Yamaha raptor 700 мануал

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5. Raptor 700R YFM70RSPX
6. Owner’s manual

• Page 1
  READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM70RSPX This A WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-21-12 1S3-28199-15…
• Page 2
  EBU17091…
• Page 3
  Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
• Page 4
  EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury WARNING…
• Page 5
  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.

• Page 6: Table Of Contents

  EWB00010 Clutch lever ……….4-6 WARNING Brake lever ……….4-6 Brake pedal ……….4-7 Indicates a potential hazard that could result in Parking brake lever ……..4-7 serious injury or death. Shift pedal ……….4-8 Reverse knob “REV” ……..4-9 Fuel tank cap ……….

• Page 7
  Starting the engine ……..6-1 Periodic maintenance chart for the emission control system ……8-3 Operating the reverse knob and driving in reverse ………… 6-2 General maintenance and lubrication chart …………8-4 Shifting …………6-3 Removing and installing the panel ….. 8-7 Engine break-in ………
• Page 8
  Checking and lubricating the brake and YAMAHA EXTENDED SERVICE shift pedals ……….8-37 (Y.E.S.) ……….11-7 Checking the wheel hub bearings … 8-37 Lubricating the swingarm pivots ….8-37 Lubricating the upper and lower arm pivots …………. 8-38 Battery …………. 8-39 Replacing a fuse ……..

• Page 9: Safety Information

  EBU17430 SAFETY INFORMATION SAFETY INFORMATION EBU26661 – A child under 16 years old should never oper- ate an ATV with engine size greater than 90 cc. AN ATV IS NOT A TOY AND CAN BE HAZARD- Never allow a child under age 16 to operate an OUS TO OPERATE.

• Page 10
  that is proper for the terrain, visibility, operating before attempting larger hills. conditions, and your experience. Always follow proper procedures for climbing Never attempt wheelies, jumps, or other stunts. hills as described in this manual. Check the ter- Always inspect your ATV each time you use it to rain carefully before you start up any hill.
• Page 11
  ing, use the proper gear and maintain a steady Always be sure there are no obstacles or people speed when climbing a hill. If you stall or roll behind you when you operate in reverse. When backwards, follow the special procedure for it is safe to proceed in reverse, go slowly.
• Page 12
  EWB02320 HOW TO AVOID THE HAZARD WARNING If you should swallow some gasoline or in- POTENTIAL HAZARD hale a lot of gasoline vapor, or get some gas- Improper handling of gasoline. oline in your eyes, seek medical help WHAT CAN HAPPEN immediately.

• Page 13: Location Of The Warning And Specification Labels

  EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS…

• Page 14
  Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer.
• Page 15
  WARNING WARNING Improper ATV use can result in SEVERE INJURY or DEATH. UNDER ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR Operating this ATV if you are under NEVER operate : without proper training or instruction.
• Page 16
  WARNING WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN NEVER ride as a CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE passenger. INJURY OR DEATH. OPERATING TIRE PRESSURE: Set with tires cold Passengers can cause Recommended : FRONT : 27.5 kPa, { 0.275 kgf/cm } 4.0 psi a loss of control, REAR : 27.5 kPa, { 0.275 kgf/cm…

• Page 17: Description

  EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Engine oil tank 1. Spark arrester 2. Coolant reservoir 2. Seat 3. Idle adjusting screw 3. Headlight 4. Tail/brake light 4. Brake pedal 5. Shift pedal…

• Page 18: Controls And Instruments

  EBU17712 from the figures shown in this manual. Controls and instruments 1. Clutch lever 2. Parking brake lever 3. Main switch 4. Brake lever 5. Throttle lever 6. Reverse knob 7. Fuel tank cap 8. Handlebar switches NOTE: The ATV you have purchased may differ slightly…

• Page 19: Instrument And Control Functions

  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: 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.

• Page 20: Indicator Lights And Warning Lights

  The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on, and then go off, have a Yamaha dealer check the electrical circuit. ECB00010 CAUTION: 1. Neutral indicator light “N”…

• Page 21: Handlebar Switches

  ” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the self-diagnosis system. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning 1.

• Page 22: Throttle Lever

  EBU18090 tle lever will increase the engine speed. Start switch “START” Regulate the speed of the ATV by varying the Push this switch to crank the engine with the start- throttle position. Because the throttle is spring- loaded, the ATV will decelerate, and the engine will ECB00050 return to an idle any time the hand is removed from CAUTION:…

• Page 23: Speed Limiter

  Check the operation of the throttle lever be- fore 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. 1. Locknut EBU18311 2.

• Page 24: Clutch Lever

  EWB00190 off system.) WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Im- proper throttle operation could result. You could lose control, have an accident or be in- jured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in).

• Page 25: Brake Pedal

  1. Brake lever 1. Brake pedal 2. Locknut 3. Brake lever position adjusting bolt EBU18510 4. Distance between brake lever and handlebar grip Parking brake lever Use the parking brake before starting the engine or EBU18432 Brake pedal parking the ATV, especially on a slope. To apply the parking brake, move the parking brake lever in The brake pedal is located on the right side of the direction (a).

