
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 roll-
ing backwards.
Apply the front brake.
When fully stopped, apply rear brake
as well, and then lock the parking
brake.
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Dismount on uphill side or to a side if
pointed straight uphill. Turn the ATV
around and remount, following the pro-
cedure described in the Owner’s Manu-
al.
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RIDING DOWNHILL
WARNING
When riding your ATV downhill, shift your
weight as far to the rear and uphill side of the
ATV as possible. Move back on the seat and
sit with your arms straight. Choose a low gear
which will allow the engine compression to do
most of the braking for you. Improper braking
may cause a loss of traction.
Use caution while descending a hill with loose
or slippery surfaces. Braking ability and trac-
tion may be adversely affected by these sur-
faces. Improper braking may also cause a
loss of traction.
POTENTIAL HAZARD
Going down a hill improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause
ATV to overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for go-
ing down hills as described in this Own-
er’s Manual. Note: a special technique is
required when braking as you go down
a hill.
Always check the terrain carefully be-
fore you start down any hill.
Shift your weight backward. Never go
down a hill at high speed.
Whenever possible, ride your ATV straight
downhill. Avoid sharp angles which could al-
low the ATV to tip or roll over. Carefully
choose your path and ride no faster than you
will be able to react to obstacles which may
appear.
Avoid going down a hill at an angle that
would cause the vehicle to lean sharply
to one side. Go straight down the hill
where possible.
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CROSSING A SLOPE
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.
Traversing a sloping surface on your ATV re-
quires you to properly position your weight to
maintain proper balance. Be sure that you
have learned the basic riding skills on flat
ground before attempting to cross a sloping
surface. Avoid slopes with slippery surfaces
or rough terrain that may upset your balance.
WARNING
POTENTIAL HAZARD
Improperly crossing hills or turning on
hills.
WHAT CAN HAPPEN
Could cause loss of control or cause
ATV to overturn.
HOW TO AVOID THE HAZARD
Never attempt to turn the ATV around
on any hill until you have mastered the
turning technique as described in the
Owner’s Manual on level ground. Be
very careful when turning on any hill.
Avoid crossing the side of a steep hill if
possible.
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 sur-
faces by pointing the front wheels slightly up-
hill. When riding on slopes be sure not to
make sharp turns either up or down hill.
7-32
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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.
7-33
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CROSSING THROUGH SHALLOW WATER
The ATV can be used to cross slow moving,
shallow water of up to a maximum of 35 cm
(14 in) in depth. Before entering the water,
choose your path carefully. Enter where there
is no sharp drop off, and avoid rocks or other
obstacles which may be slippery or upset the
ATV. Drive slowly and carefully.
Remember that wet brakes may have re-
duced stopping ability. Test your brakes
after leaving water. If necessary, apply
them several times to let friction dry out
the linings.
WARNING
POTENTIAL HAZARD
Operating this ATV through deep or fast
flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction
and loss of control, which could lead to
an accident.
HOW TO AVOID THE HAZARD
Never operate this ATV in fast flowing
water or in water deeper than that spec-
ified in your Owner’s Manual.
7-34
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Test your brakes after leaving the water. Do
not continue to ride your ATV without verifying
that you have regained proper braking ability.
CAUTION:
_
After riding your ATV in water, be sure to
drain the trapped water by removing the
check hose at the bottom of the air filter
case. Wash the ATV in fresh water if it has
been operated in salt water or muddy con-
ditions.
_
1. Check hose
7-35
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RIDING OVER ROUGH TERRAIN
WARNING
Riding over rough terrain should be done with
caution. Look out for obstacles which could
cause damage to the ATV or could lead to an
upset or accident. Be sure to keep your feet
firmly mounted on the footboards at all times.
Avoid jumping the ATV as loss of control and
damage to the ATV may result.
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Could cause loss of control or a colli-
sion. Could cause the ATV to overturn.
HOW TO AVOID THE HAZARD
Before operating in a new area, check
for obstacles.
Never attempt to ride over large obsta-
cles, such as large rocks or fallen trees.
When you go over obstacles, always fol-
low proper procedures as described in
the Owner’s Manual.
7-36
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7-37
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SLIDING AND SKIDDING
If the rear wheels of your ATV start to slide
sideways, control can usually be regained (if
there is room to do so) by steering in the direc-
tion of the slide. Applying the brakes or accel-
erating is not recommended until you have
corrected the slide.
Care should be used when riding on loose or
slippery surfaces since the ATV may slide. If
unexpected and uncorrected, sliding could
lead to an accident.
To reduce the tendency for the front wheels to
slide in loose or slippery conditions, position-
ing your weight over the front wheels will
sometimes help.
7-38
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With practice, over a period of time, skill at
controlled sliding can be developed. The ter-
rain should be chosen carefully before at-
tempting such maneuvers, since both stability
and control are reduced. Bear in mind that
sliding maneuvers should always be avoided
on extremely slippery surfaces such as ice,
since all control may be lost.
WARNING
POTENTIAL HAZARD
Skidding or sliding improperly.
WHAT CAN HAPPEN
You may lose control of this ATV. You
may also regain traction unexpectedly,
which may cause the ATV to overturn.
HOW TO AVOID THE HAZARD
Learn to safely control skidding or slid-
ing by practicing at low speeds and on
level, smooth terrain.
On extremely slippery surfaces, such as
ice, go slowly and be very cautious in
order to reduce the chance of skidding
or sliding out of control.
7-39
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WHAT TO DO IF ...
G If your ATV starts to slide sideways:
Steer in the direction of the slide if you have
the room.
This section is designed to be a reference
guide only. Be sure to read each section on
riding techniques completely.
