OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM7FGPW 3B4-28199-61
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ IMPRESO EN PAPEL RECICLADO PRINTED IN JAPAN 2006.08-2.
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U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM EBU27850 EC Declaration of Conformity conforming to Directive 98/37/EC We YAMAHA MOTOR CO., LTD.
U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM EBU17170 INTRODUCTION EBU17290 Congratulations on your purchase of the Yamaha YFM7FGPW. 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.
U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM EBU17350 IMPORTANT NOTICE EBU17370 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway. Please check your local riding laws and regulations before operating this ATV. EBU17390 YFM7FGPW OWNER’S MANUAL ©2006 by Yamaha Motor Co., Ltd. 1st edition, July 2006 All rights reserved.
U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM EBU17420 TABLE OF CONTENTS SAFETY INFORMATION .............................. 1-1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ............................ 2-1 DESCRIPTION .............................................. 3-1 Left view ...................................................... 3-1 Right view.................................................... 3-1 Controls and instruments ............................ 3-2 INSTRUMENT AND CONTROL FUNCTIONS .
U3B461E0.book Page 2 Tuesday, November 21, 2006 1:51 PM Operating the drive select lever and driving in reverse ...................................... 6-2 Engine break-in .......................................... 6-4 Parking ....................................................... 6-5 Parking on a slope ..................................... 6-5 Accessories and loading ............................ 6-6 RIDING YOUR ATV ...................................... 7-1 GETTING TO KNOW YOUR ATV...............
U3B461E0.book Page 3 Tuesday, November 21, 2006 1:51 PM Checking and lubricating the cables ........ 8-52 Checking and lubricating the front and rear brake levers .................................... 8-52 Checking and lubricating the brake pedal ...................................... 8-53 Checking the wheel bearings ................... 8-54 Lubricating the drive shaft universal joint ......................................... 8-54 Checking the stabilizer bushes ................
U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM EBU17430 SAFETY INFORMATION ● EBU27250 ● 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.
U3B461E0.book Page 2 Tuesday, November 21, 2006 1:51 PM ● 1 ● ● ● ● ● ● Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful when operating on unfamiliar terrain.
U3B461E0.book Page 3 Tuesday, November 21, 2006 1:51 PM ● ● ● ● ● steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees.
U3B461E0.book Page 4 Tuesday, November 21, 2006 1:51 PM 1 ● ● nition such as the pilot lights of water heaters and clothes dryers. Gasoline can catch fire and you could be burned. When transporting the ATV in another vehicle, be sure it is kept upright. Otherwise, fuel may leak out of the fuel tank. Gasoline is poisonous. If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, seek medical help immediately.
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U3B461E0.book Page 2 Tuesday, November 21, 2006 1:51 PM EBU27150 2 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replacement label from your Yamaha dealer.
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U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. 2. 3. 4. 5. 6. 7. 8. 1. Rear shock absorber assembly spring preload adjusting ring 2. Rear storage compartment and tool kit 3. Fuel tank cap cover 4. Idle adjusting screw 5. Front shock absorber assembly spring preload adjusting ring 6. Spark plug 7. Brake pedal 8.
U3B461E0.book Page 2 Tuesday, November 21, 2006 1:51 PM EBU17712 NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual. Controls and instruments 3 1. 2. 3. 4. 5. 6. 7. 8. Drive select lever Rear brake lever Handlebar switches Horn switch Rear brake fluid reservoir Multifunction meter unit Front brake fluid reservoir On-Command four-wheel-drive/differential gear lock switch 9. Front brake lever 10.Throttle lever 11.Front storage compartment 12.Main switch 13.
U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM EBU17730 INSTRUMENT AND CONTROL FUNCTIONS EBU17760 Main switch The positions of the main switch are as follows: 4 ON All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed. OFF All electrical systems are off. The key can be removed. 1.
U3B461E0.book Page 2 Tuesday, November 21, 2006 1:51 PM EBU26691 EBU17830 Indicator lights and warning lights Reverse indicator light “ ” This indicator light comes on when the transmission is in the reverse position. EBU17860 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. EBU28662 Coolant temperature warning light “ ” This warning light comes on when the engine overheats.
U3B461E0.book Page 3 Tuesday, November 21, 2006 1:51 PM ● ● 4 ter the engine is started, the EPS system may be defective. When this occurs, have a Yamaha dealer check the EPS system. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on, have a Yamaha dealer check the electrical circuit. The engine may also overheat if mud or dirt has accumulated on the radiator (i.e., after riding in wet terrain).
U3B461E0.book Page 4 Tuesday, November 21, 2006 1:51 PM The On-Command differential gear lock indicator “ ” in the On-Command four-wheel-drive indicator also comes on when the On-Command differential gear lock switch is set to the “LOCK” position. EBU18001 On-Command differential gear lock indicator light “DIFF. LOCK” This indicator light and the On-Command differential gear lock indicator in the display come on when the On-Command differential gear lock switch is set to the “LOCK” position. DIFF.
U3B461E0.book Page 5 Tuesday, November 21, 2006 1:51 PM ● EBU27291 Multifunction display ● ● ● Odometer and tripmeter modes Pushing the “SELECT” 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 “SELECT” button, and then push the “RESET” button for at least three seconds.
U3B461E0.book Page 6 Tuesday, November 21, 2006 1:51 PM CLOCK → HOUR → CLOCK NOTE: This fuel meter is equipped with a self-diagnosis system. If the electrical circuit is defective, all the display segments and fuel level warning indicator will start flashing. If this occurs, have a Yamaha dealer check the electrical circuit. To set the clock 1. Set the display to the clock mode. 2. Push the “SELECT” button and “RESET” button together for at least three seconds. 3.
U3B461E0.book Page 7 Tuesday, November 21, 2006 1:51 PM Self-diagnosis device EBU18060 Handlebar switches 4 1. Error code display 1. 2. 3. 4. 5. This model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the multifunction display will indicate a two-digit error code. If the multifunction display indicates such an error code, note the code number, and then have a Yamaha dealer check the vehicle.
