Yamaha 2009 Service

Yamaha · 2009 · service manual · 386 pages

Yamaha
2009
Service manual
386 pages
ATV

Technical data

Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.

Tightening torque

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Nut) B (bolt	6 N·m	0.6 kgf·m · 4.3 ft·lb	p. 39
Nut) B (bolt	15 N·m	1.5 kgf·m · 11 ft·lb	p. 39
Nut) B (bolt	30 N·m	3 kgf·m · 22 ft·lb	p. 39
Camshaft cap bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 40
Cylinder head blind plug	28 N·m	2.8 kgf·m · 20 ft·lb	p. 40
Spark plug	13 N·m	1.3 kgf·m · 9.4 ft·lb	p. 40
Exhaust pipe stud bolt	15 N·m	1.5 kgf·m · 11 ft·lb	p. 40
Cylinder head cover bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 40
Balancer driven gear weight	12 N·m	1.2 kgf·m · 8.7 ft·lb	p. 40
Balancer driven gear nut	50 N·m	5 kgf·m · 36 ft·lb	p. 40
Timing chain guide	10 N·m	1 kgf·m · 7.2 ft·lb	p. 40
Timing chain tensioner cap bolt	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 40
Coolant drain bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 40
Oil filter element drain bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 40
Idle gear shaft screw	10 N·m	1 kgf·m · 7.2 ft·lb	p. 40
LT Oil strainer bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 40
LT Oil pump assembly bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 40
Throttle body joint bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 40
Throttle body joint clamp bolt	3.3 N·m	0.33 kgf·m · 2.4 ft·lb	p. 40
Air filter joint clamp bolt	2.7 N·m	0.27 kgf·m · 2 ft·lb	p. 40
Screw Air filter element bolt	2 N·m	0.2 kgf·m · 1.4 ft·lb	p. 40
Air filter joint clamp bolt	2.3 N·m	0.23 kgf·m · 1.7 ft·lb	p. 40
Throttle body case cover bolt	2 N·m	0.2 kgf·m · 1.4 ft·lb	p. 40
Throttle cable and locknut	0.8 N·m	0.08 kgf·m · 0.6 ft·lb	p. 40
Muffler joint bolt	20 N·m	2 kgf·m · 14 ft·lb	p. 40
Muffler bolt	34 N·m	3.4 kgf·m · 24 ft·lb	p. 40
Generator rotor cover bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 41
Right crankcase cover bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 41
Clutch cover bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 41
Crankshaft end accessing screw	10 N·m	1 kgf·m · 7.2 ft·lb	p. 41
Timing mark accessing screw	6 N·m	0.6 kgf·m · 4.3 ft·lb	p. 41
Engine oil drain bolt	20 N·m	2 kgf·m · 14 ft·lb	p. 41
Bearing retainer screw	22 N·m	2.2 kgf·m · 16 ft·lb	p. 41
Bearing retainer screw	12 N·m	1.2 kgf·m · 8.7 ft·lb	p. 41
Bearing retainer bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 41
Starter clutch bolt	16 N·m	1.6 kgf·m · 11 ft·lb	p. 41
Primary drive gear nut	110 N·m	11 kgf·m · 80 ft·lb	p. 41
Clutch spring bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 41
Clutch boss nut	75 N·m	7.5 kgf·m · 54 ft·lb	p. 41
Washer	75 N·m	7.5 kgf·m · 54 ft·lb	p. 41
Drive sprocket nut	100 N·m	10 kgf·m · 72 ft·lb	p. 41
Stake Shift drum segment bolt	30 N·m	3 kgf·m · 22 ft·lb	p. 41
Shift guide bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 41
LT Stopper lever bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 41
LT Stator coil bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 41
LT Generator rotor nut	65 N·m	6.5 kgf·m · 47 ft·lb	p. 41
Neutral switch	17 N·m	1.7 kgf·m · 12 ft·lb	p. 41
Washer	30 N·m	3 kgf·m · 22 ft·lb	p. 41
Washer	20 N·m	2 kgf·m · 14 ft·lb	p. 41
Engine stay bolt	33 N·m	3.3 kgf·m · 24 ft·lb	p. 43
Engine mounting bolt	40 N·m	4 kgf·m · 29 ft·lb	p. 43
Engine bracket bolt	48 N·m	4.8 kgf·m · 35 ft·lb	p. 43
Engine mounting nut	66 N·m	6.6 kgf·m · 48 ft·lb	p. 43
Frame complete screw	30 N·m	3 kgf·m · 22 ft·lb	p. 43
Pipe nut	54 N·m	5.4 kgf·m · 39 ft·lb	p. 43
Tank rail and sub frame com	27 N·m	2.7 kgf·m · 19 ft·lb	p. 43
Swingarm bracket and main	54 N·m	5.4 kgf·m · 39 ft·lb	p. 43
Coolant reservoir tank bolt	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 43
Rear fender bracket and frame	20 N·m	2 kgf·m · 14 ft·lb	p. 43
Pivot shaft nut	100 N·m	10 kgf·m · 72 ft·lb	p. 43
Rear shock absorber nut	55 N·m	5.5 kgf·m · 40 ft·lb	p. 43
Relay arm and swingarm nut	55 N·m	5.5 kgf·m · 40 ft·lb	p. 43