Applying the brakes or accelerating is not
recommended until you have corrected the
slide. (See pages 7-38–7-39.)
WHAT TO DO ...
G If your ATV doesn’t turn when you want it
to:
G If your ATV can’t make it up a hill you are
trying to climb:
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 pages 7-23–7-24.)
Turn the ATV around if you still have for-
ward 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. Dismount the ATV on the uphill side.
(See pages 7-25–7-29.)
G If your ATV begins to tip while turning:
Lean more into the turn to regain balance. If
necessary, gradually let off the throttle and/
or steer to the outside of the turn. (See pag-
es 7-23–7-24.)
7-40
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G If your ATV is traversing a sloping surface:
Be sure to ride with your weight positioned
towards the uphill side of the ATV to main-
tain 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 dis-
cover that the ATV is going to tip over, dis-
mount on the uphill side. (See pages 7-32–
7-33.)
G If your ATV encounters shallow water:
Ride slowly and carefully through slow
moving water, watching for obstacles. Be
sure to let water drain from the ATV and
CHECK YOUR BRAKES FOR PROPER
OPERATION when you come out of the
water. Do not continue to ride your ATV un-
til you have regained adequate braking
ability. (See pages 7-34–7-35.)
WARNING
_
Indicates a potential hazard that could
result in serious injury or death.
7-41
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EBU00515
PERIODIC MAINTENANCE AND
ADJUSTMENT
Have a Yamaha dealer perform service if
you are not familiar with machine ser-
vice.
Periodic inspection, adjustment and lubrica-
tion will keep your machine in the safest and
most efficient condition possible. Safety is an
obligation of the machine owner. The most
important points of machine inspection, ad-
justment and lubrication are explained on the
following pages.
EBU01299
Owner’s manual and tool kit
You are recommended to put this owner’s
manual in the vinyl bag and always carry it on
the bottom of the seat as shown. Put the own-
er’s tool kit and low-pressure tire gauge in the
storage box.
WARNING
POTENTIAL HAZARD
Servicing an engine while it is running.
WHAT CAN HAPPEN
Moving parts can catch clothing or parts
of the body, causing injury.
Electrical components can cause
shocks or can start fires.
HOW TO AVOID THE HAZARD
Turn off the engine when performing
maintenance unless otherwise specified.
1. Owner’s manual
8-1
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WARNING
1
POTENTIAL HAZARD
Operating this ATV with improper modi-
fications.
2
3
WHAT CAN HAPPEN
4
Improper installation of accessories or
modification of this vehicle may cause
changes in handling which in some situ-
ations could lead to an accident.
HOW TO AVOID THE HAZARD
Never modify this ATV through improp-
er installation or use of accessories. All
parts and accessories added to this ve-
hicle 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 autho-
rized Yamaha ATV dealer.
1. Owner’s tool kit
2. Low-pressure tire gauge
5
The service information included in this man-
ual is intended to provide you, the owner, with
the necessary information for completing your
own preventive maintenance and minor re-
pairs. The tools provided in the Owner’s tool
kit are sufficient for this purpose, except that a
torque wrench is also necessary to properly
tighten nuts and bolts.
6
7
8
9
10
11
12
13
14
NOTE:
_
If you do not have a torque wrench available
during a service operation requiring one, take
your machine to a Yamaha dealer to check
the torque settings and adjust them as neces-
sary.
_
8-2
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EBU00261
PERIODIC MAINTENANCE/LUBRICATION
INITIAL
3
EVERY
ITEM
ROUTINE
1
6
6
1
year
month months months months
• Check valve clearance.
• Adjust if necessary.
Valves*
• Check condition.
• Adjust gap and clean.
• Replace if necessary.
Spark plug
• Clean.
• Replace if necessary.
Every 20–40 hours
(More often in wet or dusty areas.)
Air filter element
Carburetor*
• Check idle speed/starter operation.
• Adjust if necessary.
Cylinder head cover
breather system*
• Check breather hose for cracks or damage.
• Replace if necessary.
• Check leakage.
• Tighten if necessary.
Exhaust system*
• Replace gasket(s) if necessary.
Spark arrester
Fuel line*
• Clean.
• Check fuel hose for cracks or damage.
• Replace if necessary.
Engine oil
• Replace (warm engine before draining).
• Clean.
• Replace if necessary.
Engine oil filter element
Engine oil strainer
Final gear oil
• Clean.
• Check oil level/oil leakage.
• Replace every 12 months.
• Check operation/fluid leakage/See NOTE page 8-4.
• Correct if necessary.
Front brake*
Rear brake*
Clutch*
• Check operation.
• Adjust if necessary.
• Check operation.
• Adjust if necessary.
8-3
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INITIAL
3
EVERY
ITEM
ROUTINE
1
6
6
1
month months months months
year
• Check operation.
• Adjust if necessary.
Reverse release cable*
Wheels*
• Check balance/damage/run out.
• Replace if necessary.
• Check bearing assembly for looseness/damage.
• Replace if damaged.
Wheel bearings*
• Check operation.
• Replace if damaged.
• Check toe-in.
Steering system*
• Adjust if necessary.
Drive shaft universal joint* • Lubricate.
• Check all chassis fittings and fasteners.
• Correct if necessary.
Fittings and fasteners*
* Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
NOTE:
G Recommended brake fluid: DOT 4
G Brake fluid replacement:
• When disassembling the master cylinder
or caliper cylinder, replace the brake flu-
id. Normally check the brake fluid level
and add fluid as required.
• On the inner parts of the master cylinder
and caliper cylinder, replace the oil seals
WARNING
every two years.
Indicates a potential hazard that could
result in serious injury or death.