U3B461E0.book Page 8 Tuesday, November 21, 2006 1:51 PM EBU18100 EBU18190 Start switch “ ” Push this switch to crank the engine with the starter. Override switch “OVERRIDE” ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. 4 EBU18151 Light switch “ / /OFF” Set this switch to “ ” to turn on the low beams and the taillight. Set the switch to “ ” to turn on the high beams and the taillight. Set the switch to “OFF” to turn off all the lights. 1.
U3B461E0.book Page 9 Tuesday, November 21, 2006 1:51 PM es with the riding speed. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling. EBU26602 On-Command four-wheel-drive switch “2WD”/“4WD” This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice-versa. Select the appropriate drive according to the terrain and the conditions. ● “2WD” (two-wheel drive): Power is supplied to the rear wheels.
U3B461E0.book Page 10 Tuesday, November 21, 2006 1:51 PM EBU18252 On-Command differential gear lock switch “4WD”/“LOCK” This ATV is equipped with a switch allowing you to lock the differential gear when in four-wheel drive. Select the appropriate switch position according to the terrain and the conditions. ● “4WD” (four-wheel drive): Power is supplied to the rear and front wheels.
U3B461E0.book Page 11 Tuesday, November 21, 2006 1:51 PM To lock the differential gear in four-wheel drive, make sure the On-Command four-wheel-drive switch is pushed in to the “4WD” position. 4 1. On-Command differential gear lock switch “4WD”/“LOCK” To release the differential gear lock, stop the ATV and push the switch to the “4WD” position. 1. Differential gear lock lever 2.
U3B461E0.book Page 12 Tuesday, November 21, 2006 1:51 PM ● pectedly. This could distract the operator and increase the risk of losing control and causing an accident. EWB00140 ● WARNING Always ride at a slow speed when the ATV is in differential gear lock, and allow extra time and distance for maneuvers. All wheels turn at the same speed when the differential gear is locked, so it takes more effort to turn the ATV. The effort needed to turn increases with the riding speed.
U3B461E0.book Page 13 Tuesday, November 21, 2006 1:51 PM EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. 1. Loosen the locknut. 2. To increase the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (a).
U3B461E0.book Page 14 Tuesday, November 21, 2006 1:51 PM 3. Tighten the locknut. EWB00240 WARNING Improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation. You could lose control, have an accident or be injured. Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttle cable could be damaged. Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in). (See page 8-44.) 4 1.
U3B461E0.book Page 15 Tuesday, November 21, 2006 1:51 PM EBU18611 Drive select lever The drive select lever is used to shift your ATV into the low-range, high-range, neutral, reverse and park positions. See the “Operating the drive select lever and driving in reverse” section on page 6-2 for the drive select lever operation. 4 1. Brake pedal 1.
U3B461E0.book Page 16 Tuesday, November 21, 2006 1:51 PM To install the fuel tank cap Install the fuel tank cap by turning it clockwise until a click is heard, and then close the fuel tank cap cover. EBU18750 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. 1. Fuel tank cap cover 1. Fuel level 2. Fuel tank filler tube 1.
U3B461E0.book Page 17 Tuesday, November 21, 2006 1:51 PM ● Recommended fuel: UNLEADED GASOLINE ONLY For Europe: Regular unleaded gasoline only with a research octane number of 91 or higher Fuel tank capacity: 20.0 L (5.28 US gal) (4.40 Imp.gal) Fuel reserve amount: 4.5 L (1.19 US gal) (0.99 Imp.gal) 4 ● ● Be careful not to spill fuel, especially on the engine or exhaust pipe which can cause a fire and severe injury. Wipe up any spilled fuel immediately.
U3B461E0.book Page 18 Tuesday, November 21, 2006 1:51 PM The front storage compartment is located at the front right side of the ATV. To access the storage compartment, remove the storage compartment cover by turning it counterclockwise. 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. NOTE: Make sure that the seat is securely fitted. 4 1. Front storage compartment cover 1. Projection 2.
U3B461E0.book Page 19 Tuesday, November 21, 2006 1:51 PM 4 1. Front storage compartment 1. Rear storage compartment cover The rear storage compartment is located under the seat. (See page 4-17.) To access the storage compartment, remove the storage compartment cover. 1.
U3B461E0.book Page 20 Tuesday, November 21, 2006 1:51 PM When storing any documents in the storage compartments, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartments. ECB00830 CAUTION: Do not store metal or sharply edged objects, like tools, in the storage compartments. If they must be stored, wrap them in appropriate cushion material to prevent damaging the storage compartments. ● ● 4 1.
U3B461E0.book Page 21 Tuesday, November 21, 2006 1:51 PM EBU18960 Front carrier ● ● Do not exceed the load limit of 45.0 kg (99 lb) for the front carrier. Do not exceed the maximum load of 220.0 kg (485 lb) for the ATV. EBU18970 4 Rear carrier ● ● Do not exceed the load limit of 85.0 kg (187 lb) for the rear carrier. Do not exceed the maximum load of 220.0 kg (485 lb) for the ATV. 1. Spring preload adjusting ring 2.
U3B461E0.book Page 22 Tuesday, November 21, 2006 1:51 PM EWB00400 WARNING Always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. EBU19180 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.
U3B461E0.book Page 23 Tuesday, November 21, 2006 1:51 PM 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. ECB00120 CAUTION: ● Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to blow.
U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM EBU19200 PRE-OPERATION CHECKS EBU19220 Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
U3B461E0.book Page 2 Tuesday, November 21, 2006 1:51 PM ITEM Rear brake Throttle lever 5 Control cables Wheels and tires Brake pedal Brake levers Axle boots Chassis fasteners Instruments, lights and switches ROUTINE • Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check pedal free play, and adjust if necessary. • Check brake pads for wear, and replace if necessary. • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.
U3B461E0.book Page 3 Tuesday, November 21, 2006 1:51 PM EBU19540 EBU19600 Fuel Differential gear oil Make sure that there is sufficient fuel in the tank. (See page 4-16.) Make sure that the differential gear oil is at the specified level. Add oil as necessary. (See page 8-29.) EWB00520 ● ● ● ● WARNING Do not overfill the fuel tank. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun.
