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YFZ450W Owner`s Manual

1. 1 Tailpipe 2 Spark arrester 8 4 5 6 Insert the tailpipe into the muffler and align the bolt holes Install the bolt and tighten it Remove the purging bolt 8 29 T gt gt Z DAK 1 Purging bolt 2 Gasket 7 Start the engine and rev it up approximately twenty times while momentarily creating ex haust system back pressure by blocking the end of the muffler with a shop towel 8 Stop the engine and allow the exhaust pipe to cool 9 Install the purging bolt and tighten it EWB01930 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 Never run the engine in an enclosed area Make sure there are no combustible materi als in the area EBU23940 Adjusting the carburetor The carburetor should be checked and if neces sary adjusted at the intervals specified in the peri odic maintenance and lubrication chart The carburetor is an important part of the engine and requires very sophisticated adjustment Therefore most carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sion
2. ceeccsecccsecceeecseeeeeeseeeeeeees 4 14 Adjusting the rear shock absorber assembly csissisceveesiseasteceneessenwesdnvesmaaeienes 4 18 PRE OPERATION CHECKS wscsiisnssicscavaserasiaias 5 1 Pre operation Check list cccecceseeeeneeee 5 1 3E E E cise eee ce oe oe canes snes eee 5 4 ESTING OI cisste cases transe sina suite necteigen anneleveeascatens 5 4 COONAN inte sade nace a a cece EA 5 4 Front and rear brakes cccccesseeeneeeeneees 5 5 Throttle lever scesscetsecceine dt asesterteesoncceenescneven 5 5 Drive chain Sancececaecnencsecenseaseeseateetecectyasecosetes 5 6 DEE EE E E A TA A AE 5 7 Measuring the tire pressure a se 5 8 Tire wear limit soneecessssnsesujasdieecgesseneecssesesee 5 9 Chassis fasteners ccccescccssseeceeeeesneeees 5 9 Instruments lights and switches 5 9 OF ERA TION peer ee ee ne re 6 1 Periodic maintenance chart for the Starting a cold engine ce eeeeeeeeeeeeeeees 6 1 emission control System sesser 8 3 Starting a warm engine seeen 6 3 General maintenance and lubrication SHIFING ecessescesssesesecsessescsesnsessesseneeseen 6 3 chart oes coteeeteesenteneasensaetasettetencaneatente 8 5 Engine break in cceccccecsecesessessesereereeserees 6 5 Removing and installing the panel 8 9 Parking seresa ernai 6 6 Checking the spark plug sirisassssiisessyiis 8 10 Parking on a Slope ceececesesseseecereerereerees 6 6 Engine oil and oil filter elemen
3. EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS EBU17670 Read and understand all of the labels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace mas ment label from your Yamaha dealer 2 2 A WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 5FE 21697 01 2 3 A WARNING Improper ATV use can result in SEVERE INJURY or DEATH SA ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions eon public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For replacement manual call 1 800 532 1558 5FE 21568 01 PREMIUM UNLEADED GASOLINE ONLY A WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN 91 Min Pump
4. 44 Nm 4 4 m kgf 33 ft lbf ECB00080 CAUTION Always tighten the locknut against the adjust ing nut and then tighten it to the specified torque 7 Place the air filter case in the original position connect the air intake duct and then tighten the clamp screw at the carburetor side Install the bolts and then connect the hose Install the seat 8 9 Rebound damping force Turn the adjusting screw in direction a to increase the rebound damping force and thereby harden the damping and in direction b to decrease the rebound damping force and thereby soften the damping 4 22 SS yj AAA 1 Position indicator marks 2 Rebound damping force adjusting screw Rebound damping setting Minimum soft Adjusting screw fully turned out Standard Adjusting screw 1 1 4 turns out from the fully turned in position Maximum hard Adjusting screw fully turned in NOTE gt Make sure that the position indicator marks are aligned when the shock absorber assembly is set to the standard setting Compression damping force 1 Remove the seat See page 4 13 2 Turn the adjusting screw in direction a to in crease the compression damping force and thereby harden the damping and in direction b to decrease the compression damping force and Ne soften the damping 1 Compression damping force adjusting screw 2 Position indicator marks 4 23 Compression damping setting Minimum
5. ceee 8 44 Checking and lubricating the cables 8 44 PERIODIC MAINTENANCE AND MINOR Checking and lubricating the brake and REPAIR 8 1 clutch levers nununununnnunnnnnnnnnunununnnnnununnnnnnnnN 8 45 E EEE EEE EA E E Ghecking and lubreating ine orake and Owner s manual and tool kit seresseeeeen 8 1 shift pedals o i ana anren 8 46 Checking the wheel bearings 8 46 Lubricating the swingarm pivots 8 46 Lubricating the upper and lower arm 6 0 gee eee eee ee ree 8 47 BAHOTY sesmaria ienie nr aada 8 47 Replacing the fuse ccccseeeeeeeeeeeees 8 49 Replacing a headlight bulb 8 50 Adjusting a headlight beam 6 8 52 Replacing the tail orake light bulb 8 52 Removing a wheel cccceeceeeeeeneeeenees 8 52 Installing a wheel ce eeeceeeeseeeeneeeenees 8 53 Troubleshooting sisncenacccinencusccuntmctataceemaedas 8 53 Troubleshooting charts c ccccseeeeeeee 8 55 CLEANING AND STORAGE 9 1 Cleaning sca snniiesiwdnaannbadiimeecestnanenansienebinns tine 9 1 RO Ae EE E E T T 9 2 SPECIFICATIONS scacasancdsdietsvenscnsdsemsneianien 10 1 CONSUMER INFORMATION 008 11 1 Identification numbers s ssesessesenenennnen 11 1 Noise regulation scicutiseccctuisccaciudoncadeciess 11 3 Maintenance record ccsccseseeeeseeeneees 11 4 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY
6. versely across the incline shift into first gear stop the engine apply the parking brake and then block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easily 1 Bring the ATV toa stop by applying the brakes in first gear 2 Stop the engine and release the clutch lever 3 With the rear brake applied apply the parking brake and slowly release the brake pedal 1 Locked position 6 6 EBU20910 Accessories and loading EBU20920 Accessories Accessories can affect the handling and control of your ATV Keep the following in mind when consid ering an accessory or operating an ATV which has accessories Choose only accessories designed for your ATV Your Yamaha dealer has a variety of gen uine Yamaha accessories Other accessories may also be available on the market However it is not possible for Yamaha to test all non Yamaha accessories nor control over their qual 6 7 ity or Suitability Choose a genuine Yamaha ac cessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attach
7. 2500 5000 first mi 200 800 1600 1600 3200 f hours 20 j 80 160 160 e Change e Check ATV for oil leakage and correct if neces y y y sary PN JINE ON TEL EIE e Clean or replace if necessary V Pf vp ment Cooling system and correct if necessary e Replace coolant Every 2 years Moving parts and a Lubricate J cables TES e Check operation and correct if necessary Throttle lever hous e Check throttle cable free play and adjust if neces N J ing and cable sary e Lubricate throttle lever housing and cable Ez i EOREANG Sar DrAKE cheek operation and correct if necessary y y switches e Check operation and correct if necessary e Adjust headlight beams co Lights and switches 8 7 EBU23070 NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas Hydraulic brake service e Regularly check and if necessary correct the brake fluid level e Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 8 8 EWB00010 EBU23180 Panel A Indicates a potential hazard that could result in To remove the panel serious injury or death 1 Remove the seat See page 4 13 BU23080 2 Remove the quick fastener screw and the Removing and installing the panel bolts and then
8. Operating without protective clothing in creases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants 7 5 Protective clothing Goggles Gloves Boots Helmet anrkwWwWNDN Do not operate after consuming alcohol or drugs The operators performance capability is reduced by the influence of alcohol or drugs EWB00930 A WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV 7 6 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 A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and mainte nance p
9. To remove the seat Insert your hand between the rear of the seat and the rear fender pull the seat lock lever upward and pull up the seat at the rear 4 13 1 Seat lock lever To install the seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE Make sure that the seat is securely fitted WHAT CAN HAPPEN The shock absorber assemblies could ex plode causing injury or property damage Cylinder damage could also result in poor handling which could cause an accident HOW TO AVOID THE HAZARD Do not tamper with or attempt to open the cylinder assemblies Do not subject the shock absorber assem blies to an open flame or other high heat Do not deform or damage the cylinders in any way 1 Projection i 2 Seatholder Do not dispose of a damaged or worn out shock absorber assembly yourself Take EBU19000 the shock absorber assembly to a Yamaha Adjusting the front shock absorber dealer for any service assemblies Spring preload 1 Loosen the locknut 2 Turn the adjusting nut in direction a to in crease the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension The spring preload rebound damping and com pression damping forces of the front shock absorb er assemblies can be adjusted to suit the rider s weight and the riding conditions
10. brakes transmission seals and electrical de vices Many expensive repair bills have result 9 1 ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach places Rinse the ATV off immediately with clean wa ter and dry all surfaces with a chamois clean towel or soft absorbing cloth Dry the chain and lubricate it to prevent it from rusting Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy Automotive type wax may be applied to all painted and chrome plated surfaces Avoid combination cleaner waxes Many contain abrasives which may mar the paint or protec tive finish When finished cleaning start the engine and let it idle for several minutes EWB02300 A WARNING POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping abil ity 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 EBU25932 Storage Short term Always store your ATV in a cool dry place and if necessary protect it against dust with a porous cover ECB00720 CAUTION Storing the ATV in a poorly ventila
11. um to light tan the ideal color when the ATV is ridden normally NOTE gt If the spark plug shows a distinctly different color the engine could be operating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and 2 Clean the surface of the spark plug gasket replace it if necessary and its mating surface and then wipe off any grime from the spark plug threads Specified spark plug 3 Install the spark plug with the spark plug NGK CR8E wrench and then tighten it to the specified torque To install the spark plug 1 Measure the spark plug gap with a wire thick Tightening torque ness gauge and if necessary adjust the gap Spark plug Spark plug gap NOTE 0 7 0 8 mm 0 028 0 031 in 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 ER soon as possible 4 Install the spark plug cap 5 Place the fuel tank in the original position and then install the bolt 1 6 Remove the fuel tank cap by turning it coun terclockwise 7 Place the panel in the original position 1 Spark plug gap 8 14 3 1 Projection 2 Slot Install the fuel tank cap by turning it clockwise Install the bolts and the quic
12. 11 2 EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of de sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system e Muffler e Exhaust pipe e Silencer Intake system e Air cleaner case e Air cleaner element e Intake duct 11 3 EBU26080 Maintenance record Copies of work orders and or receipts for parts you purchase and install will be required to document main tenance 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 MAINTENANCE INTERVAL SERVICE NAME AND ADDRESS 320 200 2 1300 800 E D 2500 1600 16 eee 5000 8200 OO OO ee 500 ey l oo oo OO ee 15000 9600 17500 11200 112 20000 12800 128 22500 14400 144 25000 16000 160 E
13. Fuel tank capacity 10 0 L 2 64 US gal 2 20 Imp gal Fuel reserve amount 1 9 L 0 50 US gal 0 42 Imp gal ECB00070 CAUTION Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston 4 10 rings as well as to the exhaust system Your Yamaha engine has been designed to use premium unleaded gasoline with a pump octane number R M 2 of 91 or higher or a research oc tane number of 97 or higher If knocking or pinging occurs use a different brand of gasoline Unlead ed fuel will give you longer spark plug life and re duced maintenance cost Gasohol There are two types of gasohol gasohol contain ing ethanol and that containing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recommended by Yamaha be cause it can cause damage to the fuel system or ATV performance problems EWB00270 A WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and se vere injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed secure
14. Size POTENTIAL HAZARD AT20 x 10 9 Operating this ATV with improper tires or Type with improper or uneven tire pressure Tubeless WHAT CAN HAPPEN The tires should be set to the recommend Use of improper tires on this ATV or opera ed pressure tion of this ATV with improper or uneven tire Recommended tire pressure pressure may cause loss of control increas Front ing your risk of accident 27 5 kPa 4 0 psi 0 275 kgf cm HOW TO AVOID THE HAZARD Rear The tires listed below have been approved 30 0 kPa 4 4 psi 0 300 kgf cm by Yamaha Motor Co Ltd for this model o Check and adjust tire pressures when Other tire combinations are not recom the tires are cold mended e Tire pressures must be equal on both Front sides Manufacturer model DUNLOP KT341 Radial Size AT21 x 7 10 Type Tubeless 5 7 Tire pressure below the minimum speci dirt in the gauge could cause the first reading to be fied could cause the tire to dislodge from incorrect the rim under severe riding conditions Minimum tire pressure Front 24 5 kPa 3 5 psi 0 245 kgf cm Rear 27 0 kPa 3 9 psi 0 270 kgf cm Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 36 psi 2 5 kgf cm Rear 250 kPa 36 psi 2 5 kgf cm 1 Low pressure tire gauge Higher pressures and fast inflation may cause a tire to burst Inflate the tires very set the tire pressure when the t
15. Wait for the bulb to cool before touching or removing it 5 Place a new headlight bulb into position 8 51 1 Do not touch the glass part of the bulb 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 affect ed Thoroughly clean off any dirt and finger prints on the headlight bulb using a cloth moistened with alcohol or thinner 6 Install the headlight bulb holder by pushing it in and turning it clockwise 7 Install the headlight bulb holder cover 8 Connect the headlight coupler e 9 Install the headlight unit by installing the bolts Replacing the tail brake light bulb 10 Adjust the headlight beam if necessary If the tail orake light bulb burns out have a Yamaha dealer replace it EBU25550 Adjusting a headlight beam EBU25650 ECB00690 Removing a wheel CAUTION 1 Loosen the wheel nuts It is advisable to have a Yamaha dealer make Front this adjustment To raise a headlight beam turn the adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b 1 Nut 1 Headlight beam adjusting screw 8 52 1 Nut 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel EBU25670 Installing a wheel 1 Install the wheel and the nut
16. the purchase registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your new ATV please advise us of your new address by sending a postcard listing your ATV model name V I N frame number dealer number or dealer s name as it is shown on your warranty card your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 Attention Warranty Department This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law EBU26122 YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service Y E S e Y E S is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction You get uninterrupted factory backed coverage for extra peace of mind e Y E G is flexible You choose the plan that s right for you 12 months 24 months or 36 months beyond your warranty period e Y E S is designed and administered by the same Yamaha people who handle your warranty and it shows in the comprehensive coverage benefits There are no mileage limitations Coverage isn t limited to moving parts or the drive train like many other plans And Y E S covers manufacturing defects just like the warranty See the sample contr
17. turn the handlebars in the desired direction As you do so put your weight on the footboard to the out side of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly 7 1 Lean towards inside of turn 2 Support your weight on the outer footrest This procedure should be practiced at slow speed many times in a large off road area with no obsta cles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the proce dure again If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter 7 18 curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body move ments 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 out side of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the o
18. EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN JURY OR DEATH Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury WARNING or death to the ATV operator a bystander or a person inspecting or repairing the ATV A CAUTION indicates special precautions that must be taken to avoid CAUTION damage to the ATV NOTE A NOTE provides key information to make procedures easier or clearer Product and specifications are subject to change without notice 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 EBU17381 YFZ450W OWNER S MANUAL 2006 by Yamaha Motor Corporation U S A 1st edition April 2006 AFFIX DEALER All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly proh
19. EE 4 9 Fuss FSI ACING sessirnar sodnar erani 8 49 Handlebar SWHCNESivccctecnsenicrntletdsensuesmenieentdesnensaesanbenese 4 3 Headlight beam adjusting sseseseeneseeeeneneeeeerrnreeeen 8 52 Headlight bulb replacing aisesacncscndeninactndtavecendeateacsainew 8 50 Identification numbers s casseiivoncnsdeccenceseetwensnerectnenvadetres 11 1 Indicator light and warning light seeseseseseesesseeeerrerssseen 4 2 Instruments lights and switches eeeeeeeeeeeeeeeeee 5 9 K Shock absorber assemblies adjusting the front 4 14 Key identification NUMDET c ccccccccceeessseeeeeeessrseees 11 1 Shock absorber assembly adjusting the rear 4 18 L Spark arrester CICANING cccsseceeceeeesseeeeeeeeesseeeeees 8 28 Label IOGAT OMS asiendata arretir 2 1 Spark plug CHECKING eee eee 8 10 PTGS e eee oe tgca cece sauteed EE EAT E EEEE 4 3 SPECIFICATIONS eect naaa se 10 1 M Speed limiter ee cccecsseseeeeeceeessseeeeceeesseeeeeeeessseeeeeees 4 4 Main NE ere N 4 1 Starter CNOKE ss sesseseeseestees tes eeseteseteteeneetteteeneeettens 4 12 Maintenance and lubrication Chart cccccccccccececeeeee 8 5 Start switch ceccinavineanodsaacapnesceccienoasscanduancaedtadtaseceasdennntncaacaeoe 4 3 Maintenance chart emission control system EESE 8 3 Storage ante Bases E duabae tana acide 9 2 Maintenance record secistcssciscisncscateveasinccwaduonsstiseenvacwuasies 1
20. EWBO00360 POTENTIAL HAZARD These shock absorber assemblies contain highly pressurized nitrogen gas 4 14 0 06 in n D Y Spring preload setting Minimum hard Distance A 246 5 mm 9 7 in Standard L7 Distance A 255 mm 10 0 in Maximum soft Distance A 261 5 mm 10 3 in DO Ry SHRP PS x SAY SS A gt C W LXX 1 Spring preload adjusting nut 2 Locknut 3 Special wrench gt lt pae A la wW Z NOTE gt A special wrench can be obtained at a Yamaha dealer to make this adjustment The spring preload setting is determined by measuring distance A shown in the illustration S The shorter distance A is the higher the spring T preload the longer distance A is the lower the 1 Distance A spring preload With each complete turn of the adjusting nut distance A is changed by 1 5 mm AA S Se 72 Irs aD 4 15 y 7 rT 3 Tighten the locknut to the specified torque Tightening torque Locknut S 2 30 Nm 3 0 m kgf 22 ft lbf ECB00080 b CAUTION Always tighten the locknut against the adjust O ing nut and then tighten it to the specified XK torque 1 Rebound damping force adjusting screw N N Jr a eo N US a A b Rebound damping force Turn the adjusting screw in direction a to increase the rebound damping force and thereby harden Rebou
21. HAZARD Suspension components become hot during operation WHAT CAN HAPPEN You could be burned EWB00350 A WARNING POTENTIAL HAZARD Improper shock absorber assembly adjust ment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Never touch the compression damping force adjusting screw rebound damping force ad justing screw or oil reservoir with your bare HOW TO AVOID THE HAZARD Always adjust the shock absorber assem blies on the left and right side to the same hand or skin until suspension components setting have cooled EBU19110 Adjusting the rear shock absorber assembly The spring preload rebound damping and com pression damping forces of the rear shock absorb er assembly can be adjusted to suit the riders weight and the riding conditions 4 18 EWB00380 A WARNING POTENTIAL HAZARD This shock absorber assembly contains highly pressurized nitrogen gas WHAT CAN HAPPEN The shock absorber assembly could ex plode causing injury or property damage Cylinder damage could also result in poor handling which could cause an accident HOW TO AVOID THE HAZARD O Do not tamper with or attempt to open the cylinder assembly Do not subject the shock absorber assem bly to an open flame or other high heat Do not deform or damage the cylinder in any way Do not dispose of a damaged or worn out shock ab
22. POSTAGE NECESSARY IF MAILED IN THE UNITED STATES
23. Review this IMPORTANT SAFETY CARD before operating your ATV If card is not attached call 1 800 344 6418 Dear New Yamaha ATV Owner CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV You have purchased a quality Yamaha product that with proper use and care will provide hours of riding pleasure BEFORE YOU OPERATE YOUR NEW ATV Yamaha recommends these important points READ YOUR OWNER S MANUAL A CHILD UNDER 6 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 50CC OR GREATER A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER THAN 90CC TAKE THE FREE HANDS ON TRAINING COURSE OFFERED BY YAMAHA ASK YOUR DEALER FOR DETAILS OR CALL 1 800 887 2887 If you have any questions about these points or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership please fill out the information below and mail this card to yamaha today Name ATV Model Purchase Date Lo o MO DAY YR Address Primary I D Engine Number E i w J E Tt dI AT t 4 Dealer Name amp Address Telephone CAREFULLY READ BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 4 CYPRESS CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U S A P O BOX 6555 CYPRESS CALIFORNIA 90630 9989 ATTN SALES ADMINISTRATION NO
24. THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding Loss of control which could cause an acci ECBO00150 dent or injury HOW TO AVOID THE HAZARD CAUTION Read the Owner s Manual carefully If there is See the Engine break in section on page 6 5 a control or function you do not understand prior to operating the engine for the first time ask your Yamaha dealer a Suaepaanesee a SSS Set the parking brake 2 Turn the fuel cock to ON 3 Turn the main switch to ON and the engine stop switch to RUN 4 Shift the transmission into neutral The neutral indicator light should come on If the indicator 6 1 light does not come on have a Yamaha deal er check the electrical circuit NOTE gt This model is equipped with an ignition circuit cut off system The engine can be started under the following conditions The transmission is in neutral The clutch is disengaged with the transmission in gear However it is recommended to shift into neutral before starting the engine BEM 5 Use the starter choke in reference to the fig ure Position 1 Cold engine start with ambient temperature be low 5 C 40 F Position 2 Cold engine start with ambient temperature be tween 0 C 30 F and 30 C 90 F Position 3 Cold engine start with ambient temperature above 25 C 80 F 6 2 A
25. acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Not recommended for children under 16 years of age EWBO0901 POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not recom mended for their age can lead to severe inju ry or death of the child 7 3 HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc This ATV is designed to carry operator only passengers prohibited EWB00910 A WARNING POTENTIAL HAZARD Carrying a passenger on this ATV WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passen ger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying pas Apparel sengers EWB00920 POTENTIAL HAZARD Operating this ATV without wearing an ap proved motorcycle helmet eye protection and protective clothing 7 4 WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an acci dent Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident
26. before each ride and adjusted if necessary To check the drive chain slack 1 Place the ATV ona level surface NOTE When checking and adjusting the drive chain slack there should be no weight on the ATV and all tires must be touching the ground 2 Move the ATV back and forth to locate the tightest portion of the drive chain and then measure the drive chain slack as shown Drive chain slack 25 0 35 0 mm 0 98 1 38 in 8 42 3 Drive chain slack If the drive chain slack is incorrect adjust it as follows To adjust the drive chain slack 1 2 Loosen the rear axle pinch bolts Insert a rod of a diameter of 8 mm and a length of 10 cm into one of the holes in the drive chain tensioner as shown 1 Rear wheel axle pinch bolt 2 Rod 3 Drive chain tensioner 8 4 Hole NOTE gt gt A rod can be obtained at a Yamaha dealer to make this adjustment 3 4 ECB00541 CAUTION Improper drive chain slack will overload the en gine as well as other vital parts of the ATV and can lead to drive chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 5 Pull the rod out and then tighten the rear axle pinch bolts to the specified torque in the order shown Shift the transmission into neutral To tighten the drive chain push the ATV back ward To loosen the drive chain push the ATV Tightening torque forward Rear axle
27. km 320 1300 2500 2500 5000 first mi 200 800 1600 1600 3200 e Check for leakage and replace gasket s if neces 7 sary EXNAUStEYSIEM e Check for looseness and tighten all screw clamps y y and joints if necessary 7 Spark arrester Clean aa 8 4 EBU21862 General maintenance and lubrication chart INITIAL EVERY CHECK OR MAINTENANCE Whichev monn 1 3 e 6 12 mi 200 800 1600 1600 3200 hours 20 80 160 160 320 Every 20 40 hours more often in wet or Air filter element e Clean and replace if necessary dusty areas Clutch e Check operation and adjust if necessary e Check operation and correct if necessary e Check fluid level and ATV for fluid leakage and correct if necessary e Replace brake pads Whenever worn to the limit e Check operation and correct if necessary e Check brake lever free play and adjust if neces sary y y y y y Rear brake e Check fluid level and ATV for fluid leakage and correct if necessary Front brake e Replace brake pads Whenever worn to the limit e Check for cracks or other damage and replace if r J J F Brake hoses necessary Every 4 years Parking brake e Check operation and adjust if necessary ON e Check runout and for damage and replace if nec J J a J essary e Check tread depth and for damage and replace if necessary af af af af e Check air pressure and balance
28. lever NOTE gt The ATV you have purchased may differ slightly 3 2 from the figures shown in this manual EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 Indicates a potential hazard that could result in serious injury or death EBU17740 Main switch The positions of the main switch are as follows ON All electrical systems are supplied with power and the engine can be started The key cannot be re moved OFF All electrical systems are off The key can be re moved 4 1 1 Main switch OFF i ON x 1 EBU17802 Indicator light and warning light 1 Neutral indicator light N 2 Coolant temperature warning light _F 7 AN EBU17860 Neutral indicator light N This indicator light comes on when the transmis sion is in the neutral position EBU17930 Coolant temperature warning light E This warning light comes on when the engine over heats When this occurs during operation stop the engine as soon as it is safe to do so and allow it to cool down for about 10 minutes 4 2 The electrical circuit of the warning light can be checked according to the following procedure 1 Setthe engine stop switch to and turn the key to ON 2 Shift the transmission into the neutral position or pull the clutch lever 3 Push the start switch If the warning light does not come on while the start switch is pushed have a Yamaha dealer check the elec
29. maintain proper balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that the ATV is going to tip over dismount on the uphill side See page 7 18 If your ATV encounters shallow water 7 29 Ride slowly and carefully through slow moving water watching for obstacles Be sure to let wa ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability See page 7 24 EWBO00010 WARNING Indicates a potential hazard that could result in serious injury or death EBU21641 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21660 Safety is an obligation of the owner Periodic in spection adjustment and lubrication will keep your ATV in the safest and best operating condition possible The most important points of inspection adjustment and lubrication are explained on the following pages The intervals given in the periodic maintenance and lubrication chart should be considered as a general guide under normal riding conditions However DEPENDING ON THE WEATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED EWB01820 POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury E
30. 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 7 14 Do not ride in areas posted no trespassing Do not ride on private property without getting per mission EWB01060 7 A WARNING Select a large flat area off road to become familiar ce POTENTIAL HAZARD with your ATV Make sure that this area is free of ar bstacles and other riders You should practice Operating in areas wher might not be B _ bi i by i eroii ee y Sa aaa control of the throttle brakes shifting procedures WHAT CAN HAPPEN and turning techniques in this area before trying y i llision Y ae more difficult terrain Always avoid riding on paved oy come re Nea colciom recount surfaces the ATV is designed for off road use only and handling maneuvers are more difficult to perform on pavement Set the parking brake 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 As you get on the ATV be sure not to accidentally move jured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch carefully for other vehicles 7 15 the shift pedal Remember that the engine and ex haust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling pull the clutch lever to dis engag
