EBU00438 READ THIS MANUAL CAREFULLY! It contains important safety information. WARNING Improper ATV use can result in SEVERE INJURY or DEATH. BEER BEER ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns.
EBU00776
U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM EBU00941 INTRODUCTION 1- Congratulations on your purchase of the Yamaha YFM450FA. It represents the result of many years of 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.
U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
U1D910.book Page 2 Thursday, May 27, 2004 11:08 AM EBU15000 IMPORTANT NOTICE 1- 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. Please check your local riding laws and regulations before operating this ATV.
U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM EBU00014 WARNING Indicates a potential hazard that could result in serious injury or death. CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS....... 1-1 2 SAFETY INFORMATION.................. 2-1 3 DESCRIPTION AND MACHINE IDENTIFICATION ............................. 3-1 Identification number records.......... 3-2 Key identification number................ 3-2 Vehicle identification number .......... 3-3 Model label .........................
U1D910.book Page 2 Thursday, May 27, 2004 11:08 AM 5 6 PRE-OPERATION CHECKS ........... 5-1 Front and rear brakes ..................... 5-2 Fuel ................................................. 5-4 Engine oil ........................................ 5-6 Final gear oil.................................... 5-6 Differential gear oil .......................... 5-6 Coolant............................................ 5-7 Throttle lever ................................... 5-7 Fittings and fasteners.............
U1D910.book Page 3 Thursday, May 27, 2004 11:08 AM 8 PERIODIC MAINTENANCE AND ADJUSTMENT.................................. 8-1 Owner’s manual and tool kit............ 8-1 Periodic maintenance/ lubrication ...................................... 8-3 Panel removal and installation ........ 8-6 Engine oil and oil filter cartridge .... 8-12 Final gear oil .................................. 8-17 Differential gear oil......................... 8-20 Cooling system..............................
U1D910.book Page 4 Thursday, May 27, 2004 11:08 AM Tail/brake light bulb replacement ................................ 8-58 Troubleshooting ............................ 8-59 Troubleshooting charts ................. 8-61 9 CLEANING AND STORAGE............ 9-1 A. Cleaning...................................... 9-1 B. Storage ....................................... 9-3 10 SPECIFICATIONS.......................... 10-1 11 NOISE REGULATION.................... 11-1 12 MAINTENANCE RECORD ............
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U1D910.book Page 2 Thursday, May 27, 2004 11:08 AM 1 Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. 1 WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident. Never exceed the maximum front cargo limit of : 40kg (88 lbs) NEVER sit on the carrier. Refer to instructions in the Owner's Manual. Never remove any labels from your ATV.
U1D910.book Page 3 Thursday, May 27, 2004 11:08 AM 4 6 WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident. Never exceed the maximum rear cargo limit of : 80kg (176 lbs) NEVER sit on the carrier. Refer to instructions in the Owner's Manual. 5ND-F4897-00 5 MAXIMUM .
U1D910.book Page 4 Thursday, May 27, 2004 11:08 AM 7 8 WARNING UNDER Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. 9 WARNING NEVER operate this ATV if you are under age 16. Turning the ATV in 4WD-LOCK ( “DIFF. LOCK” ) takes more effort. YAMAHA 4XE-F415A-00 Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control.
U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM EBU13351 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.
U1D910.book Page 2 Thursday, May 27, 2004 11:08 AM ● ● ● ● ● ● ● ● ● ● 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 jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions.
U1D910.book Page 3 Thursday, May 27, 2004 11:08 AM ● ● ● ● ● 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.
U1D910.book Page 4 Thursday, May 27, 2004 11:08 AM ● ● ● ● ● ● ● 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.
U1D910.book Page 5 Thursday, May 27, 2004 11:08 AM WARNING 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. 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.
U1D910.book Page 6 Thursday, May 27, 2004 11:08 AM 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.
U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1- 1. Rear shock absorber assembly spring preload adjusting ring 2. Spark arrester 3. Storage compartment and tool kit 4. Spark plug 5. Rear brake fluid reservoir 6. Front shock absorber assembly spring preload adjusting ring 7. Brake pedal 8. V-belt case 9. Radiator cap 10. Fuel cock 11. Air filter case 12. Fuses 13. Tail/brake light 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
U1D910.book Page 2 Thursday, May 27, 2004 11:08 AM EBU00600 EBU00035 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: Key identification number The key identification number is stamped on the key as shown in the following illustration.
U1D910.book Page 3 Thursday, May 27, 2004 11:08 AM EBU00036 EBU00787 Vehicle identification number The vehicle identification number is stamped into the frame. 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. Vehicle identification number NOTE: The vehicle identification number is used to identify your machine. 1.
U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM EBU00039 CONTROL FUNCTIONS 1- 1 WARNING 2 Indicates a potential hazard that could result in serious injury or death. 3 4 EBU09420 5 Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights 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. 6 1.
U1D910.book Page 2 Thursday, May 27, 2004 11:08 AM EBU08020 EBU10601 Indicator and warning lights Differential gear lock indicator light “DIFF. LOCK” This indicator light and the differential gear lock indicator in the display come on when the differential gear lock switch is set to the “4WDLOCK” position. NOTE: When the switch is set to “LOCK”, the differential gear lock indicator light will flash until the differential gear is locked. _ _ 1. 2. 3. 4. 5. 6. 7. 8.
U1D910.book Page 3 Thursday, May 27, 2004 11:08 AM EBU09720 EBU11312 Neutral indicator light “N” This indicator light comes on when the drive select lever is in the “N” position. Four-wheel-drive indicator “ ”/“ ” This indicator comes on when the “2WD”/ “4WD” switch is set to the “4WD” position. The differential gear lock indicator “DIFF.LOCK” in the four-wheel-drive indicator also comes on when the “LOCK”-“4WD” switch is set to the “4WD-LOCK” position. DIFF.
