READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM45FGW WARNING LIT-11626-20-17 This ATV should not be ridden by anyone under 16 years of age.
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U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM EBU17170 INTRODUCTION EBU17270 Congratulations on your purchase of the Yamaha YFM45FGW. 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.
U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM 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....................................................
U1D913E0.book Page 2 Thursday, April 20, 2006 2:47 PM Tires ........................................................... 5-7 Measuring the tire pressure ....................... 5-8 Tire wear limit ............................................. 5-9 Chassis fasteners ....................................... 5-9 Instruments, lights and switches ................ 5-9 OPERATION .................................................. 6-1 Starting a cold engine ................................ 6-1 Starting a warm engine .
U1D913E0.book Page 3 Thursday, April 20, 2006 2:47 PM Adjusting the drive select lever safety system cable .......................................... 8-38 Checking the front and rear brake pads ....................................................... 8-38 Checking the brake fluid level .................. 8-39 Changing the brake fluid .......................... 8-40 Checking the front brake lever free play .........................................................
U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM EBU17430 SAFETY INFORMATION ● EBU17482 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.
U1D913E0.book Page 2 Thursday, April 20, 2006 2:47 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.
U1D913E0.book Page 3 Thursday, April 20, 2006 2:47 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.
U1D913E0.book Page 4 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 5 Thursday, April 20, 2006 2:47 PM 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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U1D913E0.book Page 2 Thursday, April 20, 2006 2:47 PM 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.
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U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Radiator cap 2. Fuel cock 3. Recoil starter 4. Throttle stop screw 5. Air filter case 6. Battery 7. Fuses 8. Tail/brake light 9. Engine oil filler cap 10.Oil filter cartridge 11.Coolant reservoir 12.V-belt cooling duct check hose 1. Rear shock absorber assembly spring preload adjusting ring 2. Spark arrester 3. Storage compartment and tool kit 4. Spark plug 5.
U1D913E0.book Page 2 Thursday, April 20, 2006 2:47 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. 9. Rear brake lever Handlebar switches Starter (choke) Drive select lever Multifunction meter unit Main switch Fuel tank cap Auxiliary DC jack On-Command four-wheel-drive/differential gear lock switch 10.Throttle lever 11.
U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 4 EBU17760 Main switch The positions of the main switch are as follows: 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. 1. Main switch OFF All electrical systems are off.
U1D913E0.book Page 2 Thursday, April 20, 2006 2:47 PM EBU17812 NOTE: If the indicator light flashes or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. Indicator lights and warning light EBU17860 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. EBU17920 Coolant temperature warning light “ ” This warning light comes on when the engine overheats.
U1D913E0.book Page 3 Thursday, April 20, 2006 2:47 PM EBU17961 EBU17980 On-Command four-wheel-drive/differential gear lock indicator “ ”/“ ” The On-Command four-wheel-drive indicator “ ” comes on when the On-Command four-wheeldrive switch is set to the “4WD” position. 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.
U1D913E0.book Page 4 Thursday, April 20, 2006 2:47 PM ● EBU18031 Multifunction display 1. 2. 3. 4. 5. 6. 7.
U1D913E0.book Page 5 Thursday, April 20, 2006 2:47 PM 4 To set the clock 1. Set the display to the clock mode. 2. Push the “ ”/“ ” button until the clock starts flashing. 3. Set the hours by pushing the “H” button. 4. Set the minutes by pushing the “M” button. 5. Push the “ ”/“ ” button, and then release it to start the clock. NOTE: If the ATV runs out of fuel, move the fuel cock lever to the “RES” position. Approximately 4.5 L (1.19 US gal) (0.99 Imp.gal) of fuel will be remaining in the tank.
U1D913E0.book Page 6 Thursday, April 20, 2006 2:47 PM EBU18080 ECB00040 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. The engine will not start or run when this switch is set to “ ”.
U1D913E0.book Page 7 Thursday, April 20, 2006 2:47 PM switch to override the differential gear lock speed limiting function. (See page 4-9.) Releasing the switch restores the speed limiting function. While the override switch is pushed, the segments of the speedometer digits will appear as shown in the figure. EWB00110 NOTE: If the digits of the speedometer appear as shown when the switch is NOT being pushed, this could indicate a malfunction in the electrical system.
U1D913E0.book Page 8 Thursday, April 20, 2006 2:47 PM ● “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. Then, the four-wheel-drive indicator “ ” comes on in the multifunction meter unit display. To change from four-wheel drive to two-wheel drive, stop the ATV and push the switch in to the “2WD” position.
U1D913E0.book Page 9 Thursday, April 20, 2006 2:47 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. EBU18243 4 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.
U1D913E0.book Page 10 Thursday, April 20, 2006 2:47 PM WHAT CAN HAPPEN The ATV handles differently in four-wheel drive than in differential gear lock in some circumstances. Changing from four-wheel drive to differential gear lock or vice-versa while moving may cause the ATV to handle differently unexpectedly. This could distract the operator and increase the risk of losing control and causing an accident.
U1D913E0.book Page 11 Thursday, April 20, 2006 2:47 PM ● EWB00101 WARNING 4 POTENTIAL HAZARD Riding too fast while the ATV is in fourwheel-drive differential gear lock. 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.
U1D913E0.book Page 12 Thursday, April 20, 2006 2:47 PM HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can’t find or solve the problem yourself. EBU18311 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.
U1D913E0.book Page 13 Thursday, April 20, 2006 2:47 PM 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 8-37.) EBU18391 Front brake lever The front brake lever is located on the right handlebar. To apply the front brake, pull the brake lever toward the handlebar grip. 4 1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in) 3. Tighten the locknut.
U1D913E0.book Page 14 Thursday, April 20, 2006 2:47 PM 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. 4 1. Rear brake lever 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.
U1D913E0.book Page 15 Thursday, April 20, 2006 2:47 PM 4 1. Drive select lever 1. Recoil starter EWB00290 EBU18680 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 setting the drive select lever to the park position. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident.
U1D913E0.book Page 16 Thursday, April 20, 2006 2:47 PM 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: 15.0 L (3.96 US gal) (3.30 Imp.gal) Fuel reserve amount: 4.5 L (1.19 US gal) (0.99 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.
U1D913E0.book Page 17 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 18 Thursday, April 20, 2006 2:47 PM ON OFF 4 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.
U1D913E0.book Page 19 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 20 Thursday, April 20, 2006 2:47 PM 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. EBU18941 Storage compartment The storage compartment is located under the seat. (See page 4-19.) When storing any documents in the storage compartment, be sure to wrap them in a plastic bag so that they will not get wet.
U1D913E0.book Page 21 Thursday, April 20, 2006 2:47 PM ECB00130 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. 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. 4 1. Storage compartment check hose EBU18960 Front carrier 1.
U1D913E0.book Page 22 Thursday, April 20, 2006 2:47 PM EBU18970 Rear carrier ● ● Do not exceed the load limit of 80.0 kg (176 lb) for the rear carrier. Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV. 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.
U1D913E0.book Page 23 Thursday, April 20, 2006 2:47 PM 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 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.
U1D913E0.book Page 24 Thursday, April 20, 2006 2:47 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. ● If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine starting may become difficult.
U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM EBU19200 PRE-OPERATION CHECKS EBU19210 Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table. 5 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.
U1D913E0.book Page 2 Thursday, April 20, 2006 2:47 PM ITEM Rear brake Throttle lever 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 lever 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.
U1D913E0.book Page 3 Thursday, April 20, 2006 2:47 PM 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. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
U1D913E0.book Page 4 Thursday, April 20, 2006 2:47 PM EBU19530 EBU19590 Fuel Final gear oil Make sure that there is sufficient fuel in the tank. (See page 4-16.) Make sure that the final gear oil is at the specified level. Add oil as necessary. (See page 8-21.) EWB00500 WARNING 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.
U1D913E0.book Page 5 Thursday, April 20, 2006 2:47 PM ● EWB00490 WARNING 5 POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap. Check the operation of the brake levers and pedal.
U1D913E0.book Page 6 Thursday, April 20, 2006 2:47 PM EWB00540 WARNING POTENTIAL HAZARD Riding with improperly operating brakes. 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.
U1D913E0.book Page 7 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 8 Thursday, April 20, 2006 2:47 PM ● ● ● 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.