31. over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper pro cedures as described in the Owner s Manual SLIDING AND SKIDDING Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help 7 27 If the rear wheels of your ATV start to slide side ways 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 7 aa With practice over a period of time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are re duced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost EWB01170 POTENTIAL HAZARD Skidding or sliding improperly 7 28 WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extrem
32. pinch bolt 21 Nm 2 1 m kof 15 2 ft lbf 8 43 EBU24880 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows 1 O rings ECB00560 CAUTION The drive chain must be lubricated after wash ing the ATV or riding in the rain 1 Clean the drive chain with kerosene and a 8 44 small soft brush ECB00570 CAUTION To prevent damaging the O rings do not clean the drive chain with steam cleaners high pres sure washers or inappropriate solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECB00580 CAUTION Do not use engine oil or any other lubricants for the drive chain as they may contain sub stances that could damage the O rings EBU24890 Checking and lubricating the cables The operation and the condition of all control ca bles should be checked before each ride and the cables and cable ends should be lubricated if nec essary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it Recommended lubricant Engine oil EWB02120 Brake lever A WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged and cabl
33. play 3 Tighten the locknut EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the inter vals specified in the periodic maintenance and lu brication chart EBU24130 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic main tenance and lubrication chart EBU27711 Front brake pads 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 indica tor grooves If a brake pad has worn to the point that the wear indicator grooves are almost in con tact with the disc plate have a Yamaha dealer re place the brake pads as a set 8 32 1 Wear indicator groove NOTE The wheels need to be removed to check the brake pads See page 8 52 EBU27721 Rear brake pads 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 indica tor grooves If a brake pad has worn to the point that the wear indicator grooves are almost in con tact with the disc plate have a Yamaha dealer re place the brake pads as a set 1 Wear i
34. remove the panel by pulling it out from the front of the ATV The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time the panel needs to be removed and installed ae aati Y EA OR So KEE 1 Quick fastener screw 2 Bolt 1 Panel A 8 9 To install the panel 1 Place the panel in the original position and then install the quick fastener screw and the bolts 1 Projection 2 Slot 2 Install the seat EBU23231 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 accor 8 10 dance with the periodic maintenance and lubrica tion chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the seat See page 4 13 2 Remove the bolts and the quick fastener screws shown 3 Remove the fuel tank cap by turning it coun terclockwise 8 11 1 Panel 2 Bolt 3 Quick fastener screw 4 Fuel tank cap EWB01860 POTENTIAL HAZARD Improper handling of gasoline WHAT CAN HAPPEN Gasoline can catch fire and you could be burned HOW TO AVOID THE HAZARD Always turn off the engine before removing FN the fuel tank cap LE J Do not remove the fuel tank cap immed
35. soft Adjusting screw fully turned out Standard Adjusting screw 1 3 4 turns out from the fully turned in position Maximum hard Adjusting screw fully turned in ECB00090 CAUTION Never turn an adjusting mechanism beyond the minimum and maximum settings NOTE gt Make sure that the position indicator marks are aligned when the shock absorber assembly is set to the standard setting 3 Install the seat EWB00370 A WARNING POTENTIAL HAZARD Suspension components become hot during operation WHAT CAN HAPPEN You could be burned HOW TO AVOID THE HAZARD Never touch the compression damping force adjusting screw rebound damping force ad justing screw or oil reservoir with your bare hand or skin until suspension components have cooled EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death 4 24 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 gt 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 5 Yamaha dealer e Check fuel level in fuel tank and add recommended fuel if neces sary 4 9 5 4 e Check fuel line for leakage Correct if necessary e Check oil level in engine an
36. time of sale and upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain effective CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha ATV dealer within the continental United States Be sure to bring your warranty registration card or other valid proof of the original date of purchase If a question or problem arises regarding warranty first contact the owner of the dealership Since all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model V I N frame number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and recall This list is compiled from
37. to overfill the en gine oil tank the oil level rises faster starting from the half level portion on the dipstick 6 Insert the dipstick into the engine oil tank filler hole and then tighten the engine oil tank filler cap ECB00360 CAUTION Make sure that the engine oil tank filler cap is securely tightened otherwise oil may seep out when the engine is running To change the engine oil with or without oil filter element replacement 1 Place the ATV on a level surface 2 Remove the engine guard by removing the bolts r D 1 Engine guard 1 Crankcase engine oil drain bolt 2 Bolt 6 Remove the engine oil tank filler cap and the 8 3 Start the engine warm it up for several min engine oil tank drain bolt utes and then turn it off 4 Place an oil pan under the engine to collect the used oil 5 Remove the crankcase engine oil filler cap and the crankcase engine oil drain bolt 8 17 1 Engine oil tank drain bolt 7 Check the washers for damage and replace if necessary NOTE Skip steps 8 11 if the oil filter element is not being replaced 8 Remove the oil filter element cover by remov ing the bolts and then remove the oil filter el ement 8 18 1 Oil filter element cover 2 Bolt 9 Check the O rings for damage and replace them if necessary ES 1 Oil filter element 2 O ring Eg 10 Install a new oil filter element and the O rings NOTE Make sure that the O rin
38. 0 Adjusting the clutch lever free play 8 The clutch lever free play must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart The clutch lever free play should measure 8 0 13 0 mm 0 31 0 51 in as shown If the free play is incorrect adjust it as follows 8 40 1 Clutch lever free play 2 Clutch lever free play adjusting bolt l 2 A Loosen the locknut at the clutch lever To increase the clutch lever free play turn the adjusting bolt at the clutch lever in direction a and to decrease it turn the bolt in direction b Tighten the locknut at the clutch lever If the specified free play cannot be obtained proceed with the following steps Loosen the locknut at the clutch lever Fully turn the adjusting bolt at the clutch lever in direction a to loosen the clutch cable Loosen the locknut at the crankcase 7 To increase the clutch lever free play turn the adjusting nut at the crankcase in direction a and to decrease it turn the nut in direction b 1 Locknut 2 Clutch lever free play adjusting nut crankcase 8 Tighten the locknut at the crankcase and the clutch lever NOTE gt If the specified free play cannot be obtained as de scribed above or if the clutch does not operate cor rectly have a Yamaha dealer check the internal clutch mechanism EBU26860 Drive chain slack The drive chain slack should be checked
39. 1 4 Suspension lubricating the upper and lower arm CAE E E E 11 2 eae i S alas tae aise cael N Swingarm pivots lubricating cceceeeeeeeeeeeeeneeeeeees 8 46 Neutral indicator HONU sensies 4 2 T l l l Noise regulation ccccccssssssessesessessessessesseseeseusensneas 11 3 Tail brake light bulb replacing seseseeereeteetees 8 52 O Throttle cable free play AGjUSTING ccccsseeseeeeeeeees 8 30 Gummer E TT eee i ce 8 1 Throttle FS Clas eceesteace etter ieeeeeeneeeeeieeneeneaeenie 4 3 5 5 P Tire pressure MEASUFING ccceceeeeeeeceeeeeeeteeeeeeeeeees 5 8 E E A E A A E 5 7 Panel removing and installing c cceeeeeeeeeeeeeeeees 8 9 tet Tire wear limit ocpcsstesseccenndaeseancace teas taniviaudenesandecvuscweieeasideeds 5 9 FUN aera ee eee 6 6 ees WW FOUISSHOOUNG secsoneeeceactactenueenoctancanseactassemupstoesauteaatadads 8 53 Parking brake free play ACjUSTING c0ccceceeeeeeeeees 8 38 Troubleshooting Charts ccatsatine tte voce teeenceviaeterncteyredacteriecs 8 55 Parking brake lever vice 2ce22encecessessewneosanedsacmner teense ecteoven ae 4 7 Parking O A SOC oie esas cece seg dah pad ac eee dca upeocentennt 6 6 V Part locations 3 1 NU MINS GS UMA A ct sctiee ce eect sagan aeceae neceectencatteened 8 31 Pre operation o ote oe hace eter toe ote orcs 5 4 Vehicle identification NUMbET cceeteteeteeeeee 11 1 sn ree eee w mT Warranty extended ise viii ccicane
40. 11 5 YAMAHA EXTENDED SERVICE YES cccccscssecscsssssesessessessesesssseseseeseeecen EBU17430 4d SAFETY INFORMATION EBU17571 AN ATV IS NOT A TOY AND CAN BE HAZARD OUS 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 SEVERE INJURY OR DEATH can result if you do not follow these instructions Read this manual and all labels carefully and fol low the operating procedures described Never operate an ATV without proper training or instruction Take a Training Course Beginners should receive training from a certified instruc tor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you Always follow the age recommendation A child under 16 years old should never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and streets Never operate an ATV on any public street road or highway even a dirt or gravel one Never ope
41. BU26501 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 sub ject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha ATVs shall be six 6 months from the date of purchase DURING THE PERIOD OF WARRANTY any authorized Yamaha ATV dealer will free of charge repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corp U S A GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Competition or racing use b Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse Lack of proper maintenance Accident or collision damage Modification to original parts Damage due to improper transportation Q 4 0 AO SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance such as spark plugs oil oil filter air filter and brake shoes THE CUSTOMER S RESPONSIBILITY under this war ranty sh
42. C magneto Battery Model GT7B 4 Voltage capacity 12 V 6 5 Ah Headlight Bulb type Krypton bulb Bulb voltage wattage x quantity Headlight 12 V 30 0 30 0 W x 2 Tail brake light 12 V 0 5 3 9 W x 1 Neutral indicator light 12V 1 7Wx1 Coolant temperature warning light 12V 1 7Wx1 Fuses Main fuse 15 0A 10 4 EBU25981 CONSUMER INFORMATION EBU2601 1 Identification numbers Record the key identification number vehicle iden tification number and model label information in the spaces provided below for assistance when or dering spare parts from a Yamaha dealer or for ref erence in case the ATV is stolen KEY IDENTIFICATION NUMBER a VEHICLE IDENTIFICATION NUMBER a MODEL LABEL INFORMATION 11 1 EBU26020 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 1 Key identification number EBU26030 o Vehicle identification number The vehicle identification number is stamped into the frame 1 Vehicle identification number 1 Model label NOTE The vehicle identification number is used to identi fy your ATV EBU26050 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha deal er
43. Circuits 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 Specified fuse 15 0 A EWB02151 a WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rating Never use a material in place of the proper fuse 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU25430 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the headlight unit by removing the 1 Headlight bulb holder cover 2 Headlight coupler 4 Remove the headlight bulb holder by pushing it in and turning it counterclockwise and then remove the defective bulb 1 Headlight assembly 2 Bolt 2 Disconnect the headlight coupler 3 Remove the headlight bulb holder cover 8 50 O 1 Headlight bulb holder EWB02180 a WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and im mediately 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
44. Octane R M 2 CAUSE LOSS OF CONTROL SPW 2415E 11 LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires cold e Recommended FRONT 27 5kPa 0 275kgf cm 4 0 psi REAR 30kPa 0 30kgf cm 4 4psi Minimum FRONT 24 5 kPa 0 245kaf cm 3 5psi REAR 27kPa 0 27kgf cm 3 9psi Never set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING e Maximum Vehicle Load 100kg 220lbs Includes weight of operator cargo and accessories 5TG 21696 30 A WARNING NEVER ride as a passenger Passengers can cause SN AWARNING __ resulting in SEVERE A WARNING INJURY or DEATH This unit contains high pressure nitrogen gas Mishandling can cause explosion 5FE 2151H 01 Read owner s manual for instructions Do not incinerate puncture or open 4AA 22259 80 2 4 EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view RG 3 on R Ti SIA j AG OP ji Headlights Fuel cock Starter choke Throttle stop screw Fuse Tail brake light Coolant reservoir Shift pedal Engine oil tank Spark arrester Seat Fuel tank cap Radiator cap Oil filter element Brake pedal OMONDOAR WD oOahwond 3 1 EBU17712 Controls and instruments 1 2 4 5 6 1 Clutch lever 2 Handlebar switches 3 Parking brake 4 5 6 Main switch Throttle lever Brake
45. Thirty 30 months from the original purchase date YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION U S A AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 gt O gt O gt O gt O O WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period 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 What are some examples of abnormal strain neglect or abuse These terms are general and overlap each other in areas Specific examples include Running the machine
46. YAMAHA EBU17170 INTRODUCTION EBU17300 Congratulations on your purchase of the Yamaha YFZ450W This ATV represents the result of many years of Yamaha experience in the production of fine sporting touring and pacesetting 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 This manual will provide you with a good basic understanding of the features and operation of this ATV This manual includes important safety information It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETE LY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV CALL 1 800 887 2887 FOR MORE INFORMA TION THIS ATV AND ANY OTHER ATV OVER 90 cc SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE THIS ATV IS A HIGH PERFORMANCE ATV FOR OFF ROAD USE ONLY FOR SPORT TYPE REC REATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS
47. Yamaha dealer Brake fluid level Check the brake fluid level Add fluid if necessary See page 8 33 Recommended brake fluid DOT 4 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or master cylinder Apply the brakes firmly for one minute If there is any leaking have the ATV checked by a Yamaha dealer 5 5 Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance check the brake pads for wear See page 8 32 EWB00530 a WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any prob lem with the brakes If a problem cannot be corrected by the adjustment procedures pro vided in this manual have the ATV checked by a Yamaha dealer EBU19761 Throttle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU19770 Drive chain Check the condition of the drive chain and check the drive chain slack Lubricate and adjust the drive chain as necessary See page 8 42 5 6 EBU19781 k Rear Tires HOPA Manufacturer model DUNLOP KT355A Radial
48. act at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be e You don t have to pay anything for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs e n addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period e Y E S coverage is honored at any authorized Yamaha dealer nationwide e Y E S coverage is transferable to a new owner if you sell or trade in your ATV That can make your Yamaha much more valuable This excellent Y E S plan coverage is only available to Yamaha owners like you and only while your Yamaha is still within the Yamaha Limited Warranty period So visit your authorized Yamaha dealer to get all the facts He can show you how easy it is to protect your investment with Yamaha Extended Service 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 fa
49. al knowledge and experience The adjustment 8 30 described in the following section however may be performed by the owner as part of routine main tenance ECB00480 CAUTION The carburetor has been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor performance of or damage to the engine EBU24030 Checking the engine idling speed A special tester is needed to check the engine idling speed on this model Therefore take the ATV to a Yamaha dealer to have the engine idling speed checked and adjust ed Engine idling speed 1750 1850 r min EBU24043 Adjusting the throttle cable free play The throttle cable free play should be checked and if necessary adjusted at the intervals speci fied in the periodic maintenance and lubrication chart The throttle cable free play should measure 2 0 4 0 mm 0 08 0 16 in at the throttle lever Period ically check the throttle cable free play and if nec essary adjust it as follows NOTE gt The engine idling speed must be checked and ad justed if necessary before adjusting the throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting bolt in direction a To decrease the throttle cable free play turn the adjusting bolt in direction b 1 Locknut 2 Throttle cable free play adjusting bolt 3 Throttle lever free
50. all be to 1 Operate and maintain the ATV as specified in the appropriate owner s manual 2 Give notice to an authorized Yamaha ATV dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealers place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation USA also warrants to the ultimate purchaser and each subsequent pur chaser of each 2006 and later model Yamaha ATV covered by this warranty that the vehicle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the period listed immediately below Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and or lack of proper maintenance are not covered by this warranty All Models
51. and correct if necessary ho e Parking brake INITIAL INTIAL CHECK OR MAINTENANCE Whichev pmonth 1 3 6 6 12 JOB er comes 320 1300 2500 2500 5000 first EA 200 800 1600 1600 3200 gt e Check for looseness or damage and replace if nh a Eana e Check P and for excessive play and Swingarm pivots replace bearings if necessary L L e Lubricate with molybdenum disulfide grease safe Upper and lower e Lubricate with lithium soap based grease arm pivots e Check chain slack and adjust if necessary Drive chain e Check rear wheel alignment and correct if necess sary pl omen e Clean and lubricate 18 Drive chain rollers Check for wear and replace if necessary amine e een properly tightened 15 assemblies Oneok forol leakage and enlace f necessary assemblies e Check for oil leakage and replace if necessary Rear suspension relay arm and con e Check operation and correct if necessary L necting arm pivot e Lubricate with lithium soap based grease ing points 17 Steering shaft e Lubricate with lithium soap based grease e Check operation and repair or replace if s oat bab Steering system e Check toe in and adjust if necessary e Check for cracks or other damage and replace if j r r necessary HH EIRE EIRE INITIAL EVERY CHECK ORMAINTENANCE Whichev month 1 3 6 6 12 JOB ercomes km 320 1300 2500
52. arm pivots must be lubricated at the intervals specified in the periodic mainte nance and lubrication chart Lubricate the pivoting points using a grease gun Recommended lubricant Lithium soap based grease Left side 1 Upper grease nipple 2 Lower grease nipple 8 47 Right side 1 Upper grease nipple 2 Lower grease nipple EBU25212 Battery This model is equipped with a sealed type MF battery which does not require any maintenance There is no need to check the electrolyte or to add distilled water Check and if necessary tighten the battery lead connections ECB00620 CAUTION Never attempt to remove the battery cell seals as this would permanently damage the battery EWB02140 WARNING POTENTIAL HAZARD Failure to handle batteries or battery electro lyte carefully WHAT CAN HAPPEN You could be poisoned You could be severe ly burned by the sulfuric acid in battery elec trolyte Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Al ways shield eyes when working near batter ies Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical at tention EYES Flush with water for 15 minutes and get prompt medical attention Keep batteries away from sparks flames cigarettes or other sources o
53. at the brake pedal position is cor rect 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 EBU24700 Adjusting the parking brake free play The parking brake free play must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart Cable length A should measure 47 51 mm 1 9 2 0 in Adjust the parking brake free play as fol lows 8 38 oO D Ln op 1 Adjusting bolt 2 Cable length A 3 Locknut 1 2 Release the parking brake by moving the ER parking brake lever to the right Fully loosen the locknut and the adjusting bolt at the rear brake caliper Loosen the locknut on the brake cable Turn the adjusting nut on the brake cable in di rection a to increase the cable length and in direction b to decrease it together with the locknut ome a _ 2P ox 6 SA a a ta Tightening torque Locknut rear brake caliper 21 Nm 2 1 m kof 15 2 ft lbf EWB02030 A WARNING E POTENTIAL HAZARD vou 4 Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN 1 Locknut eee eee The brakes could malfunction causing re 2 Adjusting nut A ak duced braking performance This could in crease
54. bles and the pivoting points of all levers and pedals Check and if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative ly turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot Cover the muffler outlet with a plastic bag to prevent moisture from entering it Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in 9 3 formation on storing the battery see page 8 47 NOTE gt Make any necessary repairs before storing the ATV EBU25960 SPECIFICATIONS EBU25975 Compression ratio Dimensions 11 40 1 Overall length Starting system 1840 mm 72 4 in Electric starter Overall width Lubrication system 1170 mm 46 1 in Dry sump Overall height Engine oil 1090 mm 42 9 in Type Seat height YAMALUBE 4 SAE5W30 or SAE10W30 or SAE20W40 810 mm 31 9 in Wheelbase 0 10 30 50 70 90 110 130 F 1280 mm 50 4 in Ground clearance 255 mm 10 0 in YAMALUBE 4 20W40 or SAE 20W40 Minimum turning radius 3 e 3500 mm 138 in YAMALUBE 4 10W30 or SAE 10W30 Weight l With oil and fuel JAE aves 169 0 kg 373 Ib 20 10 0 10 20 30 40 50 C Engine Eng
55. buretor 25 16 1 562 Manufacturer Ath KEIHIN 23 18 1 277 10 2 5th 21 20 1 050 Chassis Frame type Steel tube frame Caster angle 5 0 Trail 21 0 mm 0 83 in Front tire Type Tubeless Size AT21 x 7 10 Manufacturer model DUNLOP KT341 Radial Rear tire Type Tubeless Size AT20 x 10 9 Manufacturer model DUNLOP KT355A Radial Loading Maximum loading limit 100 0 kg 220 Ib Total weight of rider cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 27 5 kPa 4 0 psi 0 275 kgf cm Rear 30 0 kPa 4 4 psi 0 300 kgf cm Minimum Front 24 5 kPa 3 5 psi 0 245 kgf cm Rear 27 0 kPa 3 9 psi 0 270 kgf cm Maximum Front 30 5 kPa 4 4 psi 0 305 kgf cm Rear 33 0 kPa 4 8 psi 0 330 kgf cm Front wheel Wheel type Panel wheel Rim size 10x5 5AT Rear wheel Wheel type Panel wheel Rim size 9x8 5AT Front brake Type Dual disc brake Operation Right hand operation 10 3 Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 Front suspension Type Double wishbone Spring shock absorber type Coil spring gas oil damper Wheel travel 230 mm 9 1 in Rear suspension Type Swingarm link Suspension Spring shock absorber type Coil spring gas oil damper Wheel travel 10 270 mm 10 6 in Electrical system Ignition system DC CDI Charging system A
56. ciently slowed before engaging a lower gear Improper use of the brakes or shifting can cause the tires to lose traction reducing con trol and increasing the possibility of an accident EWB01070 A WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating This could cause loss of control an accident and injury It could also cause engine or drive train dam age HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear TURNING YOUR ATV To achieve maximum traction while riding off road the two rear wheels are mounted solidly on one axle and turn together at the same speed There fore unless the wheel on the inside of the turn is al lowed to slip or lose some traction the ATV will resist turning A special turning technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed 7 17 EWB01220 WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN The ATV could go out of control causing a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner s Manual Prac tice turning at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the condi tions As you approach a curve slow down and begin to
57. coolant re place it with coolant as soon as possible 10 Nm 1 0 m kof 7 2 ft lbf otherwise the engine may not be sufficiently cooled and the cooling system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze con tent of the coolant as soon as possible oth erwise the effectiveness of the coolant will be reduced 12 Install the radiator cap start the engine let it idle for several minutes and then turn it off 13 Remove the radiator cap to check the coolant level in the radiator If it is low add sufficient coolant until it reaches the top of the radiator and then install the radiator cap 8 14 Start the engine and then check for coolant leakage NOTE If any leakage is found have a Yamaha dealer check the cooling system 15 Install the panel EBU23690 Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean the air filter element more frequently if you are riding in unusually wet or dusty areas 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 fil ter case 1 Air filter case check hose 1 Remove the seat See page 4 13 2 Remove the air filter case cover by unhooking the ho
58. ctory 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 Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 11 8 Y YAMAHA EXTENDED SERVICE Indicates a potential hazard that could result in serious injury or death EBU26132 PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts and Accessories See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual INDEX A B C Accessories and loading surceccseascasqassaunneusexensdarensesenacendads 6 7 Air filter element Cleaning ccccceeeceeeeeeeseseeeeeeees 8 25 OU t AAEE EAN E A T EE EA E E 8 47 Brake and clutch levers checking and lubricating 8 45 Brake and shift pedals checking and lubricating 8 46 Brake fluid CHANGING ssitinscccnsassestusivartaceentenioddrmewactsniescass 8 36 Brake fluid level CNECKING ccccccceeseeseseeeeeeeeeeees 8 33 Brake IOV SM arisen csccacasetccneciesvecasasgiscdenednndetedaaneeveineacsidanesesl 4 6 Brake lever free play checking the front 0008 8 36 Brake light switches 0 2 lt c0 000 ssseestennedsiencneintevsediverntensse 8 39 Brake pads chec
59. d In addition do not use oils labeled ENERGY CONSERV ING II or higher Make sure that no foreign material enters the 8 20 crankcase 15 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 16 Turn the engine off and then check the oil lev el and correct it if necessary Install the engine guard by installing the bolts and then tighten them to the specified torque 17 Tightening torque Engine guard bolt 7 Nm 0 7 m kgf 5 1 ft lbf ECB00370 CAUTION Be sure to apply LOCTITE to the engine guard bolts before installing them EBU23470 Coolant The coolant level should be checked before each ride In addition the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart EBU23490 To check the coolant level 1 Place the ATV on a level surface NOTE The coolant level must be checked on a cold en gine since the level varies with engine tempera ture 2 Check the coolant level in the coolant reser voir NOTE The coolant should be between the minimum and maximum level marks 1 Maximum level mark 2 Minimum level mark 3 Coolant reservoir 4 Coolant reservoir cap 3 If the coolant is at or below the minimum level mark remove panel A See page 8 9 4 Remove the reservoir cap add coolant or dis
60. d add recommended oil to specified level if necessary 5 4 8 15 e Check ATV for oil leakage Correct if necessary e Check coolant level in reservoir and add recommended coolant to Coolant specified level if necessary 5 4 8 20 e Check cooling system for leakage Correct if necessary e Check operation If soft or spongy have Yamaha dealer bleed hydraulic system e Check brake pads for wear and replace if necessary T a Front brake e Check brake fluid level in reservoir and add recommended brake 5 5 8 32 8 33 8 36 fluid to specified level if necessary e Check hydraulic system for leakage Correct if necessary 5 1 e Check operation If soft or spongy have Yamaha dealer bleed hydraulic system e Check lever free play and adjust if necessary Rear brake e Check brake pads for wear and replace if necessary 5 5 8 32 8 33 8 37 e Check brake fluid level in reservoir and add recommended brake fluid to specified level if necessary e Check hydraulic system for leakage Correct if necessary e Check operation and correct if necessary Clutch e Lubricate cable if necessary 8 40 e Check lever free play and adjust if necessary e Make sure that operation is smooth Lubricate cable and lever hous Throttle lever ing if necessary 5 5 8 30 e Check cable free play and adjust if necessary Control cables e Make sure that operation is smooth Lubricate if necessary e Check chain slack and adjust if necessary EN i e Chec
61. dic maintenance and lubrication chart The brake lever should have a free play of zero mm zero in as shown If the free play is incorrect have a Yamaha dealer check the brake system 1 Brake lever free play EWB02010 A WARNING POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer EBU24601 Checking the brake pedal position The brake pedal position must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart The top of the brake pedal should be positioned 11 7 mm 0 46 in below the top of the footrest as 8 37 shown If the brake pedal is not positioned as spec ified have a Yamaha dealer adjust it 1 Brake pedal position EWB02060 POTENTIAL HAZARD Operating with improperly serviced or ad justed brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and th
62. e the chance of an accident including over turn HOW TO AVOID THE HAZARD Open the throttle gradually Release the clutch lever gradually EBU20640 To decelerate When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly As you slow down shift to a lower gear Be sure that the engine has sufficiently slowed before engaging a lower gear Improper use of the brakes or shifting can cause the tires to lose traction reducing con trol and increasing the possibility of an accident EWBO00650 A WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating and lose trac tion This could cause loss of control an ac cident and injury It could also cause engine or drive train damage HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear ECB00180 CAUTION Even with the transmission in the neutral po sition do not coast for long periods of time with the engine off and do not tow the ATV for long distances The transmission is prop erly lubricated only when the engine is run ning Inadequate lubrication may damage the transmission Always use the clutch when changing gears The engine transmission and drive train are not designed to withstand the shock of 6 5 forced shifting and can be damaged by shift ing without using the clutch EBU20670 En
63. e completely removing the cap There is Have a Yamaha dealer check The coolant level is low leakage and repair the cooling system Check the cooling system for leakage There is Wait until the Check the coolant level in the no leakage engine has cooled reservoir and radiator Add coolant See NOTE Start the engine If the engine overheats again have a Yamaha dealer check and repair the cooling system The coolant level is OK NOTE gt If coolant is not available tap water can be temporarily used instead provided that it is changed to the rec ommended coolant as soon as possible 8 56 EBU25860 CLEANING AND STORAGE EBU25890 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 3 Before cleaning the ATV a Block off the end of the exhaust pipe to prevent water entry A plastic bag and strong rubber band may be used b Make sure the spark plug and all filler caps are properly installed If the engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to the chain sprockets or wheel ax les Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job ECB00710 CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings
64. e parking brake move the parking brake lever in direction a To release the parking brake move the parking brake lever in direction b 4 7 1 Parking brake lever locked position WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before start ing the engine This could cause loss of con trol or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine EWB00170 Always be sure you have released the park ing brake before you begin to ride 1 Parking brake lever unlocked position POTENTIAL HAZARD Improper use of the parking brake Shift pedal EBU18530 This ATV is equipped with a constant mesh 5 speed transmission The shift pedal is located on the left side of the engine and is used in combina tion with the clutch when shifting 4 8 1 Shift pedal EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter clockwise a aaa Nr e in iw LQ 2 JT 1 Fuel tank cap EBU18800 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 4 9 pra 1 Fuel level 2 Filler tube Recommended fuel PREMIUM UNLEADED GASOLINE ONLY
65. e the clutch and shift into 1st gear and then release the parking brake Open the throttle grad ually and at the same time release the clutch le ver slowly Once the ATV has attained adequate speed release the throttle lever and at the same time quickly pull in the clutch lever and shift into 2nd gear Open the throttle part way and gradually release the clutch Use this same procedure as you move into the higher gears Be sure to coordi nate the use of the throttle and shift pedal properly If the throttle is applied too abruptly or if the throttle is not released during shifting or if the shift pedal is not released before applying the throttle the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds un til you are thoroughly familiar with the operation of your ATV 7 16 EWB01240 A WARNING POTENTIAL HAZARD Opening the throttle abruptly or releasing the clutch lever too quickly WHAT CAN HAPPEN The ATV could wheelie This would increase the chance of an accident including over turn HOW TO AVOID THE HAZARD Open the throttle gradually Release the clutch lever gradually ECB00230 CAUTION Do not shift gears without releasing the throt tle Damage to the engine or drive train may oc cur When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly As you slow down shift to a lower gear Be sure that the engine has suffi
66. ecautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking performance Recommended brake fluid DOT 4 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly 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 imme diately As the brake pads wear it is normal for the brake fluid level to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause EBU24290 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the peri odic maintenance and lubrication chart In addi tion have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are dam aged or leaking Oil seals Replace every two years Brake hoses Replace every four years 8 36 EBU24380 Checking the front brake lever free play The brake lever free play must be checked at the intervals specified in the perio
67. ed to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when riding an ATV with ac cessories The ATV may handle differently than it does without accessories EBU20930 Loading As originally equipped this ATV is not designed to Carry cargo or tow a trailer If you choose to add ac cessories so that you can carry cargo or tow a trail er you must use common sense and good judgment as the stability and handling of an ATV can be changed When adding accessories keep the following points in mind Never exceed the weight limits shown An over loaded ATV can be unstable MAXIMUM LOADING LIMIT ATV loading limit total weight of rider cargo accessories and tongue 100 0 kg 220 Ib f you are carrying cargo and towing a trailer in clude the tongue weight in the maximum ATV load limit Load cargo on the carriers as close to the center of the ATV as possible Put cargo at the rear of the front carrier at the front of the rear carrier and center it Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load does not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although condi
68. ely slippery surfaces such as ice go slowly and be very cautious in order to re duce the chance of skidding or sliding out of control WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each section on riding tech niques completely WHAT TO DO f your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight over the front wheels for better control See page 7 17 f your ATV begins to tip while turning Lean more into the turn to regain balance If nec essary gradually let off the throttle and or steer to the outside of the turn See page 7 17 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide See page 7 27 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 18 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to
69. engine with the throttle slightly open 6 3 EBU20520 Shifting This ATV has a 5 speed forward transmission The transmission allows you to control the amount of power you have available at a given speed or for starting accelerating climbing hills etc To shift into neutral return the throttle lever to the closed position apply the clutch and then repeat edly depress the shift pedal until it stops When it stops it will be in first gear Raise the pedal slightly to reach the neutral position 1 Shift pedal 2 Neutral position EBU20560 To start out and accelerate a Release the throttle lever ECB00200 CAUTION Always close the throttle before shifting gears otherwise damage to the engine and drive train may result 2 3 4 Pull the clutch lever to disengage the clutch Shift into first gear Open the throttle gradually and at the same time release the clutch lever slowly Once the ATV has attained adequate speed release the throttle and at the same time quickly pull in the clutch lever Shift the transmission into second gear Make sure not to shift the transmission into neutral Open the throttle part way and gradually re lease the clutch lever Follow the same procedure when shifting to the next higher gear 6 4 EWB00680 a WARNING POTENTIAL HAZARD Opening the throttle abruptly or releasing the clutch lever too quickly WHAT CAN HAPPEN The ATV could wheelie This would increas
70. er case 15 Install the seat NOTE gt The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air tight seal Tighten all fit tings securely to avoid the possibility of unfiltered air entering the engine ECB00460 CAUTION Make sure that the air filter element is prop erly seated in the air filter case Never operate the engine with the air filter el ement removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Addition ally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine over heating EBU23872 Cleaning the spark arrester Select a well ventilated area free of combustible materials and make sure the exhaust and muffler are cool 1 Remove the bolt w ee iV AO L lt a gt B 1 oe 1 Bolt 2 Remove the tailpipe by pulling it out of the muffler 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 3
71. es can also be come frayed or kinked which could restrict the operation of controls and lead to an acci dent or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Clutch lever EBU24920 Checking and lubricating the brake and a lutch 2 ciutcn levers ZA G is The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lubricated if necessary A S Recommended lubricant Lithium soap based grease all purpose grease 8 45 EBU24930 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lubricated if necessary Recommended lubricant Lithium soap based grease all purpose grease Brake pedal EBU24961 Checking the wheel bearings The front and rear wheel bearings must be 8 46 checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EBU24992 Lubricating the swingarm pivots The swingarm pivots must be lubricated at the in tervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease Grease nipple EBU25030 Lubricating the upper and lower arm pivots The upper and lower
72. f ignition Ventilate when charging or using in a closed space 8 48 To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri cal accessories 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 ful ly charge it if necessary To install the battery NOTE Be sure the battery is fully charged 1 Place the battery in its compartment 2 Make sure to properly connect the battery leads to the battery terminals ECB00630 CAUTION Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a spe cial constant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have access to a constant voltage battery charg er have a Yamaha dealer charge your bat tery EBU25252 Replacing the fuse om Dfl VAX Ni PER JEL N e 1 Fuse 2 Spare fuse The fuse holder is located on the right side of the ATV If the fuse is blown replace it as follows 1 Turn the key to OFF and turn off all electrical
73. fill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and is still very hot EBU19560 Engine oil Make sure that the engine oil is at the specified lev el Add oil as necessary See page 8 15 5 4 EBU19620 Coolant Make sure that the coolant is at the specified level Add coolant as necessary See page 8 20 NOTE The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EWB00490 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 es cape before completely removing the cap EBU19680 Front and rear brakes Brake levers and brake pedal Check for correct free play in the brake levers and brake pedal If the free play is incorrect have a Yamaha dealer check the brake system See pages 8 36 and 8 37 Check the operation of the brake levers and brake pedal They should move smoothly and there should be a firm feeling when the brakes are applied If not have the ATV checked by a
74. gine break in There is never a more important period in the life of your engine than the first 20 hours of riding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive 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 peri od prolonged full throttle operation or any condi tion that might result in engine overheating must be avoided 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine through the gears freely but do not use full throttle at any time 20 hours and beyond EBU20850 The ATV can now be operated normally Parking on a slope ECB00220 EWBO00790 CAUTION WARNING If any engine trouble should occur during the POTENTIAL HAZARD gt engine break in period immediately have a Parking on a hill or other incline Yamaha dealer check the ATV WHAT CAN HAPPEN T The ATV could roll out of control increasing BU20721 the chance of an accident Parking HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you When parking the ATV stop the engine shift into 6 first gear apply the parking brake and then turn must park on an incline place the ATV trans the fuel cock to OFP
75. gs are properly seated 11 Install the oil filter element cover by installing the bolts and then tighten them to the speci fied torque Tightening torque Oil filter element cover bolt 10 Nm 1 0 m kof 7 2 ft lbf 8 19 12 Install the crankcase engine oil drain bolt and the engine oil tank drain bolt and then tighten them to the specified torques Tightening torques Crankcase engine oil drain bolt 20 Nm 2 0 m kof 14 ft lbf Engine oil tank drain bolt 19 Nm 1 9 m kof 14 ft lbf 13 Pour the specified amount of the recommend ed engine oil through the engine oil tank filler hole and then install and tighten the engine oil tank filler cap 14 Pour the specified amount of the recommend ed engine oil through the crankcase engine oil filler hole and then install and tighten the crankcase engine oil filler cap Recommended oil See page 10 1 Oil quantity Without oil filter element replacement Quantity in oil tank 1 55 L 1 64 US qt 1 36 Imp qt Quantity in crankcase 0 20 L 0 21 US qt 0 18 Imp qt With oil filter element replacement Quantity in oil tank 1 55 L 1 64 US qt 1 36 Imp qt Quantity in crankcase 0 30 L 0 32 US qt 0 26 Imp qt ECB00300 CAUTION In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specifie
