Yamaha YFM09RY User Manual

This A

READ THIS MANUAL CAREFULLY!

It contains important safety information.

LIRE ATTENTIVEMENT CE MANUEL!

II comprend d’importantes informations de s

!

LEA ESTE MANUAL ATENTAMENTE!

Contiene indicaciones importantes acerca de la seguridad.

écurité

.

OWNER’S MANUAL

MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO

YFM90RY

43D-F8199-60

PRINTED ON RECYCLED PAPER
IMPRIMÉ SUR PAPIER RECYCLÉ
IMPRESO EN PAPEL RECICLADO

YAMAHA MOTOR CO., LTD.

PRINTED IN TAIWAN

2008.07
(E,F,S)

READ THIS MANUAL CAREFULLY!

It contains important safety information.

OWNER’S MANUAL

YFM90RY

43D-F8199-60-E0

Read this manual carefully before operating this vehicle.This manual should stay with this ve-

hicle if it is sold.

EC Declaration of Conformity

conforming to Directive 98/37/EC

We, YAMAHA MOTOR CO.,LTD. 2500 Shingai, Iwata, Japan,declare in sole responsibility, that the product

YFM90RY (RK1AB07W080000001~)

(Make, model)

to which this declaration applies, conforms to the essential health
and safety requirements of Directive 98/37/EC,

(If applicable)

and to the other relevant Directives of EEC

(Title and/or number and date of issue of the other Directives of EEC)
(If applicable)

To effect correct application of the essential health and safety requirements
stated in the Directives of EEC, the following-standards and/or technical
specifications were consulted:

(Title and/or number and date of issue of standards and/or specifications)

Manufacturer

E-TON POWER TECH.,LTD
498, Section2, Bentian Road, Tainan, TAIWAN

Authorized Representative

YAMAHA MOTOR EUROPE N.V.
Koolhovenlaan 101,1119NC Schiphol-Rijk,The Netherlands

98/336/EEC or 2004/108/EC

EN292 ANSI/SVIA 1-2007

Signature ________________

Shinya Shimada

General Manager
RV Engineering Division

RV Company
Date of Issue 19 February, 2008

INTRODUCTION

Congratulations on your purchase of the Yamaha YFM90RY. 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 proce-

dures. If you have any questions regarding the operation or maintenance of your ATV, please consult a
Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE:

READ THIS MANUAL COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU
UNDERSTAND ALL INSTRUCTIONS.
PAY CLOSE ATTENTION TO THE WARNING AND NOTICE LABELS ON THE ATV.

THIS ATV, AND ANY OTHER ATV OVER 70 cc, SHOULD NOT BE OPERATED BY A CHILD UNDER
12 YEARS OF AGE.

AN IMPORTANT NOTE TO PARENTS:

This ATV is not a toy. Before you let your child ride this ATV, you should understand the instructions and
warnings in this Owner’s Manual. Then be sure your child understands and will follow them. Children differ

in skills, physical abilities and judgment. Some children may not be able to operate an ATV safely. Parents
should supervise their child’s use of the ATV at all times. Parents should permit continued use only if they
determine that the child has the ability to operate the ATV safely.

Your ATV was delivered with an adjustable speed limiter . Yamaha recommends that all beginners start off
to limit the amount of speed available while they learn. The adjusting screw may be gradually turned out
as the beginner becomes more familiar with operating the ATV. Parents should decide when to adjust
the ATV for more power as their youngster’s riding skills improve. Once the ATV rider can operate with
skill at the top speed permitted by adjusting the vehicle speed limiter alone, the engine speed limiter
plate can be removed. Since removal of this limiter will result in a significant increase in power, turn the
vehicle speed limiter adjusting screw completely back in again; adjust it out in stages as done previously.

If your child is a beginner or is inexperienced, he or she should take a training course.

IMPORTANT MANUAL INFORMATION

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN­JURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this

symbol to avoid possible injury or death.

WARNING

N O T I C E

TIP

* Product and specifications are subject to change without notice.

A WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

IMPORTANT NOTICE

Welcome to the Yamaha world of motor sports!
This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate this
ATV on any paved surface, paved street, paved road or motorway.
Please check your local riding laws and regulations before operating this ATV.

YFM90RY

OWNER’S MANUAL

©2008 by Yamaha Motor Co., Ltd.

1st edition, July 2008

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

Printed in Taiwan.

