Yamaha Raptor 80 Owners Manual

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READ THIS MANUAL CAREFULLY!

It contains important safety information.
OWNER’S MANUAL
YFM80RV
w This ATV should not be ridden by anyone under 12 years of age.
LIT-11626-19-64 5TH-28199-15
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EBU13310
INTRODUCTION
Congratulations on your purchase of the Yamaha YFM80R. It represents the result of many years of
Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With
the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability
that have made Yamaha a leader in these fields.
This manual will provide you with a good basic understanding of the features and operation of this
machine.
This manual includes important safety information. It provides information about special tech-
niques and skills necessary to ride your machine.
It also includes basic maintenance and inspection procedures. If you have any questions regarding the
operation or maintenance of your machine, please consult a Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:

8 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COM-
PLETELY BEFORE OPERATING YOUR MACHINE. MAKE SURE YOU UNDERSTAND ALL
INSTRUCTIONS.
8 PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MACHINE.
8 NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING
IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFOR-
MATION.
8 THIS ATV, AND ANY OTHER ATV OVER 70cc, SHOULD NOT BE OPERATED BY A CHILD
UNDER 12 YEARS OF AGE.
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AN IMPORTANT NOTE TO PARENTS:

This ATV is not a toy. Before you let your child ride this ATV, you should understand the instructions
and warnings in this Owner’s Manual. Then be sure your child understands and will follow them.
Children differ in skills, physical abilities and judgment. Some children may not be able to operate an
ATV safely. Parents should supervise their child’s use of the ATV at all times. Parents should permit
continued use only if they determine that the child has the ability to operate the ATV safely.
Your ATV was delivered with an adjustable speed limiter and also with an air intake restrictor plate.
Yamaha recommends that all beginners start off with the speed limiter screw turned in and the air
intake restrictor plate installed to limit the amount of speed available while they learn. The limiter screw
may be gradually turned out to increase maximum speed as the beginner becomes more familiar with
operating the ATV. Parents should decide when to adjust the ATV for more power as their youngster’s
riding skills improve. Once the ATV rider can operate with skill at the top speed permitted by adjusting
the speed limiter alone, the air intake restrictor plate can be removed. Since removal of this plate will
result in a significant increase in power, turn the speed limiter back in again; adjust it out in stages as
you did before.
If your child is a beginner or is inexperienced, he or she should take a training course. See the previ-
ous page for information about the free training available to purchasers of new ATVs.
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EBU00801
IMPORTANT MANUAL INFORMATION

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN
SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
Q The Safety Alert Symbol means ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!
w Failure to follow WARNING instructions could result in severe injury or

death to the machine operator, a bystander or a person inspecting or
repairing the machine.
cC A CAUTION indicates special precautions that must be taken to avoid

damage to the machine.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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EBU15000
IMPORTANT NOTICE
This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate
this ATV on any public street, road or highway.
This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations
in effect at the time of manufacture.
Please check your local riding laws and regulations before operating this ATV.
EBU13330 YFM80RV
OWNER’S MANUAL
©2005 by Yamaha Motor Corporation, U.S.A.
AFFIX DEALER 1st edition, June 2005
LABEL HERE All rights reserved.
Any reprinting or unauthorized use
without the written permission
of Yamaha Motor Corporation,
U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-19-64
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EBU00014
w
Indicates a potential hazard that could result
in serious injury or death.
CONTENTS
1 LOCATION OF THE WARNING AND Speed limiter ........................................4-4

SPECIFICATION LABELS .......................1-1 Front brake lever ..................................4-5
Brake pedal and rear brake lever .........4-5
2 SAFETY INFORMATION .........................2-1 Parking brake .......................................4-6
Shift pedal ............................................4-8
3 DESCRIPTION AND MACHINE Fuel tank cap ........................................4-8
IDENTIFICATION.....................................3-1 Fuel cock ..............................................4-9
Identification number records ...............3-2 Choke lever ........................................4-10
Key identification number .....................3-2 Seat ....................................................4-10
Vehicle identification number ...............3-3
Model label ...........................................3-3 5 PRE-OPERATION CHECKS....................5-1
Front and rear brakes ...........................5-2
CONTROL FUNCTIONS..........................4-1 Fuel ......................................................5-3
4
Main switch...........................................4-1 Engine oil.............................................5-5
Indicator lights ......................................4-1 Final gear oil .........................................5-5
Handlebar switches ..............................4-2 Throttle lever ........................................5-6
Throttle lever ........................................4-3 Tires .....................................................5-6
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How to measure tire pressure ..............5-7 Be careful where you ride...................7-16

Tire wear limit .......................................5-8 Turning your ATV ...............................7-23
Fittings and fasteners ...........................5-9 Climbing uphill ....................................7-25
Switches ...............................................5-9 Riding downhill ...................................7-30
Battery ..................................................5-9 Crossing a slope.................................7-32
Crossing through shallow water .........7-34
OPERATION ............................................6-1 Riding over rough terrain ....................7-36
6
Starting a cold engine...........................6-1 Sliding and skidding ...........................7-38
Starting a warm engine ........................6-3 What to do if .......................................7-40
Warming up ..........................................6-3 What to do ..........................................7-40
Shifting .................................................6-4
To start out and accelerate...................6-4 8 PERIODIC MAINTENANCE AND
To decelerate .......................................6-5 ADJUSTMENT .........................................8-1
Engine break-in ....................................6-6 Owner’s manual and tool kit .................8-1
Parking .................................................6-7 Periodic maintenance chart for the
Parking on a slope................................6-8 emission control system .....................8-3
Accessories and loading ......................6-9 General maintenance and lubrication
chart ...................................................8-4
7 Riding Your ATV ......................................7-1 Engine oil..............................................8-6
Getting to know your ATV.....................7-3 Final gear oil .........................................8-8
Ride with care and good Spark plug inspection .........................8-10
judgement...........................................7-4 Air filter cleaning .................................8-11
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Air intake restrictor plate removal .......8-14 Fuse replacement...............................8-30

Spark arrester cleaning ......................8-15 Troubleshooting..................................8-31
Carburetor adjustment........................8-17 Troubleshooting chart.........................8-32
Idle speed adjustment ........................8-17
Valve clearance adjustment ...............8-18 9 CLEANING AND STORAGE ....................9-1
Cam chain adjustment........................8-18 A. Cleaning ...........................................9-1
Front and rear brake shoe B. Storage ............................................9-3
inspection .........................................8-18
10 SPECIFICATIONS .................................10-1
Front brake lever free play
adjustment ........................................8-19
Rear brake lever and pedal 11 NOISE REGULATION ............................11-1
adjustment ........................................8-21
Clutch adjustment...............................8-24 12 MAINTENANCE RECORD.....................12-1
Cable inspection and lubrication ........8-25
13 ATV LIMITED WARRANTY....................13-1
Brake and shift pedal/brake lever
lubrication .........................................8-25
14 YAMAHA EXTENDED SERVICE
Knuckle shaft and steering shaft (Y.E.S.) ...................................................14-1
lubrication .........................................8-26
Wheel removal ...................................8-26
Wheel installation ...............................8-26
Battery ................................................8-27
Replenishing the battery fluid .............8-29
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EBU00464
LOCATION OF THE WARNING AND

SPECIFICATION LABELS
Read and understand all of the labels on your

machine. They contain important information for
safe and proper operation of your ATV.
1
Never remove any labels from your ATV. If a label
becomes difficult to read or comes off, a replace-
2 ment label is available from your Yamaha dealer.
3
4
1-1
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1 2 q WARNING 1
q WARNING Improper ATV use can result in SEVERE
INJURY or DEATH.
UNDER
12 ALWAYS USE NEVER USE NEVER CARRY NEVER USE
AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS
HELMET AND
PROTECTIVE
ROADS OR ALCOHOL
GEAR
Operating this ATV if you are under NEVER operate :
the age of 12 increases your chance 9 without proper training or instruction.
of severe injury or death. 9 at speeds too fast for your skills or
Adult supervision required for children the conditions.
under age 16. 9 on public roads-a collision can occur
with another vehicle.
NEVER permit children under age 12 9 with a passenger-passengers affect balance
to operate this ATV. and steering and increase risk
of losing control.
4EM-21697-31
4EM-21697-31
ALWAYS :
9 use proper riding techniques to avoid
vehicle overturns on hills and rough terrain
and it turns.
9 avoid paved surfaces-pavement may
seriously affect handling and control.
LOCATE AND READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
5FE-21568-11
5FE-21568-11
1-2
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3 q 4
WARNING q WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING CAN
CAUSE LOSS OF CONTROL. NEVER ride as a
LOSS OF CONTROL CAN RESULT IN SEVERE
INJURY OR DEATH. passenger.
OPERATING TIRE PRESSURE: Set with tires cold
9Recommended : FRONT : 20 kPa, { 0.20 kgf/cm 2 } 2.9 psi Passengers can cause
9Minimum
REAR : 20 kPa, { 0.20 kgf/cm 2 } 2.9 psi a loss of control,
: FRONT : 17 kPa, { 0.17 kgf/cm 2 } 2.5 psi
REAR : 17 kPa, { 0.17 kgf/cm 2 } 2.5 psi resulting in SEVERE
9Never set tire pressure below minimum.
It could cause the tire to dislodge from the rim.
INJURY or DEATH.
LOADING 5FE-2151H-01
5FE-2151H-01
9Maximum Vehicle Load : 95 kg, (209 lbs).
Includes weight of operator, cargo and accessories.
4EM-21696-11
4EM-21696-11
1-3
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EBU13390
q SAFETY INFORMATION 2
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from
other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during
routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper pre-
cautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
8 Read this manual and all labels carefully and follow the operating procedures described.
8 Never operate an ATV without proper training or instruction. Take a Training Course. Beginners
should receive training from a certified instructor. Contact an authorized ATV dealer or call
1-800-887-2887 to find out about the training courses nearest you.
8 Always follow the age recommendation:
- A child under 12 years old should never operate an ATV with engine size greater than 70cc.
- A child under 16 years old should never operate an ATV with engine size greater than 90cc.
8 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow con-
tinued use of an ATV by a child if he or she does not have the abilities to operate it safely.
8 Never carry a passenger on an ATV.
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8 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots
and streets.
8 Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
8 Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket,
and long pants.
8 Never consume alcohol or drugs before or while operating this ATV.
8 Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is prop-
er for the terrain, visibility and operating conditions, and your experience.
8 Never attempt wheelies, jumps, or other stunts.
8 Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always
follow the inspection and maintenance procedures and schedules described in this manual.
8 Always keep both hands on the handlebars and both feet on the footrests of the ATV during opera-
tion.
8 Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.
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8 Never operate on excessively rough, slippery or loose terrain until you have learned and practiced
the skills necessary to control the ATV on such terrain. Always be especially cautious on these
kinds of terrain.
8 Always follow proper procedures for turning as described in this manual. Practice turning at low
speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
8 Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills
before attempting larger hills.
8 Always follow proper procedures for climbing hills as described in this manual. Check the terrain
carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never
go over the top of a hill at high speed.
8 Always follow proper procedures for going down hills and for braking on hills as described in this
manual. Check the terrain carefully before you start down any hill. Shift your weight backward.
Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle
to lean sharply to one side. Go straight down the hill where possible.
8 Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid
hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
Never attempt to turn the ATV around on any hill until you have mastered the turning technique
described in this manual on level ground. Avoid crossing the side of a steep hill if possible.
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8 Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling,
use proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, fol-
low the special procedure for braking described in this manual. Dismount on the uphill side or to a
side if pointed straight uphill. Turn the ATV around and remount, following the procedure described
in this manual.
8 Always check for obstacles before operating in a new area.
Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow
proper procedures when operating over obstacles as described in this manual.
8 Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing
at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly
and be very cautious in order to reduce the chance of skidding or sliding out of control.
8 Never operate an ATV in fast flowing water or in water deeper than that recommended in this manu-
al. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving
water. If necessary, apply them several times to let friction dry out the linings.
8 Always use the size and type tires specified in this manual. Always maintain proper tire pressure as
described in this manual.
8 Never modify an ATV through improper installation or use of accessories.
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8 Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling
a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission
at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.
2-5
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qWARNING When transporting the ATV in another

vehicle, be sure it is kept upright and that
POTENTIAL HAZARD
the fuel cock is in the “OFF” position.
Improper handling of gasoline.
Otherwise, fuel may leak out of the carbu-
WHAT CAN HAPPEN retor or fuel tank.
Gasoline can catch fire and you could be WHAT CAN HAPPEN
burned.
Gasoline is poisonous and can cause
HOW TO AVOID THE HAZARD injuries.
Always turn off the engine when refueling. HOW TO AVOID THE HAZARD
Do not refuel right after the engine has
If you should swallow some gasoline or
been running and is still very hot.
inhale a lot of gasoline vapor, or get some
Do not spill gasoline on the engine or
gasoline in your eyes, see your doctor
exhaust pipe/muffler when refueling.
immediately.
Never refuel while smoking, or while in the
If gasoline spills on your skin, wash with
vicinity of sparks, open flames, or other
soap and water. If gasoline spills on your
sources of ignition such as the pilot lights
clothing, change your clothes.
of water heaters and clothes dryers.
2-6
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qWARNING
POTENTIAL HAZARD
Starting or running the engine in a closed
area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
HOW TO AVOID THE HAZARD
Always operate your ATV in an area with
adequate ventilation.
2-7
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EBU00032
DESCRIPTION AND MACHINE IDENTIFICATION

q w e t
ur o i u y
!0 !1 !2 !3 1. Spark arrester 10. Rear brake lever
2. Seat 11. Parking brake
3. Front cover 12. Neutral indicator light
4. Brake pedal 13. Front brake lever
5. Fuel cock 14. Throttle lever
6. Rear wheel 15. Main switch
7. Footrest 16. Fuel tank cap
8. Shift pedal 17. Handlebar switches
9. Front wheel
NOTE:
The machine you have purchased may differ
slightly from those shown in the figures of this
!7 !6 !5 !4 manual.
3-1
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EBU00600 EBU00035
Identification number records Key identification number