76. he hill If you start to roll backwards DO NOT apply the rear brake to stop or try to put the ATV in gear The ATV could easily tip over backwards Instead ap ply the front brake gradually or dismount the ATV 7 21 immediately on the uphill side EWBO01251 A WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dis mounting while climbing a hill WHAT CAN HAPPEN Could result in the ATV overturning HOW TO AVOID THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking brake after you are stopped If you begin rolling backwards Keep weight uphill Never apply the rear brake while rolling backwards Apply the front brake When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and re mount following the procedure described in the Owner s Manual RIDING DOWNHILL When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as pos sible Move back on the seat and sit with your arms straight Choose a low gear which will allow the en gine compression to do most of the braking for you Improper braking may cause a loss of trac tion Use caution while descending a hill with loose or slippery surfaces Braking ability and
77. hrottle suddenly or make sudden gear changes The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 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 EWB01190 POTENTIAL HAZARD Improperly crossing hills or turning on hills 7 20 WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if pos sible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV OK If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to lose control If you are unable to continue up the hill dismount the ATV on the up hill side Physically turn the ATV around and then descend t
78. hways WHAT CAN HAPPEN You can collide with another vehicle 7 12 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 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 A WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operat ing on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV 7 13 EWB01050 A WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Could cause loss of traction or ATV control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slip pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especial ly cautious on these kinds of terrain When riding in an area where you might
79. iately wes JAS after the engine has been running and is still ry very hot Do not spill gasoline on the engine Y os or exhaust pipe muffler Never remove the a 1 a fuel tank cap while smoking or in the vicinity Wer X of sparks open flames or other sources of Sy m AN ignition such as the pilot lights of water heat R E ers and clothes dryers Before lifting the fuel tank make sure that the fuel cock is in the OFF position and the fuel tank cap is securely tightened Otherwise fuel may leak out of the carburetor or fuel tank 1 Bolt 7 Remove the spark plug cap 4 Pullthe panel backward and then remove the panel 5 Install the fuel tank cap by turning it clockwise 6 Remove the bolt lift the rear of the fuel tank and then tilt it back 8 12 Ue O 1 Spark plug cap ECB00390 CAUTION Do not use any tools to remove or install the spark plug cap otherwise the ignition coil cou pler may be damaged The spark plug cap may be difficult to remove because the rubber seal on the end of the cap fits tightly To remove the spark plug cap simply twist it back and forth while pulling it out to install it twist it back and forth while pushing it in 8 Remove the spark plug as shown with the spark plug wrench included in the owner s tool 8 13 1 Spark plug wrench To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi
80. ibited Printed in Japan P N LIT 11626 20 13 LABEL HERE EWB00010 Indicates a potential hazard that could result in serious injury or death EBU17420 TABLE OF CONTENTS SAFETY INFORMATION c cceeeeeeee 1 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS c 0c0ceceee 2 1 DESCRIPTION sssciccsdcaccceetacconcdecnconeseceechecdoass 3 1 Left WICW scccioccsas docednwntannadewanenebeeeecdabeadeeee dimes 3 1 RIONU WIC WY soosis aaa 3 1 Controls and instruments c0cceceeeees 3 2 INSTRUMENT AND CONTROL FUNG TIONS siesisiesnccecrieatenacenietesvcacviasemcnds E tances 4 1 Main switch wasicencitcacsteddevessastacsuentdamavoeiodtess 4 1 Indicator light and warning light 4 2 Handlebar switches c ccceceseeeeceeeeeeeeeens 4 3 Throttle lever oo cece eeeececececeeeeeeeeeeseeeeeees 4 3 Speed limiter cecenaiantensesauaiseaeiscnahvmecesieees 4 4 Clutch lever ccennch once onnccesedaiiatossnconaseesaciaenees 4 5 Brake IOV CN sccdsswccudeseewentacteaiendaesaateuacereceueaees 4 6 Brake pedal cccccsccssseeceseeeeseeenseeeneees 4 6 Parking brake lever ccccsseceseeeeneseeneees 4 7 Shift pedal once ancl foeneSamtacuecseioveuneesisebeneedaucte 4 8 Fuel tank cap siicccecescerseenaenctsidebemasiccceanonia 4 9 Fe E E E E EA 4 9 PS COCKE sorone yenn E e 4 11 Starner CROKE Mik capisse 4 12 S e E E EEE 4 13 Adjusting the front shock absorber assemblies
81. ide if pointed straight up hill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating ina new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obsta cles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to re duce the chance of skidding or sliding out of con trol Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always use the size and type of tires specified in this manual Always maintain proper tire pressure as de scribed in this manual fe Never modify an ATV through improper installa tion or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow in structions in this manual for carrying cargo or pulling a trailer Allow greater distance for brak ing FOR MORE INFORMATION ABOUT ATV SAFE TY call the Consumer Produc
82. ine type 10 Liquid cooled 4 stroke DOHC Cylinder arrangement Forward inclined single cylinder Displacement Recommended engine oil grade 449 0 cm 27 40 cu in API service SE SF SG type or higher Bore x stroke 95 0 x 63 4 mm 3 74 x 2 50 in 10 1 Engine oil quantity Type x quantity Without oil filter element replacement FCR39H x 1 1 75 L 1 85 US qt 1 54 Imp qt Spark plug s Quantity in oil tank Manufacturer model 1 55 L 1 64 US qt 1 36 Imp qt NGK CR8E Quantity in crankcase Spark plug gap 0 20 L 0 21 US qt 0 18 Imp qt 0 7 0 8 mm 0 028 0 031 in With oil filter element replacement Clutch 1 85 L 1 96 US qt 1 63 Imp qt Clutch type Quantity in oil tank Wet multiple disc Quantity in crankcase Primary reduction system l 0 30 L 0 32 US qt 0 26 Imp qt Spur gear Cooling system Primary reduction ratio Coolant reservoir capacity up to the maximum level mark 62 22 2 818 0 29 L 0 31 US qt 0 26 Imp qt Secondary reduction system Radiator capacity including all routes Chain drive 1 30 L 1 37 US qt 1 14 Imp qt Secondary reduction ratio Air filter 38 14 2 714 Air filter element Transmission type Wet element Constant mesh 5 speed Fuel Operation 10 Recommended fuel Left foot operation Premium unleaded gasoline only 1st Fuel tank capacity 29 12 2 416 10 0 L 2 64 US gal 2 20 Imp gal 2nd Fuel reserve amount 27 14 1 928 1 9 L 0 50 US gal 0 42 Imp gal 3rd Car
83. ires are cold Set slowly and carefully EBU19820 Measuring the tire pressure Use the low pressure tire gauge NOTE The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or 5 8 the tire pressures to the following specifications Recommended pressure Front 27 5 kPa 4 0 psi 0 275 kgf cm Rear 30 0 kPa 4 4 psi 0 300 kgf cm Minimum Front 24 5 kPa 3 6 psi 0 245 kgf cm Rear 27 0 kPa 3 9 psi 0 270 kgf cm Maximum Front 30 5 kPa 4 4 psi 0 305 kgf cm Rear 33 0 kPa 4 8 psi 0 330 kgf cm EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm 0 12 in 1 Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary EBU19870 OPERATION EWBO00010 EBU20091 A WARNING Starting a cold engine Indicates a potential hazard that could result in meen serious injury or death EBU19890 EWB00610 A WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls WHAT CAN HAPPEN 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
84. k chain condition Lubricate if necessary Erra Ga e Check wheel condition and replace if damaged Wheels and tires e Check tire condition and tread depth Replace if necessary 5 7 5 8 5 9 e Check air pressure Correct if necessary e Make sure that operation is smooth Lubricate pedal pivoting points e Make sure that operation is smooth Lubricate lever pivoting points _ Chassis fasteners e Make sure that all nuts bolts and screws are properly tightened Instruments and switches e Check operation and correct if necessary e Ea ngais ag e Check operation and correct if necessary 5 2 EWB00470 A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual 5 3 EBU19530 Fuel Make sure that there is sufficient fuel in the tank See page 4 9 EWB00500 WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and se vere 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 over
85. k fastener screws 10 Install the seat EBU23303 Engine oil and oil filter element The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter element replaced at the intervals spec ified in the periodic maintenance and lubrication chart 8 15 To check the engine oil level 1 Place the ATV on a level surface 2 Start the engine warm it up until the engine oil has reached a normal temperature of 40 C 104 F let it continue to idle for ten seconds or more and then turn the engine off NOTE gt To achieve the proper engine oil temperature for an accurate oil level reading the engine must have first completely cooled down and then warmed up again for several minutes to normal operating tem perature 3 Remove the engine oil tank filler cap wipe the dipstick off with a clean rag Insert the dipstick into the filler hole without screwing it in and then remove it again to check the oil level 4 oo SA 1 Engine oil tank filler cap 2 Dipstick 3 Engine oil tank 4 Engine oil filler cap 5 Maximum level mark 6 Minimum level mark NOTE eee The engine oil should be between the minimum and maximum level marks 5 If the engine oil is at or below the minimum level mark add sufficient oil of the recom mended type through the engine oil tank filler hole to raise it to the correct level 8 16 NOTE gt When adding oil be careful not
86. king the front and rear 0008 8 32 BARS DCC All acrasieuersestanctoctinesnennendeacaaitauiicienioataninerredtecue 4 6 Brake pedal position checking cccseeeeeeeeeeeeeeees 8 37 Brakes front And rear ccccccccecc cece eeeeeeeeesueeeeeneaeseaeenes 5 5 Cables checking and lubricating cccccessseeeeeees 8 44 Carburetor US MAG cain csinncocdanapenotiavedenaeaeeadunadedarebenses 8 30 Chassis faSt nels cccccccceeccsessseeeeceeesseeeeseenessseeseees 5 9 E a E T E T E T A TE 9 1 Ba E E E A E A E AE 4 5 Clutch lever free play adjusting ccccceceeeeeeeeeeees 8 40 Cool eee ne eee E en ee tre reer eee 5 4 8 20 Coolant temperature warning light cccceeeeeeeeeeees 4 2 D DUVE CNA aarep EaR 5 6 Drive chain lubricating n0000nnoooonnneneeoneenneeeenn 8 44 Drive chain SIACK aiicececnvsassactemnnseiscureenssaneetieacsenrseemeas 8 42 Engine break in sco Boece yeaa cee s eenn eene eerrrrneerrnn enneren 6 5 Engine cold STA iianoaiue i 6 1 Engine idling SPCC icsiacc ccc arcasies svtevats unearcendes eniai 8 30 ENGINE OI secies ee ere er ar ee eee oe 5 4 Engine oil and oil filter element ceeeeeeeeeeeees 8 15 Engine starting a Warm sic evaeccecesstecsscniedentendeaiee 6 3 Engine stop switch sic santoretysedateqiuadeamenaverdedeate slaamenepen ded 4 3 UCU E E A EAE T N EAE T 4 9 5 4 UCI COCK osaceae 4 11 Fueltank GAD cctcecousactcen cian
87. lders ds a mel case cover 1 Wing bolt 2 Air filter case holder 2 Sponge material 3 Loosen the wing bolt l 5 Remove the wing bolt from the air filter ele 4 Remove the air filter element together with the ment ea wing bolt 6 Remove the sponge material from the air filter element frame 8 26 1 Sponge material 2 Air filter element frame 7 Wash the sponge material gently but thor oughly in solvent EWB01900 POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode 8 27 HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material 8 Squeeze the excess solvent out of the sponge material and let it dry ECB00440 CAUTION Do not twist the sponge material when squeez ing it 9 Check the sponge material and replace it if damaged 10 Apply Yamaha foam air filter oil or other qual ity foam air filter oil to the soonge material NOTE The sponge material should be wet but not drip ping 11 Pull the sponge material over the air filter ele ment frame 12 Insert the wing bolt into the hole in the air filter element frame 13 Insert the air filter element into the air filter case and then tighten the wing bolt 14 Install the air filter case cover by hooking the holders onto the air filt
88. lectrical components can cause shocks or start fires HOW TO AVOID THE HAZARD Turn off the engine when performing mainte nance unless otherwise specified Have a Yamaha dealer perform the service if you are not familiar with maintenance work EBU27100 Owner s manual and tool kit Be sure to put this owner s manual in the plastic bag and to always carry it as well as the owner s tool kit and the low pressure tire gauge in their re spective compartments under the seat it for you X EWB01830 7 GN N POTENTIAL HAZARD A Operating this ATV with improper modifica S tions WHAT CAN HAPPEN Improper installation of accessories or mod ification of this ATV may cause changes in handling which in some situations could lead to an accident 1 Low pressure tire gauge HOW TO AVOID THE HAZARD 2 Owner s tool kit Never modify this ATV through improper in 3 Owner s manual stallation or use of accessories All parts and accessories added to this ATV should be The service information included in this manual genuine Yamaha or equivalent components and the tools provided in the owner s tool kit are in designed for use on this ATV and should be tended to assist you in the performance of preven installed and used according to instructions tive maintenance and minor repairs However If you have questions consult an authorized additional tools such as a torque wrench may be Yamaha ATV dealer necessary to perform certain
89. ler hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ve hicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose sur faces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique described in this manual on level ground Avoid crossing the side of a steep hill if possible Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stall ing use the proper gear and maintain a 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 s
90. ly Do not refuel right after the engine has been running and is still very hot EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations OFF 1 Arrow mark positioned over OFF With the fuel cock lever in this position fuel will not flow Always turn the fuel cock lever to this position when the engine is not running 1 Arrow mark positioned over ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding 4 12 1 Arrow mark positioned over RES This indicates reserve With the fuel cock lever in this position the fuel reserve is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18850 Starter choke Nj Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke Move the starter choke in direction b to turn off the starter choke See the Starting a cold engine section on page 6 1 for proper operation 1 Starter choke NI EBU18890 Seat
