maintenance YAMAHA YFM90R 2009 Owners Manual

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 tech-
niques 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

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
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
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 AND STORAGE.........................9-1
Cleaning ..................................................... 9-1
Storage ...................................................... 9-2 Brakes ..................................................... 8-22

1-2
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. Al-
ways 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 op-
eration.Always go slowly and be extra careful when op-
erating 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 prac-
ticed 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 fasterspeeds 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 ter-
rain carefully before you start up any hill. Never
climb hills with excessively slippery or loose sur-
faces. 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 ve-
hicle 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 sur-
faces. 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 tech-
nique described in this manual on level ground.

5-1

PRE-OPERATION CHECKS
Pre-operation check listBefore operating this ATV, be sure to check the items listed in the following table.TIPThe maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the "Periodicmaintenance and lubrication charts" on page 8-3 to determine which service should be performed by a
Yamaha dealer.
5

WARNING
Always inspect your ATV each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Owner’sManual. Failure to inspect increases the possibility of an accident or equipment damage.

8-1
PERIODIC MAINTENANCE AND MINOR REPAIR
Safety is an obligation of the owner. Periodic in-
spection, adjustment and lubrication will keep your
ATV in the safest and best operating condition
possible. The most important points of inspection,
adjustment, and lubrication are explained on the
following pages.
The intervals given in the periodic maintenance
and lubrication chart should be considered as a
general guide under normal riding conditions.
However, DEPENDING ON THE WEATHER,
TERRAIN, GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORTENED.
Owner’s manual and tool kit Be sure to put this owner’s manual in the plastic
bag and to always carry it as well as the owner’s
tool kit and the low-pressure tire gauge in their re-
spective compartments under the seat.
8
WARNING
Never service an engine while it is running.
Moving parts can catch clothing or parts of the
body, causing injury. Electrical components
can cause shocks or start fires. Turn off the en-
gine when performing maintenance unlessotherwise specified. Have a Yamaha dealer
perform the service if you are not familiar with
maintenance work.

8-2
it for you.
1. Owner ’s manual
2. Low-pressure tire gauge
3. Owner ’s tool kitThe service information included in this manual
and the tools provided in the owner’s tool kit are in-
tended to assist you in the performance of preven-
tive maintenance and minor repairs. However,
additional tools such as a torque wrench may be
necessary to perform certain maintenance work
correctly.
TIPIf you do not have the tools or experience required
for a particular job, have a Yamaha dealer perform
5TH-28199-66YFM90ROWNER'S MANUAL
1626-21-38This ATV
shoul
d not be ridden by anyone under
years.
e
g
a
f
o
WARNING
READ THIS MANUAL CAREFULLY!
It contains important safety information.
8
1
23
WARNING
Never modify this ATV through improper in-
stallation or use of accessories, as it may
cause changes in handling, which in some sit-
uations could lead to an accident. All parts and
accessories added to this ATV should be gen-
uine Yamaha or equivalent components de-
signed for use on this ATV and should be
installed and used according to instructions. If
you have questions, consult an authorizedYamaha ATV dealer.

8-3
Periodic maintenance chart for the emission control system TIPFor ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-
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.NO.ITEM CHECK OR MAINTENANCE
JOB INITIAL
EVERY
Whichev- er comes rst month 1 3 6 6 12
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 3201 *Fuel line
Check fuel hoses for cracks or other damage, and
replace if necessary. √ √ √
2 Spark plugCheck condition and clean, regap, or replace if
necessary. √ √ √ √ √
3 *ValvesCheck valve clearance and adjust if necessary.
√√ √ √
4 *CarburetorCheck choke operation and correct if necessary.Check engine idling speed and adjust if neces-
sary. √ √ √ √
5 *
Crankcase breather
systemCheck breather hose for cracks or other damage,
and replace if necessary. √ √ √
8
vals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance

8-4
6
*Exhaust system
Check for leakage and replace gasket(s) if neces-
sary.Check for looseness and tighten all screw clamps
and joints if necessary.
7 Spark arresterClean.
NO.ITEM CHECK OR MAINTENANCE
JOB INITIAL
EVERY
Whichev- er comes rst month 1 3 6 6 12
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320
8

8-5
General maintenance and lubrication chart NO.ITEM CHECK OR MAINTENANCE
JOB INITIAL
EVERY
Whichev- er comes rst month 1 3 6 6 12
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 3201 *Timing chain
Check chain tension.Adjust if necessary. √
√ √ √
2 Air lter elementClean and replace if necessary. Every 20–40 hours (more often in wet or
dusty areas)
4 *Front brakeCheck operation and correct if necessary.Check brake lever free play and adjust if neces-
sary. √ √ √ √ √Replace brake shoes.
Whenever worn to the limit
7
*Wheels
Check runout and for damage, and replace if nec-
essary. √
√ √ √
8 *TiresCheck tread depth and for damage, and replace if
necessary.Check air pressure and balance, and correct if
necessary. √
√ √ √
8
5
*Rear brake
Check operation and correct if necessary.Check uid level and ATV for uid leakage, and
correct if necessary. √ √ √ √ √Replace brake pads.
Whenever worn to the limit
6 *Brake hosesCheck for cracks or other damage, and replace if
necessary. √ √ √ √Replace.
Every 4 years
3
*Clutch
Check operation.
√√ √ √

8-6
11
*Shock absorber
assemblies
Check operation and correct if necessary.Check for oil leakage and replace if necessary. √ √ √
12 *
Front knuckle piv-
otsLubricate with lithium-soap-based grease.
√ √ √
13 *Steering shaftLubricate with lithium-soap-based grease.
√ √ √
14 *Steering systemCheck operation and repair or replace if damaged.Check toe-in and adjust if necessary. √ √ √ √ √
Engine oilChange.Check ATV for oil leakage, and correct if neces-
sary. √
√ √ √Change.
NO.ITEM CHECK OR MAINTENANCE
JOB INITIAL
EVERY
Whichev- er comes rst month 1 3 6 6 12
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 32017
Check ATV for oil leakage, and correct if neces-
sary. √
√
18 *
Moving parts and
cablesLubricate.
√ √ √ √
8
9
*Wheel hub bearings
Check for looseness or damage, and replace if
necessary. √
√ √ √
10 *Chassis fastenersMake sure that all nuts, bolts, and screws are
properly tightened. √ √ √ √ √
1516
Engine oil strainer Clean.
√√ √
Final transmission oil