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Yamaha YFM125GZ Owner's Manual
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Yamaha YFM125GZ Owner's Manual

Yamaha YFM125GZ Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM125GZ
This A
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-23-13
1C5-28199-16

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Summary of Contents for Yamaha YFM125GZ

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM125GZ This A WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-23-13 1C5-28199-16...
  • Page 2 EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold.
  • Page 3 Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 4 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 5 Please check your local riding laws and regulations before operating this ATV. EBU17382 YFM125GZ OWNER’S MANUAL ©2009 by Yamaha Motor Corporation, U.S.A. 1st edition, February 2009 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

  • Page 6: Table Of Contents

    EWB00011 Rear brake lever ........4-5 WARNING Parking brake ..........4-5 Drive select lever ........4-6 Indicates a hazardous situation which, if not Fuel tank cap ..........4-7 avoided, could result in death or serious injury. Fuel ............4-7 Fuel cock ........... 4-8 Starter (choke) .........
  • Page 7 Parking ............6-5 Transmission oil ........8-13 Parking on a slope ........6-5 Cleaning the engine and V-belt case air filter elements ........8-15 Accessories and loading ......6-6 Cleaning the spark arrester ..... 8-22 V-belt case drain plug ......8-23 RIDING YOUR ATV ........
  • Page 8 Cleaning ............ 9-1 Storage ............9-2 SPECIFICATIONS ........10-1 CONSUMER INFORMATION ...... 11-1 Identification numbers ......11-1 Noise regulation ........11-4 Maintenance record ........ 11-5 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY ..11-6 YAMAHA EXTENDED SERVICE (Y.E.S.) ..........11-8...

  • Page 9: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 10 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 11: Load Limit

    WA R N IN G LOAD LIMIT Imprope r tire pressure or overloading can cause loss of cont rol. 11 Ibs. ( 5 kg ) Loss of control can result in severe injury or death. 3LD-24877-U0 OPERATING TIRE PRESSURE : Set with tires cold Re commended : Front : 2.9 psi ( 20.0 kPa) Rear : 3.6 psi ( 25.0 kPa) Minimum...
  • Page 12 This ATV complies with applicable provisions of ANSI / SVIA 1 - 2007 and is subject to an approved 5FE-21568-01 ATV action plan submitted by YAMAHA and on file with the U.S. Consumer Product Safety Commission. YAMAHA MOTOR CORPORATION U.S.A.

  • Page 13: Safety Information

    EBU17431 SAFETY INFORMATION SAFETY INFORMATION EBU17445 ate an ATV with engine size greater than 90 cc. Never allow a child under age 16 to operate an AN ATV IS NOT A TOY AND CAN BE HAZARD- ATV without adult supervision, and never allow OUS TO OPERATE.
  • Page 14 Never attempt wheelies, jumps, or other stunts. hills as described in this manual. Check the ter- Always inspect your ATV each time you use it to rain carefully before you start up any hill. Never make sure it is in safe operating condition. Al- climb hills with excessively slippery or loose sur- ways follow the inspection and maintenance faces.
  • Page 15 backwards, follow the special procedure for it is safe to proceed in reverse, go slowly. braking described in this manual. Dismount on Always use the size and type of tires specified in the uphill side or to a side if pointed straight up- this manual.
  • Page 16 monoxide can linger for hours or days in en- closed or poorly ventilated areas. If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT. Do not run engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels.

  • Page 17: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 4 5 6 1. Seat 1. Front carrier 2. Drive select lever 2. Starter (choke) 3. Headlight 3. Fuel cock 4. Tail/brake light 5. Rear carrier 6. Spark arrester 7. Footboard...

  • Page 18: 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 3. Reverse indicator light 4. Neutral indicator light 5. Front brake lever 6. Throttle lever 7.

  • Page 19: Instrument And Control Functions

    EBU17725 INSTRUMENT AND CONTROL FUNCTIONS EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU17740 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power, and the engine can be started.

  • Page 20: Indicator Lights

    EBU17792 EBU18061 Indicator lights Handlebar switches 1. Reverse indicator light “R” 1. Light switch “ /OFF” 2. Neutral indicator light “N” 2. Engine stop switch “ ” 3. Start switch “ ” EBU17830 Reverse indicator light “ ” EBU18080 This indicator light comes on when the transmis- Engine stop switch “...