• Page 26: Shift Pedal

  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 start- ing the engine. This could cause loss of con- trol or a collision. The brake could overheat if you ride the ATV without releasing the parking brake.

• Page 27: Reverse Knob «Rev

  when shifting. 1. Reverse knob “REV” 1. Shift pedal EBU18720 Fuel tank cap EBU18641 Reverse knob “REV” Remove the fuel tank cap by turning it counter- The reverse knob is used to shift into reverse. See clockwise. the “Operating the reverse knob and driving in re- verse”…

• Page 28: Fuel

  1. Filler tube 1. Fuel tank cap 2. Fuel level EBU18730 Fuel Recommended fuel: Make sure that there is sufficient fuel in the tank. UNLEADED GASOLINE ONLY Fill the fuel tank to the bottom of the filler tube as Fuel tank capacity: shown.

• Page 29: Seat

  WHAT CAN HAPPEN Fuel can spill, which can cause a fire and se- Your Yamaha engine has been designed to use vere injury. regular unleaded gasoline with a pump octane Fuel expands when it heats up. If the fuel…

• Page 30: Adjusting The Front Shock Absorber Assemblies

  1. Seat lock lever 1. Projection 2. Seat holder To install the seat EBU27892 Insert the projections on the front of the seat into Adjusting the front shock absorber the seat holders and push down on the seat at the assemblies rear.

• Page 31
  Do not dispose of a damaged or worn out shock absorber assembly yourself. Take NOTE: the shock absorber assembly to a Yamaha A special wrench can be obtained at a Yamaha dealer for any service. dealer to make this adjustment. The spring preload setting is determined by Spring preload measuring distance A, shown in the illustration.
• Page 32
  adjusting nut, distance A is changed by 1.5 mm 3. Tighten the locknut to the specified torque. (0.06 in). Tightening torque: Locknut: Spring preload setting: 30 Nm (3.0 m·kgf, 22 ft·lbf) Minimum (hard): Distance A = 246.5 mm (9.7 in) ECB00080 Standard: CAUTION:…
• Page 33
  Compression damping force Compression damping force (for fast compression damping) 1. To increase the compression damping force and thereby harden the compression damp- ing, turn the adjusting bolt in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting bolt in direction (b).
• Page 34
  Compression damping setting (for fast com- pression damping): Minimum (soft): Adjusting bolt 3 turn(s) out from the fully turned in position Standard: Adjusting bolt 1 1/4 turn(s) out from the ful- ly turned in position Maximum (hard): Adjusting bolt fully turned in 1.

• Page 35: Specifications

  the minimum and maximum settings. EWB00350 WARNING NOTE: POTENTIAL HAZARD Improper shock absorber assembly adjust- Although the total number of clicks of a damping ment. force adjusting mechanism may not exactly match WHAT CAN HAPPEN the above specifications due to small differences in Uneven adjustment can cause poor handling production, the actual number of clicks always rep- and loss of stability, which could lead to an…

• Page 36
  Do not dispose of a damaged or worn out shock absorber assembly yourself. Take NOTE: the shock absorber assembly to a Yamaha A special wrench can be obtained at a Yamaha dealer for any service. dealer to make this adjustment. The spring preload setting is determined by Spring preload measuring distance A, shown in the illustration.
• Page 37
  adjusting nut, distance A is changed by 1.5 mm 3. Tighten the locknut to the specified torque. (0.06 in). Tightening torque: Locknut: Spring preload setting: 42 Nm (4.2 m·kgf, 30 ft·lbf) Minimum (hard): Distance A = 228 mm (8.98 in) ECB00080 Standard: CAUTION:…
• Page 38
  damping) 1. To increase the compression damping force and thereby harden the compression damp- ing, turn the adjusting bolt in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting bolt in direction (b). 1.
• Page 39
  Compression damping setting (for fast com- pression damping): Minimum (soft): Adjusting bolt 4 turn(s) out from the fully turned in position Standard: Adjusting bolt 2 turn(s) out from the fully turned in position Maximum (hard): Adjusting bolt fully turned in 1.
• Page 40
  the minimum and maximum settings. EWB00010 WARNING NOTE: Indicates a potential hazard that could result in Although the total number of clicks of a damping serious injury or death. force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always rep- resents the entire adjusting range.

• Page 41: Pre-Operation Checks

  Always follow the inspection and maintenance procedures and schedules described in the Own- er’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.

• Page 42
  Coolant specified level if necessary. 5-4, 8-14 Check cooling 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. Front brake 5-5, 8-25, 8-26, 8-28 Check brake fluid level in reservoir, and add recommended brake…
• Page 43
  ITEM ROUTINE PAGE Check wheel condition, and replace if damaged. Wheels and tires Check tire condition and tread depth. Replace if necessary. 5-6, 5-7, 5-8 Check air pressure. Correct if necessary. Make sure that operation is smooth. Lubricate pedal pivoting points Brake and shift pedals 8-37 if necessary.