Record the key identification number, vehicle The key identification number is stamped on the
identification number and model label informa- key as shown in the following illustration. This
tion in the spaces provided for assistance when number can be used for ordering a new key. 3
ordering spare parts from a Yamaha dealer or
for reference in case the vehicle is stolen.
1. KEY IDENTIFICATION NUMBER:
q
2. VEHICLE IDENTIFICATION NUMBER:
1. Key identification number

3. MODEL LABEL INFORMATION:
1
6
3-2
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EBU00036 EBU00787
Vehicle identification number Model label

The vehicle identification number is stamped The model label is affixed to the location in the
into the frame. illustration. Record the information on this label
in the space provided. This information will be
needed to order spare parts from your Yamaha
dealer.
1. Vehicle identification number
NOTE: 1. Model label

The vehicle identification number is used to
identify your machine.
3-3
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EBU00039 EBU00043
CONTROL FUNCTIONS Indicator lights
w EBU00603
Indicates a potential hazard that could result Neutral indicator light “N”
in serious injury or death. This indicator light comes on when the transmis-
4
EBU00042 sion is in neutral.
Main switch
Functions of the respective switch positions are
as follows:
ON:
The engine can be started only at this position.
OFF:
All electrical circuits are switched off. The key q
can be removed in this position.
OFF ON
1. Neutral indicator light “N”
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EBU00053 EBU00056
Handlebar switches Start switch “START”

The starter motor cranks the engine when this
switch is pushed.
cC
See starting instructions prior to starting
engine (see page 6-1 for details).
q w
NOTE:
If the starter switch is pushed with the main
1. Engine stop switch “ENG. STOP”
2. Start switch “START” switch “ON” and the engine stop switch “OFF”,
the starter motor will be activated but the engine
EBU11580 will not start. To start the engine, be sure to
Engine stop switch “ENG. STOP” position the engine stop switch at “RUN”.
Make sure that the engine stop switch is in the
“RUN” position before starting the engine. The
engine stop switch controls ignition and can be
used at all times to stop the engine, especially in
an emergency. The engine will not start or run
when the engine stop switch is turned to “OFF”.
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EBU00062
Throttle lever Before starting the engine, check the throttle to

Once the engine is running, movement of the be sure it is operating smoothly. Make sure it
throttle lever will increase the engine speed. returns to the idle position as soon as the lever
Regulate the speed of the machine by varying is released.
the throttle position. Because the throttle is
spring-loaded, the machine will decelerate, and
qWARNING
the engine will return to an idle any time the POTENTIAL HAZARD
hand is removed from the throttle lever. Malfunction of throttle.
WHAT CAN HAPPEN
The throttle could be hard to operate, mak-
ing it difficult to speed up or slow down
when you need to. This could cause an
accident.
Check the operation of the throttle lever
q before you start the engine. If it does not
work smoothly, check for the cause.
1. Throttle lever Correct the problem before riding the ATV.
Consult a Yamaha dealer if you can’t find
or solve the problem yourself.
4-3
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EBU15650
removal of this plate will result in a significant
Speed limiter increase in power, turn the speed limiter com-
The speed limiter keeps the throttle from fully pletely back in again; adjust it out in stages as
opening, even when the throttle lever is pushed you did before.
to the maximum. Screwing in the adjuster limits Adjusting for maximum throttle lever movement
the maximum engine power available and without removing the air intake restrictor plate
decreases the maximum speed of the ATV. will cause the engine to run roughly at higher
Your ATV was delivered with an adjustable speeds.
speed limiter and also with an air intake restric- For air intake restrictor plate removal instruc-
tor plate. Yamaha recommends that all begin- tions, see page 8-14.
ning riders start off with the speed limiter screw
turned in and the air intake restrictor plate
installed to limit the amount of speed available
while they learn. The limiter screw may be grad-
ually turned out to increase maximum speed as a
the beginner becomes more familiar with operat-
ing the ATV. Parents should decide when to
adjust the ATV for more power as their young-
ster’s riding skills improve. Once the ATV rider
q w
can operate with skill at the top speed permitted
by adjusting the speed limiter alone, the air 1. Locknut 2. Adjuster a. No more than 20 mm (0.8 in)
intake restrictor plate can be removed. Since
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EBU00070
qWARNING Front brake lever

The front brake lever is located on the right han-
POTENTIAL HAZARD
dlebar. Pull it toward the handlebar to apply the
Improper adjustment of the speed limiter front brake.
and throttle.
WHAT CAN HAPPEN
The throttle cable could be damaged. q
Improper throttle operation could result.
You could lose control, have an accident
or be injured.
Do not turn the speed adjuster out more
than 20 mm (0.8 in).
1. Front brake lever

EBU00732
Brake pedal and rear brake lever

The brake pedal is located on the right side of
the ATV and the rear brake lever is located on
the left handlebar. Push down on the pedal or
pull the lever toward the handlebar to apply the
rear brake.
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EBU00074
Parking brake
Use the parking brake when you have to start
the engine or park the machine, especially on a
slope. Apply the rear brake lever and push down
the lock plate to apply the parking brake.
Squeeze the rear brake lever to release the
parking brake.
q
q
1. Brake pedal
1. Lock plate
1. Rear brake lever
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qWARNING
POTENTIAL HAZARD
Improper use of the parking brake.
WHAT CAN HAPPEN
The ATV could start moving unexpectedly
if the parking brake is not applied before
starting the engine. This could cause loss
of control or a collision.
The brake could overheat if you ride the
ATV without releasing the parking brake.
You could lose braking performance
which could cause an accident. You could
also wear out the brakes prematurely.
Always set the parking brake before start-
ing the engine.
q Always be sure you have released the
parking brake before you begin to ride.
1. Locked position
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EBU00083 EBU00092
Shift pedal Fuel tank cap

This machine is equipped with a constant-mesh Remove the fuel tank cap by turning it counter-
3-speed transmission. The shift pedal is located clockwise.
on the left side of the engine. Neutral is at the
bottom position.
q
3
2
1
N
1. Fuel tank cap
q
1. Shift pedal N. Neutral position
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EBU00093
Fuel cock
The fuel cock supplies fuel from the fuel tank to
the carburetor.
The fuel cock has three positions.
OFF: With the lever in this position fuel will not
flow. Always turn the lever to this position
when the engine is not running.
ON: With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
RES: This indicates reserve. If you run out of
fuel while riding, turn the lever to this
position. THEN FILL THE FUEL TANK
AT THE FIRST OPPORTUNITY. After
refuelling, return the fuel cock lever to the
“ON” position.
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EBU00096 EBU00566
Choke lever Seat

The choke is used to start a cold engine. Refer To remove the seat, pull the seat lock lever
to “Starting a cold engine” for proper operation. upward and pull up the seat at the rear.
(See page 6-1.)
a q
q w
e
1. Seat lock lever
a. Choke lever
1. Fully open “ON” 2. Half open (warming up position)
3. Closed “OFF”
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To install the seat, insert the projection on the

front of the seat into the seat holder and push
down on the seat at the rear.
w
1. Projection 2. Seat holder
NOTE:
Make sure that the seat is securely fitted.
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EBU00112
w
4-12
5TH-9-15-1 6/15/05 2:55 PM Page 4-13
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE

9 Check operation, condition and free play.
Brakes 9 Adjust if necessary. 5-2–5-3, 8-18–8-23
9 Check fuel level. 5-3–5-4
Fuel 9 Fill with fuel if necessary.
5
9 Check oil level. 5-5, 8-6–8-7
Engine oil 9 Fill with oil if necessary.
Final gear oil 9 Check for leakage. 5-5, 8-8–8-9
Throttle 9 Check for proper throttle cable operation. 5-6
Wheels and tires 9 Check tire pressure, wear and damage. 5-6–5-8, 8-26
Fittings and fasteners 9 Check all fittings and fasteners. 5-9
Switches 9 Check operation. 5-9
9 Check fluid level.
Battery 9 Fill with distilled water if necessary. 5-9, 8-27–8-29
5-1
5TH-9-15-1 6/15/05 2:55 PM Page 4-14
EBU04762
qWARNING Front and rear brakes
POTENTIAL HAZARD Brake levers and brake pedal
Failure to inspect the ATV before operat- 8 Check for correct free play in the brake levers
ing. and brake pedal. If the free play is incorrect,
Failure to properly maintain the ATV. adjust it. (See pages 8-19–8-23.)
WHAT CAN HAPPEN

8 Check operation of the brake levers and
Increases the possibility of an accident or
brake pedal. They should move smoothly and
equipment damage.
there should be a firm feeling when the
HOW TO AVOID THE HAZARD brakes are applied. If not, have the ATV
Always inspect your ATV each time you inspected by a Yamaha dealer.
use it to make sure the ATV is in safe
operating condition. Brake operation
Always follow the inspection and mainte- Test the brakes at slow speed after starting out
nance procedures and schedules to make sure they are working properly. If the
described in the Owner’s Manual. brakes do not provide proper braking perfor-
mance, inspect the brake linings for wear. (See
page 8-18–8-19.)
5-2
5TH-9-15-1 6/15/05 2:55 PM Page 4-15
EBU13410
qWARNING Fuel
Make sure there is sufficient gasoline in the
POTENTIAL HAZARD tank.
Riding with improperly operating brakes.
Recommended fuel:
WHAT CAN HAPPEN UNLEADED GASOLINE ONLY
You could lose braking ability, which Fuel tank capacity:
could lead to an accident. Total:
6.8 L (1.5 Imp gal, 1.8 US gal)
Reserve:
Always check the brakes at the start of 0.9 L (0.2 Imp gal, 0.2 US gal)
every ride. Do not ride the ATV if you find
any problem with the brakes. If a problem cC
cannot be corrected by the adjustment Use only unleaded gasoline. The use of leaded
procedures provided in this manual, have gasoline will cause severe damage to internal
the ATV inspected by a Yamaha dealer. engine parts, such as the valves and piston
rings, as well as to the exhaust system.
Your Yamaha engine has been designed to use reg-

ular unleaded gasoline with a pump octane number
([R+M]/2) of 86 or higher, or research octane number
of 91 or higher. If knocking or pinging occurs, use a
different brand of gasoline or premium unleaded fuel.
5-3
5TH-9-15-1 6/15/05 2:55 PM Page 4-16
Unleaded fuel will give you longer spark plug life qWARNING
and reduced maintenance cost.
POTENTIAL HAZARD
Gasohol Improper care when refueling.
There are two types of gasohol; gasohol con- WHAT CAN HAPPEN
taining ethanol and that containing methanol. Fuel can spill, which can cause a fire and
Gasohol containing ethanol can be used if severe injury.
ethanol content does not exceed 10%. Gasohol Fuel expands when it heats up. If the fuel
containing methanol is not recommended by tank is overfilled, fuel could spill out due
Yamaha because it may cause fuel system to heat from the engine or the sun.
damage or vehicle performance problems. HOW TO AVOID THE HAZARD
Do not overfill the fuel tank. Be careful not
to spill fuel, especially on the engine or
exhaust pipe. Wipe up any spilled fuel
immediately. Be sure the fuel tank cap is
closed securely.
Do not refuel right after the engine has
been running and is still very hot.
1. Filler tube 2. Fuel level

5-4
5TH-9-15-1 6/15/05 2:55 PM Page 4-17
EBU10842 EBU00493
Engine oil Final gear oil

Make sure the engine oil is at the specified level. Make sure the final gear oil is at the specified
Add oil as necessary. (See page 8-6.) level. Add oil as necessary. (See pages 8-8–8-9
cC for details.)
8 In order to prevent clutch slippage (since
Recommended oil:
the engine oil also lubricates the clutch),
SAE80API “GL-4” Hypoid gear oil
do not mix any chemical additives. Do not
use oils with a diesel specification of “CD” If desired, an SAE 80W90 hypoid gear oil may
or oils of a higher quality than specified. In be used for all conditions.
addition, do not use oils labeled “ENERGY NOTE:
CONSERVING II” or higher. GL-4 is a quality and additive rating, GL-5 or
8 Make sure that no foreign material enters GL-6 rated hypoid gear oils may also be used.
the crankcase.
Recommended engine oil type and quantity:

See page 10-2.
5-5
5TH-9-15-1 6/15/05 2:55 PM Page 4-18
EBU01083 EBU00157
Throttle lever Tires