  • Page 21: Throttle Lever

    EBU18101 throttle position. Because the throttle is spring- Start switch “ ” loaded, the ATV will decelerate, and the engine will Push this switch to crank the engine with the start- return to an idle any time the hand is removed from er.

  • Page 22: Front Brake Lever

    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). To de- crease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b).

  • Page 23: Rear Brake Lever

    1. Front brake lever 1. Rear brake lever EBU18401 EBU18460 Rear brake lever Parking brake The rear brake lever is located on the left handle- Use the parking brake before starting the engine or bar. To apply the rear brake, pull the brake lever to- parking the ATV, especially on a slope.

  • Page 24: Drive Select Lever

    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 25: Fuel Tank Cap

    EBU18720 1. Before refueling, turn off the engine and be 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 26: Fuel Cock

    Fuel reserve amount: rings, as well as to the exhaust system. 1.3 L (0.34 US gal, 0.29 Imp.gal) Your Yamaha engine has been designed to use 3. Wipe up any spilled fuel immediately. regular unleaded gasoline with a pump octane...
  • Page 27 buretor while also filtering it. The fuel cock lever positions are explained as fol- lows and shown in the illustrations. FUEL FUEL 1. Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this 1.

  • Page 28: Starter (Choke)

    the 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 29: 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 rear. Make sure that the seat is securely fitted. Do not exceed the load limit of 5.0 kg (11 lb) for the front carrier.
  • Page 30 EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 4-12...

  • Page 31: 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 32 ITEM ROUTINE PAGE Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary. 5-3, 8-25 Check cable free play, and adjust if necessary. Control cables Make sure that operation is smooth. Lubricate if necessary. 8-36 Check chain slack, and adjust if necessary.

  • Page 33: 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 34 pressures must be equal on both sides. tire pressure and use the second reading. Dust or WARNING! Operation of this vehicle with im- dirt in the gauge could cause the first reading to be proper tire pressure may cause severe injury incorrect.

  • Page 35: Chassis Fasteners

    After extensive tests, only the tires listed below EBU19840 Chassis fasteners have been approved for this model by Yamaha Motor Co., Ltd. Make sure that all nuts, bolts and screws are prop- erly tightened.

  • Page 36: Instruments, Lights And Switches

    EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary. EBU19860 Battery Check the fluid level in the battery. Fill with distilled water if necessary. (See page 8-39.)

  • Page 37: Operation

    The neutral indicator light should come on. If the indicator light does not come on, Read the Owner’s Manual carefully before riding have a Yamaha dealer check the electrical cir- the ATV. If there is a control or function you do not cuit.

  • Page 38: Starting A Warm Engine

    Ambient temp./starter (choke) position as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. 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.

  • Page 39: Operating The Drive Select Lever And Driving In Reverse

    EBU20361 Operating the drive select lever and driving in reverse ECB00170 NOTICE Before shifting, stop the ATV, otherwise the transmission may be damaged. Shifting: Forward 1. Bring the ATV to a complete stop. 2. Shift from neutral to forward and vice versa by moving the drive select lever along the shift 1.

  • Page 40: 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 41: Parking

    ATV to roll out of control, increasing the Yamaha dealer check the ATV. chance of an accident. If you must park on an incline, place the ATV transversely across the...

  • Page 42: 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- Do not mount an accessory where it could inter- duce.
  • Page 43 ples include (but are not limited to) a heavy or Never exceed the weight limits shown. An over- bulky object attached to the handlebars which loaded ATV can be unstable. could make steering difficult, an accessory that MAXIMUM LOADING LIMIT limits your ability to move around on the seat, or ATV loading limit (total weight of rider, cargo, one that limits your view.
  • Page 44 Allow more braking distance. A heavier ATV takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV. EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 45: Riding Your Atv

    EBU21132 RIDING YOUR ATV...

  • Page 46: Getting To Know Your Atv

    Before you begin to ride, be sure you complete the certified training course offered by have read this Owner’s Manual completely and un- Yamaha. They should then regularly practice the derstand the operation of the controls. Pay partic- skills learned in the course and the operating tech- ular attention to the safety information on pages niques described in this Owner’s Manual.
  • Page 47 information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. 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.
  • Page 48 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 49 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 Perform the pre-operation checks listed on page 5. Helmet 5-1. Always follow the inspection and maintenance procedures and schedules described in the Own- Do not operate after or while consuming alco- er’s Manual.
  • Page 50 the maximum. Turning in the adjusting screw limits EWB01461 WARNING the maximum engine power available and de- creases the maximum speed of the ATV. Turning Improper loading or towing can increase the in the adjusting screw decreases top speed, and risk of loss of control, an overturn, or other ac- turning it out increases top speed.
  • Page 51 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 52 ATV should be tremely hot during operation and remain hot after genuine Yamaha or equivalent components de- the engine has stopped. To reduce the risk of fire signed for use on this ATV and should be installed during operation or after leaving the ATV, do not let and used according to instructions.

  • Page 53: Be Careful Where You Ride

    children are not likely to touch it. BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Do not ride on any public road, street, or highway. WARNING! Paved surfaces may seriously af- Riding on public roads can result in collisions with fect handling and control of the ATV, and may other vehicles.
  • Page 54 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. WARNING! Do not operate on rough, slippery, or loose terrain The ATV could go out of control if you do not until you have learned and practiced the skills nec- have enough time to react to hidden rocks,...
  • Page 55 When riding in an area where you might not easily Do not ride in areas posted “no trespassing”. be seen, such as desert terrain, mount a caution Do not ride on private property without getting per- flag on the ATV. DO NOT use the flag pole bracket mission.

  • Page 56: 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 57: Climbing Uphill

    As you approach a curve, slow down and begin to many times in a large off-road area with no obsta- turn the handlebars in the desired direction. As you cles. If an incorrect technique is used, your ATV do so, put your weight on the footboard to the out- may continue to go straight.
  • Page 58 Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
  • Page 59 Do not attempt to climb hills until you have mas- to do so) and go down the hill. tered basic maneuvers on flat ground. Always If your ATV has stalled or stopped and you believe check the terrain carefully before attempting any you can continue up the hill, restart carefully to hill.

  • Page 60: Riding Downhill

    side of the hill. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side. Go straight down the hill where possi- ble. Improper braking can cause the wheels on the uphill side to come off the ground or cause loss of traction.

  • Page 61: Crossing A Slope

    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 62: Crossing Through Shallow Water

    The ATV can be used to cross slow moving, shallow water of up to a maximum of 20 cm (8 in) in depth. Before entering the water, choose your path care- fully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slip- pery or upset the ATV.
  • Page 63 1. Air filter case check hose 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. Also, remove the V-belt case drain plug to drain any water that may have accumulated.

  • Page 64: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN practicing at low speeds and on level, EWB01651 smooth terrain. WARNING On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re- Riding improperly over obstacles could cause duce the chance of skidding or sliding out of loss of control or a collision.

  • Page 65: What To Do If

    ways, control can usually be regained (if there is only. Be sure to read each section on riding tech- room to do so) by steering in the direction of the niques completely. slide. Applying the brakes or accelerating is not WHAT TO DO...
  • Page 66 (See page 7-13.) If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.

  • Page 67: Periodic Maintenance And Adjustment

    If you are not fa- EBU27111 Owner’s manual and tool kit miliar with vehicle service, have a Yamaha dealer perform the service. Be sure to put this owner’s manual in the plastic bag and to always carry it as well as the owner’s...
  • Page 68 However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform...

  • Page 69: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 70 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 71: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Engine and V-belt Every 20–40 hours (more often in wet or case air filter ele- Clean and replace if necessary.
  • Page 72 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check chain slack and adjust if necessary. Check rear wheel alignment and correct if neces- √ √ √ √...
  • Page 73 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check operation and correct if necessary. Throttle lever hous- Check throttle cable free play and adjust if neces- √...

  • Page 74: Checking The Spark Plug

    EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU23211 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- 1.
  • Page 75 If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 1. Spark plug gap 2. Check the spark plug for electrode erosion...