• Page 44: Fuel

  EBU19530 EBU19620 Fuel Coolant Make sure that there is sufficient fuel in the tank. Make sure that the coolant is at the specified level. (See page 4-10.) Add coolant as necessary. (See page 8-14.) EWB00500 NOTE: WARNING The coolant level must be checked on a cold en- POTENTIAL HAZARD gine since the level varies with engine tempera- Improper care when refueling.

• Page 45: Front And Rear Brakes

  Check that there is no free play in the brake le- make sure they are working properly. If the brakes ver. If there is free play, have a Yamaha dealer do not provide proper braking performance, check check the brake system.

• Page 46: Drive Chain

  HOW TO AVOID THE HAZARD The tires listed below have been approved EBU19770 by Yamaha Motor Co., Ltd. for this model. Drive chain Other tire combinations are not recom- Check the condition of the drive chain and check mended.

• Page 47: Measuring The Tire Pressure

  The tires should be set to the recommend- Maximum tire seating pressure: ed pressure: Front: Recommended tire pressure: 250 kPa (36 psi) (2.5 kgf/cm Front: Rear: 27.5 kPa (4.0 psi) (0.275 kgf/cm 250 kPa (36 psi) (2.5 kgf/cm Rear: Higher pressures and fast inflation may 27.5 kPa (4.0 psi) (0.275 kgf/cm cause a tire to burst.

• Page 48: Tire Wear Limit

  Recommended pressure: Front 27.5 kPa (4.0 psi) (0.275 kgf/cm Rear 27.5 kPa (4.0 psi) (0.275 kgf/cm Minimum: Front 24.5 kPa (3.5 psi) (0.245 kgf/cm Rear 24.5 kPa (3.5 psi) (0.245 kgf/cm 1. Low-pressure tire gauge Maximum: Front Set the tire pressure when the tires are cold. Set 30.5 kPa (4.4 psi) (0.305 kgf/cm the tire pressures to the following specifications: Rear…

• Page 49: Chassis Fasteners

  1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.

• Page 50: Operation

  See the “Engine break-in” section on page 6-5 a control or function you do not understand, prior to operating the engine for the first time. ask your Yamaha dealer. 1. Set the parking brake. 2. Turn the main switch to “ON” and the engine stop switch to “RUN”.

• Page 51: Operating The Reverse Knob And Driving In Reverse

  For maximum engine life, always warm the en- indicator light should come on, if it does not gine up before starting off. Never accelerate come on, have a Yamaha dealer check the hard when the engine is cold! electrical circuit.

• Page 52: Shifting

  If the indicator light does not come on, closed position, apply the clutch, and then repeat- have a Yamaha dealer check the electrical circuit. edly depress the shift pedal until it stops. 4. Check behind you for people or obstacles, When it stops, it will be in first gear.

• Page 53
  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.

• Page 54: Engine Break-In

  tle and apply the brakes smoothly and evenly. As ning. Inadequate lubrication may damage you slow down, shift to a lower gear. Be sure that the transmission. the engine has sufficiently slowed before engaging Always use the clutch when changing gears. a lower gear.

• Page 55: Parking

  ECB00220 CAUTION: If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV. EBU26760 Parking When parking the ATV, stop the engine, shift into first gear, and then apply the parking brake.

• Page 56: Parking On A Slope

  EBU20870 4. With the front and rear brakes applied, pull the Parking on a slope clutch lever, shift into first gear, and then re- EWB00800 lease the clutch lever, brake lever and brake WARNING pedal. POTENTIAL HAZARD NOTE: Parking on a hill or other incline. Make sure that the neutral indicator light goes off.

• Page 57
  However, judgment as the stability and handling of an ATV it is not possible for Yamaha to test all non- can be changed. When adding accessories, keep Yamaha accessories, nor control over their qual- the following points in mind: ity or suitability.
• Page 58
  Make sure the load does not interfere with con- HOW TO AVOID THE HAZARD trols or your ability to see where you are going. Never exceed the stated load capacity for Ride more slowly than you would without a load. this ATV.

• Page 59: Riding Your Atv

  EBU21131 RIDING YOUR ATV…

• Page 60: Getting To Know Your Atv

  EWB00010 RIDE WITH CARE AND GOOD JUDGEMENT WARNING Get training if you are inexperienced. Indicates a potential hazard that could result in Beginners should get training from a certified in- serious injury or death. structor. Become familiar with this ATV at slow speeds first, EBU21591 even if you are an experienced operator.