• Replace the brake hoses every four
years, or if cracked or damaged.
8-4
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EBU01181
Engine oil
4. Remove the dipstick, and then check the
oil level.
Engine oil level measurement
1. Place the ATV on a level surface.
2. Warm up the engine for several minutes,
and then stop it.
NOTE:
_
The oil level should be between the maximum
and minimum level marks.
_
3. Remove the engine oil filler cap, and then
wipe the dipstick off with a clean rag. In-
sert the dipstick in the filler hole without
screwing it in.
5. If the engine oil is below the minimum
level mark, add sufficient oil of the recom-
mended type to raise it to the correct lev-
el.
CAUTION:
_
Be sure no foreign material enters the
crankcase.
_
1. Engine oil filler cap
NOTE:
_
Wait a few minutes until the oil level settles
before checking.
_
8-5
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6. Insert the dipstick into the oil filler hole,
and then tighten the engine oil filler cap.
Engine oil replacement and oil filter ele-
ment cleaning
1. Place the ATV on a level surface.
2. Warm up the engine for several minutes
and stop it.
3. Place a container under the engine to
collect the used oil.
4. Remove the engine oil filler cap, and then
remove the drain bolt to drain the oil.
CAUTION:
_
When removing the drain bolt, the com-
pression spring, oil strainer and O-ring will
1. Dipstick
3. Minimum level mark
2. Maximum level mark
fall out. Take care not to lose these parts.
_
8-6
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6. Clean the oil strainer and oil filter element
with solvent.
7. Check the O-ring for damage and re-
place it if necessary.
8. Install the oil filter element and O-ring.
9. Install the oil filter cover by installing the
bolts.
10. Install the oil strainer, compression
spring, O-ring and drain bolt. Tighten the
drain bolt and oil filter cover bolts to the
specified torques.
1. Engine oil drain bolt
3. Compression spring
2. O-ring
4. Engine oil strainer
5. Remove the oil filter cover by removing the
bolts and then remove the oil filter element.
CAUTION:
_
Before installing the drain bolt, be sure to
install the O-ring, compression spring and
oil strainer.
_
1. Engine oil filter cover
2. Engine oil filter cover bolt (× 3)
8-7
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Recommended oil:
See page 10-2.
Oil quantity:
Periodic oil change:
2.9 L (2.6 Imp qt, 3.1 US qt)
With oil filter replacement:
3.0 L (2.6 Imp qt, 3.2 US qt)
Total amount:
3.5 L (3.1 Imp qt, 3.7 US qt)
1. O-ring
2. Engine oil filter element
CAUTION:
Tightening torques:
Drain bolt:
_
G In order to prevent clutch slippage
(since the engine oil also lubricates
the clutch), do not mix any chemical
additives. Do not use oils with a diesel
specification of “CD” or oils of a high-
er quality than specified. In addition,
do not use oils labeled “ENERGY
CONSERVING II” or higher.
32 Nm (3.2 m·kgf, 23 ft·lbf)
Filter cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
11. Add the specified amount of the recom-
mended engine oil, and then install the
engine oil filler cap.
G Make sure that no foreign material en-
ters the crankcase.
_
8-8
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EBU01145
12. Start the engine, and then let it idle for
several minutes while checking it for oil
leakage. If oil is leaking, immediately turn
the engine off and check for the cause.
13. Turn the engine off, and then check the
oil level and correct it if necessary.
Final gear oil
Final gear oil measurement
1. Place the machine on a level surface.
2. Remove the oil filler bolt, and then check
the oil level in the final gear case.
NOTE:
_
The oil level should be at the brim of the filler
hole.
_
3. If the oil is below the brim of the filler hole,
add sufficient oil of the recommended
type to raise it to the correct level.
CAUTION:
_
Be sure no foreign material enters the final
gear case.
_
4. Install the oil filler bolt.
8-9
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Final gear oil replacement
1. Remove the final gear case cover by re-
moving the bolts.
1. Final gear oil
2. Correct oil level
3. Final gear oil filler bolt
1. Final gear case cover
2. Bolt (× 2)
8-10
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2. Place the machine on a level surface.
3. Place a container under the final gear
case to collect the used oil.
4. Remove the oil filler bolt and the drain
bolt to drain the oil.
6. Add the recommended final gear oil to
the brim of the filler hole.
Recommended oil:
See page 10-3.
Oil quantity:
0.25 L (0.22 Imp qt, 0.26 US qt)
CAUTION:
_
Be sure no foreign material enters the final
gear case.
_
7. Install the oil filler bolt.
8. Check for oil leakage. If oil leakage is
found, check for the cause.
9. Install the final gear case cover bolts, and
then tighten them to the specified torque.
1. Final gear oil drain bolt
5. Install the drain bolt, and then tighten it to
the specified torque.
Tightening torque:
Final gear case cover bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
8-11
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EBU01182
Spark plug inspection
Before installing the spark plug, measure the
electrode gap with a wire thickness gauge
and adjust it to specification.
The spark plug is an important engine compo-
nent and is easy to inspect. The condition of
the spark plug can indicate the condition of
the engine.
For example, a very white center electrode
porcelain color could indicate an intake air
leak or carburetion problem for that cylinder.
Do not attempt to diagnose such problems
yourself.
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Instead, take the ATV to a Yamaha dealer.
You should periodically remove and inspect
the spark plug because heat and deposits will
cause the spark plug to slowly break down
and erode. If electrode erosion becomes ex-
cessive, you should replace the spark plug
with one of the proper type.
a. Spark plug gap
When installing the spark plug, always clean
the gasket surface and its mating surface.
Wipe off any grime from the threads and tight-
en it to the specified torque.