Check to see that the throttle lever operates cor-
qWARNING
rectly. It must open smoothly and spring back to
the idle position when released. Have a Yamaha POTENTIAL HAZARD
dealer repair as necessary for proper operation. Operating this ATV with improper tires, or
with improper or uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or oper-
ation of this ATV with improper or uneven
tire pressure, may cause loss of control,
increasing your risk of accident.
1. The tires listed below have been
approved by Yamaha Motor Co., Ltd.
for this model. Other tire combinations
are not recommended.
Manufacturer Size Type
Front DUNLOP AT18 × 7–7 KT586
Rear DUNLOP AT18 × 8–7 KT587
5-6
5TH-9-15-1 6/15/05 2:55 PM Page 4-19
2. The tires should be set to the recom- 4. Use no more than the following pres-
mended pressure: sures when seating the tire beads.
8 Recommended tire pressure Front 230 kPa (2.3 kgf/cm2, 33 psi)
Front 20 kPa (0.20 kgf/cm2, 2.9 psi) Rear 230 kPa (2.3 kgf/cm2, 33 psi)
Rear 20 kPa (0.20 kgf/cm2, 2.9 psi) Higher pressures may cause the tire to
8 Check and adjust tire pressures when burst. Inflate the tires very slowly and
the tires are cold.
carefully. Fast inflation could cause
8 Tire pressures must be equal on both
the tire to burst.
sides.
3. Tire pressure below the minimum
specified could cause the tire to dis-
EBU00159
lodge from the rim under severe riding
How to measure tire pressure
conditions. The following are mini-
Use the low-pressure tire gauge.
mums:
Front 17 kPa (0.17 kgf/cm2, 2.5 psi)
Rear 17 kPa (0.17 kgf/cm2, 2.5 psi) NOTE:
The low-pressure tire gauge is included as stan-
dard equipment. Make two measurements of the
tire pressure and use the second reading. Dust
or dirt in the gauge could cause the first reading
to be incorrect.
5-7
5TH-9-15-1 6/15/05 2:55 PM Page 4-20
EBU00160
Set pressure with tires cold. Tire wear limit

Set tire pressures to the following specifications: When the tire groove decreases to 3 mm (0.12 in)
due to wear, replace the tire.
Recommended
Minimum Maximum
pressure
20 kPa 17 kPa 23 kPa
Front (0.20 kgf/cm2, (0.17 kgf/cm2, (0.23 kgf/cm2,
2.9 psi) 2.5 psi) 3.3 psi)
20 kPa 17 kPa 23 kPa
Rear (0.20 kgf/cm2, (0.17 kgf/cm2, (0.23 kgf/cm2,
2.9 psi) 2.5 psi) 3.3 psi) a
q
a. Tire wear limit
1. Low-pressure tire gauge
5-8
5TH-9-15-1 6/15/05 2:55 PM Page 4-21
EBU11620
Fittings and fasteners

Always check the tightness of chassis fittings
and fasteners before a ride. Take the machine
to a Yamaha dealer or refer to the Service
Manual for correct tightening torque.
EBU11700
Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper
operation.
EBU00499
Battery
Check fluid level and fill if necessary. Use only
distilled water if refilling is necessary. (See
pages 8-27–8-29.)
5-9
5TH-9-15-1 6/15/05 2:55 PM Page 6-1
EBU00161 EBU00579
OPERATION Starting a cold engine
qWARNING
w
POTENTIAL HAZARD
in serious injury or death. Freezing control cables in cold weather.
WHAT CAN HAPPEN
qWARNING You could be unable to control the ATV,
POTENTIAL HAZARD which could lead to an accident or colli-
Operating ATV without being familiar with sion.
all controls. HOW TO AVOID THE HAZARD
WHAT CAN HAPPEN When riding in cold weather, always make
Loss of control, which could cause an sure all control cables work smoothly
accident or injury. before you begin riding.

1. Set the parking brake.
Read the Owner’s Manual carefully. If 2. Turn the fuel cock to “ON”.
there is a control or function you do not 3. Turn the main switch to “ON” and the engine
understand, ask your Yamaha dealer. stop switch to “RUN”.
4. Shift the transmission into neutral.
6-1
5TH-9-15-1 6/15/05 2:55 PM Page 6-2
NOTE: Position 2: Warming up position.

This model is equipped with an ignition circuit Position 3: Cold engine start-
cut-off system. ambient temperature above 25°C
The engine can be started under the following (80°F) and warm engine start posi-
conditions. tion.
a. When the transmission is in neutral. At this
AMBIENT TEMP. / CHOKE LEVER POSITION
time the neutral indicator light should come
0° 10° 20° 30° °C
on. If the light does not come on, ask a 6
Yamaha dealer to inspect it. q 30° 50° 70° 90° °F
b. When the transmission is in gear and the e
rear brake lever is applied. However, it is
recommended to shift into neutral before
a
starting the engine.
F
OF
CHO
KE
ON
e
5. Use the choke lever in reference to the fig- q w
ure:
a. Choke lever
1. Fully open “ON” 2. Half open (warming up position)
Position 1: Cold engine start- 3. Closed “OFF”
ambient temperature below 30°C
(90°F).
6-2
5TH-9-15-1 6/15/05 2:55 PM Page 6-3
6. Completely close the throttle lever and start cC

the engine by pushing the start switch. See the “Engine break-in” section prior to
NOTE: operating engine for the first time.
If the engine fails to start, release the start
switch, then push it again. Pause a few seconds EBU00181
before the next attempt. Each cranking should Starting a warm engine
be as short as possible to preserve battery ener- To start a warm engine, refer to the “Starting a
gy. Do not crank the engine more than 10 sec- cold engine” section. The choke lever should not
onds on each attempt. be used. The throttle should be opened slightly.
7. If the engine is started with the starter EBU00184
(choke) in position 1 , the choke lever Warming up

should be returned to position 2 to warm up To get maximum engine life, always warm up
the engine. If the engine is started with the the engine before starting off. Never accelerate
starter (choke) in position 2 , keep the hard with a cold engine! To see whether or not
starter (choke) in this position to warm up the engine is warm, check if it responds to the
the engine. throttle normally with the choke lever turned off.
8. Continue warming up the engine until it idles
smoothly and return the choke lever to posi-
tion 3 before riding.
6-3
5TH-9-15-1 6/15/05 2:55 PM Page 6-4
EBU00200
Shifting cC
This model has a 3-speed forward transmission Do not coast for long periods with the engine
with centrifugal automatic clutch. The transmis- off, and do not tow the machine a long dis-
sion allows you to control the amount of power tance. Even with gears in neutral, the trans-
you have available at a given speed or for start- mission is only properly lubricated when the
ing accelerating, climbing, etc. To shift into neu- engine is running. Inadequate lubrication
tral, return the throttle lever to its original posi- may damage the transmission.
tion and repeatedly depress the shift pedal until
it stops. EBU00205
To start out and accelerate:

1. Release the throttle lever.
cC
Always close the throttle while shifting
3 gears. Otherwise, damage to the engine and
2 drive train may result.
1
N
2. Shift into first gear and release the shift
q pedal.
1. Shift pedal N. Neutral position 3. Open the throttle gradually.
6-4
5TH-9-15-1 6/15/05 2:55 PM Page 6-5
EBU00207
4. Once the machine has attained adequate To decelerate:

speed, release the throttle lever. When slowing down or stopping, release the throttle
5. Shift into second gear and release the shift and apply the brakes smoothly and evenly. As you
pedal. slow down, shift to a lower gear. Be sure that the
6. Open the throttle gradually. engine has sufficiently slowed before engaging a
7. Follow the same procedure when shifting to lower gear. Improper use of the brakes or shifting
the next higher gear. can cause the tires to lose traction, reducing control
and increasing the possibility of an accident.
qWARNING
qWARNING
POTENTIAL HAZARD POTENTIAL HAZARD
Opening the throttle before releasing the Engaging a lower gear when the engine
shift pedal. speed is too high.
WHAT CAN HAPPEN WHAT CAN HAPPEN
The machine could wheelie. This would The wheels could stop rotating. This could
increase the chance of an accident, cause loss of control, an accident and
including overturn. injury. It could also cause engine or drive
HOW TO AVOID THE HAZARD train damage.
Release the shift pedal before opening the HOW TO AVOID THE HAZARD
throttle. Open the throttle gradually. Make sure the engine has sufficiently
slowed before shifting to a lower gear.
6-5
5TH-9-15-1 6/15/05 2:55 PM Page 6-6
EBU02092
If any abnormality is noticed during this period,
Engine break-in consult a Yamaha dealer.
There is never a more important period in the
life of your machine than the period between 0-10 hours:
zero and 20 hours. Avoid continuous operation above half throttle.
For this reason, we ask that you carefully read Allow a cooling off period of five to ten minutes
the following material. Because the engine is after every hour of operation. Vary the speed of
brand new, you must not put an excessive load the machine from time to time. Do not operate it
on it for the first several hours of running. During at one set throttle position.
the first 20 hours, the various parts in the engine
wear and polish themselves to the correct oper- 10-20 hours:
ating clearances. Avoid prolonged operation above 3/4 throttle.
During this period, prolonged full throttle opera- Rev the machine freely through the gears but do
tion or any condition which might result in exces- not use full throttle at any time.
sive engine heating must be avoided. However,
momentary (2-3 seconds maximum) full throttle After break-in:
operation under load does not harm the engine. Avoid prolonged full throttle operation. Vary
Each full throttle acceleration sequence should speeds occasionally.
be followed with a substantial rest period for the
engine by cruising at lower r/min so the engine
can rid itself of the temporary build up of heat.
6-6
5TH-9-15-1 6/15/05 2:55 PM Page 6-7
EBU02111
Parking
When parking, stop the engine and shift into first
gear. Turn the fuel cock to “OFF” and apply the
parking brake.
1. Lock plate
1. Locked position
6-7
5TH-9-15-1 6/15/05 2:55 PM Page 6-8
EBU12960
Parking on a slope 1. Bring the ATV to a stop by applying the

brakes in low gear.
qWARNING 2. Stop the engine.
POTENTIAL HAZARD 3. With the rear brake lever and pedal
Parking on a hill or other incline. applied, apply the parking brake and slowly
release the brake pedal.
WHAT CAN HAPPEN
The ATV could roll out of control, increas-
ing the chance of an accident.
Avoid parking on hills or other inclines. If
you must park on an incline, put the ATV
in low gear, apply the parking brake, and
block the front and rear wheels with rocks
or other objects.
Do not park the ATV at all on hills that are
so steep you could not walk up them easi-
ly.
6-8
5TH-9-15-1 6/15/05 2:55 PM Page 6-9
EBU00221
Accessories and loading 8 Accessories should be rigidly and securely

mounted. An accessory which can shift posi-
EBU00222 tion or come off while you are riding could
Accessories affect your ability to control the ATV.
Accessories can affect the handling and control 8 Do not mount an accessory where it could
of your ATV. Keep the following in mind when interfere with your ability to control the ATV.
considering an accessory or operating an ATV Examples include (but are not limited to) a
which has accessories. heavy or bulky object attached to the handle-
8 Choose only accessories designed for your bars which could make steering difficult, an
ATV. Your Yamaha dealer has a variety of accessory that limits your ability to move
genuine Yamaha accessories. Other acces- around on the seat, or one that limits your
sories may also be available on the market. view.
However, it is not possible for Yamaha to test 8 Use extra caution when riding an ATV with
all non-Yamaha accessories, nor have any accessories. The ATV may handle differently
control over the quality or suitability of them. than it does without accessories.
Choose a genuine Yamaha accessory, or one
that is equivalent in design and quality.
6-9
5TH-9-15-1 6/15/05 2:55 PM Page 6-10
EBU00584
8 Tie down cargo securely to the carriers. Make
Loading sure cargo in the trailer cannot move around.
As originally equipped, this ATV is not designed A shifting load can cause an accident.
to carry cargo or tow a trailer. If you choose to 8 Make sure the load does not interfere with
add accessories so that you can carry cargo or controls or your ability to see where you are
tow a trailer, you must use common sense and going.
good judgment. Keep the following points in 8 Ride more slowly than you would without a
mind: load. The more weight you carry, the slower
8 Never exceed the weight limits shown. An you should go. Although conditions vary, it is
overloaded ATV can be unstable. good practice not to exceed 2nd gear when-
ever you are carrying heavier loads or when
MAXIMUM LOADING LIMIT towing a trailer.
Vehicle loading limit (total weight of 8 Allow more braking distance. A heavier vehi-
cargo, rider and accessories): cle takes longer to stop.
95 kg (209 lb) 8 Avoid making sharp turns unless at very slow
speeds.
8 Load cargo on the carriers as close to the 8 Avoid hills and rough terrain. Choose terrain
center of the vehicle as possible. Put cargo at carefully. Added weight affects the stability
the rear of the front carrier and at the front of and handling of the ATV.
the rear carrier. Center the load from side to
side.
6-10
5TH-9-15-1 6/15/05 2:55 PM Page 6-11
qWARNING
POTENTIAL HAZARD
Overloading this ATV or carrying or tow-
ing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle handling
which could lead to an accident.
Never exceed the stated load capacity for
this ATV.
Cargo should be properly distributed and
securely attached.
Reduce speed when carrying cargo or
pulling a trailer. Allow greater distance for
braking.
6-11
5TH-9-15-1 6/15/05 2:55 PM Page 6-13
EBU13541
w
6-13
5TH-9-15-2 6/15/05 2:55 PM Page 7-1
OK OK
OK
Riding 7
Your
ATV
OK
7-1
5TH-9-15-2 6/15/05 2:55 PM Page 7-3
w
GETTING TO KNOW YOUR ATV completely and understand the operation of the
This ATV is for recreation use. This section, controls. Pay particular attention to the safety
Riding your ATV, provides general ATV riding information on pages 2-1–2-7. Please also read
instructions for recreational riding. The skills and all caution and warning labels on your ATV.
techniques described in this section, however,
are appropriate for all types of riding. Riding
your ATV requires special skills acquired
through practice over a period of time. Take the
time to learn the basic techniques well before
attempting more difficult maneuvers.
Riding your new ATV can be a very enjoyable

activity, providing you with hours of pleasure.
But it is essential to familiarize yourself with the
operation of the ATV to achieve the skill neces-
sary to enjoy riding safely. Before you begin to
ride, be sure you have read this Owner’s Manual
7-3
5TH-9-15-2 6/15/05 2:55 PM Page 7-4
RIDE WITH CARE AND GOOD JUDGEMENT

