User manual YAMAHA RAPTOR 350-2008

READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER'S MANUAL YFM35RX WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-21-10 5YT-28199-15 EBU17091 EBU17170 INTRODUCTION EBU17300 Congratulations on your purchase of the Yamaha YFM35RX. This ATV 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 ATV. This manual includes important safety information. It provides information about special techniques and skills necessary to ride the ATV. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer. AN IMPORTANT SAFETY MESSAGE: G READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. G PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV. G NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMATION. G THIS ATV, AND ANY OTHER ATV OVER 90 cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE. G THIS ATV IS A HIGH-PERFORMANCE ATV FOR OFF-ROAD USE ONLY, FOR SPORT-TYPE RECREATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS. EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or repairing the ATV. A CAUTION indicates special precautions that must be taken to avoid damage to the ATV. A NOTE provides key information to make procedures easier or clearer. WARNING CAUTION: NOTE: * Product and specifications are subject to change without notice. EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! 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. EBU17381 AFFIX DEALER LABEL HERE YFM35RX OWNER'S MANUAL ©2007 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2007 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-11626-21-10 EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17420 TABLE OF CONTENTS SAFETY INFORMATION .............................. 1-1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ............................ 2-1 DESCRIPTION .............................................. 3-1 Left view ...................................................... 3-1 Right view.................................................... 3-1 Controls and instruments ............................ 3-2 INSTRUMENT AND CONTROL FUNCTIONS .................................................. 4-1 Main switch ................................................ 4-1 Indicator lights ............................................ 4-2 Handlebar switches .................................... 4-2 Throttle lever .............................................. 4-3 Speed limiter .............................................. 4-4 Clutch lever .................................................4-5 Brake lever ..................................................4-5 Brake pedal .................................................4-6 Parking brake lever .....................................4-6 Shift pedal ...................................................4-7 Drive select lever ........................................4-8 Fuel tank cap ..............................................4-8 Fuel .............................................................4-9 Fuel cock ..................................................4-10 Starter (choke) ..........................................4-12 Seat ..........................................................4-12 Adjusting the front shock absorber assemblies ..............................................4-13 Adjusting the rear shock absorber assembly .................................................4-15 PRE-OPERATION CHECKS ..........................5-1 Pre-operation check list ..............................5-1 Fuel .............................................................5-4 Engine oil ....................................................5-4 Front and rear brakes .................................5-5 Throttle lever ...............................................5-6 Drive chain ..................................................5-6 Tires ............................................................5-7 Measuring the tire pressure ........................5-8 Tire wear limit .............................................5-9 Chassis fasteners .......................................5-9 Instruments, lights and switches ................ 5-9 OPERATION .................................................. 6-1 Starting a cold engine ................................ 6-1 Starting a warm engine .............................. 6-3 Operating the drive select lever and driving in reverse ...................................... 6-3 Shifting ....................................................... 6-5 Engine break-in .......................................... 6-7 Parking ....................................................... 6-7 Parking on a slope ..................................... 6-8 Accessories and loading ............................ 6-9 RIDING YOUR ATV ...................................... 7-1 GETTING TO KNOW YOUR ATV............... 7-2 RIDE WITH CARE AND GOOD JUDGEMENT............................................ 7-3 BE CAREFUL WHERE YOU RIDE........... 7-11 TURNING YOUR ATV .............................. 7-17 CLIMBING UPHILL ................................... 7-18 RIDING DOWNHILL.................................. 7-21 CROSSING A SLOPE............................... 7-23 CROSSING THROUGH SHALLOW WATER ................................................... 7-25 RIDING OVER ROUGH TERRAIN ........... 7-27 SLIDING AND SKIDDING......................... 7-27 WHAT TO DO IF... .................................... 7-28 WHAT TO DO............................................7-28 PERIODIC MAINTENANCE AND MINOR REPAIR ..........................................................8-1 Owner's manual and tool kit .......................8-1 Periodic maintenance chart for the emission control system ...........................8-3 General maintenance and lubrication chart ..........................................................8-5 Checking the spark plug .............................8-9 Engine oil and oil filter element .................8-11 Cleaning the air filter element ...................8-14 Cleaning the spark arrester ......................8-18 Adjusting the carburetor ............................8-20 Adjusting the engine idling speed .............8-20 Adjusting the throttle cable free play .........8-21 Valve clearance ........................................8-22 Checking the front and rear brake pads ...8-22 Checking the brake fluid level ...................8-23 Changing the brake fluid ...........................8-24 Checking the front brake lever free play ...8-25 Checking the brake pedal position ............8-25 Adjusting the parking brake free play .......8-26 Brake light switches ..................................8-28 Adjusting the clutch lever free play ...........8-29 Drive chain slack .......................................8-30 Lubricating the drive chain ........................8-32 Checking and lubricating the cables ........ 8-33 Checking and lubricating the brake and clutch levers ........................................... 8-33 Checking and lubricating the brake and shift pedals ............................................. 8-34 Checking the wheel hub bearings ............ 8-35 Lubricating the swingarm pivots ............... 8-35 Lubricating the rear suspension relay arm and connecting arm pivoting points ........ 8-35 Lubricating the upper and lower arm pivots ...................................................... 8-36 Lubricating the steering shaft ................... 8-37 Battery ...................................................... 8-38 Replacing the fuse ................................... 8-40 Replacing a headlight bulb ....................... 8-40 Adjusting a headlight beam ...................... 8-43 Replacing the tail/brake light bulb ............ 8-43 Removing a wheel .................................... 8-44 Installing a wheel ...................................... 8-44 Troubleshooting ....................................... 8-45 Troubleshooting chart .............................. 8-46 CLEANING AND STORAGE.......................... 9-1 Cleaning ..................................................... 9-1 Storage ....................................................... 9-2 SPECIFICATIONS .......................................10-1 CONSUMER INFORMATION.......................11-1 Identification numbers ...............................11-1 Noise regulation ........................................11-3 Maintenance record ..................................11-4 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY .........11-5 YAMAHA EXTENDED SERVICE (Y.E.S.) ...................................................11-7 EBU17430 SAFETY INFORMATION EBU17442 1 G AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: G Read this manual and all labels carefully and follow the operating procedures described. G Never operate an ATV without proper training or instruction. Take a Training Course. Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1800-887-2887 to find out about the training courses nearest you. G Always follow the age recommendation: ­ A child under 16 years old should never operate an ATV with engine size greater than 90 cc. 1-1 G G G G G G G Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely. Never carry a passenger on an ATV. Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. Never operate an ATV on any public street, road or highway, even a dirt or gravel one. 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, a long-sleeved shirt or a jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the riding conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience. Never attempt wheelies, jumps, or other stunts. G 1 G G G G G 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. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. 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. Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds and never turn at excessive speeds. Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. G G G G 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. 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. 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. Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use the proper gear and maintain a steady 1-2 G G G G speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. 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. 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. Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings. G Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. G Always use the size and type of tires specified in this manual. G Always maintain proper tire pressure as described in this manual. G Never modify an ATV through improper installation or use of accessories. G Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor's Safety Hotline at 1-800-852-5344. 1 1-3 EWB00021 WARNING 1 POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling. Never refuel while smoking, or in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers. When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the "OFF" position. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, seek medical help immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. EWB00030 WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. 1-4 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. 1 1-5 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 2 2-1 EBU17670 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replacement label from your Yamaha dealer. 2 2-2 2 2-3 EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 3 1. Front shock absorber assembly spring preload adjusting ring 2. Fuel cock 3. Throttle stop screw 4. Air filter case 5. Battery 6. Owner's tool kit 7. Oil filter element 8. Shift pedal 1. Spark arrester 2. Fuse 3. Rear shock absorber assembly spring preload adjusting nut 4. Drive select lever 5. Fuel tank cap 6. Spark plug 7. Engine oil filler cap 8. Brake pedal 9. Rear brake light switch 10.Rear brake fluid reservoir 3-1 EBU17712 Controls and instruments 3 1. 2. 3. 4. 5. 6. 7. Clutch lever Parking brake lever Front brake fluid reservoir Brake lever Throttle lever Main switch Handlebar switches NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual. 3-2 EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17760 Main switch The positions of the main switch are as follows: ON All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed. OFF All electrical systems are off. The key can be removed. 4 1. Main switch 4-1 EBU17791 EBU18061 Indicator lights Handlebar switches 4 1. Reverse indicator light "R" 2. Neutral indicator light "N" EBU17830 1. Light switch " / 2. Engine stop switch " 3. Start switch " " EBU18080 /OFF" / " Reverse indicator light " " This indicator light comes on when the transmission is in the reverse position. EBU17860 Neutral indicator light " " This indicator light comes on when the transmission is in the neutral position. Engine stop switch " / " Set this switch to " " before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation. The engine will not start or run when this switch is set to " ". 4-2 EBU18100 EBU18270 Start switch " " Push this switch to crank the engine with the starter. ECB00050 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the ATV by varying the throttle position. Because the throttle is springloaded, the ATV will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. CAUTION: See the starting instructions on page 6-1 prior to starting the engine. EBU18151 4 Light switch " / /OFF" Set this switch to " " to turn on the low beams and the taillight. Set the switch to " " to turn on the high beams and the taillight. Set the switch to "OFF" to turn off all the lights. ECB00040 CAUTION: Do not use the headlights with the engine turned off for an extended period of time, otherwise the battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. 1. Throttle lever Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. 4-3 EWB00200 WARNING POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident. HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can't find or solve the problem yourself. EBU18311 crease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b). 4 1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in) 3. Tighten the locknut. EWB00190 Speed limiter Your ATV was delivered with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (a). To de4-4 WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 2.0­4.0 mm (0.08­0.16 in). (See page 8-21.) EBU18382 4 Clutch lever The clutch lever is located on the left handlebar and the ignition circuit cut-off system is incorporated in the clutch lever holder. To disengage the clutch, pull the clutch lever toward the handlebar grip. To engage the clutch, release the clutch lever. The clutch lever should be pulled rapidly and released slowly for smooth clutch operation. (See page 6-1 for a description of the ignition circuit cutoff system.) 1. Clutch lever EBU18411 Brake lever The brake lever is located at the right handlebar grip. To apply the front brake, pull the brake lever toward the handlebar grip. 4-5 4 1. Brake lever EBU18432 1. Brake pedal EBU18510 Brake pedal The brake pedal is located on the right side of the ATV. To apply the rear brake, push down on the brake pedal. Parking brake lever Use the parking brake before starting the engine or parking the ATV, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a). To release the parking brake, move the parking brake lever in direction (b). 4-6 EWB00170 WARNING 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. HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine. Always be sure you have released the parking brake before you begin to ride. EBU18530 4 1. Parking brake lever (locked position) Shift pedal 1. Parking brake lever (unlocked position) This ATV is equipped with a constant-mesh 6speed transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting. 4-7 4 1. Shift pedal EBU18571 1. Drive select lever EBU18720 Drive select lever The drive select lever is used for driving the ATV either forward or in reverse. See the "Operating the drive select lever and driving in reverse" section on page 6-3 for the drive select lever operation. Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 4-8 4 1. Fuel tank filler tube 2. Fuel level 1. Fuel tank cap EBU18730 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 9.0 L (2.38 US gal) (1.98 Imp.gal) Fuel reserve amount: 2.7 L (0.71 US gal) (0.59 Imp.gal) ECB00070 CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. 4-9 Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost. 4 Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or ATV performance problems. EWB00270 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. EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while also filtering it. The fuel cock lever positions are explained as follows and shown in the illustrations. WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. 4-10 OFF ON 4 1. Arrow mark pointing to "OFF" 1. Arrow mark pointing to "ON" With the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running. With the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding. 4-11 RES Move the starter (choke) in direction (b) to turn off the starter (choke). See the "Starting a cold engine" section on page 6-1 for proper operation. 4 1. Arrow mark pointing to "RES" This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to "ON"! EBU18850 1. Starter (choke) " EBU18880 " Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear. Starter (choke) " " Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the starter (choke) in direction (a) to turn on the starter (choke). 4-12 4 1. Seat lock lever 1. Projection 2. Seat holder EBU18980 To install the seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted. Adjusting the front shock absorber assemblies The spring preload can be adjusted to suit the rider's weight and the riding conditions. Adjust the spring preload as follows. Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to decrease the spring preload and thereby soften the suspension. 4-13 4 1. Spring preload adjusting ring 2. Position indicator 1. Special wrench NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. Spring preload setting: Minimum (soft): 1 Standard: 3 Maximum (hard): 5 EWB00350 WARNING POTENTIAL HAZARD Improper shock absorber assembly adjustment. 4-14 WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorber assemblies on the left and right side to the same setting. EBU19030 4 Adjusting the rear shock absorber assembly The spring preload can be adjusted to suit the rider's weight and the riding conditions. Adjust the spring preload as follows. 1. Loosen the locknut. 2. Turn the adjusting nut in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to decrease the spring preload and thereby soften the suspension. 1. Locknut 2. Spring preload adjusting nut NOTE: G A special wrench can be obtained at a Yamaha dealer to make this adjustment. G The spring preload setting is determined by measuring distance A, shown in the illustration. The shorter distance A is, the higher the spring preload; the longer distance A is, the lower the spring preload. With each complete turn of the adjusting nut, distance A is changed by 1.5 mm (0.06 in). 4-15 1 4 1. Special wrench 1. Distance A Spring preload setting: Minimum (hard): Distance A = 218.5 mm (8.6 in) Standard: Distance A = 228.5 mm (9.0 in) Maximum (soft): Distance A = 233.5 mm (9.2 in) ECB00090 3. Tighten the locknut to the specified torque. Tightening torque: Locknut: 42 Nm (4.2 m·kgf, 30 ft·lbf) ECB00080 CAUTION: Never turn an adjusting mechanism beyond the minimum and maximum settings. CAUTION: Always tighten the locknut against the adjusting nut, and then tighten it to the specified torque. 4-16 EWB00380 WARNING POTENTIAL HAZARD This shock absorber assembly contains highly pressurized nitrogen gas. WHAT CAN HAPPEN The shock absorber assembly could explode, causing injury or property damage. Cylinder damage could also result in poor handling which could cause an accident. HOW TO AVOID THE HAZARD G Do not tamper with or attempt to open the cylinder assembly. G Do not subject the shock absorber assembly to an open flame or other high heat. G Do not deform or damage the cylinder in any way. G Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha dealer for any service. EWB00010 4 WARNING Indicates a potential hazard that could result in serious injury or death. 4-17 EBU19200 PRE-OPERATION CHECKS EBU19212 Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table. EWB00470 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer. ITEM Fuel ROUTINE · Check fuel level in fuel tank, and add recommended fuel if necessary. · Check fuel line for leakage. Correct if necessary. PAGE 4-9, 5-4 5 5-1 ITEM Engine oil ROUTINE · Check oil level in engine, and add recommended oil to specified level if necessary. · Check ATV for oil leakage. Correct if necessary. · Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. · Check brake pads for wear, and replace if necessary. · Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary. · Check hydraulic system for leakage. Correct if necessary. · Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. · Check brake pads for wear, and replace if necessary. · Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary. · Check hydraulic system for leakage. Correct if necessary. · Check operation, and correct if necessary. · Lubricate cable if necessary. · Check lever free play, and adjust if necessary. · Make sure that operation is smooth. Lubricate cable and lever housing if necessary. · Check cable free play, and adjust if necessary. · Make sure that operation is smooth. Lubricate if necessary. · Check chain slack, and adjust if necessary. · Check chain condition. Lubricate if necessary. · Check wheel condition, and replace if damaged. · Check tire condition and tread depth. Replace if necessary. · Check air pressure. Correct if necessary. · Make sure that operation is smooth. Lubricate pedal pivoting points if necessary. · Make sure that operation is smooth. Lubricate lever pivoting points if necessary. 5-2 PAGE 5-4, 8-11 Front brake 5-5, 8-22, 8-23, 8-25 5 5-5, 8-22, 8-23, 8-25 Rear brake Clutch 8-29 Throttle lever Control cables Drive chain Wheels and tires Brake and shift pedals Brake and clutch levers 5-6, 8-21 8-33 5-6, 8-30, 8-32 5-7, 5-8, 5-9 8-34 8-33 ITEM Chassis fasteners Instruments, lights and switches ROUTINE · Make sure that all nuts, bolts and screws are properly tightened. · Check operation, and correct if necessary. PAGE 5-9 5-9 5 5-3 EBU19530 Fuel Make sure that there is sufficient fuel in the tank. (See page 4-9.) EWB00500 WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely. Do not refuel right after the engine has been running and is still very hot. EBU19560 5 Engine oil Make sure that the engine oil is at the specified level. Add oil as necessary. (See page 8-11.) 5-4 EBU19700 Front and rear brakes Brake lever and brake pedal G Check that there is no free play in the brake lever. If there is free play, have a Yamaha dealer check the brake system. G Check for correct brake pedal height. (See page 8-25.) If the pedal height is incorrect, have a Yamaha dealer adjust it. G Check the operation of the lever and pedal. They should move smoothly and there should be a firm feeling when the brakes are applied. If not, have a Yamaha dealer check the brake system. Brake fluid level Check the brake fluid level. Add fluid if necessary. (See page 8-23.) Recommended brake fluid: DOT 4 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs. Apply the brakes firmly for one minute. If there is any leakage, have a Yamaha dealer check the brake system. Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, check the brake pads for wear. (See page 8-22.) EWB00540 5 WARNING POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have a Yamaha dealer check for the cause. 5-5 EBU19761 Throttle lever Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary. EBU19770 Drive chain Check the condition of the drive chain and check the drive chain slack. Lubricate and adjust the drive chain as necessary. (See page 8-30.) 5 5-6 EBU19781 Tires EWB00561 WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. HOW TO AVOID THE HAZARD G The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. Other tire combinations are not recommended. Front: Manufacturer/model: DUNLOP/KT851B Size: AT21 x 7-10 Type: Tubeless G 5 Rear: Manufacturer/model: DUNLOP/KT877A Size: AT20 x 10-9 Type: Tubeless The tires should be set to the recommended pressure: Recommended tire pressure: Front: 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Rear: 25.0 kPa (3.6 psi) (0.250 kgf/cm²) · Check and adjust tire pressures when the tires are cold. · Tire pressures must be equal on both sides. 5-7 G G G Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure: Front: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Use no more than the following pressures when seating the tire beads. Maximum tire seating pressure: Front: 250 kPa (36 psi) (2.5 kgf/cm²) Rear: 250 kPa (36 psi) (2.5 kgf/cm²) Higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully. NOTE: The low-pressure tire gauge is included as standard 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 1. Low-pressure tire gauge EBU19820 Measuring the tire pressure Use the low-pressure tire gauge. Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications: 5-8 5 Recommended pressure: Front 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: Front 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Rear 28.0 kPa (4.1 psi) (0.280 kgf/cm²) EBU19830 1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened. EBU19850 Tire wear limit Replace the tire when the tire groove decreases to 3 mm (0.12 in). Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary. 5-9 EBU19870 OPERATION EWB00010 EBU20151 WARNING Indicates a potential hazard that could result in serious injury or death. EBU19890 Starting a cold engine EWB00620 WARNING POTENTIAL HAZARD Frozen control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or collision. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding. ECB00150 EWB00610 WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner's Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer. 6 CAUTION: See the "Engine break-in" section on page 6-7 prior to operating the engine for the first time. 1. Set the parking brake. 2. Turn the fuel cock to "ON". 3. Turn the main switch to "ON" and the engine stop switch to " ". 6-1 4. Shift the transmission into neutral. The neutral indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. NOTE: This model is equipped with an ignition circuit cutoff system. The engine can be started under the following conditions. G The transmission is in neutral. G The clutch is disengaged with the shift pedal and the drive select lever in any position. However, it is recommended to shift into neutral before starting the engine. 5. Use the starter (choke) in reference to the figure: Position (1): Cold engine start with ambient temperature below 5 °C (40 °F). Position (2): Cold engine start with ambient temperature between 0 °C (30 °F) and 30 °C (90 °F). Position (3): Cold engine start with ambient temperature above 25 °C (80 °F). Ambient temp./starter (choke) position 6 1. 2. 3. 4. Fully open Half open Closed Starter (choke) 6. Completely close the throttle lever and start the engine by pushing the start switch. NOTE: If the engine fails to start, release the start switch, then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. 6-2 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the engine. If the engine is started with the starter (choke) in position (2), keep the starter (choke) in this position to warm up the engine. ECB00160 EBU20330 Operating the drive select lever and driving in reverse ECB00170 CAUTION: Before shifting, stop the ATV, otherwise the transmission may be damaged. Shifting: Reverse to Forward 1. Bring the ATV to a complete stop. 2. Pull in the clutch lever to disengage the clutch. 3. Apply the brake pedal. 4. While pulling the drive select lever handle upward, move the drive select lever forward until it completely stops. CAUTION: For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold! 8. Continue warming up the engine until it idles smoothly, then return the starter (choke) to position (3) before riding. NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off. EBU20291 6 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. 6-3 NOTE: When in reverse, the reverse indicator light should be on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 5. Check behind you for people or obstacles, and then release the brake pedal. 6. Open the throttle lever gradually and release the clutch lever slowly. Continue to watch to the rear while backing. EWB00660 6 1. 2. 3. 4. Drive select lever Drive select lever handle For forward drive For reverse drive WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or even a person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no people or obstacles behind you. When it is safe to proceed, go slowly. 5. Release the brake pedal. 6. Open the throttle lever gradually and release the clutch lever slowly. Shifting: Forward to Reverse 1. Bring the ATV to a complete stop. 2. Pull in the clutch lever to disengage the clutch. 3. Apply the brake pedal. 4. While pulling the drive select lever handle upward, move the drive select lever to the rear until it completely stops. 6-4 EBU20530 EBU20580 Shifting This ATV has a 6-speed forward and 1-speed reverse transmission. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, return the throttle lever to the closed position, apply the clutch, and then repeatedly depress the shift pedal until it stops. When it stops, it will be in first gear. Raise the pedal slightly to reach the neutral position. To start out and accelerate 1. Release the throttle lever, and then release the parking brake. ECB00200 CAUTION: Always close the throttle before shifting gears, otherwise damage to the engine and drive train may result. 2. Pull the clutch lever to disengage the clutch. 3. Shift into first gear. 4. Open the throttle gradually and at the same time, release the clutch lever slowly. 5. Once the ATV has attained adequate speed, release the throttle, and at the same time, quickly pull in the clutch lever. 6. Shift the transmission into second gear. (Make sure not to shift the transmission into neutral) 7. Open the throttle part way and gradually release the clutch lever. 8. Follow the same procedure when shifting to the next higher gear. 6 1. Shift pedal 2. Neutral position 6-5 EWB00680 EWB00650 WARNING POTENTIAL HAZARD Opening the throttle abruptly or releasing the clutch lever too quickly. WHAT CAN HAPPEN The ATV could wheelie. This would increase the chance of an accident, including overturn. HOW TO AVOID THE HAZARD Open the throttle gradually. Release the clutch lever gradually. EBU20640 WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating and lose traction. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear. ECB00180 6 To decelerate When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident. CAUTION: G Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the ATV for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission. 6-6