READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM66FGX WARNING LIT-11626-21-03 This ATV should not be ridden by anyone under 16 years of age.
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U23D10E0.book Page 1 Wednesday, March 14, 2007 1:50 PM EBU17170 INTRODUCTION EBU17270 Congratulations on your purchase of the Yamaha YFM66FGX. 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.
U23D10E0.book Page 1 Wednesday, March 14, 2007 1:50 PM EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
U23D10E0.book Page 1 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 1 Wednesday, March 14, 2007 1:50 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....................................................
U23D10E0.book Page 2 Wednesday, March 14, 2007 1:50 PM 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 ..............................
U23D10E0.book Page 3 Wednesday, March 14, 2007 1:50 PM Checking the front and rear brake pads ... 8-39 Checking the brake fluid level .................. 8-40 Changing the brake fluid .......................... 8-42 Checking the front brake lever free play ................................................. 8-42 Adjusting the rear brake lever free play and checking the brake pedal position ... 8-43 Axle boots ................................................ 8-45 Brake light switches ..........................
U23D10E0.book Page 1 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 2 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 3 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 4 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 5 Wednesday, March 14, 2007 1:50 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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U23D10E0.book Page 2 Wednesday, March 14, 2007 1:50 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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U23D10E0.book Page 1 Wednesday, March 14, 2007 1:50 PM EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Radiator cap 2. Fuel tank cap 3. Fuel cock 4. Oil filter cartridge 5. Throttle stop screw 6. Fuses 7. Engine oil filler cap 8. Recoil starter 9. Coolant reservoir 10.Drive select lever box check hose 11.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. Battery 5. Air filter case 6.
U23D10E0.book Page 2 Wednesday, March 14, 2007 1:50 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. Drive select lever Rear brake lever Handlebar switches Starter (choke) Multifunction display Main switch On-Command four-wheel-drive/differential gear lock switch 8. Throttle lever 9. Front brake lever 10.
U23D10E0.book Page 1 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 2 Wednesday, March 14, 2007 1:50 PM Furthermore, this indicator light flashes when the engine is being raced for 10 seconds or more. EBU17813 Indicator lights and warning light NOTE: If the indicator light flashes under any other circumstances or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. 4 EBU17860 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. 1.
U23D10E0.book Page 3 Wednesday, March 14, 2007 1:50 PM ● Start the engine after making sure that the warning light is out. Continuous use while the warning light is on may cause damage to the engine. EBU17970 Park indicator light “ ” This indicator light comes on when the transmission is in the park position. EBU17980 High-range indicator light “ ” This indicator light comes on when the transmission is in the high-range position.
U23D10E0.book Page 4 Wednesday, March 14, 2007 1:50 PM ● EBU18040 Multifunction display ● ● ● 1. 2. 3. 4. 5. 6. 7. 8.
U23D10E0.book Page 5 Wednesday, March 14, 2007 1:50 PM Clock mode Pushing the “ ”/“ ” button switches the display between the clock mode “CLOCK” and the hour meter mode “HOUR” in the following order: CLOCK → HOUR → CLOCK 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. 1.
U23D10E0.book Page 6 Wednesday, March 14, 2007 1:50 PM EBU18061 EBU18100 Handlebar switches Start switch “ ” Push this switch to crank the engine with the starter. ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. 4 EBU18151 1. 2. 3. 4. Light switch “ / /OFF” Set this switch to “ ” to turn on the low beams and the taillight. Set the switch to “ ” to turn on the high beams and the taillight. Set the switch to “OFF” to turn off all the lights.
U23D10E0.book Page 7 Wednesday, March 14, 2007 1:50 PM EBU18180 Override switch “OVERRIDE” 4 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. In this case, take the ATV to a Yamaha dealer at the first opportunity. 1. Override switch “OVERRIDE” Top speed is normally limited when operating in differential gear lock.
U23D10E0.book Page 8 Wednesday, March 14, 2007 1:50 PM 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 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.
U23D10E0.book Page 9 Wednesday, March 14, 2007 1:50 PM EWB00120 EBU18243 On-Command differential gear lock switch “4WD”/“LOCK” This ATV is equipped with a switch allowing you to lock the differential gear when in four-wheel drive. Select the appropriate switch position according to the terrain and the conditions. ● “4WD” (four-wheel drive): Power is supplied to the rear and front wheels.
U23D10E0.book Page 10 Wednesday, March 14, 2007 1:50 PM To lock the differential gear in four-wheel drive, make sure the On-Command four-wheel-drive switch is pushed in to the “4WD” position. 4 1. On-Command differential gear lock switch “4WD”/“LOCK” To release the differential gear lock, stop the ATV and push the switch to the “4WD” position. 1. Differential gear lock lever 2.
U23D10E0.book Page 11 Wednesday, March 14, 2007 1:50 PM WHAT CAN HAPPEN All wheels turn at the same speed when the differential gear is locked, so it takes more effort to turn the ATV. The effort needed to turn increases with the riding speed. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling. HOW TO AVOID THE HAZARD Always ride at a slow speed when the ATV is in differential gear lock, and allow extra time and distance for maneuvers.
U23D10E0.book Page 12 Wednesday, March 14, 2007 1:50 PM ● When the ATV is in four-wheel-drive differential gear lock, the maximum traveling speed is limited to 35 km/h (22 mi/h). However, if conditions require full engine power to be available, push and hold the override switch to disable the differential gear lock speed limiter. (See page 4-7 for a detailed explanation of this switch.) 4 EBU18270 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed.
U23D10E0.book Page 13 Wednesday, March 14, 2007 1:50 PM crease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b). EWB00200 WARNING 4 POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident. HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine.
U23D10E0.book Page 14 Wednesday, March 14, 2007 1:50 PM WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in). (See page 8-38.) 4 EBU18391 1. Front brake lever Front brake lever The front brake lever is located on the right handlebar.
U23D10E0.book Page 15 Wednesday, March 14, 2007 1:50 PM EBU18611 Drive select lever The drive select lever is used to shift your ATV into the low-range, high-range, neutral, reverse and park positions. See the “Operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation. 4 1. Brake pedal 1. Drive select lever EBU18680 Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt.
U23D10E0.book Page 16 Wednesday, March 14, 2007 1:50 PM EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 4 1. Recoil starter EWB00290 WARNING 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. HOW TO AVOID THE HAZARD Set the drive select lever to the park position before starting the engine. 1.
U23D10E0.book Page 17 Wednesday, March 14, 2007 1:50 PM ECB00070 CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel.
U23D10E0.book Page 18 Wednesday, March 14, 2007 1:50 PM OFF 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.
U23D10E0.book Page 19 Wednesday, March 14, 2007 1:50 PM ON RES 1. Arrow mark pointing to “ON” 1. Arrow mark pointing to “RES” 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. 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.
U23D10E0.book Page 20 Wednesday, March 14, 2007 1:50 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. 4 1. Seat 2. Seat lock lever 1. Starter (choke) “ 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. ” EBU18880 Seat NOTE: Make sure that the seat is securely fitted.
U23D10E0.book Page 21 Wednesday, March 14, 2007 1:50 PM ECB00130 CAUTION: Do not store metal or sharply edged objects, like tools, in the storage compartment. If they must be stored, wrap them in appropriate cushion material to prevent damaging the storage compartment. 4 1. Projection 2. Seat holder EBU27090 Storage compartment The storage compartment is located under the seat. (See page 4-20.
U23D10E0.book Page 22 Wednesday, March 14, 2007 1:50 PM Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to decrease the spring preload and thereby soften the suspension. EBU18960 Front carrier ● ● Do not exceed the load limit of 45.0 kg (99 lb) for the front carrier. Do not exceed the maximum load of 220.0 kg (485 lb) for the ATV. EBU18970 Rear carrier ● ● 4 Do not exceed the load limit of 85.
U23D10E0.book Page 23 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 24 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 1 Wednesday, March 14, 2007 1:50 PM EBU19200 PRE-OPERATION CHECKS EBU19212 Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table. EWB00470 WARNING 5 POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage.
U23D10E0.book Page 2 Wednesday, March 14, 2007 1:50 PM ITEM Engine oil Final gear oil Differential gear oil Coolant Front brake Rear brake Throttle lever Control cables Wheels and tires Brake pedal ROUTINE • Check oil level in engine, and add recommended oil to specified level if necessary. • Check ATV for oil leakage. Correct if necessary. • Check ATV for oil leakage. Correct if necessary. • Check ATV for oil leakage. Correct if necessary.
U23D10E0.book Page 3 Wednesday, March 14, 2007 1:50 PM ITEM Brake levers Axle boots Chassis fasteners Instruments, lights and switches ROUTINE PAGE • Make sure that operation is smooth. Lubricate lever pivoting points if necessary. • Check for cracks or damage, and replace if necessary. • Make sure that all nuts, bolts and screws are properly tightened. 8-45 5-9 • Check operation, and correct if necessary.
U23D10E0.book Page 4 Wednesday, March 14, 2007 1:50 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 8-22.) 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.
U23D10E0.book Page 5 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 6 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 7 Wednesday, March 14, 2007 1:50 PM EBU19781 Tires EWB00561 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 Co., Ltd. for this model.
U23D10E0.book Page 8 Wednesday, March 14, 2007 1:50 PM ● ● ● Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure: Front: 32.0 kPa (4.6 psi) (0.320 kgf/cm²) Rear: 27.0 kPa (3.9 psi) (0.270 kgf/cm²) Use no more than the following pressures when seating the tire beads. Maximum tire seating pressure: Front: 250 kPa (36 psi) (2.5 kgf/cm²) Rear: 250 kPa (36 psi) (2.
U23D10E0.book Page 9 Wednesday, March 14, 2007 1:50 PM 5 Recommended pressure: Front 35.0 kPa (5.0 psi) (0.350 kgf/cm²) Rear 30.0 kPa (4.3 psi) (0.300 kgf/cm²) Minimum: Front 32.0 kPa (4.6 psi) (0.320 kgf/cm²) Rear 27.0 kPa (3.9 psi) (0.270 kgf/cm²) Maximum: Front 38.0 kPa (5.5 psi) (0.380 kgf/cm²) Rear 33.0 kPa (4.8 psi) (0.330 kgf/cm²) 1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened.
U23D10E0.book Page 1 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 2 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 3 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 4 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 5 Wednesday, March 14, 2007 1:50 PM ● ● Due to the synchronizing mechanism in the engine, the indicator light may not come on until the ATV starts moving. For ATVs not equipped with an odometer or hour meter, follow the figures given in hours. There is never a more important period in the life of your engine than the first 320 km (200 mi) or 20 hours of riding. For this reason, you should read the following material carefully.
U23D10E0.book Page 6 Wednesday, March 14, 2007 1:50 PM HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the ATV transversely across the incline, stop the engine, shift the drive select lever to the park position, and then block the front and rear wheels with rocks or other objects. Do not park the ATV at all on hills that are so steep you could not walk up them easily.
U23D10E0.book Page 7 Wednesday, March 14, 2007 1:50 PM EBU20910 Accessories and loading EBU20920 ● Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. ● Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market.
U23D10E0.book Page 8 Wednesday, March 14, 2007 1:50 PM ● MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, cargo, accessories, and tongue): 220.0 kg (485 lb) Front carrier: 45.0 kg (99 lb) Rear carrier: 85.0 kg (187 lb) Storage compartment: 2.0 kg (4 lb) Trailer hitch: Pulling load (total weight of trailer and cargo): 5390.00 N (1212 lbf) (550 kgf) Tongue weight (vertical weight on trailer hitch point): 147.00 N (33 lbf) (15 kgf) 6 ● ● ● ● ● ● Do not exceed the maximum tongue weight.
U23D10E0.book Page 9 Wednesday, March 14, 2007 1:50 PM EWB00750 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.
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U23D10E0.book Page 2 Wednesday, March 14, 2007 1:50 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. EBU21201 GETTING TO KNOW YOUR ATV This ATV is mainly for utility use, but may also be used for recreation. This section, Riding your ATV, provides general ATV riding instructions for recreational riding.
U23D10E0.book Page 3 Wednesday, March 14, 2007 1:50 PM RIDE WITH CARE AND GOOD JUDGEMENT HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating techniques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-8872887. Get training if you are inexperienced.
U23D10E0.book Page 4 Wednesday, March 14, 2007 1:50 PM WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc. 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.
U23D10E0.book Page 5 Wednesday, March 14, 2007 1:50 PM Apparel EWB00920 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.
U23D10E0.book Page 6 Wednesday, March 14, 2007 1:50 PM 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 7 1. 2. 3. 4. 5.
U23D10E0.book Page 7 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 8 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 9 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 10 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 11 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 12 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 13 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 14 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 15 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 16 Wednesday, March 14, 2007 1:50 PM EWB01050 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 ATV 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.
U23D10E0.book Page 17 Wednesday, March 14, 2007 1:50 PM 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. 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”. Do not ride on private property without getting permission.
U23D10E0.book Page 18 Wednesday, March 14, 2007 1:50 PM surfaces: the ATV is designed for off-road use only, and handling maneuvers are more difficult to perform on pavement. Shift to the park position and follow the instruction on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your ATV. Remember that the engine and exhaust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components.
U23D10E0.book Page 19 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 20 Wednesday, March 14, 2007 1:50 PM Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over.
U23D10E0.book Page 21 Wednesday, March 14, 2007 1:50 PM CLIMBING UPHILL Use proper riding techniques to avoid ATV 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.
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U23D10E0.book Page 23 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 24 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 25 Wednesday, March 14, 2007 1:50 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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U23D10E0.book Page 27 Wednesday, March 14, 2007 1:50 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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U23D10E0.book Page 29 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 30 Wednesday, March 14, 2007 1:50 PM 1. Air filter case check hose ECB00270 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 and the drive select lever box check hose. Also, remove the V-belt case drain plug to drain any water that may have accumulated. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. 1.
U23D10E0.book Page 31 Wednesday, March 14, 2007 1:50 PM 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. EWB01160 WARNING POTENTIAL HAZARD Improperly operating over obstacles.
U23D10E0.book Page 32 Wednesday, March 14, 2007 1:50 PM SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help.
U23D10E0.book Page 33 Wednesday, March 14, 2007 1:50 PM 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. WHAT TO DO IF... This section is designed to be a reference guide only.
U23D10E0.book Page 34 Wednesday, March 14, 2007 1:50 PM ● ● THE REAR BRAKE IF THE ATV IS IN 2WD – the ATV may tip over on top of you. Dismount the ATV on the uphill side. (See page 7-21.) 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.
U23D10E0.book Page 1 Wednesday, March 14, 2007 1:50 PM EBU21646 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.
U23D10E0.book Page 2 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 3 Wednesday, March 14, 2007 1:50 PM EBU21742 Periodic maintenance chart for the emission control system NOTE: ● For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
U23D10E0.book Page 4 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 5 Wednesday, March 14, 2007 1:50 PM EBU21863 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 hub bearings • Clean and replace if necessary. • Check operation and correct if necessary.
U23D10E0.book Page 6 Wednesday, March 14, 2007 1:50 PM INITIAL NO. ITEM 8 * V-belt 9 * Chassis fasteners 10 * Shock absorber assemblies 11 * Stabilizer bushes 12 13 * * Rear knuckle pivots Steering shaft 14 * Steering system 15 * Engine mount 16 * Axle boots month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 • Check for wear, cracks or other damage, and replace if necessary. • Make sure that all nuts, bolts, and screws are properly tightened.
U23D10E0.book Page 7 Wednesday, March 14, 2007 1:50 PM INITIAL NO. 8 ITEM 20 Final gear oil 21 Cooling system Moving parts and cables Drive select lever safety system cable 22 * 23 * 24 * Throttle lever housing and cable 25 * Front and rear brake switches 26 * Lights and switches CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 • Change. • Check ATV for oil leakage, and correct if necessary.
U23D10E0.book Page 8 Wednesday, March 14, 2007 1:50 PM ● 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.
U23D10E0.book Page 9 Wednesday, March 14, 2007 1:50 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 D Panel E Panel F Panel G EBU27052 Panels A and D To remove one of the panels 1. Remove the seat. (See page 4-20.) 2.
U23D10E0.book Page 10 Wednesday, March 14, 2007 1:50 PM To install one of the panels 1. Insert the panel projections in the numerical order shown in the illustration, and then push inward on the area shown. 1. Panel A 1. Panel A 1.
U23D10E0.book Page 11 Wednesday, March 14, 2007 1:50 PM 1. Panel D 1. Panel B 2. Bolt 2. Install the seat. 8 To install the panel Place the panel in the original position and install the bolts. Panel B To remove the panel Remove the bolts, and then take the panel off. ECB00380 CAUTION: When installing the panel, be sure not to pinch the cables or wires. Panel C To remove the panel 1. Remove the front carrier by removing the stay covers, then by removing the bolts.
U23D10E0.book Page 12 Wednesday, March 14, 2007 1:50 PM 1. Front carrier stay cover 1. Carrier bolt (top) 8 1. Carrier bolt (top) 1. Carrier bolt (under the fenders) 2. Remove the quick fastener screws and pull the panel upward.
U23D10E0.book Page 13 Wednesday, March 14, 2007 1:50 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 install the quick fastener screws. 2. Install the front carrier by installing the bolts and tightening them to the specified torques. 1. Panel E 2. Bolt To install the panel Place the panel in the original position and install the bolts.
U23D10E0.book Page 14 Wednesday, March 14, 2007 1:50 PM Panel G To remove the panel 1. Remove the seat. (See page 4-20.) 2. Remove the rear carrier by removing the bolts. 1. Panel F To install the panel Place the panel in its original position. 8 1.
U23D10E0.book Page 15 Wednesday, March 14, 2007 1:50 PM 1. Carrier bolt (under the fenders) 1. Seat under bracket 2. Panel G 3. Remove the seat under bracket and the panel by pulling them off. To install the panel 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. 8 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.
U23D10E0.book Page 16 Wednesday, March 14, 2007 1:50 PM 3. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. 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.
U23D10E0.book Page 17 Wednesday, March 14, 2007 1:50 PM 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/DPR8EA-9 To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 1. Spark plug gap Spark plug gap: 0.8–0.9 mm (0.031–0.035 in) 2.
U23D10E0.book Page 18 Wednesday, March 14, 2007 1:50 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. NOTE: If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil settles for an accurate reading. 4.
U23D10E0.book Page 19 Wednesday, March 14, 2007 1:50 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. 1. Maximum level mark 2.
U23D10E0.book Page 20 Wednesday, March 14, 2007 1:50 PM NOTE: Skip steps 6–10 if the oil filter cartridge is not being replaced. 6. Remove panels D and E. (See page 8-9.) 7. Remove the oil filter cartridge with an oil filter wrench. 1. O-ring 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. 1. Oil filter cartridge 2.
U23D10E0.book Page 21 Wednesday, March 14, 2007 1:50 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: 1.90 L (2.01 US qt) (1.67 Imp.qt) With oil filter cartridge replacement: 2.00 L (2.11 US qt) (1.76 Imp.qt) 1. Torque wrench 8 NOTE: Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down.
U23D10E0.book Page 22 Wednesday, March 14, 2007 1:50 PM ● Make sure that no foreign material enters the crankcase. 2. Remove the final gear oil level check bolt, and then check the oil level in the final gear case. 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, wait at least ten minutes, and then check the oil level and correct it if necessary. 15.
U23D10E0.book Page 23 Wednesday, March 14, 2007 1:50 PM 3. Remove the final gear oil filler bolt, final gear oil level check bolt, and the final gear oil drain bolt to drain the oil from the final gear case. 1. Final gear oil filler bolt 4. Install the oil level check bolt and oil filler bolt, and then tighten them to the specified torques. 8 1. Final gear oil drain bolt Tightening torques: Final gear oil level check bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Final gear oil filler bolt: 23 Nm (2.
U23D10E0.book Page 24 Wednesday, March 14, 2007 1:50 PM Tightening torques: Final gear oil level check bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 7. Check the final gear case for oil leakage. If oil is leaking, check for the cause. EBU23421 Differential gear oil The differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV.
U23D10E0.book Page 25 Wednesday, March 14, 2007 1:50 PM 2. Remove the differential gear oil filler bolt, and then check the oil level in the differential gear case. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) To change the differential gear oil 1. Place the ATV on a level surface. 2. Place an oil pan under the differential gear case to collect the used oil. 3.
U23D10E0.book Page 26 Wednesday, March 14, 2007 1:50 PM ECB00410 Tightening torque: Differential gear oil drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) CAUTION: Be sure no foreign material enters the differential gear case. 5. Add the recommended differential gear oil to the brim of the filler hole as shown. 6. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 7.
U23D10E0.book Page 27 Wednesday, March 14, 2007 1:50 PM 3. If the coolant is at or below the minimum level mark, remove panel D. (See page 8-9.) 4. Remove the reservoir cap, add coolant or distilled water to the maximum level mark, install the reservoir cap, and then install the panel. NOTE: The coolant level must be checked on a cold engine since the level varies with engine temperature. 2. Check the coolant level in the coolant reservoir. Coolant reservoir capacity (up to the maximum level mark): 0.
U23D10E0.book Page 28 Wednesday, March 14, 2007 1:50 PM 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.) NOTE: ● The radiator fan is automatically switched on or off according to the coolant temperature in the radiator. ● If the engine overheats, see page 8-59 for further instructions.
U23D10E0.book Page 29 Wednesday, March 14, 2007 1:50 PM 1. Trough 8 1. Radiator cap 4. Remove the front carrier and panel C. (See page 8-9.) 5. Remove the 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.
U23D10E0.book Page 30 Wednesday, March 14, 2007 1:50 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): 1.80 L (1.90 US qt) (1.58 Imp.qt) Coolant reservoir capacity (up to the maximum level mark): 0.30 L (0.32 US qt) (0.26 Imp.qt) 1. Coolant reservoir hose 9.
U23D10E0.book Page 31 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 32 Wednesday, March 14, 2007 1:50 PM 1. Air filter case holder 2. Air filter case cover 1. Air filter element 4. Remove the sponge material from the air filter element frame. 3. Pull the air filter element out of the air filter case. 8 1. Unlock.
U23D10E0.book Page 33 Wednesday, March 14, 2007 1:50 PM 6. Squeeze the excess solvent out of the sponge material and let it dry. ECB00440 CAUTION: Do not twist the sponge material when squeezing it. 1. Air filter element frame 2. Sponge material 8 5. Wash the sponge material gently but thoroughly in solvent. EWB01900 WARNING POTENTIAL HAZARD Using low-flash-point solvents or gasoline to clean the sponge material. WHAT CAN HAPPEN Low-flash-point solvents or gasoline can catch fire or explode.
U23D10E0.book Page 34 Wednesday, March 14, 2007 1:50 PM eas. 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. Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine. 9. Pull the sponge material over the air filter element frame. 10.
U23D10E0.book Page 35 Wednesday, March 14, 2007 1:50 PM 1. Bolt 8 1. Tailpipe 2. Spark arrester 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install and tighten the bolts. EWB01910 WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester.
U23D10E0.book Page 36 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 37 Wednesday, March 14, 2007 1:50 PM ECB00480 CAUTION: The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine. EBU24010 Adjusting the engine idling speed The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart. 1.
U23D10E0.book Page 38 Wednesday, March 14, 2007 1:50 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). 5. Install the panel.
U23D10E0.book Page 39 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 40 Wednesday, March 14, 2007 1:50 PM 1. Brake pad 2. Lining thickness 1. Brake pad 2. Lining thickness NOTE: The wheels need to be removed to check the brake pads. (See page 8-55.) EBU24261 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary.
U23D10E0.book Page 41 Wednesday, March 14, 2007 1:50 PM Front brake NOTE: To check the rear brake fluid level, remove panel B. (See page 8-9.) Observe these precautions: ● When checking the fluid level, make sure that the top of the brake fluid reservoir is level. ● Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4 1. Minimum level mark Rear brake ● 8 ● ● 1.
U23D10E0.book Page 42 Wednesday, March 14, 2007 1:50 PM ● As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause. EBU24290 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart.
U23D10E0.book Page 43 Wednesday, March 14, 2007 1:50 PM EWB02010 NOTE: ● Always perform this maintenance completely in the following order whenever adjusting the rear brake. ● Before adjusting the brake lever free play and checking the brake pedal position, check the rear brake pads for wear. WARNING 8 POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.
U23D10E0.book Page 44 Wednesday, March 14, 2007 1:50 PM 2. Turn the brake lever free play adjusting bolt in direction (a) to increase the free play, and in direction (b) to decrease it. 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. 1. Locknut 2. Brake lever free play adjusting bolt 8 1. Distance between brake pedal and footboard 3.
U23D10E0.book Page 45 Wednesday, March 14, 2007 1:50 PM EWB02050 WARNING 8 POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct. ● Make sure the brakes do not drag. ● Make sure the brakes are not spongy. All air must be bled from the brake system.
U23D10E0.book Page 46 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 47 Wednesday, March 14, 2007 1:50 PM Front brake lever 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.
U23D10E0.book Page 48 Wednesday, March 14, 2007 1:50 PM EBU24951 EBU24962 Checking and lubricating the brake pedal Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bearings.
U23D10E0.book Page 49 Wednesday, March 14, 2007 1:50 PM EBU25212 Battery This model is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. Check and, if necessary, tighten the battery lead connections. ECB00620 CAUTION: Never attempt to remove the battery cell seals, as this would permanently damage the battery. 1.
U23D10E0.book Page 50 Wednesday, March 14, 2007 1:50 PM 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. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Get prompt medical attention.
U23D10E0.book Page 51 Wednesday, March 14, 2007 1:50 PM ECB00630 EBU25313 Replacing a fuse CAUTION: ● Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. ● To charge a sealed-type (MF) battery, a special constant-voltage battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charger, have a Yamaha dealer charge your battery. 1. 2. 3. 4. 5. 6. 7. 8. 9.
U23D10E0.book Page 52 Wednesday, March 14, 2007 1:50 PM ECB00640 EWB02151 WARNING CAUTION: To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 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. 2.
U23D10E0.book Page 53 Wednesday, March 14, 2007 1:50 PM 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. 1. Cover at the rear of the headlight 2. Remove the headlight bulb holder cover by pulling it off. 1. Headlight bulb holder 4. Remove the defective bulb by pulling it out. 8 EWB02180 WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off.
U23D10E0.book Page 54 Wednesday, March 14, 2007 1:50 PM 7. Install the bulb holder cover and the cover at the rear of the headlight. 5. Insert a new headlight bulb into the bulb holder by pushing it in. ECB00670 CAUTION: Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 8. Adjust the headlight beam if necessary. EBU25550 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make this adjustment. 1.
U23D10E0.book Page 55 Wednesday, March 14, 2007 1:50 PM 1. Headlight beam adjusting screw 1. Tail/brake light bulb holder 3. Remove the defective bulb by pushing it in and turning it counterclockwise. 4. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 5. Install the bulb holder (together with the bulb) by turning it clockwise. 6. Install the panel.
U23D10E0.book Page 56 Wednesday, March 14, 2007 1:50 PM ● Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel. 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. 1. Arrow mark 8 EBU25700 Installing a wheel 1. Install the wheel and the nuts. NOTE: ● The arrow mark on the tire must point toward the rotating direction of the wheel.
U23D10E0.book Page 57 Wednesday, March 14, 2007 1:50 PM 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. The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself.
U23D10E0.book Page 58 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 59 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 60 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 1 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 2 Wednesday, March 14, 2007 1:50 PM ● EWB02300 WARNING POTENTIAL HAZARD Operation with wet brakes after washing. 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. To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored.
U23D10E0.book Page 3 Wednesday, March 14, 2007 1:50 PM 6. 7. 9 8. 9. sively cold or warm place [less than 0 °C (30 °F) or more than 30 °C (90 °F)]. For more information on storing the battery, see page 8-49. b. Pour a teaspoonful of engine oil into the spark plug bore. 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.
U23D10E0.book Page 1 Wednesday, March 14, 2007 1:50 PM EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.10 :1 Starting system: Electric and recoil starter Lubrication system: Wet sump Overall length: 2085 mm (82.1 in) Overall width: 1150 mm (45.3 in) Overall height: 1210 mm (47.6 in) Seat height: 880 mm (34.6 in) Wheelbase: 1275 mm (50.2 in) Ground clearance: 275 mm (10.
U23D10E0.book Page 2 Wednesday, March 14, 2007 1:50 PM Type x quantity: BSR42 x 1 With oil filter cartridge replacement: 2.00 L (2.11 US qt) (1.76 Imp.qt) Final gear oil: Spark plug (s): Type: SAE80 API GL-4 Hypoid gear oil Quantity: 0.25 L (0.26 US qt) (0.22 Imp.qt) Manufacturer/model: NGK/DPR8EA-9 Spark plug gap: 0.8–0.9 mm (0.031–0.035 in) Differential gear oil: Clutch: Type: SAE80 API GL-4 Hypoid gear oil Quantity: 0.28 L (0.30 US qt) (0.25 Imp.
U23D10E0.book Page 3 Wednesday, March 14, 2007 1:50 PM Caster angle: 5.0 ° Trail: 26.0 mm (1.02 in) Rear: 27.0 kPa (3.9 psi) (0.270 kgf/cm²) Maximum: Front: 38.0 kPa (5.5 psi) (0.380 kgf/cm²) Rear: 33.0 kPa (4.8 psi) (0.330 kgf/cm²) Front tire: Type: Tubeless Size: AT25 x 8-12 Manufacturer/model: DUNLOP/KT131 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: DUNLOP/KT135 Wheel type: Panel wheel Rim size: 12 x 7.
U23D10E0.book Page 4 Wednesday, March 14, 2007 1:50 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: 170 mm (6.
U23D10E0.book Page 5 Wednesday, March 14, 2007 1:50 PM Four-wheel-drive motor fuse: 3.
U23D10E0.book Page 1 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 2 Wednesday, March 14, 2007 1:50 PM 1. Vehicle identification number (front left side) 1. Model label 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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U23D10E0.book Page 4 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 5 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 6 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 7 Wednesday, March 14, 2007 1:50 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.
U23D10E0.book Page 8 Wednesday, March 14, 2007 1:50 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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U23D10E0.book Page 1 Wednesday, March 14, 2007 1:50 PM INDEX A D Accessories and loading ................................................ 6-7 Accessories, auxiliary jack ........................................... 4-23 Air filter element, cleaning ............................................ 8-31 Axle boots .................................................................... 8-45 Differential gear lock indicator light ................................ 4-3 Differential gear oil ...........................
U23D10E0.book Page 2 Wednesday, March 14, 2007 1:50 PM Indicator lights and warning light .................................... 4-2 Instruments, lights and switches .................................... 5-9 Recoil starter ................................................................ 4-15 Reverse indicator light .................................................... 4-2 Riding your ATV ............................................................. 7-1 K Key identification number ............................
U23D10E0.book Page 3 Wednesday, March 14, 2007 1:50 PM W Warranty, extended ...................................................... 11-7 Warranty, limited .......................................................... 11-5 Wheel hub bearings, checking ..................................... 8-48 Wheel, installing ........................................................... 8-56 Wheel, removing ..........................................................
B6-yoko.
B6-yoko.
EBU26141 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.