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

Handlebar switches ................................... 4-2

Throttle lever ............................................. 4-3

Speed limiters............................................. 4-3

Vehicle speed limiter ................................. 4-4

Engine speed limiter plate.......................... 4-5

Front brake lever ........................................ 4-6

Rear brake lever ....................................... 4-6

Parking brake ............................................ 4-7

Fuel tank cap ............................................ 4-8

Fuel ........................................................... 4-8

Fuel cock .............................................. 4-10

Choke ..................................................... 4-11

Seat ........................................................ 4-11

Kick starter ............................................. 4-12

PRE-OPERATION CHECKS.........................5-1

Pre-operation check list............................5-1

Fuel ........................................................... 5-3

Engine oil .................................................. 5-3

Final transmission oil ................................ 5-3

Front and rear brakes ............................... 5-3

Throttle lever ............................................. 5-4

Tires .......................................................... 5-4

Measuring the tire pressure ...................... 5-5

Tire wear limit ........................................... 5-6

Chassis fasteners ..................................... 5-7

Instruments and switches ......................... 5-7

OPERATION................................................6-1

Starting a cold engine ............................... 6-1

Starting a warm engine ............................. 6-3

Engine break-in ........................................ 6-4

Parking ..................................................... 6-4

Parking on a slope ................................... 6-5

Accessories and loading .......................... 6-6

RIDING YOUR ATV ...................................... 7-1

GETTING TO KNOW YOUR ATV...............7-2

RIDE WITH CARE AND GOOD

JUDGEMENT............................................ 7-2

BE CAREFUL WHERE YOU RIDE...........7-11

TURNING YOUR ATV..............................7-15

CLIMBING UPHILL....................................7-17

RIDING DOWNHILL..................................7-20

CROSSING A SLOPE................................7-21

CROSSING THROUGH SHALLOW

WATER ................................................... 7-22

RIDING OVER ROUGH TERRAIN...........7-24

SLIDING AND SKIDDING.........................7-25

WHAT TO DO IF.......................................7-26

WHAT TO DO... ........................................ 7-26

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 ................................................. 8-11

Final transmission oil ................................ 8-14

Cleaning the air filter element .................. 8-15

Cleaning the spark arrester ...................... 8-19

Adjusting the carburetor ........................... 8-20

Adjusting the engine idling speed ............ 8-20

Checking the throttle cable free play ....... 8-21

Timing chain ............................................ 8-22

Valve clearance ....................................... 8-22

Brakes ..................................................... 8-22

Checking the front brake shoes................ 8-22

Adjusting the front brake lever free

play ....................................................... 8-23

Checking the rear brake pads ................. 8-25

Checking the brake fluid level ................. 8-25

Changing the rear brake fluid .................. 8-26

Checking the rear brake lever free

play ........................................................8-26

Checking and lubricating the cables........ 8-27

Checking and lubricating the front

and rear brake levers............................... 8-27

Checking the wheel hub bearings ............ 8-28

Battery ..................................................... 8-28

Replacing the fuse ................................... 8-30

Removing a wheel ................................... 8-32

Installing a wheel ..................................... 8-33

Troubleshooting ....................................... 8-34

Troubleshooting chart .............................. 8-35

CLEANING AND STORAGE.........................9-1

Cleaning ..................................................... 9-1

Storage ...................................................... 9-2

SPECIFICATIONS ..................................... 10-1

CONSUMER INFORMATION..................... 11-1

Identification numbers ............................ 11-1

1

SAFETY INFORMATION

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:

Read this manual and all labels carefully and fol­low the operating procedures described.
Never operate an ATV without proper training or
instruction.

Always follow the age recommendation:

– A child under 12 years old should never oper­ate an ATV with engine size greater than 70 cc.
– A child under 16 years old should never oper­ate an ATV with engine size greater than 90 cc.

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 paved street,
paved road or motorway.

Watch carefully for other vehicles when operat

-ing on unpaved public streets or roads. Make
sure you know your country’s laws and regula

-tions before you ride on unpaved public streets
or roads.

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

1-1

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.
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 footrests 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.
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.

1

1-2

Avoid crossing the side of a steep hill if possible.
Always use proper procedures if you stall or roll

1

backwards when climbing a hill. To avoid stall­ing, use the proper gear and maintain a steady
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.
Always use the size and type of tires specified in
this manual.
Always maintain proper tire pressure as de­scribed in this manual.
Never modify an ATV through improper installa­tion or use of accessories.
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.

WARNING

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. Gasoline can catch

1-3

fire and you could be burned.
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.
Gasoline is poisonous. 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.

WARNING

Always operate your ATV in an area with ade­quate ventilation. Never start or run the engine

in a closed area. Exhaust fumes are poisonous
and may cause loss of consciousness and
death within a short time.

1

1-4

LOCATION OF THE WARNING AND SPECIFICATION LABELS

2

1
2

3

4

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.

5

6

2-1

For Europe

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2-2

For Oceania

For Oceania

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DESCRIPTION

Left view Right view

1. Fuel cock

2. Rear wheel

3. Footrest

4. Front wheel

1

4

2

3

1

1. Spark arrester

2. Seat

3. Footrest

3-1

2

3

3

Controls and instruments

1

3

8 7 6

1. Rear brake lever

2. Parking brake

3. Front brake lever

4. Throttle lever

5. Main switch

6. Fuel tank cap

7. Handlebar switches

8. Choke

5

2 3

4

TIP

The ATV you have purchased may differ slightly
from the figures shown in this manual.

3-2

INSTRUMENT AND CONTROL FUNCTIONS

Main switch

The positions of the main switch are as follows:

OFF

ON

ON

All electrical systems are supplied with power, and
the engine can be started. The key cannot be re­moved.

OFF

All electrical systems are off. The key can be re­moved.

1. Main switch

4-1

I

G

O F F

N

I

T

4

1

I

N

O

Handlebar switches

1

4

2

1. Engine stop switch “ENG. STOP”

2. Start switch “START”

Engine stop switch “ENG. STOP”

Set this switch to “RUN” 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 “OFF”.

Start switch “START”

Push this switch to crank the engine with the start­er.

See the starting instructions on page 6-1 prior

to starting the engine.

4-2

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.

1

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.

WARNING

Malfunction of the throttle could make it diffi­cult to speed up or slow down when you need
to. This could cause an accident. Check the op­eration of the throttle lever before you start the
engine. If the throttle does not work smoothly,
check for the cause. Correct the problem be-

fore riding the ATV or consult a Yamaha dealer.

Speed limiters

Your ATV was delivered with two speed limiter
devices. A vehicle speed limiter adjusting screw
and a removable engine speed limiter plate.
Yamaha recommends that all beginning riders start
off with the vehicle speed limiter adjusting screw fully
turned in and the engine speed limiter plate installed
to limit the amount of speed available while they learn.

4

4-3

The vehicle speed limiter keeps the throttle from fully
opening, even when the throttle lever is pushed to the
maximum. The adjusting screw may be gradually
turned out as the beginner becomes more familiar with
operating the ATV. Parents should decide when to
adjust the ATV for more power as their youngster’s
riding skills improve. Once the ATV rider can operate

4

4

with skill at the top speed permitted by adjusting the
vehicle speed limiter alone, the engine speed limiter
plate can be removed. Since removal of this limiter
will result in a significant increase in power, turn the
vehicle speed limiter adjusting screw completely back

in again; adjust it out in stages as done previously.

Vehicle speed limiter

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 decrease
the maximum engine power available and the
maximum speed of the ATV, turn the adjusting
screw in direction (b).

3

1

2

1. Locknut

2. Adjusting screw

3. No more than 11 mm (0.4 in)

3. Tighten the locknut.

(b)

(a)

4-4

WARNING

Improper adjustment of the speed limiter and
throttle could cause throttle cable damage or
improper throttle operation. You could lose
control, have an accident or be injured. Do not
turn the adjusting screw out more than 5 mm
(0.2 in).

4. Tighten the screw.

5. Install the seat.

2

4

1

Engine speed limiter plate

With this plate installed, the engine speed is limited
to 4800 r/min. With this plate removed, top engine
speed (8000 r/min) is available.

Remove the plate as follows.

1. Remove the seat. (See page 4-11.)

2. Loosen the screws.

3. Pull the plate out of its case.

1. Speed limiter plate

2. Screws

TIP

Store the speed limiter plate with the owner’s manual
so that it is readily available whenever you want to
reduce the top engine speed.

4-5

Front brake lever

The front brake lever is located on the right handle­bar. To apply the front brake, pull the brake lever
toward the handlebar grip.

Rear brake lever

The rear brake lever is located on the left handle­bar. To apply the rear brake, pull the brake lever to­ward the handlebar grip.

4

1. Front brake lever

1

1. Rear brake lever

4-6

1

Parking brake

Use the parking brake before starting the engine or
parking the ATV, especially on a slope. Apply the
front bake lever and push down the lock button to
apply the parking brake. Squeeze the front brake
lever to release the parking brake.

1

1. Parking brake lock button

WARNING

Always set the parking brake before starting
the engine. The ATV could start moving un­expectedly if the parking brake is not ap­plied. This could cause loss of control or a
collision.
Always be sure you have released the park­ing brake before you begin to ride. 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.

4

4-7

Fuel tank cap

Remove the fuel tank cap by turning it counter­clockwise.

1

4

Fuel tank cap

1.

Fuel

Make sure that there is sufficient fuel in the tank.
Fill the fuel tank to the bottom of the filler tube as
shown.

1

2

1. Fuel level

2. Filler tube

Recommended fuel:

UNLEADED GASOLINE ONLY

Fuel tank capacity:

4.8 L (1.27 US gal) (1.06 Imp.gal)

Fuel reserve amount:

1.0 L (0.26 US gal) (0.22 Imp.gal)

4-8

NOTIC E

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.

WARNING

Do not overfill the fuel tank. 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.
Be careful not to spill fuel, especially on the
engine or exhaust pipe which can cause a
fire and severe injury. Wipe up any spilled
fuel immediately.
Do not refuel right after the engine has been
running and is still very hot.
Be sure the fuel tank cap is closed securely.

4

4-9

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.

OFF

5

4

1.Lever positioned over “OFF”

1

OFF

F

F

O

FUEL

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.

RES

1

RES

E

S

F

F

O

FUEL

R

N

O

E

S

R

N

O

1. Lever positioned over “RES”

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.

ON

E

S

R

F

F

O

N

1. Lever positioned over “ON”

1

O

FUEL

ON

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”!

4-10