READ THIS MANUAL CAREFULLY! It contains important safety information.
EBU00776
U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU00010 INTRODUCTION 1- Congratulations on your purchase of the Yamaha YXR66FAV. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing vehicles. 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.
U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU00021 IMPORTANT MANUAL INFORMATION 1- FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
U5UG12.book Page 2 Thursday, June 23, 2005 9:02 AM EVU00030 IMPORTANT NOTICE 2- ● ● ● This vehicle is designed and manufactured for off-road use only. It is illegal to operate this vehicle on any public street, road, or highway. Such use is prohibited by law. Check the laws and regulations in force before choosing where to operate this vehicle. It is illegal to operate this vehicle on public lands where vehicles its size are prohibited.
U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU00050 Brake pedal....................................4-16 Parking brake lever........................4-17 Drive select lever ...........................4-18 Fuel tank cap .................................4-18 Fuel level check window ................4-19 Starter (choke) ...............................4-19 Seats ..............................................4-20 Seat belts .......................................4-21 Glove compartment ....................
U5UG12.book Page 2 Thursday, June 23, 2005 9:02 AM Learning to operate your vehicle..... 7-5 Turning your vehicle ........................ 7-6 Braking............................................. 7-7 Going uphill...................................... 7-7 Going downhill ................................. 7-9 Crossing through shallow water .... 7-11 Riding over rough terrain............... 7-13 Riding in brush or wooded areas............................................
U5UG12.book Page 3 Thursday, June 23, 2005 9:02 AM Axle boots...................................... 8-18 Spark plug inspection.................... 8-20 Cleaning the air filter elements...... 8-22 V-belt cooling duct check hose ..... 8-27 V-belt case drain plug.................... 8-28 Cleaning the spark arrester........... 8-29 Carburetor adjustment................... 8-30 Idle speed adjustment ................... 8-31 Valve clearance adjustment .......... 8-31 Front brake pad check ..................
U5UG12.book Page 4 Thursday, June 23, 2005 9:02 AM 13 YAMAHA MOTOR CORPORATION, U.S.A. SIDE × SIDE VEHICLE LIMITED WARRANTY ................... 13-1 14 YAMAHA EXTENDED SERVICE (Y.E.S.) ..........................................
U5UG12.
U5UG12.book Page 2 Thursday, June 23, 2005 9:02 AM 2 Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. OPERATING TIRE PRESSURE: Set with tires cold. RECOMMENDED: FRONT: 70kPa, {.70kgf/cm}, 10psi REAR: 98kPa, {.98kgf/cm}, 14psi MINIMUM: FRONT: 63kPa, {.63kgf/cm}, 9psi REAR: 91kPa, {.
U5UG12.book Page 3 Thursday, June 23, 2005 9:02 AM 3 4 WARNING WARNING Keep hands, body, other persons away when closing bed. Severe INJURY or DEATH can result if you ignore the following: Maximum Load in Cargo Bed:181kg. (400lb). Never carry passengers in cargo bed. Cargo can affect handling and stability. Read Owner’s Manual before loading or towing. When loading with cargo or towing a trailer: Reduce speed and allow more room to stop. Avoid hills and rough terrain.
U5UG12.book Page 4 Thursday, June 23, 2005 9:02 AM 5 6 WARNING Improperly loading a trailer and failure to use extra care when pulling trailer can cause an accident or injury. Never load more than 50kg (110 lbs) tongue weight on the towing bracket. Do not tow more than 550kg (1212 lbs) rolling weight (trailer plus cargo). Operate in low-range gears only, allow for increased braking distance, and use extreme caution when operating on inclines.
U5UG12.book Page 5 Thursday, June 23, 2005 9:02 AM 7 WARNING Turning the off road vehicle in 4WD-LOCK (“DIFF.LOCK”) takes more effort. Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control. 5UG-F1558-00 8 WARNING Improper use can result in Severe INJURY or DEATH. This off-highway utility vehicle will handle and maneuver differently from an ordinary passenger car or other vehicle. Vehicle capacity: 1 operator and 1 passenger.
U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU00070 SAFETY INFORMATION This off-highway utility vehicle handles differently from other vehicles including cars and ATVs. SEVERE INJURY OR DEATH can result if you do not follow these instructions: ● Read this manual and all labels carefully and follow the operating procedures described. ● This vehicle is designed to carry the driver and one passenger. Never carry passengers in the cargo bed.
U5UG12.book Page 2 Thursday, June 23, 2005 9:02 AM ● ● ● ● ● ● ● ● Always inspect your vehicle each time you use it to be sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. Always keep both hands, arms, feet, and legs inside the vehicle at all times during operation. Keep your feet on the floorboard. Never hold onto the enclosure except when using the handgrip inside the enclosure.
U5UG12.book Page 3 Thursday, June 23, 2005 9:02 AM ● ● ● ● ● ● ● ● ● Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of you. Never go over the top of a hill at speed if you cannot see what is on the other side. Always follow proper procedures for going uphill. If you lose momentum and cannot continue up a hill, back down the hill with the engine in reverse gear. Use engine braking to help you go slowly.
U5UG12.book Page 4 Thursday, June 23, 2005 9:02 AM WARNING When transporting the vehicle in another vehicle, be sure it is kept in an upright position. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water.
U5UG12.book Page 5 Thursday, June 23, 2005 9:02 AM WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your vehicle in an area with adequate ventilation.
U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU00080 DESCRIPTION AND VEHICLE IDENTIFICATION 1- 1. Headlights 2. Front shock absorber assembly adjusting ring 3. Brake fluid reservoir 4. Air filter element (engine and air intake duct) 5. V-belt case 6. Driver seat 7. Driver seat belt 8. Spark plug 9. Cargo bed 10. Tail/brake lights 11. Rear shock absorber assembly adjusting ring 12. Cargo bed release levers 13. Spark arrester 14. Passenger seat belt 15. Passenger seat 16. Oil filter cartridge 17.
U5UG12.book Page 2 Thursday, June 23, 2005 9:02 AM 1 2 3 4 5 6 7 8 9 24. Light switch 25. Steering wheel 26. Starter (choke) 27. Main switch 28. On-Command four-wheel drive and differential gear lock switches 29. Indicator and warning lights 30. Multi-function meter unit (special edition models) 31. Auxiliary DC jack 32. Drive select lever 33. Parking brake lever 34. Accelerator pedal 35.
U5UG12.book Page 3 Thursday, June 23, 2005 9:02 AM EVU00090 EVU00100 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. Key identification number The key identification number is stamped on the key as shown in the following illustration. This number can be used for ordering a new key. 1.