91. m on the ATV is very hot during and following operation To prevent burns avoid touching the exhaust system Park the ATV ina place where pedestrians or children are not likely to touch it EWB01010 POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible ma terial accumulated around the engine area could catch fire Someone touching the exhaust system dur ing or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry EWB01020 grass or other dry ground cover WARNING Keep the engine area free of dry grass POTENTIAL HAZARD brush or other combustible material Operating this ATV on paved surfaces Do not touch the hot exhaust system WHAT CAN HAPPEN Do not park the ATV in a place where others ATVs are designed for off road use only might be likely to touch it Paved surfaces may seriously affect han dling and control of the ATV and may cause the ATV to go out of control HOW TO AVOID THE HAZARD Always avoid paved surfaces including side walks driveways parking lots and streets BE CAREFUL WHERE YOU RIDE This ATV is designed for off road use only Riding on paved surfaces can cause loss of control 7 11 Do not ride on any public road street or highway Riding on public roads can result in collisions with other vehicles EWB01030 POTENTIAL HAZARD Operating this ATV on public streets roads or hig
92. maintenance work correctly NOTE SS If you do not have the tools or experience required for a particular job have a Yamaha dealer perform 8 2 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 inter vals However keep in mind that if the ATV isn t used for a long period of time the month maintenance intervals should be followed Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills INITIAL EVERY wey CHECK OR MAINTENANCE Whichev month 1 3 6 6 12_ JOB ercomes km 320 1300 2500 2500 5000 first mi 200 800 1600 1600 3200 5 e Check fuel hoses for cracks or other damage and replace if necessary Valves e Check valve clearance and adjust if necessary lL 4 pot te e Check starter choke operation and correct if nec Carburetor eka y y y e Check engine idling speed and adjust if neces sary Crankcase breather e Check breather hose for cracks or other damage J y system and replace if necessary 8 3 e Check condition and clean regap or replace if Spark plug necessary i INITIAL EVERY CHECK OR MAINTENANCE Whichev month 1 3 6 6 12 JOB ercomes
93. may float causing loss of traction and loss of control which could lead to an acci dent HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water Test your brakes after leaving the water Do not or in water deeper than that specified in your continue to ride your ATV without verifying that you Owner s Manual have regained proper braking ability Remember that wet brakes may have re duced stopping ability Test your brakes af ter leaving water If necessary apply them several times to let friction dry out the lin ings 7 25 ECB00240 CAUTION After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case Wash the ATV in fresh water if it has been operated in salt water or muddy conditions 7 26 1 Air filter case check hose RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau tion Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac cident 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 re sult EWBO01160 POTENTIAL HAZARD Improperly operating over obstacles 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 ob stacles Never attempt to ride
94. mbient temp starter choke position AMBIENT TEMP STARTER CHOKE POSITION 0 10 20 30 C S oa o a a 50 70 90 F 3 2 4 maa IO OOK lo o rrr 1 2 3 1 Fully open 2 Half open 3 Closed 4 Starter choke 6 Completely close the throttle lever and start the engine by pushing the start switch NOTE gt If the engine fails to start release the start switch then push it again Pause a few seconds before the next attempt Each cranking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt 7 Ifthe engine is started with the starter choke in position 1 the starter choke should be returned to position 2 to warm up the engine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine ECB00160 CAUTION For maximum engine life always warm the en gine up before starting off Never accelerate hard when the engine is cold 8 Continue warming up the engine until it idles smoothly then return the starter choke to position 3 before riding NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the starter choke is not required when the engine is warm Instead start the
95. n crossing the side of a hill the front wheels slightly uphill When riding on Always follow proper procedures as de slopes be sure not to make sharp turns either up scribed in the Owner s Manual or down hill Avoid hills with excessively slippery or loose If your ATV does begin to tip over gradually steer surfaces in the downhill direction if there are no obstacles in Shift your weight to the uphill side of the your path As you regain proper balance gradually ATV steer again in the direction you wish to travel EWB01141 POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV _ to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on ANS level ground Be very careful when turning Ae on any hill Avoid crossing the side of a steep hill if possible CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving shal low water of up to a maximum of 35 cm 14 in in 7 24 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 care fully EWB01150 WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires
96. nd damping setting Minimum soft the damping and in direction b to decrease the rebound damping force and thereby soften the 25 click s in direction b damping Standard 11 click s in direction b Maximum hard 1 click s in direction b With the adjusting screw fully turned in di rection a Compression damping force Turn the adjusting screw in direction a to increase 4 16 the compression damping force and thereby hard en the damping and in direction b to decrease the compression damping force and thereby soft en the damping es _ amp LS Lee aes Soy je 1 Compression damping force adjusting screw 4 17 Compression damping setting Minimum soft 20 click s in direction b Standard 11 click s in direction b Maximum hard 1 click s in direction b With the adjusting screw fully turned in di rection a ECB00090 CAUTION Never turn an adjusting mechanism beyond the minimum and maximum settings NOTE Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production the actual number of clicks always rep resents the entire adjusting range To obtain a pre cise adjustment it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary EWB00370 A WARNING POTENTIAL
97. ndicator groove EBU26831 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly causing it to become inef fective Before riding check that the brake fluid is above the minimum level mark and replenish if neces sary 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 8 33 Front brake 1 Minimum level mark Rear brake N 3 r 1 Minimum level mark NOTE To check the rear brake fluid level remove the seat See page 4 13 If the rear brake fluid level is low replenish as fol lows 1 Remove the brake fluid reservoir bracket bolt 8 34 1 Bolt 2 Pullthe brake fluid reservoir out to the side as shown a LL Saw 1 Brake fluid reservoir cap ECB00780 CAUTION Do not tilt the rear brake fluid reservoir exces sively when removing or installing the rear brake fluid reservoir Also do not twist or pull the hose of the reservoir 3 Remove the brake fluid reservoir cap and then refill with brake fluid 4 Install the brake fluid reservoir cap 5 Insert the projection on the brake fluid reser voir bracket into the hole in the frame 8 35 1 Frame 2 Projection 3 Brake fluid reservoir bracket 4 Bolt 6 Install the brake fluid reservoir bracket bolt Observe these pr
98. of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 1 1 1 5 Please also read all caution and warning la bels on your ATV 7 2 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified in structor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until you are totally familiar with the ATV s handling and performance characteristics EWB01280 POTENTIAL HAZARD Operating this ATV without proper instruc tion WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regu larly 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 autho rized ATV dealer or call 1 800 887 2887 Riding your ATV requires skills
99. ottle position Because the throttle is spring loaded the ATV will decelerate and the engine will return to an idle any time the hand is removed from HOW TO AVOID THE HAZARD the throttle lever Check the operation of the throttle lever be fore you start the engine If it does not work smoothly check for the cause Correct the problem before riding the ATV Consult a Yamaha dealer if you can t find or solve the problem yourself EBU18311 Speed limiter Your ATV was delivered with an adjustable speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum 1 Loosen the locknut 2 Toincrease the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction a To de crease the maximum engine power available and the maximum speed of the ATV turn the adjusting screw in direction b 1 Throttle lever Before starting the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released EWB00200 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 4 4 1 Locknut 2 Adjusting screw 3 No more than 12 mm 0 47 in 3 Tighten the locknut EWB00190 POTENTIAL HAZARD Improper adju
100. out of oil sustained high rpm full throttle operating the machine with a broken or damaged part which causes another part to fail damage or failure due to improper or careless transportation and or tie down If you have any specific questions on operation or maintenance please contact your dealer for advice Does the warranty cover incidental costs such as towing or transportation due to a failure No The warranty is limited to repair of the machine itself May perform any or all of the recommended maintenance shown in the Owner s Manual instead of having the dealer do them Yes if you are a qualified mechanic and follow the procedures specified in the Owner s and Service Manual We do recommend however that items requiring special tools or equipment be done by a Yamaha ATV dealer Will the warranty be void or cancelled if do not operate or maintain my new ATV exactly as specified in the Owner s Manual A No The warranty on a new ATV cannot be voided or cancelled However PO gt O if a particular failure is caused by operation or maintenance other than as described in the Owner s Manual that failure may not be covered under warranty What responsibility does my dealer have under this warranty Each Yamaha ATV dealer is expected to 1 Completely set up every new machine before sale 2 Explain the operation maintenance and warranty requirements to your satis faction at the
101. peration of your ATV CLIMBING UPHILL Use proper riding techniques to avoid ATV over turns on hills Be sure that you can maneuver your ATV well on flat ground before attempting any in cline and then practice riding first on gentle slopes Try more difficult climbs only after you have devel oped your skill In all cases avoid inclines with slip pery or loose surfaces or obstacles that might cause you to lose control EWB01090 POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The ATV can overturn more easily on ex tremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by leaning forward and on steeper inclines standing on the footboards and leaning forward over the handlebars EWB01100 POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn 7 19 HOW TO AVOID THE HAZARD Always follow proper procedures for climb ing hills as described in this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the t
102. rate an ATV without wearing an ap proved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots a long sleeved shirt or a jacket and long pants Never consume alcohol or drugs before or while operating this ATV Never operate at speeds too fast for your skills or the riding conditions Always go at a speed that is proper for the terrain visibility operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe operating condition Al ways follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footpegs of the ATV during op eration Always go slowly and be extra careful when op erating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Never operate on excessively rough slippery or loose terrain until you have learned and prac ticed the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds and never turn at excessive speeds Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smal
103. rocedures and schedules described in the Owner s Manual EWB00950 WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or opera tion of this ATV with improper or uneven tire pressure may cause loss of control increas ing your risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual for this ATV on page 5 7 Always maintain proper tire pressure as de scribed in the Owner s Manual on page 5 8 EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death 7 7 Do not operate at speeds too fast for your skills or the conditions EWB00960 a WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain visibility and operating conditions and your experience Speed limiter For riders less experienced with this model the throttle lever housing is equipped with a speed lim iter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum Turning in the adjusting screw limits the maximum engine power available and de creases the ma
104. s NOTE When installing a front wheel make sure its arrow mark points toward the rotating direction of the wheel 8 53 1 Arrow mark 2 Lower the ATV to the ground 3 Tighten the wheel nuts to the specified torques Tightening torques Front wheel nut 45 Nm 4 5 m kof 33 ft lbf Rear wheel nut 45 Nm 4 5 m kof 33 ft lbf EBU25730 Troubleshooting Although Yamaha ATVs receive a thorough in spection before shipment from the factory trouble may occur during operation Any problem in the fu el compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself However should your ATV re quire any repair take it toa Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills EWB02260 POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe in jury or property damage 8 54 HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys tem Make sure there are no open flames or sparks in the area including pilot lights from
105. se wheels 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 HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation Avoid wheelies and jumping You may lose control i of the ATV or overturn EWB00990 A WARNING POTENTIAL HAZARD Attempting wheelies jumps and other EWB00980 stunts WHAT CAN HAPPEN POTENTIAL HAZARD Increases the chance of an accident includ Removing hands from handlebars or feet ing an overturn from footboards during operation HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off 7 9 Modifications EWB01000 POTENTIAL HAZARD Operating this ATV with improper modifica tions WHAT CAN HAPPEN Improper installation of accessories or mod ification of this ATV may cause changes in handling which in some situations could lead to an accident 7 10 HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation 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 Exhaust system The exhaust syste
