Yamaha YFS200R User Manual
READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YFS200R
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LIT-11626-16-37
This ATV should not be ridden by anyone under 16 years of age.
5VM-28199-10
EBU01200
INTRODUCTION
Congratulations on your purchase of the Yamaha YFS200. It represents the result of many years of
Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With
the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability
that have made Yamaha a leader in these fields.
This manual will provide you with a good basic understanding of the features and operation of this
ATV. This manual includes important safety information. It provides information about special
techniques and skills necessary to ride your 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:
8 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COM-
PLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.
8 PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.
8 NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING
IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMATION.
8 THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER
16 YEARS OF AGE.
8 THIS ATV IS A HIGH PERFORMANCE ATV FOR OFF-ROAD USE ONLY, FOR SPORT TYPE
RECREATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS.
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IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
w Failure to follow WARNING instructions could result in severe injury or
death to the machine operator, a bystander or a person inspecting or
repairing the machine.
cC A CAUTION indicates special precautions that must be taken to avoid
damage to the machine.
NOTE: A NOTE provides key information to make procedures easier or clearer.
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IMPORTANT NOTICE
This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this machine on any public street, road or highway.
This machine 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 machine.
YFS200R
EBU00981
©2002 by Yamaha Motor Corporation,
AFFIX DEALER LABEL HERE
Any reprinting or unauthorized use
of Yamaha Motor Corporation, U.S.A.
OWNER’S MANUAL
U.S.A.
1st edition, June 2002
All rights reserved.
without the written permission
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-16-37
EBU00014
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Indicates a potential hazard that could result
in serious injury or death.
CONTENTS
LOCATION OF THE WARNING AND
1
SPECIFICATION LABELS.......................1-1
SAFETY INFORMATION.........................2-1
2
DESCRIPTION AND MACHINE
3
IDENTIFICATION.....................................3-1
Identification number records ...............3-2
Key identification number .....................3-2
Vehicle identification number ...............3-3
Model label ...........................................3-3
CONTROL FUNCTIONS..........................4-1
4
Main switch...........................................4-1
Indicator lights ......................................4-1
Oil level warning light checking
method ...............................................4-2
Handlebar switches ..............................4-3
Throttle lever ........................................4-4
Throttle OverRide System ....................4-5
Speed limiter ........................................4-6
Clutch lever ..........................................4-7
Brake lever ...........................................4-7
Brake pedal ..........................................4-8
Parking brake .......................................4-8
Shift pedal ..........................................4-10
Kick starter .........................................4-10
Fuel tank cap......................................4-11
Fuel cock ............................................4-11
Starter (choke)....................................4-12
Seat ....................................................4-12
Front shock absorber
adjustment........................................4-14
Rear shock absorber
adjustment........................................4-15
PRE-OPERATION CHECKS ...................5-1
5
Front and rear brakes ...........................5-2
Fuel ......................................................5-4
Engine oil.............................................5-6
Transmission oil ...................................5-6
Chain ....................................................5-7
Throttle lever ........................................5-7
Fittings and fasteners ...........................5-7
Lights....................................................5-7
Switches ...............................................5-7
Tires .....................................................5-8
How to measure tire pressure ..............5-9
Tire wear limit .....................................5-10
OPERATION ............................................6-1
6
Starting a cold engine...........................6-1
Starting a warm engine ........................6-3
Warming up ..........................................6-3
Shifting .................................................6-4
To start out and accelerate...................6-5
To decelerate .......................................6-6
Engine break-in ....................................6-7
Parking .................................................6-8
Parking on a slope................................6-9
Accessories and loading ....................6-10
RIDING YOUR ATV .................................7-1
7
Getting to know your ATV.....................7-3
Ride with care and good
judgement...........................................7-4
Be careful where you ride...................7-16
Turning your ATV ...............................7-23
Climbing uphill ....................................7-25
Riding downhill ...................................7-30
Crossing a slope.................................7-32
Crossing through shallow water .........7-34
Riding over rough terrain....................7-36
Sliding and skidding ...........................7-38
What to do if... ...................................7-40
What to do... ......................................7-40
PERIODIC MAINTENANCE AND
8
ADJUSTMENT.........................................8-1
Owner’s manual and tool kit .................8-1
Periodic maintenance/Lubrication ........8-3
Transmission oil ...................................8-6
Spark plug inspection ...........................8-8
Air filter cleaning.................................8-10
Spark arrester cleaning ......................8-13
Carburetor settings.............................8-15
Idle speed adjustment ........................8-21
Throttle lever adjustment....................8-22
Brake fluid level check........................8-22
Brake fluid replacement......................8-24
Front brake pad inspection.................8-24
Rear brake pad inspection .................8-25
Front brake lever free play .................8-26
Brake pedal height adjustment...........8-27
Parking brake adjustment...................8-28
Adjusting the rear brake light switch...8-30
Clutch adjustment...............................8-31
Autolube pump adjustment.................8-31
Drive chain slack check......................8-32
Drive chain slack adjustment..............8-32
Lubricating the drive chain .................8-33
Cable inspection and lubrication ........8-35
Brake and shift pedal/brake and
clutch lever lubrication......................8-35
Front upper arm and lower arm pivot
lubrication .........................................8-35
Steering shaft lubrication....................8-36
Wheel removal ...................................8-37
Wheel installation ...............................8-37
Replacing a headlight bulb .................8-38
Headlight beam adjustment................8-42
Tail/brake light bulb replacement .......8-42
Troubleshooting..................................8-43
Troubleshooting chart.........................8-45
No spark .............................................8-46
CLEANING AND STORAGE....................9-1
9
A. Cleaning ...........................................9-1
B. Storage ............................................9-3
10
SPECIFICATIONS .................................10-1
11
NOISE REGULATION............................11-1
12
MAINTENANCE RECORD ....................12-1
13
ATV LIMITED WARRANTY ...................13-1
YAMAHA EXTENDED SERVICE
14
(Y.E.S.)...................................................14-1
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2
3
4
5
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1-1
Read and understand all of the labels on your
machine. They contain important information for
safe and proper operation of your ATV.
