EBU00438 READ THIS MANUAL CAREFULLY! It contains important safety information. WARNING Improper ATV use can result in SEVERE INJURY or DEATH. BEER BEER ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns.
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EE.book Page 1 Tuesday, March 9, 2004 10:33 AM EBU00941 INTRODUCTION 1- Congratulations on your purchase of the Yamaha YFM660FA. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM EBU00801 IMPORTANT MANUAL INFORMATION 1- FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM EBU15000 IMPORTANT NOTICE 2- 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.
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM EBU00014 WARNING Indicates a potential hazard that could result in serious injury or death. CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS....... 1-1 2 SAFETY INFORMATION.................. 2-1 3 DESCRIPTION AND MACHINE IDENTIFICATION ............................. 3-1 Identification number records.......... 3-2 Key identification number................ 3-2 Vehicle identification number .......... 3-3 Model label .............................
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM 5 6 PRE-OPERATION CHECKS ........... 5-1 Front and rear brakes ..................... 5-3 Fuel ................................................. 5-5 Engine oil ........................................ 5-7 Final gear oil.................................... 5-7 Differential gear oil .......................... 5-8 Coolant............................................ 5-9 Throttle lever ................................. 5-10 Fittings and fasteners..................
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM 8 PERIODIC MAINTENANCE AND ADJUSTMENT.................................. 8-1 Owner’s manual and tool kit............ 8-1 Periodic maintenance/ lubrication ...................................... 8-3 Panel removal and installation ........ 8-6 Engine oil and oil filter cartridge .... 8-15 Final gear oil .................................. 8-21 Differential gear oil......................... 8-23 Cooling system.............................. 8-25 Axle boots.........
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM Troubleshooting charts ................. 8-63 9 CLEANING AND STORAGE............ 9-1 A. Cleaning...................................... 9-1 B. Storage ....................................... 9-3 10 SPECIFICATIONS.......................... 10-1 11 NOISE REGULATION.................... 11-1 12 MAINTENANCE RECORD ............ 12-1 13 ATV LIMITED WARRANTY ........... 13-1 14 YAMAHA EXTENDED SERVICE (Y.E.S.) ...........................................
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EE.book Page 2 Tuesday, March 9, 2004 10:33 AM Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 1 2 WARNING 1 NEVER sit here.
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EE.book Page 4 Tuesday, March 9, 2004 10:33 AM 8 9 WARNING UNDER Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 5FE-21697-01 0 WARNING Turning the ATV in 4WD-LOCK(“DIFF. LOCK”) takes more effort. Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control.
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM EBU01129 SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM ● ● ● ● ● ● ● ● ● ● Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions.
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM ● ● ● ● Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high speed. Always follow proper procedures for going down hills and for braking on hills as described in this manual.
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM ● ● ● ● ● ● ● ● Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain.
EE.book Page 5 Tuesday, March 9, 2004 10:33 AM WARNING When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately.
EE.book Page 6 Tuesday, March 9, 2004 10:33 AM WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation.
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1. Rear shock absorber spring preload adjusting ring 2. Storage compartment and tool kit 3. Air filter case 4. Front brake fluid reservoir 5. Front shock absorber spring preload adjusting ring 6. Rear brake fluid reservoir 7. Brake pedal 8. V-belt case drain plug 9. Radiator cap 10. Drive select lever 11. Fuel tank cap 12. Fuel cock 13. Battery 14. Fuses 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM EBU00600 EBU00035 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. Key identification number The key identification number is stamped on the key as shown in the following illustration. This number can be used for ordering a new key. 1 2 3 4 5 6 1.
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM EBU00036 EBU00787 Vehicle identification number The vehicle identification number is stamped into the frame. Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Vehicle identification number NOTE: The vehicle identification number is used to identify your machine. 1.
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM EBU00039 CONTROL FUNCTIONS 1 WARNING 2 Indicates a potential hazard that could result in serious injury or death. 3 4 EBU00942 5 Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights and taillight come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position. 6 1.
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM EBU00802 EBU10601 Indicator and warning lights Differential gear lock indicator light “DIFF. LOCK” This indicator light and the differential gear lock indicator in the display come on when the differential gear lock switch is set to the “4WD-LOCK” position. NOTE: When the switch is set to “LOCK”, the differential gear lock indicator light will flash until the differential gear is locked. _ _ 1. 2. 3. 4. 5. 6. 7. 8.
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM EBU00972 EBU11312 Neutral indicator light “N” This indicator light comes on when the drive select lever is in the “N” position. Four-wheel-drive indicator “ ”/“ ” This indicator comes on when the “2WD”/ “4WD” switch is set to the “4WD” position. The differential gear lock indicator “DIFF.LOCK” in the four-wheel-drive indicator also comes on when the “LOCK”-“4WD” switch is set to the “4WD-LOCK” position. DIFF.
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM EBU00860 EBU15100 Coolant temperature warning light “ ” When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes. Speedometer unit CAUTION: _ ● ● The engine may overheat if the ATV is overloaded. If this happens, reduce the load to specification.
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EE.book Page 6 Tuesday, March 9, 2004 10:33 AM EBU00053 Fuel meter The fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter disappear towards “E” (Empty) as the fuel level decreases. When the “E” segment disappears and the fuel level warning indicator flashes, set the fuel cock to reserve and refuel as soon as possible. Handlebar switches 1. 2. 3. 4. Light switch “ / /OFF” Start switch “ ” Engine stop switch “ / ” Override switch “OVERRIDE” EBU12040 1.
EE.book Page 7 Tuesday, March 9, 2004 10:33 AM EBU12050 Engine stop switch “ / ” Make sure that the engine stop switch is set to “ ” before starting the engine. The engine stop switch controls ignition and can be used at all times to stop the engine, especially in an emergency. The engine will not start or run when the engine stop switch is set to “ ”. CAUTION: _ Do not use the headlights with the engine turned off for more than thirty minutes.
EE.book Page 8 Tuesday, March 9, 2004 10:33 AM 1. Override switch “OVERRIDE” EBU13781 Override switch “OVERRIDE” Top speed is normally limited when operating in 4WD-LOCK. If conditions require more engine power when riding forward, push and hold this switch to override the 4WD-LOCK speed limiting function. (See page 4-11 for a detailed explanation about the differential gear lock switch and its function.) Releasing the switch restores the speed limiting function.
EE.book Page 9 Tuesday, March 9, 2004 10:33 AM WARNING POTENTIAL HAZARD Riding too fast while the ATV is in 4WD-LOCK. WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the ATV. The amount of effort is more the faster you go. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling.
EE.book Page 10 Tuesday, March 9, 2004 10:33 AM ● ● Four-wheel drive (4WD): Power is supplied to the rear and front wheels. Four-wheel drive with the differential gear locked (4WD-LOCK): Power is supplied to the rear and front wheels when the differential gear is locked (“DIFF.LOCK”). Unlike the 4WD mode, all wheels turn at the same speed. WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 4WD-LOCK (“DIFF.LOCK”), or vice-versa while the ATV is moving.
EE.book Page 11 Tuesday, March 9, 2004 10:33 AM 1. Lever 2. On-Command four-wheel drive switch “2WD”/“4WD” 1. Differential gear lock switch “LOCK”/“4WD” 2. Lever On-Command four-wheel drive switch “2WD”/“4WD” To change from 2WD to 4WD, stop the ATV, and then set the switch to “4WD”. When the ATV is in 4WD, the 4WD indicator “ ” will come on in the speedometer unit display. To change from 4WD to 2WD, stop the ATV, be sure the lever is set to position a, and then set the switch to “2WD”.
EE.book Page 12 Tuesday, March 9, 2004 10:33 AM NOTE: ● When the switch is set to “LOCK”, the differential gear lock indicator light will flash until the differential gear is locked. ● When the indicator light is flashing, turning the handlebar back and forth will help the differential gear lock to engage. ● Riding before the differential gear lock is properly engaged (e.g., when the indicator light is flashing) will cause the engine speed to be limited until engagement is complete.
EE.book Page 13 Tuesday, March 9, 2004 10:33 AM EBU00062 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. Before starting the engine, check the throttle to be sure it is operating smoothly.
EE.book Page 14 Tuesday, March 9, 2004 10:33 AM EBU11590 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. 1. Locknut a. 12 mm (0.47 in) WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result.
EE.book Page 15 Tuesday, March 9, 2004 10:33 AM EBU00070 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 1. Brake pedal 1. Front brake lever EBU00732 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. Push down on the pedal or pull the lever toward the handlebar to apply the rear brake. 1.
EE.book Page 16 Tuesday, March 9, 2004 10:33 AM EBU00608 EBU00855 Drive select lever The drive select lever is used to shift your machine into the low, high, neutral, reverse and park positions. (Refer to page 6-4 for the drive select lever operation.) 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. 1. Drive select lever 1.
EE.book Page 17 Tuesday, March 9, 2004 10:33 AM EBU00092 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. WARNING POTENTIAL HAZARD Starting the engine without setting the drive select lever to the park position “P”. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident. HOW TO AVOID THE HAZARD Set the drive select lever to the park position before starting the engine. 1.
EE.book Page 18 Tuesday, March 9, 2004 10:33 AM EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES: This indicates reserve.
EE.book Page 19 Tuesday, March 9, 2004 10:33 AM EBU00095 Starter (choke) “ ” Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to “Starting a cold engine” for proper operation. (See page 6-1.) RES Position 1. Arrow mark 1.
EE.book Page 20 Tuesday, March 9, 2004 10:33 AM EBU00567 Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted. 1. Seat 2. Seat lock lever 1. Projection (× 2) 4-20 2.
EE.book Page 21 Tuesday, March 9, 2004 10:33 AM EBU00858 EBU00582 Storage compartment The storage compartment is located under the seat. (See page 4-20 for seat removal and installation procedures.) When storing the owner’s manual or other documents in the storage compartment, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartment.
EE.book Page 22 Tuesday, March 9, 2004 10:33 AM EBU01124 Front and rear shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. NOTE: When adjusting the rear shock absorbers, the rear wheels need to be removed. (See pages 8-53–8-54 for removal and installation procedures.) _ _ Adjust the spring preload as follows. To increase the spring preload, turn the adjusting ring in direction a.
EE.book Page 23 Tuesday, March 9, 2004 10:33 AM WARNING POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting. 1.
EE.book Page 24 Tuesday, March 9, 2004 10:33 AM EBU01002 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running. 1. Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack: DC 12 V, 120 W (10 A) 1. Auxiliary DC jack cap 1. Set the light switch to “OFF”. 2. Start the engine. (See pages 6-1–6-3.) 3.
EE.book Page 25 Tuesday, March 9, 2004 10:33 AM 4. When the auxiliary DC jack is not being used, cover it with the cap. 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.
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE Brakes • Check operation, free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary. 5-3–5-4, 8-43–8-50 Fuel • Check fuel level. • Fill with fuel if necessary. Engine oil • Check oil level. • Fill with oil if necessary. 5-7, 8-15–8-20 Coolant reservoir tank • Check coolant level in reservoir. • Fill with coolant if necessary.
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM WARNING 1 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 the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM EBU11011 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs. Apply the brakes firmly for one minute. If the lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake system should be inspected by a Yamaha dealer. Front and rear brakes Brake levers and brake pedal ● Check that there is no free play in the front brake lever.
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM 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.
EE.book Page 5 Tuesday, March 9, 2004 10:33 AM EBU01085 Fuel Make sure there is sufficient gasoline in the tank. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost.
EE.book Page 6 Tuesday, March 9, 2004 10:33 AM WARNING 1. Fuel level 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. 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.
EE.book Page 7 Tuesday, March 9, 2004 10:33 AM EBU10842 EBU00493 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-15– 8-20.) Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-21– 8-22 for details.) CAUTION: Recommended oil: SAE 80 API GL-4 Hypoid gear oil _ ● ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
EE.book Page 8 Tuesday, March 9, 2004 10:33 AM EBU00678 Differential gear oil Make sure the differential gear oil is at the specified level. Add oil as necessary. (See pages 8-23–8-25 for details.
EE.book Page 9 Tuesday, March 9, 2004 10:33 AM EBU12530 Coolant Check the coolant level in the coolant reservoir when the engine is cold. (The coolant level will vary with engine temperature.) The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir. If the coolant level is at or below the minimum level mark, add distilled water to bring the level up to maximum level mark. Change the coolant every two years. (See pages 8-25–8-30 for details.
EE.book Page 10 Tuesday, March 9, 2004 10:33 AM EBU01083 EBU11700 Throttle lever Check to see that the throttle lever operates correctly. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer repair as necessary for proper operation. Switches Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation. EBU11620 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride.
EE.book Page 11 Tuesday, March 9, 2004 10:33 AM EBU00157 Tires 2. The tires should be set to the recommended pressure: ● Recommended tire pressure Front 35 kPa (0.35 kgf/cm2, 5.0 psi) Rear 30 kPa (0.30 kgf/cm2, 4.3 psi) ● Check and adjust tire pressures when the tires are cold. ● Tire pressures must be equal on both sides. 3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums: Front 32 kPa (0.32 kgf/cm2, 4.
EE.book Page 12 Tuesday, March 9, 2004 10:33 AM 4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst.
EE.book Page 13 Tuesday, March 9, 2004 10:33 AM EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set pressure with tires cold. Set tire pressures to the following specifications: ACE-02EACE-02E Recommended pressure Minimum Maximum Front 35 kPa (0.35 kgf/cm2, 5.
EE.book Page 14 Tuesday, March 9, 2004 10:33 AM EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a.
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM EBU00161 EBU15110 OPERATION Starting a cold engine WARNING WARNING POTENTIAL HAZARD Freezing control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or collision. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding. Indicates a potential hazard that could result in serious injury or death.
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM Position 3 : Cold engine startambient temperature above 25 °C (80 °F) and warm engine start position. NOTE: ● When the drive select lever is in the neutral or park position, if either indicator light does not come on, ask a Yamaha dealer to inspect the respective electric circuit. ● The engine can be started in any gear if the rear brake lever or brake pedal is applied. However, it is recommended to shift into neutral or park before starting the engine.
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM NOTE: ● If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. ● If the battery is discharged, pull the recoil starter to start the engine. CAUTION: _ _ See the “Engine break-in” section prior to operating the engine for the first time.
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM EBU08461 Drive select lever operation and reverse driving CAUTION: _ Before shifting, you must stop the ATV and return the throttle lever to the closed position, otherwise the transmission may be damaged. _ Shifting: Neutral to High and High to Low 1. Bring the ATV to a complete stop and return the throttle lever to the closed position. 2. Apply the brakes, then shift by moving the drive select lever along the shift guide. 1. Drive select lever 3.
EE.book Page 5 Tuesday, March 9, 2004 10:33 AM Shifting: Neutral to Reverse and Reverse to Park NOTE: The drive select lever cannot be shifted into or from reverse or park without applying the rear brake. _ _ 1. Bring the ATV to a complete stop and return the throttle lever to the closed position. 2. Apply the brake pedal. 3. Shift from neutral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide. 1.
EE.book Page 6 Tuesday, March 9, 2004 10:33 AM 5. Open the throttle lever gradually and continue to watch to the rear while backing. WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.
EE.book Page 7 Tuesday, March 9, 2004 10:33 AM EBU02101 Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances.
EE.book Page 8 Tuesday, March 9, 2004 10:33 AM EBU00612 10–20 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely but do not use full throttle at any time. Parking When parking, stop the engine and shift the drive select lever into the park position, then turn the fuel cock to the “OFF” position. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally.
EE.book Page 9 Tuesday, March 9, 2004 10:33 AM EBU06151 Parking on a slope 1. Bring the machine to a stop by applying the brakes. 2. Stop the engine. 3. With the brake pedal applied, shift the drive select lever to the park position “P”. WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines.
EE.book Page 10 Tuesday, March 9, 2004 10:33 AM EBU00221 Accessories and loading ● EBU00222 Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. ● Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market.
EE.book Page 11 Tuesday, March 9, 2004 10:33 AM EBU09601 Loading Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: ● Never exceed the weight limits shown. An overloaded ATV can be unstable.
EE.book Page 12 Tuesday, March 9, 2004 10:33 AM ● ● ● ● Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer. Allow more braking distance. A heavier vehicle takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully.
EE.book Page 13 Tuesday, March 9, 2004 10:33 AM EBU15121 WARNING _ Indicates a potential hazard that could result in serious injury or death.
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EE.book Page 3 Tuesday, March 9, 2004 10:33 AM WARNING _ Indicates a potential hazard that could result in serious injury or death. ride, be sure you have read this Owner’s Manual completely and understand the operation of the controls. Pay particular attention to the safety information on pages 2-1–2-6. Please also read all caution and warning labels on your ATV. GETTING TO KNOW YOUR ATV This ATV is mainly for utility use, but may also be used for recreation.
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM RIDE WITH CARE AND GOOD JUDGEMENT HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating techniques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Get training if you are inexperienced.
EE.book Page 5 Tuesday, March 9, 2004 10:33 AM Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc.
EE.book Page 6 Tuesday, March 9, 2004 10:33 AM This ATV is designed to carry operator and cargo only - passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.
EE.book Page 7 Tuesday, March 9, 2004 10:33 AM Apparel Operating without protective clothing increases your chances of severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing.
EE.book Page 8 Tuesday, March 9, 2004 10:33 AM Do not operate after consuming alcohol or drugs. Operator’s performance capability is reduced by the influence of alcohol or drugs. WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
EE.book Page 9 Tuesday, March 9, 2004 10:33 AM Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the ATV. WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident.
EE.book Page 10 Tuesday, March 9, 2004 10:33 AM Speed limiter For riders less experienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV. Turning the screw in decreases top speed and turning it out increases top speed.
EE.book Page 11 Tuesday, March 9, 2004 10:33 AM Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Reduce your speed when adding additional loads. WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
EE.book Page 12 Tuesday, March 9, 2004 10:33 AM During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.
EE.book Page 13 Tuesday, March 9, 2004 10:33 AM Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
EE.book Page 14 Tuesday, March 9, 2004 10:33 AM Modifications WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories.
EE.book Page 15 Tuesday, March 9, 2004 10:33 AM Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it. WARNING POTENTIAL HAZARD Hot exhaust system.
EE.book Page 16 Tuesday, March 9, 2004 10:33 AM BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.
EE.book Page 17 Tuesday, March 9, 2004 10:33 AM Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
EE.book Page 18 Tuesday, March 9, 2004 10:33 AM Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control.
EE.book Page 19 Tuesday, March 9, 2004 10:33 AM WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.
EE.book Page 20 Tuesday, March 9, 2004 10:33 AM When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. WHAT CAN HAPPEN You could be in a collision. You could be injured. HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles. Do not ride in areas posted “no trespassing”.
EE.book Page 21 Tuesday, March 9, 2004 10:33 AM With the engine idling, shift the drive select lever to the low position “L” or the high position “H”. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the throttle is applied too abruptly, the front wheels may lift off the ground resulting in a loss of directional control. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV.
EE.book Page 22 Tuesday, March 9, 2004 10:33 AM TURNING YOUR ATV To achieve maximum traction while riding offroad in 2WD or 4WD, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Furthermore, when riding in 4WD-LOCK (“DIFF. LOCK”), the front wheels also turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning.
EE.book Page 23 Tuesday, March 9, 2004 10:33 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.
EE.book Page 24 Tuesday, March 9, 2004 10:33 AM CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.
EE.book Page 25 Tuesday, March 9, 2004 10:33 AM WARNING An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner’s Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
EE.book Page 26 Tuesday, March 9, 2004 10:33 AM If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.
EE.book Page 27 Tuesday, March 9, 2004 10:33 AM When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
EE.book Page 28 Tuesday, March 9, 2004 10:33 AM the front and rear brakes gradually, or dismount the ATV immediately on the uphill side. If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then descend the hill.
EE.book Page 29 Tuesday, March 9, 2004 10:33 AM If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brake while rolling backwards. Apply the front brake. 4WD or 4WD-LOCK: Apply both front and rear brakes gradually. When fully stopped, shift to the parking position “P”. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner’s Manual.
EE.book Page 30 Tuesday, March 9, 2004 10:33 AM RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you. For maximum engine compression braking effect, select low range “L” and change to 4WD or 4WD-LOCK before beginning to descend the hill. Improper braking may cause a loss of traction.
EE.book Page 31 Tuesday, March 9, 2004 10:33 AM WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. Always follow proper procedures for going down hills as described in this Owner’s Manual. Note: a special technique is required when braking as you go down a hill. HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed.
EE.book Page 32 Tuesday, March 9, 2004 10:33 AM CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills.
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EE.book Page 34 Tuesday, March 9, 2004 10:33 AM CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and carefully. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water.
EE.book Page 35 Tuesday, March 9, 2004 10:33 AM Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. CAUTION: _ After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose and the drive select lever box check hose. Also, remove the V-belt case drain plug to drain any water that may have accumulated.
EE.book Page 36 Tuesday, March 9, 2004 10:33 AM 1. V-belt cooling duct check hose (Left side) 1. Drive select lever box check hose 1.
EE.book Page 37 Tuesday, March 9, 2004 10:33 AM RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision.
EE.book Page 38 Tuesday, March 9, 2004 10:33 AM SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide.
EE.book Page 39 Tuesday, March 9, 2004 10:33 AM With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost. WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV.
EE.book Page 40 Tuesday, March 9, 2004 10:33 AM WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. ● WHAT TO DO ... ● If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See pages 7-22–7-23.
EE.book Page 41 Tuesday, March 9, 2004 10:33 AM ● ● If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 7-32– 7-33.
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM EBU00515 PERIODIC MAINTENANCE AND ADJUSTMENT Have a Yamaha dealer perform service if you are not familiar with machine service. Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages.
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the Owner’s tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts. WARNING POTENTIAL HAZARD Operating this ATV with improper modifications.
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM EBU02611 PERIODIC MAINTENANCE/LUBRICATION NOTE: _ ● For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. How- ever, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM ITEM Fuel line* Engine oil Engine oil filter cartridge Final gear oil Differential gear oil ROUTINE • • • • Check fuel hose for cracks or damage. Replace if necessary. Replace (Warm engine before draining). Replace. • Check oil level/oil leakage. • Replace.
EE.book Page 5 Tuesday, March 9, 2004 10:33 AM ITEM Fittings and fasteners* Lights and switches* Whichever month comes first km (mi) hours ROUTINE • • • • 1 320 (200) 20 INITIAL 3 1,200 (750) 75 6 2,400 (1,500) 150 EVERY 6 12 2,400 4,800 (1,500) (3,000) 150 300 Check all chassis fittings and fasteners. Correct if necessary. Check operation. Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
EE.book Page 6 Tuesday, March 9, 2004 10:33 AM EBU00614 Panel removal and installation The panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a panel has to be removed or reinstalled. 1. Panel D 3. Panel F 1. Panel A 3. Panel B 2. Panel C 8-6 2. Panel E 4.
EE.book Page 7 Tuesday, March 9, 2004 10:33 AM EBU00879 Panels A and D To remove 1. Remove the seat. (See page 4-20 for seat removal and installation procedures.) 2. Pull outward on the area shown, and then pull upward as shown. 1. Panel D 1.
EE.book Page 8 Tuesday, March 9, 2004 10:33 AM To install 1. Insert the panel projections in the numerical order shown in the illustration, and then push inward on the area shown. 2. Install the seat. 1. Panel D 1.
EE.book Page 9 Tuesday, March 9, 2004 10:33 AM EBU00962 Panel B To remove Remove the bolts. To install Place the panel in the original position and install the bolts. 1. Panel B CAUTION: _ When installing the panel, be sure not to pinch the cables or wires. _ 2.
EE.book Page 10 Tuesday, March 9, 2004 10:33 AM EBU01141 Panel C To remove 1. Remove the front carrier by removing the stay covers at the rear, then by removing the bolts. 1. Bolt (× 2) (top) 1. Front carrier stay cover (× 2) 1.
EE.book Page 11 Tuesday, March 9, 2004 10:33 AM To install 1. Place the panel in the original position and install the quick fasteners. 2. Install the front carrier by installing the bolts and tightening them to the specified torques. Tightening torques: Carrier bolt (top): 26 Nm (2.6 m·kgf, 19 ft·lbf) Carrier bolt (under fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 1. Bolt (× 2) (Under fenders) 2. Remove the quick fasteners and pull the panel upward. 3. Install the stay covers. 1. Quick fastener (× 2) 2.
EE.book Page 12 Tuesday, March 9, 2004 10:33 AM EBU01013 Panel E To remove Remove the bolts, and then take the panel off. To install Place the panel in the original position, and then install the bolts. 1. Panel E 2.
EE.book Page 13 Tuesday, March 9, 2004 10:33 AM EBU00638 Panel F To remove Pull outward on the areas shown. To install Place the panel in its original position. 1.
EE.book Page 14 Tuesday, March 9, 2004 10:33 AM EBU15041 Panel G To remove 1. Remove the seat. (See page 4-20 for seat removal and installation procedures.) 2. Remove the rear carrier by removing the bolts. 1. Bolt (× 2) (Under fenders) 3. Remove the seat under bracket and the panel by pulling them off. 1. Bolt (× 4) 8-14 1. Seat under bracket 2.
EE.book Page 15 Tuesday, March 9, 2004 10:33 AM EBU10992 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. To install 1. Place the panel and the seat under bracket in the original position. 2. Install the rear carrier by installing the bolts and tightening them to the specified torques.
EE.book Page 16 Tuesday, March 9, 2004 10:33 AM 5. Remove the engine oil filler cap and wipe off the dipstick with a clean rag. 6. Insert the dipstick in the oil 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. _ _ 1. Engine oil filler cap 2. Dipstick 1. Maximum level mark 8-16 2.
EE.book Page 17 Tuesday, March 9, 2004 10:33 AM To change the engine oil (with or without oil filter cartridge replacement) 1. Remove panel F. (See page 8-13 for panel removal and installation procedures.) 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap. 4. Remove the engine oil drain bolt to drain the oil from the crankcase. 7.
EE.book Page 18 Tuesday, March 9, 2004 10:33 AM NOTE: Skip steps 5–9 if the oil filter cartridge is not being replaced. 7. Apply a light coat of engine oil to the O-ring of the new oil filter cartridge. _ NOTE: Make sure the O-ring is seated properly. _ _ 5. Remove panels D and E. (See pages 8-7–8-8 and 8-12 for panel removal and installation procedures.) 6. Remove the oil filter cartridge with an oil filter wrench. _ 1. O-ring 1. Engine oil filter cartridge 2.
EE.book Page 19 Tuesday, March 9, 2004 10:33 AM 8. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. 9. Install panels D and E. 10. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 30 Nm (3.0 m·kgf, 22 ft·lbf) 11. Add the specified amount of recommended engine oil, and then install the engine oil filler cap and tighten it.
EE.book Page 20 Tuesday, March 9, 2004 10:33 AM CAUTION: _ ● ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. Make sure that no foreign material enters the crankcase. _ 12. Start the engine and warm it up for several minutes.
EE.book Page 21 Tuesday, March 9, 2004 10:33 AM EBU08801 Final gear oil The final 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. Replacing the final gear oil 1. Place the ATV on a level surface. 2. Place a container under the final gear case to collect the used oil. 3. Remove the oil filler bolt and the drain bolt to drain the oil. 1. Final gear oil drain bolt 4.
EE.book Page 22 Tuesday, March 9, 2004 10:33 AM Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.25 L (0.22 Imp qt, 0.26 US qt) CAUTION: _ Be sure no foreign material enters the final gear case. _ 6. Install the filler bolt and tighten it to the specified torque. Tightening torque: Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 16 ft·lbf) 7. Check for oil leakage. If oil leakage is found, check for the cause.
EE.book Page 23 Tuesday, March 9, 2004 10:33 AM EBU07062 Differential gear oil Differential gear oil measurement 1. Place the ATV on a level surface. 2. Remove the differential gear oil filler bolt and check the oil level. It should be up to the brim of the filler hole. If the level is low, add sufficient oil of the recommended type to raise it to the specified level. CAUTION: Be sure no foreign material enters the differential gear case. _ 3. Install the differential gear oil filler bolt. 1.
EE.book Page 24 Tuesday, March 9, 2004 10:33 AM Differential gear oil replacement 1. Place the ATV on a level surface. 2. Place a container under the differential gear case to collect the used oil. 3. Remove the differential gear oil filler bolt and differential gear oil drain bolt to drain the oil. 4. Install the differential gear oil drain bolt and tighten it to the specified torque. Tightening torque: Differential gear oil drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 5.
EE.book Page 25 Tuesday, March 9, 2004 10:33 AM EBU12560 Cooling system 1. Place the ATV on a level surface. 2. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 16 ft·lbf) 7. Check for oil leakage. If oil leakage is found, check for the cause. NOTE: The coolant should be between the minimum and maximum level marks. _ _ 1. Coolant reservoir tank cap 3.
EE.book Page 26 Tuesday, March 9, 2004 10:33 AM NOTE: ● If water is added, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible. ● The radiator fan operation is completely automatic. It is switched on or off according to the coolant temperature in the radiator. 3. If the coolant is at or below the minimum level mark, remove panel D (See pages 8-7–8-8 for panel removal and installation procedures.
EE.book Page 27 Tuesday, March 9, 2004 10:33 AM EBU12572 Changing the coolant 1. Place the ATV on a level surface. 2. Remove panels E and F. (See pages 8-12–8-13 for panel removal and installation procedures.) 3. Place a container under the engine, and then remove the coolant drain bolt. (Use a trough or a similar object as shown to prevent coolant from spilling on the footrest.) WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot.
EE.book Page 28 Tuesday, March 9, 2004 10:33 AM 1. Radiator cap 1. Trough 4. Remove the front carrier and panel C. (See pages 8-10 and 8-11 for removal and installation procedures.) 5. Remove the radiator cap. 6. Remove panel D. (See pages 8-7–8-8 for panel removal and installation procedures.) 7. Remove the coolant reservoir cap. 8. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir.
EE.book Page 29 Tuesday, March 9, 2004 10:33 AM 11. Install the coolant reservoir hose. 12. Pour the recommended coolant into the reservoir to the maximum level mark, and then install the reservoir cap and panel D. 13. Pour the recommended coolant into the radiator until it is full, and then install the radiator cap. Recommended antifreeze: High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines. Antifreeze and water mixing ratio: 1:1 Total amount: 1.8 L (1.
EE.book Page 30 Tuesday, March 9, 2004 10:33 AM CAUTION: _ Hard water or salt water is harmful to the engine. You may use soft water if you cannot get distilled water. _ 14. Start the engine and let it idle for several minutes. Stop the engine, and then check the coolant level in the radiator. If it is low, add more coolant until it reaches the top of the radiator. 15. Check for coolant leakage. NOTE: If any leakage is found, have a Yamaha dealer check the cooling system. _ _ 16.
EE.book Page 31 Tuesday, March 9, 2004 10:33 AM EBU00862 Axle boots Check the protective boots for holes or tears. If any damage is found, have them replaced by a Yamaha dealer. 1. Rear axle boot (× 2 each side) 1.
EE.book Page 32 Tuesday, March 9, 2004 10:33 AM EBU00864 Spark plug inspection Removal 1. Remove panel A. (See pages 8-7–8-8 for panel removal and installation procedures.) 2. Remove the spark plug cap. 1. Spark plug wrench 1. Spark plug cap 3. Use the spark plug wrench in the tool kit to remove the spark plug as shown.
EE.book Page 33 Tuesday, March 9, 2004 10:33 AM Installation 1. Measure the electrode gap with a wire thickness gauge and, if necessary, adjust the gap to specification. Inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. The ideal color on the white insulator around the center electrode is a mediumto-light tan color for a ATV that is being ridden normally.
EE.book Page 34 Tuesday, March 9, 2004 10:33 AM EBU12111 Air filter element cleaning Tightening torque: Spark plug: 17.5 Nm (1.75 m·kgf, 12.5 ft·lbf) 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. _ NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight.
EE.book Page 35 Tuesday, March 9, 2004 10:33 AM 1. Holder (× 5) 2. Air filter case cover 3. Remove the air filter element. 1. Frame 1. Air filter element 8-35 2.
EE.book Page 36 Tuesday, March 9, 2004 10:33 AM 4. Remove the air filter element from its frame. 5. Wash the air filter element gently but thoroughly in solvent. 7. Inspect the air filter element and replace it if damaged. 8. Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter element. WARNING NOTE: The air filter element should be wet but not dripping. POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element.
EE.book Page 37 Tuesday, March 9, 2004 10:33 AM 11. Install the air filter case cover and be sure to connect the hose. 12. Install the seat. CAUTION: _ Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating.
EE.book Page 38 Tuesday, March 9, 2004 10:33 AM EBU01066 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe. 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install and tighten the bolts. 1. Bolt (× 3) 1.
EE.book Page 39 Tuesday, March 9, 2004 10:33 AM EBU06411 V-belt cooling duct check hose If dust or water collects in the V-belt cooling duct check hose, remove the hose and clean it. WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire.
EE.book Page 40 Tuesday, March 9, 2004 10:33 AM EBU08741 EBU00296 V-belt case drain plug After riding in water deep enough to allow it to enter the V-belt case, remove this plug to drain the water from the case. Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so.
EE.book Page 41 Tuesday, March 9, 2004 10:33 AM EBU12580 Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. _ _ 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Remove panel D. (See pages 8-7 and 8-8 for removal and installation procedures.) 3.
EE.book Page 42 Tuesday, March 9, 2004 10:33 AM EBU00307 EBU03050 Throttle lever adjustment Select lever safety system cable adjustment The select lever safety system cable stretches with use, resulting in improper function. To prevent this, the cable must be adjusted regularly. This adjustment, however, should be left to a Yamaha dealer. NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2.
EE.book Page 43 Tuesday, March 9, 2004 10:33 AM EBU13090 EBU08781 Front brake pad check Check the brake pads for damage and wear. If a brake pad thickness is less than 1 mm (0.04 in), have a Yamaha dealer replace the pads as a set. Checking the rear brake pads Check the brake pads for damage and wear. If the thickness is less than 1.0 mm (0.04 in), have a Yamaha dealer replace the pads. 1. Brake pad 1. Brake pad a. Brake pad thickness a.
EE.book Page 44 Tuesday, March 9, 2004 10:33 AM EBU08751 Checking the brake fluid level Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level and replenish when necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.
EE.book Page 45 Tuesday, March 9, 2004 10:33 AM Observe these precautions: ● When checking the fluid level, make sure the top of the master cylinder reservoirs are level. ● Use only the designated quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor brake performance. ● ● Recommended brake fluid: DOT 4 ● ● Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance.
EE.book Page 46 Tuesday, March 9, 2004 10:33 AM EBU11860 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. ● Replace the oil seals every two years. ● Replace the brake hoses every four years.
EE.book Page 47 Tuesday, March 9, 2004 10:33 AM EBU11870 Front brake lever free play The front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a Yamaha dealer check the brake system. WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct.
EE.book Page 48 Tuesday, March 9, 2004 10:33 AM EBU09631 2. Turn the adjusting bolt in direction a to increase free play, and in direction b to decrease free play. 3. Tighten the locknut. If correct free play cannot be obtained, ask a Yamaha dealer to make that adjustment. Adjusting the rear brake lever and brake pedal Adjusting the rear brake lever The rear brake lever free play should be 0.5– 2 mm (0.02–0.08 in). 1. Loosen the locknut.
EE.book Page 49 Tuesday, March 9, 2004 10:33 AM Adjusting the brake pedal The top of the brake pedal should be positioned 72 mm (2.8 in) above the top of the footrest. If not, ask a Yamaha dealer to adjust it. WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct.
EE.book Page 50 Tuesday, March 9, 2004 10:33 AM EBU12590 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and rear brake lever, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1. Remove panel B. (See page 8-9 for panel removal and installation procedures.) 2. Turn the adjusting nut while holding the rear brake light switch in place.
EE.book Page 51 Tuesday, March 9, 2004 10:33 AM EBU00356 EBU00717 Cable inspection and lubrication Brake lever and brake pedal lubrication Lubricate the pivoting parts. WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently.
EE.book Page 52 Tuesday, March 9, 2004 10:33 AM EBU13110 Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun. 1. Upper knuckle 2.
EE.book Page 53 Tuesday, March 9, 2004 10:33 AM EBU01112 EBU01121 Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Wheel installation 1. Install the wheel and the nuts. NOTE: ● Tapered nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel. ● The arrow mark on the tire must point toward the rotating direction of the wheel. _ _ 1. Nut (× 4) 1.