Get training if you are inexperienced. Beginning and inexperienced operators

Beginners should get training from a certified should complete the certified training
instructor. course offered by Yamaha. They should
Become familiar with this ATV at slow speeds then regularly practice the skills learned in
first, even if you are an experienced operator. the course and the operating techniques
Do not attempt to operate at maximum perfor- described in this Owner’s Manual.
mance until you are totally familiar with the For more information about the training
ATV’s handling and performance characteristics. course, contact an authorized ATV dealer
or call 1-800-887-2887.
qWARNING
POTENTIAL HAZARD Riding your ATV requires skills acquired
through practice over a period of time.
Operating this ATV without proper instruc-
Take the time to learn the basic techniques well
tion.
before attempting more difficult maneuvers.
WHAT CAN HAPPEN
The risk of an accident is greatly
increased if the operator does not know
how to operate the ATV properly in differ-
ent situations and on different types of ter-
rain.
7-4
5TH-9-15-2 6/15/05 2:55 PM Page 7-5
Not recommended for children under 12

years of age.
qWARNING
POTENTIAL HAZARD
Failure to follow the age recommendations
for this ATV.
WHAT CAN HAPPEN
Use by children of ATVs that are not rec-
ommended for their age can lead to severe
injury or death of the child.
A child under 12 should never operate an
ATV with engine size greater than 70cc.
7-5
5TH-9-15-2 6/15/05 2:55 PM Page 7-6
This ATV is designed to carry operator only -

passengers prohibited.
qWARNING
POTENTIAL HAZARD
Carrying a passenger on this ATV.
WHAT CAN HAPPEN
Greatly reduces your ability to balance
and control this ATV. Could cause an acci-
dent, resulting in harm to you and/or your
passenger.
Never carry a passenger. The long seat is
to allow the operator to shift position as
needed during operation. It is not for car-
rying passengers.
7-6
5TH-9-15-2 6/15/05 2:55 PM Page 7-7
Apparel
Operating without protective clothing
qWARNING increases your chances of severe injury in
the event of an accident.
POTENTIAL HAZARD
Operating this ATV without wearing an
approved motorcycle helmet, eye protec- Always wear an approved motorcycle hel-
tion and protective clothing. met that fits properly.
You should also wear:
WHAT CAN HAPPEN
eye protection
Operating without an
(goggles or face shield)
approved motorcycle
gloves
helmet increases Protective
clothing Goggles boots
your chances of a
long-sleeved shirt or jacket
severe head injury or
long pants.
death in the event of Helmet
Gloves
an accident.
Operating without
eye protection can Boots
result in an accident
and increases your
chances of a severe
injury in the event of
an accident.
7-7
5TH-9-15-2 6/15/05 2:55 PM Page 7-8
Do not operate after consuming alcohol or

qWARNING
drugs.
Operator’s performance capability is reduced by POTENTIAL HAZARD
the influence of alcohol or drugs. Operating this ATV after consuming alco-
hol or drugs.
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
Never consume alcohol or drugs before or
while driving this ATV.
7-8
5TH-9-15-2 6/15/05 2:55 PM Page 7-9
Pre-operation checks
qWARNING
Always perform the pre-operation checks listed
on page 5-1 before riding for safety and proper POTENTIAL HAZARD
care of the ATV. Operating this ATV with improper tires, or
with improper or uneven tire pressure.
qWARNING WHAT CAN HAPPEN
Use of improper tires on this ATV, or oper-
POTENTIAL HAZARD
ation of this ATV with improper or uneven
Failure to inspect the ATV before operat- tire pressure, may cause loss of control,
ing. increasing your risk of an accident.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Always use the size and type tires speci-
Increases the possibility of an accident or fied in the Owner’s Manual for this vehicle
equipment damage. on pages 5-6–5-7.
HOW TO AVOID THE HAZARD Always maintain proper tire pressure as
Always inspect your ATV each time you described in the Owner’s Manual on page
use it to make sure the ATV is in safe 5-8.
operating condition. Always follow the
inspection and maintenance procedures
and schedules described in the Owner’s
Manual.
7-9
5TH-9-15-2 6/15/05 2:55 PM Page 7-10
w Speed limiter
For riders inexperienced with this model, this
model is equipped with a speed limiter in the throt-
in serious injury or death. tle lever housing. The speed limiter limits the
power and top speed of the ATV. Turning the
screw in decreases top speed, and turning it out
Do not operate at speeds too fast for your increases top speed. This model also has an
skills or the conditions. intake restrictor plate to limit the amount of engine
power available.
qWARNING Yamaha recommends that all beginning riders
POTENTIAL HAZARD start off with the speed limiter turned in and the air
Operating this ATV at speeds too fast for intake restrictor plate installed to limit the amount
of speed available while they learn. The limiter may
your skills or the conditions.
be gradually adjusted to increase maximum speed
WHAT CAN HAPPEN as the beginner becomes more familiar with oper-
Increases your chances of losing control ating the ATV. Parents should decide when to
of the ATV, which can result in an acci- adjust the ATV for more power as their youngster’s
dent. riding skills improve. Once the ATV rider can oper-
ate with skill at the top speed permitted by adjust-
ing the speed limiter alone, the air intake restrictor
Always go at a speed that is proper for the plate can be removed. Since removal of this plate
terrain, visibility and operating conditions, will result in a significant increase in power, turn
and your experience. the speed limiter back in again; adjust it out in
stages as you did before.
7-10
5TH-9-15-2 6/15/05 2:55 PM Page 7-11
Adjusting for maximum throttle lever movement MAXIMUM LOADING LIMIT

without removing the air intake restrictor plate Vehicle loading limit(total weight of
will cause the engine to run roughly at higher cargo, rider and accessories):
speeds. 95 kg (209 lb)
For air intake restrictor plate removal instruc-
tions, see page 8-14.
qWARNING
POTENTIAL HAZARD
Overloading this ATV or carrying or tow-
ing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle handling
which could lead to an accident.
q w
Never exceed the stated load capacity for this
1. Locknut 2. Adjuster ATV.
Cargo should be properly distributed and
securely attached.
Loading and accessories Reduce speed when carrying cargo or pulling
Use extra caution when riding the ATV with addi- a trailer. Allow greater distance for braking.
tional loads, such as accessories or cargo. The Always follow the instructions in your
ATV’s handling may be adversely affected. Owner’s Manual for carrying cargo or pulling
Reduce your speed when adding additional loads. a trailer.
7-11
5TH-9-15-2 6/15/05 2:55 PM Page 7-12
During operation
qWARNING
Always keep your feet on the footboards during
operation. Otherwise your feet may contact the POTENTIAL HAZARD
rear wheels. Removing hands from handlebars or feet
from footboards during operation.
WHAT CAN HAPPEN
Removing even one hand or foot can
reduce your ability to control the ATV or
could cause you to lose your balance and
fall off of the ATV. If you remove a foot
from a footboard, your foot or leg may
come into contact with the rear wheels,
which could injure you or cause an acci-
dent.
Always keep both hands on the handle-
bars and both feet on the footboards of
your ATV during operation.
7-12
5TH-9-15-2 6/15/05 2:55 PM Page 7-13
Avoid wheelies and jumping. You may lose con-

trol of the ATV or overturn.
qWARNING
POTENTIAL HAZARD
Attempting wheelies, jumps, and other
stunts.
WHAT CAN HAPPEN
Increases the chance of an accident,
including an overturn.
Never attempt stunts, such as wheelies or
jumps. Don’t try to show off.
7-13
5TH-9-15-2 6/15/05 2:55 PM Page 7-14
Modifications
qWARNING
POTENTIAL HAZARD
Operating this ATV with improper modifi-
cations.
WHAT CAN HAPPEN
Improper installation of accessories or
modification of this vehicle may cause
changes in handling which in some situa-
tions could lead to an accident.
Never modify this ATV through improper
installation or use of accessories. All parts
and accessories added to this vehicle
should be genuine Yamaha or equivalent
components designed for use on this ATV
and should be installed and used accord-
ing to instructions. If you have questions,
consult an authorized ATV dealer.
7-14
5TH-9-15-2 6/15/05 2:55 PM Page 7-15
Exhaust system
The exhaust system on the ATV is very hot dur- HOW TO AVOID THE HAZARD
ing and following operation. To prevent burns, Do not operate, idle, or park the ATV in dry
avoid touching the exhaust system. Park the grass or other dry ground cover.
ATV in a place where pedestrians or children Keep the engine area free of dry grass,
are not likely to touch it. brush, or other combustible material. Do
not touch the hot exhaust system. Do not
qWARNING park the ATV in a place where others might
POTENTIAL HAZARD be likely to touch it.
Hot exhaust system.
WHAT CAN HAPPEN
Dry grass or brush or other combustible
material accumulated around the engine
area could catch fire. Someone touching
the exhaust system during or after opera-
tion could be burned.
7-15
5TH-9-15-2 6/15/05 2:55 PM Page 7-16
BE CAREFUL WHERE YOU RIDE

This ATV is designed for off-road use only.
Riding on paved surfaces can cause loss of con-
trol.
qWARNING
POTENTIAL HAZARD
Operating this ATV on paved surfaces.
WHAT CAN HAPPEN
ATVs are designed for off-road use only.
Paved surfaces may seriously affect han-
dling and control of the ATV, and may
cause the vehicle to go out of control.
Always avoid paved surfaces, including
sidewalks, driveways, parking lots and
streets.
7-16
5TH-9-15-2 6/15/05 2:55 PM Page 7-17
Do not ride on any public road, street, or high-

way. Riding on public roads can result in colli-
sions with other vehicles.
qWARNING
POTENTIAL HAZARD
Operating this ATV on public streets,
roads or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
Never operate this ATV on any public
street, road or highway, even a dirt or
gravel one.
In many states it is illegal to operate ATVs
on public streets, roads and highways.
7-17
5TH-9-15-2 6/15/05 2:55 PM Page 7-18
Know the terrain where you ride. Ride cautiously

in unfamiliar areas. Stay alert for holes, rocks,
or roots in the terrain, and other hidden haz-
ards which may cause the ATV to upset.
qWARNING
POTENTIAL HAZARD
Failure to use extra care when operating
this ATV on unfamiliar terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks, bumps,
or holes, without enough time to react.
Could result in the ATV overturning or
going out of control.
Go slowly and be extra careful when oper-
ating on unfamiliar terrain.
Always be alert to changing terrain condi-
tions when operating the ATV.
7-18
5TH-9-15-2 6/15/05 2:55 PM Page 7-19
qWARNING
POTENTIAL HAZARD
Failure to use extra care when operating
on excessively rough, slippery or loose
terrain.
WHAT CAN HAPPEN
Could cause loss of traction or vehicle
control, which could result in an accident,
including an overturn.
Do not operate on excessively rough, slip-
pery or loose terrain until you have
learned and practiced the skills necessary
to control the ATV on such terrain. Always
be especially cautious on these kinds of
terrain.
7-19
5TH-9-15-2 6/15/05 2:55 PM Page 7-20
When riding in an area where you might not WHAT CAN HAPPEN
easily be seen, such as desert terrain, mount a
You could be in a collision. You could be
caution flag on the ATV. DO NOT use the flag
injured.
pole bracket as a trailer hitch.
Always mount a caution flag on the ATV to
make you more visible. Watch carefully for
other vehicles.
Do not ride in areas posted “no trespassing”. Do

not ride on private property without getting per-
mission.
qWARNING
POTENTIAL HAZARD
Operating in areas where you might not be
seen by other off-road vehicles.
7-20
5TH-9-15-2 6/15/05 2:55 PM Page 7-21
Select a large, flat area off-road to become With the engine idling, lift the shift pedal to the
familiar with your ATV. Make sure that this area 1st gear position and then release the parking
is free of obstacles and other riders. You should brake. Apply the throttle slowly and smoothly.
practice control of the throttle, brakes, shifting The centrifugal clutch will engage and you will
procedures, and turning techniques in this area start to accelerate. Once the ATV has attained
before trying more difficult terrain. Always avoid adequate speed, release the throttle and lift the
riding on paved surfaces: the ATV is designed shift pedal to the 2nd gear position. Release the
for off-road use only, and handling maneuvers shift pedal and apply the throttle smoothly. Use
are more difficult to perform on pavement. this same procedure as you move into the high-
er gears. Be sure to coordinate the use of the
Set the parking brake and follow the instruction throttle and shift pedal properly. If the throttle is
on page 6-1 to start the engine. Once it has applied too abruptly or if the throttle is not
warmed up you are ready to begin riding your released during shifting, or if the shift pedal is
ATV. As you get on the ATV, be sure not to not released before applying the throttle, the
accidentally move the shift pedal. Remember front wheels may lift off the ground resulting in a
that the engine and exhaust pipe will be hot loss of directional control. Avoid higher speeds
when riding and afterwards; do not allow skin or until you are thoroughly familiar with the opera-
clothing to come in contact with these compo- tion of your ATV.
nents.
7-21
5TH-9-15-2 6/15/05 2:55 PM Page 7-22
cC qWARNING
Do not shift gears without releasing the
POTENTIAL HAZARD
throttle. Damage to the engine or drive train
Engaging a lower gear when the engine
may occur.
speed is too high.
When slowing down or stopping, release the WHAT CAN HAPPEN

throttle and apply the brakes smoothly and The wheels could stop rotating. This could
evenly. As you slow down, shift to a lower gear. cause loss of control, an accident and
Be sure that the engine has sufficiently slowed injury. It could also cause engine or drive
before engaging a lower gear. Improper use of train damage.
the brakes or shifting can cause the tires to lose HOW TO AVOID THE HAZARD
traction, reducing control and increasing the Make sure the engine has sufficiently
possibility of an accident. slowed before shifting to a lower gear.
7-22
5TH-9-15-2 6/15/05 2:55 PM Page 7-23
TURNING YOUR ATV