Never remove any labels from your ATV. If a label
becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.
q
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WARNING
NEVER ride as a
passenger.
Passengers can cause
a loss of control,
resulting in SEVERE
INJURY or DEATH.
5FE-2151H-01
1
5FE-21697-01
3JM-21696-41
1-2
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WARNING
This unit contains high pressure nitrogen gas.
Mishandling can cause explosion.
8 Read owner’s manual for instructions.
8 Do not incinerate, puncture or open.
4AA-22259-80
1-3
5FE-21568-01
EBU00927
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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:
8 Read this manual and all labels carefully and follow the operating procedures described.
8 Never operate an ATV without proper training or instruction. Take a Training Course. Beginners
should receive training from a certified instructor. Contact an authorized ATV dealer or call
1-800-887-2887 to find out about the training courses nearest you.
8 Always follow these age recommendation:
–A child under 16 years old should never operate an ATV with engine size greater than 90cc.
8 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow con-
tinued use of an ATV by a child if he or she does not have the abilities to operate it safely.
8 Never carry a passenger on an ATV.
SAFETY INFORMATION
2-1
2
8 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots
and streets.
8 Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
8 Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket,
and long pants.
8 Never consume alcohol or drugs before or while operating this ATV.
8 Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is prop-
er for the terrain, visibility and operating conditions, and your experience.
8 Never attempt wheelies, jumps, or other stunts.
8 Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always
follow the inspection and maintenance procedures and schedules described in this manual.
8 Always keep both hands on the handlebars and both feet on the footpegs of the ATV during opera-
tion.
8 Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.
2-2
8 Never operate on excessively rough, slippery or loose terrain until you have learned and practiced
the skills necessary to control the ATV on such terrain. Always be especially cautious on these
kinds of terrain.
8 Always follow proper procedures for turning as described in this manual. Practice turning at low
speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
8 Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills
before attempting larger hills.
8 Always follow proper procedures for climbing hills as described in this manual. Check the terrain
carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never
go over the top of a hill at high speed.
8 Always follow proper procedures for going down hills and for braking on hills as described in this
manual. Check the terrain carefully before you start down any hill. Shift your weight backward.
Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle
to lean sharply to one side. Go straight down the hill where possible.
8 Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid
hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
Never attempt to turn the ATV around on any hill until you have mastered the turning technique
described in this manual on level ground. Avoid crossing the side of a steep hill if possible.
2-3
8 Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling,
use proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, 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.
8 Always check for obstacles before operating in a new area.
Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow
proper procedures when operating over obstacles as described in this manual.
8 Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing
at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly
and be very cautious in order to reduce the chance of skidding or sliding out of control.
8 Never operate an ATV in fast flowing water or in water deeper than that recommended in this manu-
al. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving
water. If necessary, apply them several times to let friction dry out the linings.
8 Always use the size and type tires specified in this manual.
Always maintain proper tire pressure as described in this manual.
8 Never modify an ATV through improper installation or use of accessories.
2-4
8 Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling
a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission
at 1-800-638-2772, or the ATV Distributor's Safety Hotline at 1-800-852-5344.
2-5
2-5
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WARNING
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 while 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 machine 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, see your doctor
immediately.
If gasoline spills on your skin, wash with
soap and water. If gasoline spills on your
clothing, change your clothes.
2-6
q
WARNING
POTENTIAL HAZARD
Starting or running the engine in a closed
area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
HOW TO AVOID THE HAZARD
Always operate your ATV in an area with
adequate ventilation.
2-7
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DESCRIPTION AND MACHINE IDENTIFICATION
1. Spark arrester 12. Rear shock absorber
2. Seat 13. Tail/brake light
3. Fuel tank cap 14. Rear wheel
4. Headlight 15. Shift pedal
5. Brake pedal 16. Clutch lever
6. Rear brake light switch 17. Parking brake
7. Kick starter 18. Main switch
8. Front shock absorber 19. Brake lever
9. Front wheel 20. Throttle lever
10. Fuel cock 21. Handlebar switches
11. Starter (choke)
NOTE:
The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
3-1
EBU00600
Identification number records
Record the key identification number, vehicle
identification number and model label information in the spaces provided for assistance when
ordering spare parts from a Yamaha dealer or
for reference in case the vehicle is stolen.