U3B461E0.book Page 4 Tuesday, November 21, 2006 1:51 PM 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 a lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake system should be checked by a Yamaha dealer. EBU27790 Front and rear brakes 5 Brake levers and brake pedal ● Check that there is no free play in the front and rear brake levers.
U3B461E0.book Page 5 Tuesday, November 21, 2006 1:51 PM EBU19761 Throttle lever Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary. EBU19791 Tires EWB00601 WARNING 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 accident. Pay attention to the following.
U3B461E0.book Page 6 Tuesday, November 21, 2006 1:51 PM 5 Minimum tire pressure: Front: 32.0 kPa (4.6 psi) (0.320 kgf/cm²) Rear: 27.0 kPa (3.9 psi) (0.270 kgf/cm²) • Use no more than the following pressures when seating the tire beads. Maximum tire seating pressure: Front: 250 kPa (36 psi) (2.5 kgf/cm²) Rear: 250 kPa (36 psi) (2.5 kgf/cm²) Higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully. 1.
U3B461E0.book Page 7 Tuesday, November 21, 2006 1:51 PM Recommended pressure: Front 35.0 kPa (5.0 psi) (0.350 kgf/cm²) Rear 30.0 kPa (4.3 psi) (0.300 kgf/cm²) Minimum: Front 32.0 kPa (4.6 psi) (0.320 kgf/cm²) Rear 27.0 kPa (3.9 psi) (0.270 kgf/cm²) Maximum: Front 38.0 kPa (5.5 psi) (0.380 kgf/cm²) Rear 33.0 kPa (4.8 psi) (0.330 kgf/cm²) 5 1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened.
U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM EBU19880 OPERATION EBU19900 ECB00150 CAUTION: See the “Engine break-in” section on page 6-4 prior to operating the engine for the first time. Read the Owner’s Manual carefully before riding the ATV. EWB00630 6 1. Turn the main switch to “ON” and the engine stop switch to “ ”. WARNING Read the Owner’s Manual carefully to become familiar with all controls in order to help prevent any loss of control, which could cause an accident or injury.
U3B461E0.book Page 2 Tuesday, November 21, 2006 1:51 PM ECB00160 NOTE: This model is equipped with an ignition circuit cutoff system. The engine can be started under the following conditions: ● The drive select lever is in the neutral or park position. ● The rear brake lever or brake pedal is applied with the drive select lever in any position. However, it is recommended to shift into the neutral or park position before starting the engine.
U3B461E0.book Page 3 Tuesday, November 21, 2006 1:51 PM Shifting: Neutral to Reverse and Reverse to Park NOTE: Make sure that the drive select lever is completely shifted into position. NOTE: The drive select lever cannot be shifted into or from reverse or park without applying the brake pedal. 1. Bring the ATV to a complete stop. 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. 6 1. 2. 3. 4. 5. 6.
U3B461E0.book Page 4 Tuesday, November 21, 2006 1:51 PM 4. Check behind for people or obstacles, and then release the brake pedal. 5. Open the throttle lever gradually and continue to watch to the rear while backing. EWB00720 1. 2. 3. 4. 5. 6. WARNING Improper operation in reverse could make you hit an obstacle or even a person behind you, resulting in serious injury. When you shift into reverse, make sure there are no people or obstacles behind you. When it is safe to proceed, go slowly.
U3B461E0.book Page 5 Tuesday, November 21, 2006 1:51 PM 0–10 hours Avoid prolonged operation above 1/2 throttle. Vary the speed of the ATV regularly. Do not operate it at one set throttle position. EBU20820 Parking on a slope EWB00860 WARNING Avoid parking on hills or other inclines. Parking on a hill or other incline could cause the ATV to roll out of control, increasing the chance of an accident.
U3B461E0.book Page 6 Tuesday, November 21, 2006 1:51 PM ● ● EBU20910 Accessories and loading ● EBU20920 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.
U3B461E0.book Page 7 Tuesday, November 21, 2006 1:51 PM MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, cargo, accessories, and tongue): 220.0 kg (485 lb) Front carrier: 45.0 kg (99 lb) Rear carrier: 85.0 kg (187 lb) Front storage compartment: 0.5 kg (1 lb) Rear storage compartment: 2.
U3B461E0.book Page 8 Tuesday, November 21, 2006 1:51 PM EWB00820 WARNING Never exceed the stated load capacity for this ATV. Overloading this ATV or carrying or towing cargo improperly could cause changes in ATV handling which could lead to an accident. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.
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U3B461E0.book Page 2 Tuesday, November 21, 2006 1:51 PM RIDE WITH CARE AND GOOD JUDGEMENT EBU27411 Get training if you are inexperienced. Beginners should get training from a certified instructor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum performance until you are totally familiar with the ATV’s handling and performance characteristics.
U3B461E0.book Page 3 Tuesday, November 21, 2006 1:51 PM Not recommended for children under 16 years of age. This ATV is designed to carry operator and cargo only – passengers prohibited. EWB01390 EWB01400 WARNING A child under 16 should never operate an ATV with engine size greater than 90 cc. Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. WARNING Never carry a passenger.
U3B461E0.book Page 4 Tuesday, November 21, 2006 1:51 PM Apparel 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 7 1. 2. 3. 4. 5.
U3B461E0.book Page 5 Tuesday, November 21, 2006 1:51 PM EWB01410 WARNING Never operate this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.
U3B461E0.book Page 6 Tuesday, November 21, 2006 1:51 PM in the Owner’s Manual. Failure to inspect the ATV before operating or failure to properly maintain the ATV increases the possibility of an accident or equipment damage. Speed limiter For riders less experienced with this model, the throttle lever housing is equipped with a speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum.
U3B461E0.book Page 7 Tuesday, November 21, 2006 1:51 PM 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. 7 EWB01460 ● ● MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 220.0 kg (485 lb) Front carrier: 45.0 kg (99 lb) Rear carrier: 85.0 kg (187 lb) Front storage compartment: 0.
U3B461E0.book Page 8 Tuesday, November 21, 2006 1:51 PM Avoid wheelies and jumping. You may lose control of the ATV or overturn. EWB01480 WARNING Never attempt stunts, such as wheelies or jumps. Don’t try to show off. 7 EWB01470 WARNING Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation. 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.
U3B461E0.book Page 9 Tuesday, November 21, 2006 1:51 PM installed and used according to instructions. Improper installation of accessories or modification of this ATV may cause changes in handling which in some situations could lead to an accident. If you have questions, consult an authorized ATV dealer. 7 Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system.
U3B461E0.book Page 10 Tuesday, November 21, 2006 1:51 PM EWB01520 WARNING Never operate this ATV on any paved street, paved road or motorway. You can collide with another vehicle. In many areas, it is illegal to operate ATVs on public streets, roads and highways. 7 While riding on unpaved public streets or roads may be legal in your area, such operation can increase the risk of collision with other vehicles. Watch carefully for other vehicles.
U3B461E0.book Page 11 Tuesday, November 21, 2006 1:51 PM ATV on such terrain. Failure to use extra care when operating on excessively rough, slippery or loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. EWB01530 WARNING Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.
U3B461E0.book Page 12 Tuesday, November 21, 2006 1:51 PM Select a large, flat, unpaved area to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Always avoid riding on paved surfaces: the ATV is designed for use on unpaved surfaces only, and handling maneuvers are more difficult to perform on pavement.
U3B461E0.book Page 13 Tuesday, November 21, 2006 1:51 PM 7 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. A special turning technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. With the engine idling, shift the drive select lever into the low-range position or the high-range position.
U3B461E0.book Page 14 Tuesday, November 21, 2006 1:51 PM 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. It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over.
U3B461E0.book Page 15 Tuesday, November 21, 2006 1:51 PM ● EWB01580 WARNING Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills. Practice on smaller hills before attempting large hills. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.
U3B461E0.book Page 16 Tuesday, November 21, 2006 1:51 PM EWB01600 WARNING Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. 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.
U3B461E0.book Page 17 Tuesday, November 21, 2006 1:51 PM could come off the ground. The ATV could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the ATV immediately on the uphill side. EWB01801 7 WARNING Use the proper gear and maintain a steady speed when climbing a hill. If you lose all forward speed: ● Keep weight uphill. ● Apply the brakes. ● Shift into the park position after you are stopped. If you begin rolling backwards: ● Keep weight uphill.
U3B461E0.book Page 18 Tuesday, November 21, 2006 1:51 PM ● When this ATV is in 4WD or 4WD-LOCK, all wheels (front and rear) are interconnected by the drive train. This means that applying either the front brake or the rear brake will brake all wheels. When descending hills, using either brake lever or the brake pedal will brake the wheels on the downhill side. Avoid sudden application of either the front or rear brake because the wheels on the uphill side could come off the ground.
U3B461E0.book Page 19 Tuesday, November 21, 2006 1:51 PM ● to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes, be sure not to make sharp turns either up or down hill.
U3B461E0.book Page 20 Tuesday, November 21, 2006 1:51 PM Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. EWB01640 WARNING Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.
U3B461E0.book Page 21 Tuesday, November 21, 2006 1:51 PM 1. Air filter case check hose 1. Storage compartment drain plug 1. Air filter case check hose 1.
U3B461E0.book Page 22 Tuesday, November 21, 2006 1:51 PM you go over obstacles, always follow proper procedures as described in the Owner’s Manual. 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. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help. 1.
U3B461E0.book Page 23 Tuesday, November 21, 2006 1:51 PM 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. EWB01661 WARNING Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain.
U3B461E0.book Page 24 Tuesday, November 21, 2006 1:51 PM ● ● ● ● BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See page 7-19.) If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See page 7-22.
U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM EBU21656 PERIODIC MAINTENANCE AND MINOR REPAIR otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with maintenance work. EBU21670 8 Safety is an obligation of the owner. Periodic inspection, 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.
U3B461E0.book Page 2 Tuesday, November 21, 2006 1:51 PM The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.
U3B461E0.book Page 3 Tuesday, November 21, 2006 1:51 PM EBU22403 Periodic maintenance and lubrication chart 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. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
U3B461E0.book Page 4 Tuesday, November 21, 2006 1:51 PM INITIAL NO. 6 7 * ITEM Rear brake CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1200 (750) hours 20 75 150 150 300 √ √ √ √ √ • Check operation and correct if necessary. • Check brake pedal free play and adjust if necessary. • Check fluid level and ATV for fluid leakage, and correct if necessary. • Replace brake pads. • Check for cracks or other damage, and replace if necessary. • Replace.
U3B461E0.book Page 5 Tuesday, November 21, 2006 1:51 PM INITIAL NO.
U3B461E0.book Page 6 Tuesday, November 21, 2006 1:51 PM INITIAL NO. ITEM 28 Differential gear oil 29 Final gear oil 30 Cooling system Moving parts and cables Drive select lever safety system cable 31 * 32 * 33 * Throttle lever housing and cable 34 * Exhaust system 35 36 * Spark arrester Front and rear brake switches CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1200 (750) hours 20 75 • Change.
U3B461E0.book Page 7 Tuesday, November 21, 2006 1:51 PM INITIAL NO. 37 * ITEM Lights and switches CHECK OR MAINTENANCE JOB Whichever comes first • Check operation and correct if necessary. • Adjust headlight beams. EVERY month 1 3 km (mi) 320 (200) 1200 (750) 6 6 12 hours 20 75 150 150 300 √ √ √ √ √ 2400 2400 4800 (1500) (1500) (3000) EBU23070 8 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
U3B461E0.book Page 8 Tuesday, November 21, 2006 1:51 PM EBU23090 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. Panel E 2. Panel H 3. Panel I EBU27381 8 1. 2. 3. 4. 5. 6. Panel A Panel B Panel C Panel D Panel F Panel G Panel A To remove the panel Pull upward on the areas shown.
U3B461E0.book Page 9 Tuesday, November 21, 2006 1:51 PM Panel B To remove the panel 1. Remove panel A. 2. Remove the front carrier by removing the bolts. 1. Panel A To install the panel Place the panel in the original position. 8 1.
U3B461E0.book Page 10 Tuesday, November 21, 2006 1:51 PM 1. Carrier bolt (top) 1. Front carrier stay bolt 3. Remove the front carrier stays by removing the bolts. 4. Remove the quick fastener screws, and then pull the panel upward to remove it. 8 1.
U3B461E0.book Page 11 Tuesday, November 21, 2006 1:51 PM 1. Panel B 2. Quick fastener screw 8 2. Install the front carrier stays by installing the bolts and tightening them to the specified torque. To install the panel 1. Place the panel in the original position, and then install the quick fastener screws. Tightening torque: Front carrier stay bolt: 26 Nm (2.6 m·kgf, 19 ft·lbf) 3. Install the front carrier by installing the bolts and tightening them to the specified torques.
U3B461E0.book Page 12 Tuesday, November 21, 2006 1:51 PM Tightening torques: Carrier bolt (top): 26 Nm (2.6 m·kgf, 19 ft·lbf) Carrier bolt (under the fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 4. Install panel A. Panel C To remove the panel 1. Remove the seat. (See page 4-17.) 2. Remove panel A. 3. Remove the quick fastener screws, and then pull the panel upward as shown to remove it. 1. Panel C 2. Quick fastener screw To install the panel 1.
U3B461E0.book Page 13 Tuesday, November 21, 2006 1:51 PM 1. Panel D 2. Quick fastener screw 2. Install panel A. 3. Install the seat. Panels D and E 8 To remove one of the panels 1. Remove panel C. 2. Remove the quick fastener screw and bolt, and then pull the panel upward as shown to remove it. NOTE: To ease removal of panel D, shift the drive select lever into the reverse position. 1.
U3B461E0.book Page 14 Tuesday, November 21, 2006 1:51 PM To install one of the panels 1. Place the panel in the original position, and then install the bolt and quick fastener screw. 1. Panel E 2. Quick fastener screw 8 1. Bolt 2. Install panel C.
U3B461E0.book Page 15 Tuesday, November 21, 2006 1:51 PM Panel F To remove the panel Pull outward on the areas shown. Panel G 8 To remove the panel Remove the nut, bolts, and quick fastener, and then pull the panel downward while pushing the tab. 1. Panel F To install the panel Place the panel in the original position.
U3B461E0.book Page 16 Tuesday, November 21, 2006 1:51 PM 1. 2. 3. 4. 5. Panel G Nut Bolt Quick fastener Tab Panel H To remove the panel Remove the nut, bolts, and quick fasteners, and then pull the panel downward while pushing the tab. To install the panel Place the panel in the original position, and then install the bolts, nut, and quick fastener.
U3B461E0.book Page 17 Tuesday, November 21, 2006 1:51 PM 8 1. 2. 3. 4. 5. Panel H Nut Bolt Quick fastener Tab Panel I To remove the panel 1. Remove the seat. (See page 4-17.) 2. Remove the rear carrier by removing the bolts. To install the panel Place the panel in the original position, and then install the bolts, nut, and quick fasteners.
U3B461E0.book Page 18 Tuesday, November 21, 2006 1:51 PM 1. Carrier bolt (under the fenders) 1. Carrier bolt (lower) 3. Remove the quick fasteners, and then push inward on the areas shown. 8 1.
U3B461E0.book Page 19 Tuesday, November 21, 2006 1:51 PM 1. Panel I 2. Quick fastener 8 2. Install the rear carrier by installing the bolts and tightening them to the specified torques. To install the panel 1. Place the panel in the original position, and then install the quick fasteners. Tightening torques: Carrier bolt (upper): 48 Nm (4.8 m·kgf, 35 ft·lbf) Carrier bolt (lower): 48 Nm (4.8 m·kgf, 35 ft·lbf) Carrier bolt (under the fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 3. Install the seat.
U3B461E0.book Page 20 Tuesday, November 21, 2006 1:51 PM EBU28671 EBU23211 Removing the radiator grills Checking the spark plug The radiator grills can be removed to access the radiator for cleaning. The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart.
U3B461E0.book Page 21 Tuesday, November 21, 2006 1:51 PM 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/CPR7EA-9 To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. Spark plug gap: 0.8–0.9 mm (0.031–0.035 in) 1.
U3B461E0.book Page 22 Tuesday, November 21, 2006 1:51 PM NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4. Install the spark plug cap. EBU27460 Engine oil and oil filter cartridge The engine oil level should be checked before each ride.
U3B461E0.book Page 23 Tuesday, November 21, 2006 1:51 PM 4. Remove the dipstick, and then wipe it off with a clean rag. 1. Maximum level mark 2. Minimum level mark 1. Dipstick 8 NOTE: The engine oil should be between the minimum and maximum level marks. 5. Insert the dipstick completely into the oil filler hole, and then remove it again to check the oil level. 6. 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. 7.
U3B461E0.book Page 24 Tuesday, November 21, 2006 1:51 PM ECB00850 NOTE: Skip steps 5–9 if the oil filter cartridge is not being replaced. CAUTION: Be sure the engine oil is at the correct level, otherwise engine damage may result. 5. Remove panel G. (See page 8-8.) 6. Remove the oil filter cartridge with an oil filter wrench. To change the engine oil (with or without oil filter cartridge replacement) 1. Place the ATV on a level surface. 2. Remove panel F. (See page 8-8.) 3.
U3B461E0.book Page 25 Tuesday, November 21, 2006 1:51 PM 1. O-ring 1. Torque wrench Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf) NOTE: Make sure that the O-ring is properly seated. 8 8. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. 9. Install panel G. 10. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 30 Nm (3.
U3B461E0.book Page 26 Tuesday, November 21, 2006 1:51 PM 11. Add the specified amount of the recommended engine oil, and then insert the dipstick completely into the oil filler hole. 12. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 13. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary. 14. Install panel F.
U3B461E0.book Page 27 Tuesday, November 21, 2006 1:51 PM NOTE: The oil level should be at the brim of the check hole. 1. Final gear oil filler bolt 4. Install the oil level check bolt and oil filler bolt, and then tighten them to the specified torques. 8 1. Final gear oil 2. Final gear oil level check bolt 3. Correct oil level Tightening torques: Final gear oil level check bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 3.
U3B461E0.book Page 28 Tuesday, November 21, 2006 1:51 PM 3. Remove the final gear oil filler bolt, final gear oil level check bolt, and the final gear oil drain bolt to drain the oil from the final gear case. 1. Final gear oil 2. Final gear oil level check bolt 3. Correct oil level 1. Final gear oil drain bolt Recommended final gear oil: See page 10-1. 4. Install the drain bolt, and then tighten it to the specified torque. ECB00420 Tightening torque: Final gear oil drain bolt: 23 Nm (2.
U3B461E0.book Page 29 Tuesday, November 21, 2006 1:51 PM 2. Remove the differential gear oil filler bolt, and then check the oil level in the differential gear case. Tightening torques: Final gear oil level check bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 7. Check the final gear case for oil leakage. If oil is leaking, check for the cause. EBU23421 Differential gear oil 8 The differential gear case must be checked for oil leakage before each ride.
U3B461E0.book Page 30 Tuesday, November 21, 2006 1:51 PM Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) Tightening torque: Differential gear oil drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 5. Add the recommended differential gear oil to the brim of the filler hole as shown. To change the differential gear oil 1. Place the ATV on a level surface. 2. Place an oil pan under the differential gear case to collect the used oil. 3.
U3B461E0.book Page 31 Tuesday, November 21, 2006 1:51 PM ECB00410 NOTE: The coolant level must be checked on a cold engine since the level varies with engine temperature. CAUTION: Be sure no foreign material enters the differential gear case. 6. Install the oil filler bolt, and then tighten it to the specified torque. 2. Check the coolant level in the coolant reservoir. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.
U3B461E0.book Page 32 Tuesday, November 21, 2006 1:51 PM 4. Remove the reservoir cap, add coolant or distilled water to the maximum level mark, install the reservoir cap, and then install the panel. ECB00401 CAUTION: If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine.
U3B461E0.book Page 33 Tuesday, November 21, 2006 1:51 PM EBU27761 To change the coolant EWB01890 WARNING Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by hot fluid and steam blown out under pressure. Always place a thick rag over the cap when opening. Allow any remaining pressure to escape before completely removing the cap. 8 1. Place the ATV on a level surface. 2. Remove panels D and F. (See page 8-8.) 3.
U3B461E0.book Page 34 Tuesday, November 21, 2006 1:51 PM 1. Radiator cap 1. Coolant reservoir hose 8. After draining the coolant, thoroughly flush the cooling system with clean tap water. 9. Replace the coolant drain bolt washer if it is damaged, install the coolant drain bolt, and then tighten it to the specified torque. 6. Remove the coolant reservoir cap. 7. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir.
U3B461E0.book Page 35 Tuesday, November 21, 2006 1:51 PM ● 12. Pour the recommended coolant into the reservoir to the maximum level mark, and then install the reservoir cap. Antifreeze/water mixture ratio: 1:1 Recommended antifreeze: High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Coolant quantity: Radiator capacity (including all routes): 1.99 L (2.10 US qt) (1.75 Imp.qt) Coolant reservoir capacity (up to the maximum level mark): 0.17 L (0.18 US qt) (0.15 Imp.
U3B461E0.book Page 36 Tuesday, November 21, 2006 1:51 PM Tightening torque: Water pump air bleed bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 15. Remove panel E. (See page 8-8.) 16. Loosen the clamp screw, and then remove the V-belt cooling duct. 1. Cylinder head air bleed bolt 18. When coolant begins to flow out of the bolt hole, tighten the cylinder head air bleed bolt to the specified torque. Tightening torque: Cylinder head air bleed bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 1. V-belt cooling duct 2.
U3B461E0.book Page 37 Tuesday, November 21, 2006 1:51 PM 22. Stop the engine and allow it to cool. If the coolant level has dropped after the engine has cooled, add sufficient coolant until it reaches the top of the radiator, and then install the radiator cap. 23. Start the engine, and then check for coolant leakage. the panels.) Check the hoses periodically and, if dust or water collects in them, empty them and clean the air filter element and air filter case.
U3B461E0.book Page 38 Tuesday, November 21, 2006 1:51 PM 1. Air filter case check hose 1. Air filter case holder 2. Air filter case cover 1. Remove panel C. (See page 8-8.) 2. Remove the air filter case cover by unhooking the holders. 3. Remove the sponge material and the mesh from the air filter case.
U3B461E0.book Page 39 Tuesday, November 21, 2006 1:51 PM ECB00440 CAUTION: Do not twist the sponge material when squeezing it. 7. Check the sponge material and replace it if damaged. 8. Apply Yamaha foam air filter oil or other quality foam air filter oil to the sponge material. NOTE: The sponge material should be wet but not dripping. 1. Sponge material 2. Air filter mesh 8 9. Install the mesh and the sponge material into the air filter case. 10.
U3B461E0.book Page 40 Tuesday, November 21, 2006 1:51 PM ECB00760 CAUTION: Make sure that the air filter element is properly seated in the air filter case. ● Never operate the engine with the air filter element removed. This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect the fuel injection system with subsequent poor performance and possible engine overheating. ● 11. Install the panel.
U3B461E0.book Page 41 Tuesday, November 21, 2006 1:51 PM 1. Bolt 8 1. Tailpipe 2. Spark arrester 3. Gasket 2. Remove the tailpipe, by pulling it out of the muffler, and then remove the gasket. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 4. Install the gasket, and then insert the tailpipe into the muffler and align the bolt holes. 5.
U3B461E0.book Page 42 Tuesday, November 21, 2006 1:51 PM EWB02380 WARNING Never run the engine in an enclosed area when purging the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poisoning, possibly leading to death, and start a fire. ● Always let the exhaust system cool prior to touching exhaust components. ● Always wear eye protection, and make sure no one is behind the ATV. ● Make sure there are no combustible materials in the area. 1. Purging bolt 7.
U3B461E0.book Page 43 Tuesday, November 21, 2006 1:51 PM NOTE: The engine is warm when it quickly responds to the throttle. 2. Remove panel C. (See page 8-8.) 3. Attach the tachometer to the spark plug lead. 4. Check the engine idling speed and, if necessary, adjust it to specification by turning the idle adjusting screw. To increase the engine idling speed, turn the idle adjusting screw in direction (a), and to decrease it, turn the screw in direction (b). 1.
U3B461E0.book Page 44 Tuesday, November 21, 2006 1:51 PM 2. To increase the throttle cable free play, turn the adjusting bolt in direction (a). To decrease the throttle cable free play, turn the adjusting bolt in direction (b). Engine idling speed: 1550–1650 r/min NOTE: If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 5. Install the panel.
U3B461E0.book Page 45 Tuesday, November 21, 2006 1:51 PM must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. NOTE: The wheels need to be removed to check the brake pads. (See page 8-63.) EBU24070 Adjusting the drive select lever safety system cable Front brake The drive select lever safety system cable stretches with use, which can result in improper function.
U3B461E0.book Page 46 Tuesday, November 21, 2006 1:51 PM Rear brake NOTE: The wheels need to be removed to check the brake hose protectors. (See page 8-63.) 1. Wear indicator groove EBU27842 Checking the rear brake hose protectors 1. 2. 3. 4. The rear brake hoses protectors must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake hose protector is provided with a wear indicator.
U3B461E0.book Page 47 Tuesday, November 21, 2006 1:51 PM Rear brake Before riding, check that the brake fluid is above the minimum level mark and replenish if 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. Front brake 1.
U3B461E0.book Page 48 Tuesday, November 21, 2006 1:51 PM ● ● ● Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. As the brake pads wear, it is normal for the brake fluid level to gradually go down.
U3B461E0.book Page 49 Tuesday, November 21, 2006 1:51 PM Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. Rear brake EBU27780 Adjusting the brake pedal free play and checking the brake pedal position The brake pedal free play must be adjusted and brake pedal position must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. 1.
U3B461E0.book Page 50 Tuesday, November 21, 2006 1:51 PM 1. Brake pedal free play 1. Locknut 2. Brake pedal free play adjusting nut 1. Remove panel H. (See page 8-8.) 2. Loosen the locknut. 3. Turn the brake pedal free play adjusting nut in direction (a) to increase the free play, and in direction (b) to decrease it. 4. Tighten the locknut. 5. Install the panel. If the correct free play cannot be obtained, have a Yamaha dealer adjust it.
U3B461E0.book Page 51 Tuesday, November 21, 2006 1:51 PM ● Checking the brake pedal position The top of the brake pedal should be positioned 56.7 mm (2.23 in) above the top of the footrest. If the brake pedal position is incorrect, have a Yamaha dealer adjust it. Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer.
U3B461E0.book Page 52 Tuesday, November 21, 2006 1:51 PM EWB02130 WARNING Inspect cables frequently and replace if damaged. Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could restrict the operation of controls and lead to an accident or injury. EBU24911 Checking and lubricating the front and rear brake levers 1.
U3B461E0.book Page 53 Tuesday, November 21, 2006 1:51 PM Front brake lever EBU24950 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. NOTE: To access the brake pedal pivot, remove panel H. (See page 8-8.
U3B461E0.book Page 54 Tuesday, November 21, 2006 1:51 PM EBU24961 EBU25040 Checking the wheel bearings Lubricating the upper and lower arm pivots The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings.
U3B461E0.book Page 55 Tuesday, November 21, 2006 1:51 PM Recommended lubricant: Lithium-soap-based grease EBU25222 Battery This model is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. Check and, if necessary, tighten the battery lead connections. ECB00620 1. Grease nipple CAUTION: Never attempt to remove the battery cell seals, as this would permanently damage the battery.
U3B461E0.book Page 56 Tuesday, November 21, 2006 1:51 PM 1. Place the battery in its compartment. 2. Make sure to properly connect the battery leads to the battery terminals. EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes or other sources of ignition away. Ventilate when charging or using in an enclosed space. KEEP OUT OF REACH OF CHILDREN.
U3B461E0.book Page 57 Tuesday, November 21, 2006 1:51 PM access to a constant-voltage battery charger, have a Yamaha dealer charge your battery. EBU27750 Replacing a fuse 1. 2. 3. 4. 5. 6. 7. 8 1. 2. 3. 4. 5. 6.
U3B461E0.book Page 58 Tuesday, November 21, 2006 1:51 PM ECB00640 Specified fuses: Main fuse: 40.0 A Headlight fuse: 15.0 A Ignition fuse: 10.0 A Four-wheel-drive motor fuse: 10.0 A Signaling system fuse: 5.0 A Auxiliary DC jack fuse: 15.0 A Radiator fan fuse: 15.0 A Fuel injection system fuse: 15.0 A EPS fuse: 40.0 A CAUTION: To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage.
U3B461E0.book Page 59 Tuesday, November 21, 2006 1:51 PM EWB02171 WARNING Always use a fuse of the specified rating, and never use a substitute object in place of the proper fuse. An improper fuse or a substitute object can cause damage to the electrical system, which could lead to a fire. 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 1.
U3B461E0.book Page 60 Tuesday, November 21, 2006 1:51 PM 1. Headlight coupler 1. Headlight bulb holder 2. Headlight bulb 4. Unhook the headlight bulb holder, and then remove the defective bulb. EWB02220 WARNING A headlight bulb is hot when it is on and immediately after it is turned off. Wait for the bulb to cool before touching or removing it. You can be burned or a fire could start if the bulb touches something flammable. 5.
U3B461E0.book Page 61 Tuesday, November 21, 2006 1:51 PM ECB00670 CAUTION: Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 9. Adjust the headlight beam if necessary. EBU25550 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make this adjustment. 1. Do not touch the glass part of the bulb.
U3B461E0.book Page 62 Tuesday, November 21, 2006 1:51 PM 1. Headlight beam adjusting screw 1. Tail/brake light bulb holder 3. Remove the defective bulb by pushing it in and turning it counterclockwise. EBU25640 Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as follows. 1. Remove panel I. (See page 8-8.) 2. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 8 1.