To achieve maximum traction while riding off-
Always follow proper procedures for turn-
road, the two rear wheels are mounted solidly
ing as described in this Owner’s Manual.
on one axle and turn together at the same
Practice turning at low speeds before
speed. Therefore, unless the wheel on the
attempting to turn at faster speeds. Do not
inside of the turn is allowed to slip or lose some
turn at speeds too fast for your skills or
traction, the ATV will resist turning. A special
the conditions.
turning technique must be used to allow the ATV
to make turns quickly and easily. It is essential As you approach a curve, slow down and begin
that this skill be learned first at low speed. to turn the handlebars in the desired direction.
As you do so, put your weight on the footboard
qWARNING
to the outside of the turn (opposite your desired
POTENTIAL HAZARD direction) and lean your upper body into the
Turning improperly. turn. Use the throttle to maintain an even speed
WHAT CAN HAPPEN through the turn. This maneuver will let the
The ATV could go out of control, causing wheel on the inside of the turn slip slightly,
a collision or overturn. allowing the ATV to make the turn properly.
7-23
5TH-9-15-2 6/15/05 2:55 PM Page 7-24
Once you have learned this technique you

should be able to perform it at higher speeds or
Lean towards Support your in tighter curves.
inside of turn weight on the
outer footrest
Improper riding procedures such as abrupt throt-
tle changes, excessive braking, incorrect body
movements, or too much speed for the sharp-
ness of the turn may cause the ATV to tip. If the
ATV begins to tip over to the outside while nego-
tiating a turn, lean more to the inside. It may
also be necessary to gradually let off on the
throttle and steer to the outside of the turn to
avoid tipping over.
This procedure should be practiced at slow
Remember: Avoid higher speeds until you are
speed many times in a large off-road area with
thoroughly familiar with the operation of your
no obstacles. If an incorrect technique is used,
ATV.
your ATV may continue to go straight. If the ATV
doesn’t turn, come to a stop and then practice
the procedure again. If the riding surface is slip-
pery or loose, it may help to position more of
your weight over the front wheels by moving for-
ward on the seat.
7-24
5TH-9-15-2 6/15/05 2:55 PM Page 7-25
CLIMBING UPHILL
Use proper riding techniques to avoid vehicle
Never operate the ATV on hills too steep
overturns on hills. Be sure that you can maneu-
for the ATV or for your abilities.
ver your ATV well on flat ground before attempt-
Practice on smaller hills before attempting
ing any incline and then practice riding first on
large hills.
gentle slopes. Try more difficult climbs only after
you have developed your skill. In all cases avoid
inclines with slippery or loose surfaces, or obsta- It is important when climbing a hill to make sure
cles that might cause you to lose control. that your weight is transferred forward on the
ATV. This can be accomplished by leaning for-
qWARNING ward and, on steeper inclines, standing on the
footboards and leaning forward over the handle-
POTENTIAL HAZARD bars.
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle can overturn more easily on
extremely steep hills than on level sur-
faces or small hills.
7-25
5TH-9-15-2 6/15/05 2:55 PM Page 7-26
qWARNING Never go over the top of any hill at high

speed. An obstacle, a sharp drop, or
POTENTIAL HAZARD
another vehicle or person could be on the
Climbing hills improperly.
other side of the hill.
WHAT CAN HAPPEN
Could cause loss of control or cause the
ATV to overturn.
HOW TO AVOID THE HAZARD OK
Always follow proper procedures for
climbing hills as described in this Owner’s
Manual.
Always check the terrain carefully before
you start up any hill.
Never climb hills with excessively slippery
or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly or make
sudden gear changes. The ATV could flip
over backwards.
7-26
5TH-9-15-2 6/15/05 2:55 PM Page 7-27
If you are climbing a hill and you find that you When crossing the side of a hill:
have not properly judged your ability to make it
Always follow proper procedures as
to the top, you should turn the ATV around while
described in the Owner’s Manual.
you still have forward motion (provided you have
Avoid hills with excessively slippery or
the room to do so) and go down the hill.
loose surfaces.
qWARNING Shift your weight to the uphill side of the
ATV.
POTENTIAL HAZARD
Improperly crossing hills or turning on
hills.
WHAT CAN HAPPEN OK
ATV to overturn.
Never attempt to turn the ATV around on
any hill until you have mastered the turn-
ing technique as described in the Owner’s
Manual on level ground. Be very careful
when turning on any hill.
Avoid crossing the side of a steep hill if
possible.
7-27
5TH-9-15-2 6/15/05 2:55 PM Page 7-28
If your ATV has stalled or stopped and you qWARNING

believe you can continue up the hill, restart care-
fully to make sure you do not lift the front wheels POTENTIAL HAZARD
which could cause you to lose control. If you are Stalling, rolling backwards or improperly
unable to continue up the hill, dismount the ATV dismounting while climbing a hill.
on the uphill side. Physically turn the ATV WHAT CAN HAPPEN
around and then descend the hill. Could result in the ATV overturning.
If you start to roll backwards, DO NOT use the
Use proper gear and maintain steady
rear brake to stop or try to put the ATV in gear.
speed when climbing a hill.
The ATV could easily tip over backwards.
Instead, apply the front brake gradually, or dis- If you lose all forward speed:
mount the ATV immediately on the uphill side. Keep weight uphill.
Apply the brakes.
Lock the parking brake, after you are
stopped.
If you begin rolling backwards:
Keep weight uphill.
Never apply the rear brake while rolling
backwards. Apply the front brake.
7-28
5TH-9-15-2 6/15/05 2:55 PM Page 7-29
When fully stopped, apply the rear

brake as well, and then lock the parking
brake.
Dismount on uphill side or to a side if
pointed straight uphill. Turn the ATV
around and remount, following the proce-
dure described in the Owner’s Manual.
7-29
5TH-9-15-2 6/15/05 2:55 PM Page 7-30
RIDING DOWNHILL
qWARNING
When riding your ATV downhill, shift your weight
as far to the rear and uphill side of the ATV as POTENTIAL HAZARD
possible. Move back on the seat and sit with Going down a hill improperly.
your arms straight. Choose a low gear which will WHAT CAN HAPPEN
allow the engine compression to do most of the
braking for you. Improper braking may cause a
ATV to overturn.
loss of traction.
Use caution while descending a hill with loose or
slippery surfaces. Braking ability and traction Always follow proper procedures for
may be adversely affected by these surfaces. going down hills as described in this
Improper braking may also cause a loss of trac- Owner’s Manual. Note: a special technique
tion. is required when braking as you go down
a hill.
Whenever possible, ride your ATV straight Always check the terrain carefully before
downhill. Avoid sharp angles which could allow you start down any hill.
the ATV to tip or roll over. Carefully choose your Shift your weight backward.
path and ride no faster than you will be able to Never go down a hill at high speed.
react to obstacles which may appear. Avoid going down a hill at an angle that
would cause the vehicle to lean sharply to
one side. Go straight down the hill where
possible.
7-30
5TH-9-15-2 6/15/05 2:55 PM Page 7-31
OK
7-31
5TH-9-15-2 6/15/05 2:55 PM Page 7-32
CROSSING A SLOPE
qWARNING
Traversing a sloping surface on your ATV
requires you to properly position your weight to POTENTIAL HAZARD
maintain proper balance. Be sure that you have Improperly crossing hills or turning on
learned the basic riding skills on flat ground hills.
before attempting to cross a sloping surface. WHAT CAN HAPPEN
Avoid slopes with slippery surfaces or rough ter-
rain that may upset your balance.
ATV to overturn.
As you travel across a slope, lean your body in
the uphill direction. It may be necessary to cor- Never attempt to turn the ATV around on
rect the steering when riding on loose surfaces any hill until you have mastered the turn-
by pointing the front wheels slightly uphill. When ing technique as described in the Owner’s
riding on slopes be sure not to make sharp turns Manual on level ground. Be very careful
either up or down hill. when turning on any hill. Avoid crossing
the side of a steep hill if possible.
If your ATV does begin to tip over, gradually When crossing the side of a hill:
steer in the downhill direction if there are no Always follow proper procedures as
obstacles in your path. As you regain proper bal- described in the Owner’s Manual.
ance, gradually steer again in the direction you Avoid hills with excessively slippery or
wish to travel. loose surfaces.
7-32
5TH-9-15-2 6/15/05 2:55 PM Page 7-33
Shift your weight to the uphill side of the

ATV.
OK
7-33
5TH-9-15-2 6/15/05 2:55 PM Page 7-34
CROSSING THROUGH SHALLOW WATER

Remember that wet brakes may have
The ATV can be used to cross slow moving,
reduced stopping ability. Test your brakes
shallow water of up to a maximum of 20 cm (7.9
after leaving water. If necessary, apply
inches) in depth. Before entering the water,
them several times to let friction dry out
choose your path carefully. Enter where there is
the linings.
no sharp drop off, and avoid rocks or other
obstacles which may be slippery or upset the
ATV. Drive slowly and carefully.
qWARNING
POTENTIAL HAZARD
Operating this ATV through deep or fast
flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction
and loss of control, which could lead to an
accident.
Never operate this ATV in fast flowing
water or in water deeper than that speci-
fied in your Owner’s Manual.
7-34
5TH-9-15-2 6/15/05 2:55 PM Page 7-35
Test your brakes after leaving the water. Do not cC

continue to ride your ATV without verifying that After riding your ATV in water, be sure to
you have regained proper braking ability. drain the trapped water by removing the
check hose at the bottom of the air filter
case. Wash the ATV in fresh water if it has
been operated in salt water or muddy condi-
tions.
1. Check hose
7-35
5TH-9-15-2 6/15/05 2:55 PM Page 7-36
RIDING OVER ROUGH TERRAIN

qWARNING
Riding over rough terrain should be done with
caution. Look out for obstacles which could POTENTIAL HAZARD
cause damage to the ATV or could lead to an Improperly operating over obstacles.
upset or accident. Be sure to keep your feet WHAT CAN HAPPEN
firmly mounted on the footboards at all times.
Could cause loss of control or a collision.
Avoid jumping the ATV as loss of control and
Could cause the ATV to overturn.
damage to the ATV may result.
Before operating in a new area, check for
obstacles.
Never attempt 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.
7-36
5TH-9-15-2 6/15/05 2:55 PM Page 7-38
SLIDING AND SKIDDING If the rear wheels of your ATV start to slide side-
Care should be used when riding on loose or ways, control can usually be regained (if there is
slippery surfaces since the ATV may slide. If room to do so) by steering in the direction of the
unexpected and uncorrected, sliding could lead slide. Applying the brakes or accelerating is not
to an accident. recommended until you have corrected the
slide.
To reduce the tendency for the front wheels to
slide in loose or slippery conditions, positioning
your weight over the front wheels will sometimes
help.
7-38
5TH-9-15-2 6/15/05 2:55 PM Page 7-39
With practice, over a period of time, skill at con- qWARNING

trolled sliding can be developed. The terrain
should be chosen carefully before attempting POTENTIAL HAZARD
such maneuvers, since both stability and control Skidding or sliding improperly.
are reduced. Bear in mind that sliding maneu- WHAT CAN HAPPEN
vers should always be avoided on extremely You may lose control of this ATV. You
slippery surfaces such as ice, since all control may also regain traction unexpectedly,
may be lost. which may cause the ATV to overturn.
Learn to safely control skidding or sliding
by practicing at low speeds and on level,
smooth terrain.
On extremely slippery surfaces, such as
ice, go slowly and be very cautious in
order to reduce the chance of skidding or
sliding out of control.
7-39
5TH-9-15-2 6/15/05 2:55 PM Page 7-40
WHAT TO DO IF ... 8 If your ATV starts to slide sideways:

This section is designed to be a reference guide Steer in the direction of the slide if you have
only. Be sure to read each section on riding the room.
techniques completely. Applying the brakes or accelerating is not rec-
ommended until you have corrected the slide.
WHAT TO DO ... (See pages 7-38–7-39.)
8 If your ATV doesn’t turn when you want it to: 8 If your ATV can’t make it up a hill you are try-
Bring the ATV to a stop and practice the turning to climb:
ing maneuvers again. Be sure you are putting Turn the ATV around if you still have forward
your weight on the footboard to the outside of speed. If not, stop, dismount on the uphill side
the turn. Position your weight over the front of the ATV and physically turn the ATV
wheels for better control. (See pages 7-23– around. If the ATV starts to slip backwards
7-24.) DO NOT USE THE REAR BRAKE - the ATV
8 If your ATV begins to tip while turning: may tip over on top of you. Instead, apply the
Lean more into the turn to regain balance. If front brake or dismount the ATV on the uphill
necessary, gradually let off the throttle and/or side. (See pages 7-25–7-29.)
steer to the outside of the turn. (See pages
7-23–7-24.)
7-40
5TH-9-15-2 6/15/05 2:55 PM Page 7-41
8 If your ATV is traversing a sloping surface:

Be sure to ride with your weight positioned
towards the uphill side of the ATV to maintain
proper balance. If the ATV starts to tip, steer
down the hill (if there are no obstacles in your
way) to regain balance. If you discover that
the ATV is going to tip over, dismount on the
uphill side. (See pages 7-32–7-33.)
8 If your ATV encounters shallow water:
Ride slowly and carefully through slow mov-
ing water, watching for obstacles. Be sure to
let water drain from the ATV and CHECK
YOUR BRAKES FOR PROPER OPERATION
when you come out of the water. Do not con-
tinue to ride your ATV until you have regained
adequate braking ability. (See pages 7-34–
7-35.) w
7-41
5TH-9-15-2 6/15/05 2:55 PM Page 7-42
EBU00515
PERIODIC HOW TO AVOID THE HAZARD

MAINTENANCE AND Turn off the engine when performing
ADJUSTMENT maintenance unless otherwise specified.
Have a Yamaha dealer perform service if
Periodic inspection, adjustment and lubrication
you are not familiar with machine service.
will keep your machine in the safest and most
efficient condition possible. Safety is an obliga- EBU01221
tion of the machine owner. The most important Owner’s manual and tool kit
points of machine inspection, adjustment and You are recommended to put this owner’s man-
lubrication are explained on the following pages. ual and low-pressure tire gauge in the vinyl bag
qWARNING and always carry them along with the owner’s
tool kit under the seat.
POTENTIAL HAZARD
e
Servicing an engine while it is running.
WHAT CAN HAPPEN
Moving parts can catch clothing or parts
of the body, causing injury.
Electrical components can cause shocks q
or can start fires.
w
1. Owner’s manual 2. Low-pressure tire gauge

8-1 3. Owner’s tool kit
5TH-9-15-3 6/15/05 2:56 PM Page 8-2
The service information included in this manual qWARNING

is intended to provide you, the owner, with the
necessary information for completing your own POTENTIAL HAZARD
preventive maintenance and minor repairs. The Operating this ATV with improper modifi-
tools provided in the owner’s tool kit are suffi- cations.
cient for this purpose, except that a torque WHAT CAN HAPPEN
wrench is also necessary to properly tighten Improper installation of accessories or
nuts and bolts. modification of this vehicle may cause
changes in handling which in some situa-
NOTE: tions could lead to an accident.
If you do not have a torque wrench available HOW TO AVOID THE HAZARD 8
during a service operation requiring one, take
Never modify this ATV through improper
your machine to a Yamaha dealer to check the
installation or use of accessories. All parts
torque settings and adjust them as necessary.
and accessories added to this vehicle
should be genuine Yamaha or equivalent
components designed for use on this ATV
and should be installed and used accord-
ing to instructions. If you have questions,
consult an authorized Yamaha ATV dealer.
8-2
5TH-9-15-3 6/15/05 2:56 PM Page 8-3
EBU02611
Periodic maintenance chart for the emission control system

NOTE:
8 For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
8 For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the
ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
INITIAL EVERY
Whichever month 1 3 6 6 12
ITEM ROUTINE comes first km 320 1300 2500 2500 5000
(mi) (200) (800) (1600) (1600) (3200)
hours 20 80 160 160 320
9 Check valve clearance.
Valves* 2 2 2 2
9 Adjust if necessary.
9 Check chain tension.
Cam chain* 2 2 2 2
9 Check condition.
Spark plug 9 Adjust gap and clean. 2 2 2 2 2
9 Replace if necessary.
9 Check idle speed/choke lever operation.
Carburetor* 2 2 2 2
Crankcase breather 9 Check breather hose for cracks or damage.
2 2 2
system* 9 Replace if necessary.
9 Check for leakage.
Exhaust system* 9 Tighten if necessary. 2 2 2
9 Replace gasket if necessary.
Spark arrester 9 Clean. 2 2 2
9 Check fuel hose for cracks or damage.
Fuel line* 2 2 2
9 Replace if necessary.
8-3
5TH-9-15-3 6/15/05 2:56 PM Page 8-4
General maintenance and lubrication chart

INITIAL EVERY
(mi) (200) (800) (1600) (1600) (3200)
hours 20 80 160 160 320
9 Clean. Every 20–40 hours
Air filter element
9 Replace if necessary. (more often in wet or dusty areas)
Engine oil 9 Replace (warm engine before draining). 2 2 2 2
9 Check oil level/oil leakage.
Final gear oil 2 2
9 Replace every 12 months.
9 Check operation.
Brakes* 2 2 2 2 2
9 Check operation.
Clutch* 2 2 2 2
9 Check balance/damage/runout.
Wheels* 9 Replace if necessary. 2 2 2 2
9 Check brearing assemblies for looseness/

Wheel bearings* damage. 2 2 2 2
9 Replace if damaged.
9 Check operation.
9 Replace if damaged.
Steering system* 2 2 2 2 2
9 Check toe-in.
Knuckle shafts/ 9 Lubricate every 6 months with Lithium-soap-based
2 2 2
steering shaft* grease.
9 Check all chassis fittings and fasteners.
Fittings and fasteners* 2 2 2 2 2
9 Correct if necessary.
8-4
5TH-9-15-3 6/15/05 2:56 PM Page 8-5
INITIAL EVERY
(mi) (200) (800) (1600) (1600) (3200)
hours 20 80 160 160 320
9 Check specific gravity.
Battery* 9 Check breather hose for correct routing. 2 2 2 2 2
9 Correct if necessary.
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
w
8-5
5TH-9-15-3 6/15/05 2:56 PM Page 8-6
EBU08682
Engine oil
Engine oil level measurement w
q
1. Place the ATV on a level surface. e
2. Warm up the engine for several minutes
and stop it.
3. Remove the dipstick and wipe it off with a
clean rag. Insert the dipstick in the filler
hole without screwing it in.
NOTE:
Wait a few minutes until the oil level settles 1. Dipstick 2. Maximum level mark
3. Minimum level mark
before checking.
Engine oil replacement

4. Remove the dipstick and inspect the oil
1. Place the ATV on a level surface.
level.
2. Warm up the engine for several minutes
5. The oil level should be between the maxi-
and stop it.
mum and minimum marks. If the level is
3. Place a container under the engine.
low, add oil to raise it to the specified level.
4. Remove the dipstick and drain bolt to drain
cC the oil.
Be sure no foreign material enters the 5. Inspect the O-ring and replace if damaged.
crankcase.
8-6
5TH-9-15-3 6/15/05 2:56 PM Page 8-7
Recommended oil type:

YAMALUBE 4 (20W40) or SAE 20W40
YAMALUBE 4 (10W30) or SAE 10W30
SAE 5W30
Recommended oil classification:
API Service SE, SF, SG type or higher
Oil quantity:
Periodic oil change:
q
0.8 L (0.70 Imp qt, 0.85 US qt)
1. Drain bolt
cC
6. Install the drain bolt and tighten to specifi- Be sure no foreign material enters the
cation. crankcase.
Tightening torque 8. Warm up the engine for several minutes at

Drain bolt: idle speed. Check for oil leakage while
20 Nm (2.0 m0kgf, 14 ft0lbf) warming up.
7. Fill the engine with oil and install the dip-

cC
stick.
If oil leakage is found, stop the engine imme-
diately and check for the cause.
8-7
5TH-9-15-3 6/15/05 2:56 PM Page 8-8
EBU00869
Final gear oil

Final gear oil measurement 2
1. Place the ATV on a level surface. 3
2. Remove the dipstick and wipe it off with a
clean rag. Insert the dipstick in the filler 1
hole without screwing it in.
3. Remove the dipstick and inspect the oil
level.
4. The oil level should be between the maxi-
mum and minimum marks. If the level is 1. Dipstick 2. Maximum level mark
3. Minimum level mark
low, add oil to raise it to the proper level.
Final gear oil replacement

cC 1. Place the ATV on a level place.
Be sure no foreign material enters the final 2. Place a container under the final gear
gear case. case.
3. Remove the dipstick and drain bolt to drain
5. Install the dipstick. the oil.
8-8
5TH-9-15-3 6/15/05 2:56 PM Page 8-9
5. Fill the final gear case with oil.
Recommended oil:
SAE80API “GL-4” Hypoid gear oil
Oil quantity:
0.12L (0.11 Imp qt, 0.13 US qt)
q cC
Be sure no foreign material enters the final
1. Drain bolt
gear case.
4. Install the drain bolt and tighten to specifi-

6. Install the dipstick.
cation.
7. Check for oil leakage. If oil leakage is
found, check for the cause.
Tightening torque
Drain bolt:
23 Nm (2.3 m0kgf, 17 ft0lbf)
8-9
5TH-9-15-3 6/15/05 2:56 PM Page 8-10
EBU11820
Spark plug inspection Before installing the spark plug, measure the
The spark plug is an important engine compo- electrode gap with a wire thickness gauge and
nent and is easy to inspect. The condition of the adjust it to specification.
spark plug can indicate the condition of the
engine. Spark plug gap:
For example, a very white center electrode 0.6–0.7 mm (0.024–0.028 in)
porcelain color could indicate an intake air leak
or carburetion problem for that cylinder. Do not
attempt to diagnose such problems yourself.
Instead, take the ATV to a Yamaha dealer. You
should periodically remove and inspect the
spark plug because heat and deposits will cause
the spark plug to slowly break down and erode. a
If electrode erosion becomes excessive, you
should replace the spark plug with one of the
proper type.
a. Spark plug gap
Standard spark plug:
CR7HSA (NGK)
8-10
5TH-9-15-3 6/15/05 2:56 PM Page 8-11
When installing the spark plug, always clean the

gasket surface and its mating surface. Wipe off
any grime from the threads and tighten it to the
specified torque.
Tightening torque: q
Spark plug:
12.5 Nm (1.25 m0kgf, 9.1 ft0lbf)
1. Check hose
EBU10343 1. Remove the front cover by removing the

Air filter cleaning bolts.
NOTE:
w
There is a check hose at the bottom of the air fil- w
ter case. If dust or water collects in this hose,
empty the hose and clean the air filter element
and air filter case.
8-11 1. Front cover 2. Bolt (×2)

5TH-9-15-3 6/15/05 2:56 PM Page 8-12
w w
q
q
1. Air filter case cover 2. Fastener (×4) 1. Fastener 2. Air filter element
2. Remove the air filter case cover by 3. Remove the air filter element by unhooking
unhooking the fasteners. the fastener.
4. Wash the air filter element gently but thor-
oughly in solvent.
8-12
5TH-9-15-3 6/15/05 2:56 PM Page 8-13
qWARNING 6. Inspect the air filter element. If damaged,

replace it.
POTENTIAL HAZARD 7. Apply Yamaha foam air filter oil or other
Using low flash point solvents or gasoline quality foam air filter oil to the air filter ele-
to clean the air filter element. ment.
WHAT CAN HAPPEN
Low flash point solvents or gasoline can NOTE:
catch fire or explode. The air filter element should be wet but not drip-
HOW TO AVOID THE HAZARD ping.
Use parts cleaning solvent to clean the air
filter element. 8. Install the air filter element.
9. Install the air filter case cover by hooking
the fasteners onto the air filter case.
5. Squeeze the excess solvent out of the air 10. Install the front cover by installing the bolts.
filter element and let it dry.
cC
Do not twist the air filter element when
squeezing it.
8-13
5TH-9-15-3 6/15/05 2:56 PM Page 8-14
EBU01035
NOTE: Air intake restrictor plate removal

The air filter element should be cleaned every To obtain full engine performance capability,
20-40 hours. It should be cleaned and lubricated removing the air intake restrictor plate is
more often if the machine is operated in required.
extremely dusty areas. Each time air filter ele- 1. Remove the air filter element. (See page
ment maintenance is performed, check the air 8-11 for removal and installation procedures.)
inlet of the air filter case for obstructions. Check 2. Remove the air intake restrictor plate.
the air cleaner rubber joint to the carburetor and
manifold fittings for an airtight seal. Tighten all
fittings securely to avoid the possibility of unfil- q
tered air entering the engine.
cC
Never operate the engine with the air filter
element removed. This will allow unfiltered
air to enter the engine, causing rapid engine
wear and possible engine damage. 1. Air intake restrictor plate
Additionally, operation without the filter ele-

ment will affect carburetor jetting with sub-
sequent poor performance and possible
engine overheating.
8-14
5TH-9-15-3 6/15/05 2:56 PM Page 8-15
EBU13600
NOTE: Spark arrester cleaning