  • Page 76: Engine Oil

    2. Clean the surface of the spark plug gasket To check the engine oil level and its mating surface, and then wipe off any 1. Place the ATV on a level surface. grime from the spark plug threads. 2. Check the engine oil level on a cold engine. 3.
  • Page 77 4. Insert the dipstick into the filler hole (without may result. [ECB00851] screwing it in), and then remove it again to 6. Insert the dipstick into the oil filler hole, and check the oil level. then tighten the engine oil filler cap. To change the engine oil 1.
  • Page 78 Tightening torque: Engine oil drain bolt: 32 Nm (3.2 m·kgf, 23.1 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 79: Transmission 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. EBU27025 Transmission oil The transmission oil level should be checked be- fore each ride.
  • Page 80 To change the transmission 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 transmission to col- lect the used oil. 4.

  • Page 81: Cleaning The Engine And V-Belt Case Air Filter Elements

    off the engine and check for the cause. Tightening torque: 8. Turn the engine off, and then check the oil lev- Transmission oil drain bolt: el and correct it if necessary. 23 Nm (2.3 m·kgf, 16.6 ft·lbf) EBU23843 6. Refill with the specified amount of the recom- Cleaning the engine and V-belt case air mended transmission oil, and then install and filter elements...
  • Page 82 1. Check hose 1. Breather hose 2. Clamp screw 1. Place the ATV on a level surface. 2. Remove the seat. (See page 4-10.) 4. Remove the air filter case cover by removing 3. Remove the breather hose, and then loosen the screws.
  • Page 83 1. Bolt 1. Air filter case cover 2. Washer 2. Screw 3. Sponge material 5. Pull the air filter element out of the air filter 4. Air filter element frame case. 7. Wash the sponge material gently but thor- 6. Remove the bolt and washer shown, and then oughly in solvent.
  • Page 84 9. Check the sponge material and replace it if 1. Washer damaged. 10. Apply Yamaha foam air filter oil or other qual- 13. Install the air filter element into the air filter ity foam air filter oil to the sponge material.
  • Page 85 15. Install the breather hose and then tighten the clamp screw. 16. 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 86 1. Panel 1. Panel 2. Quick fastener 2. Coupler 4. Disconnect the coupler shown. 5. Remove the air filter case cover by removing the screw. 8-20...
  • Page 87 1. Air filter case cover 1. Air filter element 2. Screw 7. Tap the air filter element lightly to remove 6. Remove the air filter element. most of the dust and dirt. Blow out the remain- ing dirt with compressed air as shown. 8-21...

  • Page 88: Cleaning The Spark Arrester

    fore cleaning the spark arrester. 1. Remove the screws. 1. Air filter element 8. Check the air filter element and replace it if 1. Screw damaged. 9. Install the air filter element into the air filter 2. Remove the tailpipe by pulling it out of the case.

  • Page 89: V-Belt Case Drain Plug

    V-belt case, remove this plug to drain the water from the case. If water drains from the V-belt case after removing the plug, have a Yamaha dealer check the ATV as the water may affect other engine parts. 1. Screw 2.

  • Page 90: Adjusting The Carburetor

    The engine is warm when it quickly responds to the most carburetor adjustments should be left to a throttle. Yamaha dealer, who has the necessary profes- 2. Attach the tachometer to the spark plug lead. sional knowledge and experience. The adjustment 3.

  • Page 91: Adjusting The Throttle Cable Free Play

    (a). To decrease the throttle cable free play, turn the adjusting bolt in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. EBU24045 Adjusting the throttle cable free play...

  • Page 92: Valve Clearance

    Yamaha dealer replace the must be adjusted by a Yamaha dealer at the inter- brake shoes as a set. vals specified in the periodic maintenance and lu- brication chart.

  • Page 93: Adjusting The Front Brake Lever Free Play

    Front brake Rear brake 1. Wear limit line 1. Wear limit line 2. Wear indicator 2. Wear indicator EBU24371 Adjusting the front brake lever free play The brake lever free play must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 94 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. Front carrier 2. Bolt 2. Remove the panel shown by removing the 1. Brake lever free play quick fasteners, then disconnect the coupler shown.
  • Page 95 1. Panel 1. Panel 2. Quick fastener 2. Coupler 3. Remove the V-belt air filter element cover by removing the screw. 8-29...
  • Page 96 1. Locknut 1. V-belt air filter element cover 2. Brake lever free play adjusting bolt 2. Screw 5. Make sure the brake cable joint in the equaliz- 4. Loosen the locknut and fully turn in the adjust- er is straight when the brake is applied. If the ing bolt at the brake lever.
  • Page 97 a=a' 1. Brake equalizer 1. Locknut 2. Cable joint 2. Adjusting nut 6. Tighten the locknut on each brake cable. 7. Turn the adjusting bolt in direction (a) to in- crease the free play, and in direction (b) to de- crease it.

  • Page 98: Adjusting The Rear Brake Lever Free Play

    (b) to decrease it. The brake lever free play must be checked and, if If the correct free play cannot be obtained, have a necessary, adjusted at the intervals specified in Yamaha dealer adjust it. 8-32...

  • Page 99: Drive Chain Slack

    2. Move the ATV back and forth to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown. Drive chain slack: 30.0 mm (1.18 in) 1. Brake lever free play adjusting nut EBU24873 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary.
  • Page 100 the hub stopper bolt. age. To prevent this from occurring, keep 3. Loosen the axle holding bolts. the drive chain slack within the specified limits. [ECB00542] 1. Hub stopper bolt 2. Locknut 1. Locknut 3. Axle holding bolt (lower) 2. Drive chain slack adjusting bolt 4.

  • Page 101: Lubricating The Drive Chain

    ECB00550 Service the drive chain as follows. NOTICE If measurement “A” of the drive chain adjust- ing bolt is less than 27 mm (1.06 in), have a Yamaha dealer replace the drive chain. 1. O-ring 1. Measurement A 8-35...

  • Page 102: Checking And Lubricating The Cables

    The operation of the front and rear brake levers essary. If a cable is damaged or does not move should be checked before each ride, and the lever smoothly, have a Yamaha dealer check or replace pivots should be lubricated if necessary. 8-36...

  • Page 103: Checking The Wheel Hub Bearings

    Front brake lever maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bear- ings. EBU25032 Lubricating the upper and lower arm...

  • Page 104: Lubricating The Front Knuckle Pivots

    Left side Right side 1. Grease nipple 1. Grease nipple EBU28822 Lubricating the front knuckle pivots The front knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Lubricate the front knuckle pivots using a grease gun.

  • Page 105: Lubricating The Steering Shaft

    1. Grease nipple 1. Grease nipple EBU25090 EBU25122 Lubricating the steering shaft Battery The steering shaft must be lubricated at the inter- A poorly maintained battery will corrode and dis- vals specified in the periodic maintenance and lu- charge quickly. The electrolyte level, battery lead brication chart.

  • Page 106: Battery

    1. Maximum level mark 1. Battery 2. Minimum level mark 2. Battery breather hose 3. Guide EWB02160 WARNING Battery electrolyte is poisonous and danger- The electrolyte should be between the minimum ous, as it contains sulfuric acid, which can and maximum level marks. cause severe burns.
  • Page 107 EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes or other sources of ig- nition away. Ventilate when charging or using in an enclosed space. KEEP OUT OF REACH OF CHILDREN. 4.
  • Page 108 To install the battery Be sure the battery is fully charged. 1. Install the battery. 2. Connect the positive lead first, and then con- nect the negative lead. 3. Make sure that the breather hose is properly routed, in good condition, and not obstructed. NOTICE: If the breather hose is positioned in such a way that the frame is exposed to electrolyte or gas expelled from the bat-...

  • Page 109: Replacing The Fuse

    1. Fuse 4. If the fuse immediately blows again, have a 2. Spare fuse Yamaha dealer check the electrical system. The fuse holder is located on the right side of the EBU25481 Replacing a headlight bulb ATV.
  • Page 110 1. Cover at the rear of the headlight 1. Headlight bulb holder cover 2. Headlight bulb holder 2. Remove the headlight bulb holder cover by pulling it off. 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. 4.

  • Page 111: Adjusting A Headlight Beam

    EBU25551 Adjusting a headlight beam ECB00690 NOTICE It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b).

