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Yamaha GRIZZLY 125 YFM125GD Owner's Manual
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Yamaha GRIZZLY 125 YFM125GD Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
LIRE ATTENTIVEMENT CE MANUEL!
Il comprend d'importantes informations de sécurité.
¡LEA ESTE MANUAL ATENTAMENTE!
Contiene indicaciones importantes acerca de la seguridad.
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
OWNER'S MANUAL
YFM125GD
1PY-28199-61

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Summary of Contents for Yamaha GRIZZLY 125 YFM125GD

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. LIRE ATTENTIVEMENT CE MANUEL! Il comprend d’importantes informations de sécurité. ¡LEA ESTE MANUAL ATENTAMENTE! Contiene indicaciones importantes acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM125GD 1PY-28199-61...
  • Page 2 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2012.03-0.3×1 CR IMPRESO EN PAPEL RECICLADO (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM125GD WARNING This ATV should not be ridden by anyone under 16 years of age. 1PY-28199-61-E0...
  • Page 4 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. EC Declaration of Conformity conforming to Directive 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM125A (YFM125G) (JY4AE02W0C0015330–)
  • Page 5 Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 6 EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 7 Please check your local riding laws and regulations before operating this ATV. EBU17390 YFM125GD OWNER’S MANUAL ©2012 by Yamaha Motor Co., Ltd. 1st edition, March 2012 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 8: Table Of Contents

    EBU17420 TABLE OF CONTENTS LOCATION OF THE WARNING AND Starter (choke) ..........4-10 SPECIFICATION LABELS ......1-1 Seat ............4-10 Front carrier ..........4-11 SAFETY INFORMATION ......2-1 Rear carrier ..........4-11 DESCRIPTION ..........3-1 PRE-OPERATION CHECKS ......5-1 Left view ............3-1 Fuel .............5-3 Right view............
  • Page 9 Parking on a slope ........6-5 Engine oil ..........8-11 Accessories and loading ......6-6 Transmission oil ........8-14 Cleaning the engine and V-belt case air RIDING YOUR ATV ........7-1 filter elements .........8-17 GETTING TO KNOW YOUR ATV....7-2 Cleaning the spark arrester ......8-23 RIDE WITH CARE AND GOOD V-belt case drain screw ......8-24 JUDGMENT ..........
  • Page 10 Adjusting a headlight beam ...... 8-47 Replacing the tail/brake light bulb .... 8-47 Removing a wheel ........8-48 Installing a wheel ........8-48 Troubleshooting ........8-49 Troubleshooting chart ......8-51 CLEANING AND STORAGE......9-1 Cleaning ............. 9-1 Storage ............9-2 SPECIFICATIONS ........

  • Page 11: Location Of The Warning And Specification Labels

    Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer.
  • Page 12 < 5 kg ( 11 Ibs ) 1C5-2817R-00 1AS-2816P-00 < 10 kg ( 22 Ibs ) 1C5-2817R-10 20.0 25.0 0.20 kgf/cm 0.25 kgf/cm 1C5-2816M-M0...
  • Page 13 1PD-2811R-00 YFM125A 6.5kW 152kg 1C5-2156A-20 43P-2816R-01 2012 YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN 8AC-2817L-00...
  • Page 14 Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. NEVER use on paved roads. ALWAYS use an approved helmet and NEVER carry passengers. protective gear.
  • Page 15 This unit contains high-pressure nitrogen Turning 4WD-LOCK gas. (“DIFF.LOCK”) takes more effort. Mishandling can cause an explosion. Do not Operate at a slow speed and allow extra incinerate, puncture or open. time and distance for maneuvers to avoid loss of control. This pictogram shows the loading limits and/or maximum load capacity for this ATV.
  • Page 16 Model Name ****** Max. Power *** kW *** kg Mass In Running Order 1 Year of construction **** YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN...