Store the air intake restrictor plate with the Be sure the exhaust pipe and muffler are cool
owner’s manual so that you can install it when- before cleaning the spark arrester.
ever you want to reduce the top speed available. 1. Remove the screws.
3. Install the air filter element.
1. Screw (×2)
8-15
5TH-9-15-3 6/15/05 2:56 PM Page 8-16
2. Remove the tailpipe by pulling it out of the

qWARNING
muffler.
3. Tap the tailpipe lightly, then use a wire POTENTIAL HAZARD
brush to remove any carbon deposits from Improper cleaning of the spark arrester.
the spark arrester portion of the tailpipe. Hot exhaust system
WHAT CAN HAPPEN
q
e Could injure the eyes.
w Could cause burns.
Could cause carbon monoxide poisoning,
possibly leading to death.
Could start a fire.
When cleaning the spark arrester:
1. Tailpipe 2. Spark arrester
Always let the exhaust system cool prior
3. Screw (×2) to touching exhaust components.
Do not start the engine when cleaning the
4. Insert the tailpipe into the muffler and align
exhaust system.
the screw holes.
5. Install the screws and tighten them.
8-16
5TH-9-15-3 6/15/05 2:56 PM Page 8-17
EBU00296 EBU13020
Carburetor adjustment Idle speed adjustment

The carburetor is a vital part of the engine and NOTE:
requires very sophisticated adjustment. Most A diagnostic tachometer must be used for this
adjusting should be left to a Yamaha dealer who procedure.
has the professional knowledge and experience
to do so. However, the idling speed may be per- 1. Start the engine and warm it up for a few
formed by the owner as a part of the usual main- minutes at approximately 1,000 to 2,000
tenance routine. r/min. Occasionally rev the engine to 4,000
to 5,000 r/min. The engine is warm when it
cC quickly responds to the throttle.
The carburetor was set at the Yamaha facto-
ry after many tests. If the settings are dis-
turbed by someone without sufficient techni-
cal knowledge, poor engine performance and
damage may result.
8-17
5TH-9-15-3 6/15/05 2:56 PM Page 8-18
EBU00303
2. Connect the tachometer to the spark plug Valve clearance adjustment

lead, and then set the idle to the specified The correct valve clearance changes with use,
idling speed by adjusting the throttle stop resulting in improper fuel/air supply or engine
screw. Turn the screw in direction a to noise. To prevent this, the valve clearance must
be adjusted regularly. This adjustment however,
increase the engine speed, and in direction
should be left to a professional Yamaha service
b to decrease the engine speed.
technician.
Specified idle speed:
EBU00304
1,750–1,850 r/min Cam chain adjustment
The cam chain becomes loose with use, result-
ing in improper valve timing and engine noise.
To prevent this, the cam chain tensioner must
be adjusted regularly. This adjustment should be
left to a Yamaha service technician.
b a
EBU01218
Front and rear brake shoe inspection

A wear indicator is provided on each brake. The
indicators allows checking of brake shoe wear
q
without disassembling the brake. Apply the brake
1. Throttle stop screw and check the position of the indicator. If the indi-
cator reaches the wear limit line or mark, ask a
Yamaha dealer to replace the shoes as a set.
8-18
5TH-9-15-3 6/15/05 2:56 PM Page 8-19
EBU00323
Front Front brake lever free play adjustment
NOTE:
Before adjusting the brake, inspect the front
brake shoes.
w q
The front brake lever free play should be adjust-
ed to 10–12 mm (0.4–0.5 in) at the brake lever
pivot. If the free play is incorrect, adjust as fol-
1. Wear limit line 2. Wear indicator
lows:
Rear a
a. Free play
1. Wear limit mark 2. Wear indicator
8-19
5TH-9-15-3 6/15/05 2:56 PM Page 8-20
1. Loosen the upper locknut and fully turn in 5. While applying the front brake, turn out the
the adjusting bolt. upper adjusting bolt until the upper and
2. Loosen the lower locknut. lower cable lengths are equal. The cable
3. Turn the lower adjusting bolt until specified joint will become vertical.
free play is obtained.
a a=a’
q q
w
a’
r
e
1. Cable joint
1. Upper locknut 2. Upper adjusting bolt
3. Lower locknut 4. Lower adjusting bolt 6. Tighten the upper locknut.
Specified free play:

10–12 mm (0.4–0.5 in)
4. Tighten the lower locknut.

8-20
5TH-9-15-3 6/15/05 2:56 PM Page 8-21
EBU03351
qWARNING Rear brake lever and brake pedal adjustment

Brake lever free play adjustment
POTENTIAL HAZARD
1. Loosen the brake cable locknut.
Operating with improperly serviced or 2. Turn the adjusting bolt at the brake lever
adjusted brakes. until brake lever free play is 5–8 mm
WHAT CAN HAPPEN (0.20–0.30 in).
You could lose braking ability, which 3. Tighten the locknut.
could lead to an accident. q w
a
After servicing:
8 Make sure the brakes operate smooth-
ly and that the free play is correct.
8 Make sure the brakes do not drag.
Replacement of brake components
requires professional knowledge. These
procedures should be performed by
a. Free play
Yamaha dealer. 1. Locknut 2. Adjusting bolt
8-21
5TH-9-15-3 6/15/05 2:56 PM Page 8-22
NOTE: Brake pedal free play adjustment

If specified free play cannot be obtained, tighten Turn the brake rod adjusting nut at the rear
the brake cable adjusting nut at the rear wheel wheel hub until brake pedal free play is 20–
hub until brake lever free play is 5–8 mm 30 mm (0.8–1.2 in).
(0.20–0.30 in).
a. Free play
q
1. Brake cable adjusting nut
8-22
5TH-9-15-3 6/15/05 2:56 PM Page 8-23
qWARNING
POTENTIAL HAZARD
Operating with improperly serviced or
adjusted brakes.
WHAT CAN HAPPEN
q
You could lose braking ability, which
could lead to an accident.
1. Brake rod adjusting nut
After servicing:
8 Make sure the brakes operate smooth-
ly and that the free play is correct.
8 Make sure the brakes do not drag.
Replacement of brake components
requires professional knowledge. These
procedures should be performed by a
Yamaha dealer.
8-23
5TH-9-15-3 6/15/05 2:56 PM Page 8-24
EBU00872
Clutch adjustment NOTE:

1. Remove the rubber cap. Turn the adjusting bolt clockwise to decrease
2. Loosen the locknut. the clutch free play and turn it counterclockwise
3. Slowly turn the adjusting bolt clockwise to increase the free play.
until resistance is felt. Then turn it 1/8
counterclockwise. 5. Install the rubber cap securely.
qw
1. Rubber cap 2. Locknut 3. Adjusting bolt

4. Tighten the locknut to the specified torque.
Tightening torque:
8 Nm (0.8 m0kgf, 5.8 ft0lbf)
8-24
5TH-9-15-3 6/15/05 2:56 PM Page 8-25
EBU00356
Cable inspection and lubrication Lubricate the inner cables and the cable ends. If
the cables do not operate smoothly, ask a
qWARNING Yamaha dealer to replace them.
POTENTIAL HAZARD
Recommended lubricant:
Damaged control cables.
Yamaha chain and cable lube or
WHAT CAN HAPPEN
SAE 10W30 motor oil
Corrosion can result when the outer cov-
ering of control cables becomes damaged. EBU00727
Cables can also become frayed or kinked. Brake and shift pedal/brake lever lubrication
Operation of controls could be restricted, Lubricate the pivoting parts of each lever and
which could cause an accident or injury. pedal.
Inspect cables frequently. Replace dam- Recommended lubricant:
aged cables. Lithium-soap-based grease
(all-purpose grease)
8-25
5TH-9-15-3 6/15/05 2:56 PM Page 8-26
EBU01220
Knuckle shaft and steering shaft lubrication Front Rear
Lubricate the pivot points using a grease gun. q w

Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
1. Wheel nut (×4) 2. Wheel nut (×3)

EBU00871
Wheel installation
When installing the wheel, reverse the removal
1 procedure.
1 Tighten the wheel nuts to the specified torques.
1. Grease nipple
EBU01112
Tightening torque:
Wheel removal Wheel nut:
1. Loosen the wheel nuts. Front: 28 Nm (2.8 m0kgf, 20 ft0lbf)
2. Elevate the ATV and place a suitable stand Rear: 28 Nm (2.8 m0kgf, 20 ft0lbf)
under the frame.
3. Remove the nuts from the wheel.
4. Remove the wheel. 8-26
5TH-9-15-3 6/15/05 2:56 PM Page 8-27
EBU00378
Battery
Check the level of the battery fluid and see if the
terminals are tight. Add distilled water if the fluid
level is low. q
w
cC
Do not leave or store the battery on its side.
When inspecting the battery, be sure the
breather hose is routed correctly. If it touch-
1. Battery 2. Battery breather hose
es the frame or exists in such a way as to
cause battery electrolyte or gas to exit onto
the frame, structural and cosmetic damage
to the machine can occur.
8-27
5TH-9-15-3 6/15/05 2:56 PM Page 8-28
qWARNING EYES: Flush with water for 15 minutes and

POTENTIAL HAZARD get prompt medical attention. Keep batter-
ies away from sparks, flames, cigarettes
Failure to handle batteries or battery elec-
or other sources of ignition. Ventilate
trolyte carefully.
when charging or using in a closed space.
WHAT CAN HAPPEN
You could be poisoned. You could be
severely burned by the sulfuric acid in bat-
tery electrolyte.
Batteries produce explosive gases.
Avoid contact with skin, eyes or clothing.
Always shield eyes when working near
batteries. Keep out of reach of children.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water
or milk. Follow with milk of magnesia,
beaten egg or vegetable oil. Get prompt
medical attention.
8-28
5TH-9-15-3 6/15/05 2:56 PM Page 8-29
EBU11950
Replenishing the battery fluid cC

A poorly maintained battery will corrode and dis- Normal tap water contains minerals which
charge quickly. The battery fluid should be are harmful to a battery. Therefore, refill only
checked at least once a month. with distilled water.
1. The level should be between the maximum
and minimum level marks. Use only dis- 4. When the machine is not to be used for a
tilled water if refilling is necessary. month or longer, remove the battery and
store it in a cool, dark place. Completely
recharge the battery before using.
5. If the battery is to be stored for a longer
period than the above, check the specific
r gravity at least once a month and recharge
q the battery when it is too low.
6. Always make sure the connections are cor-
e rect when putting the battery back in the
w
machine. Make sure the breather hose is
1. Maximum level mark 2. Minimum level mark properly connected and is not damaged or
3. Negative lead 4. Positive lead obstructed.
2. Disconnect the negative (–) lead.
3. Disconnect the positive (+) lead, and then
remove the battery.
8-29
5TH-9-15-3 6/15/05 2:56 PM Page 8-30
EBU00390
Fuse replacement qWARNING

1. The fuse case is located under the seat.
POTENTIAL HAZARD
2. If the fuse is blown, turn off the main switch
and install a new fuse of the specified Using an improper fuse.
amperage. Then turn on the switches. If WHAT CAN HAPPEN
the fuse immediately blows again, consult An improper fuse can cause damage to
a Yamaha dealer. the electrical system which could lead to a
fire.
Specified fuse: 5 A
Always use a fuse of the specified rating.
q Never use a material in place of the proper
fuse.
cC
To prevent accidental short-circuiting, turn
off the main switch when checking or replac-
w ing a fuse.
1. Fuse 2. Spare fuse
8-30
5TH-9-15-3 6/15/05 2:56 PM Page 8-31
EBU00412
Troubleshooting qWARNING
Although Yamaha machines receive a rigid
POTENTIAL HAZARD
inspection before shipment from the factory,
trouble may occur during operation. Any prob- Checking the fuel system while smoking
lem in the fuel, compression, or ignition systems or near an open flame.
can cause poor starting and loss of power. The WHAT CAN HAPPEN
troubleshooting chart describes a quick, easy Fuel can ignite or explode, causing severe
procedure for making checks. If your machine injury or property damage.
requires any repair, take it to a Yamaha dealer. HOW TO AVOID THE HAZARD
Do not smoke when checking the fuel sys-
The skilled technicians at a Yamaha dealership
tem. Make sure there are no open flames
have the tools, experience, and know-how to
or sparks in the area, including pilot lights
properly service your machine. Use only gen-
from water heaters or furnaces.
uine Yamaha parts on your machine. Imitation
parts may look like Yamaha parts, but they are
often inferior. Consequently, they have a shorter
service life and can lead to expensive repair
bills.
8-31
5TH-9-15-3 6/15/05 2:56 PM Page 8-32
EBU00440 Remove the Water or dirt Clean the fuel filter

Troubleshooting chart fuel hose from mixed in fuel and the fuel tank
the fuel cock.
Turn the fuel
Check fuel flow No fuel Fuel cock clogged
cock to “ON”
Turn the fuel
There is fuel Clean fuel cock
1. Fuel cock to “OFF”
Check if there is
Turn the fuel
fuel in the fuel Some fuel Restart engine
cock to “RES”
tank
No fuel Supply fuel

2. Compression
Use electric starter
There is compresson Compression normal
to see if there is
compression
No compression Ask a Yamaha dealer to inspect
3. Ignition Wipe clean with dry

Wet
cloth
Remove spark Spark good Ignition system normal
plug and check
electrodes Attach spark plug Use electric
Dry Spark weak
cap and ground to starter
chassis Adjust spark plug
No spark
gap or replace
4. Battery Engine turns spark plug
Battery good
over quickly
Use electric Ask a Yamaha dealer to inspect
starter
Engine turns Check fluid, recharge,
over slowly check connections
8-32
5TH-9-15-3 6/15/05 2:56 PM Page 8-33
EBU00419
CLEANING AND STORAGE 3. Rinse the dirt and degreaser off with a gar-
den hose. Use only enough pressure to do
the job.
A. CLEANING
Frequent, thorough cleaning of your machine
will not only enhance its appearance but will cC
improve its general performance and extend the Excessive water pressure may cause water
useful life of many components. seepage and deterioration of wheel bearings,
1. Before cleaning the machine: brakes, transmission seals and electrical
a. Block off the end of the exhaust pipe to devices. Many expensive repair bills have
prevent water entry. A plastic bag and resulted from improper high pressure deter-
strong rubber band may be used. gent applications such as those available in
b. Make sure the spark plug and all filler caps coin-operated car washers.
are properly installed.
2. If the engine case is excessively greasy, 4. Once the majority of the dirt has been
apply degreaser with a paint brush. Do not hosed off, wash all surfaces with warm
apply degreaser to the wheel axles. water and mild, detergent-type soap. An
old toothbrush or bottle brush is handy for
hard-to-get-at places.
9-1
5TH-9-15-3 6/15/05 2:56 PM Page 8-34
5. Rinse the machine off immediately with qWARNING

clean water and dry all surfaces with a
chamois, clean towel or soft absorbent POTENTIAL HAZARD
cloth. Operation with wet brakes after washing.
6. Clean the seat with a vinyl upholstery WHAT CAN HAPPEN
cleaner to keep the cover pliable and Wet brakes may have reduced stopping
glossy. ability, increasing the chance of an acci-
7. Automotive type wax may be applied to all dent.
painted and chrome plated surfaces. Avoid
combination cleaner-waxes. Many contain
Test the brakes after washing. Apply the
abrasives which may mar the paint or pro-
brakes several times at slow speeds to let
tective finish.
friction dry out the linings. 9
When finished, start the engine and let it
idle for several minutes.
9-2
5TH-9-15-3 6/15/05 2:56 PM Page 8-35
EBU00530
B. STORAGE reinstall the spark plug. Ground the spark

Long term storage (60 days or more) of your plug wire and turn the engine over several
machine will require some preventive proce- times to coat the cylinder wall with oil.
dures to guard against deterioration. After thor- 3. Lubricate all control cables.
oughly cleaning the machine, prepare for stor- 4. Block up the frame to raise all wheels off
age as follows: the ground.
1. Fill the fuel tank with fresh fuel and add the 5. Tie a plastic bag over the exhaust pipe out-
specified amount of Yamaha Fuel let to prevent moisture from entering.
Stabilizer and Conditioner or an equivalent 6. If storing in a humid or salt-air atmosphere,
product. coat all exposed metal surfaces with a light
Specified amount: film of oil. Do not apply oil to any rubber
1 oz of stabilizer to each gallon of fuel parts or the seat cover.
(or 7.5 cc of stabilizer to each liter of fuel) 7. Remove the battery and charge it. Store it
in a dry place and recharge it once a
NOTE: month. Do not store the battery in an
Use of fuel stabilizer and conditioner eliminates
excessively warm or cold place (less than
the need to drain the fuel system. Consult a
0˚C (30˚F) or more than 30˚C (90˚F).
Yamaha dealer if the fuel system needs to be
NOTE:
drained instead.
Make any necessary repairs before storing the
2. Remove the spark plug, pour about one machine.
tablespoon of SAE 10W30 or 20W40
motor oil in the spark plug hole and
9-3
5TH-9-15-3 6/15/05 2:56 PM Page 8-36
EBU00428
SPECIFICATIONS
Model YFM80R
Dimension:
Overall length 1,537 mm (60.5 in)
Overall width 841 mm (33.1 in)
Overall height 940 mm (37.0 in)
Seat height 669 mm (26.3 in)
Wheel base 1,030 mm (40.6 in)
Ground clearance 100 mm ( 3.94 in)
Minimum turning radius 2,400 mm (94.5 in)
Basic weight:
With oil and full fuel tank 116 kg (256 lb)
Engine:
Type Air cooled, 4-stroke, SOHC 10
Cylinder arrangement Single cylinder, Forward inclined
Displacement 79 cm3 (4.82 cu.in)
Bore × Stroke 47.0 × 45.6 mm (1.85 × 1.80 in)
Compression ratio 9.6 : 1
Starting system Electric starter
Lubrication system Wet sump
10-1
5TH-9-15-3 6/15/05 2:56 PM Page 8-37
Model YFM80R
Engine oil:
0° 10° 30° 50° 70° 90° 110° 130°F
Type
YAMALUBE 4 (20W40) or SAE20W40
YAMALUBE 4 (10W30) or SAE10W30
SAE 5W30
–20° –10° 0° 10° 20° 30° 40° 50°C
Recommended engine oil classification: API Service SE, SF, SG type or higher
cC
In order to prevent clutch slippage (since the
engine oil also lubricates the clutch), do not
mix any chemical additives. Do not use oils
with a diesel specification of “CD” or oils of
a higher quality than specified. In addition,
do not use oils labeled “ENERGY CONSERV-
ING II” or higher.
Quantity:
Periodic oil change 0.80 L (0.70 lmp qt, 0.85 US qt)
10-2
5TH-9-15-3 6/15/05 2:56 PM Page 8-38
Model YFM80R
Final gear oil:
Type SAE80API “GL-4” Hypoid gear oil
Quantity:
Total amount 0.12 L (0.11 Imp qt, 0.13 US qt)
Air filter: Wet type element
Fuel:
Type UNLEADED GASOLINE ONLY
Tank capacity 6.8 L (1.5 Imp gal, 1.8 US gal)
Reserve amount 0.9 L (0.2 Imp gal, 0.2 US gal)
Carburetor:
Type/manufacturer VM16SH/MIKUNI
Spark plug:
Type/manufacturer CR7HSA/NGK
Gap 0.6–0.7 mm (0.024–0.028 in)
Clutch type: Wet, multiple-disc automatic
10-3
5TH-9-15-3 6/15/05 2:56 PM Page 8-39
Model YFM80R
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 65/20 (3.250)
Secondary reduction system Shaft drive
Secondary reduction ratio 19/18 × 34/10 (3.588)
Transmission type Constant mesh 3-speed
Operation Left foot operation
Gear ratio:
1st 39/11 (3.545)
2nd 35/17 (2.059)
3rd 31/22 (1.409)
Chassis:
Frame type Steel tube
Caster angle 1°
Trail 3.8 mm (0.15 in)
Tire:
Type Tubeless
Size : Front AT18 × 7-7
: Rear AT18 × 8-7
Manufacturer/type
Front DUNLOP/KT586
Rear DUNLOP/KT587
10-4
5TH-9-15-3 6/15/05 2:56 PM Page 8-40
Model YFM80R
Brake:
Front brake type Drum brake
Operation Right hand operation
Rear brake type Drum brake
Operation Left hand and right foot operation
Suspension:
Front Leading arm
Rear Swingarm
Shock Absorber:
Front Coil spring/Oil damper
Rear Coil spring/Oil damper
Wheel travel:
Front 57 mm (2.24 in)
Rear 56 mm (2.2 in)
Electrical:
Ignition system C.D.I.
Charging system A.C. magneto
Battery type/voltage, capacity 12N7D-3B/12V, 7Ah
Indicator light voltage, wattage × quantity:
Neutral 12V, 1.7W × 1
Fuse: 5A
10-5
5TH-9-15-3 6/15/05 2:56 PM Page 8-41
EBU13640
NOISE REGULATION
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inopera-
tive by any person other than for purposes of maintenance, repair, or replacement of any device or
element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or
element of design has been removed or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED
BELOW.”
These acts include tampering with the following systems; i.e., modification, removal, etc.
Muffler
Exhaust system Exhaust pipe
Silencer
Air cleaner case
Intake system Air cleaner element
Intake duct
11-1
5TH-9-15-3 6/15/05 2:56 PM Page 8-42
EBU13653
MAINTENANCE RECORD
Copies of work orders and/or receipts for parts you purchase and install will be required to document
maintenance done in accordance with the warranty. The chart below is printed only as a reminder to
you that the maintenance work is required. It is not acceptable proof of maintenance work.
MAINTENACE
INTERVAL DATE OF SERVICING DEALER
MILEAGE REMARKS
SERVICE NAME AND ADDRESS
month km (mi) hours
1 320 (200) 20
3 1,300 (800) 80
6 2,500 (1,600) 160
12 5,000 (3,200) 320
18 7,500 (4,800) 480
24 10,000 (6,400) 640
30 12,500 (8,000) 800
36 15,000 (9,600) 960
11
42 17,500 (11,200) 1,120
12
48 20,000 (12,800) 1,280
54 22,500 (14,400) 1,440
60 25,000 (16,000) 1,600
12-1
5TH-9-15-3 6/15/05 2:56 PM Page 8-43
EBU26310
YAMAHA MOTOR CORPORATION, U.S.A.

ATV LIMITED WARRANTY
13-1
5TH-9-15-3 6/15/05 2:56 PM Page 8-44
13
13-2
5TH-9-15-3 6/15/05 2:56 PM Page 8-45
EBU00435
14-1
5TH-9-15-3 6/15/05 2:56 PM Page 8-46
14
14-2
5TH-9-15-3 6/15/05 2:56 PM Page 8-47
EBU00436
w
Indicates a potential hazard that could
result in serious injury or death.
5TH-9-15-3 6/15/05 2:56 PM Page 8-49
EBU00437
5TH-9-15 hyoshi 7/15/05 1:06 PM Page 4
EBU00438
qWARNING
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 operate: ALWAYS:
9 without proper training or instruction. 9 use proper riding techniques to avoid
9 at speeds too fast for your skills or the vehicle overturns on hills and rough
conditions. terrain and in turns.
9 on public roads - a collision can occur with 9 avoid paved surfaces - pavement may
another vehicle. seriously affect handling and control.
9 with a passenger - passengers affect
balance and steering and increase risk
of losing control.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
(For replacement manual, call 1-800-532-1558)
YAMAHA MOTOR CO., LTD.

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2005.7-2.7x1 !
(E)
ATV card for US 4/2/03 9:06 AM Page 1
before operating your ATV [If card is not attached, call 1-800-344-6418].
Dear Yamaha ATV Owner: Please Review this IMPORTANT SAFETY CARD
Dear New Yamaha ATV Owner:
CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV. You have purchased a quality
Yamaha product that, with proper use and care, will provide hours of riding pleasure. BEFORE YOU
OPERATE YOUR NEW ATV, Yamaha recommends these important points:
C A R E F U L LY
8 READ YOUR OWNER’S MANUAL
8 A CHILD UNDER 6 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 50CC OR GREATER
8 A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER
8 A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER
THAN 90CC
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.
Name: ATV Model: Purchase Date:
MO. DAY YR.
READ
Address: Primary I.D. [Engine Number]:
Dealer Name & Address:

Telephone:
[ ]
ATV card for US 4/2/03 9:06 AM Page 2
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

Yamaha Raptor 80 Owners Manual

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5TH-9-15 hyoshi 7/15/05 1:06 PM Page 1

READ THIS MANUAL CAREFULLY!

AN IMPORTANT SAFETY MESSAGE:

AN IMPORTANT NOTE TO PARENTS:

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:

Q The Safety Alert Symbol means ATTENTION! BECOME ALERT!

w Failure to follow WARNING instructions could result in severe injury or

cC A CAUTION indicates special precautions that must be taken to avoid

NOTE: A NOTE provides key information to make procedures easier or clearer.

1 LOCATION OF THE WARNING AND Speed limiter ........................................4-4

How to measure tire pressure ..............5-7 Be careful where you ride...................7-16

Air intake restrictor plate removal .......8-14 Fuse replacement...............................8-30

LOCATION OF THE WARNING AND

Read and understand all of the labels on your

qWARNING When transporting the ATV in another

DESCRIPTION AND MACHINE IDENTIFICATION

Identification number records Key identification number

1. Key identification number

Vehicle identification number Model label

1. Vehicle identification number

NOTE: 1. Model label

CONTROL FUNCTIONS Indicator lights

Handlebar switches Start switch “START”

Throttle lever Before starting the engine, check the throttle to

qWARNING Front brake lever

1. Front brake lever

Brake pedal and rear brake lever

1. Rear brake lever

Shift pedal Fuel tank cap

1. Shift pedal N. Neutral position

Choke lever Seat

1. Seat lock lever

To install the seat, insert the projection on the

ITEM ROUTINE PAGE

WHAT CAN HAPPEN

Your Yamaha engine has been designed to use reg-

1. Filler tube 2. Fuel level

Engine oil Final gear oil

Recommended engine oil type and quantity:

Throttle lever Tires

Set pressure with tires cold. Tire wear limit

1. Low-pressure tire gauge

Fittings and fasteners

OPERATION Starting a cold engine

HOW TO AVOID THE HAZARD

NOTE: Position 2: Warming up position.

6. Completely close the throttle lever and start cC

7. If the engine is started with the starter EBU00184

(choke) in position 1 , the choke lever Warming up

To start out and accelerate:

4. Once the machine has attained adequate To decelerate:

Parking on a slope 1. Bring the ATV to a stop by applying the

Accessories and loading 8 Accessories should be rigidly and securely

Riding your new ATV can be a very enjoyable

RIDE WITH CARE AND GOOD JUDGEMENT

Get training if you are inexperienced. Beginning and inexperienced operators

Not recommended for children under 12

This ATV is designed to carry operator only -