EE.book Page 54 Tuesday, March 9, 2004 10:33 AM 1. Tapered nut 2. Lower the ATV so that the wheel is on the ground. 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear: 55 Nm (5.
EE.book Page 55 Tuesday, March 9, 2004 10:33 AM EBU00380 Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a Yamaha dealer. 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.
EE.book Page 56 Tuesday, March 9, 2004 10:33 AM EBU00385 EBU08762* Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. Fuse replacement 1. The main fuse and the fuse box are located under the seat. 2. If a fuse is blown, turn off the main switch and the switch of the circuit in question. Then, install a new fuse of the specified amperage. Turn on the main switch.
EE.book Page 57 Tuesday, March 9, 2004 10:33 AM WARNING 1. 3. 5. 7. 8. 9. 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. Main fuse 2. Spare main fuse Headlight fuse 4. Ignition fuse Auxiliary DC jack fuse 6.
EE.book Page 58 Tuesday, March 9, 2004 10:33 AM EBU11252 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the cover at the rear of the headlight by pulling it off. 1. Headlight bulb holder cover 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. 1. Cover 2. Remove the headlight bulb holder cover by pulling it off. 8-58 1.
EE.book Page 59 Tuesday, March 9, 2004 10:33 AM 4. Remove the defective bulb by pulling it out. 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. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner.
EE.book Page 60 Tuesday, March 9, 2004 10:33 AM EBU01089 Headlight beam adjustment CAUTION: _ It is advisable to have a Yamaha dealer make this adjustment. _ To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b. 1. Do not touch the glass part of the bulb. 6. Install the bulb holder by pushing it in and turning it clockwise. 7. Install the bulb holder cover and the cover at the rear of the headlight. 1.
EE.book Page 61 Tuesday, March 9, 2004 10:33 AM EBU15050 Tail/brake light bulb replacement 1. Remove panel G. (See pages 8-14–8-15 for removal and installation procedures.) 2. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 5. Install the bulb holder (together with the bulb). 6. Install the panel. 1. Bulb holder 3. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 4.
EE.book Page 62 Tuesday, March 9, 2004 10:33 AM EBU00412 Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer.
EE.book Page 63 Tuesday, March 9, 2004 10:33 AM EBU08061 Troubleshooting charts Starting problems or poor engine performance Turn the fuel cock lever to “ON”. There is fuel. Turn the fuel cock lever to “OFF”. Remove the fuel hose from the fuel cock. Some fuel. Turn the fuel cock lever to “RES”. Restart the engine. No fuel. Supply fuel. 1. Fuel Check if there is fuel in the fuel tank. 2. Compression Use the electric starter to see if there is compression. 3. Ignition There is compression.
EE.book Page 64 Tuesday, March 9, 2004 10:33 AM Engine overheating WARNING 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. POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. Leakage.
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM EBU00419 CLEANING AND STORAGE CAUTION: ¯ Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers. A.
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM 6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes. WARNING POTENTIAL HAZARD Operation with wet brakes after washing.
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM EBU00530 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equivalent product. 2.
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM 7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)). NOTE: Make any necessary repairs before storing the machine.
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM EBU00428 SPECIFICATIONS Model YFM660FA Dimensions: Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Starting system Lubrication system 2,085 mm (82.1 in) 1,150 mm (45.3 in) 1,210 mm (47.6 in) 880 mm (34.6 in) 1,275 mm (50.2 in) 275 mm (10.8 in) 3,200 mm (126.
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM Model YFM660FA 1 Engine oil: Type 0° 10° 30° 50° 70° 90° 110° 130°F 2 YAMALUBE 4 (20W40) or SAE 20W40 3 YAMALUBE 4 (10W30) or SAE 10W30 4 SAE 5W30 -20° Recommended engine oil classification -10° 5 0° 10° 20° 30° 40° 50°C API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM Model YFM660FA Final gear case oil: Type Quantity Differential gear case oil: Type Quantity Radiator capacity (including all routes): Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount Carburetor: Type / quantity Manufacturer Spark plug: Type/manufacturer Spark plug gap Clutch type: SAE80 API GL-4 Hypoid gear oil 0.25 L (0.22 Imp qt, 0.26 US qt) SAE80 API GL-4 Hypoid gear oil 0.28 L (0.25 Imp qt, 0.30 US qt) 1.80 L (1.58 Imp qt, 1.
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM Model Transmission: Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Reverse gear Sub transmission ratio Chassis: Frame type Caster angle Trail Tire: Type Size YFM660FA V-belt Shaft drive 41/21 × 24/18 × 33/9 (9.544) V-belt automatic Left hand operation 25/17 (1.471) 35/17 (2.058) 26/21 (1.238) low high Steel tube frame 5° 26 mm (1.
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EE.book Page 1 Tuesday, March 9, 2004 10:33 AM EBU13653 1- MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM EBU00432 YAMAHA MOTOR CORPORATION, U.S.A.
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EE.book Page 1 Tuesday, March 9, 2004 10:33 AM EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM 1 2 3 4 5 6 7 8 9 10 11 12 13 EBU00436 14 WARNING _ Indicates a potential hazard that could result in serious injury or death.
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EBU00438 READ THIS MANUAL CAREFULLY! It contains important safety information. WARNING Improper ATV use can result in SEVERE INJURY or DEATH. BEER BEER ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns.