READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM35FGIX WARNING LIT-11626-21-40 This ATV should not be ridden by anyone under 16 years of age.
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U4S211E0.book Page 1 Friday, May 25, 2007 9:38 AM EBU17170 INTRODUCTION EBU17270 Congratulations on your purchase of the Yamaha YFM35FGIX. This ATV 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.
U4S211E0.book Page 1 Friday, May 25, 2007 9:38 AM EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
U4S211E0.book Page 1 Friday, May 25, 2007 9:38 AM EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! 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.
U4S211E0.book Page 1 Friday, May 25, 2007 9:38 AM EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 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....................................................
U4S211E0.book Page 2 Friday, May 25, 2007 9:38 AM Tire wear limit ............................................. 5-7 Chassis fasteners ....................................... 5-7 Instruments, lights and switches ................ 5-7 OPERATION .................................................. 6-1 Starting a cold engine ................................ 6-1 Starting a warm engine .............................. 6-3 Operating the drive select lever and driving in reverse ......................................
U4S211E0.book Page 3 Friday, May 25, 2007 9:38 AM Checking the brake fluid level .................. 8-30 Changing the brake fluid .......................... 8-31 Checking the front brake lever free play ................................................. 8-31 Adjusting the brake pedal and rear brake lever free play and checking the brake pedal position .......... 8-32 Axle boots ................................................ 8-37 Brake light switches .................................
U4S211E0.book Page 1 Friday, May 25, 2007 9:38 AM EBU17430 SAFETY INFORMATION ● EBU17542 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.
U4S211E0.book Page 2 Friday, May 25, 2007 9:38 AM ● 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. Always be alert to changing terrain conditions when operating the ATV.
U4S211E0.book Page 3 Friday, May 25, 2007 9:38 AM ● ● ● ● ● 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.
U4S211E0.book Page 4 Friday, May 25, 2007 9:38 AM 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, seek medical help immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. EWB00021 WARNING 1 POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned.
U4S211E0.book Page 5 Friday, May 25, 2007 9:38 AM 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.
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U4S211E0.book Page 2 Friday, May 25, 2007 9:38 AM EBU17670 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. 2 1 WARNING Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident.
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U4S211E0.book Page 1 Friday, May 25, 2007 9:38 AM EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Front shock absorber assembly spring preload adjusting ring 2. Fuel cock 3. Throttle stop screw 4. Fuses 5. Battery 6. Rear shock absorber assembly spring preload adjusting ring 7. Recoil starter 8. Engine oil filler cap 9. Oil filter cartridge 10.V-belt cooling duct check hose 1. 2. 3. 4. 5. 6. 7.
U4S211E0.book Page 2 Friday, May 25, 2007 9:38 AM 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. 9. Rear brake lever Handlebar switches Starter (choke) Parking brake lock plate Drive select lever Speedometer Main switch Fuel tank cap On-Command four-wheel-drive/differential gear lock switch 10.Throttle lever 11.
U4S211E0.book Page 1 Friday, May 25, 2007 9:38 AM EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 4 EBU17770 Main switch The positions of the main switch are as follows: ON All electrical systems are supplied with power. The headlights, meter lighting and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed. 1. Main switch OFF All electrical systems are off.
U4S211E0.book Page 2 Friday, May 25, 2007 9:38 AM EBU17813 NOTE: If the indicator light flashes under any other circumstances or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. Indicator lights and warning light EBU17870 Neutral indicator light “NEUTRAL” This indicator light comes on when the transmission is in the neutral position. EBU26931 1. 2. 3. 4. 5.
U4S211E0.book Page 3 Friday, May 25, 2007 9:38 AM If the warning light stays on, allow the engine to cool. If the warning light stays on when the engine is cool, have a Yamaha dealer check the electrical circuit. EBU28341 On-Command differential gear lock indicator light “ ” This indicator light and the On-Command fourwheel-drive indicator light “ ” come on when the On-Command differential gear lock switch is set to the “LOCK” position.
U4S211E0.book Page 4 Friday, May 25, 2007 9:38 AM EBU18061 Handlebar switches 4 1. 2. 3. 4. Reset knob Speedometer Odometer Tripmeter 1. 2. 3. 4. Light switch “ / /OFF” Start switch “ ” Engine stop switch “ / ” Override switch “OVERRIDE” EBU18080 Engine stop switch “ / ” Set this switch to “ ” before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation.
U4S211E0.book Page 5 Friday, May 25, 2007 9:38 AM EBU18100 EBU28350 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 EBU18160 Light switch “ / /OFF” Set this switch to “ ” to turn on the low beams, the taillight and the meter lighting. Set the switch to “ ” to turn on the high beams, the taillight and the meter lighting.