U5UG12.book Page 4 Thursday, June 23, 2005 9:02 AM EVU00110 EVU00120 Vehicle identification number The vehicle identification number is stamped into the frame. Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Vehicle identification number NOTE: The vehicle identification number is used to identify your vehicle. _ 1.
U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU00130 CONTROL FUNCTIONS Functions of the respective switch positions are as follows: ON: All electrical circuits are supplied with power, and the headlights and taillights come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position. START: The electric starter is engaged by turning and holding the key in this position. Release the key when the engine starts. 1- EVU00140 Main switch 1.
U5UG12.book Page 2 Thursday, June 23, 2005 9:02 AM CAUTION: 1 _ ● ● ● Do not operate the electric starter continuously for more than 5 seconds, or starter damage could occur. Wait at least 5 seconds between each operation of the electric starter to let it cool. Do not turn the key to the “START” position with the engine running, or damage to the electric starter can result. See starting instructions prior to starting the engine. (See pages 6-1–6-3 for details.
U5UG12.book Page 3 Thursday, June 23, 2005 9:02 AM EVU00150 EVU00210 Indicator and warning lights Parking brake indicator light “P” This indicator light comes on when the parking brake is applied. EVU00160 Reverse indicator light “R” This indicator light comes on when the drive select lever is in the “R” reverse position. NOTE: If the indicator light flashes while riding, have a Yamaha dealer check the speed sensor circuit. _ 1. 2. 3. 4. 5. 6.
U5UG12.book Page 4 Thursday, June 23, 2005 9:02 AM EVU00200 EVU00180 Four-wheel-drive indicator light “ ” This indicator light comes on when the “2WD/ 4WD” switch is in the “4WD” position. Coolant temperature warning light “ ” When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.
U5UG12.book Page 5 Thursday, June 23, 2005 9:02 AM EVU00190 Coolant temperature warning light checking method Turn the main switch to “ON”. Coolant temperature warning light does not come on. Coolant temperature warning light comes on. Turn the main switch to “START” with the transmission in the neutral position. Coolant temperature warning light comes on momentarily. Coolant temperature warning light does not come on. Coolant temperature and electrical circuit are OK. Go ahead with riding.
U5UG12.book Page 6 Thursday, June 23, 2005 9:02 AM EVU00150* EVU01130 Indicator and warning lights (special edition models) Differential gear lock indicator light “DIFF. LOCK” This indicator light and the differential gear lock indicator in the display come on when the differential gear lock switch is set to the “4WDLOCK” position. NOTE: When the switch is set to “LOCK”, the differential gear lock indicator light will flash until the differential gear is locked. _ _ 1. 2. 3. 4. 5. 6. 7. 8.
U5UG12.book Page 7 Thursday, June 23, 2005 9:02 AM EVU00170 EVU01160 Neutral indicator light “N” This indicator light comes on when the drive select lever is in the “N” position. Four-wheel-drive indicator “ ”/“ ” This indicator comes on when the “2WD”/ “4WD” switch is set to the “4WD” position. The differential gear lock indicator “DIFF.LOCK” in the four-wheel-drive indicator also comes on when the “LOCK”-“4WD” switch is set to the “4WD-LOCK” position. DIFF.
U5UG12.book Page 8 Thursday, June 23, 2005 9:02 AM CAUTION: _ ● ● The engine may overheat if the vehicle is overloaded. If this happens, reduce the load to specification. After restarting, make sure that the light is out. Continuous use while the light is on may cause damage to the engine.
U5UG12.book Page 9 Thursday, June 23, 2005 9:02 AM EVU01171* Multi-function meter unit (special edition models) ● ● ● 1. 3. 5. 6. Speedometer 2. “H” button “M” button 4. Clock/Hour meter Odometer/Tripmeter A/Tripmeter B “TRIP/ODO” button 7.
U5UG12.book Page 10 Thursday, June 23, 2005 9:02 AM Odometer and tripmeter modes Pushing the “TRIP/ODO” button switches the display between the odometer mode “ODO” and the tripmeter modes “A” and “B” in the following order: ODO→TRIP A→TRIP B→ODO To reset a tripmeter, select it by pushing the “TRIP/ODO” button, and then push the “TRIP/ ODO” button for at least three seconds. The tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel.
U5UG12.book Page 11 Thursday, June 23, 2005 9:02 AM EVU00230 Switches CAUTION: _ Do not use the headlights with the engine turned off for an extended period of time. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. _ 1. Light switch “OFF/ L / H ” EVU00240 Light switch “OFF/ L / H ” Set the switch to “ L ” to turn on the low beam and the taillights.
U5UG12.book Page 12 Thursday, June 23, 2005 9:02 AM EVU01580 On-Command four-wheel drive and differential gear lock switches ● ● 1. On-Command four-wheel drive switch “2WD”/“4WD” 2. Differential gear lock switch “LOCK”/“4WD” This vehicle is equipped with an On-Command four-wheel drive switch “2WD”/“4WD” and a differential gear lock switch “LOCK”/ “4WD”. Select the appropriate drive according to terrain and the conditions. ● Two-wheel drive (“2WD”): Power is supplied to the rear wheels only.
U5UG12.book Page 13 Thursday, June 23, 2005 9:02 AM On-Command four-wheel drive switch “2WD”/“4WD” WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 4WD-LOCK (“DIFF.LOCK”), or vice-versa while the vehicle is moving. WHAT CAN HAPPEN The vehicle handles differently in 2WD than in 4WD and in 4WD-LOCK in some circumstances. Changing from 2WD to 4WD or from 4WD to 4WD-LOCK, or vice-versa while moving may cause the vehicle to unexpectedly handle differently.
U5UG12.book Page 14 Thursday, June 23, 2005 9:02 AM Differential gear lock switch “LOCK”/ “4WD” multi-function meter unit display will come on. To release the differential gear lock, stop the vehicle and set the switch to “4WD”. WARNING POTENTIAL HAZARD Riding too fast while the vehicle is in 4WD-LOCK. WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the vehicle. The amount of effort required is greater the faster you go.
U5UG12.book Page 15 Thursday, June 23, 2005 9:02 AM EVU00260 Accelerator pedal Press the accelerator pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the accelerator pedal returns normally before starting the engine. NOTE: ● If the differential gear lock is not engaging properly, turn the steering wheel back and forth to help it engage.
U5UG12.book Page 16 Thursday, June 23, 2005 9:02 AM EVU00270 Brake pedal Press the brake pedal to slow or stop the vehicle. Before starting the engine, check the accelerator pedal to be sure it is operating smoothly. Make sure the accelerator pedal fully returns to the idle position as soon as it is released. WARNING POTENTIAL HAZARD Malfunction of the accelerator pedal. WHAT CAN HAPPEN The accelerator pedal could be hard to operate, making it difficult to speed up or slow down when you need to.