U1D910.book Page 4 Thursday, May 27, 2004 11:08 AM EBU00860 EBU00052 Coolant temperature warning light “ ” When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes. Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank.
U1D910.book Page 5 Thursday, May 27, 2004 11:08 AM EBU11322 Speedometer unit ● ● ● 1. 3. 5. 6. Speedometer 2. Clock/Hour meter 4. Clock/Hour button “ “H” button 7.
U1D910.book Page 6 Thursday, May 27, 2004 11:08 AM Odometer and tripmeter modes Pushing the “TRIP/ODO” button switches the display between the odometer mode “ODO” and the tripmeter modes “A” and “B” in the following order: ODO→TRIP A→TRIP B→ODO To reset a tripmeter, select it by pushing the “TRIP/ODO” button, and then push the “TRIP/ ODO” button for at least three seconds. The tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel.
U1D910.book Page 7 Thursday, May 27, 2004 11:08 AM EBU00053 Handlebar switches CAUTION: _ Do not use the headlights with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. _ EBU12050 1. 2. 3. 4. Engine stop switch “ / ” Make sure that the engine stop switch is set to “ ” before starting the engine.
U1D910.book Page 8 Thursday, May 27, 2004 11:08 AM EBU00607 Start switch “ ” The starter motor cranks the engine when this switch is pushed. CAUTION: See starting instructions prior to starting the engine. (See page 6-1 for details.) 1. Override switch “OVERRIDE” EBU13781 4-8 Override switch “OVERRIDE” Top speed is normally limited when operating in 4WD-LOCK. If conditions require more engine power when riding forward, push and hold this switch to override the 4WD-LOCK speed limiting function.
U1D910.book Page 9 Thursday, May 27, 2004 11:08 AM WARNING POTENTIAL HAZARD Riding too fast while the ATV is in 4WD-LOCK. WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the ATV. The amount of effort is more the faster you go. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling.
U1D910.book Page 10 Thursday, May 27, 2004 11:08 AM ● ● 1. On-Command four-wheel drive switch “2WD”/“4WD” 2. Differential gear lock switch “LOCK”/“4WD” EBU14091 On-Command four-wheel drive and differential gear lock switches This ATV is equipped with an On-Command four-wheel drive switch “2WD”/“4WD” and a differential gear lock switch “LOCK”/“4WD”. Select the appropriate drive according to terrain and the conditions. ● Two-wheel drive (2WD): Power is supplied to the rear wheels only.
U1D910.book Page 11 Thursday, May 27, 2004 11:08 AM WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 4WD-LOCK (“DIFF.LOCK”), or vice-versa while the ATV is moving. WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD and in 4WD-LOCK in some circumstances. Changing from 2WD to 4WD or from 4WD to 4WD-LOCK, or vice-versa while moving may cause the ATV to unexpectedly handle differently. This could distract the operator and increase the risk of losing control and an accident.
U1D910.book Page 12 Thursday, May 27, 2004 11:08 AM WARNING POTENTIAL HAZARD Riding too fast while the ATV is in 4WD-LOCK. WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the ATV. The amount of effort is more the faster you go. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling.
U1D910.book Page 13 Thursday, May 27, 2004 11:08 AM EBU00062 NOTE: ● When the switch is set to “LOCK”, the differential gear lock indicator light will flash until the differential gear is locked. ● When the indicator light is flashing, turning the handlebar back and forth will help the differential gear lock to engage. ● Riding before the differential gear lock is properly engaged (e.g., when the indicator light is flashing) will cause the engine speed to be limited until engagement is complete.
U1D910.book Page 14 Thursday, May 27, 2004 11:08 AM EBU01159 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. 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.
U1D910.book Page 15 Thursday, May 27, 2004 11:08 AM EBU00070 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 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).
U1D910.book Page 16 Thursday, May 27, 2004 11:08 AM EBU00608 Drive select lever The drive select lever is used to shift your machine into the low, high, neutral, reverse and park positions. (Refer to page 6-4 for the drive select lever operation.) 1. Brake pedal 1. Drive select lever 1.
U1D910.book Page 17 Thursday, May 27, 2004 11:08 AM EBU00855 Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out. WARNING POTENTIAL HAZARD Starting the engine without setting the drive select lever to the park position “P”. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident.
U1D910.book Page 18 Thursday, May 27, 2004 11:08 AM EBU00092 EBU00930 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position, fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.
U1D910.book Page 19 Thursday, May 27, 2004 11:08 AM OFF Position RES Position 1. Arrow mark pointing to “OFF” 1. Arrow mark pointing to “RES” ON Position 1.
U1D910.book Page 20 Thursday, May 27, 2004 11:08 AM EBU00095 EBU05670 Starter (choke) “ ” Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to “Starting a cold engine” for proper operation. (See page 6-1.) Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. 1. Seat 1.
U1D910.book Page 21 Thursday, May 27, 2004 11:08 AM EBU15230 To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. Storage compartment NOTE: Make sure that the seat is securely fitted. The storage compartment is located under the seat. (See page 4-20 for seat removal and installation procedures.) When storing any documents in the storage compartment, be sure to wrap them in a plastic bag so that they will not get wet.
U1D910.book Page 22 Thursday, May 27, 2004 11:08 AM EBU00582 Front carrier Maximum load limit: 40 kg (88 lb) EBU00583 Rear carrier Maximum load limit: 80 kg (176 lb) 1. Storage compartment 1.
U1D910.book Page 23 Thursday, May 27, 2004 11:08 AM EBU15220 Front and rear shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direction b. 1. Spring preload adjusting ring 2. Position indicator NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment.
U1D910.book Page 24 Thursday, May 27, 2004 11:08 AM WARNING POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting. 1.
U1D910.book Page 25 Thursday, May 27, 2004 11:08 AM EBU10020 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running. 1. Set the light switch to “OFF”. Maximum rated capacity for the auxiliary DC jack: DC 12 V, 120 W (10 A) 4. When the auxiliary DC jack is not being used, cover it with the cap. CAUTION: _ ● ● ● 1.
U1D910.book Page 26 Thursday, May 27, 2004 11:08 AM 1. Auxiliary DC jack EBU00112 WARNING Indicates a potential hazard that could result in serious injury or death.
U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM 1- PRE-OPERATION CHECKS 1 Before using this machine, check the following points: 2 ITEM ROUTINE PAGE Front brake • Check operation, lever free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary. 5-2–5-3, 8-39–8-43 4 Rear brake • Check operation, lever free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary. 5-2–5-3, 8-40–8-45 5 Fuel • Check fuel level. • Fill with fuel if necessary.
U1D910.book Page 2 Thursday, May 27, 2004 11:08 AM EBU11011 Front and rear brakes Brake levers and brake pedal ● Check that there is no free play in the front brake lever. If there is free play, have a Yamaha dealer adjust it. ● Check for correct free play in the rear brake lever. If the free play is incorrect, adjust it. (See pages 8-44–8-45.) ● Check for correct brake pedal height. If the pedal height is incorrect, have a Yamaha dealer adjust it. ● Check the operation of the brake levers and pedal.
U1D910.book Page 3 Thursday, May 27, 2004 11:08 AM Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs. Apply the brakes firmly for one minute. If the lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake system should be inspected by a Yamaha dealer. WARNING POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.
U1D910.book Page 4 Thursday, May 27, 2004 11:08 AM EBU01085 Fuel Make sure there is sufficient gasoline in the tank. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost.
U1D910.book Page 5 Thursday, May 27, 2004 11:08 AM Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems. 1. Fuel level WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury.
U1D910.book Page 6 Thursday, May 27, 2004 11:08 AM EBU10842 EBU00493 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-12– 8-17.) Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-17– 8-20 for details.) CAUTION: Recommended oil: SAE 80 API GL-4 Hypoid gear oil _ ● ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
U1D910.book Page 7 Thursday, May 27, 2004 11:08 AM EBU12530 Coolant Check the coolant level in the coolant reservoir when the engine is cold. (The coolant level will vary with engine temperature.) The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir. If the coolant level is at or below the minimum level mark, add distilled water to bring the level up to maximum level mark. Change the coolant every two years. (See pages 8-22–8-27 for details.
U1D910.book Page 8 Thursday, May 27, 2004 11:08 AM EBU11620 EBU00157 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. Tires WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure.
U1D910.book Page 9 Thursday, May 27, 2004 11:08 AM 2. The tires should be set to the recommended pressure: ● Recommended tire pressure Front 25 kPa (0.25 kgf/cm2, 3.6 psi) Rear 25 kPa (0.25 kgf/cm2, 3.6 psi) ● Check and adjust tire pressures when the tires are cold. ● Tire pressures must be equal on both sides. 3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums: Front 22 kPa (0.22 kgf/cm2, 3.
U1D910.book Page 10 Thursday, May 27, 2004 11:08 AM EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set pressure with tires cold. Set tire pressures to the following specifications: ACE-02EACE-02E Recommended pressure Minimum Maximum Front 25 kPa (0.25 kgf/cm2, 3.
U1D910.book Page 11 Thursday, May 27, 2004 11:08 AM EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a.
U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM EBU00161 EBU15110 OPERATION Starting a cold engine 1- WARNING WARNING POTENTIAL HAZARD Freezing control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or collision. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding. Indicates a potential hazard that could result in serious injury or death.
U1D910.book Page 2 Thursday, May 27, 2004 11:08 AM Position 3 : Cold engine startambient temperature above 25 °C (80 °F) and warm engine start position. NOTE: ● When the drive select lever is in the neutral or park position, if either indicator light does not come on, ask a Yamaha dealer to inspect the respective electric circuit. ● The engine can be started in any gear if the rear brake lever or brake pedal is applied. However, it is recommended to shift into neutral or park before starting the engine.
U1D910.book Page 3 Thursday, May 27, 2004 11:08 AM NOTE: ● If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. ● If the battery is discharged, pull the recoil starter to start the engine. CAUTION: _ _ See the “Engine break-in” section prior to operating the engine for the first time.
U1D910.book Page 4 Thursday, May 27, 2004 11:08 AM EBU08461 Drive select lever operation and reverse driving CAUTION: _ Before shifting, you must stop the ATV and return the throttle lever to the closed position, otherwise the transmission may be damaged. _ Shifting: Neutral to High and High to Low 1. Bring the ATV to a complete stop and return the throttle lever to the closed position. 2. Apply the brakes, then shift by moving the drive select lever along the shift guide. 1. Drive select lever 3.
U1D910.book Page 5 Thursday, May 27, 2004 11:08 AM Shifting: Neutral to Reverse and Reverse to Park NOTE: The drive select lever cannot be shifted into or from reverse or park without applying the rear brake. _ _ 1. Bring the ATV to a complete stop and return the throttle lever to the closed position. 2. Apply the brake pedal. 3. Shift from neutral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide. 1.
U1D910.book Page 6 Thursday, May 27, 2004 11:08 AM 5. Open the throttle lever gradually and continue to watch to the rear while backing. WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.
U1D910.book Page 7 Thursday, May 27, 2004 11:08 AM EBU02101 Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances.
U1D910.book Page 8 Thursday, May 27, 2004 11:08 AM EBU00612 10–20 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely but do not use full throttle at any time. Parking When parking, stop the engine and shift the drive select lever into the park position, then turn the fuel cock to the “OFF” position. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally.
U1D910.book Page 9 Thursday, May 27, 2004 11:08 AM EBU06151 Parking on a slope 1. Bring the machine to a stop by applying the brakes. 2. Stop the engine. 3. With the brake pedal applied, shift the drive select lever to the park position “P”. WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines.
U1D910.book Page 10 Thursday, May 27, 2004 11:08 AM EBU00221 Accessories and loading ● EBU00222 Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. ● Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market.