U1D913E0.book Page 9 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM EBU19870 OPERATION EBU20042 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.
U1D913E0.book Page 2 Thursday, April 20, 2006 2:47 PM Ambient temp./starter (choke) position 3. Shift the drive select lever into the neutral or park position. The corresponding 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 or park position. ● The rear brake lever is applied with the drive select lever in any position.
U1D913E0.book Page 3 Thursday, April 20, 2006 2:47 PM ● 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.
U1D913E0.book Page 4 Thursday, April 20, 2006 2:47 PM 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. Drive select lever L (Low-range) H (High-range) N (Neutral) R (Reverse) P (Park) 1. 2. 3. 4. 5. 6. 3. Release the brake pedal, and then open the throttle lever gradually.
U1D913E0.book Page 5 Thursday, April 20, 2006 2:47 PM ● Since the engine is brand new, do not put an excessive load on it for the first 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. Due to the synchronizing mechanism in the engine, the indicator light may not come on until the ATV starts moving. 4.
U1D913E0.book Page 6 Thursday, April 20, 2006 2:47 PM 2. Stop the engine. 3. With the brake pedal applied, shift the drive select lever to the park position. EBU20690 Parking When parking the ATV, stop the engine, shift the drive select lever into the park position, and then turn the fuel cock to the “OFF” position. EBU20810 Parking on a slope EWB00780 WARNING 6 POTENTIAL HAZARD Parking on a hill or other incline.
U1D913E0.book Page 7 Thursday, April 20, 2006 2:47 PM ● ● ● ● it is not possible for Yamaha to test all nonYamaha accessories, nor control over their quality or suitability. Choose a genuine Yamaha accessory, or one that is equivalent in design and quality. Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV.
U1D913E0.book Page 8 Thursday, April 20, 2006 2:47 PM ● ● ● 6 ● ● ● ● the weight on the hitch. If you are carrying cargo and towing a trailer, include the tongue weight in the maximum ATV load limit. Load cargo on the carriers as close to the center of the ATV as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, and center it. Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident.
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U1D913E0.book Page 2 Thursday, April 20, 2006 2:47 PM 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. RIDE WITH CARE AND GOOD JUDGEMENT EBU21471 7 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.
U1D913E0.book Page 3 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 4 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 5 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 6 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 7 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 8 Thursday, April 20, 2006 2:47 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. 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.
U1D913E0.book Page 9 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 10 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 11 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 12 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 13 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 14 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 15 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 16 Thursday, April 20, 2006 2:47 PM be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components. With the engine idling, shift the drive select lever into the low-range position or the high-range position. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is applied too abruptly, the front wheels may lift off the ground, resulting in a loss of directional control.
U1D913E0.book Page 17 Thursday, April 20, 2006 2:47 PM TURNING YOUR ATV To achieve maximum traction while riding off-road in 2WD or 4WD, the two rear wheels turn together at the same speed. Furthermore, when riding in 4WD-LOCK (“DIFF. LOCK”), the front wheels also turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning.
U1D913E0.book Page 18 Thursday, April 20, 2006 2:47 PM may continue to go straight. If the ATV doesn’t turn, come to a stop and then practice the procedure again. If the riding surface is slippery or loose, it may help to position more of your weight over the front wheels by moving forward on the seat. Once you have learned this technique, you should be able to perform it at higher speeds or in tighter curves.
U1D913E0.book Page 19 Thursday, April 20, 2006 2:47 PM oped your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control. EWB01090 WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities.
U1D913E0.book Page 20 Thursday, April 20, 2006 2:47 PM It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars. 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.
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U1D913E0.book Page 22 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 23 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 24 Thursday, April 20, 2006 2:47 PM 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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U1D913E0.book Page 26 Thursday, April 20, 2006 2:47 PM 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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U1D913E0.book Page 28 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 29 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 30 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 31 Thursday, April 20, 2006 2:47 PM 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. SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide.
U1D913E0.book Page 32 Thursday, April 20, 2006 2:47 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. EWB01170 WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn.
U1D913E0.book Page 33 Thursday, April 20, 2006 2:47 PM ● WHAT TO DO... ● If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See page 7-17.) ● If your ATV begins to tip while turning: Lean more into the turn to regain balance.
U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM EBU21641 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 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.
U1D913E0.book Page 2 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 3 Thursday, April 20, 2006 2:47 PM EBU21741 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.
U1D913E0.book Page 4 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 5 Thursday, April 20, 2006 2:47 PM EBU21862 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 8 3 4 Air filter element * * * Front brake Rear brake Brake hoses 5 * Wheels 6 * Tires 7 * Wheel bearings • Clean and replace if necessary. • Check operation and correct if necessary.
U1D913E0.book Page 6 Thursday, April 20, 2006 2:47 PM INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 8 * Upper and lower arm pivots • Lubricate with lithium-soap-based grease. 9 * V-belt • Check for wear, cracks or other damage, and replace if necessary. 10 * Drive shaft universal joint • Lubricate with lithium-soap-based grease.
U1D913E0.book Page 7 Thursday, April 20, 2006 2:47 PM INITIAL NO.
U1D913E0.book Page 8 Thursday, April 20, 2006 2:47 PM EBU23070 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.
U1D913E0.book Page 9 Thursday, April 20, 2006 2:47 PM EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 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. 2. 3. 4. 8 Panel C Panel D Panel E Panel F EBU27600 Panels A and D To remove one of the panels 1. Remove the seat. (See page 4-19.) 2.
U1D913E0.book Page 10 Thursday, April 20, 2006 2:47 PM To install one of the panels 1. Place the panel in its original position.
U1D913E0.book Page 11 Thursday, April 20, 2006 2:47 PM Panel B To remove the panel Remove the bolt, and then take the panel off. 1. Bolt 2. Panel B 8 To install the panel Place the panel in the original position and install the bolt. ECB00380 CAUTION: When installing the panel, be sure not to pinch the cables or wires. 2. Install the seat.
U1D913E0.book Page 12 Thursday, April 20, 2006 2:47 PM Panel C To remove the panel 1. Remove the carrier top bolts. 1. Carrier bolt (under the fenders) 3. Remove the quick fastener screws, and then pull the panel upward to remove it. 1. Carrier bolt (top) 8 2. Remove the carrier bolts under the fenders, and then take the carrier off.
U1D913E0.book Page 13 Thursday, April 20, 2006 2:47 PM Panel E To remove the panel Remove the bolts, and then take the panel off. 1. Quick fastener screw 2. Panel C 8 To install the panel 1. Place the panel in the original position, and then install the quick fastener screws. 2. Place the carrier in the original position, and then install the carrier bolts under the fenders. 3. Install the carrier top bolts, and then tighten all bolts to the specified torques. 1. Panel E 2.
U1D913E0.book Page 14 Thursday, April 20, 2006 2:47 PM EBU23221 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. In addition, the condition of the spark plug can reveal the condition of the engine. To remove the spark plug 1. Remove panel A. (See page 8-9.) 2.
U1D913E0.book Page 15 Thursday, April 20, 2006 2:47 PM 3. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. NOTE: If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.
U1D913E0.book Page 16 Thursday, April 20, 2006 2:47 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. 5. Install the panel. EBU23322 Engine oil and oil filter cartridge 1. Spark plug gap The engine oil level should be checked before each ride.
U1D913E0.book Page 17 Thursday, April 20, 2006 2:47 PM 1. Engine oil filler cap 8 1. Dipstick 2. Maximum level mark 3. Minimum level mark 6. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level. NOTE: The engine oil should be between the minimum and maximum level marks. 7. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. 8.
U1D913E0.book Page 18 Thursday, April 20, 2006 2:47 PM To change the engine oil (with or without oil filter cartridge replacement) 1. Remove panel F. (See page 8-9.) 2. Place the ATV on a level surface. 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Place an oil pan under the engine to collect the used oil. 5. Remove the engine oil filler cap, and then remove the engine oil drain bolt to drain the oil from the crankcase.
U1D913E0.book Page 19 Thursday, April 20, 2006 2:47 PM 8 1. Oil filter wrench 1. O-ring NOTE: An oil filter wrench is available at a nearby Yamaha dealer. NOTE: Make sure that the O-ring is properly seated. 9. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. 8. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.