  • Page 112: Removing A Wheel

    follows. 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 1. Tail/brake light bulb 2. Tail/brake light bulb holder 3. Insert a new bulb into the bulb holder, push it 1. Tail/brake light bulb holder in, and then turn it clockwise until it stops. 2.

  • Page 113: Installing A Wheel

    Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. 1. Wheel nut 3. Elevate the ATV and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 1.

  • Page 114: Troubleshooting

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

  • Page 115: 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 116: Cleaning And Storage

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

  • Page 117: Storage

    EBU25933 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 118 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 119: Specifications

    EBU25960 SPECIFICATIONS EBU2597E Compression ratio: 9.00 :1 Dimensions: Starting system: Overall length: Electric starter 1700 mm (66.9 in) Lubrication system: Overall width: Wet sump 990 mm (39.0 in) Engine oil: Overall height: Recommended brand: 980 mm (38.6 in) YAMALUBE Seat height: Type: 685 mm (27.0 in) SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W-...
  • Page 120 Transmission oil: Secondary reduction ratio: 32/12 (2.666) Quantity: Transmission type: 0.6 L (0.63 US qt, 0.53 Imp.qt) V-belt automatic Air filter: Operation: Air filter element: Centrifugal automatic type Wet element Reverse gear: Fuel: 49/14 × 49/15 × 40/17 (26.902) Recommended fuel: Chassis: Unleaded gasoline only Frame type:...
  • Page 121 Loading: Rear brake: Maximum loading limit: Type: 105.0 kg (231 lb) Drum brake (Total weight of rider, cargo, accessories, and tongue) Operation: Tire air pressure (measured on cold tires): Left hand operation Front suspension: Recommended: Front: Type: 20.0 kPa (0.200 kgf/cm , 2.9 psi) Swing axle Rear:...
  • Page 122 Headlight: Bulb type: Krypton bulb Bulb voltage, wattage × × × × quantity: Headlight: 12 V, 30/30 W × 2 Tail/brake light: 12 V, 5.0/21.0 W × 1 Neutral indicator light: 12 V, 1.7 W × 1 Reverse indicator light: 12 V, 1.7 W ×...

  • Page 123: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 124 Model label ment Canada. The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- 11-2...
  • Page 125 1. Vehicle Emission Control Information label 11-3...

  • Page 126: Noise Regulation

    EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 127: Maintenance Record

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

  • Page 128: Yamaha Motor Corporation, U.s.a. Atv Limited Warranty

    (6) months from the date of purchase. appropriate owner’s manual; YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 2. Give notice to an authorized Yamaha ATV dealer OTHER WARRANTY OF ANY KIND, EXPRESSED OR of any and all apparent defects within ten (10) days DURING THE PERIOD OF WARRANTY any authorized IMPLIED.
  • Page 129 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

  • Page 130: Yamaha Extended Service (Y.e.s.)

    Yamaha people who handle your warranty – and it Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn’t limited to much more valuable! “moving par ts”...
  • Page 131 Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
  • Page 132 EBU26132 11-10...
  • Page 133 INDEX Accessories and loading ..........6-6 Engine break-in .............. 6-4 Air filter elements, engine and V-belt filter cleaning ..8-15 Engine, cold start ............6-1 Engine idling speed............8-24 Engine oil ............. 5-3 8-10 Battery..............5-6 8-39 Engine, starting a warm ..........6-2 Brake lever free play, adjusting the front......
  • Page 134 Suspension, lubricating the upper and lower arm pivots................8-37 Main switch ..............4-1 Maintenance and lubrication chart ......... 8-5 Maintenance chart, emission control system ....8-3 Tail/brake light bulb, replacing ........8-45 Maintenance record ............. 11-5 Throttle cable free play, adjusting ........ 8-25 Model label..............
  • Page 136 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2009.03-0.4x1 !
  • Page 137 8 TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA – ASK YOUR DEALER FOR DETAILS OR CALL 1-800-887-2887 If you have any questions about these points, or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership, please fill out the information below and mail this card to yamaha today.
  • Page 138 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES FIRST CLASS PERMIT NO. 4 CYPRESS, CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U.S.A. P.O. BOX 6555 CYPRESS, CALIFORNIA 90630-9989 ATTN: SALES ADMINISTRATION...

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