U1D910.book Page 11 Thursday, May 27, 2004 11:08 AM EBU15260 Loading Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: ● Never exceed the weight limits shown. An overloaded ATV can be unstable.
U1D910.book Page 12 Thursday, May 27, 2004 11:08 AM ● ● ● ● Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer. Allow more braking distance. A heavier vehicle takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully.
U1D910.book Page 13 Thursday, May 27, 2004 11:08 AM EBU15280 WARNING _ Indicates a potential hazard that could result in serious injury or death.
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U1D910.book Page 3 Thursday, May 27, 2004 11:08 AM WARNING _ Indicates a potential hazard that could result in serious injury or death. Owner’s Manual completely and understand the operation of the controls. Pay particular attention to the safety information on pages 2-1–2-6. Please also read all caution and warning labels on your ATV. GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use. This section, Riding your ATV, provides general ATV riding instructions for recreational riding.
U1D910.book Page 4 Thursday, May 27, 2004 11:08 AM RIDE WITH CARE AND GOOD JUDGEMENT HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating techniques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Get training if you are inexperienced.
U1D910.book Page 5 Thursday, May 27, 2004 11:08 AM Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc.
U1D910.book Page 6 Thursday, May 27, 2004 11:08 AM This ATV is designed to carry operator and cargo only – passengers prohibited. 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 passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.
U1D910.book Page 7 Thursday, May 27, 2004 11:08 AM Apparel Operating without protective clothing increases your chances of severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing.
U1D910.book Page 8 Thursday, May 27, 2004 11:08 AM Do not operate after consuming alcohol or drugs. Operator’s performance capability is reduced by the influence of alcohol or drugs. WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident.
U1D910.book Page 9 Thursday, May 27, 2004 11:08 AM Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the ATV. WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident.
U1D910.book Page 10 Thursday, May 27, 2004 11:08 AM Speed limiter For riders less experienced with this model, this model is equipped with a speed limiter in the throttle lever housing. 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. Turning the adjusting screw in decreases top speed and turning it out increases top speed.
U1D910.book Page 11 Thursday, May 27, 2004 11:08 AM Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Reduce your speed when adding additional loads. WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident.
U1D910.book Page 12 Thursday, May 27, 2004 11:08 AM During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.
U1D910.book Page 13 Thursday, May 27, 2004 11:08 AM Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
U1D910.book Page 14 Thursday, May 27, 2004 11:08 AM Modifications WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories.
U1D910.book Page 15 Thursday, May 27, 2004 11:08 AM Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it. WARNING POTENTIAL HAZARD Hot exhaust system.
U1D910.book Page 16 Thursday, May 27, 2004 11:08 AM BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.
U1D910.book Page 17 Thursday, May 27, 2004 11:08 AM Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. 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.
U1D910.book Page 18 Thursday, May 27, 2004 11:08 AM Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. 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.
U1D910.book Page 19 Thursday, May 27, 2004 11:08 AM 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 vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.
U1D910.book Page 20 Thursday, May 27, 2004 11:08 AM When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. WHAT CAN HAPPEN You could be in a collision. You could be injured. HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles. Do not ride in areas posted “no trespassing”.
U1D910.book Page 21 Thursday, May 27, 2004 11:08 AM With the engine idling, shift the drive select lever to the low position “L” or the high position “H”. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is applied too abruptly, the front wheels may lift off the ground resulting in a loss of directional control. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV.
U1D910.book Page 22 Thursday, May 27, 2004 11:08 AM TURNING YOUR ATV To achieve maximum traction while riding offroad in 2WD or 4WD, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Furthermore, when riding in 4WD-LOCK (“DIFF. LOCK”), the front wheels also turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning.
U1D910.book Page 23 Thursday, May 27, 2004 11:08 AM Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, 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.
U1D910.book Page 24 Thursday, May 27, 2004 11:08 AM CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.
U1D910.book Page 25 Thursday, May 27, 2004 11:08 AM WARNING An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner’s Manual. Always check the terrain carefully before you start up any hill.
U1D910.book Page 26 Thursday, May 27, 2004 11:08 AM If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.
U1D910.book Page 27 Thursday, May 27, 2004 11:08 AM When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
U1D910.book Page 28 Thursday, May 27, 2004 11:08 AM the front and rear brakes gradually, or dismount the ATV immediately on the uphill side. If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then descend the hill.
U1D910.book Page 29 Thursday, May 27, 2004 11:08 AM If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brake while rolling backwards. Apply the front brake. When fully stopped, shift to the parking position “P”. 4WD or 4WD-LOCK: Apply both front and rear brakes gradually. When fully stopped, shift to the parking position “P”. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner’s Manual.
U1D910.book Page 30 Thursday, May 27, 2004 11:08 AM RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you. For maximum engine compression braking effect, select low range “L” and change to 4WD or 4WD-LOCK before beginning to descend the hill. Improper braking may cause a loss of traction.
U1D910.book Page 31 Thursday, May 27, 2004 11:08 AM WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. Always follow proper procedures for going down hills as described in this Owner’s Manual. Note: a special technique is required when braking as you go down a hill. HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed.
U1D910.book Page 32 Thursday, May 27, 2004 11:08 AM CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills.
U1D910.
U1D910.book Page 34 Thursday, May 27, 2004 11:08 AM CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) 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 carefully. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water.
U1D910.book Page 35 Thursday, May 27, 2004 11:08 AM Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. CAUTION: _ After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose, the drive select lever box check hose and the storage compartment check hose.
U1D910.book Page 36 Thursday, May 27, 2004 11:08 AM 1. V-belt cooling duct check hose (left front side of ATV) 1. Storage compartment check hose 1. Drive select lever box check hose 1.
U1D910.book Page 37 Thursday, May 27, 2004 11:08 AM RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision.
U1D910.book Page 38 Thursday, May 27, 2004 11:08 AM SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide.