• Page 61
  A child under 16 should never operate an should complete the certified training course ATV with engine size greater than 90 cc. offered by Yamaha. They should then regu- larly practice the skills learned in the course and the operating techniques described in this Owner’s Manual.
• Page 62
  This ATV is designed to carry operator only – passengers prohibited. EWB00910 WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passen- ger.
• Page 63
  WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an acci- dent. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.
• Page 64
  Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety. EWB00940 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 EWB00930…
• Page 65
  WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Use of improper tires on this ATV, or opera- Always go at a speed that is proper for the tion of this ATV with improper or uneven tire terrain, visibility and operating conditions, pressure, may cause loss of control, increas- and your experience.
• Page 66
  MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 100.0 kg (220 lb) EWB00970 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. 1. Locknut WHAT CAN HAPPEN 2. Adjusting screw Could cause changes in ATV handling which could lead to an accident.
• Page 67
  During operation WHAT CAN HAPPEN Always keep your feet on the footboards during op- Removing even one hand or foot can reduce eration, otherwise they may contact the rear your ability to control the ATV or could cause wheels. you to lose your balance and fall off of the ATV.
• Page 68
  Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions.

• Page 69: Be Careful Where You Ride

  EWB01020 HOW TO AVOID THE HAZARD WARNING Do not operate, idle, or park the ATV in dry POTENTIAL HAZARD grass or other dry ground cover. Operating this ATV on paved surfaces. Keep the engine area free of dry grass, WHAT CAN HAPPEN brush, or other combustible material.

• Page 70
  HOW TO AVOID THE HAZARD 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. Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles.
• Page 71
  EWB01040 WARNING 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.
• Page 72
  EWB01050 WARNING 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 ATV control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control…
• Page 73
  mission. EWB01060 Select a large, flat area off-road to become familiar WARNING with your ATV. Make sure that this area is free of POTENTIAL HAZARD obstacles and other riders. You should practice Operating in areas where you might not be control of the throttle, brakes, shifting procedures, seen by other off-road vehicles.
• Page 74
  do not allow skin or clothing to come in contact with WHAT CAN HAPPEN these components. The ATV could wheelie. This would increase With the engine idling, pull the clutch lever to dis- the chance of an accident, including over- engage the clutch and shift into 1st gear, and then turn.

• Page 75: Turning Your Atv

  WHAT CAN HAPPEN HOW TO AVOID THE HAZARD The wheels could stop rotating. This could Always follow proper procedures for turning cause loss of control, an accident and injury. as described in this Owner’s Manual. Prac- It could also cause engine or drive train dam- tice turning at low speeds before attempting age.

• Page 76: Climbing Uphill

  be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside.

• Page 77
  WHAT CAN HAPPEN HOW TO AVOID THE HAZARD The ATV can overturn more easily on ex- Always follow proper procedures for climb- tremely steep hills than on level surfaces or ing hills as described in this Owner’s Manual. small hills. Always check the terrain carefully before you HOW TO AVOID THE HAZARD start up any hill.
• Page 78
  WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground.
• Page 79
  EWB01251 WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dis- mounting while climbing a hill. WHAT CAN HAPPEN Could result in the ATV overturning. HOW TO AVOID THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.

• Page 80: Riding Downhill

  braking may also cause a loss of traction. Whenever possible, ride your ATV straight down- hill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- stacles which may appear.

• Page 81: Crossing A Slope

  HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owner’s Man- ual. Note: a special technique is required when braking as you go down a hill. Always check the terrain carefully before you start down any hill.

• Page 82: Crossing Through Shallow Water

  steering when riding on loose surfaces by pointing When crossing the side of a hill: the front wheels slightly uphill. When riding on Always follow proper procedures as de- slopes, be sure not to make sharp turns either up scribed in the Owner’s Manual. or down hill.

• Page 83
  low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and care- fully.

• Page 84: Riding Over Rough Terrain

  1. Air filter case check hose RIDING OVER ROUGH TERRAIN ECB00240 Riding over rough terrain should be done with cau- CAUTION: tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- After riding your ATV in water, be sure to drain cident.

• Page 85: Sliding And Skidding

  WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for ob- stacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper pro- cedures as described in the Owner’s Manual.

• Page 86: What To Do If

  HOW TO AVOID THE HAZARD 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 re- duce the chance of skidding or sliding out of control.

• Page 87
  Steer in the direction of the slide if you have the you come out of the water. Do not continue to room. Applying the brakes or accelerating is not ride your ATV until you have regained adequate recommended until you have corrected the braking ability.

• Page 88: Periodic Maintenance And Minor Repair

  Safety is an obligation of the owner. Periodic in- nance unless otherwise specified. Have a spection, adjustment and lubrication will keep your Yamaha dealer perform the service if you are ATV in the safest and best operating condition not familiar with maintenance work.

• Page 89
  If you have questions, consult an authorized additional tools such as a torque wrench may be Yamaha ATV dealer. necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform…

• Page 90: Periodic Maintenance Chart For The Emission Control System

  However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

• Page 91: General Maintenance And Lubrication Chart

  EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element Clean and replace if necessary. dusty areas) √…

• Page 92
  INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Upper and lower √ √ √ 10 * Lubricate with lithium-soap-based grease. arm pivots Check chain slack and adjust if necessary. Check rear wheel alignment and correct if necess- √…
• Page 93
  INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Moving parts and √ √ √ √ 20 * Lubricate. cables Check operation and correct if necessary. Throttle lever hous- Check throttle cable free play and adjust if neces- √…

• Page 94: Removing And Installing The Panel

  EWB00010 EBU23100 Panel A WARNING To remove the panel Indicates a potential hazard that could result in Remove the bolts, and then take the panel off. serious injury or death. EBU23080 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter.

• Page 95: Checking The Spark Plug

  Do not spark plug wrench included in the owner’s tool attempt to diagnose such problems yourself. In- kit. stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and…

• Page 96: Engine Oil And Oil Filter Element

  replace it if necessary. and its mating surface, and then wipe off any grime from the spark plug threads. Specified spark plug: 3. Install the spark plug with the spark plug NGK/CR8E wrench, and then tighten it to the specified torque.

• Page 97
  To check the engine oil level 1. Place the ATV on a level surface. 2. Start the engine, warm it up until the engine oil has reached a normal temperature of 60 °C (141 °F), let it continue to idle for ten seconds or more, and then turn the engine off.
• Page 98
  NOTE: When adding oil, be careful not to overfill the en- gine oil tank; the oil level rises faster starting from the half-level-portion on the dipstick. 6. Insert the dipstick into the engine oil tank filler hole, and then tighten the engine oil tank filler cap.
• Page 99
  5. Remove the engine oil tank filler cap and the engine oil tank drain bolt. 1. Oil filter element cover 2. Bolt 1. Engine oil tank drain bolt 8. Check the O-rings for damage, and replace them if necessary. 6. Check the washers for damage, and replace if necessary.
• Page 100
  11. Install the crankcase engine oil drain bolt and the engine oil tank drain bolt, and then tighten them to the specified torques. Tightening torques: Crankcase engine oil drain bolt: 23 Nm (2.3 m·kgf, 16.6 ft·lbf) Engine oil tank drain bolt: 19 Nm (1.9 m·kgf, 13.7 ft·lbf) 12.

• Page 101: Coolant

  16. Install and tighten the engine oil tank filler cap. is leaking, immediately turn the engine off and check for the cause. Recommended oil: 18. Turn the engine off, and then check the oil lev- See page 10-1. el and correct it if necessary. Oil quantity: Without oil filter element replacement: EBU23470…

• Page 102
  If water has been added to the coolant, have a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, oth- erwise the effectiveness of the coolant will be reduced.
• Page 103
  4. Remove the radiator cap. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always place a thick rag over the cap.
• Page 104
  voir to the maximum level mark, and then in- stall the reservoir cap. 11. Pour the recommended coolant into the radia- tor until it is full. Antifreeze/water mixture ratio: Recommended antifreeze: High-quality ethylene glycol antifreeze con- taining corrosion inhibitors for aluminum en- gines Coolant quantity: 1.

• Page 105: Cleaning The Air Filter Element

  14. Start the engine, and then check for coolant leakage. NOTE: If any leakage is found, have a Yamaha dealer check the cooling system. 15. Install the panel. 1. Air filter case check hose EBU26791 1.

• Page 106
  1. Wing bolt 1. Air filter case cover 2. Air filter element 2. Air filter case cover holder 5. Remove the wing bolt and washer from the air 3. Loosen the wing bolt. filter element. 4. Remove the air filter element together with the 6.
• Page 107
  WHAT CAN HAPPEN 9. Check the sponge material and replace it if Low-flash-point solvents or gasoline can damaged. catch fire or explode. 10. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material. 8-20…
• Page 108
  13. Insert the air filter element into the air filter NOTE: case, and then tighten the wing bolt. The sponge material should be wet but not drip- 14. Install the air filter case cover by hooking the ping. holders onto the air filter case. 11.

• Page 109: Cleaning The Spark Arrester

  will affect the fuel injection system with sub- brush to remove any carbon deposits from the sequent poor performance and possible en- spark arrester portion of the tailpipe and inside gine overheating. of the tailpipe housing. EBU23872 Cleaning the spark arrester Select a well-ventilated area free of combustible materials and make sure the exhaust and muffler are cool.

• Page 110: Adjusting The Engine Idling Speed

  WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When purging the exhaust system: Always let the exhaust system cool prior to touching exhaust components.

• Page 111: Adjusting The Throttle Cable Free Play

  If the specified idling speed cannot be obtained as 2. Attach the tachometer to the spark plug lead. described above, have a Yamaha dealer make the 3. Check the engine idling speed and, if neces- adjustment. sary, adjust it to specification by turning the idle adjusting screw.

• Page 112: Valve Clearance

  The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- 1. Wear indicator groove vals specified in the periodic maintenance and lu-…

• Page 113: Checking The Brake Fluid Level

  Front brake 1. Minimum level mark 1. Wear indicator groove Rear brake EBU26821 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective. Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary.