Standard spark plug:
DR8EA (NGK)
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.5 ft·lbf)
8-12
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EBU01301
Air filter element cleaning
NOTE:
_
There is a check hose at the bottom of the air
filter case. If dust or water collects in this
hose, empty the hose and clean the air filter
element and air filter case.
_
1. Air filter case cover
2. Holder (× 3)
3. Pull the air filter element out.
1. Check hose
1. Remove the seat. (See page 4-15 for
seat removal and installation proce-
dures.)
2. Remove the air filter case cover by un-
hooking the holders.
1. Air filter element
8-13
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4. Remove the foam cover from the air filter
element.
5. Tap the element lightly to remove most of
the dust and dirt. Blow out the remaining
dirt with compressed air as shown. If the
air filter element is damaged, replace it.
1. Air filter element
2. Foam cover
6. Wash the foam cover gently but thor-
oughly in water or solvent.
8-14
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10. Install the air filter element.
11. Install the air filter case cover by fasten-
ing the holders.
WARNING
POTENTIAL HAZARD
Using low flash point solvents or gaso-
line to clean the foam cover.
WHAT CAN HAPPEN
Low flash point solvents or gasoline can
catch fire or explode.
HOW TO AVOID THE HAZARD
Use parts cleaning solvent to clean the
foam cover.
12. Install the seat.
NOTE:
_
The air filter element should be cleaned every
20–40 hours. It should be cleaned more often
if the ATV is operated in extremely dusty ar-
eas. Each time air filter element maintenance
is performed, check the air inlet to the air filter
case for obstructions. Check the air filter ele-
ment rubber joint to the carburetor and mani-
fold fittings for an airtight seal. Tighten all
fittings securely to avoid the possibility of unfil-
7. Squeeze the excess water or solvent out
of the foam cover and let it dry.
CAUTION:
tered air entering the engine.
_
_
G Do not twist the foam cover when
squeezing it.
G Do not apply oil to the foam cover.
_
8. Inspect the foam cover. If damaged, re-
place it.
9. Install the foam cover onto the air filter el-
ement.
8-15
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CAUTION:
_
Never operate the engine with the air filter
element removed. This will allow unfiltered
air to enter, causing rapid engine wear and
possible engine damage. Additionally, op-
eration without the air filter element will af-
fect carburetor jetting with subsequent
poor performance and possible engine
overheating.
_
8-16
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EBU00754
Spark arrester cleaning
2. Start the engine and rev it up approxi-
mately twenty times while momentarily
creating exhaust system back pressure
by blocking the end of the muffler with a
shop towel.
Select a well-ventilated area free of combusti-
ble materials and make sure the exhaust pipe
and muffler are cool.
1. Remove the purging bolt.
3. Stop the engine and allow the exhaust
pipe to cool.
4. Install the purging bolt and tighten it.
1. Purging bolt
8-17
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EBU00296
Carburetor adjustment
WARNING
The carburetor is a vital part of the engine and
requires very sophisticated adjustment. Most
adjusting should be left to a Yamaha dealer
who has the professional knowledge and ex-
perience to do so. However, the idling speed
may be performed by the owner as a part of
the usual maintenance routine.
POTENTIAL HAZARD
Improperly purging the exhaust system.
Hot exhaust system.
WHAT CAN HAPPEN
Could injure the eyes.
Could cause burns.
Could cause carbon monoxide poison-
ing, possibly leading to death.
Could start a fire.
CAUTION:
The carburetor was set at the Yamaha fac-
tory after many tests. If the settings are
disturbed by someone without sufficient
technical knowledge, poor engine perfor-
mance and damage may result.
HOW TO AVOID THE HAZARD
When cleaning the spark arrester:
Always let the exhaust system cool pri-
or to touching exhaust components.
Always wear eye protection, and make
sure no one is behind the vehicle.
Never run the engine in an enclosed
area.
Make sure there are no combustible ma-
terials in the area.
8-18
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EBU01302
Idle speed adjustment
NOTE:
_
A diagnostic tachometer must be used for this
procedure.
_
1. Start the engine and warm it up for a few
minutes at approximately 1,000 to
2,000 r/min. Occasionally rev the engine
to 4,000 to 5,000 r/min. The engine is
warm when it quickly responds to the
throttle.
1. Throttle stop screw
2. Connect the tachometer to the spark plug
lead, and then set the idle to the specified
idling speed by adjusting the throttle stop
screw. Turn the screw in direction a to
increase the engine speed, and in direc-
tion b to decrease the engine speed.
Specified idle speed:
1,450–1,550 r/min
8-19
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EBU00303
EBU00307
Valve clearance adjustment
Throttle lever adjustment
The correct valve clearance changes with
use, resulting in improper fuel/air supply or
engine noise. To prevent this, the valve clear-
ance must be adjusted regularly. This adjust-
ment however, should be left to a professional
Yamaha service technician.
NOTE:
Adjust the engine idling speed before adjust-
ing the throttle lever free play.
1. Loosen the locknut.
2. Turn the adjusting bolt until the throttle le-
ver free play is 3–5 mm (0.12–0.20 in).
3. Tighten the locknut.
1. Locknut
2. Adjusting bolt
a. Throttle lever free play
8-20
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EBU01303
EBU00313
Front brake pad check
Rear brake shoe inspection
Inspect the brake pads for damage and wear.
If the brake pad thickness is less than 1 mm
(0.04 in), have a Yamaha dealer replace the
pads.
A wear indicator is provided on the rear brake.
This indicator allows checking of brake shoe
wear without disassembling the brake.