106. sinrsacinrsasnasacswsenad eaeeerdstiaends 11 7 Riding your A TV snrnid a iar 7 1 l EA Warranty WG i acarpeaccaccpdoesuessesaceoseusteuuasmenunianetaasned 11 5 Safety information sicsinve sede eevacetennnsbbadudenusewiauutetateRdaadecewely 1 1 ence Bearings CREO NING E o Seat 4 13 Wheel installing esencssinnioa annue 8 53 AO Wheel reMOVING cecsccccccccccccscssssssssssssssssssseseeseeveessessssse 8 52 SA E ASE OAA EA E E E EET T 6 3 oin pedal orras care vicgcceraceenenscreciaasdunecusaekartcomanianenc onl 4 8 EBU26141 AWARNING Improper ATV use can result in SEVERE INJURY or DEATH NEVER USE ON PUBLIC ROADS ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions eon public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For replacement manual call 1 800 532 1558 YAMAHA YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006 04 5 0x1 A E Dear Yamaha ATV Owner Please
107. sorber assembly yourself Take the shock absorber assembly to a Yamaha dealer for any service 1 1 Clamp screw 3 Disconnect the hose and then remove the air filter case by removing the bolts Spring preload 1 Remove the seat See page 4 13 2 Loosen the clamp screw at the carburetor side and then disconnect the air intake duct 4 19 1 Hose 1 Bolt 2 Air filter case 4 Loosen the locknut 5 Turn the adjusting nut in direction a to in crease the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension 4 20 1 Spring preload adjusting nut 2 Locknut 3 Special wrench NOTE SSS A special wrench can be obtained at a Yamaha dealer to make this adjustment e The spring preload setting is determined by measuring distance A shown in the illustration The shorter distance A is the higher the spring preload the longer distance A is the lower the spring preload With each complete turn of the adjusting nut distance A is changed by 1 5 mm 0 06 in Spring preload setting Minimum hard Distance A 250 mm 9 8 in Standard Distance A 257 mm 10 1 in Maximum soft Distance A 265 mm 10 4 in t G KC AU y w Q pear ZF 1 Distance A 6 Tighten the locknut to the specified torque Tightening torque Locknut
108. stment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Im proper throttle operation could result You could lose control have an accident or be in jured 4 5 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 2 0 4 0 mm 0 08 0 16 in See page 8 30 EBU18382 Clutch lever The clutch lever is located on the left handlebar and the ignition circuit cut off system is incorporat ed in the clutch lever holder To disengage the clutch pull the clutch lever toward the handlebar grip To engage the clutch release the clutch lever The clutch lever should be pulled rapidly and re leased slowly for smooth clutch operation See page 6 1 for a description of the ignition circuit cut off system 1 Clutch lever EBU1841 1 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the brake lever toward the handlebar grip 4 6 1 Brake lever 2 Locknut 3 Brake lever position adjusting bolt 4 Distance between brake lever and handlebar grip EBU18432 Brake pedal The brake pedal is located on the right side of the ATV To apply the rear brake push down on the brake pedal 1 Brake pedal EBU18510 Parking brake lever Use the parking brake before starting the engine or parking the ATV especially on a slope To apply th
109. t 8 15 Accessories and loading a amiga eas aaeea 6 7 Coolant PE nee PEPEE A ARE E E a E 8 20 Cleaning the air filter element 8 25 RIDING YOUR ATV eere 7 1 Cleaning the spark arrester eee 8 28 GETTING TO KNOW YOUR ATV 7 2 Adjusting the carburetor E T 8 30 RIDE WITH CARE AND GOOD Checking the engine idling speed dria inmate date 8 30 JUDGEMENT eccosunebctentassercavensvnsascene 7 2 Adjusting the throttle cable tree play 8 30 BE CAREFUL WHERE YOU BIDE 7 11 Valve clearance S dein dein bslemen siesta inwsseceaied 8 31 TURNING YOUR ATV oere 7 17 Checking the front and rear brake pads 8 32 CLIMBING UPHILL ossessi 7 18 Checking the brake fluid level 0 8 33 RIDING DOWNHILL c ccsccceseseseetenen 7 22 Changing the brake fluid eeeees 8 36 CROSSING A SLOPE 7 23 Checking the front brake lever free play 8 36 CROSSING THROUGH SHALLOW Checking the brake pedal position 8 37 WAIE ER iari 7 24 Adjusting the parking brake free play 8 38 RIDING OVER ROUGH TERRAIN 7 26 Brake light switches ccccsseeseeeeeeees 8 39 SLIDING AND SKIDDING c000e 7 27 Adjusting the clutch lever free play 8 40 WHAT TO DO Fico coccccccccccccccccccccccccccceccese 7 28 Drive chain slack cccceeeeeeceeeeeeeeeeeeeees 8 42 WHAT TO DO w ccececcesseseeseesescestestereeeees 7 28 Lubricating the drive Chain
110. ted room or covering it with a tarp while it is still wet will allow water and humidity to seep in and cause rust To prevent corrosion avoid damp cellars 9 2 stables because of the presence of ammo nia and areas where strong chemicals are stored Long term Before storing your ATV for several months 1 Follow all the instructions in the Cleaning section of this chapter 2 Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosen ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing Specified amount 7 5 ml of stabilizer to each liter of fuel or 1 oz of stabilizer to each gallon of fuel 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparking during the next step d Turn the engine over several times with the starter This will coat the cylinder wall with oil e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap Lubricate all control ca
111. the chance of a collision or accident NOTE If the cable length cannot be adjusted to specifica tion consult a Yamaha dealer HOW TO AVOID THE HAZARD After adjusting the parking brake free play block the rear of the ATV off the ground and 5 Tighten the locknut on the brake cable spin the rear wheels Check to make sure 6 Turn in the adjusting bolt at the rear brake cal there is no brake drag If brake drag is no iper until it feels tight then turn it out 1 8 turn ticed perform the adjustment again and tighten its locknut to the specified torque ECB00520 EBU24740 CAUTION Brake light switches When tightening the locknut hold the adjust The operation of the brake light switches must be ing bolt with a wrench so that it does not turn checked and if necessary adjusted at the inter 8 39 vals specified in the periodic maintenance and lu brication chart The brake light switch for the brake pedal can be adjusted as follows but the other brake light switches should be adjusted by a Yamaha dealer NOTE gt The brake light switch is properly adjusted when the brake light comes on just before braking takes effect Turn the adjusting nut while holding the brake light switch in place To make the brake light come on 1 Brake light switch earlier turn the adjusting nut in direction a To 2 Brake light switch adjusting nut make the brake light come on later turn the adjust ing nut in direction b EBU2482
112. tilled water to the maximum level mark install the reservoir cap and then install the panel Coolant reservoir capacity up to the maximum level mark 0 29 L 0 31 US qt 0 26 Imp qt ECB00400 CAUTION If coolant is not available use distilled water or soft tap water instead Do not use hard wa ter or salt water since it is harmful to the en gine If water has been used instead of coolant re place it with coolant as soon as possible otherwise the engine may not be sufficiently cooled and the cooling system will not be protected against frost and corrosion if water has been added to the coolant have a Yamaha dealer check the antifreeze con tent of the coolant as soon as possible oth erwise the effectiveness of the coolant will be reduced NOTE If the engine overheats see page 8 55 for further instructions 8 22 EBU23550 To change the coolant EWB01880 WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always place a thick rag over the cap Allow any remaining pressure to escape before completely removing the 1 Place the ATV on a level surface Remove panel A See page 8 9 Place a container under the engine and then remove the coolant drain bolt Use a
113. tions vary it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trail er Allow more braking distance A heavier ATV 6 8 takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV EWB00750 A 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 se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing EWBO00010 Indicates a potential hazard that could result in serious injury or death EBU21131 RIDING YOUR ATV EWB00010 Indicates a potential hazard that could result in serious injury or death EBU21591 GETTING TO KNOW YOUR ATV This ATV is intended for recreational use by expe rienced operators only Even if you are an experi enced operator of all other all terrain ATVs or motorcycles riding the ATV requires special skills acquired through practice Take your time to fully learn techniques before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable ac tivity providing you with hours
114. traction may be adversely affected by these surfaces Improper 7 22 braking may also cause a loss of traction Whenever possible ride your ATV straight down hill 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 ob stacles which may appear EWB01130 POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owner s Man ual Note a special technique is required when braking as you go down a hill Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where possi ble 7 23 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 slip pery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loose surfaces by pointing Whe
115. trical cir cuit ECB00010 CAUTION The engine may overheat if the ATV is over loaded In this case reduce the load to spec ification 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 EBU18060 Handlebar switches 1 Light switch LIGHTS 2 Engine stop switch ENG STOP 3 Start switch START EBU18070 Engine stop switch ENG STOP Set this switch to RUN before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run when this switch is set to OFP 4 3 EBU18090 Start switch START Push this switch to crank the engine with the start er ECB00050 CAUTION See the starting instructions on page 6 1 prior to starting the engine EBU18120 Light switch LIGHTS Set this switch to LO to turn on the low beams and the taillight Set the switch to HI to turn on the high beams and the taillight Set the switch to OFF to turn off all the lights NOTE The headlights and the taillight can be turned on only when the engine is running EBU18270 Throttle lever Once the engine is running movement of the throt tle lever will increase the engine speed Regulate the speed of the ATV by varying the thr
116. trough or a similar object as shown j NS IK ee aL K mA 2 1 Coolant drain bolt 1 Radiator cap 2 Trough 5 Remove the coolant reservoir by removing the 8 4 Remove the radiator cap bolts 6 Remove the coolant reservoir cap and then turn the coolant reservoir upside down to empty it 8 23 10 Pour the recommended coolant into the reser voir to the maximum level mark and then in stall the reservoir cap 11 Pour the recommended coolant into the radia tor until it is full Antifreeze water mixture ratio 1 1 Recommended antifreeze High quality ethylene glycol antifreeze con taining corrosion inhibitors for aluminum en gines 1 Coolant reservoir cap Coolant quantity 2 Coolant reservoir Radiator capacity including all routes BON 1 30 L 1 37 US qt 1 14 Imp qt _ Coolant reservoir capacity up to the maxi 7 After draining the coolant thoroughly flush the mum level mark cooling system with clean tap water 0 29 L 0 31 US at 0 26 Imp at 8 Install the coolant reservoir by installing the bolts ECB00400 9 Replace the coolant drain bolt washer if it is CAUTION damaged install the coolant drain bolt and _ If coolant is not available use distilled water then tighten it to the specified torque or soft tap water instead Do not use hard wa Ti ter or salt water since it is harmful to the en ightening torque gine Coolant drain bolt If water has been used instead of
117. ts Safety Commis sion at 1 800 638 2772 or the ATV Distributor s Safety Hotline at 1 800 852 5344 Suen HOW TO AVOID THE HAZARD If you should swallow some gasoline or in gy POTENTIAL HAZARD hale a lot of gasoline vapor or get some gas Improper handling of gasoline oline in your eyes seek medical help WHAT CAN HAPPEN immediately If gasoline spills on your skin Gasoline can catch fire and you could be wash with soap and water If gasoline spills burned on your clothing change your clothes HOW TO AVOID THE HAZARD Always turn off the engine when refueling Do not refuel right after the engine has been running and is still very hot Do not spill gasoline on the engine or ex haust pipe muffler when refueling Never refuel while smoking or in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heat ers and clothes dryers When transporting the ATV in another vehi cle be sure it is kept upright and that the fuel cock is in the OFF position Otherwise fuel EWB00030 may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Bi POTENTIAL HAZARD Gasoline is poisonous and can cause inju Starting or running the engine in a closed ar ries ea WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death with in a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad equate ventilation
118. water heaters or furnaces EBU25771 Troubleshooting charts Starting problems or poor engine performance 1 Fuel There is enough fuel Check the compression The engine does not start Th fuel H Supply fual Check the compression There is compression Check the ignition Check the fuel level in the fuel tank 2 Compression Operate the electric starter Have a Yamaha dealer check the ATV Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV There is no compression 3 Ignition Open the throttle halfway and operate the electric starter The engine does not start Check the battery The engine turns over quickly The engine does not start Operate the electric starter Have a Yamaha dealer The engine turns over Check the battery lead connections check the ATV slowly and charge the battery if necessary Remove the spark plug and check the electrodes 4 Battery The battery is good 8 55 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 befor
119. ximum speed of the ATV Turning in the adjusting screw decreases top speed and turning it out increases top speed See page 4 4 duce your speed when adding additional loads MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and tongue 100 0 kg 220 Ib EWBO00970 A WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly 1 Adjusting screw WHAT CAN HAPPEN 2 Locknut Could cause changes in ATV handling which could lead to an accident Loading and accessories HOW TO AVOID THE HAZARD As originally equipped this ATV is not designed to Never exceed the stated load capacity for carry cargo or tow a trailer If you choose to add ac this ATV cessories so that you can carry cargo or tow a trail Cargo should be properly distributed and se er you must use common sense and good curely attached judgment 7 Reduce speed when carrying cargo or pull Use extra caution when riding the ATV with addi ing a trailer Allow greater distance for brak tional loads such as accessories or cargo The ing ATV s handling may be adversely affected Re Always follow the instructions in your Own er s Manual for carrying cargo or pulling a trailer 7 8 During operation WHAT CAN HAPPEN Always keep your feet on the footboards during op Removing even one hand or foot can reduce eration otherwise they may contact the rear your ability to control the ATV or could cau

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