1. KEY IDENTIFICATION NUMBER:
2. VEHICLE IDENTIFICATION NUMBER:
3. MODEL LABEL INFORMATION:
1
6
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Key identification number
The key identification number is stamped on the
key as shown in the following illustration. This
number can be used for ordering a new key.
q
1. Key identification number
3
3-2
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Vehicle identification number
The vehicle identification number is stamped
into the frame.
1. Vehicle identification number
EBU00787
Model label
The model label is affixed to the location in the
illustration. Record the information on this label
in the space provided. This information will be
needed to order spare parts from your Yamaha
dealer.
1
NOTE:
The vehicle identification number is used to
identify your machine.
1. Model label
3-3
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ON
OFF
1
2
CONTROL FUNCTIONS
EBU00043
Indicator lights
w
Indicates a potential hazard that could result
in serious injury or death.
EBU00041
Main switch
Functions of the respective switch positions are
as follows:
ON:
Engine can be started only at this position and
the headlight and taillight come on when the
light switch is on.
OFF:
All electrical circuits are switched off. The key
can be removed in this position.
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Oil level warning light “7”
This light comes on when the oil level is low.
The light circuit can be checked by the following
procedure.
cC
Always make sure there is enough engine oil
before starting the engine.
1. Main switch 2. Oil level warning light “7”
4-1
4
EBU00757
Oil level warning light checking method
Turn the main switch to
“ON” and the engine
stop switch to “RUN”.
Start the engine.
Oil level warning light
does not come on
(see NOTE).
The oil level warning light
goes off.
Ask a Yamaha dealer to
inspect the electrical circuit.
Engine oil level and
electrical circuit are OK.
NOTE:
If the main switch is turned off after the oil level
warning light goes off and the engine is immediately started again, the oil level warning light
may not come on. This does not indicate a circuit failure.
Oil level warning
light comes on.
Wait a few seconds.
The oil level warning
light stays on.
Supply engine oil.
4-2
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Handlebar switches
EBU01158
Engine stop switch “ENG. STOP”
Make sure that the engine stop switch is in the
“RUN” position before starting the engine. The
engine stop switch controls ignition and can be
used at all times to stop the engine, especially in
an emergency. The engine will not start or run
when the engine stop switch is turned to “OFF”.
1. Light switch “LIGHTS”
2. Engine stop switch “ENG. STOP”
EBU01286
Light switch “LIGHTS”
Set the switch to the “LO” position to switch on
the low beam and the taillight.
Set the switch to the “HI” position to switch on
the high beam and the taillight.
Set the switch to the “OFF” position to switch off
all the lights.
NOTE:
The headlight and the taillight can be turned on
only when the engine is started.
4-3
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Throttle lever
Once the engine is running, movement of the
throttle lever will increase the engine speed.
Regulate the speed of the machine by varying
the throttle position. Because the throttle is
spring-loaded, the machine will decelerate, and
the engine will return to an idle any time the
hand is removed from the throttle lever.
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.
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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.
4-4
EBU00064
Throttle OverRide System
If during operation, the carburetor or the throttle
cable should malfunction and will not close fully,
take your thumb off the throttle lever. The throttle override system immediately cuts off the ignition.
q
WARNING
POTENTIAL HAZARD
Continuing to ride the ATV after the
Throttle OverRide System (T.O.R.S.) has
stopped the engine.
WHAT CAN HAPPEN
Riding with a malfunction increases the
chance for an accident and injury.
HOW TO AVOID THE HAZARD
Make sure that the cause of the malfunction is corrected before restarting the
engine. You should have the ATV inspected by a Yamaha dealer.
4-5
EBU01159
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Speed limiter
The speed limiter keeps the throttle from fully
opening, even when the throttle lever is pushed
to the maximum. Turning in the adjusting screw
limits the maximum engine power available and
decreases the maximum speed of the ATV.
1. Locknut 2. Adjusting screw
a. No more than 12 mm (0.47 in)
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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
4–6 mm (0.16–0.24 in). See page 8-22.
4-6
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Clutch lever
The clutch lever is located on the left handlebar.
Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage
the clutch. The lever should be pulled rapidly
and released slowly for smooth clutch operation.
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1. Clutch lever
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Brake lever
The brake lever is located on the right handlebar. Pull it toward the handlebar to apply the
front brake.
1. Brake lever
4-7
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Brake pedal
The brake pedal is located on the right side of
the machine. Push down on the pedal to apply
the rear brake.
1. Brake pedal
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Parking brake
Use the parking brake when you have to start
the engine or park the machine, especially on a
slope. Squeeze the clutch lever while pushing
the button, then push in the lock plate to apply
the parking brake. Squeeze the clutch lever to
release the parking brake.
NOTE:
When the parking brake is used, engine speed
is limited to 2,300 r/min. Be sure the parking
brake is released before moving the throttle
lever. Otherwise, the engine will misfire, preventing normal operation.
4-8
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