• Page 114
  NOTE: To check the rear brake fluid level, remove the seat. (See page 4-11.) If the rear brake fluid level is low, replenish as fol- lows. 1. Remove the cowling bolt and quick fastener. 1. Cowling 2. Brake fluid reservoir cap 3.

• Page 115: Changing The Brake Fluid

  (zero in) as shown. If the free result in vapor lock. play is incorrect, have a Yamaha dealer check the Brake fluid may deteriorate painted surfaces or brake system.

• Page 116: Checking The Brake Pedal Position

  EWB02010 shown. If the brake pedal is not positioned as spec- WARNING ified, have a Yamaha dealer adjust it. POTENTIAL HAZARD Operating with improperly serviced or ad- justed brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.

• Page 117: Adjusting The Parking Brake Free Play

  Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. 1. Cable length “A” EBU26840 Adjusting the parking brake free play 1.

• Page 118: Brake Light Switches

  Yamaha dealer. The brake light switch for the brake pedal can be adjusted as follows, but the other brake light 4. Tighten the locknut on the brake cable. switches should be adjusted by a Yamaha dealer. EWB02030 WARNING NOTE:…

• Page 119: Adjusting The Clutch Lever Free Play

  switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a). To make the brake light come on later, turn the adjust- ing nut in direction (b). 1. Locknut 2. Clutch lever free play adjusting bolt 3.

• Page 120: Drive Chain Slack

  Drive chain slack: clutch lever. 25.0–35.0 mm (0.98–1.38 in) NOTE: If the specified free play cannot be obtained as de- scribed above or if the clutch does not operate cor- rectly, have a Yamaha dealer check the internal clutch mechanism. 8-33…

• Page 121
  To adjust the drive chain slack NOTE: 1. Loosen the rear axle pinch bolts. A rod can be obtained at a Yamaha dealer to make 2. Insert a rod of a diameter of 8 mm (0.3 in) and this adjustment.

• Page 122: Lubricating The Drive Chain

  ECB00541 EBU24880 Lubricating the drive chain CAUTION: The drive chain must be cleaned and lubricated at Improper drive chain slack will overload the en- the intervals specified in the periodic maintenance gine as well as other vital parts of the ATV and and lubrication chart, otherwise it will quickly wear can lead to drive chain slippage or breakage.

• Page 123: Checking And Lubricating The Cables

  If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil 8-36…

• Page 124: Shift Pedals

  If there is play in a wheel hub or if a wheel does not turn smoothly, Recommended lubricants: have a Yamaha dealer check the wheel hub bear- Brake lever: ings. Silicone grease Clutch lever: EBU24992 Lubricating the swingarm pivots…

• Page 125: Lubricating The Upper And Lower Arm Pivots

  1. Grease nipple EBU25030 Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart. Lubricate the pivoting points using a grease gun. Recommended lubricant: Lithium-soap-based grease 1.

• Page 126: Battery

  Left side Right side 1. Upper grease nipple 1. Upper grease nipple 2. Lower grease nipple 2. Lower grease nipple EBU25212 Battery This model is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water.

• Page 127
  EWB02140 To charge the battery WARNING Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in POTENTIAL HAZARD mind that the battery tends to discharge more Failure to handle batteries or battery electro- quickly if the ATV is equipped with optional electri- lyte carefully.

• Page 128: Replacing A Fuse

  To charge a sealed-type (MF) battery, a spe- cial constant-voltage battery charger is re- quired. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charg- er, have a Yamaha dealer charge your bat- tery. 8-41…

• Page 129
  fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuses: Main fuse: 20.0 A Headlight fuse: 15.0 A Ignition fuse: 10.0 A Signaling system fuse: 1. Signaling system fuse 10.0 A 2. Headlight fuse Fuel injection system fuse: 3.

• Page 130: Replacing A Headlight Bulb

  2. Bolt circuits to check if the devices operate. 4. If the fuse immediately blows again, have a 2. Disconnect the headlight coupler. Yamaha dealer check the electrical system. 3. Remove the headlight bulb holder cover. EBU25430 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.

• Page 131
  1. Headlight bulb holder 1. Headlight bulb holder cover 2. Headlight coupler EWB02180 WARNING 4. Remove the headlight bulb holder by pushing POTENTIAL HAZARD it in and turning it counterclockwise, and then A headlight bulb is hot when it is on and im- remove the defective bulb.

• Page 132: Adjusting A Headlight Beam

  EBU25560 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the adjusting bolt in direction (a). 1. Do not touch the glass part of the bulb.

• Page 133: Tail/Brake Light

  Rear Tail/brake light This model is equipped with an LED type of tail/ brake light. If the tail/brake light does not come on, have a Yamaha dealer check it. EBU25650 Removing a wheel 1. Loosen the wheel nuts. Front 1. Nut 2.

• Page 134
  Front Rear 1. Arrow mark 1. Arrow mark 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified torques. Tightening torques: Front wheel nut: 45 Nm (4.5 m·kgf, 33 ft·lbf) Rear wheel nut: 45 Nm (4.5 m·kgf, 33 ft·lbf) 8-47…

• Page 135: Troubleshooting

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

• Page 136: Troubleshooting Charts

  EBU27680 Troubleshooting charts Starting problems or poor engine performance 1. Fuel 2. Compression 3. Ignition 4. Battery 8-49…

• Page 137
  Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible.

• Page 138: Cleaning And Storage

  EBU25860 CLEANING AND STORAGE EBU25890 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.

• Page 139: Storage

  EWB02300 nia) and areas where strong chemicals are WARNING stored. POTENTIAL HAZARD Operation with wet brakes after washing. Long-term WHAT CAN HAPPEN Before storing your ATV for several months: Wet brakes may have reduced stopping abil- 1. Follow all the instructions in the “Cleaning” ity, increasing the chance of an accident.

• Page 140
  plug, and then place the spark plug on the 8-39. cylinder head so that the electrodes are NOTE: grounded. (This will limit sparking during Make any necessary repairs before storing the the next step.) ATV. d. Turn the engine over several times with the starter.

• Page 141: Specifications

  EBU25960 SPECIFICATIONS EBU2597A Compression ratio: Dimensions: 9.20 :1 Overall length: Starting system: 1845 mm (72.6 in) Electric starter Overall width: Lubrication system: 1170 mm (46.1 in) Dry sump Overall height: Engine oil: 1130 mm (44.5 in) Type: Seat height: YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 815 mm (32.1 in) Wheelbase: 0˚…

• Page 142
  Engine oil quantity: Spark plug (s): Without oil filter element replacement: Manufacturer/model: 1.75 L (1.85 US qt) (1.54 Imp.qt) NGK/CR8E With oil filter element replacement: Spark plug gap: 1.85 L (1.96 US qt) (1.63 Imp.qt) 0.7–0.8 mm (0.028–0.031 in) Cooling system: Clutch: Coolant reservoir capacity (up to the maximum level mark): Clutch type:…
• Page 143
  Reverse gear: Rear: 24/13 × 29/12 (4.462) 27.5 kPa (4.0 psi) (0.275 kgf/cm Chassis: Minimum: Front: Frame type: 24.5 kPa (3.5 psi) (0.245 kgf/cm Aluminum die-cast and steel tube frame Rear: Caster angle: 24.5 kPa (3.5 psi) (0.245 kgf/cm 5.0 ° Maximum: Trail: Front:…
• Page 144
  Rear brake: Headlight: Type: Bulb type: Single disc brake Krypton bulb Operation: Bulb voltage, wattage x quantity: Right foot operation Headlight: 12 V, 30.0/30.0 W × 2 Recommended fluid: DOT 4 Neutral indicator light: Front suspension: Type: Fuel level warning light: Double wishbone Spring/shock absorber type: Reverse indicator light:…

• Page 145: Consumer Information

  Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.

• Page 146: Model Label

  EBU26050 Model label The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- 11-2…

• Page 147: Noise Regulation

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

• Page 148: Maintenance Record

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

• Page 149: Yamaha Motor Corporation, U.s.a. Atv Limited Warranty

  (6) months from the date of purchase. appropriate owner’s manual; YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 2. Give notice to an authorized Yamaha ATV dealer OTHER WARRANTY OF ANY KIND, EXPRESSED OR of any and all apparent defects within ten (10) days DURING THE PERIOD OF WARRANTY any authorized IMPLIED.

• Page 150
  Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.
• Page 151
  Yamaha people who handle your warranty – and it Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn’t limited to much more valuable! “moving par ts”…
• Page 152
  Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
• Page 153
  EBU26132 11-9…
• Page 154
  INDEX Drive chain, lubricating……….8-35 Drive chain slack …………8-33 Accessories and loading ……….6-7 Air filter element, cleaning……….8-18 Engine break-in ………….. 6-5 Engine idling speed…………8-23 Battery…………….8-39 Engine oil …………… 5-4 Brake and clutch levers, checking and lubricating ..8-36 Engine oil and oil filter element ……..
• Page 155
  Shift pedal …………..4-8 Shock absorber assemblies, adjusting the front ..4-12 Label locations …………..2-1 Shock absorber assembly, adjusting the rear….4-17 Light switch …………..4-4 Spark arrester, cleaning……….8-22 Spark plug, checking…………8-7 Main switch …………..4-1 Specifications…………… 10-1 Maintenance and lubrication chart ……..8-4 Speed limiter …………..
• Page 156
  LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2007.04-1.6×1 !
• Page 157
  8 TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA – ASK YOUR DEALER FOR DETAILS OR CALL 1-800-887-2887 If you have any questions about these points, or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership, please fill out the information below and mail this card to yamaha today.
• Page 158
  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…

EBS00002

NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EBS00003

IMPORTANT INFORMATION

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

EBS00008

TABLE OF CONTENTS

ENGINE

ENG 4

COOLING SYSTEM

COOL 5

FUEL INJECTION SYSTEM

FI 6

CHASSIS

CHAS 7

CONTENTS

CHAPTER 1

GENERAL INFORMATION

GEN

VEHICLE IDENTIFICATION INFO

EBS00009

GENERAL INFORMATION

VEHICLE IDENTIFICATION

EBS00010

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped into the left side of the frame.

EBS00011

MODEL LABEL

The model label 1 is affixed to the air filter case cover. This information will be needed to order spare parts.

GEN

FEATURES INFO

EAS20170

FEATURES

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

Despite the same volume of intake air, the fuel volume requirement varies with the engine operating conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine.

As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors.

The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions.

The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm2, 46.1 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser the volume of fuel that is supplied.

The injection duration and the injection timing are controlled by the ECU. Signals that are input from the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, coolant temperature sensor and speed sensor enable the ECU to determine the injection duration. The injection timing is determined through the signals from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions.

Illustration is for reference only.

GEN INFO

Usually, for vehicles equipped with a parking brake that must be adjusted manually, it is necessary to adjust the adjusting bolt 5 to achieve the proper clearance between the brake caliper piston 7 and the adjusting bolt 5.

This adjustment procedure is unnecessary for vehicles equipped with a self-adjusting parking brake mechanism. The proper clearance is automatically maintained at all times, ensuring stable braking performance when parking the vehicle.

GEN INFO

When the parking brake is operated, the parking brake cable turns the parking brake arm 1. The rotation of the parking brake arm is changed to axial thrust in the parking brake shaft 2 and the adjusting bolt 3 is pushed against the adjusting bolt sleeve 4.

When the adjusting bolt sleeve receives the force, the dark shaded area in the above illustration is pushed and the brake pad 6 is pushed against the brake disc.

When the brake pad wears, the clearance between the brake caliper piston 5 and the brake pad becomes larger and the force applied to the brake pad becomes weaker.

If this occurs, the self-adjusting parking brake mechanism adjusts automatically to achieve the proper clearance.

GEN INFO

When the brake pedal is operated, the brake fluid pressure in the master cylinder increases and the brake caliper piston 1 and the nut 2 are pushed.

When there is proper clearance between the brake caliper piston and the brake pad, no other parts move because the movement of the brake caliper piston and the nut is absorbed by the backlash of the threads of the nut and the adjusting bolt 3.

When the movement of the nut is greater than the backlash between the nut and the adjusting bolt, the parking brake adjusts automatically.

The amount of the adjustment varies with brake fluid pressure. Operating the parking brake makes no adjustment.

The adjustment operation is as follows.

1.When the brake pedal is operated, the brake fluid pressure increases and the brake caliper piston and the nut move.

2.When the movement of the brake caliper piston and the nut is greater than the backlash of the threads of the nut and the adjusting bolt, the force È will be required to pull the adjusting bolt. The force to pull the adjusting bolt will be turned into the rotation torque É by the shape of the threads of the nut and the adjusting bolt.

3.At this time, the clutch torque Ê between the adjusting bolt and the adjusting bolt sleeve 4 will decrease depending on the force required to pull the adjusting bolt.

When the rotation torque exceeds the clutch torque, the adjusting bolt rotates and the clearance between the brake caliper piston and the brake pad decreases by the movement of the threads of the nut and the adjusting bolt.

GEN INFO

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND

DISASSEMBLY

1.Before removal and disassembly remove all dirt, mud, dust and foreign material.

2.Use only the proper tools and cleaning equipment.

Refer to “SPECIAL TOOLS”.

3.When disassembling always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly.

4.During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.

5.Keep all parts away from any source of fire.

EBS00014

REPLACEMENT PARTS

1.Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

EBS00015

GASKETS, OIL SEALS AND O-RINGS

1.When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.

2.During reassembly properly oil all mating parts and bearings, and lubricate the oil seal lips with grease.

1 — 7

GEN INFO

LOCK WASHERS/PLATES AND COTTER PINS

After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.

EBS00017

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

1 Oil seal

CAUTION:

Do not spin the bearing with compressed air because this will damage the bearing surfaces.

1 Bearing

EBS00018

CIRCLIPS

Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip 1, make sure the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives.

4 Shaft

1 — 8

GEN INFO

The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided.

When placing an order, refer to the list provided below to avoid any mistakes. For US and CDN

P/N. YM-, YU-, YS-, YK-, ACCExcept for US and CDN

P/N. 90890-

1 — 10

GENERAL SPECIFICATIONS SPEC

EBS01001

Oil type or grade

GENERAL SPECIFICATIONS SPEC

ENGINE SPECIFICATIONS SPEC

EBS01002

ENGINE SPECIFICATIONS

A

ENGINE SPECIFICATIONS SPEC