  • Page 17: Safety Information

    EBU17431 SAFETY INFORMATION ● EBU17537 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 18 ● Never operate at speeds too fast for your skills ● Never operate the ATV on hills too steep for the or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills.
  • Page 19 ● Always use proper procedures if you stall or roll reduced stopping ability. Test your brakes after backwards when climbing a hill. To avoid stall- leaving water. If necessary, apply them several ing, maintain a steady speed when climbing a times to let friction dry out the linings.
  • Page 20 In the event of an accident tion. If necessary, contact your riding party or 1. If serious injuries are incurred, you may be local authorities to let them know where you safer staying next to your vehicle; it may are and what has happened. shield you from oncoming riders.
  • Page 21 This im- While you may find aftermarket products similar in proper position limits the freedom of movement design and quality to genuine Yamaha accesso- of the operator and may limit control ability, ries, recognize that some aftermarket accessories...
  • Page 22 ● Do not run engine outdoors where engine EWB00072 WARNING exhaust can be drawn into a building through openings such as windows and Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, doors. a deadly gas. Breathing carbon monoxide can EWB02591 cause headaches, dizziness, drowsiness, nau- WARNING...

  • Page 23: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 5 6 7 1. Owner’s tool kit 1. Front carrier 2. Battery 2. Starter (choke) 3. Drive select lever 3. Fuel cock 4. Spark plug 4. Throttle stop screw 5. Headlight 5. Tail/brake light 6.

  • Page 24: Controls And Instruments

    EBU17712 Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Rear brake lever 2. Parking brake lock plate 3. Reverse indicator light 4. Neutral indicator light 5. Front brake lever 6.

  • Page 25: Instrument And Control Functions

    EBU17734 INSTRUMENT AND CONTROL FUNCTIONS EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.

  • Page 26: Indicator Lights

    EBU17793 EBU18061 Indicator lights Handlebar switches 1. Reverse indicator light “R” 1. Horn switch “ ” 2. Neutral indicator light “N” 2. Light switch “ /OFF” 3. Engine stop switch “ ” EBU17860 4. Start switch “ ” Neutral indicator light “ ”...

  • Page 27: Throttle Lever

    EBU18101 EBU18282 Start switch “ ” Throttle lever Push this switch to crank the engine with the start- Once the engine is running, pushing the throttle le- er. See the starting instructions on page 6-1 prior ver will increase the engine speed. to starting the engine.

  • Page 28: Speed Limiter

    EBU18323 Speed limiter Your ATV is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power avail- able and the maximum speed of the ATV, turn the adjusting screw in direction (a).

  • Page 29: Rear Brake Lever

    1. Front brake lever 1. Rear brake lever EBU18401 EBU18461 Rear brake lever Parking brake The rear brake lever is located on the left handle- Use the parking brake before starting the engine or bar. To apply the rear brake, pull the brake lever to- after parking the ATV, especially on a slope.

  • Page 30: Drive Select Lever

    braking performance which could cause an accident. You could also wear out the brakes prematurely. EBU18581 Drive select lever The drive select lever is used to shift your ATV into the forward, neutral and reverse positions. See the “Operating the drive select lever and driving in re- verse”...

  • Page 31: Fuel Tank Cap

    1. Before refueling, turn off the engine and be EBU18720 Fuel tank cap sure that no one is sitting on the vehicle. Nev- Remove the fuel tank cap by turning it counter- er refuel while smoking, or while in the vicinity clockwise.

  • Page 32: Fuel Cock

    Fuel reserve amount: 1.3 L (0.34 US gal, 0.29 Imp.gal) Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane 3. Wipe up any spilled fuel immediately.
  • Page 33 FUEL FUEL 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor.

  • Page 34: Starter (Choke)

    Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. FUEL 1. Arrow mark positioned over “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

  • Page 35: Front Carrier

    1. Seat lock lever 1. Projection 2. Seat holder To install the seat Insert the projections on the front of the seat into EBU18962 Front carrier the seat holders and push down on the seat at the ● Do not exceed the load limit of 5.0 kg (11 lb) for rear.

  • Page 36: Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 37 ITEM ROUTINE PAGE • Check operation, and correct if necessary. Rear brake • Lubricate cable if necessary. 5-3, 8-28, 8-33 • Check lever free play, and adjust if necessary. • Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary.

  • Page 38: Fuel

    Check the operation of the throttle lever. It must open smoothly and spring back to the idle position EBU19580 when released. Have a Yamaha dealer correct if Transmission oil necessary. Make sure that the transmission oil is at the speci- fied level.
  • Page 39 Tire pressure Recommended tire pressure: Use the low-pressure tire gauge to check and ad- Front just tire pressures when the tires are cold. Tire 20.0 kPa (0.200 kgf/cm², 2.9 psi) pressures must be equal on both sides. Rear WARNING! Operation of this vehicle with im- 25.0 kPa (0.250 kgf/cm², 3.6 psi) proper tire pressure may cause severe injury Minimum tire pressure:...
  • Page 40 EWB02551 WARNING Use of improper tires on this ATV may cause loss of control, increasing your risk of an acci- dent. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.