U1D910.book Page 39 Thursday, May 27, 2004 11:08 AM With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost. WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV.
U1D910.book Page 40 Thursday, May 27, 2004 11:08 AM WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. ● WHAT TO DO ... ● If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See pages 7-22–7-23.
U1D910.book Page 41 Thursday, May 27, 2004 11:08 AM ● ● If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 7-32– 7-33.
U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM EBU00515 PERIODIC MAINTENANCE AND ADJUSTMENT Have a Yamaha dealer perform service if you are not familiar with machine service. 1- Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages.
U1D910.book Page 2 Thursday, May 27, 2004 11:08 AM The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the Owner’s tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts. WARNING POTENTIAL HAZARD Operating this ATV with improper modifications.
U1D910.book Page 3 Thursday, May 27, 2004 11:08 AM EBU02611 PERIODIC MAINTENANCE/LUBRICATION NOTE: _ ● For 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 intervals. How- ever, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
U1D910.book Page 4 Thursday, May 27, 2004 11:08 AM ITEM Fuel line* Engine oil Engine oil filter cartridge Engine oil strainer* Final gear oil Differential gear oil Front brake* Rear brake* Select lever safety system cable* V-belt* Wheels* Wheel bearing* Front and rear suspension* Steering system* Rear upper and lower knuckle pivots* Drive shaft universal joint* Engine mount* Front and rear axle boots* Whichever month comes first km (mi) hours ROUTINE • • • • • Check fuel hose for cracks or damage.
U1D910.book Page 5 Thursday, May 27, 2004 11:08 AM ITEM Whichever month comes first km (mi) hours ROUTINE 1 320 (200) 20 INITIAL 3 1,200 (750) 75 6 2,400 (1,500) 150 EVERY 6 12 2,400 4,800 (1,500) (3,000) 150 300 Stabilizer bushes* • Check for cracks or damage. • Check all chassis fittings and fasteners. • Correct if necessary. • Check operation. Lights and switches* • Adjust headlight beams.
U1D910.book Page 6 Thursday, May 27, 2004 11:08 AM EBU00614 Panel removal and installation The panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a panel has to be removed or reinstalled. 1. Panel C 3. Panel E 1. Panel A 2. Panel B 8-6 2. Panel D 4.
U1D910.book Page 7 Thursday, May 27, 2004 11:08 AM EBU00700 Panel A, D To remove 1. Remove the seat. 2. Pull outward on the areas shown, and then pull upward.
U1D910.book Page 8 Thursday, May 27, 2004 11:08 AM To install 1. Place the panel in its original position. 2. Install the seat.
U1D910.book Page 9 Thursday, May 27, 2004 11:08 AM EBU01147 EBU15370 Panel B To remove Remove the bolt, and then take the panel off. To install Place the panel in the original position and install the bolt. Panel C To remove 1. Remove the top carrier bolts. CAUTION: _ When installing the panel, be sure not to pinch the cables or wires. _ 1. Carrier bolt (× 4) (top) 2. Remove the carrier bolts under the fenders, and then take the carrier off. 1. Bolt 2.
U1D910.book Page 10 Thursday, May 27, 2004 11:08 AM To install 1. Place the panel in the original position, and then install the quick fastener screws. 2. Place the carrier in the original position, and then install the carrier bolts under the fenders. 3. Install the top carrier bolts, and then tighten all bolts to the specified torques. 1. Bolt (× 2) (under fenders) Tightening torque: Carrier bolt (top): 34 Nm (3.4 m·kgf, 25 ft·lbf) Carrier bolt (under fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 3.
U1D910.book Page 11 Thursday, May 27, 2004 11:08 AM EBU01013 EBU00638 Panel E To remove Remove the bolts, and then take the panel off. To install Place the panel in the original position, and then install the bolts. Panel F To remove Pull outward on the areas shown. 1. Panel F 1. Panel E 2.
U1D910.book Page 12 Thursday, May 27, 2004 11:08 AM EBU10992 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. To install Place the panel in its original position. To check the engine oil level 1. Remove panel F. (See page 8-11 for panel removal and installation procedures.) 2. Place the ATV on a level surface.
U1D910.book Page 13 Thursday, May 27, 2004 11:08 AM 1. Maximum level mark 1. Engine oil filler cap 6. Insert the dipstick in the oil filler hole (without screwing it in), and then remove it again to check the oil level. 2. Minimum level mark 7. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. 8. Insert the dipstick into the oil filler hole, and then tighten the oil filler cap. 9. Install the panel.
U1D910.book Page 14 Thursday, May 27, 2004 11:08 AM NOTE: Skip steps 5–9 if the oil filter cartridge is not being replaced. To change the engine oil (with or without oil filter cartridge replacement) 1. Remove panel F. (See page 8-11 for panel removal and installation procedures.) 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap. 4.
U1D910.book Page 15 Thursday, May 27, 2004 11:08 AM 1. Oil filter wrench 1. O-ring NOTE: An oil filter wrench is available at a nearby Yamaha dealer. 8. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. _ _ 7. Apply a light coat of engine oil to the O-ring of the new oil filter cartridge. Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf) NOTE: Make sure the O-ring is seated properly.
U1D910.book Page 16 Thursday, May 27, 2004 11:08 AM Recommended engine oil: See page 10-2. Oil quantity: Without oil filter cartridge replacement: 2.30 L (2.02 Imp qt, 2.43 US qt) With oil filter cartridge replacement: 2.40 L (2.11 Imp qt, 2.54 US qt) CAUTION: 1. Torque wrench _ ● 9. Install panels E and D. 10. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 23 Nm (2.3 m·kgf, 16 ft·lbf) 11.
U1D910.book Page 17 Thursday, May 27, 2004 11:08 AM EBU15380 Final gear oil Checking the final gear oil level 1. Place the ATV on a level surface. 2. Remove the oil filler bolt, and then check the oil level in the final gear case. 12. Start the engine and warm it up for several minutes. While warming up, check for oil leakage. If oil leakage is found, turn the engine off immediately and check for the cause. 13. Turn the engine off, and then check the oil level and correct it if necessary. 14.
U1D910.book Page 18 Thursday, May 27, 2004 11:08 AM Changing the final gear oil 1. Remove the engine guard and the final gear case guard by removing the bolts. CAUTION: _ Be sure no foreign material enters the final gear case. _ 4. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 16 ft·lbf) 1. Engine guard 3. Bolt (× 11) 2. Final gear case guard 2. Place the ATV on a level surface. 3.
U1D910.book Page 19 Thursday, May 27, 2004 11:08 AM 6. Add the recommended final gear oil to the brim of the filler hole. 4. Remove the oil filler bolt and the drain bolt to drain the oil. Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.23 L (0.20 Imp qt, 0.24 US qt) CAUTION: _ Be sure no foreign material enters the final gear case. _ 7. Install the oil filler bolt, and then tighten it to the specified torque. 1. Final gear oil drain bolt 5.
U1D910.book Page 20 Thursday, May 27, 2004 11:08 AM EBU07063 Differential gear oil Checking the differential gear oil 1. Place the ATV on a level surface. 2. Remove the differential gear oil filler bolt and check the oil level. It should be up to the brim of the filler hole. If the level is low, add sufficient oil of the recommended type to raise it to the specified level. 9. Install the engine guard and the final gear case guard by installing the bolts, and then tightening them to the specified torques.
U1D910.book Page 21 Thursday, May 27, 2004 11:08 AM CAUTION: _ Be sure no foreign material enters the differential gear case. _ 3. Install the differential gear oil filler bolt, and then tighten it to the specified torque. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 16 ft·lbf) 1. Differential gear oil drain bolt 4. Install the differential gear oil drain bolt and tighten it to the specified torque. Replacing the differential gear oil 1. Place the ATV on a level surface. 2.
U1D910.book Page 22 Thursday, May 27, 2004 11:08 AM EBU12560 Cooling system 1. Place the ATV on a level surface. 2. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature. Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.23 L (0.20 Imp qt, 0.24 US qt) CAUTION: NOTE: The coolant should be between the minimum and maximum level marks. _ _ Be sure no foreign material enters the differential gear case. _ _ 6.
U1D910.book Page 23 Thursday, May 27, 2004 11:08 AM 3. If the coolant is at or below the minimum level mark, remove panel D (See pages 8-7–8-8, 8-11 for panel removal and installation procedures.), remove the reservoir cap, add coolant to the maximum level mark, install the reservoir cap, and then install the panel. NOTE: ● If water is added, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible. ● The radiator fan operation is completely automatic.
U1D910.book Page 24 Thursday, May 27, 2004 11:08 AM EBU12572 Changing the coolant 1. Place the ATV on a level surface. 2. Remove panels E and F. (See pages 8-11–8-12 for panel removal and installation procedures.) 3. Place a container under the engine, and then remove the coolant drain bolt. (Use a trough or a similar object as shown to prevent coolant from spilling on the footrest.) WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot.
U1D910.book Page 25 Thursday, May 27, 2004 11:08 AM 1. Radiator cap 1. Trough 4. Remove the front carrier and panel C. (See pages 8-9–8-10 for removal and installation procedures.) 5. Remove the radiator cap. 6. Remove panel D. (See pages 8-7–8-8 for panel removal and installation procedures.) 7. Remove the coolant reservoir cap. 8. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir.
U1D910.book Page 26 Thursday, May 27, 2004 11:08 AM 11. Install the coolant reservoir hose. 12. Pour the recommended coolant into the reservoir to the maximum level mark, and then install the reservoir cap and panel D. 13. Pour the recommended coolant into the radiator until it is full, and then install the radiator cap. Recommended antifreeze: High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines. Antifreeze and water mixing ratio: 1:1 Total amount: 1.30 L (1.
U1D910.book Page 27 Thursday, May 27, 2004 11:08 AM EBU00862 Axle boots Check the protective boots for holes or tears. If any damage is found, have them replaced by a Yamaha dealer. CAUTION: _ Hard water or salt water is harmful to the engine. You may use soft water if you cannot get distilled water. _ 14. Start the engine and let it idle for several minutes. Stop the engine, and then check the coolant level in the radiator. If it is low, add more coolant until it reaches the top of the radiator. 15.
U1D910.book Page 28 Thursday, May 27, 2004 11:08 AM EBU00864 Spark plug inspection Removal 1. Remove panel A. (See pages 8-7–8-8 for panel removal and installation procedures.) 2. Remove the spark plug cap. 1. Rear axle boot (× 2 each side) 1.
U1D910.book Page 29 Thursday, May 27, 2004 11:08 AM Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug. 3.
U1D910.book Page 30 Thursday, May 27, 2004 11:08 AM NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. _ _ 4. Install the spark plug cap. 5. Install the panel. a. Spark plug gap 2. Clean the gasket surface. Wipe off any grime from the threads. 3. Install the spark plug and tighten it to the specified torque.
U1D910.book Page 31 Thursday, May 27, 2004 11:08 AM EBU15140 Air filter element cleaning NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. _ _ 1. Fastener (× 4) 2. Air filter case cover 3. Remove the air filter element assembly. 1. Air filter case check hose 1. Remove the seat. (See pages 4-20–4-21 for seat removal and installation procedures.) 2.
U1D910.book Page 32 Thursday, May 27, 2004 11:08 AM 4. Pull off the lock plate, and then remove the air filter element from its frame. 1. Air filter element frame 3. Lock plate WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element. 6.
U1D910.book Page 33 Thursday, May 27, 2004 11:08 AM NOTE: The air filter element should be cleaned every 20–40 hours. It should be cleaned and lubricated more often if the machine is operated in extremely dusty areas. Each time the air filter element maintenance is performed, check the air inlet to the filter case for obstructions. Check the air filter case rubber joint to the carburetor and manifold fittings for an airtight seal.
