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Yamaha Raptor YFM7RB Owner's Manual
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Yamaha Raptor YFM7RB Owner's Manual

Yamaha Raptor YFM7RB Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM7RB
YFM7RSEB
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-25-01
1AS-28199-12

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Summary of Contents for Yamaha Raptor YFM7RB

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM7RB YFM7RSEB WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-25-01 1AS-28199-12...
  • 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 pacesetting racing ma- chines. 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 YFM7RB/YFM7RSEB OWNER’S MANUAL ©2011 by Yamaha Motor Corporation, U.S.A. 1st edition, January 2011 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 Speed limiter ..........4-7 WARNING Clutch lever ..........4-7 Indicates a hazardous situation which, if not Brake lever ..........4-8 avoided, could result in death or serious injury. Brake pedal ..........4-8 Parking brake lever ........4-9 Shift pedal ..........4-10 Reverse knob “REV” .........4-10 EBU17420 Fuel tank cap ..........4-11 TABLE OF CONTENTS...
  • Page 7 OPERATION ..........6-1 PERIODIC MAINTENANCE AND Starting the engine ........6-1 ADJUSTMENT..........8-1 Shifting ............6-2 Owner’s manual and tool kit .......8-2 Operating the reverse knob and Periodic maintenance chart for driving in reverse ........6-4 the emission control system .....8-3 Engine break-in ..........
  • Page 8 Checking and lubricating the brake Noise regulation ........11-4 pedal ............8-40 Maintenance record ........11-5 Checking the wheel hub bearings .... 8-41 YAMAHA MOTOR CORPORATION, Lubricating the swingarm pivots ....8-41 U.S.A. ATV LIMITED WARRANTY ..11-6 Lubricating the rear suspension relay arm YAMAHA EXTENDED SERVICE and connecting arm pivoting points ..

  • Page 9: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 10 Certification of Compliance This ATV complies with applicable provisions of ANSI/SVIA 1-2010 and is subject to an approved ATV action plan submitted by YAMAHA and on file with the U.S. Consumer Product Safety Commission. YAMAHA MOTOR CORPORATION U.S.A. 6555 Katella Avenue, Cypress, California 90630-5101, U.S.A.
  • Page 11 WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 5FE-2151H-01...
  • Page 12 WARNING WARNING Improper tire pressure or overloading can cause This unit contains high pressure nitrogen gas. loss of control. Mishandling can cause explosion. Loss of control can result in severe injury of • Read owner’s manual for instructions. death. • Do not incinerate, puncture or open. OPERATING TIRE PRESSURE : Set with tires cold •...

  • Page 13: Safety Information

    EBU17431 SAFETY INFORMATION EBU26664 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 14 Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 15 speed when climbing a hill. If you stall or roll Always be sure there are no obstacles or people backwards, follow the special procedure for behind you when you operate in reverse. When braking described in this manual. Dismount on it is safe to proceed in reverse, go slowly.
  • Page 16 EWB00072 Do not run engine outdoors where engine WARNING exhaust can be drawn into a building Avoid Carbon Monoxide Poisoning through openings such as windows and All engine exhaust contains carbon monoxide, doors. a deadly gas. Breathing carbon monoxide can FOR MORE INFORMATION ABOUT ATV SAFE- cause headaches, dizziness, drowsiness, nau- TY, call the Consumer Products Safety Commis-...

  • Page 17: Description

    EBU17680 DESCRIPTION EBU17690 10.Engine oil tank drain bolt Left view 1. Engine oil tank filler cap 2. Coolant reservoir 3. Idle adjusting screw 4. Fuses 5. Rear shock absorber assembly rebound damping force adjusting screw 6. Rear shock absorber assembly compression damping force adjusting bolt (for fast compression damping) 7.

  • Page 18: Right View

    EBU17700 13.Brake pedal Right view 14.Rear brake light switch 5 6 7 8,9,10 13 12 1. Spark arrester 2. Air filter case 3. Battery 4. Rear brake fluid reservoir 5. Crankcase engine oil filler cap 6. Oil filter element 7. Spark plug 8.

  • Page 19: Controls And Instruments

    EBU17712 Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Clutch lever 2. Parking brake lever 3. Main switch 4. Front brake fluid reservoir 5. Brake lever 6. Throttle lever 7.

  • Page 20: 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. 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 1.

  • Page 21: Indicator Lights And Warning Lights

    If the warning light does not come on initially when the key is turned to “ON”, or if the warning light re- mains on, have a Yamaha dealer check the electri- cal circuit. 1. Neutral indicator light “N”...

  • Page 22: Multi-Function Display

    “ON”, or if the warning light re- This warning light comes on when the fuel level mains on, have a Yamaha dealer check the electri- drops below approximately 2.6 L (0.69 US gal, cal circuit.
  • Page 23 two tripmeters (which show the distance trav- Clock mode eled since they were last set to zero) Push and hold “SELECT” button for at least three a clock seconds to switch the display between the clock an hour meter (which shows the total time the mode “CLOCK”...

  • Page 24: Handlebar Switches

    1. Light switch “ /OFF” If the multi-function display indicates an error code, 2. Engine stop switch “ ” note the code number, and then have a Yamaha 3. Start switch “ ” dealer check the vehicle.

  • Page 25: Throttle Lever

    EBU18080 If this should happen, remove the battery and Engine stop switch “ ” recharge it. See page 8-44 for battery charging Set this switch to “ ” before starting the engine. information. The engine stop switch controls the ignition and stops the engine when it is running.

  • Page 26: Speed Limiter

    Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. EBU18323 Speed limiter Your ATV is equipped with an adjustable speed limiter.

  • Page 27: Brake Lever

    leased slowly for smooth clutch operation. (See page 6-1 for a description of the ignition circuit cut- off system.) 1. Brake lever 2. Locknut 3. Brake lever position adjusting bolt 4. Distance between brake lever and handlebar grip 1. Clutch lever EBU18432 EBU18423 Brake pedal...

  • Page 28: Parking Brake Lever

    1. Parking brake lever (locked position) 1. Brake pedal EBU18520 Parking brake lever Use the parking brake before starting the engine or parking the ATV, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a).

  • Page 29: Shift Pedal

    EWB00220 WARNING Always set the parking brake before starting the engine. The ATV could start moving un- expectedly if the parking brake is not ap- plied. This could cause loss of control or a collision. Always be sure you have released the park- ing brake before you begin to ride.

  • Page 30: Fuel Tank Cap

    1. Reverse knob “REV” 1. Fuel tank cap EBU18720 EBU18731 Fuel tank cap Fuel Remove the fuel tank cap by turning it counter- Make sure there is sufficient gasoline in the tank. clockwise. EWB02521 WARNING Gasoline and gasoline vapors are extremely flammable.
  • Page 31 of sparks, open flames, or other sources of ig- Recommended fuel: nition such as the pilot lights of water heaters UNLEADED GASOLINE ONLY and clothes dryers. Fuel tank capacity: 2. Do not overfill the fuel tank. When refueling, 11.0 L (2.91 US gal, 2.42 Imp.gal) be sure to insert the pump nozzle into the fuel Fuel reserve amount: tank filler hole.

  • Page 32: Seat

    Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research oc- tane number of 91 or higher.

  • Page 33: Adjusting The Front Shock Absorber Assemblies

    EWB02491 WARNING Suspension components become hot during operation. Never touch the compression damping force adjusting bolt and screw, the rebound damping force adjusting screw or the oil reservoir with your bare hand or skin until suspension components have cooled. Always adjust the shock absorber assem- blies on the left and right side to the same setting.
  • Page 34 A special wrench can be obtained at a Yamaha nism and to modify the specifications as neces- dealer to make this adjustment. sary.
  • Page 35 Rebound damping force Turn the rebound damping force adjusting screw in direction (a) to increase the rebound damping force and thereby harden the damping, and in di- rection (b) to decrease the rebound damping force and thereby soften the damping. 1.
  • Page 36 Rebound damping setting: Minimum (soft): 20 click(s) in direction (b)* Standard: 12 click(s) in direction (b)* Maximum (hard): 3 click(s) in direction (b)* * With the adjusting screw fully turned in direc- tion (a) Compression damping force 1. Compression damping force adjusting bolt (for fast compression damping) Compression damping force (for fast compression damping)
  • Page 37 Compression damping force (for slow compres- Compression damping setting (for slow com- sion damping) pression damping): To increase the compression damping force and Minimum (soft): thereby harden the compression damping, turn the 16 click(s) in direction (b)* compression damping force adjusting screw in di- Standard: rection (a).

  • Page 38: Adjusting The Rear Shock Absorber Assembly

    Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha deal- er for any service. Although the total number of clicks or turns of a...
  • Page 39 A special wrench can be obtained at a Yamaha sary. dealer to make this adjustment. The spring preload setting is determined by Spring preload measuring distance A, shown in the illustration.
  • Page 40 Rebound damping force Turn the rebound damping force adjusting screw in direction (a) to increase the rebound damping force and thereby harden the damping, and in di- rection (b) to decrease the rebound damping force and thereby soften the damping. 1.
  • Page 41 Rebound damping setting: Minimum (soft): 20 click(s) in direction (b)* Standard: 13 click(s) in direction (b)* Maximum (hard): 3 click(s) in direction (b)* * With the adjusting screw fully turned in direc- tion (a) 1. Compression damping force adjusting bolt (for fast compression damping) Compression damping force Compression damping setting (for fast com-...
  • Page 42 Compression damping force (for slow compres- Compression damping setting (for slow com- sion damping) pression damping): To increase the compression damping force and Minimum (soft): thereby harden the compression damping, turn the 16 click(s) in direction (b)* compression damping force adjusting screw in di- Standard: rection (a).
  • Page 43 Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha deal- er for any service. EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 44: 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 45 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-4, 8-29, 8-30, 8-33 • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.
  • Page 46 ITEM ROUTINE PAGE • Make sure that operation is smooth. Lubricate lever pivoting points if Brake and clutch levers 8-40 necessary. Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. Instruments, lights and • Check operation, and correct if necessary. switches...

  • Page 47: Fuel

    Check that there is no free play in the brake le- Test the brakes at slow speed after starting out to ver. If there is free play, have a Yamaha dealer make sure they are working properly. If the brakes check the brake system.

  • Page 48: Throttle Lever

    [EWB02541] Check the operation of the throttle lever. It must pressures to the following specifications: open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if Recommended tire pressure: necessary. Front 27.5 kPa (0.275 kgf/cm², 4.0 psi)
  • Page 49 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 50: Chassis Fasteners

    EBU19850 Front: Instruments, lights and switches Manufacturer/model: Check that all instruments, lights and switches are DUNLOP/KT341 Radial working properly. Correct if necessary. Size: AT21 x 7R10 Type: Tubeless Rear: Manufacturer/model: DUNLOP/KT345 Radial Size: AT20 x 10R9 Type: Tubeless Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling,...

  • Page 51: Operation

    3. Shift the transmission into neutral. The neutral indicator light should come on, if it does not come on, have a Yamaha dealer check the EBU29484 Starting the engine electrical circuit.

  • Page 52: Shifting

    The clutch is disengaged with the transmission To shift into neutral, release the throttle lever, ap- in gear. However, it is recommended to shift into ply the clutch, and then repeatedly depress the neutral before starting the engine. shift pedal until it stops. When it stops, it will be in first gear.
  • Page 53 ECB00200 EBU20650 To decelerate NOTICE When slowing down or stopping, release the throt- Always close the throttle before shifting gears, tle and apply the brakes smoothly and evenly. As otherwise damage to the engine and drive train you slow down, shift to a lower gear. Be sure that may result.

  • Page 54: Operating The Reverse Knob And Driving In Reverse

    erly lubricated only when the engine is run- 1. Bring the ATV to a complete stop, apply the ning. Inadequate lubrication may damage clutch lever, and then shift the transmission the transmission. into first gear. Always use the clutch when changing gears. 2.

  • Page 55: Engine Break-In

    If the indicator light does not come on, polish themselves to the correct operating clear- have a Yamaha dealer check the electrical circuit. ances. During this period, prolonged full-throttle operation or any condition that might result in en- 4.

  • Page 56: Parking

    EBU26761 incline, shift into first gear, stop the engine, ap- Parking ply the parking brake, and then block the front When parking the ATV, shift into first gear, stop the and rear wheels with rocks or other objects. engine, and then apply the parking brake. Never park the ATV on hills that are too steep to walk up easily.

  • Page 57: 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 58 EBU20941 If you are carrying cargo and towing a trailer, in- Loading clude the tongue weight in the maximum ATV EWB00820 load limit. WARNING Load cargo on the carriers as close to the center Never exceed the stated load capacity for this of the ATV as possible.
  • Page 59 EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 60: Riding Your Atv

    EBU21132 RIDING YOUR ATV...

  • Page 61: 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-...
  • Page 62 niques described in this Owner’s Manual. For more 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 63 proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. [EWB01411] Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury. Eye protection, such as a face shield or goggles, may reduce the risk of foreign material getting in your eyes and help prevent loss of vision.
  • Page 64 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 65 opening, even when the throttle lever is pushed to Do not exceed the maximum loading limits the maximum. Turning in the adjusting screw limits for the vehicle (see “MAXIMUM LOADING the maximum engine power available and de- LIMIT” below or vehicle labeling). creases the maximum speed of the ATV.
  • Page 66 All parts and accessories added to this ATV should be genuine Yamaha or equivalent components de- signed for use on this ATV and should be installed and used according to instructions. If you have...
  • Page 67 WARNING! Operating this ATV with improper erating in areas where combustible materials may modifications may cause changes in handling have collected. Do not idle or park the vehicle in which in some situations could lead to an acci- long dry grass or other dry ground cover. dent.

  • Page 68: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE ATVs on public streets, roads and highways. This ATV is designed for off-road use only. WARNING! Never operate this ATV on any pub- WARNING! Paved surfaces may seriously af- lic street, road or highway, even a dirt or gravel fect handling and control of the ATV, and may one.
  • Page 69 ful when operating on unfamiliar terrain. Al- ways be alert to changing terrain conditions when operating the ATV. [EWB01531] 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.
  • Page 70 Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain.

  • Page 71: Turning Your Atv

    trol. NOTICE: Do not shift gears without To achieve maximum traction while riding off-road, [EWB02631] releasing the throttle. Damage to the engine or the two rear wheels turn together at the same drive train may occur. speed. Therefore, unless the wheel on the inside [ECB01071] Use this same procedure as you move into the of the turn is allowed to slip or lose some traction,...

  • Page 72: Climbing Uphill

    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 move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip.
  • Page 73 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. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.
  • Page 74 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footrests and leaning forward over the handlebars. Whenever possible, ride straight up hills.
  • Page 75 If you start to roll backwards, DO NOT apply the rear brake, and apply the front brake gradually. The ATV could easily tip over backwards. When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount the ATV im- mediately on the uphill side or to a side if pointed straight uphill.

  • Page 76: Riding Downhill

    RIDING DOWNHILL When riding your ATV downhill, shift your weight EWB01131 as far to the rear and uphill side of the ATV as pos- WARNING sible. Move back on the seat and sit with your arms Going down a hill improperly could cause straight.

  • Page 77: Crossing A Slope

    Avoid crossing the side of a steep hill. 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.

  • Page 78: Crossing Through Shallow Water

    than the depth specified in your Owner’s Man- ual, as tires may float, increasing the risk of an overturn. The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth.

  • Page 79: Riding Over Rough Terrain

    Test your brakes after leaving the water. If neces- Wash the ATV in fresh water if it has been operat- sary, apply them several times to let friction dry out ed in salt water or muddy conditions. the linings. Do not continue to ride your ATV with- out verifying that you have regained proper braking ability.

  • Page 80: Sliding And Skidding

    Riding over rough terrain should be done with cau- To reduce the tendency for the front wheels to slide tion. Look out for obstacles which could cause in loose or slippery conditions, positioning your damage to the ATV or could lead to an upset or ac- weight over the front wheels will sometimes help.

  • Page 81: What To Do If

    WHAT TO DO... If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footrest to the outside of the turn. Position your weight over the front wheels for better control.
  • Page 82 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 83: 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 84: 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 85: 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 86 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 87: 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.
  • Page 88 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses • Replace. Every 4 years √...
  • Page 89 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Make sure that all nuts, bolts, and screws are √ √ √ √ √ 14 * Chassis fasteners properly tightened.
  • Page 90 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Reverse lock re- • Check operation and adjust or replace if neces- √ √ √ lease cable sary. •...

  • Page 91: Removing And Installing The Panel

    EWB00011 EBU23101 Panel A WARNING Indicates a hazardous situation which, if not To remove the panel avoided, could result in death or serious injury. Remove the bolts, and then take the panel off. EBU23080 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter.
  • Page 92 If the spark plug shows a distinctly different color, spark plug wrench included in the owner’s tool the engine could be operating improperly. Do not kit. attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-10...
  • Page 93 2. Check the spark plug for electrode erosion To install the spark plug and excessive carbon or other deposits, and 1. Clean the surface of the spark plug gasket replace it if necessary. and its mating surface, and then wipe off any grime from the spark plug threads.

  • Page 94: Engine Oil And Oil Filter Element

    EBU26786 Engine oil and oil filter element The engine oil should be between the minimum The engine oil level should be checked before and maximum level marks. each ride. In addition, the oil must be changed and the oil filter element replaced at the intervals spec- ified in the periodic maintenance and lubrication chart.
  • Page 95 Be sure the engine oil is at the correct lev- el, otherwise engine damage may result. [ECB00851] When adding oil, be careful not to overfill the en- gine oil tank; the oil level rises faster starting from the half-level-portion on the dipstick. 6.
  • Page 96 5. Remove the engine oil tank filler cap, and then remove the engine oil tank drain bolt and its gasket. 1. Oil filter element cover 2. Bolt 7. Remove the oil filter element and the O-rings. 1. Engine oil tank drain bolt 2.
  • Page 97 10. Install the crankcase engine oil drain bolt, the engine oil tank drain bolt and their new gasket, and then tighten the bolts to the specified torques. Tightening torques: Crankcase engine oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) Engine oil tank drain bolt: 19 Nm (1.9 m·kgf, 14 ft·lbf) 11.

  • Page 98: Coolant

    14. Remove the engine oil tank filler cap, and then a higher quality than specified. In addition, gradually fill the oil tank with the remaining oil do not use oils labeled “ENERGY CONSERV- quantity while regularly checking the oil level ING II”...
  • Page 99 If water has been added to the coolant, have a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced.
  • Page 100 EBU23543 To change the coolant EWB01890 WARNING Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by hot fluid and steam blown out under pressure. Always place a thick rag over the cap when opening.
  • Page 101 5. Remove the coolant reservoir cap. 6. Disconnect the coolant reservoir hose on the coolant reservoir side, and then drain the cool- ant from the coolant reservoir. 1. Coolant drain bolt 2. Gasket 4. Remove the radiator cap. 1. Coolant reservoir cap 2.

  • Page 102: Cleaning The Air Filter Element

    Do not use hard water or salt water since they are If any leakage is found, have a Yamaha dealer harmful to the engine. [ECB00991] check the cooling system.
  • Page 103 1. Air filter case check hose 1. Air filter case cover 2. Air filter case cover holder 1. Place the ATV on a level surface. 2. Remove the seat. (See page 4-13.) 4. Fully loosen the wing bolt. 3. Remove the air filter case cover by unhooking 5.
  • Page 104 1. Air filter element 1. Sponge material 2. Washer 2. Air filter element frame 3. Wing bolt 8. Wash the sponge material gently but thor- 6. Remove the wing bolt and washer from the air oughly in solvent. WARNING! Always use filter element.
  • Page 105 10. Check the sponge material and replace it if damaged. 14. Install the washer onto the air filter element 11. Apply Yamaha foam air filter oil or other qual- frame, and then insert the wing bolt into the ity foam air filter oil to the sponge material.

  • Page 106: Cleaning The Spark Arrester

    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. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions.
  • Page 107 1. Tailpipe 1. Tailpipe 2. Spark arrester 2. Tailpipe bolt 4. Insert the tailpipe into the muffler and align the 2. Remove the tailpipe by pulling it out of the bolt holes. muffler. 5. Install the bolt and tighten it to the specified 3.

  • Page 108: Adjusting The Engine Idling Speed

    Tightening torque: Purging bolt: 27 Nm (2.7 m·kgf, 20 ft·lbf) EWB02380 WARNING Never run the engine in an enclosed area when purging the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monox- ide poisoning, possibly leading to death, and start a fire.

  • Page 109: Adjusting The Throttle Lever Free Play

    1. Start the engine and warm it up. If the specified idling speed cannot be obtained as 2. Attach the tachometer to the spark plug lead. described above, have a Yamaha dealer make the 3. Check the engine idling speed and, if neces- adjustment.

  • Page 110: Valve Clearance

    3. To increase the throttle lever free play, turn must be adjusted by a Yamaha dealer at the inter- the throttle lever free play adjusting bolt in di- vals specified in the periodic maintenance and lu- rection (a). To decrease the throttle lever free brication chart.

  • Page 111: Checking The Front And Rear Brake Pads

    If a brake pad has worn to the point that the wear indicator grooves have almost disap- peared, have a Yamaha dealer replace the brake The wheels need to be removed to check the pads as a set.

  • Page 112: Checking The Brake Fluid Level

    Front brake 1. Wear indicator groove 1. Minimum level mark EBU26824 Rear brake Checking the brake fluid level Before riding, check that the brake fluid is above the minimum level mark. Check the brake fluid lev- el with the top of the reservoir level. Replenish the brake fluid if necessary.
  • Page 113 To check the rear brake fluid level, remove the seat. (See page 4-13.) To access the rear brake fluid reservoir for replen- ishing: 1. Remove the cowling bolt and quick fastener screw. 1. Cowling 2. Brake fluid reservoir cap 3. After replenishing, place the cowling in the original position, and then install the bolt and quick fastener screw.

  • Page 114: Changing The Brake Fluid

    If the brake fluid level goes down suddenly, mance. have a Yamaha dealer check the cause before fur- Clean the filler cap before removing. Use ther riding. only DOT 4 brake fluid from a sealed contain-...

  • Page 115: Checking The Front Brake Lever Free Play

    If the brake pedal is not positioned as spec- intervals specified in the periodic maintenance and ified, have a Yamaha dealer adjust it. lubrication chart. The brake lever should have no free play as shown. If there is free play, have a Yamaha dealer check the brake system.
  • Page 116 If the cable length cannot be adjusted to specifica- 3. Loosen the locknut. tion, consult a Yamaha dealer. 4. Turn the parking brake free play adjusting nut in direction (a) to increase the cable length, 5. Tighten the locknut.

  • Page 117: Brake Light Switches

    2. Rear brake light switch adjusting nut adjusted as follows, but the front brake light switch EBU29750 should be adjusted by a Yamaha dealer. Adjusting the clutch lever free play Turn the adjusting nut while holding the brake light The clutch lever free play must be checked and, if switch in place.
  • Page 118 7. Fully turn the adjusting bolt at the clutch lever in direction (a) to loosen the clutch cable. 8. Loosen the locknut at the crankcase. 9. To increase the clutch lever free play, turn the adjusting nut at the crankcase in direction (a), and to decrease it, turn the nut in direction (b).

  • Page 119: Drive Chain Slack

    If the specified free play cannot be obtained as de- scribed above or if the clutch does not operate cor- rectly, have a Yamaha dealer check the internal clutch mechanism. EBU26864 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary.
  • Page 120 1. Rear wheel axle pinch bolt 2. Rod 3. Drive chain tensioner 4. Hole A rod can be obtained at a Yamaha dealer to make this adjustment. Tightening torque: Rear axle pinch bolt: 4. Shift the transmission into neutral.

  • Page 121: Lubricating The Drive Chain

    EBU24882 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. ECB00561 NOTICE The drive chain must be lubricated after wash-...

  • Page 122: Checking And Lubricating The Brake And Clutch Levers

    If a cable is damaged or does not move EBU24922 Checking and lubricating the brake and smoothly, have a Yamaha dealer check or replace clutch levers The operation of the brake and clutch levers Recommended lubricant: should be checked before each ride, and the lever Engine oil pivots should be lubricated if necessary.

  • Page 123: Checking The Wheel Hub Bearings

    Recommended lubricant: Lubricating the swingarm pivots Lithium-soap-based grease The swingarm pivots must be lubricated by a Yamaha dealer at the intervals specified in the pe- EBU24963 riodic maintenance and lubrication chart. Checking the wheel hub bearings The front and rear wheel hub bearings must be...

  • Page 124: Lubricating The Rear Suspension Relay Arm And Connecting Arm Pivoting Points

    EBU25004 Lubricating the rear suspension relay arm and connecting arm pivoting points The rear suspension relay arm and connecting arm pivoting points must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart. For parts equipped with a grease nipple, use a grease gun.

  • Page 125: Lubricating The Upper And Lower Arm Pivots

    Left side 1. Grease nipple 1. Upper grease nipple 2. Lower grease nipple EBU25033 Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. For parts equipped with a grease nipple, use a grease gun.

  • Page 126: Lubricating The Steering Shaft

    EBU25092 when working near batteries. Lubricating the steering shaft Antidote: The steering shaft must be lubricated by a Yamaha EXTERNAL: Flush with water. dealer at the intervals specified in the periodic INTERNAL: Drink large quantities of water or maintenance and lubrication chart.
  • Page 127 2. Positive battery lead (red) 4. Pull the battery out of its compartment. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in 1. Bolt mind that the battery tends to discharge more 2.
  • Page 128 ECB00931 2. Connect the positive battery lead first, then NOTICE connect the negative battery lead by installing their bolt.NOTICE: When installing the bat- To charge a VRLA (Valve Regulated Lead Acid) tery, the main switch must be off, and the battery, a special (constant-voltage) battery positive lead must be connected before charger is required.

  • Page 129: Replacing A Fuse

    1. Battery holding plate 1. Main fuse 2. Battery box 2. Spare main fuse 4. Install the battery holding plate with the bat- tery cover by installing the bolts and the quick fastener screws. 5. Install the seat. (See page 4-13.) EBU25326 Replacing a fuse The main fuse and the fuse box are located under...
  • Page 130 3. Turn the key to “ON” and turn on the electrical To prevent accidental short-circuiting, turn off circuits to check if the devices operate. the main switch when checking or replacing a 4. If the fuse immediately blows again, have a fuse. Yamaha dealer check the electrical system. 8-48...

  • Page 131: Replacing A Headlight Bulb

    EBU29670 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the bolts. 1. Headlight bulb holder cover 2. Headlight coupler 4. Remove the headlight bulb holder by pushing it in and turning it counterclockwise, and then remove the burnt-out bulb.

  • Page 132: Adjusting A Headlight Beam

    10. Adjust the headlight beam if necessary. off any dirt and fingerprints on the head- light bulb using a cloth moistened with al- EBU25561 Adjusting a headlight beam cohol or thinner. [ECB00651] ECB00690 NOTICE It is advisable to have a Yamaha dealer make this adjustment. 8-50...

  • Page 133: Tail/Brake Light

    1. Place the ATV on a level surface. If the tail/brake light does not come on, have a 2. Install the wheel and the nuts. Yamaha dealer check it. EBU25651 Removing a wheel 1. Place the ATV on a level surface.

  • Page 134: 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 135: Troubleshooting Charts

    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 136 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible.

  • Page 137: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25902 may cause water seepage and deteriora- 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 138: Storage

    EBU27261 3. Perform the following steps to protect the cyl- Storage inder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark Short-term plug. Always store your ATV in a cool, dry place and, if b. Pour a teaspoonful of engine oil into the necessary, protect it against dust with a porous spark plug bore.
  • Page 139 6. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 7. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an exces- sively cold or warm place [less than 0 °C (30 °F) or more than 30 °C (90 °F)].

  • Page 140: Specifications

    EBU25961 SPECIFICATIONS Dimensions: Compression ratio: 9.20 : 1 Overall length: Starting system: 1845 mm (72.6 in) Electric starter Overall width: Lubrication system: 1170 mm (46.1 in) Dry sump Overall height: Engine oil: 1130 mm (44.5 in) Seat height: Recommended brand: 815 mm (32.1 in) YAMALUBE Wheelbase:...
  • Page 141 Engine oil quantity: Clutch: Without oil filter element replacement: Clutch type: 1.75 L (1.85 US qt, 1.54 Imp.qt) Wet, multiple-disc With oil filter element replacement: Transmission: 1.85 L (1.96 US qt, 1.63 Imp.qt) Primary reduction system: Cooling system: Spur gear Coolant reservoir capacity (up to the maximum level mark): Primary reduction ratio: 0.25 L (0.26 US qt, 0.22 Imp.qt)
  • Page 142 Caster angle: Rear: 5.0 ° 24.5 kPa (0.245 kgf/cm², 3.6 psi) Trail: Front wheel: 21.0 mm (0.83 in) Wheel type: Front tire: Panel wheel Type: Rim size: Tubeless 10 x 5.5AT Rear wheel: Size: AT21 x 7R10 Wheel type: Manufacturer/model: Panel wheel DUNLOP/KT341 Radial Rim size:...
  • Page 143 Wheel travel: Fuel level warning light: 230 mm (9.1 in) Rear suspension: Reverse indicator light: Type: Coolant temperature warning light: Swingarm (link suspension) Spring/shock absorber type: Engine trouble warning light: Coil spring/gas-oil damper Wheel travel: Fuses: 256 mm (10.1 in) Electrical system: Main fuse: 20.0 A...

  • Page 144: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 145 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 146 1. Vehicle Emission Control Information label 11-3...

  • Page 147: 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 ul- timate 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 148: 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 149: 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 150 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 151: 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 152 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 153 INDEX Drive chain slack ............8-37 Accessories and loading ..........6-7 Air filter element, cleaning ..........8-20 Engine break-in .............. 6-5 Engine idling speed ............. 8-26 Engine oil ............... 5-4 Battery ................8-44 Engine oil and oil filter element ........8-12 Brake and clutch levers, checking and lubricating ..
  • Page 154 Shock absorber assembly, adjusting the rear ....4-19 Spark arrester, cleaning ..........8-24 Main switch ..............4-1 Spark plug, checking ............8-9 Maintenance and lubrication chart ......... 8-5 Specifications ............... 10-1 Maintenance chart, emission control system ....8-3 Speed limiter ..............4-7 Maintenance record .............
  • Page 155 EBU30390 For your best ownership experience, think Genuine Yamaha! Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect.
  • Page 156 EBU26141 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER ALWAYS operate: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough...

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