  • Page 41: Chassis Fasteners

    EBU19850 Front: Instruments, lights and switches Manufacturer/model: Check that all instruments, lights and switches are DURO/DI-K635A working properly. Correct if necessary. Size: AT20 x 7-8 EBU19860 Battery Type: Tubeless Check the fluid level in the battery. Fill with distilled Rear: water if necessary.

  • Page 42: Operation

    Read the Owner’s Manual carefully before riding on. If the indicator light does not come on, the ATV. If there is a control or function you do not have a Yamaha dealer check the electrical cir- understand, ask your Yamaha dealer. cuit.
  • Page 43 Position (3): be as short as possible to preserve battery ener- Cold engine start with ambient temperature gy. Do not crank the engine more than 10 sec- above 25 °C (80 °F). onds on each attempt. ● If the battery is discharged, pull the recoil starter Ambient temp./starter (choke) position to start the engine.

  • Page 44: Starting A Warm Engine

    EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. EBU20361 Operating the drive select lever and driving in reverse ECB00170...

  • Page 45: Engine Break-In

    If the indicator light does not come on, cessive load on it for the first 320 km (200 mi) or 20 have a Yamaha dealer check the electrical circuit. hours. The various parts in the engine wear and polish themselves to the correct operating clear- 4.

  • Page 46: Parking

    If any engine trouble should occur during the WARNING engine break-in period, immediately have a Avoid parking on hills or other inclines. Park- Yamaha dealer check the ATV. ing on a hill or other incline could cause the ATV to roll out of control, increasing the EBU30020 chance of an accident.

  • Page 47: Accessories And Loading

    An accessory which can shift position sories or offer other modifications for Yamaha or come off while you are riding could affect your vehicles. Yamaha is not in a position to test the ability to control the ATV. products that these aftermarket companies pro-...
  • Page 48 ● Do not mount an accessory where it could inter- sense and good judgment as the stability and han- fere with your ability to control the ATV. Exam- dling of an ATV can be changed. When adding ac- ples include (but are not limited to) a heavy or cessories, keep the following points in mind: ●...
  • Page 49 ● Ride more slowly than you would without a load. The more weight you carry, the slower you should go. ● Allow more braking distance. A heavier ATV takes longer to stop. ● Avoid making sharp turns unless at very slow speeds.

  • Page 50: Riding Your Atv

    EBU21141 RIDING YOUR ATV...

  • Page 51: Getting To Know Your Atv

    RIDE WITH CARE AND GOOD JUDGMENT EBU21316 Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is for recreation and utility use. This sec- WARNING tion, Riding your ATV, provides general ATV riding ● Do not operate this ATV or allow anyone else instructions for recreational riding.
  • Page 52 Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics. Take the time to learn the basic techniques well before attempting more difficult maneuvers.
  • Page 53 Apparel Always wear the following to reduce risk of injury in an accident: ● Approved motorcycle helmet that fits properly ● Eye protection (goggles, helmet face shield, or protective eyewear) ● Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
  • Page 54 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance Do not operate after or while consuming alco- procedures and schedules described in the Own- hol or drugs.
  • Page 55 opening, even when the throttle lever is pushed to EWB01462 WARNING the maximum. Turning in the adjusting screw limits the maximum engine power available and de- Improper loading or towing can increase the creases the maximum speed of the ATV. Turning risk of loss of control, an overturn, or other ac- in the adjusting screw decreases top speed, and cident.
  • Page 56 MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 105.0 kg (231 lb) Front carrier: 5.0 kg (11 lb) Rear carrier: 10.0 kg (22 lb) Drive more slowly than you would without a load. The more weight you carry, the slower you should go.
  • Page 57 ATV should be The muffler and other engine parts become ex- genuine Yamaha or equivalent components de- tremely hot during operation and remain hot after signed for use on this ATV and should be installed the engine has stopped.

  • Page 58: Be Careful Where You Ride

    To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for use on unpaved surfaces children are not likely to touch it. only. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control.
  • Page 59 Watch carefully for other vehicles. Make sure you bumps, or holes. Go slowly and be extra care- know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do not ways be alert to changing terrain conditions ride on any paved public street, road or motorway.
  • Page 60 loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. [EWB01541] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.

  • Page 61: Turning Your Atv

    a loss of directional control. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. When slowing down or stopping, release the throt- tle and apply the brakes smoothly and evenly. Im- proper use of the brakes can cause the tires to lose traction, reducing control and increasing the possi- bility of an accident.
  • Page 62 As you approach a curve, slow down and begin to This procedure should be practiced at slow speed turn the handlebars in the desired direction. As you many times in a large unpaved area with no obsta- do so, put your weight on the footboard to the out- cles.

  • Page 63: Climbing Uphill

    CLIMBING UPHILL ● Avoid crossing the side of a steep hill if pos- sible. When crossing the side of a hill, shift EWB01671 WARNING your weight to the uphill side of the ATV. Climbing hills improperly can cause overturns or loss of control. Use proper riding tech- niques described in this Owner’s Manual.
  • Page 64 on steeper inclines, standing on the footboards and leaning forward over the handlebars. Whenev- er possible, ride straight up hills. Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side – there could be another person, an obstacle, or a sharp drop-off.

  • Page 65: Riding Downhill

    mediately on the uphill side or to a side if pointed RIDING DOWNHILL straight uphill. Turn the ATV around and remount, EWB01131 WARNING following the procedure described in the Owner’s Manual. WARNING! Stalling, rolling backwards Going down a hill improperly could cause or improperly dismounting while climbing a hill overturns or loss of control.

  • Page 66: Crossing A Slope

    When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as pos- sible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you.

  • Page 67: Crossing Through Shallow Water

    ● Shift your weight to the uphill side of the ATV. ● Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill.
  • Page 68 The ATV can be used to cross slow moving, shal- ability. WARNING! Wet brakes may have re- low water of up to a maximum of 20 cm (8 in) in duced stopping ability, which could cause loss depth. Before entering the water, choose your path of control.

  • Page 69: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN EWB01651 WARNING Riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual.
  • Page 70 ● Learn to safely control skidding or sliding by If the rear wheels of your ATV start to slide side- practicing at low speeds and on level, ways, control can usually be regained (if there is smooth terrain. room to do so) by steering in the direction of the ●...

  • Page 71: What To Do If

    WHAT TO DO IF... THE REAR BRAKE – the ATV may tip over on This section is designed to be a reference guide top of you. Dismount the ATV on the uphill side. only. Be sure to read each section on riding tech- (See page 7-14.) ●...

  • Page 72: Periodic Maintenance And Adjustment

    The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.

  • Page 73: Owner's Manual And Tool Kit

    If you do not have the tools or experience required spective compartments under the seat. for a particular job, have a Yamaha dealer perform it for you. 1. Owner’s manual 2.

  • Page 74: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. INITIAL...
  • Page 75 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 76: General Maintenance And Lubrication Chart

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. INITIAL...
  • Page 77 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check runout and for damage, and replace if nec- √ √ √ √ Wheels essary. • Check tread depth and for damage, and replace if necessary.
  • Page 78 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours √ √ √ Steering shaft • Lubricate with lithium-soap-based grease. • Check operation and repair or replace if damaged. √...
  • Page 79 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check electrolyte level and specific gravity, and correct if necessary. √ √ √ √ √ 23 * Battery •...

  • Page 80: Checking The Spark Plug

    2. Remove the spark plug as shown, with the EBU23213 Checking the spark plug spark plug wrench included in the owner’s tool The spark plug is an important engine component, kit. which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica-...
  • Page 81 If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

  • Page 82: Engine Oil

    Tightening torque: Spark plug: If the engine was started before checking the oil 13 Nm (1.3 m·kgf, 9.4 ft·lbf) level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading. If a torque wrench is not available when installing 3.
  • Page 83 To change the engine oil 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil. 4.
  • Page 84 Tightening torque: Engine oil drain bolt: 32 Nm (3.2 m·kgf, 23 ft·lbf) 8. Refill with the specified amount of the recom- mended engine oil, and then install and tight- en the engine oil filler cap. Recommended oil: See page 10-1. Oil quantity: 1.25 L (1.32 US qt, 1.10 Imp.qt) 1.

  • Page 85: Transmission Oil

    9. 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. 10. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary.
  • Page 86 8. Install the transmission oil filler bolt and its gasket, and then tighten the bolt to the speci- fied torque. Tightening torque: Transmission oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) To change the transmission oil 1. Place the ATV on a level surface. 2.
  • Page 87 Recommended transmission oil: See page 10-1. Oil quantity: 0.6 L (0.63 US qt, 0.53 Imp.qt) 7. Check the oil filler bolt gasket for damage, and replace it if necessary. 8. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.

  • Page 88: Cleaning The Engine And V-Belt Case Air Filter Elements

    1. Place the ATV on a level surface. EBU2384C Cleaning the engine and V-belt case air 2. Remove the seat. (See page 4-10.) filter elements 3. Remove the breather hose by pulling it out, Both air filter elements should be cleaned at the and then loosen the air filter joint screw.
  • Page 89 1. Screw 1. Air filter case cover 2. Washer 2. Screw 3. Sponge material 5. Remove the screw and washer shown, and 4. Air filter element frame then pull the sponge material off from the air 5. Air filter case cover filter element frame.
  • Page 90 8. Check the sponge material and replace it if side facing outward as shown. damaged. [ECB00453] 9. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material. The sponge material should be wet but not drip- ping.
  • Page 91 15. Install the air filter case cover by installing the screws, and then tighten the air filter joint screw. 16. Install the breather hose. 17. Install the seat. The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar- eas.
  • Page 92 1. Front carrier bolt 1. Panel 2. Front carrier 2. Quick fastener 3. Remove the panel by removing the quick fas- 4. Disconnect the coupler shown. teners, and then pulling it upward as shown. 1. Coupler 8-21...
  • Page 93 5. Remove the air filter case cover by removing the screw. 1. Air filter element 7. Tap the air filter element lightly to remove 1. Air filter case cover most of the dust and dirt. Blow out the remain- 2. Screw ing dirt with compressed air as shown.

  • Page 94: Cleaning The Spark Arrester

    EBU27632 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be- fore cleaning the spark arrester. 1. Remove the tailpipe screws and their gasket. 1. Air filter element 8. Check the air filter element and replace it if damaged.

  • Page 95: V-Belt Case Drain Screw

    4. Insert the tailpipe into the muffler and align the If water drains from the V-belt case after removing screw holes. the screw, have a Yamaha dealer check the ATV 5. Check the gaskets for damage, and replace as the water may affect other engine parts.

  • Page 96: Adjusting The Carburetor

    1. V-belt case drain screw most carburetor adjustments should be left to a 2. Gasket Yamaha dealer, who has the necessary profes- sional knowledge and experience. The adjustment To drain the water from the V-belt case described in the following section, however, may 1.

  • Page 97: Adjusting The Engine Idling Speed

    3. Check the engine idling speed and, if neces- If the specified idling speed cannot be obtained as sary, adjust it to specification by turning the described above, have a Yamaha dealer make the throttle stop screw at the carburetor. To in- adjustment.

  • Page 98: Valve Clearance

    The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart.

  • Page 99: Brakes

    If a brake shoe has worn to the point that the wear indicator reaches the wear limit line or mark, have a Yamaha dealer replace the brake shoes as a set. 8-28...

  • Page 100: Adjusting The Front Brake Lever Free Play

    Rear brake The brake lever free play should measure 5.0–8.0 mm (0.20–0.31 in) as shown. If the free play is in- correct, adjust it as follows. 1. Wear limit line 2. Wear indicator 1. Brake lever free play EBU24374 Adjusting the front brake lever free 1.
  • Page 101 1. Front carrier 1. Panel 2. Front carrier bolt 2. Quick fastener 2. Remove the panel by removing the quick fas- 3. Disconnect the coupler shown. teners, and then pulling it upward as shown. 1. Coupler 8-30...
  • Page 102 4. Remove the V-belt air filter element cover by removing the screw. 1. Locknut 2. Brake lever free play adjusting bolt 1. V-belt air filter element cover 6. Make sure the brake cable joint in the equaliz- 2. Screw er is straight when the brake is applied. If the cable joint isn’t straight, loosen the locknuts, 5.
  • Page 103 7. Tighten the locknut on each brake cable. 8. Turn the brake lever free play adjusting bolt in direction (a) to increase the free play, and in direction (b) to decrease it. a=a' 1. Brake equalizer 2. Cable joint 1. Locknut 2.

  • Page 104: Adjusting The Rear Brake Lever Free Play

    Tightening torque: Front carrier bolt: 7 Nm (0.7 m·kgf, 5.1 ft·lbf) EBU30440 Adjusting the rear brake lever free play The brake lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. Before adjusting the brake lever free play, check 1.

  • Page 105: Drive Chain Slack

    (a), and then adjust the free play us- locknut. If the correct free play cannot be ob- ing the brake lever free play adjusting nut on tained, have a Yamaha dealer adjust it. the rear wheel hub. 4. Turn the brake lever free play adjusting nut on...
  • Page 106 To adjust the drive chain slack 1. Place the ATV on a level surface. When checking and adjusting the drive chain 2. Loosen the hub stopper bolt locknut and then slack, there should be no weight on the ATV and the hub stopper bolt.
  • Page 107 NOTICE If measurement “A” of the drive chain slack ad- justing bolt is less than 27 mm (1.06 in), have a Yamaha dealer replace the drive chain. 1. Locknut 2. Drive chain slack adjusting bolt 5. Tighten the drive chain slack adjusting bolt locknut and the axle holding bolts to the spec- ified torques.

  • Page 108: Lubricating The Drive Chain

    6. Tighten the hub stopper bolt and hub stopper bolt locknut to the specified torques. Tightening torques: Hub stopper bolt: 16 Nm (1.6 m·kgf, 12 ft·lbf) Hub stopper bolt locknut: 16 Nm (1.6 m·kgf, 12 ft·lbf) EBU24882 Lubricating the drive chain The drive chain must be cleaned and lubricated at 1.

  • Page 109: Checking And Lubricating The Front And Rear Brake Levers

    If a cable is damaged or does not move EBU28702 Checking and lubricating the front and smoothly, have a Yamaha dealer check or replace rear brake levers The operation of the front and rear brake levers Recommended lubricant: should be checked before each ride, and the lever Yamaha Chain and Cable Lube or engine oil pivots should be lubricated if necessary.

  • Page 110: Checking The Wheel Hub Bearings

    If there is play in a wheel hub or if a wheel does not turn smoothly, For parts equipped with a grease nipple, use a have a Yamaha dealer check the wheel hub bear- grease gun. ings.

  • Page 111: Lubricating The Front Knuckle Pivots

    Left side EBU28823 Lubricating the front knuckle pivots The front knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. For parts equipped with a grease nipple, use a grease gun. Recommended lubricant: Lithium-soap-based grease 1.

  • Page 112: Lubricating The Steering Shaft

    EBU25092 EBU2512A Lubricating the steering shaft Battery The steering shaft must be lubricated by a Yamaha The battery is located under the seat. (See page dealer at the intervals specified in the periodic 4-10.) maintenance and lubrication chart. A poorly maintained battery will corrode and dis- charge quickly.
  • Page 113 Batteries produce explosive gases. Keep 3. If the electrolyte is at or below the minimum sparks, flame, cigarettes or other sources of ig- level mark, add distilled water to raise it to the maximum level mark. NOTICE: Use only dis- nition away.
  • Page 114 2. Disconnect the negative lead first and then the ● If the battery will be stored for more than two positive lead. NOTICE: When removing the months, check the specific gravity of the electro- lyte at least once a month and fully charge the battery, the main switch must be off, and the negative lead must be disconnected battery whenever necessary.

  • Page 115: Replacing The Fuse

    EBU25263 Replacing the fuse 1. Battery 2. Negative battery lead (black) 3. Positive battery lead (red) 4. Battery band 1. Fuse 2. Spare fuse 3. Make sure that the breather hose is properly routed, in good condition, and not obstructed. The fuse holder is located on the right side of the NOTICE: If the breather hose is positioned ATV.

  • Page 116: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EBU25481 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
  • Page 117 1. Headlight bulb holder cover 1. Headlight bulb 2. Headlight bulb holder 6. Install the bulb holder by pushing it in and turn- 3. Remove the headlight bulb holder by pushing ing it clockwise. it in and turning it counterclockwise. 7.

  • Page 118: Adjusting A Headlight Beam

    If the tail/brake light bulb burns out, replace it as NOTICE follows. 1. Remove the tail/brake light bulb holder (to- It is advisable to have a Yamaha dealer make gether with the bulb) by turning it counter- this adjustment. clockwise.

  • Page 119: Removing A Wheel

    1. Tail/brake light bulb 1. Wheel nut 2. Tail/brake light bulb holder 3. Elevate the ATV and place a suitable stand 4. Install the bulb holder (together with the bulb) under the frame. by turning it clockwise. 4. Remove the nuts from the wheel. 5.

  • Page 120: Troubleshooting

    The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose 1. Tapered nut skilled technicians have the necessary tools, expe- 4.
  • Page 121 EWB02280 WARNING Do not smoke when checking the fuel system. Fuel can ignite or explode, causing severe inju- ry or property damage. Make sure there are no open flames or sparks in the area, including pi- lot lights from water heaters or furnaces. 8-50...

  • Page 122: Troubleshooting Chart

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

  • Page 123: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE may cause water seepage and deteriora- EBU25902 Cleaning tion of wheel bearings, brakes, transmis- Frequent, thorough cleaning of your ATV will not sion seals and electrical devices. Many only enhance its appearance but will improve its expensive repair bills have resulted from general performance and extend the useful life of improper high-pressure detergent applica-...

  • Page 124: Storage

    EBU30360 Specified amount: Storage 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel) Short-term Always store your ATV in a cool, dry place and, if 5. Perform the following steps to protect the cyl- necessary, protect it against dust with a porous inder, piston rings, etc.
  • Page 125 ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month.

  • Page 126: Specifications

    EBU25961 SPECIFICATIONS Dimensions: Cylinder arrangement: Single cylinder Overall length: Displacement: 1700 mm (66.9 in) 124 cm³ Overall width: Bore × stroke: 990 mm (39.0 in) 49.0 × 66.0 mm (1.93 × 2.60 in) Overall height: Compression ratio: 980 mm (38.6 in) 9.00 : 1 Seat height: Starting system:...
  • Page 127 Type: Fuel: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- Recommended fuel: Regular unleaded gasoline only Fuel tank capacity: 7.0 L (1.85 US gal, 1.54 Imp.gal) 50 ˚C Fuel reserve amount: 1.3 L (0.34 US gal, 0.29 Imp.gal) SAE 5W-30 Carburetor: Type ×...
  • Page 128 Reverse gear: Rear: 49/14 × 49/15 × 40/17 (26.902) 25.0 kPa (0.250 kgf/cm², 3.6 psi) Chassis: Minimum: Front: Frame type: 17.0 kPa (0.170 kgf/cm², 2.5 psi) Steel tube frame Rear: Caster angle: 22.0 kPa (0.220 kgf/cm², 3.2 psi) 6.0 ° Front wheel: Trail: 15.0 mm (0.59 in)
  • Page 129 Spring/shock absorber type: Reverse indicator light: 12 V, 1.7 W × 1 Coil spring/oil damper Wheel travel: Fuses: 70 mm (2.8 in) Main fuse: Rear suspension: 15.0 A Type: Swingarm EBU30401 Spring/shock absorber type: Coil spring/oil damper For Europe only Wheel travel: The figures quoted are emission levels and are not 80 mm (3.1 in)

  • Page 130: Consumer Information

    Record the vehicle identification number and mod- el label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number...
  • Page 131 1. Model label 11-2...
  • Page 132 INDEX Engine, cold start ............6-1 Engine idling speed ............8-26 Accessories and loading ..........6-6 Engine oil .............. 5-3, 8-11 Air filter elements, engine and V-belt filter cleaning ..8-17 Engine, starting a warm ..........6-3 Engine stop switch ............4-2 Battery ..............5-6, 8-41 Brake lever free play, adjusting the front ......
  • Page 133 Neutral indicator light ............. 4-2 Valve clearance ............8-27 V-belt case drain screw ..........8-24 Vehicle identification number ........11-1 Owner’s manual and tool kit ........... 8-2 Wheel hub bearings, checking ........8-39 Parking ................6-5 Wheel, installing ............8-48 Parking brake ..............
  • Page 134 EBU26162 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER CARRY NEVER USE NEVER USE AN APPROVED PASSENGERS WITH DRUGS ON PAVED HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER ALWAYS operate: • without proper training or instruction. •...

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