U5UG12.book Page 17 Thursday, June 23, 2005 9:02 AM EVU00280 Parking brake lever The parking brake lever is located at the right side of the driver’s seat. It will help hold the vehicle from moving while parked. To set the parking brake, pull the lever up completely. To release the parking brake, pull up on the lever, press the release button, and then push the lever all the way down. Spring pressure helps return the lever to the released position.
U5UG12.book Page 18 Thursday, June 23, 2005 9:02 AM EVU00290 EVU00300 Drive select lever The drive select lever is used to shift your vehicle into the low, high, neutral and reverse positions. (Refer to pages 6-5–6-7 for the drive select lever operation.) Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1. Fuel tank cap 1.
U5UG12.book Page 19 Thursday, June 23, 2005 9:02 AM EVU00310 EVU00320 Fuel level check window The amount of fuel in the fuel tank can be checked through the fuel level check window. If the fuel level is low, refuel as soon as possible. Starter (choke) “ ” Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke).
U5UG12.book Page 20 Thursday, June 23, 2005 9:02 AM EVU00330 Seats To remove a seat, pull its seat lock lever upward, lift the front of the seat, and then slide the seat forward and up. To install a seat, insert the projections on the rear of the seat into the seat holders and push down on the seat at the front. WARNING POTENTIAL HAZARD A loose seat. WHAT CAN HAPPEN The operator could lose control or the operator or passenger could fall if the seat is loose during operation.
U5UG12.book Page 21 Thursday, June 23, 2005 9:02 AM EVU00340 Seat belts This vehicle is equipped with three-point seat belts for both the operator and passenger. Always wear the seat belt while riding in the vehicle. 1. Seat belt (× 2) 3. Buckle (× 2) To wear the seat belt properly, do the following: 1. Hold the latch plate as you pull the belt across your lap and chest. Make sure the belt is not twisted and is not caught on any portion of the vehicle, your clothing, or any equipment you are carrying.
U5UG12.book Page 22 Thursday, June 23, 2005 9:02 AM 3. Put the lap portion of the belt low on your hips. Push down on the buckle end of the belt as you pull up on the shoulder part so the belt is snug across your hips. 4. Position the shoulder belt over your shoulder and across your chest. The shoulder belt should fit against your chest. If it is loose, pull the belt out all the way and then let it retract. 5. To release the buckle, firmly press the release button. 1.
U5UG12.book Page 23 Thursday, June 23, 2005 9:02 AM EVU01191 EVU00351 Glove compartment Cargo bed CAUTION: _ To protect from damage, do not put metal products, like tools or sharply edged products directly in the glove compartment. If they must be stored, wrap them in appropriate cushion material. _ 1. Cargo bed 3. Cargo hook (× 4) a. Unlock. b. Open. 4-23 2.
U5UG12.book Page 24 Thursday, June 23, 2005 9:02 AM Opening and closing the tailgate Lifting and lowering the cargo bed 1. Tailgate 1. Cargo bed release lever 2. Latch (× 2) To open Unhook the latches, and then lower the tailgate. To close Place the tailgate in the original position, and then hook the latches. To lift Push down the cargo bed release lever on the left or right side of the vehicle, and then slowly lift up the cargo bed until it stops.
U5UG12.book Page 25 Thursday, June 23, 2005 9:02 AM WARNING WARNING POTENTIAL HAZARD Pinch points. WHAT CAN HAPPEN You or someone else could be pinched between the cargo bed and the frame when the bed is being lowered. HOW TO AVOID THE HAZARD Before closing the bed, be sure others are standing away from the vehicle. Keep hands and fingers away from the pinch points between the bed and the frame.
U5UG12.book Page 26 Thursday, June 23, 2005 9:02 AM EVU00360 Front and rear shock absorber adjustment The spring preload can be adjusted to suit the operating conditions. You can reduce preload for a softer ride, or increase preload if frequent bottoming occurs. WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger could fall, be thrown out, or be struck by objects in the cargo bed. HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed.
U5UG12.book Page 27 Thursday, June 23, 2005 9:02 AM 1. Special wrench 1. Spring preload adjusting ring 2. Position indicator NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment.
U5UG12.book Page 28 Thursday, June 23, 2005 9:02 AM EVU00370 Trailer hitch bracket This vehicle is equipped with a 5 cm (2 in) receiver bracket for a standard trailer hitch. Trailer towing equipment can be obtained at a Yamaha dealer. (See pages 6-11–6-13 for precaution information.) WARNING POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident.
U5UG12.book Page 29 Thursday, June 23, 2005 9:02 AM EVU00380 Auxiliary DC jack The auxiliary DC jack is located at the right side of the front panel. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running. 1. Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack: DC 12 V, 120 W (10 A) 1. Auxiliary DC jack cap 1. Set the light switch to “OFF”. 2. Start the engine. (See pages 6-1–6-3.) 3.
U5UG12.book Page 30 Thursday, June 23, 2005 9:02 AM 4. When the auxiliary DC jack is not being used, cover it with the cap. CAUTION: _ ● ● ● Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to blow. If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine starting may become difficult.
U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU01200 PRE-OPERATION CHECKS 1- Before using this vehicle, check the following points: ITEM ROUTINE PAGE Brakes • Check operation, free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary. Parking brake • Check for proper operation, condition and free play. Fuel • Check fuel level. • Fill with fuel if necessary. Engine oil • Check oil level. • Fill with oil if necessary.
U5UG12.book Page 2 Thursday, June 23, 2005 9:02 AM EVU00390 Front and rear brakes Brake pedal Check for correct brake pedal free play. If the brake pedal free play is incorrect, have a Yamaha dealer adjust it. (See page 8-35.) Check the operation of the brake pedal. It should move smoothly and there should be a firm feeling when the brakes are applied. If not, have the vehicle inspected by a Yamaha dealer. WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating.
U5UG12.book Page 3 Thursday, June 23, 2005 9:02 AM Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir. Apply the brakes firmly for one minute. If there is any leakage, have the vehicle inspected by a Yamaha dealer. WARNING POTENTIAL HAZARD Driving 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.
U5UG12.book Page 4 Thursday, June 23, 2005 9:02 AM EVU00400 Fuel Make sure there is sufficient gasoline in the tank. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost.
U5UG12.book Page 5 Thursday, June 23, 2005 9:02 AM EVU00410 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-9– 8-12.) 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. 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.
U5UG12.book Page 6 Thursday, June 23, 2005 9:02 AM EVU00420 Coolant Check the coolant level in the coolant reservoir when the engine is cold. (The coolant level will vary with engine temperature.) The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir. If the coolant level is at or below the minimum level mark, add additional coolant to bring the level up to maximum level mark. If coolant is not available, add distilled water.
U5UG12.book Page 7 Thursday, June 23, 2005 9:02 AM EVU00430 EVU00450 Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-13– 8-14 for details.) Accelerator pedal Check to see that the accelerator pedal operates correctly. It must operate smoothly and fully spring back to the idle position when released. Have a Yamaha dealer repair as necessary for proper operation.
U5UG12.book Page 8 Thursday, June 23, 2005 9:02 AM EVU01230 EVU00500 Steering Park on level ground. Turn the steering wheel right and left. Check for excessive free play, abnormal noises, or a rough feeling. Have a Yamaha dealer repair as necessary for proper operation. Tires WARNING POTENTIAL HAZARD Operating this vehicle with improper tires, or with improper or uneven tire pressure.
U5UG12.book Page 9 Thursday, June 23, 2005 9:02 AM 2. The tires should be set to the recommended pressure: ● Recommended tire pressure Front 70 kPa (0.70 kgf/cm2, 10 psi) Rear 98 kPa (0.98 kgf/cm2, 14 psi) Check and adjust tire pressures when the tires are cold. Tire pressures must be equal on both sides. 3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums: Front 63 kPa (0.63 kgf/cm2, 9 psi) Rear 91 kPa (0.
U5UG12.book Page 10 Thursday, June 23, 2005 9:02 AM EVU00510 How to measure tire pressure Use the tire pressure gauge. NOTE: The tire pressure gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. _ _ Set pressure with tires cold. Set tire pressures to the following specifications: 1. Tire pressure gauge ACE-02E Recommended pressure Minimum Maximum Front 70 kPa (0.
U5UG12.book Page 11 Thursday, June 23, 2005 9:02 AM EVU00520 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a.
U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU00530 EVU00540 OPERATION Starting a cold engine 1- WARNING WARNING POTENTIAL HAZARD Operating vehicle without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner’s Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer. 1 POTENTIAL HAZARD Freezing control cables in cold weather.
U5UG12.book Page 2 Thursday, June 23, 2005 9:02 AM Position 3 : Cold engine startambient temperature above 25 °C (80 °F) and warm engine start position. NOTE: ● When the drive select lever is in the neutral position, the neutral indicator light should come on. If the neutral indicator light does not come on, ask a Yamaha dealer to inspect the electric circuit. ● The engine can be started in any gear if the brake is applied. However, it is recommended to shift into neutral before starting the engine.
U5UG12.book Page 3 Thursday, June 23, 2005 9:02 AM EVU00550 Starting a warm engine To start a warm engine, refer to the “Starting a cold engine” section. The starter (choke) should not be used. Press the accelerator pedal slightly. NOTE: If the engine fails to start, release the key, and then try starting again. Wait a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 5 seconds on each attempt.
U5UG12.book Page 4 Thursday, June 23, 2005 9:02 AM 4. Using a charged 12 V battery, connect the positive lead of the jumper cable to the positive terminal of the battery in the vehicle and the other end of the positive lead to the positive terminal of the charged battery. WARNING Do not connect the negative lead of the jumper cable to the negative terminal of the battery in the vehicle. ● Be especially careful not to: • touch the positive lead of the jumper cable to the negative lead.
U5UG12.book Page 5 Thursday, June 23, 2005 9:02 AM EVU00570 Warming up To get maximum engine life, always warm up the engine before starting off. Never accelerate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally with the starter (choke) turned off. 2. Apply the brakes, then shift by moving the drive select lever along the shift guide. NOTE: Make sure that the drive select lever is completely shifted into position.
U5UG12.book Page 6 Thursday, June 23, 2005 9:02 AM Shifting: Neutral to Reverse 1. Stop the vehicle. Keep your foot off the accelerator pedal. 2. Apply the brake pedal. 3. Shift from neutral to reverse or vice versa by moving the drive select lever along the shift guide. 1. Drive select lever NOTE: ● When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect the reverse indicator light electrical circuit.
U5UG12.book Page 7 Thursday, June 23, 2005 9:02 AM EVU00590 Engine break-in There is never a more important period in the life of your vehicle than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances.
U5UG12.book Page 8 Thursday, June 23, 2005 9:02 AM 10–20 hours: Avoid prolonged operation above 3/4 throttle. Rev the vehicle freely but do not use full throttle at any time. Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r/min so the engine can rid itself of the temporary build up of heat. If any abnormality is noticed during this period, consult a Yamaha dealer. After break-in: The vehicle can now be operated normally.
U5UG12.book Page 9 Thursday, June 23, 2005 9:02 AM EVU01210 EVU00600 Parking When parking, stop the engine and shift the drive select lever into the neutral position. Apply the parking brake to help prevent the vehicle from rolling. Parking on a slope WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The vehicle could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines.
U5UG12.book Page 10 Thursday, June 23, 2005 9:02 AM EVU00610 Accessories and loading EVU00620 Accessories Accessories can affect the handling and control of your vehicle. Keep the following in mind when considering an accessory or operating a vehicle which has accessories. ● Choose only accessories designed for your vehicle. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market.
U5UG12.book Page 11 Thursday, June 23, 2005 9:02 AM EVU00630 ● ● ● Loading Cargo or a trailer can change the stability and handling of a vehicle. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: ● Never exceed the weight limits shown. An overloaded vehicle can be unstable. Accessories should be rigidly and securely mounted.
U5UG12.book Page 12 Thursday, June 23, 2005 9:02 AM ● ● ● ● Choose a trailer hitch drawbar designed for use with a 5 cm (2 in) receiver. (See page 4-28 for more information.) Do not exceed the maximum tongue weight. You can measure tongue weight with a bathroom scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height. Adjust the load in the trailer, if necessary, to reduce the weight on hitch.
U5UG12.book Page 13 Thursday, June 23, 2005 9:02 AM WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.
U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU00640 DRIVING YOUR VEHICLE WARNING 1- POTENTIAL HAZARD Not wearing the seat belt. Wearing the seat belt improperly. WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accident. HOW TO AVOID THE HAZARD Always wear your seat belt when riding in the vehicle. Be sure the seat belt is close-fitting across your hips and chest and is latched securely.
U5UG12.book Page 2 Thursday, June 23, 2005 9:02 AM The total weight of operator, passenger, accessories, cargo, trailer tongue weight, and the vehicle itself must not exceed 907 kg (2,000 lb). (See “Loading” on page 6-11.) Carrying a passenger and cargo can affect vehicle handling. WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed. WHAT CAN HAPPEN The passenger could fall or be struck by objects in the cargo bed. HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed.
U5UG12.book Page 3 Thursday, June 23, 2005 9:02 AM The driver and passenger must always wear a seat belt and an approved motorcycle helmet. Also wear eye protection and protective clothing, including over-the-ankle boots, gloves, a long-sleeved shirt or jacket, and long pants. Keep hands and feet inside the vehicle at all times. WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident.
U5UG12.book Page 4 Thursday, June 23, 2005 9:02 AM WARNING 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 POTENTIAL HAZARD Operating this vehicle without wearing an approved motorcycle helmet, eye protection, and protective clothing.
U5UG12.book Page 5 Thursday, June 23, 2005 9:02 AM LEARNING TO OPERATE YOUR VEHICLE You should become familiar with the performance characteristics of the vehicle in a large, flat area that is free of obstacles and other vehicles. Practice control of the accelerator pedal, brakes, steering, and drive select lever. Drive first at slow speed and become comfortable at that speed before gradually increasing your speed.
U5UG12.book Page 6 Thursday, June 23, 2005 9:02 AM Position your hands on the steering wheel so that your thumbs and fingers do not wrap around the wheel. This is particularly important when driving in rough terrain. The front wheels will move right and left as they respond to the terrain, and this movement will be felt in the steering wheel. A sudden jolt could wrench the steering wheel around, and your thumbs or fingers could be injured if they are in the way of the steering wheel spokes.
U5UG12.book Page 7 Thursday, June 23, 2005 9:02 AM BRAKING Braking ability is affected by the type of terrain. In most cases, gradually application of the brakes is more effective than abrupt braking, particularly on loose surfaces like gravel. Always allow for greater braking distance on rough, loose, or slippery surfaces. GOING UPHILL Do not attempt to climb hills until you have mastered basic maneuvers on flat ground. Use proper driving techniques to avoid overturns on hills and slopes.
U5UG12.book Page 8 Thursday, June 23, 2005 9:02 AM Before climbing the hill, first be sure you are operating in low range 4WD or, if necessary, with 4WD Diff. Lock. To climb a hill, you need traction, momentum, and steady throttle. Travel fast enough to keep your momentum going, but not so fast that you cannot react to changes in the terrain as you climb.
U5UG12.book Page 9 Thursday, June 23, 2005 9:02 AM GOING DOWNHILL Check the terrain carefully before going down a hill. When possible, choose a path that lets you drive your vehicle straight downhill. Avoid sharp angles that could allow the vehicle to pitch or roll over. Carefully choose your path and drive no faster than you will be able to react to obstacles that may appear.
U5UG12.book Page 10 Thursday, June 23, 2005 9:02 AM Before starting down hill, make sure the vehicle is in low-range 4WD. On most slopes, this will let you use engine braking to help you go downhill slowly. Go as slowly as possible. If you are starting to go too fast, apply the brakes gently. Avoid sudden application of the brakes, which could cause the vehicle to start sliding. If you are sliding or skidding, try to steer in the direction the vehicle is sliding to help you regain control.
U5UG12.book Page 11 Thursday, June 23, 2005 9:02 AM CROSSING THROUGH SHALLOW WATER If you must cross shallow, slow moving water up to the depth of the vehicle’s floorboards, choose your path carefully to avoid sharp drop-offs, large rocks, or slippery surfaces that could cause the vehicle to overturn. Never operate through water deeper than 33 cm (13 in) or fast flowing water. Wet brakes may have reduced effectiveness. After leaving the water, test your brakes.
U5UG12.book Page 12 Thursday, June 23, 2005 9:02 AM CAUTION: _ After riding your vehicle in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose, the drive select lever box check hose and the V-belt case drain plug. Wash the vehicle in fresh water if it has been operated in salt water or muddy conditions. 1. Air filter case check hose _ 1.
U5UG12.book Page 13 Thursday, June 23, 2005 9:02 AM RIDING OVER ROUGH TERRAIN Operating over rough terrain should be done with caution. Look for obstacles that could cause damage to the vehicle or could lead to a rollover or accident. Avoid jumping the vehicle as injury, loss of control, and damage to the vehicle could occur. WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain.
U5UG12.book Page 14 Thursday, June 23, 2005 9:02 AM RIDING IN BRUSH OR WOODED AREAS When operating in areas with brush or trees, watch carefully on both sides and above the vehicle for obstacles such as branches that the vehicle might hit, causing an accident, or for brush that might enter the vehicle as you pass and strike the driver or passenger. Never hold onto the enclosure so your hand is outside the vehicle. Hold only onto the handgrip inside the enclosure.
U5UG12.book Page 15 Thursday, June 23, 2005 9:02 AM ENCOUNTERING OBSTACLES ON THE TRAIL If you cannot go around an obstacle such as a fallen tree trunk or a ditch, stop the vehicle where it is safe to do so. Set the parking brake and get out to inspect the area thoroughly. Look from both your approach side and the exit side. If you believe you can continue safely, decide the path that will allow you to get over the obstacle at as close to a right angle as possible to minimize vehicle tipping.
U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU00650 PERIODIC MAINTENANCE AND ADJUSTMENT Have a Yamaha dealer perform service if you are not familiar with vehicle service. 1- 1 2 Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner. The most important points of vehicle inspection, adjustment and lubrication are explained on the following pages.
U5UG12.book Page 2 Thursday, June 23, 2005 9:02 AM The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the Owner’s tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts.
U5UG12.book Page 3 Thursday, June 23, 2005 9:02 AM WARNING POTENTIAL HAZARD Operating this vehicle with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of accessories.
U5UG12.book Page 4 Thursday, June 23, 2005 9:02 AM EVU00671 PERIODIC MAINTENANCE/LUBRICATION NOTE: ● For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals. ● For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the vehicle isn’t used for a long period of time, the month maintenance intervals should be followed.
U5UG12.book Page 5 Thursday, June 23, 2005 9:02 AM ITEM Front brake* Rear brake* Accelerator pedal* V-belt* Wheels* Wheel bearings* Front and rear suspension* Steering system* Rear upper and lower knuckle pivots* Drive shaft universal joint* Engine mount* Front and rear axle boots* Stabilizer bushings* Fittings and fasteners* month km (mi) hours Check operation/brake pad wear/fluid leakage/see NOTE page 8-5. Correct if necessary. Replace pads if worn to the limit.
U5UG12.book Page 6 Thursday, June 23, 2005 9:02 AM EVU00680 Hood To open Unhook the hood latches, and then slowly tilt the hood up until it stops. 1. Hood 1.
U5UG12.book Page 7 Thursday, June 23, 2005 9:02 AM To close Lower the hood slowly to its original position, and then hook the hood latches. Secure projections 1 on the underside of the hood into slots 2 on the back of the instrument panel. Secure slots 3 on the side of the hood around projections 4 on the frame. 1. Projection (× 2) 3. Slot (× 2) CAUTION: _ ● ● _ 2. Slot (× 2) 4. Projection (× 2) 8-7 Make sure that all cables and wires are in place when closing the hood.
U5UG12.book Page 8 Thursday, June 23, 2005 9:02 AM EVU00691 Console To remove 1. Remove the seats. (See page 4-20 for seat removal and installation procedures.) 2. Remove the parking brake lever boot. 3. Pull the console upward (the drive select lever boot will come loose). To install 1. Place the console in its original position. 2. Install the parking brake lever boot. 3. Install the seats. CAUTION: _ ● ● _ 1. Console 8-8 When installing the console, be sure not to pinch the cables or wires.
U5UG12.book Page 9 Thursday, June 23, 2005 9:02 AM EVU00700 Engine oil and oil filter cartridge The engine oil level should be checked before each operation. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. NOTE: The engine oil should be between the minimum and maximum level marks. _ _ To check the engine oil level 1. Place the vehicle on a level surface. 2. Remove the console.
U5UG12.book Page 10 Thursday, June 23, 2005 9:02 AM To change the engine oil (with or without oil filter cartridge replacement) 1. Remove the console. (See page 8-8 for console removal and installation procedures.) 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap. 4. Remove the engine oil drain bolt to drain the oil from the crankcase.
U5UG12.book Page 11 Thursday, June 23, 2005 9:02 AM 6. Apply a light coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Make sure the O-ring is seated properly. _ _ 1. Oil filter cartridge 2. Torque wrench 8. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 30 Nm (3.0 m·kgf, 22 ft·lbf) 1. O-ring 7.
U5UG12.book Page 12 Thursday, June 23, 2005 9:02 AM 10. Start the engine and warm it up for several minutes. While warming up, check for oil leakage. If oil leakage is found, turn the engine off immediately and check for the cause. 11. Turn the engine off, and then check the oil level and correct it if necessary. 12. Install the console. Recommended engine oil: See page 10-2. Oil quantity: Without oil filter cartridge replacement: 1.90 L (1.67 Imp qt, 2.01 US qt) With oil filter cartridge replacement: 2.
U5UG12.book Page 13 Thursday, June 23, 2005 9:02 AM EVU00710 Final gear oil Checking the final gear oil level 1. Place the vehicle on a level surface. 2. Remove the oil filler bolt, and then check the oil level in the final gear case. 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. CAUTION: _ Be sure no foreign material enters the final gear case. _ 4.
U5UG12.book Page 14 Thursday, June 23, 2005 9:02 AM Changing the final gear oil 1. Place the vehicle on a level surface. 2. Place a container under the final gear case to collect the used oil. 3. Remove the oil filler bolt and the drain bolt to drain the oil. 5. Add the recommended final gear oil up to the brim of the filler hole. Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.25 L (0.22 Imp qt, 0.26 US qt) CAUTION: _ Be sure no foreign material enters the final gear case. _ 6.
U5UG12.book Page 15 Thursday, June 23, 2005 9:02 AM EVU00721 Differential gear oil Checking the differential gear oil level 1. Place the vehicle on a level surface. 2. Remove the differential gear oil filler bolt and check the oil level. It should be up to the brim of the filler hole. If the level is low, add sufficient oil of the recommended type to raise it to the specified level. CAUTION: _ Be sure no foreign material enters the differential gear case. _ 3.
U5UG12.book Page 16 Thursday, June 23, 2005 9:02 AM Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.32 L (0.28 Imp qt, 0.34 US qt) CAUTION: _ Be sure no foreign material enters the differential gear case. _ 6. Install the differential gear oil filler bolt, and then tighten it to the specified torque. 1. Differential gear oil drain bolt 4. Install the differential gear oil drain bolt, and tighten it to the specified torque.
U5UG12.book Page 17 Thursday, June 23, 2005 9:02 AM EVU00730 Coolant The coolant level should be checked before each ride. Checking the coolant level 1. Place the vehicle on a level surface. 2. Open the hood. (See pages 8-6–8-7 for hood opening and closing procedures.) 3. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level varies with engine temperature. 1. Coolant reservoir cap 2. Maximum level mark 3. Minimum level mark 4.
U5UG12.book Page 18 Thursday, June 23, 2005 9:02 AM EVU00740 Axle boots Check the protective boots for holes or tears. If any damage is found, have them replaced by a Yamaha dealer. CAUTION: _ Mix anti freeze with distilled water only. However, if distilled water is not available, soft water may be used for refilling. _ Changing the coolant The coolant must be changed by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
U5UG12.book Page 19 Thursday, June 23, 2005 9:02 AM 1.
U5UG12.book Page 20 Thursday, June 23, 2005 9:02 AM EVU00750 Spark plug inspection Removal 1. Lift the cargo bed up. (See pages 4-23– 4-26 for cargo bed lifting and lowering procedures.) 2. Remove the spark plug cap. 1. Spark plug wrench 1. Spark plug cap 3. Use the spark plug wrench in the tool kit to remove the spark plug as shown.
U5UG12.book Page 21 Thursday, June 23, 2005 9:02 AM Installation 1. Measure the electrode gap with a wire thickness gauge and, if necessary, adjust the gap to specification. Inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. The ideal color of the porcelain insulator around the center electrode is a medium-tolight tan for a vehicle that is being ridden normally.
U5UG12.book Page 22 Thursday, June 23, 2005 9:02 AM EVU00762 Cleaning the air filter elements Cleaning the intake duct air filter element 1. Remove the air intake duct grill by removing the quick fastener screws. 3. Install the spark plug and tighten it to the specified torque. Tightening torque: Spark plug: 17.5 Nm (1.75 m·kgf, 12.7 ft·lbf) NOTE: If a torque wrench is not available when you are installing the spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight.
U5UG12.book Page 23 Thursday, June 23, 2005 9:02 AM 2. Remove the air filter element from the air intake duct grill by pulling it out as shown. 1. Air filter element 1. Air filter element 5. Install the air filter element into the air intake duct grill. 6. Install the air intake duct grill by installing the quick fastener screws. 2. Air intake duct grill 3. Remove any large particles from the air filter element by hand. 4.
U5UG12.book Page 24 Thursday, June 23, 2005 9:02 AM Cleaning the engine air filter element 3. Remove the air filter case cover by unhooking the holders. 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. _ _ 1. Holder (× 4) 2. Air filter case cover 4. Remove the air filter element. 5. Remove the air filter element from its frame. 1. Air filter case check hose 1.
U5UG12.book Page 25 Thursday, June 23, 2005 9:02 AM 6. Wash the air filter element gently but thoroughly in solvent. WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element. 1. Air filter element 7. Squeeze the excess solvent out of the air filter element and let it dry.
U5UG12.book Page 26 Thursday, June 23, 2005 9:02 AM 9. Thoroughly apply Yamaha foam air filter oil or other quality liquid foam air filter oil (not spray type) to the air filter element. 13. Install the console. 14. Install the seats. NOTE: The air filter element should be cleaned every 20–40 hours. It should be cleaned and lubricated more often if the vehicle is operated in extremely dusty areas.
U5UG12.book Page 27 Thursday, June 23, 2005 9:02 AM EVU00770 V-belt cooling duct check hose The V-belt cooling duct check hose is located under the driver seat. (See page 4-20 for seat removal and installation procedures.) If dust or water collects in the V-belt cooling duct check hose, remove the hose and clean it. CAUTION: _ Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid engine wear and possible engine damage.
U5UG12.book Page 28 Thursday, June 23, 2005 9:02 AM EVU00780 V-belt case drain plug The V-belt case drain plug is located under the driver seat. (See page 4-20 for seat removal and installation procedures.) After riding in water deep enough to allow water to enter the V-belt case, remove the drain plug to drain any water from the case. NOTE: If water drains from the V-belt case after removing the drain plug, have a Yamaha dealer inspect the vehicle as the water may affect other engine parts. _ 1.
U5UG12.book Page 29 Thursday, June 23, 2005 9:02 AM EVU00792 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 1. Tailpipe 2. Spark arrester 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the tailpipe by installing the bolts, and then tighten the bolts to the specified torque. 1. Bolt (× 3) 2. Remove the tailpipe by pulling it out of the muffler. 3.
U5UG12.book Page 30 Thursday, June 23, 2005 9:02 AM EVU00800 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine. WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system WHAT CAN HAPPEN Could injure the eyes.
U5UG12.book Page 31 Thursday, June 23, 2005 9:02 AM EVU00810 Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. _ _ 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Remove the seats. (See page 4-20 for seat removal and installation procedures.) 3. Remove the console.
U5UG12.book Page 32 Thursday, June 23, 2005 9:02 AM EVU00830 Front brake pad check Each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set. NOTE: The wheels need to be removed to check the brake pads.
U5UG12.book Page 33 Thursday, June 23, 2005 9:02 AM EVU00840 EVU00850 Rear brake pad check Each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set. Checking the brake fluid level 1.
U5UG12.book Page 34 Thursday, June 23, 2005 9:02 AM The brake fluid reservoir is located under the hood. (See pages 8-6–8-7 for hood opening and closing procedures.) Observe these precautions: ● When checking the fluid level, make sure 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.
U5UG12.book Page 35 Thursday, June 23, 2005 9:02 AM EVU01220 Checking the brake pedal Have a Yamaha dealer check the brakes at the intervals specified in the periodic maintenance and lubrication chart. There should be no free play in the brake pedal. The brakes should operate smoothly and there should be no brake drag. If the brakes feel soft or spongy, this could indicate air in the brake system. Have a Yamaha dealer check the brake system if necessary.
U5UG12.book Page 36 Thursday, June 23, 2005 9:02 AM EVU00870 Parking brake lever free play adjustment Periodically check the parking brake lever free play and adjust it if necessary. 1. Shift the drive select lever into low gear “L”. 2. Remove the seats. (See page 4-20 for seat removal and installation procedures.) 3. Remove the console. (See page 8-8 for console removal and installation procedures.) 4. Check the parking brake lever free play.
U5UG12.book Page 37 Thursday, June 23, 2005 9:02 AM EVU00880 1. Locknut Brake light switch adjustment The brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1. Open the hood. (See pages 8-6–8-7 for hood opening and closing procedures.) 2. Turn the adjusting nut while holding the brake light switch in place.
U5UG12.book Page 38 Thursday, June 23, 2005 9:02 AM EVU00890 Cable inspection and lubrication WARNING 1. Brake light switch POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently. Replace damaged cables. 2. Adjusting nut 3. Close the hood.
U5UG12.book Page 39 Thursday, June 23, 2005 9:02 AM EVU00900 EVU00910 Brake pedal and accelerator pedal lubrication Lubricate the pivoting parts. Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun.
U5UG12.book Page 40 Thursday, June 23, 2005 9:02 AM EVU00920 EVU00930 Steering shaft lubrication Lubricate the pivot points. Wheel removal 1. Loosen the wheel nuts. 2. Elevate the vehicle and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Recommended lubricant: Lithium-soap-based grease (all purpose grease) 1.
U5UG12.book Page 41 Thursday, June 23, 2005 9:02 AM EVU00940 Wheel installation 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 nut with its tapered side towards the wheel. _ _ 1. Tapered nut 2. Lower the vehicle so that the wheel is on the ground. 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 55 Nm (5.
U5UG12.book Page 42 Thursday, June 23, 2005 9:02 AM EVU00950 Battery This vehicle is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a Yamaha dealer. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children. Antidote: EXTERNAL: Flush with water.
U5UG12.book Page 43 Thursday, June 23, 2005 9:02 AM EVU00960 Battery maintenance 1. When the vehicle is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. CAUTION: _ A special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed-type battery. Using a conventional battery charger may shorten the battery life. 1. Negative battery lead _ 2.
U5UG12.book Page 44 Thursday, June 23, 2005 9:02 AM EVU00970 Fuse replacement The main fuse and the fuse box are located under the hood. (See pages 8-6–8-7 for hood opening and closing procedures.) If a fuse is blown, turn off the main switch and install a new fuse of the specified amperage. If a fuse is blown, replace it as follows. 1. Remove the battery compartment cover by lifting it up and pulling it out.
U5UG12.book Page 45 Thursday, June 23, 2005 9:02 AM Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Signaling system fuse: Carburetor warmer fuse: Four-wheel-drive fuse: Backup fuse: WARNING 30.0 A 15.0 A 10.0 A 10.0 A 10.0 A 10.0 A 3.0 A 10.0 A 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.
U5UG12.book Page 46 Thursday, June 23, 2005 9:02 AM EVU00981 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Lift the hood up. (See pages 8-6–8-7 for hood opening and closing procedures.) 2. Remove the bulb holder cover at the rear of the headlight by pulling it off. 3. Disconnect the headlight coupler by lifting the tab as shown and pulling out the coupler. 1. Headlight coupler 1.