Connecting arm and frame nut	55 N·m	5.5 kgf·m · 40 ft·lb	p. 43
Rear shock absorber and relay	55 N·m	5.5 kgf·m · 40 ft·lb	p. 43
Relay arm and connecting arm	55 N·m	5.5 kgf·m · 40 ft·lb	p. 43
Swingarm bolt	55 N·m	5.5 kgf·m · 40 ft·lb	p. 43
Rear axle pinch bolt	21 N·m	2.1 kgf·m · 15 ft·lb	p. 43
Front upper arm nut	40 N·m	4 kgf·m · 29 ft·lb	p. 43
Front lower arm nut	55 N·m	5.5 kgf·m · 40 ft·lb	p. 43
Front shock absorber and frame	40 N·m	4 kgf·m · 29 ft·lb	p. 43
Front shock absorber and front	55 N·m	5.5 kgf·m · 40 ft·lb	p. 43
Steering stem nut	180 N·m	18 kgf·m · 130 ft·lb	p. 43
Steering stem and lower handle	64 N·m	6.4 kgf·m · 46 ft·lb	p. 43
Upper handlebar holder	23 N·m	2.3 kgf·m · 17 ft·lb	p. 44
Locknut	18 N·m	1.8 kgf·m · 13 ft·lb	p. 44
Steering knuckle and front upper	25 N·m	2.5 kgf·m · 18 ft·lb	p. 44
Steering knuckle and front lower	25 N·m	2.5 kgf·m · 18 ft·lb	p. 44
Steering knuckle and tie-rod ball	25 N·m	2.5 kgf·m · 18 ft·lb	p. 44
Pitman arm and tie-rod ball joint	25 N·m	2.5 kgf·m · 18 ft·lb	p. 44
Frame and bearing retainer (external thread)	65 N·m	6.5 kgf·m · 47 ft·lb	p. 44
Fuel pump bolt	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 44
Front wheel nut	45 N·m	4.5 kgf·m · 32 ft·lb	p. 44
Front brake caliper bolt	28 N·m	2.8 kgf·m · 20 ft·lb	p. 44
Steering knuckle and front wheel	70 N·m	7 kgf·m · 50 ft·lb	p. 44
Front brake disc bolt	28 N·m	2.8 kgf·m · 20 ft·lb	p. 44
Rear brake caliper bolt	43 N·m	4.3 kgf·m · 31 ft·lb	p. 44
Rear wheel nut	45 N·m	4.5 kgf·m · 32 ft·lb	p. 44
Rear axle and rear wheel hub	200 N·m	20 kgf·m · 145 ft·lb	p. 44
Driven sprocket nut	72 N·m	7.2 kgf·m · 52 ft·lb	p. 44
Front brake pipe flare nut	19 N·m	1.9 kgf·m · 13 ft·lb	p. 44
Frame and joint bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 44
Front upper arm and brake hose	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 44
Front brake caliper and brake	27 N·m	2.7 kgf·m · 19 ft·lb	p. 44
Front brake caliper and bleed	6 N·m	0.6 kgf·m · 4.3 ft·lb	p. 44
Rear brake disc screw	33 N·m	3.3 kgf·m · 24 ft·lb	p. 44
Front brake master cylinder bolt	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 44
Front brake master cylinder	27 N·m	2.7 kgf·m · 19 ft·lb	p. 44
Footrest bolt	78 N·m	7.8 kgf·m · 56 ft·lb	p. 44
Rear brake caliper and brake	30 N·m	3 kgf·m · 22 ft·lb	p. 44
Rear brake caliper and bleed	6 N·m	0.6 kgf·m · 4.3 ft·lb	p. 45
Rear brake master cylinder bolt	20 N·m	2 kgf·m · 14 ft·lb	p. 45
Rear brake master cylinder	30 N·m	3 kgf·m · 22 ft·lb	p. 45
Adjusting bolt locknut	16 N·m	1.6 kgf·m · 11 ft·lb	p. 45
Brake hose bolt	4 N·m	0.4 kgf·m · 2.9 ft·lb	p. 45
Parking brake cable holder bolt	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 45
Brake hose holder and swing	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 45
Brake pedal bolt	26 N·m	2.6 kgf·m · 19 ft·lb	p. 45
Brake fluid reservoir hose cover	20 N·m	2 kgf·m · 14 ft·lb	p. 45
Brake fluid reservoir hose	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 45
Front bumper bolt	23 N·m	2.3 kgf·m · 17 ft·lb	p. 45
Lean angle sensor bolt	2 N·m	0.2 kgf·m · 1.4 ft·lb	p. 45
Rear axle nuts	200 N·m	20 kgf·m · 145 ft·lb	p. 45
Timing chain and camshaft caps	10 N·m	1 kgf·m · 7.2 ft·lb	p. 85
Oil filter element cover bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 90
Without oil filter element	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 91
Exhaust pipe nut Spark arrester bolt	20 N·m	2 kgf·m · 14 ft·lb	p. 95
Exhaust pipe nut Spark arrester bolt	8 N·m	0.8 kgf·m · 5.8 ft·lb	p. 95
Muffler bolt	8 N·m	0.8 kgf·m · 5.8 ft·lb	p. 95
Engine has cooled	10 N·m	1 kgf·m · 7.2 ft·lb	p. 97
Locknut	17 N·m	1.7 kgf·m · 12 ft·lb	p. 99

Capacities

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Fuel tank	10 L		p. 26

Spark plugs

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
CR8E	—		p. 26
M12	—		p. 40

Service intervals

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Spark plug service	5 years		p. 80
Brake inspection	4 years		p. 81

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