U1D913E0.book Page 20 Thursday, April 20, 2006 2:47 PM 12. Add the specified amount of the recommended engine oil, and then install and tighten the engine oil filler cap. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.30 L (2.43 US qt) (2.02 Imp.qt) With oil filter cartridge replacement: 2.40 L (2.54 US qt) (2.11 Imp.qt) 1.
U1D913E0.book Page 21 Thursday, April 20, 2006 2:47 PM 13. 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. 14. Turn the engine off, and then check the oil level and correct it if necessary. 15. Install panel F. NOTE: The oil level should be at the brim of the filler hole. EBU23391 Final gear oil 8 The final gear case must be checked for oil leakage before each ride.
U1D913E0.book Page 22 Thursday, April 20, 2006 2:47 PM 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: 23 Nm (2.3 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.
U1D913E0.book Page 23 Thursday, April 20, 2006 2:47 PM Tightening torque: Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 8. Check the final gear case for oil leakage. If oil is leaking, check for the cause. 9. Install the engine guard and the final gear case guard by installing the bolts, and then tightening them to the specified torques. Tightening torques: Engine guard bolt: 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Final gear case guard bolt: 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 1. Final gear oil filler bolt 2.
U1D913E0.book Page 24 Thursday, April 20, 2006 2:47 PM To check the differential gear oil level 1. Place the ATV on a level surface. 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. 4. Install the oil filler bolt, and then tighten it to the specified torque. NOTE: The differential gear oil level must be checked on a cold engine. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 2.
U1D913E0.book Page 25 Thursday, April 20, 2006 2:47 PM 1. Differential gear oil drain bolt 1. Differential gear oil 2. Differential gear oil filler bolt 3. Correct oil level 4. Install the drain bolt, and then tighten it to the specified torque. 8 Recommended differential gear oil: See page 10-1. Tightening torque: Differential gear oil drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ECB00410 CAUTION: Be sure no foreign material enters the differential gear case. 5.
U1D913E0.book Page 26 Thursday, April 20, 2006 2:47 PM Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) NOTE: The coolant should be between the minimum and maximum level marks. 7. Check the differential gear case for oil leakage. If oil is leaking, check for the cause. EBU23470 Coolant The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart.
U1D913E0.book Page 27 Thursday, April 20, 2006 2:47 PM EBU23592 Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.26 US qt) (0.22 Imp.qt) To change the coolant EWB01880 WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always place a thick rag over the cap.
U1D913E0.book Page 28 Thursday, April 20, 2006 2:47 PM 4. Remove the front carrier and panel C. (See page 8-9.) 5. Remove the radiator cap. 1. Coolant drain bolt 1. Radiator cap 6. Remove panel D. (See page 8-9.) 7. Remove the coolant reservoir cap. 8. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir. 1.
U1D913E0.book Page 29 Thursday, April 20, 2006 2:47 PM 13. Pour the recommended coolant into the radiator until it is full. 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): 1.30 L (1.37 US qt) (1.14 Imp.qt) Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.26 US qt) (0.22 Imp.qt) 1. Coolant reservoir hose 8 9.
U1D913E0.book Page 30 Thursday, April 20, 2006 2:47 PM ● If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. 14.
U1D913E0.book Page 31 Thursday, April 20, 2006 2:47 PM 1. Air filter case 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.
U1D913E0.book Page 32 Thursday, April 20, 2006 2:47 PM 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. 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. 1. Air filter element frame 2. Sponge material 3.
U1D913E0.book Page 33 Thursday, April 20, 2006 2:47 PM EBU23881 NOTE: The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty areas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions. Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air-tight seal.
U1D913E0.book Page 34 Thursday, April 20, 2006 2:47 PM WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components. Do not start the engine when cleaning the exhaust system. 1. Tailpipe 2. Spark arrester EBU23920 4. Insert the tailpipe into the muffler and align the bolt holes. 5.
U1D913E0.book Page 35 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 36 Thursday, April 20, 2006 2:47 PM 4. Check the engine idling speed and, if necessary, adjust it to specification by turning the throttle stop screw at the carburetor. To increase 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.
U1D913E0.book Page 37 Thursday, April 20, 2006 2:47 PM 5. Install the panel. 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. 8 1. Locknut 2.
U1D913E0.book Page 38 Thursday, April 20, 2006 2:47 PM EBU24070 Adjusting the drive select lever safety system cable The drive select lever safety system cable stretches with use, which can result in improper function. Therefore, the safety system cable should be checked and adjusted at the intervals specified in the periodic maintenance and lubrication chart.
U1D913E0.book Page 39 Thursday, April 20, 2006 2:47 PM 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. that the wear indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set. Front brake 1.
U1D913E0.book Page 40 Thursday, April 20, 2006 2:47 PM ● Rear brake ● ● ● 1. Minimum level mark NOTE: To check the rear brake fluid level, remove panel C. (See page 8-9.) Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. 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.
U1D913E0.book Page 41 Thursday, April 20, 2006 2:47 PM 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. ● 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.
U1D913E0.book Page 42 Thursday, April 20, 2006 2:47 PM ● Before adjusting the brake lever free play and checking the brake pedal position, check the rear brake pads for wear. Adjusting the brake lever free play The brake lever free play should measure 0.5–2.0 mm (0.02–0.08 in) as shown. If the free play is incorrect, adjust it as follows. 1. Locknut 2. Brake lever free play adjusting bolt 3. Tighten the locknut. If the correct free play cannot be obtained, have a Yamaha dealer adjust it.
U1D913E0.book Page 43 Thursday, April 20, 2006 2:47 PM Checking the brake pedal position The top of the brake pedal should be positioned 72.0 mm (2.83 in) above the top of the footboard. If the brake pedal position is incorrect, have a Yamaha dealer adjust it. 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. ● Make sure the brakes are not spongy. All air must be bled from the brake system.
U1D913E0.book Page 44 Thursday, April 20, 2006 2:47 PM 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 B. (See page 8-9.
U1D913E0.book Page 45 Thursday, April 20, 2006 2:47 PM EWB02120 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. Replace damaged cables. 1. Brake light switch 2. Brake light switch adjusting nut 3. Install the panel.
U1D913E0.book Page 46 Thursday, April 20, 2006 2:47 PM EBU24950 EBU24961 Checking and lubricating the brake pedal Checking the wheel bearings 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.
U1D913E0.book Page 47 Thursday, April 20, 2006 2:47 PM Recommended lubricant: Lithium-soap-based grease 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.
U1D913E0.book Page 48 Thursday, April 20, 2006 2:47 PM WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases. 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.
U1D913E0.book Page 49 Thursday, April 20, 2006 2:47 PM To store the battery 1. If the ATV will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. 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. To install the battery NOTE: Be sure the battery is fully charged. 1. Positive battery terminal 2. Negative battery terminal 1. Place the battery in its compartment. 2.
U1D913E0.book Page 50 Thursday, April 20, 2006 2:47 PM EBU25313 Replacing a fuse 1. Main fuse 2. Spare main fuse 1. Main fuse 2.
U1D913E0.book Page 51 Thursday, April 20, 2006 2:47 PM ECB00640 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. 8 1. 2. 3. 4. 5. 6. 7. Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Ignition fuse: 10.0 A Four-wheel-drive motor fuse: 3.0 A Signaling system fuse: 10.0 A Auxiliary DC jack fuse: 10.0 A Backup fuse: 10.
U1D913E0.book Page 52 Thursday, April 20, 2006 2:47 PM EWB02151 WARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system, which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse. 1. Cover at the rear of the headlight 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4.
U1D913E0.book Page 53 Thursday, April 20, 2006 2:47 PM 3. Remove the headlight bulb holder assembly by turning it counterclockwise. 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. 4. Install a new headlight bulb holder assembly by inserting it into the headlight unit and turning it clockwise. 1.
U1D913E0.book Page 54 Thursday, April 20, 2006 2:47 PM To raise a headlight beam, turn the adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b). ECB00650 CAUTION: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected.
U1D913E0.book Page 55 Thursday, April 20, 2006 2:47 PM 1. Tail/brake light assembly 2. Nut 1. Tail/brake light assembly 2. Tail/brake light bulb holder 2. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 3. Remove the defective bulb by pushing it in and turning it counterclockwise.
U1D913E0.book Page 56 Thursday, April 20, 2006 2:47 PM 1. Tail/brake light bulb holder 2. Tail/brake light bulb 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. 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 tail/brake light assembly by installing the washers and the nuts.
U1D913E0.book Page 57 Thursday, April 20, 2006 2:47 PM ● Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel. 1. Tapered nut 8 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.
U1D913E0.book Page 58 Thursday, April 20, 2006 2:47 PM 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. EBU25730 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.
U1D913E0.book Page 59 Thursday, April 20, 2006 2:47 PM EBU25771 Troubleshooting charts Starting problems or poor engine performance 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. 8 3.
U1D913E0.book Page 60 Thursday, April 20, 2006 2:47 PM Engine overheating EWB02270 WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap. The coolant level is low.
U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 2 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 3 Thursday, April 20, 2006 2:47 PM 6. 7. 9 8. 9. °F) or more than 30 °C (90 °F)]. For more information on storing the battery, see page 8-48. 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.
U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 10.00 :1 Starting system: Electric and recoil starter Lubrication system: Wet sump Overall length: 1993 mm (78.5 in) Overall width: 1093 mm (43.0 in) Overall height: 1120 mm (44.1 in) Seat height: 830 mm (32.7 in) Wheelbase: 1233 mm (48.5 in) Ground clearance: 245 mm (9.
U1D913E0.book Page 2 Thursday, April 20, 2006 2:47 PM Type x quantity: BSR33 x 1 With oil filter cartridge replacement: 2.40 L (2.54 US qt) (2.11 Imp.qt) Final gear oil: Spark plug (s): Type: SAE80 API GL-4 Hypoid gear oil Quantity: 0.16 L (0.17 US qt) (0.14 Imp.qt) Manufacturer/model: NGK/DR8EA Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) Differential gear oil: Clutch: Type: SAE80 API GL-4 Hypoid gear oil Quantity: 0.23 L (0.24 US qt) (0.20 Imp.
U1D913E0.book Page 3 Thursday, April 20, 2006 2:47 PM Caster angle: 2.5 ° Trail: 8.5 mm (0.33 in) 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) Front tire: 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: Rear wheel: Type: Tubeless Size: AT25 x 10-12 Manufacturer/model: MAXXIS/M980 Wheel type: Panel wheel Rim size: 12 x 7.
U1D913E0.book Page 4 Thursday, April 20, 2006 2:47 PM Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Neutral indicator light: LED Reverse indicator light: LED Coolant temperature 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 Type: Double wishbone Spring/shock absorber type: Coil spring/oil damper Wheel travel: 160 mm (6.
U1D913E0.book Page 5 Thursday, April 20, 2006 2:47 PM Four-wheel-drive motor fuse: 3.
U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 2 Thursday, April 20, 2006 2:47 PM 1. Model label 1. Vehicle identification number (front left side) 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. This information will be needed when ordering spare parts from a Yamaha dealer.
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U1D913E0.book Page 4 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 5 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 6 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 7 Thursday, April 20, 2006 2:47 PM 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.
U1D913E0.book Page 8 Thursday, April 20, 2006 2:47 PM 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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U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM INDEX A D Accessories and loading ................................................ 6-6 Accessories, auxiliary jack ........................................... 4-23 Air filter element, cleaning ............................................ 8-30 Axle boots .................................................................... 8-43 Differential gear lock indicator light ................................ 4-3 Differential gear oil ............................
U1D913E0.book Page 2 Thursday, April 20, 2006 2:47 PM I Identification numbers .................................................. 11-1 Indicator lights and warning light .................................... 4-2 Instruments, lights and switches .................................... 5-9 Part locations ................................................................. 3-1 Pre-operation check list .................................................. 5-1 R Recoil starter ..........................................
U1D913E0.book Page 3 Thursday, April 20, 2006 2:47 PM V Valve clearance ........................................................... 8-37 V-belt case drain plug .................................................. 8-35 V-belt cooling duct check hose .................................... 8-34 Vehicle identification number ....................................... 11-1 W Warranty, extended ...................................................... 11-7 Warranty, limited ...............................................
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.