Apply the rear brake and check the position of
the indicator. If the indicator reaches the wear
limit line, ask a Yamaha dealer to replace
shoes as a set.
a. Brake pad thickness
1. Wear indicator
2. Wear limit
8-21
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EBU01304
Brake fluid level check
Insufficient brake fluid may let air enter the
brake system, possibly causing the brakes 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 indi-
cate 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.
1. Minimum level mark
G Refill with the same type of brake fluid. Mix-
ing fluids may result in a harmful chemical
reaction and lead to poor brake perfor-
mance.
G Be careful that water does not enter the
brake fluid reservoir when refilling. Water
will significantly lower the boiling point of
the fluid and may result in vapor lock.
Observe these precautions:
G When checking the brake fluid level, make
sure the top of the brake fluid reservoir is
level.
G Use only the designated quality brake fluid,
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
Recommended brake fluid: DOT 4
8-22
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EBU01186
G Brake fluid may deteriorate painted surfac-
es or plastic parts. Always clean up spilled
fluid immediately.
G Have a Yamaha dealer check the cause if
the brake fluid level goes down.
Brake fluid replacement
Complete fluid replacement should be done
only by trained Yamaha service personnel.
Have a Yamaha dealer replace the following
components during periodic maintenance or
when they are damaged or leaking.
G Replace the oil seals every two years.
G Replace the brake hoses every four years.
8-23
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EBU01189
Front brake lever free play
WARNING
The front brake lever should have a free play
of zero mm (zero in) at the lever end. If not,
have a Yamaha dealer adjust it.
POTENTIAL HAZARD
Operating with improperly serviced or
adjusted brakes.
WHAT CAN HAPPEN
You could lose braking ability, which
could lead to an accident.
HOW TO AVOID THE HAZARD
After servicing:
G Make sure the brakes operate
smoothly and that the free play is cor-
rect.
G Make sure the brakes do not drag.
G Make sure the brakes are not spongy.
All air must be bled from the brake
system.
a. Front brake lever free play
Replacement of brake components re-
quires professional knowledge. These
procedures should be performed by a
Yamaha dealer.
8-24
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EBU01305
Rear brake pedal and lever adjustment
Brake pedal free play adjustment
1. Fully loosen the adjusting nut on the
brake cable.
2. Turn the adjusting nut on the brake rod
until the free play is 20–30 mm (0.8–
1.2 in).
a. Rear brake pedal free play
1. Adjusting nut (brake cable)
2. Adjusting nut (brake rod)
8-25
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Brake lever free play adjustment
1. Loosen the locknut and fully turn in the
adjusting bolt at the brake lever.
2. Turn in the adjusting nut on brake cable
to provide a gap of 0–1 mm (0–0.04 in)
between the lever and the pin.
1. Locknut
2. Adjusting bolt
1. Adjusting nut (brake cable)
3. Pin
2. Lever
a. Gap
8-26
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3. Turn the adjusting bolt until the free play
at the brake lever pivot is 5–7 mm (0.20–
0.28 in).
WARNING
POTENTIAL HAZARD
Operating with improperly serviced or
adjusted brakes.
WHAT CAN HAPPEN
You could lose braking ability, which
could lead to an accident.
HOW TO AVOID THE HAZARD
After servicing:
G Make sure the brakes operate
smoothly and that the free play is cor-
rect.
G Make sure the brakes do not drag.
Replacement of brake components re-
quires professional knowledge. These
procedures should be performed by a
Yamaha dealer.
1. Locknut
a. Rear brake lever free play
2. Adjusting bolt
4. Tighten the locknut.
8-27
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EBU00834
EBU00346
Adjusting the rear brake light switch
The rear brake light switch, which is activated
by the brake pedal and brake levers, is prop-
erly adjusted when the brake light comes on
just before braking takes effect. If necessary,
adjust the brake light switch as follows.
Turn the adjusting nut while holding the rear
brake light switch in place. To make the brake
light come on earlier, turn the adjusting nut in
direction a. To make the brake light come on
later, turn the adjusting nut in direction b.
Clutch adjustment
1. Loosen the locknut.
2. Slowly turn the adjusting bolt counter-
clockwise until resistance is felt. Then,
turn it 1/8 turn clockwise.
1. Locknut
2. Adjusting bolt
1. Rear brake light switch
2. Adjusting nut
8-28
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EBU00356
3. Tighten the locknut to specification.
Cable inspection and lubrication
WARNING
Tightening torque:
15 Nm (1.5 m·kgf, 11 ft·lbf)
POTENTIAL HAZARD
Damaged control cables.
NOTE:
WHAT CAN HAPPEN
Turn the adjusting bolt counterclockwise to
decrease the clutch free play and turn it clock-
wise to increase the free play.
Corrosion can result when the outer
covering of control cables becomes
damaged. Cables can also become
frayed or kinked. Operation of controls
could be restricted, which could cause
an accident or injury.
HOW TO AVOID THE HAZARD
Inspect cables frequently. Replace dam-
aged cables.
8-29
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EBU01112
Lubricate the inner cables and the cable ends.
If the cables do not operate smoothly, ask a
Yamaha dealer to replace them.
Wheel removal
1. Loosen the wheel nuts.
2. Elevate the ATV and place a suitable
stand under the frame.
3. Remove the nuts from the wheel.
4. Remove the wheel.
Recommended lubricant:
Yamaha chain and cable lube or
SAE 10W30 motor oil
EBU00727
Brake and shift pedal/brake lever
lubrication
Lubricate the pivoting parts of each lever and
pedal.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
8-30
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EBU01121
Wheel installation
1. Install the wheel and the nuts.
2. Lower the ATV so that the wheel is on the
ground.