U5UG12.book Page 47 Thursday, June 23, 2005 9:02 AM 4. Remove the headlight bulb holder assembly by turning it counterclockwise. WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it. 1. Headlight bulb holder assembly 5.
U5UG12.book Page 48 Thursday, June 23, 2005 9:02 AM 6. Connect the headlight coupler. 7. Install the headlight bulb holder cover at the rear of the headlight. 8. Close the hood. 1. Do not touch the glass part of the bulb. 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.
U5UG12.book Page 49 Thursday, June 23, 2005 9:02 AM EVU00990 Headlight beam adjustment CAUTION: _ It is advisable to have a Yamaha dealer make this adjustment. _ To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b. 1.
U5UG12.book Page 50 Thursday, June 23, 2005 9:02 AM EVU01000 Tail/brake light bulb replacement If a tail/brake light bulb burns out, replace it as follows: 1. Remove panel A (if replacing the left tail/ brake bulb) or panel B (if replacing the right tail/brake bulb) by removing the quick fasteners and bolts. 1. Panel B 1. Panel A 1. Quick fastener (× 8) 3. Panel A 8-50 2.
U5UG12.book Page 51 Thursday, June 23, 2005 9:02 AM 2. Remove the bulb holder (together with the bulb) by turning it counterclockwise. Tightening torque: Panel bolt: 6.5 N·m (0.65 m·kgf, 4.7 ft·lbf) 1. Tail/brake light bulb holder 3. Push the defective bulb in and turn it counterclockwise to remove it from the bulb holder. 4. Push a new bulb in and turn it clockwise to install in the bulb holder. 5. Install the bulb holder (together with the bulb) by turning it clockwise. 6.
U5UG12.book Page 52 Thursday, June 23, 2005 9:02 AM EVU01010 Troubleshooting Although Yamaha vehicles receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your vehicle requires any repair, take it to a Yamaha dealer.
U5UG12.book Page 53 Thursday, June 23, 2005 9:02 AM EVU01020 Troubleshooting charts Starting problems or poor engine performance 1. Fuel There is fuel. Remove the fuel hose from the fuel pump. No fuel. Supply fuel. Check the fuel flow. No fuel. Fuel pump is clogged. Check if there is fuel in the fuel tank. 2. Compression Use the electric starter to see if there is compression. 3. Ignition There is compression. Compression normal. No compression. Ask a Yamaha dealer to inspect.
U5UG12.book Page 54 Thursday, June 23, 2005 9:02 AM Engine overheating WARNING HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap. POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. Leakage.
U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU01030 CLEANING AND STORAGE CAUTION: 1- _ Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers. A.
U5UG12.book Page 2 Thursday, June 23, 2005 9:02 AM 6. Clean the seats with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may scratch the paint or protective finish. When finished, start the engine and let it idle for several minutes. WARNING POTENTIAL HAZARD Operation with wet brakes after washing.
U5UG12.book Page 3 Thursday, June 23, 2005 9:02 AM EVU01040 B. STORAGE Long term storage (60 days or more) of your vehicle will require some preventive procedures to guard against deterioration. After thoroughly cleaning the vehicle, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or equivalent product. Operate the vehicle for at least 5 minutes to distribute treated fuel through the fuel system. 2.
U5UG12.book Page 4 Thursday, June 23, 2005 9:02 AM 8. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)). NOTE: Make any necessary repairs before storing the vehicle.
U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU01050 SPECIFICATIONS 1- 1 Model YXR66FAV 2 3 Dimensions: Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Starting system Lubrication system 2,885 mm (113.6 in) 1,385 mm (54.5 in) 1,853 mm (73.0 in) 818 mm (32.2 in) 1,910 mm (75.2 in) 280 mm (11.
U5UG12.book Page 2 Thursday, June 23, 2005 9:02 AM Model YXR66FAV Engine oil: Type 0° 10° 30° 50° 70° 90° 110° 130°F YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 -20° Recommended engine oil classification -10° 0° 10° 20° 30° 40° 50°C API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
U5UG12.book Page 3 Thursday, June 23, 2005 9:02 AM Model YXR66FAV Final gear case oil: Type Quantity: Differential gear case oil: Type Quantity: Radiator capacity (including all routes): Air filter: Engine Intake duct Fuel: Type Fuel tank capacity Carburetor: Type/quantity Manufacturer Spark plug: Type/manufacturer Spark plug gap Clutch type: SAE80 API GL-4 Hypoid gear oil 0.25 L (0.22 Imp qt, 0.26 US qt) SAE80 API GL-4 Hypoid gear oil 0.32 L (0.28 Imp qt, 0.34 US qt) 2.50 L (2.20 Imp qt, 2.
U5UG12.book Page 4 Thursday, June 23, 2005 9:02 AM Model Transmission: Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Reverse gear Sub transmission ratio Chassis: Frame type Caster angle Trail Tire: Type Size YXR66FAV V-belt Shaft drive 41/21 × 24/18 × 33/9 (9.544) V-belt automatic Right hand operation 25/17 (1.471) 35/17 (2.058) 28/19 (1.473) low high Steel tube frame 5.0° 26.0 mm (1.
U5UG12.book Page 5 Thursday, June 23, 2005 9:02 AM Model Brakes: System Type YXR66FAV Front and rear unified Dual disc brake Single disc brake Foot operation front rear Operation Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capacity Headlight type: Double wishbone Double wishbone Coil spring/oil damper Coil spring/oil damper 185.
U5UG12.book Page 6 Thursday, June 23, 2005 9:02 AM Model YXR66FAV Bulb voltage, wattage × quantity: Headlight Tail/brake light Indicator lights: Neutral indicator light 12 V 30 W/30.0 W × 2 12 V 5 W/21.0 W × 2 Reverse indicator light Coolant temperature warning light Parking brake indicator light Four-wheel-drive indicator light Differential gear lock indicator light High-range indicator light (special edition models) Low-range indicator light (special edition models) 10-6 12 V 1.
U5UG12.book Page 7 Thursday, June 23, 2005 9:02 AM Model YXR66FAV Specified fuses: Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four-wheel-drive fuse Carburetor warmer fuse Signaling system fuse Backup fuse 30.0 A 15.0 A 10.0 A 10.0 A 3.0 A 10.0 A 10.0 A 10.
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U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU01070 1- MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU01081 YAMAHA MOTOR CORPORATION, U.S.A. SIDE × SIDE VEHICLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha Side × Side vehicles purchased from an authorized Yamaha Side × Side Vehicle 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.
U5UG12.book Page 1 Thursday, June 23, 2005 9:02 AM EVU01090 YAMAHA EXTENDED SERVICE (Y.E.S.
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YAMAHA MOTOR CO., LTD. PRINTED IN USA 2005.07-4.