U3B461E0.book Page 63 Tuesday, November 21, 2006 1:51 PM 4. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 5. Install the bulb holder (together with the bulb) by turning it clockwise. 6. Install the panel. EBU25700 Installing a wheel 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.
U3B461E0.book Page 64 Tuesday, November 21, 2006 1:51 PM EBU25740 Troubleshooting Although Yamaha ATVs receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself.
U3B461E0.book Page 65 Tuesday, November 21, 2006 1:51 PM EBU27690 Troubleshooting charts Starting problems or poor engine performance 1. Fuel Check the fuel level in the fuel tank. 2. Compression There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the ATV. Operate the electric starter. 8 3. Ignition Remove the spark plug and check the electrodes. 4.
U3B461E0.book Page 66 Tuesday, November 21, 2006 1:51 PM Engine overheating EWB02290 WARNING Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by hot fluid and steam blown out under pressure. Always put a thick rag over the cap when opening. Allow any remaining pressure to escape before completely removing the cap. The coolant level is low. Check the cooling system for leakage. Wait until the engine has cooled.
U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM EBU25860 CLEANING AND STORAGE ed from improper high-pressure detergent applications such as those available in coinoperated car washers. EBU25880 Cleaning 9 Frequent, thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the ATV: a. Block off the end of the exhaust pipe to prevent water entry.
U3B461E0.book Page 2 Tuesday, November 21, 2006 1:51 PM Long-term Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” section of this chapter. 2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel from deteriorating. EWB02310 WARNING Wet brakes may have reduced stopping ability, increasing the chance of an accident. Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings.
U3B461E0.book Page 3 Tuesday, November 21, 2006 1:51 PM 4. 5. 6. 7. 9 e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. Lubricate all control cables and the pivoting points of all levers and pedals. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that all of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.
U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM EBU25960 SPECIFICATIONS Dimensions: Cylinder arrangement: Forward-inclined single cylinder Displacement: 686.0 cm³ Bore × stroke: 102.0 × 84.0 mm (4.02 × 3.31 in) Compression ratio: 9.20 :1 Starting system: Electric starter Lubrication system: Wet sump Overall length: 2065 mm (81.3 in) Overall width: 1180 mm (46.5 in) Overall height: 1240 mm (48.8 in) Seat height: 905 mm (35.6 in) Wheelbase: 1250 mm (49.2 in) Ground clearance: 275 mm (10.
U3B461E0.book Page 2 Tuesday, November 21, 2006 1:51 PM Engine oil: Differential gear oil: Type: SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 -20˚ -10˚ 0˚ 20˚ 10˚ 30˚ 40˚ Type: SAE80 API GL-4 Hypoid gear oil Quantity: 0.22 L (0.23 US qt) (0.19 Imp.qt) Cooling system: 50˚C Coolant reservoir capacity (up to the maximum level mark): 0.17 L (0.18 US qt) (0.15 Imp.qt) Radiator capacity (including all routes): 1.99 L (2.10 US qt) (1.75 Imp.
U3B461E0.book Page 3 Tuesday, November 21, 2006 1:51 PM Clutch: Size: AT25 x 8-12 Manufacturer/model: CHENG SHIN/C828-4P (AUS)(NZL) DUNLOP/KT421 (EUR) Clutch type: Wet, centrifugal automatic Transmission: Primary reduction system: V-belt Secondary reduction system: Shaft drive Secondary reduction ratio: 41/21 × 24/18 × 33/9 (9.544) Transmission type: V-belt automatic Operation: Left hand operation Reverse gear: 23/14 × 28/23 (2.000) Low range: 31/16 (1.938) High range: 29/25 (1.
U3B461E0.book Page 4 Tuesday, November 21, 2006 1:51 PM Wheel travel: 180 mm (7.1 in) Rear: 33.0 kPa (4.8 psi) (0.330 kgf/cm²) Front wheel: Rear suspension: Wheel type: Panel wheel Rim size: 12 x 6.0AT Type: Double wishbone Spring/shock absorber type: Coil spring/oil damper Wheel travel: 230 mm (9.1 in) Rear wheel: Wheel type: Panel wheel Rim size: 12 x 7.
U3B461E0.book Page 5 Tuesday, November 21, 2006 1:51 PM Reverse indicator light: LED Coolant temperature warning light: LED Engine trouble warning light: LED EPS warning light: LED Park indicator light: LED On-Command four-wheel-drive/differential gear lock indicator: LCD High-range indicator light: LED Low-range indicator light: LED Differential gear lock indicator light: LED Auxiliary DC jack fuse: 15.0 A Four-wheel-drive motor fuse: 10.0 A Radiator fan fuse: 15.0 A Fuses: Main fuse: 40.
U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM EBU26000 CONSUMER INFORMATION EBU26011 EBU26020 Identification numbers Key identification number The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key.
U3B461E0.book Page 2 Tuesday, November 21, 2006 1:51 PM 1. Vehicle identification number (front left side) 1. Vehicle identification number 2. Year of manufacture The year of manufacture is listed in the vehicle identification number as shown in the illustration. NOTE: The vehicle identification number is used to identify your ATV. EBU26050 Model label The model label is affixed at the location in the illustration. Record the information on this label in the space provided.
U3B461E0.book Page 3 Tuesday, November 21, 2006 1:51 PM 1.
U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM INDEX A Differential gear oil ................................................ 5-3, 8-29 Drive select lever ......................................................... 4-15 Drive select lever and driving in reverse ........................ 6-2 Drive select lever safety system cable, adjusting ........ 8-45 Drive shaft universal joint, lubricating .......................... 8-54 Accessories and loading ................................................
U3B461E0.book Page 2 Tuesday, November 21, 2006 1:51 PM Indicator lights and warning lights .................................. 4-2 Instruments, lights and switches .................................... 5-7 Riding your ATV ............................................................. 7-1 S K Safety information .......................................................... 1-1 Seat ..............................................................................
U3B461E0.book Page 3 Tuesday, November 21, 2006 1:51 PM W Wheel bearings, checking ............................................ 8-54 Wheel, installing ........................................................... 8-63 Wheel, removing ..........................................................
U3B461E0.book Page 1 Tuesday, November 21, 2006 1:51 PM YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006.08-2.