U1D910.book Page 34 Thursday, May 27, 2004 11:08 AM EBU06411 EBU08741 V-belt cooling duct check hose If dust or water collects in the V-belt cooling duct check hose, remove the hose and clean it. V-belt case drain plug After riding in water deep enough to allow it to enter the V-belt case, remove this plug to drain the water from the case. NOTE: If water drains from the V-belt case after removing the plug, have a Yamaha dealer inspect the ATV as the water may affect other engine parts. _ _ 1.
U1D910.book Page 35 Thursday, May 27, 2004 11:08 AM EBU01066 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the tailpipe by pulling it out of the muffler. 1. Tailpipe 2. Spark arrester 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install and tighten the bolts. 1. Bolt (× 3) 2. Tailpipe 3.
U1D910.book Page 36 Thursday, May 27, 2004 11:08 AM EBU00296 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine. WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system WHAT CAN HAPPEN Could injure the eyes.
U1D910.book Page 37 Thursday, May 27, 2004 11:08 AM EBU12580 Idle speed adjustment 3. Connect the tachometer to the spark plug lead, and then set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw in direction a to increase the engine speed, and in direction b to decrease the engine speed. NOTE: A diagnostic tachometer must be used for this procedure. _ _ 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min.
U1D910.book Page 38 Thursday, May 27, 2004 11:08 AM EBU00303 EBU00307 Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician. Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2.
U1D910.book Page 39 Thursday, May 27, 2004 11:08 AM EBU03050 EBU13090 Select lever safety system cable adjustment The select lever safety system cable stretches with use, resulting in improper function. To prevent this, the cable must be adjusted regularly. This adjustment, however, should be left to a Yamaha dealer. Front brake pad check Check the brake pads for damage and wear. If a brake pad thickness is less than 1.0 mm (0.04 in), have a Yamaha dealer replace the pads as a set. a.
U1D910.book Page 40 Thursday, May 27, 2004 11:08 AM EBU06212 NOTE: The wheels need to be removed to check the brake pads. (See pages 8-49–8-50 for wheel removal and installation procedures.) Rear brake pad check Check the brake pads for damage or wear. Wear indicator grooves are provided on the brake pads. These indicators allow checking of brake pad wear without disassembling the brake. Check the wear indicator grooves.
U1D910.book Page 41 Thursday, May 27, 2004 11:08 AM EBU06221 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish when necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.
U1D910.book Page 42 Thursday, May 27, 2004 11:08 AM Observe these precautions: ● When checking the fluid level, make sure the top of the master cylinder reservoirs are level. ● Use only the designated quality brake fluid. Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. ● ● EBU11860 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel.
U1D910.book Page 43 Thursday, May 27, 2004 11:08 AM EBU11870 Front brake lever free play The front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a Yamaha dealer check the brake system. WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct.
U1D910.book Page 44 Thursday, May 27, 2004 11:08 AM EBU09631 Adjusting the rear brake lever and brake pedal Adjusting the rear brake lever The rear brake lever free play should be 0.5– 2.0 mm (0.02–0.08 in). 1. Loosen the locknut. If correct free play cannot be obtained, ask a Yamaha dealer to make that adjustment. NOTE: When adjusting the rear brake lever free play: ● Be sure not to step on the brake pedal. ● Make sure the brake pedal does not move. _ _ 1. Locknut 2. Adjusting bolt c.
U1D910.book Page 45 Thursday, May 27, 2004 11:08 AM Adjusting the brake pedal The top of the brake pedal should be positioned 72 mm (2.83 in) above the top of the footrest. If not, ask a Yamaha dealer to adjust it. WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: sure the brakes operate ● Make smoothly and that the free play is correct.
U1D910.book Page 46 Thursday, May 27, 2004 11:08 AM EBU12590 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and rear brake lever, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1. Remove panel B. (See page 8-9 for panel removal and installation procedures.) 2. Turn the adjusting nut while holding the rear brake light switch in place.
U1D910.book Page 47 Thursday, May 27, 2004 11:08 AM EBU00356 EBU12600 Cable inspection and lubrication Lubricating the brake levers and brake pedal Lubricate the pivoting parts. WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently.
U1D910.book Page 48 Thursday, May 27, 2004 11:08 AM EBU13110 Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun. 1. Upper knuckle 2.
U1D910.book Page 49 Thursday, May 27, 2004 11:08 AM EBU01112 EBU11211 Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Wheel installation 1. Install the wheel and the nuts. NOTE: ● The arrow mark on the tire must point toward the rotating direction of the wheel. ● Tapered nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel. _ _ 1.
U1D910.book Page 50 Thursday, May 27, 2004 11:08 AM EBU00380 Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a Yamaha dealer. 2. Lower the ATV so that the wheel is on the ground. 1. Tapered nut 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear: 55 Nm (5.5 m·kgf, 40 ft·lbf) 1.
U1D910.book Page 51 Thursday, May 27, 2004 11:08 AM CAUTION: HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Get prompt medical attention. EYES: Flush with water for 15 minutes and get prompt medical attention.
U1D910.book Page 52 Thursday, May 27, 2004 11:08 AM EBU00385 EBU08762* Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. Fuse replacement 1. The main fuse and the fuse box are located under the seat. 2. If a fuse is blown, turn off the main switch and the switch of the circuit in question. Then, install a new fuse of the specified amperage. Turn on the main switch.
U1D910.book Page 53 Thursday, May 27, 2004 11:08 AM 1. Main fuse 1. Main fuse 2. Fuse box 1. 3. 5. 6. 7. Headlight fuse 2. Ignition fuse Auxiliary DC jack fuse 4. Four-wheel drive fuse Signaling system fuse Backup fuse (for odometer and clock) Spare fuse (× 3) Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Four-wheel drive fuse: Signaling system fuse: Backup fuse: 2. Spare main fuse 8-53 30.0 A 15.0 A 10.0 A 10.0 A 3.0 A 10.0 A 10.
U1D910.book Page 54 Thursday, May 27, 2004 11:08 AM EBU14560 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the bulb holder cover at the rear of the headlight by pulling it off. WARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse.
U1D910.book Page 55 Thursday, May 27, 2004 11:08 AM 2. Remove the headlight bulb holder by turning it counterclockwise. 1. Headlight bulb holder tab (× 2) 1. Headlight bulb holder 3. Remove the defective bulb by unhooking the headlight bulb holder tabs.
U1D910.book Page 56 Thursday, May 27, 2004 11:08 AM WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it. 1. Do not touch the glass part of the bulb.
U1D910.book Page 57 Thursday, May 27, 2004 11:08 AM EBU01089 Headlight beam adjustment 5. Install the headlight bulb holder by turning it clockwise. 6. Install the headlight bulb holder cover at the rear of the headlight. CAUTION: _ It is advisable to have a Yamaha dealer make this adjustment. _ To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b. 1.
U1D910.book Page 58 Thursday, May 27, 2004 11:08 AM EBU09640 Tail/brake light bulb replacement 1. Remove the nuts together with the washers. 1. Tail/brake light unit 1. Tail/brake light unit 2. Tail/brake light bulb holder 3. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 2. Nut (× 2) 2. Remove the bulb holder (together with the bulb) by turning it counterclockwise.
U1D910.book Page 59 Thursday, May 27, 2004 11:08 AM EBU00412 1. Tail/brake light bulb holder Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer.
U1D910.book Page 60 Thursday, May 27, 2004 11:08 AM WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe injury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces.
U1D910.book Page 61 Thursday, May 27, 2004 11:08 AM EBU08061 Troubleshooting charts Starting problems or poor engine performance Turn the fuel cock lever to “ON”. There is fuel. Turn the fuel cock lever to “OFF”. Remove the fuel hose from the fuel cock. Some fuel. Turn the fuel cock lever to “RES”. Restart the engine. No fuel. Supply fuel. 1. Fuel Check if there is fuel in the fuel tank. 2. Compression Use the electric starter to see if there is compression. 3. Ignition There is compression.
U1D910.book Page 62 Thursday, May 27, 2004 11:08 AM Engine overheating HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap. WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. Leakage.
U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM EBU00419 CLEANING AND STORAGE CAUTION: 1- Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers. A.
U1D910.book Page 2 Thursday, May 27, 2004 11:08 AM 6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes. WARNING POTENTIAL HAZARD Operation with wet brakes after washing.
U1D910.book Page 3 Thursday, May 27, 2004 11:08 AM EBU00530 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equivalent product. 2.
U1D910.book Page 4 Thursday, May 27, 2004 11:08 AM 7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)). NOTE: Make any necessary repairs before storing the machine.
U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM EBU00428 SPECIFICATIONS 1- Model YFM450FA Dimensions: Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Starting system Lubrication system 1,993 mm (78.5 in) 1,093 mm (43.0 in) 1,120 mm (44.1 in) 830 mm (32.7 in) 1,233 mm (48.5 in) 245 mm (9.65 in) 3,000 mm (118.
U1D910.book Page 2 Thursday, May 27, 2004 11:08 AM Model YFM450FA 1 Engine oil: Type 2 0˚ 10˚ 30˚ 50˚ 70˚ 90˚ 110˚ 130˚F 3 4 YAMALUBE 4 (20W40) or SAE 20W40 5 YAMALUBE 4 (10W30) or SAE 10W30 6 SAE 5W30 -20˚ Recommended engine oil classification -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
U1D910.book Page 3 Thursday, May 27, 2004 11:08 AM Model YFM450FA Final gear case oil: Type Quantity Differential gear case oil: Type Quantity Radiator capacity (including all routes): Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount Carburetor: Type/quantity Manufacturer SAE 80 API GL-4 Hypoid gear oil 0.23 L (0.20 Imp qt, 0.24 US qt) SAE 80 API GL-4 Hypoid gear oil 0.23 L (0.20 Imp qt, 0.24 US qt) 1.30 L (1.14 Imp qt, 1.37 US qt) Wet type element UNLEADED GASOLINE ONLY 15.0 L (3.
U1D910.book Page 4 Thursday, May 27, 2004 11:08 AM Model Spark plug: Type/manufacturer Spark plug gap Clutch type: Transmission: Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Reverse gear Sub transmission ratio Chassis: Frame type Caster angle Trail Tire: Type Size YFM450FA DR8EA / NGK 0.6–0.7 mm (0.024–0.028 in) Wet, centrifugal automatic V-belt Shaft drive 39/24 × 24/18 × 33/9 (7.944) V-belt automatic Left hand operation 29/17 (1.706) 45/16 (2.
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U1D910.book Page 6 Thursday, May 27, 2004 11:08 AM Model YFM450FA Bulb voltage, wattage × quantity: Headlight Tail/brake light Indicator light: Neutral indicator light Reverse indicator light Coolant temperature warning light Park indicator light High-range indicator light Low-range indicator light Differential gear lock indicator light Fuses: Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four-wheel drive fuse Signaling system fuse Backup fuse 12 V 30W/30.0 W × 2 12 V 5W/21.
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U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM EBU13653 1- MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM EBU00432 YAMAHA MOTOR CORPORATION, U.S.A.
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U1D910.book Page 1 Thursday, May 27, 2004 11:08 AM EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.
U1D910.book Page 2 Thursday, May 27, 2004 11:08 AM 1 2 3 4 5 6 7 8 9 10 11 12 13 EBU00436 14 WARNING _ Indicates a potential hazard that could result in serious injury or death.
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EBU00438 READ THIS MANUAL CAREFULLY! It contains important safety information. WARNING Improper ATV use can result in SEVERE INJURY or DEATH. BEER BEER ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns.