READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM7FGPW WARNING LIT-11626-20-11 This ATV should not be ridden by anyone under 16 years of age.
U3B410E0.
U3B410E0.book Page 1 Friday, April 14, 2006 9:13 AM EBU17170 INTRODUCTION EBU17270 Congratulations on your purchase of the Yamaha YFM7FGPW. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and 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.
U3B410E0.book Page 1 Friday, April 14, 2006 9:13 AM EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
U3B410E0.book Page 1 Friday, April 14, 2006 9:13 AM EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this ATV.
U3B410E0.book Page 1 Friday, April 14, 2006 9:13 AM EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17420 TABLE OF CONTENTS SAFETY INFORMATION .............................. 1-1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ............................ 2-1 DESCRIPTION .............................................. 3-1 Left view ...................................................... 3-1 Right view....................................................
U3B410E0.book Page 2 Friday, April 14, 2006 9:13 AM Instruments, lights and switches ................ 5-9 OPERATION .................................................. 6-1 Starting the engine ..................................... 6-1 Operating the drive select lever and driving in reverse ...................................... 6-3 Engine break-in .......................................... 6-4 Parking ....................................................... 6-5 Parking on a slope .............................
U3B410E0.book Page 3 Friday, April 14, 2006 9:13 AM Checking the front and rear brake lever free play ................................................. 8-48 Adjusting the brake pedal free play and checking the brake pedal position .......... 8-49 Axle boots ................................................ 8-51 Checking and lubricating the cables ........ 8-52 Checking and lubricating the front and rear brake levers .................................... 8-53 Checking and lubricating the brake pedal .........
U3B410E0.book Page 1 Friday, April 14, 2006 9:13 AM EBU17430 SAFETY INFORMATION ● EBU27230 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.
U3B410E0.book Page 2 Friday, April 14, 2006 9:13 AM ● 1 ● ● ● ● ● ● Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful when operating on unfamiliar terrain.
U3B410E0.book Page 3 Friday, April 14, 2006 9:13 AM ● ● ● ● ● 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.
U3B410E0.book Page 4 Friday, April 14, 2006 9:13 AM HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, seek medical help immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. EWB02320 WARNING 1 POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned.
U3B410E0.
U3B410E0.book Page 2 Friday, April 14, 2006 9:13 AM EBU17670 2 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replacement label from your Yamaha dealer.
U3B410E0.
U3B410E0.
U3B410E0.book Page 1 Friday, April 14, 2006 9:13 AM EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 3 1. 2. 3. 4. 5. 6. 7. 8. Radiator cap Battery Fuses Air filter case Spark arrester Engine oil dipstick Oil filter cartridge Coolant reservoir 1. Rear shock absorber assembly spring preload adjusting ring 2. Rear storage compartment and tool kit 3. Fuel tank cap cover 4. Throttle stop screw 5. Front shock absorber assembly spring preload adjusting ring 6. Spark plug 7. Brake pedal 8.
U3B410E0.book Page 2 Friday, April 14, 2006 9:13 AM EBU17712 NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual. Controls and instruments 3 1. 2. 3. 4. 5. 6. 7. Drive select lever Rear brake lever Handlebar switches Rear brake fluid reservoir Multifunction meter unit Front brake fluid reservoir On-Command four-wheel-drive/differential gear lock switch 8. Front brake lever 9. Throttle lever 10.Front storage compartment 11.Main switch 12.
U3B410E0.book Page 1 Friday, April 14, 2006 9:13 AM EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17760 4 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.
U3B410E0.book Page 2 Friday, April 14, 2006 9:13 AM EBU26691 EBU17830 Indicator lights and warning lights Reverse indicator light “ ” This indicator light comes on when the transmission is in the reverse position. EBU17860 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. 4 EBU17900 Coolant temperature warning light “ ” This warning light comes on when the engine overheats.
U3B410E0.book Page 3 Friday, April 14, 2006 9:13 AM ● The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on, have a Yamaha dealer check the electrical circuit. 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.
U3B410E0.book Page 4 Friday, April 14, 2006 9:13 AM EBU18001 NOTE: ● Due to the synchronizing mechanism in the differential gear case, the four-wheel-drive indicator may not come on until the ATV starts moving. ● When the On-Command differential gear lock switch is set to “LOCK”, the indicator “ ” will flash until the differential gear is locked. On-Command differential gear lock indicator light “DIFF.
U3B410E0.book Page 5 Friday, April 14, 2006 9:13 AM ● EBU27291 Multifunction display ● ● ● 1. 2. 3. 4. 5. 6. 7.
U3B410E0.book Page 6 Friday, April 14, 2006 9:13 AM CLOCK → HOUR → CLOCK 4 NOTE: This fuel meter is equipped with a self-diagnosis system. If the electrical circuit is defective, all the display segments and fuel level warning indicator will start flashing. If this occurs, have a Yamaha dealer check the electrical circuit. To set the clock 1. Set the display to the clock mode. 2. Push the “SELECT” button and “RESET” button together for at least three seconds. 3.
U3B410E0.book Page 7 Thursday, April 27, 2006 2:31 PM Self-diagnosis device EBU18060 Handlebar switches 4 1. Error code display 1. 2. 3. 4. This model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the multifunction display will indicate a two-digit error code. If the multifunction display indicates such an error code, note the code number, and then have a Yamaha dealer check the vehicle.
U3B410E0.book Page 8 Thursday, April 27, 2006 2:31 PM EBU18100 EBU18180 Start switch “ ” Push this switch to crank the engine with the starter. Override switch “OVERRIDE” ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. 4 EBU18151 Light switch “ / /OFF” Set this switch to “ ” to turn on the low beams and the taillight. Set the switch to “ ” to turn on the high beams and the taillight. Set the switch to “OFF” to turn off all the lights. 1.
U3B410E0.book Page 9 Friday, April 14, 2006 9:13 AM 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. HOW TO AVOID THE HAZARD Always ride at a slow speed when the ATV is in four-wheel-drive differential gear lock, and allow extra time and distance for maneuvers.
U3B410E0.book Page 10 Friday, April 14, 2006 9:13 AM 4 WHAT CAN HAPPEN The ATV handles differently in two-wheel drive than in four-wheel drive in some circumstances. Changing from two-wheel drive to four-wheel drive or from four-wheel drive to two-wheel drive while moving may cause the ATV to unexpectedly handle differently. This could distract the operator and increase the risk of losing control and of causing an accident.
U3B410E0.book Page 11 Friday, April 14, 2006 9:13 AM ● “LOCK” (four-wheel drive with the differential gear locked): Power is supplied to the rear and front wheels and the differential gear is locked. Unlike in four-wheel drive, all wheels turn at the same speed. 4 1. Differential gear lock lever 2. On-Command four-wheel-drive switch “2WD”/“4WD” Stop the ATV, move the differential gear lock lever to position (a), and then push the differential gear lock switch in to the “LOCK” position.
U3B410E0.book Page 12 Friday, April 14, 2006 9:13 AM WHAT CAN HAPPEN The ATV handles differently in four-wheel drive than in differential gear lock in some circumstances. Changing from four-wheel drive to differential gear lock or vice-versa while moving may cause the ATV to handle differently unexpectedly. This could distract the operator and increase the risk of losing control and causing an accident.
U3B410E0.book Page 13 Friday, April 14, 2006 9:13 AM 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. EBU18270 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the ATV by varying the throttle position.
U3B410E0.book Page 14 Friday, April 14, 2006 9:13 AM 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.
U3B410E0.book Page 15 Friday, April 14, 2006 9:13 AM WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in). (See page 8-44.) 4 EBU18391 1. Front brake lever Front brake lever The front brake lever is located on the right handlebar.
U3B410E0.book Page 16 Friday, April 14, 2006 9:13 AM 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.
U3B410E0.book Page 17 Friday, April 14, 2006 9:13 AM To install the fuel tank cap Install the fuel tank cap by turning it clockwise until a click is heard, and then close the fuel tank cap cover. EBU18730 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. 1. Fuel tank cap cover 1. Fuel level 2. Fuel tank filler tube 1.
U3B410E0.book Page 18 Friday, April 14, 2006 9:13 AM methanol is not recommended by Yamaha because it can cause damage to the fuel system or ATV performance problems. Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 20.0 L (5.28 US gal) (4.40 Imp.gal) Fuel reserve amount: 4.5 L (1.19 US gal) (0.99 Imp.gal) 4 EWB00270 WARNING 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.
U3B410E0.book Page 19 Friday, April 14, 2006 9:13 AM EBU18880 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear. 4 1. Projection 2. Seat holder EBU27361 Storage compartments This ATV is equipped with two storage compartments. The front storage compartment is located at the front right side of the ATV. To access the storage compartment, remove the storage compartment cover by turning it counterclockwise. 1. Seat 2.
U3B410E0.book Page 20 Friday, April 14, 2006 9:13 AM The rear storage compartment is located under the seat. (See page 4-19.) To access the storage compartment, remove the storage compartment cover. 4 1. Front storage compartment cover 1. Rear storage compartment cover 1.
U3B410E0.book Page 21 Friday, April 14, 2006 9:13 AM ● ● Do not exceed the load limit of 0.5 kg (1 lb) for the front storage compartment or 2.0 kg (4 lb) for the rear storage compartment. Do not exceed the maximum load of 220.0 kg (485 lb) for the ATV. NOTE: A drain plug is fitted at the bottom of each storage compartment. If any water collects in a storage compartment, remove the drain plug, drain the water, and then install the drain plug. 1.
U3B410E0.book Page 22 Friday, April 14, 2006 9:13 AM EBU19130 Adjusting the front and rear shock absorber assemblies The spring preload can be adjusted to suit the rider’s weight and the riding conditions. Adjust the spring preload as follows. Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to decrease the spring preload and thereby soften the suspension. 4 1.
U3B410E0.book Page 23 Friday, April 14, 2006 9:13 AM EWB00350 NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. WARNING POTENTIAL HAZARD Improper shock absorber assembly 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 absorber assemblies on the left and right side to the same setting. EBU19180 Auxiliary DC jack 1.
U3B410E0.book Page 24 Friday, April 14, 2006 9:13 AM 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.
U3B410E0.book Page 1 Friday, April 14, 2006 9:13 AM EBU19200 PRE-OPERATION CHECKS EBU19210 Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
U3B410E0.book Page 2 Friday, April 14, 2006 9:13 AM ITEM Rear brake Throttle lever 5 Control cables Wheels and tires Brake pedal Brake levers Axle boots Chassis fasteners Instruments, lights and switches ROUTINE • Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check pedal free play, and adjust if necessary. • Check brake pads for wear, and replace if necessary. • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.
U3B410E0.book Page 3 Friday, April 14, 2006 9:13 AM WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
U3B410E0.book Page 4 Friday, April 14, 2006 9:13 AM EBU19530 EBU19590 Fuel Final gear oil Make sure that there is sufficient fuel in the tank. (See page 4-17.) Make sure that the final gear oil is at the specified level. Add oil as necessary. (See page 8-26.) EWB00500 WARNING 5 EBU19600 Differential gear oil POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up.
U3B410E0.book Page 5 Friday, April 14, 2006 9:13 AM 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. Brake fluid level Check the brake fluid level. Add fluid if necessary. (See page 8-47.
U3B410E0.book Page 6 Friday, April 14, 2006 9:13 AM EWB00540 EBU19781 Tires WARNING 5 EWB00561 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.
U3B410E0.book Page 7 Friday, April 14, 2006 9:13 AM ● ● Rear: Manufacturer/model: DUNLOP/KT425 Size: AT25 x 10-12 Type: Tubeless The tires should be set to the recommended pressure: Recommended tire pressure: Front: 35.0 kPa (5.0 psi) (0.350 kgf/cm²) Rear: 30.0 kPa (4.3 psi) (0.300 kgf/cm²) • Check and adjust tire pressures when the tires are cold. • Tire pressures must be equal on both sides.
U3B410E0.book Page 8 Friday, April 14, 2006 9:13 AM 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) NOTE: The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading.
U3B410E0.book Page 9 Friday, April 14, 2006 9:13 AM 5 1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.
U3B410E0.book Page 1 Friday, April 14, 2006 9:13 AM EBU19870 OPERATION EBU27332 EWB00010 Starting the 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.
U3B410E0.book Page 2 Friday, April 14, 2006 9:13 AM ● ECB00822 CAUTION: The coolant temperature warning light and engine trouble warning light should come on, then go off. The EPS warning light should come on, then go off when the engine is started. If a warning light does not go off, see page 4-2 for the corresponding warning light circuit check. The rear brake lever or brake pedal is applied with the drive select lever in any position.
U3B410E0.book Page 3 Friday, April 14, 2006 9:13 AM EBU20430 Operating the drive select lever and driving in reverse ECB00170 CAUTION: Before shifting, stop the ATV, otherwise the transmission may be damaged. 6 Shifting: Neutral to High-range and High-range to Low-range 1. Bring the ATV to a complete stop. 2. Apply the brake pedal, and then shift by moving the drive select lever along the shift guide. 1. 2. 3. 4. 5. 6. NOTE: Make sure that the drive select lever is completely shifted into position.
U3B410E0.book Page 4 Friday, April 14, 2006 9:13 AM ● 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. Due to the synchronizing mechanism in the engine, the indicator light may not come on until the ATV starts moving. 4. Check behind for people or obstacles, and then release the brake pedal. 5. Open the throttle lever gradually and continue to watch to the rear while backing. EWB00660 WARNING 1. 2.
U3B410E0.book Page 5 Friday, April 14, 2006 9:13 AM Since the engine is brand new, do not put an excessive load on it for the first 20 hours. The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided. 6 EBU27321 Parking When parking the ATV, stop the engine, and shift the drive select lever into the park position.
U3B410E0.book Page 6 Friday, April 14, 2006 9:13 AM 3. With the brake pedal applied, shift the drive select lever to the park position. ● ● 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.
U3B410E0.book Page 7 Friday, April 14, 2006 9:13 AM ● Never exceed the weight limits shown. An overloaded ATV can be unstable. MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, cargo, accessories, and tongue): 220.0 kg (485 lb) Front carrier: 45.0 kg (99 lb) Rear carrier: 85.0 kg (187 lb) Front storage compartment: 0.5 kg (1 lb) Rear storage compartment: 2.
U3B410E0.book Page 8 Friday, April 14, 2006 9:13 AM 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.
U3B410E0.
U3B410E0.book Page 2 Friday, April 14, 2006 9:13 AM ular attention to the safety information on pages 1-1–1-4. 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. EBU27391 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.
U3B410E0.book Page 3 Friday, April 14, 2006 9:13 AM RIDE WITH CARE AND GOOD JUDGEMENT HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating techniques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-8872887. Get training if you are inexperienced.
U3B410E0.book Page 4 Friday, April 14, 2006 9:13 AM WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc.
U3B410E0.book Page 5 Friday, April 14, 2006 9:13 AM This ATV is designed to carry operator and cargo only – passengers prohibited. EWB00910 WARNING 7 POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation.
U3B410E0.book Page 6 Friday, April 14, 2006 9:13 AM Apparel HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear: ● eye protection (goggles or face shield) ● gloves ● boots ● long-sleeved shirt or jacket ● long pants EWB00920 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing.
U3B410E0.book Page 7 Friday, April 14, 2006 9:13 AM Do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety. EWB00940 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating.
U3B410E0.book Page 8 Friday, April 14, 2006 9:13 AM Do not operate at speeds too fast for your skills or the conditions. EWB00950 WARNING EWB00960 POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident.
U3B410E0.book Page 9 Friday, April 14, 2006 9:13 AM Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Reduce your speed when adding additional loads. Speed limiter For riders less experienced with this model, the throttle lever housing is equipped with a speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum.
U3B410E0.book Page 10 Friday, April 14, 2006 9:13 AM EWB00970 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.
U3B410E0.book Page 11 Friday, April 14, 2006 9:13 AM During operation Always keep your feet on the footboards during operation, otherwise they may contact the rear wheels. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.
U3B410E0.book Page 12 Friday, April 14, 2006 9:13 AM HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer. Modifications EWB01000 7 WARNING POTENTIAL HAZARD Operating this ATV with improper modifications.
U3B410E0.book Page 13 Friday, April 14, 2006 9:13 AM Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. EWB01010 WARNING 7 POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire.
U3B410E0.book Page 14 Friday, April 14, 2006 9:13 AM HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets. EWB01030 WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
U3B410E0.book Page 15 Friday, April 14, 2006 9:13 AM Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. EWB01040 WARNING 7 POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control.
U3B410E0.book Page 16 Friday, April 14, 2006 9:13 AM HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.
U3B410E0.book Page 17 Friday, April 14, 2006 9:13 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. 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.
U3B410E0.book Page 18 Friday, April 14, 2006 9:13 AM 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.
U3B410E0.book Page 19 Friday, April 14, 2006 9:13 AM 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.
U3B410E0.book Page 20 Friday, April 14, 2006 9:13 AM 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.
U3B410E0.book Page 21 Friday, April 14, 2006 9:13 AM 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. EWB01180 WARNING POTENTIAL HAZARD Climbing hills improperly.
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U3B410E0.book Page 23 Friday, April 14, 2006 9:13 AM If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
U3B410E0.book Page 24 Friday, April 14, 2006 9:13 AM If you start to roll backwards, DO NOT apply either brake abruptly. If you are in 2WD, apply only the front brake. If you are in 4WD or 4WD-LOCK, because all wheels are interconnected by the drive train, applying either brake will brake all wheels, therefore, avoid sudden application of either the front or rear brake as the wheels on the uphill side could come off the ground. The ATV could easily tip over backwards.
U3B410E0.book Page 25 Friday, April 14, 2006 9:13 AM 7 Whenever possible, ride your ATV straight downhill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear. RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight.
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U3B410E0.book Page 27 Friday, April 14, 2006 9:13 AM 7 CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. As you travel across a slope, lean your body in the uphill direction.
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U3B410E0.book Page 29 Friday, April 14, 2006 9:13 AM CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and carefully. EWB01150 WARNING 7 POTENTIAL HAZARD Operating this ATV through deep or fast flowing water.
U3B410E0.book Page 30 Friday, April 14, 2006 9:13 AM 1. Air filter case check hose ECB00840 7 CAUTION: After riding your ATV in water, be sure to drain the trapped water by removing the check hoses at the bottom of the air filter case. Also, remove the drain plugs from the front and rear storage compartments and the V-belt case to drain any water that may have accumulated. Wash the ATV with fresh water if it has been operated in salt water or muddy conditions. 1.
U3B410E0.book Page 31 Friday, April 14, 2006 9:13 AM 1. V-belt case drain plug 1. Storage compartment drain plug 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.
U3B410E0.book Page 32 Friday, April 14, 2006 9:13 AM WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual. SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide.
U3B410E0.book Page 33 Friday, April 14, 2006 9:13 AM If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide. EWB01170 WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn.
U3B410E0.book Page 34 Friday, April 14, 2006 9:13 AM ● WHAT TO DO... ● If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See page 7-19.) ● If your ATV begins to tip while turning: Lean more into the turn to regain balance.
U3B410E0.book Page 1 Friday, April 14, 2006 9:13 AM EBU21642 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.
U3B410E0.book Page 2 Friday, April 14, 2006 9:13 AM EWB01830 WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this ATV may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories.
U3B410E0.book Page 3 Friday, April 14, 2006 9:13 AM EBU21742 Periodic maintenance chart for the emission control system NOTE: ● For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
U3B410E0.book Page 4 Friday, April 14, 2006 9:13 AM 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 3 4 Air filter element * * * Front brake Rear brake Brake hoses 5 * Rear brake hose protectors 6 * Wheels 7 * Tires • Clean and replace if necessary. • Check operation and correct if necessary.
U3B410E0.book Page 5 Friday, April 14, 2006 9:13 AM INITIAL NO. 8 ITEM CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 8 * Wheel bearings • Check for looseness or damage, and replace if necessary. 9 * Upper and lower arm pivots • Lubricate with lithium-soap-based grease. 10 * V-belt • Check for wear, cracks or other damage, and replace if necessary. 11 * Drive shaft universal joint • Lubricate with lithium-soap-based grease.
U3B410E0.book Page 6 Friday, April 14, 2006 9:13 AM INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 EVERY 6 160 320 √ √ Engine oil • Change. • Check ATV for oil leakage, and correct if necessary. √ √ 22 Engine oil filter cartridge • Replace.
U3B410E0.book Page 7 Friday, April 14, 2006 9:13 AM INITIAL NO. 30 * ITEM Lights and switches CHECK OR MAINTENANCE JOB Whichever comes first • Check operation and correct if necessary. • Adjust headlight beams. EVERY month 1 3 km (mi) 320 (200) 1300 (800) 6 6 12 hours 20 80 160 160 320 √ √ √ √ √ 2500 2500 5000 (1600) (1600) (3200) EBU23070 8 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
U3B410E0.book Page 8 Friday, April 14, 2006 9:13 AM 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. 5. 6.
U3B410E0.book Page 9 Friday, April 14, 2006 9:13 AM 1. Panel E 2. Panel H 3. Panel I 1. Panel A To install the panel Place the panel in the original position. EBU27381 8 Panel A To remove the panel Pull upward on the areas shown.
U3B410E0.book Page 10 Friday, April 14, 2006 9:13 AM Panel B To remove the panel 1. Remove panel A. 2. Remove the front carrier by removing the bolts. 1. Carrier bolt (top) 3. Remove the front carrier stays by removing the bolts. 8 1. Carrier bolt (under the fenders) 1.
U3B410E0.book Page 11 Friday, April 14, 2006 9:13 AM 1. Front carrier stay bolt 1. Panel B 2. Quick fastener screw 4. Remove the quick fastener screws, and then pull the panel upward to remove it. To install the panel 1. Place the panel in the original position, and then install the quick fastener screws.
U3B410E0.book Page 12 Friday, April 14, 2006 9:13 AM Tightening torques: Carrier bolt (top): 26 Nm (2.6 m·kgf, 19 ft·lbf) Carrier bolt (under the fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 4. Install panel A. Panel C To remove the panel 1. Remove the seat. (See page 4-19.) 2. Remove panel A. 3. Remove the quick fastener screws, and then pull the panel upward as shown to remove it. 2. Install the front carrier stays by installing the bolts and tightening them to the specified torque.
U3B410E0.book Page 13 Friday, April 14, 2006 9:13 AM 1. Panel C 2. Quick fastener screw 8 2. Install panel A. 3. Install the seat. To install the panel 1. Place the panel in the original position, and then install the quick fastener screws. Panels D and E To remove one of the panels 1. Remove panel C. 2. Remove the quick fastener screw and bolt, and then pull the panel upward as shown to remove it. NOTE: To ease removal of panel D, shift the drive select lever into the reverse position.
U3B410E0.book Page 14 Friday, April 14, 2006 9:13 AM 1. Panel D 2. Quick fastener screw 1. Panel E 2. Quick fastener screw 8 1. Bolt 1.
U3B410E0.book Page 15 Friday, April 14, 2006 9:13 AM To install one of the panels 1. Place the panel in the original position, and then install the bolt and quick fastener screw. Panel F To remove the panel Pull outward on the areas shown. 1. Panel F 8 To install the panel Place the panel in the original position. 2. Install panel C.
U3B410E0.book Page 16 Friday, April 14, 2006 9:13 AM 1. 2. 3. 4. 5. Panel G To remove the panel Remove the nut, bolts, and quick fastener, and then pull the panel downward while pushing the tab. Panel G Nut Bolt Quick fastener Tab To install the panel Place the panel in the original position, and then install the bolts, nut, and quick fastener.
U3B410E0.book Page 17 Friday, April 14, 2006 9:13 AM 1. 2. 3. 4. 5. Panel H 8 To remove the panel Remove the nut, bolts, and quick fasteners, and then pull the panel downward while pushing the tab. Panel H Nut Bolt Quick fastener Tab To install the panel Place the panel in the original position, and then install the bolts, nut, and quick fasteners.
U3B410E0.book Page 18 Friday, April 14, 2006 9:13 AM 1. Carrier bolt (under the fenders) Panel I To remove the panel 1. Remove the seat. (See page 4-19.) 2. Remove the rear carrier by removing the bolts. 8 1.
U3B410E0.book Page 19 Friday, April 14, 2006 9:13 AM 1. Panel I 2. Quick fastener 1. Carrier bolt (lower) 3. Remove the quick fasteners, and then push inward on the areas shown. To install the panel 1. Place the panel in the original position, and then install the quick fasteners.
U3B410E0.book Page 20 Friday, April 14, 2006 9:13 AM EBU23211 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plug can reveal the condition of the engine. To remove the spark plug 1. Remove the spark plug cap. 2.
U3B410E0.book Page 21 Friday, April 14, 2006 9:13 AM 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/CR8E To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. Spark plug gap: 0.7–0.8 mm (0.028–0.031 in) 1.
U3B410E0.book Page 22 Friday, April 14, 2006 9:13 AM NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 4. Install the spark plug cap. EBU27460 Engine oil and oil filter cartridge The engine oil level should be checked before each ride.
U3B410E0.book Page 23 Friday, April 14, 2006 9:13 AM 4. Remove the dipstick, and then wipe it off with a clean rag. 1. Maximum level mark 2. Minimum level mark 1. Dipstick 8 NOTE: The engine oil should be between the minimum and maximum level marks. 5. Insert the dipstick completely into the oil filler hole, and then remove it again to check the oil level. 6. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. 7.
U3B410E0.book Page 24 Friday, April 14, 2006 9:13 AM ECB00850 NOTE: Skip steps 5–9 if the oil filter cartridge is not being replaced. CAUTION: Be sure the engine oil is at the correct level, otherwise engine damage may result. 5. Remove panel G. (See page 8-8.) 6. Remove the oil filter cartridge with an oil filter wrench. To change the engine oil (with or without oil filter cartridge replacement) 1. Place the ATV on a level surface. 2. Remove panel F. (See page 8-8.) 3.
U3B410E0.book Page 25 Friday, April 14, 2006 9:13 AM 1. O-ring 1. Torque wrench Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf) NOTE: Make sure that the O-ring is properly seated. 8 8. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. 9. Install panel G. 10. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 30 Nm (3.
U3B410E0.book Page 26 Friday, April 14, 2006 9:13 AM 11. Add the specified amount of the recommended engine oil, and then insert the dipstick completely into the oil filler hole. 12. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 13. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary. 14. Install panel F.
U3B410E0.book Page 27 Friday, April 14, 2006 9:13 AM NOTE: The oil level should be at the brim of the check hole. 1. Final gear oil filler bolt 4. Install the oil level check bolt and oil filler bolt, and then tighten them to the specified torques. 8 1. Final gear oil 2. Final gear oil level check bolt 3. Correct oil level Tightening torques: Final gear oil level check bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 3.
U3B410E0.book Page 28 Friday, April 14, 2006 9:13 AM 3. Remove the final gear oil filler bolt, final gear oil level check bolt, and the final gear oil drain bolt to drain the oil from the final gear case. 1. Final gear oil 2. Final gear oil level check bolt 3. Correct oil level 1. Final gear oil drain bolt Recommended final gear oil: See page 10-1. 4. Install the drain bolt, and then tighten it to the specified torque. ECB00420 Tightening torque: Final gear oil drain bolt: 23 Nm (2.
U3B410E0.book Page 29 Friday, April 14, 2006 9:13 AM 2. Remove the differential gear oil filler bolt, and then check the oil level in the differential gear case. Tightening torques: Final gear oil level check bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 7. Check the final gear case for oil leakage. If oil is leaking, check for the cause. EBU23421 Differential gear oil 8 The differential gear case must be checked for oil leakage before each ride.
U3B410E0.book Page 30 Friday, April 14, 2006 9:13 AM Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) Tightening torque: Differential gear oil drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 5. Add the recommended differential gear oil to the brim of the filler hole as shown. To change the differential gear oil 1. Place the ATV on a level surface. 2. Place an oil pan under the differential gear case to collect the used oil. 3.
U3B410E0.book Page 31 Friday, April 14, 2006 9:13 AM ECB00410 NOTE: The coolant level must be checked on a cold engine since the level varies with engine temperature. CAUTION: Be sure no foreign material enters the differential gear case. 6. Install the oil filler bolt, and then tighten it to the specified torque. 2. Check the coolant level in the coolant reservoir. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.
U3B410E0.book Page 32 Friday, April 14, 2006 9:13 AM 4. Remove the reservoir cap, add coolant or distilled water to the maximum level mark, install the reservoir cap, and then install the panel. ECB00400 CAUTION: If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine.
U3B410E0.book Page 33 Friday, April 14, 2006 9:13 AM EBU27552 To change the coolant EWB01880 WARNING 8 POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always place a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap. 1. Coolant drain bolt 1.
U3B410E0.book Page 34 Friday, April 14, 2006 9:13 AM 1. Radiator cap 1. Coolant reservoir hose 8. After draining the coolant, thoroughly flush the cooling system with clean tap water. 9. Replace the coolant drain bolt washer if it is damaged, install the coolant drain bolt, and then tighten it to the specified torque. 6. Remove the coolant reservoir cap. 7. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir.
U3B410E0.book Page 35 Friday, April 14, 2006 9:13 AM ● 12. Pour the recommended coolant into the reservoir to the maximum level mark, and then install the reservoir cap. Antifreeze/water mixture ratio: 1:1 Recommended antifreeze: High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Coolant quantity: Radiator capacity (including all routes): 1.99 L (2.10 US qt) (1.75 Imp.qt) Coolant reservoir capacity (up to the maximum level mark): 0.17 L (0.18 US qt) (0.15 Imp.
U3B410E0.book Page 36 Friday, April 14, 2006 9:13 AM 17. Loosen the cylinder head air bleed bolt, without removing it, to allow all of the air to escape from the air bleed bolt hole. 14. When coolant begins to flow out of the bolt hole, tighten the water pump air bleed bolt to the specified torque. Tightening torque: Water pump air bleed bolt: 10Nm (1.0 m·kgf, 7.2 ft·lbf) 15. Remove panel E. (See page 8-8.) 16. Loosen the clamp screw, and then remove the V-belt cooling duct. 1.
U3B410E0.book Page 37 Friday, April 14, 2006 9:13 AM 21. Pour the recommended coolant into the radiator until it is full. 22. Stop the engine and allow it to cool. If the coolant level has dropped after the engine has cooled, add sufficient coolant until it reaches the top of the radiator, and then install the radiator cap. 23. Start the engine, and then check for coolant leakage. NOTE: There are two check hoses at the bottom of the air filter case, which are located behind panels D and E.
U3B410E0.book Page 38 Friday, April 14, 2006 9:13 AM 1. Air filter case check hose 1. Air filter case holder 2. Air filter case cover 1. Remove panel C. (See page 8-9.) 2. Remove the air filter case cover by unhooking the holders. 3. Remove the sponge material and the mesh from the air filter case.
U3B410E0.book Page 39 Friday, April 14, 2006 9:13 AM HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material. 6. Squeeze the excess solvent out of the sponge material and let it dry. ECB00440 CAUTION: Do not twist the sponge material when squeezing it. 7. Check the sponge material and replace it if damaged. 8. Apply Yamaha foam air filter oil or other quality foam air filter oil to the sponge material. 1. Sponge material 2. Air filter mesh 8 4.
U3B410E0.book Page 40 Friday, April 14, 2006 9:13 AM ECB00760 CAUTION: Make sure that the air filter element is properly seated in the air filter case. ● Never operate the engine with the air filter element removed. This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect the fuel injection system with subsequent poor performance and possible engine overheating. ● 11. Install the panel.
U3B410E0.book Page 41 Friday, April 14, 2006 9:13 AM 1. Bolt 8 1. Tailpipe 2. Spark arrester 3. Gasket 2. Remove the tailpipe, by pulling it out of the muffler, and then remove the gasket. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 4. Install the gasket, and then insert the tailpipe into the muffler and align the bolt holes. 5.
U3B410E0.book Page 42 Friday, April 14, 2006 9:13 AM EWB01930 WARNING POTENTIAL HAZARD Improperly purging the exhaust system. 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. HOW TO AVOID THE HAZARD When purging the exhaust system: Always let the exhaust system cool prior to touching exhaust components. Always wear eye protection, and make sure no one is behind the ATV.
U3B410E0.book Page 43 Friday, April 14, 2006 9:13 AM NOTE: If water drains from the V-belt case after removing the plug, have a Yamaha dealer check the ATV as the water may affect other engine parts. NOTE: A diagnostic tachometer is needed to make this adjustment. 1. Start the engine and warm it up. NOTE: The engine is warm when it quickly responds to the throttle. 2. Remove panel C. (See page 8-8.) 3. Attach the tachometer to the spark plug lead. 4.
U3B410E0.book Page 44 Friday, April 14, 2006 9:13 AM EBU24043 Adjusting the throttle cable free play The throttle cable free play should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The throttle cable free play should measure 3.0– 5.0 mm (0.12–0.20 in) at the throttle lever. Periodically check the throttle cable free play and, if necessary, adjust it as follows.
U3B410E0.book Page 45 Friday, April 14, 2006 9:13 AM 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.
U3B410E0.book Page 46 Friday, April 14, 2006 9:13 AM Front brake EBU27841 Checking the rear brake hose protectors The rear brake hoses protectors must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake hose protector is provided with a wear indicator. If a protector wears to the point that its indicator becomes visible, have a Yamaha dealer replace the protector. NOTE: The wheels need to be removed to check the brake hose protectors.
U3B410E0.book Page 47 Friday, April 14, 2006 9:13 AM Rear brake EBU24251 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. 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.
U3B410E0.book Page 48 Friday, April 14, 2006 9:13 AM ● ● ● Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. As the brake pads wear, it is normal for the brake fluid level to gradually go down.
U3B410E0.book Page 49 Friday, April 14, 2006 9:13 AM Rear brake HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct. ● Make sure the brakes do not drag. ● Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU27520 Adjusting the brake pedal free play and checking the brake pedal position 1.
U3B410E0.book Page 50 Friday, April 14, 2006 9:13 AM Adjusting the brake pedal free play The brake pedal free play should measure 0.0–5.0 mm (0.00–0.20 in) as shown. If the free play is incorrect, adjust it as follows. 1. Locknut 2. Brake pedal free play adjusting nut 4. Tighten the locknut. 5. Install the panel. If the correct free play cannot be obtained, have a Yamaha dealer adjust it. 1. Brake pedal free play 1. Remove panel H. (See page 8-8.) 2. Loosen the locknut. 3.
U3B410E0.book Page 51 Friday, April 14, 2006 9:13 AM Checking the brake pedal position The top of the brake pedal should be positioned 56.7 mm (2.23 in) above the top of the footrest. If the brake pedal position is incorrect, have a Yamaha dealer adjust it. 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.
U3B410E0.book Page 52 Friday, April 14, 2006 9:13 AM EBU24890 Checking and lubricating the cables The operation and the condition of all control cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Engine oil 1. Front axle boot (each side) EWB02120 WARNING POTENTIAL HAZARD Damaged control cables.
U3B410E0.book Page 53 Friday, April 14, 2006 9:13 AM Rear brake lever EBU24911 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
U3B410E0.book Page 54 Friday, April 14, 2006 9:13 AM Recommended lubricant: Lithium-soap-based grease EBU25021 Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer replace the stabilizer bushes if necessary.
U3B410E0.book Page 55 Friday, April 14, 2006 9:13 AM EBU25100 Recommended lubricant: Lithium-soap-based grease Lubricating the steering shaft The steering shaft must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease 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.
U3B410E0.book Page 56 Friday, April 14, 2006 9:13 AM To store the battery 1. If the ATV will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. 2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases.
U3B410E0.book Page 57 Friday, April 14, 2006 9:13 AM EBU27580 Replacing a fuse 1. Positive battery terminal 2. Negative battery terminal 1. 2. 3. 4. 5. 6. ECB00630 8 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.
U3B410E0.book Page 58 Friday, April 14, 2006 9:13 AM ECB00640 CAUTION: To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. 1. 2. 3. 4. 5. 6. 7.
U3B410E0.book Page 59 Friday, April 14, 2006 9:13 AM 8 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. Specified fuses: Main fuse: 40.0 A Headlight fuse: 15.0 A Ignition fuse: 10.0 A Four-wheel-drive motor fuse: 10.0 A Signaling system fuse: 5.0 A Auxiliary DC jack fuse: 15.0 A Radiator fan fuse: 15.0 A Fuel injection system fuse: 15.
U3B410E0.book Page 60 Friday, April 14, 2006 9:13 AM 1. Cover at the rear of the headlight 1. Headlight coupler 2. Remove the headlight bulb cover. 4. Unhook the headlight bulb holder, and then remove the defective bulb. 8 1. Headlight bulb cover 3. Disconnect the headlight coupler.
U3B410E0.book Page 61 Friday, April 14, 2006 9:13 AM 5. Place a new headlight bulb into position, and then secure it with the bulb holder. 1. Headlight bulb holder 2. Headlight bulb 1. Do not touch the glass part of the bulb. EWB02180 WARNING 8 ECB00650 CAUTION: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected.
U3B410E0.book Page 62 Friday, April 14, 2006 9:13 AM ECB00670 CAUTION: Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 9. Adjust the headlight beam if necessary. EBU25550 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make this adjustment. 1. Headlight beam adjusting screw EBU25640 Replacing the tail/brake light bulb To raise a headlight beam, turn the adjusting screw in direction (a).
U3B410E0.book Page 63 Friday, April 14, 2006 9:13 AM 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. EBU25650 Removing a wheel 1. Loosen the wheel nuts. 1. Tail/brake light bulb holder 3. Remove the defective bulb by pushing it in and turning it counterclockwise. 8 1. Wheel nut 2. Elevate the ATV and place a suitable stand under the frame. 3.
U3B410E0.book Page 64 Friday, April 14, 2006 9:13 AM EBU25700 Installing a wheel 1. Install the wheel and the nuts. NOTE: ● The arrow mark on the tire must point toward the rotating direction of the wheel. ● Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel. 1. Tapered nut 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified torques. Tightening torques: Front wheel nut: 55 Nm (5.
U3B410E0.book Page 65 Friday, April 14, 2006 9:13 AM HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces. EBU25730 Troubleshooting 8 Although Yamaha ATVs receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.
U3B410E0.book Page 66 Friday, April 14, 2006 9:13 AM EBU27680 Troubleshooting charts Starting problems or poor engine performance 1. Fuel Check the fuel level in the fuel tank. 2. Compression There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the ATV. Operate the electric starter. 3. Ignition Remove the spark plug and check the electrodes. 4.
U3B410E0.book Page 67 Friday, April 14, 2006 9:13 AM 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.
U3B410E0.book Page 1 Friday, April 14, 2006 9:13 AM EBU25860 CLEANING AND STORAGE ed from improper high-pressure detergent applications such as those available in coinoperated car washers. EBU25870 Cleaning 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.
U3B410E0.book Page 2 Friday, April 14, 2006 9:13 AM ● 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.
U3B410E0.book Page 3 Friday, April 14, 2006 9:13 AM 4. 5. 6. 7. °F) or more than 30 °C (90 °F)]. For more information on storing the battery, see page 8-55. c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder wall with oil.) e.
U3B410E0.book Page 1 Friday, April 14, 2006 9:13 AM EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Starting system: Electric starter Lubrication system: Wet sump Overall length: 2065 mm (81.3 in) Overall width: 1180 mm (46.5 in) Overall height: 1240 mm (48.8 in) Seat height: 905 mm (35.6 in) Wheelbase: 1250 mm (49.2 in) Ground clearance: 275 mm (10.
U3B410E0.book Page 2 Thursday, April 27, 2006 2:31 PM Manufacturer: DENSO With oil filter cartridge replacement: 2.10 L (2.22 US qt) (1.85 Imp.qt) Final gear oil: Spark plug (s): Type: SAE80 API GL-4 Hypoid gear oil Quantity: 0.20 L (0.21 US qt) (0.18 Imp.qt) Manufacturer/model: NGK/CR8E Spark plug gap: 0.7–0.8 mm (0.028–0.031 in) Differential gear oil: Clutch: Type: SAE80 API GL-4 Hypoid gear oil Quantity: 0.22 L (0.23 US qt) (0.19 Imp.
U3B410E0.book Page 3 Friday, April 14, 2006 9:13 AM 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/KT421 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/KT425 Wheel type: Panel wheel Rim size: 12 x 7.
U3B410E0.book Page 4 Thursday, April 27, 2006 2:31 PM Front suspension: Tail/brake light: 12 V, 5.0/21.
U3B410E0.book Page 5 Friday, April 14, 2006 9:13 AM Headlight fuse: 15.0 A Signaling system fuse: 5.0 A Ignition fuse: 10.0 A Auxiliary DC jack fuse: 15.0 A Four-wheel-drive motor fuse: 10.0 A Radiator fan fuse: 15.
U3B410E0.book Page 1 Friday, April 14, 2006 9:13 AM EBU25981 CONSUMER INFORMATION EBU26011 EBU26020 Identification numbers Key identification number The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key.
U3B410E0.book Page 2 Friday, April 14, 2006 9:13 AM 1. Vehicle identification number (front left side) 1. Model label NOTE: The vehicle identification number is used to identify your ATV. EBU26050 11 Model label The model label is affixed at the location in the illustration. Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
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U3B410E0.book Page 4 Friday, April 14, 2006 9:13 AM EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
U3B410E0.book Page 5 Friday, April 14, 2006 9:13 AM EBU26501 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha ATVs purchased from an authorized Yamaha ATV dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations. THE PERIOD OF WARRANTY for Yamaha ATVs shall be six (6) months from the date of purchase.
U3B410E0.book Page 6 Friday, April 14, 2006 9:13 AM WARRANTY QUESTIONS AND ANSWERS CUSTOMER SERVICE Q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes. If your machine requires warranty service, you must take it to any authorized Yamaha ATV dealer within the continental United States.
U3B410E0.book Page 7 Friday, April 14, 2006 9:13 AM EBU26122 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Ser vice (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
U3B410E0.book Page 8 Friday, April 14, 2006 9:13 AM We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. You can also save money: Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number).
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U3B410E0.book Page 1 Friday, April 14, 2006 9:13 AM INDEX A Accessories and loading ................................................ 6-6 Accessories, auxiliary jack ........................................... 4-23 Air filter element, cleaning ............................................ 8-37 Axle boots .................................................................... 8-51 Drive select lever .......................................................... 4-16 Drive select lever and driving in reverse .......
U3B410E0.book Page 2 Friday, April 14, 2006 9:13 AM K Key identification number ............................................. 11-1 Knuckle pivots, lubricating ........................................... 8-54 Knuckle shafts, lubricating ........................................... 8-55 Reverse indicator light ................................................... 4-2 Riding your ATV ............................................................. 7-1 S Safety information .........................................
U3B410E0.book Page 3 Friday, April 14, 2006 9:13 AM W Warranty, extended ...................................................... 11-7 Warranty, limited .......................................................... 11-5 Wheel bearings, checking ............................................ 8-54 Wheel, installing ........................................................... 8-64 Wheel, removing ..........................................................
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.