NOTE:
_
G Tapered nuts are used for both the front
and rear wheels. Install the nut with its ta-
pered side towards the wheel.
G The arrow mark
on the tire must point
toward the rotating direction of the wheel.
_
1. Tapered nut
3. Tighten the wheel nuts to the specified
torque.
Wheel nut torque:
Front: 55 Nm (5.5 m·kgf, 40 ft·lbf)
Rear: 55 Nm (5.5 m·kgf, 40 ft·lbf)
1. Arrow mark
8-31
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EBU00380
Battery
HOW TO AVOID THE HAZARD
Avoid contact with skin, eyes or cloth-
ing. Always shield eyes when working
near batteries. Keep out of reach of chil-
dren.
This machine is equipped with a sealed-type
battery. Therefore it is not necessary to check
the electrolyte or add distilled water in the bat-
tery. If the battery seems to have discharged,
consult a Yamaha dealer.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of wa-
ter or milk. Follow with milk of magne-
sia, beaten egg or vegetable oil. Get
prompt medical attention.
CAUTION:
Do not try to remove the sealing caps of
the battery cells. You may damage the bat-
tery.
EYES: Flush with water for 15 minutes
and get prompt medical attention. Keep
batteries away from sparks, flames, cig-
arettes or other sources of ignition. Ven-
tilate when charging or using in a closed
space.
WARNING
POTENTIAL HAZARD
Failure to handle batteries or battery
electrolyte carefully.
WHAT CAN HAPPEN
You could be poisoned. You could be
severely burned by the sulfuric acid in
battery electrolyte. Batteries produce
explosive gases.
8-32
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EBU00385
EBU00853*
Battery maintenance
Fuse replacement
1. When the machine is not used for a
month or longer, remove the battery and
store it in a cool, dark place. Completely
recharge the battery before reinstallation.
1. The main fuse case and the fuse box are
located under the seat.
2. If a fuse is blown, turn off the main switch
and install a new fuse of the specified
amperage. Then turn on the switches. If
the fuse immediately blows again, con-
sult a Yamaha dealer.
CAUTION:
A special battery charger (constant volt-
age/ampere or constant voltage) is re-
Specified fuses:
quired for recharging
a
sealed-type
Main fuse:
Headlight fuse:
Ignition fuse:
Auxiliary DC jack fuse:
Carburetor warmer fuse:
30 A
15 A
10 A
10 A
10 A
battery. Using a conventional battery
charger may shorten the battery life.
2. Always make sure the connections are
correct when putting the battery back in
the machine.
8-33
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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 rat-
ing. Never use a material in place of the
proper fuse.
1. Main fuse
2. Spare main fuse
CAUTION:
_
To prevent accidental short-circuiting,
turn off the main switch when checking or
replacing a fuse.
_
1. Headlight fuse
2. Ignition fuse
3. Auxiliary DC jack fuse
5. Spare fuse (× 2)
4. Carburetor warmer fuse
8-34
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EBU01306
Replacing a headlight bulb
If a headlight bulb burns out, replace the bulb
as follows.
1. Remove the headlight assembly by re-
moving the screws.
2. Disconnect the headlight coupler.
3. Remove the headlight unit from the
headlight assembly by removing the
screw.
4. Remove the headlight bulb holder cover.
5. Push the headlight bulb holder inward,
turn it counterclockwise, and then re-
move the defective bulb.
1. Screw (× 3)
1. Headlight bulb holder cover
1. Screw (× 2)
2. Headlight coupler
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8-35
8. Place the headlight unit in the original po-
sition, and then install the screw.
9. Connect the headlight coupler.
10. Place the headlight unit assembly in the
original position, and then install the
screws.
WARNING
POTENTIAL HAZARD
A headlight bulb is hot when it is on and
immediately after it is turned off.
WHAT CAN HAPPEN
You can be burned, or a fire could start
if the bulb touches something flamma-
ble.
11. Adjust the headlight beam if necessary.
HOW TO AVOID THE HAZARD
Wait for the bulb to cool before touching
or removing it.
6. Put a new headlight bulb into position,
and then secure it in place with the bulb
holder.
7. Install the headlight bulb holder cover.
CAUTION:
_
Make sure the headlight bulb holder cover
is securely fitted over the bulb holder and
seated against the reflector.
_
8-36
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EBU01089
EBU00945
Headlight beam adjustment
Tail/brake light bulb replacement
1. Open the storage box. (See page 4-16.)
2. Remove the nuts together with washers.
CAUTION:
_
It is advisable to have a Yamaha dealer
make this adjustment.
_
To raise the beam, turn the adjusting screw in
direction a.
To lower the beam, turn the adjusting screw in
direction b.
1. Storage box
2. Nut (× 2)
3. Remove the bulb holder (together with
the bulb) by turning it counterclockwise.
1. Adjusting screw (× 2)
8-37
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1. Tail/brake light bulb holder
1. Tail/brake light bulb holder
2. Bulb
4. Remove the defective bulb from the bulb
holder by pushing it inward and turning it
counterclockwise.
5. Install a new bulb in the bulb holder by
pushing it inward and turning it clockwise.
6. Install the bulb holder (together with the
bulb).
7. Install the washers, and then install the
nuts.
8-38
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EBU00412
Troubleshooting
WARNING
Although Yamaha machines receive a rigid in-
spection before shipment from the factory,
trouble may occur during operation. Any prob-
lem in the fuel, compression, or ignition sys-
tems can cause poor starting and loss of
power. The troubleshooting chart describes a
quick, easy procedure for making checks. If
your machine requires any repair, take it to a
Yamaha dealer.
The skilled technicians at a Yamaha dealer-
ship have the tools, experience, and know-
how to properly service your machine. Use
only genuine Yamaha parts on your machine.
Imitation parts may look like Yamaha parts,
but they are often inferior. Consequently, they
have a shorter service life and can lead to ex-
pensive repair bills.
POTENTIAL HAZARD
Checking the fuel system while smok-
ing or near an open flame.
WHAT CAN HAPPEN
Fuel can ignite or explode, causing se-
vere injury or property damage.
HOW TO AVOID THE HAZARD
Do not smoke when checking the fuel
system. Make sure there are no open
flames or sparks in the area, including
pilot lights from water heaters or furnac-
es.
8-39
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EBU00440
Troubleshooting chart
Turn the fuel
cock to “ON”.
Check fuel
flow.
Turn the fuel
cock to “OFF”.
Fuel cock
clogged.
There is fuel.
Remove the fuel pipe.
Restart engine.
No fuel.
1. Fuel
Check if there is fuel
in the fuel tank.
Turn the fuel
cock to “RES”.
Some fuel.
No fuel.
Clean fuel
cock.
Supply fuel.
2. Compression
There is compression.
No compression.
Compression normal.
Use the electric starter
to see if there is
compression.
Ask a Yamaha dealer to inspect.
Wipe clean with
dry cloth.
3. Ignition
Wet
Dry
Ignition system
normal.
Spark good.
Remove the plug and
check the electrodes.
Attach plug cap and
ground to chassis.
Use the
electric starter.
Spark weak.
No spark.
Adjust plug gap
or replace plug.
4. Battery
Engine turns over
quickly.
Battery good.
Use the electric starter.
Engine turns over
slowly.
Recharge, check
connections.
Ask a Yamaha dealer to inspect.
8-40
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EBU00419
CLEANING AND STORAGE
CAUTION:
Excessive water pressure may cause wa-
ter seepage and deterioration of wheel
bearings, brakes, transmission seals and
electrical devices. Many expensive repair
bills have resulted from improper high
pressure detergent applications such as
those available in coin-operated car wash-
ers.
A. CLEANING
Frequent, thorough cleaning of your machine
will not only enhance its appearance but will
improve its general performance and extend
the useful life of many components.
1. Before cleaning the machine:
a. Block off the end of the exhaust pipe to
prevent water entry. A plastic bag and
strong rubber band may be used.
4. Once the majority of the dirt has been
hosed off, wash all surfaces with warm
water and mild, detergent-type soap. An
old toothbrush or bottle brush is handy for
hard-to-get-at places.
5. Rinse the machine off immediately with
clean water and dry all surfaces with a
chamois, clean towel or soft absorbent
cloth.
b. Make sure the spark plug and all filler
caps are properly installed.
2. If the engine case is excessively greasy,
apply degreaser with a paint brush. Do
not apply degreaser to the wheel axles.
3. Rinse the dirt and degreaser off with a
garden hose. Use only enough pressure
to do the job.
9-1
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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 protective finish. When finished,
start the engine and let it idle for several
minutes.
WARNING
1
POTENTIAL HAZARD
Operation with wet brakes after wash-
2
ing.
3
WHAT CAN HAPPEN
4
Wet brakes may have reduced stopping
ability, increasing the chance of an acci-
dent.
5
6
HOW TO AVOID THE HAZARD
7
Test the brakes after washing. Apply the
brakes several times at slow speeds to
let friction dry out the linings.
8
9
10
11
12
13
14
9-2
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EBU00530
B. STORAGE
2. Remove the spark plug, pour about one
tablespoon of SAE 10W30 or 20W40
motor oil in the spark plug hole and rein-
stall the spark plug. Ground the spark
plug wire and turn the engine over seve-
ral times to coat the cylinder wall with oil.
3. Lubricate all control cables.
Long term storage (60 days or more) of your
machine will require some preventive proce-
dures to guard against deterioration. After
thoroughly cleaning the machine, prepare for
storage as follows:
1. Fill the fuel tank with fresh fuel and add
the specified amount of Yamaha Fuel
Stabilizer and Conditioner or an equiva-
lent product.
4. Block up the frame to raise all wheels off
the ground.
5. Tie a plastic bag over the exhaust pipe
outlet to prevent moisture from entering.
6. If storing in a humid or salt-air atmo-
sphere, coat all exposed metal surfaces
with a light film of oil. Do not apply oil to
any rubber parts or the seat cover.
Specified amount:
1 oz of stabilizer to each gallon of fuel
(or 7.5 cc of stabilizer to each liter of
fuel)
NOTE:
Use of fuel stabilizer and conditioner elimi-
nates the need to drain the fuel system. Con-
sult a Yamaha dealer if the fuel system needs
to be drained instead.
9-3
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7. Remove the battery and charge it. Store
it in a dry place and recharge it once a
month. Do not store the battery in an ex-
cessively warm or cold place (less than
0 °C (30 °F) or more than 30 °C (90 °F)).
NOTE:
Make any necessary repairs before storing
the machine.
9-4
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EBU00428
SPECIFICATIONS
MODEL
YFM400
Dimension:
Overall length
2,007 mm (79.0 in)
Overall width
Overall height
Seat height
Wheel base
Ground clearance
1,125 mm (44.3 in)
1,172 mm (46.1 in)
855 mm (33.7 in)
1,230 mm (48.4 in)
245 mm (9.65 in)
3,000 mm (118.1 in)
Minimum turning radius
Basic weight:
With oil and full fuel tank
252 kg (556 lb)
Engine:
Type
Air cooled, 4-stroke, SOHC
Cylinder arrangement:
Displacement
Bore × stroke
Compression ratio
Starting system
Lubrication system
Forward inclined single cylinder
386 cm
83.0 × 71.5 mm (3.27 × 2.81 in)
8.6 : 1
Electric starter and recoil starter
Wet sump
3
10-1
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MODEL
YFM400
1
Engine oil:
Type
2
3
0˚
90˚
110˚ 130˚F
10˚
30˚
70˚
50˚
4
YAMALUBE 4 (20W40) or SAE 20W40
YAMALUBE 4 (10W30) or SAE 10W30
SAE 5W30
5
6
7
-20˚
30˚
40˚ 50˚C
-10˚
0˚
20˚
10˚
Recommended engine oil classification
API Service SE, SF, SG or higher
8
9
CAUTION:
In order to prevent clutch slippage (since the en-
gine oil also lubricates the clutch), do not mix any
chemical additives. Do not use oils with a diesel
specification of “CD” or oils of a higher quality
than specified. In addition, do not use oils labeled
“ENERGY CONSERVING II” or higher.
10
11
12
13
14
Quantity:
Periodic oil change
With oil filter replacement
Total amount
2.9 L (2.6 Imp qt, 3.1 US qt)
3.0 L (2.6 Imp qt, 3.2 US qt)
3.5 L (3.1 Imp qt, 3.7 US qt)
10-2
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MODEL
YFM400
Final gear oil:
Type
SAE 80 API “GL-4” Hypoid gear oil
Quantity
Periodic oil change
Total amount
0.23 L (0.20 lmp qt, 0.24 US qt)
0.25 L (0.22 lmp qt, 0.26 US qt)
Air filter:
Fuel:
Type
Dry element
UNLEADED GASOLINE ONLY
15 L (3.3 Imp gal, 4.0 US gal)
4.0 L (0.9 Imp gal, 1.1 US gal)
Tank capacity
Reserve amount
Carburetor:
Type/manufacturer
BSR33/MIKUNI
Spark plug:
Type/manufacturer
Gap
DR8EA/NGK
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Type
Wet, centrifugal automatic
10-3
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MODEL
YFM400
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Spur gear
76/24 (3.166)
Shaft drive
28/24 × 24/18 × 33/09 (5.703)
Constant mesh, 5-speed forward, 1-speed reverse
Left foot operation
Operation
Gear raito:
1st
2nd
3rd
40/12 (3.333)
34/18 (1.889)
30/22 (1.363)
4th
5th
25/26 (0.961)
19/27 (0.703)
Reverse
22/17 × 35/15 (3.019)
Chassis:
Frame type
Caster angle
Trail
Steel tube
4°
21 mm (0.83 in)
Tire:
Type
Tubeless
Size: Front
Size: Rear
AT25 × 8-12
AT25 × 11-10
Brake:
Front brake type
Operation
Rear brake type
Operation
Dual disk brake
Right hand operation
Drum brake
Left hand and right foot operation
10-4
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MODEL
YFM400
Suspension:
Front
Double wishbone
Swingarm (monocross)
Rear
Shock absorber:
Front
Coil spring/oil damper
Coil spring/oil damper
Rear
Wheel travel:
Front wheel travel
Rear wheel travel
150 mm (5.91 in)
150 mm (5.91 in)
Electrical:
Ignition system
Generator system
DC. C.D.I.
A.C. magneto
Battery type/voltage capacity
YTX20L-BS 12V, 18Ah
Headlight type:
Krypton bulb
Bulb voltage, wattage × quantity:
Headlight
12V, 30/30W × 2
12V, 5/21W × 1
12V, 3.4W × 1
Tail/brake light
Meter lighting
Indicator and warning lights:
Neutral
12V, 1.7W × 1
12V, 1.7W × 1
12V, 1.7W × 1
Reverse
Oil temperature
10-5
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MODEL
YFM400
Fuses:
Main fuse
30 A
15 A
10 A
10 A
10 A
Headlight fuse
Ignition fuse
Auxiliary DC jack fuse
Carburetor warmer fuse
10-6
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EBU00430
NOISE REGULATION
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop-
erative by any person other than for purposes of maintenance, repair, or replacement of any de-
vice or element of design incorporated into any new vehicle for the purpose of noise control prior
to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after
such device or element of design has been removed or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED
BELOW.”
These acts include tampering with the following systems; i.e., modification, removal, etc.
Muffler
Exhaust system
Intake system
Exhaust pipe
Silencer
Air cleaner case
Air cleaner element
Intake duct
11-1
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EBU00431
MAINTENANCE RECORD
1
Copies of work orders and/or receipts for parts you purchase and install will be required to docu-
ment maintenance done in accordance with the warranty. The chart below is printed only as a re-
minder to you that the maintenance work is required. It is not acceptable proof of maintenance
work.
2
3
4
5
MAINTENANCE
INTERVAL
DATE OF
SERVICE
SERVICING DEALER
NAME AND ADDRESS
MILEAGE
REMARKS
6
1 Month
3 Months
7
6 Months
8
12 Months
18 Months
24 Months
30 Months
36 Months
42 Months
48 Months
54 Months
60 Months
9
10
11
12
13
14
12-1
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EBU00432
YAMAHA MOTOR CORPORATION, U.S.A.
ATV LIMITED WARRANTY
13-1
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
13-2
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EBU00435
YAMAHA EXTENDED SERVICE (Y.E.S.)
14-1
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
14-2
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EBU00436
WARNING
Indicates a potential hazard that could
result in serious injury or death.
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EBU00437
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EBU00438
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH.
ALWAYS USE
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
AN APPROVED
HELMET AND
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 ON RECYCLED PAPER
PRINTED IN USA
2002.09-0.9 ×1 CR
(E)
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