U4S211E0.book Page 6 Friday, May 25, 2007 9:38 AM ● “4WD” (four-wheel drive): Power is supplied to the rear and front wheels. To change from two-wheel drive to four-wheel drive, stop the ATV and push the switch in to the “4WD” position. The four-wheel-drive indicator light “ ” comes on. To change from four-wheel drive to two-wheel drive, stop the ATV and push the switch in to the “2WD” position. EWB00110 WARNING POTENTIAL HAZARD Riding too fast while the ATV is in fourwheel-drive differential gear lock.
U4S211E0.book Page 7 Friday, May 25, 2007 9:38 AM EWB00120 EBU28360 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.
U4S211E0.book Page 8 Friday, May 25, 2007 9:38 AM 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.
U4S211E0.book Page 9 Friday, May 25, 2007 9:38 AM WHAT CAN HAPPEN 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. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling. HOW TO AVOID THE HAZARD Always ride at a slow speed when the ATV is in differential gear lock, and allow extra time and distance for maneuvers.
U4S211E0.book Page 10 Friday, May 25, 2007 9:38 AM 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. and hold the override switch to disable the differential gear lock speed limiter. (See page 4-5 for a detailed explanation of this switch.) EWB00200 WARNING EBU18270 Throttle lever POTENTIAL HAZARD Malfunction of throttle.
U4S211E0.book Page 11 Friday, May 25, 2007 9:38 AM WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in). (See page 8-28.) 2.
U4S211E0.book Page 12 Friday, May 25, 2007 9:38 AM 4 1. Front brake lever 1. Brake pedal EBU18442 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip. 1.
U4S211E0.book Page 13 Friday, May 25, 2007 9:38 AM WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake could overheat if you ride the ATV without releasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely. HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine.
U4S211E0.book Page 14 Friday, May 25, 2007 9:38 AM 4 1. Drive select lever 1. Recoil starter EWB00300 EBU18660 WARNING 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. POTENTIAL HAZARD Starting the engine without shifting into the neutral position. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident.
U4S211E0.book Page 15 Friday, May 25, 2007 9:38 AM EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 4 1. Fuel level 2. Fuel tank filler tube Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 13.5 L (3.57 US gal) (2.97 Imp.gal) Fuel reserve amount: 3.3 L (0.87 US gal) (0.73 Imp.gal) 1. Fuel tank cap EBU18730 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.
U4S211E0.book Page 16 Friday, May 25, 2007 9:38 AM WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. 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. HOW TO AVOID THE HAZARD Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely.
U4S211E0.book Page 17 Friday, May 25, 2007 9:38 AM OFF ON 1. Arrow mark pointing to “OFF” 1. Arrow mark pointing to “ON” With the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running. With the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding.
U4S211E0.book Page 18 Friday, May 25, 2007 9:38 AM Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. RES 4 1. Arrow mark pointing to “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding.
U4S211E0.book Page 19 Friday, May 25, 2007 9:38 AM 4 1. Seat 2. Seat lock lever 1. Projection 2. Seat holder 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. EBU18911 Storage compartment ECB00130 CAUTION: Do not store metal or sharply edged objects, like tools, in the storage compartment. If they must be stored, wrap them in appropriate cushion material to prevent damaging the storage compartment.
U4S211E0.book Page 20 Friday, May 25, 2007 9:38 AM 4 1. Storage compartment 1. Storage compartment check hose ● EBU18960 ● Do not exceed the load limit of 2.0 kg (4 lb) for the storage compartment. Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV. Front carrier ● ● NOTE: There is a check hose at the bottom of the storage compartment. If any water collects in this hose, remove the hose, empty it, and then install it. Do not exceed the load limit of 40.
U4S211E0.book Page 21 Friday, May 25, 2007 9:38 AM EBU19130 Adjusting the front and rear shock absorber assemblies 4 The spring preload can be adjusted to suit the rider’s weight and the riding conditions. Adjust the spring preload as follows. Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to decrease the spring preload and thereby soften the suspension. 1.
U4S211E0.book Page 22 Friday, May 25, 2007 9:38 AM 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 absorber assemblies on the left and right side to the same setting. 4 EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death.
U4S211E0.book Page 1 Friday, May 25, 2007 9:38 AM EBU19200 PRE-OPERATION CHECKS EBU19212 Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table. EWB00470 WARNING 5 POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage.
U4S211E0.book Page 2 Friday, May 25, 2007 9:38 AM ITEM Engine oil Final gear oil Differential gear oil Front brake Rear brake Throttle lever Control cables Wheels and tires Brake pedal Brake levers Axle boots Chassis fasteners Instruments, lights and switches ROUTINE • Check oil level in engine, and add recommended oil to specified level if necessary. • Check ATV for oil leakage. Correct if necessary. • Check ATV for oil leakage. Correct if necessary. • Check ATV for oil leakage. Correct if necessary.
U4S211E0.book Page 3 Friday, May 25, 2007 9:38 AM EBU19530 EBU19590 Fuel Final gear oil Make sure that there is sufficient fuel in the tank. (See page 4-15.) Make sure that the final gear oil is at the specified level. Add oil as necessary. (See page 8-16.) EWB00500 WARNING 5 EBU19600 Differential gear oil POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up.
U4S211E0.book Page 4 Friday, May 25, 2007 9:38 AM WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have a Yamaha dealer check for the cause. Brake fluid level (front brake) Check the brake fluid level. Add fluid if necessary. (See page 8-30.
U4S211E0.book Page 5 Friday, May 25, 2007 9:38 AM EBU19801 Tires EWB00551 WARNING 5 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 accident. HOW TO AVOID THE HAZARD ● The tires listed below have been approved by Yamaha Motor Manufacturing Corporation of America for this model.
U4S211E0.book Page 6 Friday, May 25, 2007 9:38 AM ● ● ● Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure: Front: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear: 22.0 kPa (3.2 psi) (0.220 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.
U4S211E0.book Page 7 Friday, May 25, 2007 9:38 AM 5 Recommended pressure: Front 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: Front 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Rear 28.0 kPa (4.1 psi) (0.280 kgf/cm²) 1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened.
U4S211E0.book Page 1 Friday, May 25, 2007 9:38 AM EBU19870 OPERATION EBU20021 EWB00010 Starting a cold engine WARNING Indicates a potential hazard that could result in serious injury or death. EWB00620 WARNING POTENTIAL HAZARD Frozen 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.
U4S211E0.book Page 2 Friday, May 25, 2007 9:38 AM Ambient temp./starter (choke) position 4. Shift the drive select lever into the neutral position. The neutral indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 6 NOTE: The engine can be started under the following conditions: ● The drive select lever is in the neutral position. ● The rear brake lever is applied with the drive select lever in any position.
U4S211E0.book Page 3 Friday, May 25, 2007 9:38 AM ● If the battery is discharged, pull the recoil starter to start the engine. EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the engine.
U4S211E0.book Page 4 Friday, May 25, 2007 9:38 AM NOTE: When in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. 6 1. 2. 3. 4. Drive select lever F (Forward) N (Neutral) R (Reverse) 3. Open the throttle lever gradually. 1. 2. 3. 4. Shifting: Reverse 1. Bring the ATV to a complete stop. 2. Apply the brake pedal. 3.
U4S211E0.book Page 5 Friday, May 25, 2007 9:38 AM Since the engine is brand new, do not put an excessive load on it for the first 320 km (200 mi) or 20 hours. The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided. EWB00670 WARNING POTENTIAL HAZARD Improper operation in reverse.
U4S211E0.book Page 6 Friday, May 25, 2007 9:38 AM 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. If you must park on an incline, place the ATV transversely across the incline, shift the drive select lever to the forward position, stop the engine, apply the parking brake, and then block the front and rear wheels with rocks or other objects.
U4S211E0.book Page 7 Friday, May 25, 2007 9:38 AM ● ● 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.
U4S211E0.book Page 8 Friday, May 25, 2007 9:38 AM ● MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, cargo, accessories, and tongue): 210.0 kg (463 lb) Front carrier: 40.0 kg (88 lb) Rear carrier: 80.0 kg (176 lb) Storage compartment: 2.0 kg (4 lb) Trailer hitch: Pulling load (total weight of trailer and cargo): 4900 N (1102 lbf) (500 kgf) Tongue weight (vertical weight on trailer hitch point): 147 N (33 lbf) (15 kgf) 6 ● ● ● ● ● ● ● Do not exceed the maximum tongue weight.
U4S211E0.book Page 9 Friday, May 25, 2007 9:38 AM WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. 6 EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death.
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U4S211E0.book Page 2 Friday, May 25, 2007 9:38 AM ular attention to the safety information on pages 1-1–1-5. Please also read all caution and warning labels on your ATV. EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU28480 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.
U4S211E0.book Page 3 Friday, May 25, 2007 9:38 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 1-800-8872887. Get training if you are inexperienced.
U4S211E0.book Page 4 Friday, May 25, 2007 9:38 AM 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 90 cc.
U4S211E0.book Page 5 Friday, May 25, 2007 9:38 AM This ATV is designed to carry operator and cargo only – passengers prohibited. EWB00910 WARNING 7 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.
U4S211E0.book Page 6 Friday, May 25, 2007 9:38 AM Apparel 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 EWB00920 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing.
U4S211E0.book Page 7 Friday, May 25, 2007 9:38 AM Do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety. EWB00940 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating.
U4S211E0.book Page 8 Friday, May 25, 2007 9:38 AM Do not operate at speeds too fast for your skills or the conditions. EWB00950 WARNING EWB00960 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.
U4S211E0.book Page 9 Friday, May 25, 2007 9:38 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. 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.
U4S211E0.book Page 10 Friday, May 25, 2007 9:38 AM EWB00970 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.
U4S211E0.book Page 11 Friday, May 25, 2007 9:38 AM During operation Always keep your feet on the footboards during operation, otherwise they may contact the rear wheels. 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. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.
U4S211E0.book Page 12 Friday, May 25, 2007 9:38 AM HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer. Modifications EWB01000 7 WARNING POTENTIAL HAZARD Operating this ATV with improper modifications.
U4S211E0.book Page 13 Friday, May 25, 2007 9:38 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. EWB01010 WARNING 7 POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire.
U4S211E0.book Page 14 Friday, May 25, 2007 9:38 AM HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets. EWB01030 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.
U4S211E0.book Page 15 Friday, May 25, 2007 9:38 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. EWB01040 WARNING 7 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.
U4S211E0.book Page 16 Friday, May 25, 2007 9:38 AM 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. Always be especially cautious on these kinds of terrain. 7 EWB01060 WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off-road vehicles. WHAT CAN HAPPEN You could be in a collision. You could be injured.
U4S211E0.book Page 17 Friday, May 25, 2007 9:38 AM hot when riding and afterwards; do not allow skin or clothing to come in contact with these components. With the engine idling, return the starter (choke) to the closed position, shift the drive select lever into the forward position, and then release the parking brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate.
U4S211E0.book Page 18 Friday, May 25, 2007 9:38 AM This maneuver will let the wheel on the inside of the turn slip slightly, allowing the ATV to make the turn properly. 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. EWB01310 WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn.
U4S211E0.book Page 19 Friday, May 25, 2007 9:38 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.
U4S211E0.book Page 20 Friday, May 25, 2007 9:38 AM 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. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards. Never go over the top of any hill at high speed.
U4S211E0.book Page 21 Friday, May 25, 2007 9:38 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. 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.
U4S211E0.book Page 22 Friday, May 25, 2007 9:38 AM If you start to roll backwards, DO NOT apply either brake abruptly. If you are in 2WD, apply only the front brake. If you are in 4WD or 4WD-LOCK, because all wheels are interconnected by the drive train, applying either brake will brake all wheels, therefore, avoid sudden application of either the front or rear brake as the wheels on the uphill side could come off the ground. The ATV could easily tip over backwards.
U4S211E0.book Page 23 Friday, May 25, 2007 9:38 AM 7 Whenever possible, ride your ATV straight downhill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear. 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.
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U4S211E0.book Page 25 Friday, May 25, 2007 9:38 AM 7 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. As you travel across a slope, lean your body in the uphill direction.
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U4S211E0.book Page 27 Friday, May 25, 2007 9:38 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 in) 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. EWB01150 WARNING 7 POTENTIAL HAZARD Operating this ATV through deep or fast flowing water.
U4S211E0.book Page 28 Friday, May 25, 2007 9:38 AM 1. Air filter case check hose ECB00280 7 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. Also, remove the V-belt case drain plug to drain any water that may have accumulated.
U4S211E0.book Page 29 Friday, May 25, 2007 9:38 AM 1. V-belt case drain plug 1. Drive select lever box check hose 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.
U4S211E0.book Page 30 Friday, May 25, 2007 9:38 AM WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual.
U4S211E0.book Page 31 Friday, May 25, 2007 9:38 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. 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. With practice, over a period of time, skill at controlled sliding can be developed.
U4S211E0.book Page 32 Friday, May 25, 2007 9:38 AM ● WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD 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. ● ● WHAT TO DO IF...
U4S211E0.book Page 33 Friday, May 25, 2007 9:38 AM ● If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let water drain from the ATV and CHECK YOUR 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 7-27.) EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death.
U4S211E0.book Page 1 Friday, May 25, 2007 9:38 AM EBU21647 PERIODIC MAINTENANCE AND MINOR REPAIR HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with maintenance work. EBU21660 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your ATV in the safest and best operating condition possible.
U4S211E0.book Page 2 Friday, May 25, 2007 9:38 AM EWB01830 WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this ATV 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.
U4S211E0.book Page 3 Friday, May 25, 2007 9:38 AM EBU21742 Periodic maintenance chart for the emission control system 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.
U4S211E0.book Page 4 Friday, May 25, 2007 9:38 AM INITIAL NO. 6 7 * ITEM Exhaust system Spark arrester CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 • Check for leakage and replace gasket(s) if necessary. • Check for looseness and tighten all screw clamps and joints if necessary. • Clean.
U4S211E0.book Page 5 Friday, May 25, 2007 9:38 AM EBU21864 General maintenance and lubrication chart INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) 20 80 hours 1 2 3 4 Air filter element * * * Front brake Rear brake Brake hoses 5 * Wheels 6 * Tires 7 * Wheel hub bearings 8 * V-belt • Clean and replace if necessary. • Check operation and correct if necessary.
U4S211E0.book Page 6 Friday, May 25, 2007 9:38 AM INITIAL NO.
U4S211E0.book Page 7 Friday, May 25, 2007 9:38 AM INITIAL NO. 21 ITEM Final gear oil Moving parts and cables Drive select lever safety system cable 22 * 23 * 24 * Throttle lever housing and cable 25 * Front and rear brake switches Lights and switches 26 * CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 • Change. • Check ATV for oil leakage, and correct if necessary. √ √ • Lubricate.
U4S211E0.book Page 8 Friday, May 25, 2007 9:38 AM • Every two years replace the internal components of the brake master cylinder and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.
U4S211E0.book Page 9 Friday, May 25, 2007 9:38 AM EWB00010 EBU23111 Panel A WARNING Indicates a potential hazard that could result in serious injury or death. To remove the panel Remove the bolt, and then take the panel off. EBU23080 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. 1. Panel A 2.
U4S211E0.book Page 10 Friday, May 25, 2007 9:38 AM 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. EBU23211 Checking the spark plug 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.
U4S211E0.book Page 11 Friday, May 25, 2007 9:38 AM 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/DR8EA To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 1. Spark plug gap Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) 2.
U4S211E0.book Page 12 Friday, May 25, 2007 9:38 AM 3. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag. 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. EBU23313 Engine oil and oil filter cartridge 8 The engine oil level should be checked before each ride.
U4S211E0.book Page 13 Friday, May 25, 2007 9:38 AM To change the engine oil (with or without oil filter cartridge replacement) 1. Place the ATV on a level surface. 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. 4. Remove the engine oil filler cap, and then remove the engine oil drain bolt to drain the oil from the crankcase. 1. Dipstick 2. Maximum level mark 3.
U4S211E0.book Page 14 Friday, May 25, 2007 9:38 AM 5. Remove the oil filter cartridge with an oil filter wrench. NOTE: An oil filter wrench is available at a nearby Yamaha dealer. 6. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Make sure that the O-ring is properly seated. 1. Oil filter cartridge 8 1. O-ring 7. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. 1.
U4S211E0.book Page 15 Friday, May 25, 2007 9:38 AM Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.20 L (2.33 US qt) (1.94 Imp.qt) With oil filter cartridge replacement: 2.30 L (2.43 US qt) (2.02 Imp.qt) NOTE: Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down. 1. Torque wrench ECB00300 Tightening torque: Oil filter cartridge: 17 Nm (1.
U4S211E0.book Page 16 Friday, May 25, 2007 9:38 AM 10. 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. 11. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary. NOTE: The oil level should be at the brim of the filler hole. EBU28570 Final gear oil 8 The final gear case must be checked for oil leakage before each ride.
U4S211E0.book Page 17 Friday, May 25, 2007 9:38 AM To change the final gear oil 1. Remove the engine guard and the final gear case guard by removing the bolts. 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. 1. Engine guard 2. Final gear case guard 3. Bolt Tightening torque: Final gear oil drain bolt: 24 Nm (2.4 m·kgf, 17 ft·lbf) 2. Place the ATV on a level surface. 3. Place an oil pan under the final gear case to collect the used oil. 4.
U4S211E0.book Page 18 Friday, May 25, 2007 9:38 AM ECB00420 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. Tightening torque: Final gear oil filler bolt: 24 Nm (2.4 m·kgf, 17 ft·lbf) 1. Final gear oil filler bolt 2. Correct oil level 3. Final gear oil 8 8. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 9.
U4S211E0.book Page 19 Friday, May 25, 2007 9:38 AM EBU23421 Differential gear oil The differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the differential gear oil level 1. Place the ATV on a level surface. 1. Differential gear oil 2.
U4S211E0.book Page 20 Friday, May 25, 2007 9:38 AM 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. Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case. 1. Differential gear oil 2. Differential gear oil filler bolt 3.
U4S211E0.book Page 21 Friday, May 25, 2007 9:38 AM Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 7. Check the differential gear case for oil leakage. If oil is leaking, check for the cause. EBU23631 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. 1.
U4S211E0.book Page 22 Friday, May 25, 2007 9:38 AM 1. Air filter case cover holder 2. Air filter case cover 1. Air filter element 4. Pull off the lock plate, and then remove the sponge material from the air filter element frame. 3. Pull the air filter element out of the air filter case.
U4S211E0.book Page 23 Friday, May 25, 2007 9:38 AM HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material. 6. Squeeze the excess solvent out of the sponge material and let it dry. ECB00440 CAUTION: Do not twist the sponge material when squeezing it. 1. Air filter element frame 2. Sponge material 3. Air filter element lock plate 5. Wash the sponge material gently but thoroughly in solvent.
U4S211E0.book Page 24 Friday, May 25, 2007 9:38 AM ● NOTE: The sponge material should be wet but not dripping. 9. Pull the sponge material over the air filter element frame, and then install the lock plate. 10. Insert the air filter element into the air filter case, and then install the air filter case cover by hooking the holders onto the air filter case. 11. Install the seat. 8 Never operate the engine with the air filter element removed.
U4S211E0.book Page 25 Friday, May 25, 2007 9:38 AM 2. Remove the tailpipe by pulling it out of the muffler. 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. Tightening torque: Tailpipe bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) EWB01910 WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system. WHAT CAN HAPPEN Could injure the eyes. Could cause burns.
U4S211E0.book Page 26 Friday, May 25, 2007 9:38 AM 8 1. V-belt cooling duct check hose (left front side of ATV) 1. V-belt case drain plug EBU23930 EBU23940 V-belt case drain plug Adjusting the carburetor 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. The carburetor should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.
U4S211E0.book Page 27 Friday, May 25, 2007 9:38 AM crease the engine idling speed, turn the throttle stop screw in direction (a), and to decrease it, turn the screw in direction (b). ECB00480 CAUTION: The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine.
U4S211E0.book Page 28 Friday, May 25, 2007 9:38 AM EBU24043 Adjusting the throttle cable free play The throttle cable free play should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The throttle cable free play should measure 3.0– 5.0 mm (0.12–0.20 in) at the throttle lever. Periodically check the throttle cable free play and, if necessary, adjust it as follows.
U4S211E0.book Page 29 Friday, May 25, 2007 9:38 AM EBU24070 EBU24171 Adjusting the drive select lever safety system cable Front brake pads Check each front brake pad for damage and measure the lining thickness. If a brake pad is damaged or if the lining thickness is less than 1.0 mm (0.04 in), have a Yamaha dealer replace the brake pads as a set. The drive select lever safety system cable stretches with use, which can result in improper function.
U4S211E0.book Page 30 Friday, May 25, 2007 9:38 AM EBU28421 EBU24251 Rear brake friction plates The rear brake is provided with a wear indicator, which allows you to check the brake friction plate wear without having to disassemble the brake. To check the brake friction plate wear, check the position of the wear indicator while applying the brake.
U4S211E0.book Page 31 Friday, May 25, 2007 9:38 AM ● tion, have the oil seals of the brake master cylinder and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking. ● Oil seals: Replace every two years. ● Brake hoses: Replace every four years. Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance.
U4S211E0.book Page 32 Friday, May 25, 2007 9:38 AM EWB02010 EBU28623 Adjusting the brake pedal and rear brake lever free play and checking the brake pedal position WARNING 8 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. ● Make sure the brakes do not drag.
U4S211E0.book Page 33 Friday, May 25, 2007 9:38 AM 1. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjusting bolt. 1. Brake pedal free play 1. Locknut 2. Brake lever free play adjusting bolt 2. Fully loosen the brake lever free play adjusting nut on the brake cable at the final gear case. 1.
U4S211E0.book Page 34 Friday, May 25, 2007 9:38 AM 1. Brake lever free play adjusting nut 8 1. Brake pedal free play adjusting nut 2. Brake camshaft lever 3. Gap “A” 3. Push the brake camshaft lever in direction (a) until it stops [apply approximately 50 N (5.1 kgf, 11.2 lbf) of force], and then turn the brake pedal free play adjusting nut on the brake cable at the final gear case so that gap “A” measures 2.5–3.0 mm (0.10–0.12 in). 4.
U4S211E0.book Page 35 Friday, May 25, 2007 9:38 AM 1. Brake lever free play adjusting nut 2. Brake camshaft lever 3. Gap “B” 1. Locknut 2. Brake lever free play adjusting bolt 6. Tighten the locknut at the brake lever. 5. Check the brake lever free play and, if necessary, adjust it by turning the brake lever free play adjusting bolt at the brake lever. Turn the brake lever free play adjusting bolt in direction (a) to increase the free play, and in direction (b) to decrease it.
U4S211E0.book Page 36 Friday, May 25, 2007 9:38 AM HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct. ● Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. 1. Distance between brake pedal and footboard EWB02020 WARNING 8 POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes.
U4S211E0.book Page 37 Friday, May 25, 2007 9:38 AM EBU24230 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart. Check the axle boots for tears or damage. If any damage is found, have them replaced by a Yamaha dealer. 1. Rear axle boot (each side) 8 1.
U4S211E0.book Page 38 Friday, May 25, 2007 9:38 AM EBU24751 Brake light switches The operation of the brake light switches must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. 1. Remove panel A. (See page 8-9.
U4S211E0.book Page 39 Friday, May 25, 2007 9:38 AM EWB02120 Recommended lubricants: Front brake lever: Silicone grease Rear brake lever: Lithium-soap-based grease (all-purpose grease) WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN 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. HOW TO AVOID THE HAZARD Inspect cables frequently.
U4S211E0.book Page 40 Friday, May 25, 2007 9:38 AM Rear brake lever EBU24962 Checking the wheel hub bearings EBU28831 Checking and lubricating the brake pedal 8 The front and rear wheel hub 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 hub bearings.
U4S211E0.book Page 41 Friday, May 25, 2007 9:38 AM Lubricate the universal joint using a grease gun. Recommended lubricant: Lithium-soap-based grease EBU25021 Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer replace the stabilizer bushes if necessary. 1.
U4S211E0.book Page 42 Friday, May 25, 2007 9:38 AM 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.
U4S211E0.book Page 43 Friday, May 25, 2007 9:38 AM 2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary. ECB00630 CAUTION: Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. ● To charge a sealed-type (MF) battery, a special constant-voltage battery charger is required. Using a conventional battery charger will damage the battery.
U4S211E0.book Page 44 Friday, May 25, 2007 9:38 AM EBU25313 Replacing a fuse 8 1. 2. 3. 4. 5. 1. Main fuse 2. Spare main fuse 3. Fuse box Headlight fuse Ignition fuse Four-wheel-drive motor fuse Signaling system fuse Spare fuse The main fuse and the fuse box are located under the seat. (See page 4-18.) If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off all electrical circuits.
U4S211E0.book Page 45 Friday, May 25, 2007 9:38 AM 2. Remove the blown fuse, and then install a new fuse of the specified amperage. 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. Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Ignition fuse: 15.0 A Four-wheel-drive motor fuse: 10.0 A Signaling system fuse: 10.
U4S211E0.book Page 46 Friday, May 25, 2007 9:38 AM 4. Remove the defective bulb by pulling it out. EWB02180 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. Headlight bulb holder cover 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise.
U4S211E0.book Page 47 Friday, May 25, 2007 9:38 AM ECB00670 CAUTION: Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 8. 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.
U4S211E0.book Page 48 Friday, May 25, 2007 9:38 AM 1. Headlight beam adjusting screw 1. Wheel nut 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. EBU25580 Replacing the tail/brake light bulb 8 If the tail/brake light bulb burns out, have a Yamaha dealer replace it. EBU25650 EBU25700 Removing a wheel Installing a wheel 1. Install the wheel and the nuts. 1. Loosen the wheel nuts.
U4S211E0.book Page 49 Friday, May 25, 2007 9:38 AM ● Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel. 1. Tapered nut 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified torques. 1. Arrow mark Tightening torques: Front wheel nut: 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear wheel nut: 55 Nm (5.
U4S211E0.book Page 50 Friday, May 25, 2007 9:38 AM 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. EBU25710 Troubleshooting 8 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.
U4S211E0.book Page 51 Friday, May 25, 2007 9:38 AM EBU25751 Troubleshooting chart 1. Fuel 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. Check the fuel level in the fuel tank. The engine does not start. Check the compression. 2. Compression Operate the electric starter. 3.
U4S211E0.book Page 1 Friday, May 25, 2007 9:38 AM EBU25860 CLEANING AND STORAGE ed from improper high-pressure detergent applications such as those available in coinoperated car washers. EBU25870 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.
U4S211E0.book Page 2 Friday, May 25, 2007 9:38 AM WHAT CAN HAPPEN Wet brakes may have reduced stopping ability, increasing the chance of an accident. HOW TO AVOID THE HAZARD Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings. Long-term Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” section of this chapter. 2. Turn the fuel cock lever to “OFF”. 3.
U4S211E0.book Page 3 Friday, May 25, 2007 9:38 AM 6. 7. 9 8. 9. °F) or more than 30 °C (90 °F)]. For more information on storing the battery, see page 8-42. c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder wall with oil.) e.
U4S211E0.book Page 1 Friday, May 25, 2007 9:38 AM EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Starting system: Electric and recoil starter Lubrication system: Wet sump Overall length: 1995 mm (78.5 in) Overall width: 1095 mm (43.1 in) Overall height: 1120 mm (44.1 in) Seat height: 830 mm (32.7 in) Wheelbase: 1235 mm (48.6 in) Ground clearance: 245 mm (9.
U4S211E0.book Page 2 Friday, May 25, 2007 9:38 AM Spark plug (s): With oil filter cartridge replacement: 2.30 L (2.43 US qt) (2.02 Imp.qt) Manufacturer/model: NGK/DR8EA Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) Final gear oil: Type: Yamaha Friction Modified Shaft Drive Gear Oil (Part No.: ACC-SHAFT-LU-00) Quantity: 0.50 L (0.53 US qt) (0.44 Imp.qt) Clutch: Clutch type: Wet, centrifugal automatic Differential gear oil: Transmission: Type: Yamaha Friction Modified Shaft Drive Gear Oil (Part No.
U4S211E0.book Page 3 Friday, May 25, 2007 9:38 AM Front tire: Maximum: Front: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Rear: 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Type: Tubeless Size: AT25 x 8-12 Manufacturer/model: MAXXIS/M979 Front wheel: Wheel type: Panel wheel Rim size: 12 x 6.0AT Rear tire: Type: Tubeless Size: AT25 x 10-12 Manufacturer/model: MAXXIS/M980 Rear wheel: Wheel type: Panel wheel Rim size: 12 x 7.5AT Loading: Front brake: Maximum loading limit: 210.
U4S211E0.book Page 4 Friday, May 25, 2007 9:38 AM Neutral indicator light: 12 V, 1.7 W × 1 Reverse indicator light: 12 V, 1.7 W × 1 Oil temperature warning light: 12 V, 1.7 W × 1 On-command four-wheel-drive indicator light: 12 V, 1.7 W × 1 Differential gear lock indicator light: 12 V, 1.7 W x 1 Spring/shock absorber type: Coil spring/oil damper Wheel travel: 160 mm (6.3 in) Rear suspension: Type: Double wishbone Spring/shock absorber type: Coil spring/oil damper Wheel travel: 180 mm (7.
U4S211E0.book Page 1 Friday, May 25, 2007 9:38 AM EBU25981 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.
U4S211E0.book Page 2 Friday, May 25, 2007 9:38 AM 1. Vehicle identification number (front left side) 1. Model label NOTE: The vehicle identification number is used to identify your ATV. EBU26050 11 Model label The model label is affixed at the location in the illustration. Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
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U4S211E0.book Page 4 Friday, May 25, 2007 9:38 AM EBU26080 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.
U4S211E0.book Page 5 Friday, May 25, 2007 9:38 AM EBU26501 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha ATVs purchased from an authorized Yamaha ATV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations. THE PERIOD OF WARRANTY for Yamaha ATVs shall be six (6) months from the date of purchase.
U4S211E0.book Page 6 Friday, May 25, 2007 9:38 AM WARRANTY QUESTIONS AND ANSWERS CUSTOMER SERVICE Q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes. If your machine requires warranty service, you must take it to any authorized Yamaha ATV dealer within the continental United States.
U4S211E0.book Page 7 Friday, May 25, 2007 9:38 AM EBU26122 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Ser vice (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
U4S211E0.book Page 8 Friday, May 25, 2007 9:38 AM We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. You can also save money: Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number).
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U4S211E0.book Page 1 Friday, May 25, 2007 9:38 AM INDEX A Drive select lever .......................................................... 4-13 Drive select lever and driving in reverse ........................ 6-3 Drive select lever safety system cable, adjusting ......... 8-29 Drive shaft universal joint, lubricating ........................... 8-40 Accessories and loading ................................................ 6-7 Air filter element, cleaning ............................................
U4S211E0.book Page 2 Friday, May 25, 2007 9:38 AM K S Key identification number ............................................. 11-1 Safety information .......................................................... 1-1 Seat ............................................................................. 4-18 Shock absorber assemblies, adjusting the front and rear ........................................ 4-21 Spark arrester, cleaning ............................................... 8-24 Spark plug, checking ......
U4S211E0.book Page 3 Friday, May 25, 2007 9:38 AM Warranty, limited .......................................................... 11-5 Wheel hub bearings, checking ..................................... 8-40 Wheel, installing ........................................................... 8-48 Wheel, removing ..........................................................
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EBU26151 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.
