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Yamaha YFM660FAT Owner`s manual

1. 1 Speedometer 2 Fuel meter 3 H button 4 M button 5 Clock Hour meter 6 Odometer Tripmeter A Tripmeter B 7 TRIP ODO button 8 Clock Hour P button The speedometer unit is equipped with the following a speedometer which shows the riding speed an odometer which shows the total dis tance traveled e two tripmeters which show the distance traveled since they were last set to zero a clock e an hour meter which shows the total time the key has been turned to ON a fuel meter Odometer and tripmeter modes Pushing the TRIP ODO button switches the display between the odometer mode ODO and the tripmeter modes A and B in the fol lowing order ODO TRIP A gt TRIP B gt ODO To reset a tripmeter select it by pushing the TRIP ODO button and then push the TRIP ODO button for at least three seconds The tripmeters can be used to estimate the dis tance that can be traveled with a full tank of fu el This information will enable you to plan future fuel stops NOTE Holding in the TRIP ODO button and then turning the key to ON switches the display between mph and km h 4 5 Clock mode Pushing the b button switches the display between the clock mode CLOCK and the hour meter mode HOUR in the fol lowing order CLOCK gt HOUR gt CLOCK To set
2. The machine you have purchased may differ slightly from those shown in the figures of this manual EBU00600 Identification number records Record the key identification number vehicle identification number and model label infor mation in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER O 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION 3 2 EBU00035 Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key EBU00036 Vehicle identification number The vehicle identification number is stamped into the frame 1 Vehicle identification number NOTE The vehicle identification number is used to identify your machine 3 3 EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label EBU00039 CONTROL FUNCTIONS A WARNING Indicates a potential hazard that could result in serious injury or death EBU00942 Main switch Functions of the respective switch positions are as follows ON The engine can be started only at this position and the headlights and taillight come on wh
3. 3 Remove the oil filler bolt and the drain bolt to drain the oil 1 Final gear oil filler bolt 8 21 1 Final gear oil drain bolt 4 Install the drain bolt and tighten it to the specified torque Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 16 ft lbf 5 Fill the final gear case with the specified amount of the recommended oil Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 25 L 0 22 Imp qt 0 26 US qt CAUTION Be sure no foreign material enters the final gear case 6 Install the filler bolt and tighten it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 16 ft lbf 7 Check for oil leakage If oil leakage is found check for the cause 8 22 EBU07062 Differential gear oil CAUTION Differential gear oil measurement 1 Place the ATV on a level surface 2 Remove the differential gear oil filler bolt and check the oil level It should be up to 3 Install the differential gear oil filler bolt the brim of the filler hole If the level is low add sufficient oil of the recommend ed type to raise it to the specified level Be sure no foreign material enters the dif ferential gear case 1 Differential gear oil 2 Differential gear oil filler bolt 3 Specified level 8 23 Differential gear oil replacement 4 Install the differential gear oil drain bolt 1 Place the ATV ona level surface and ti
4. 750 Fuel line Check fuel hose for cracks or damage Replace if necessary Engine oil Replace Warm engine before draining Engine oil filter cartridge Final gear oil Differential gear oil Replace Check oil level oil leakage Replace Front brake Check operation fluid leakage see NOTE page 8 5 Correct if necessary Rear brake Select lever safety system cable Check operation fluid leakage see NOTE page 8 5 Correct if necessary Check operation Adjust if necessary V belt Check operation Check for cracks or damage Wheels e Check balance damage runout Repair if necessary Wheel bearing Front and rear suspension Check bearing assemblies for looseness damage Replace if damaged e Check operation Correct if necessary Steering system Check operation Replace if damaged Check toe in Adjust if necessary Rear upper and lower knuckle pivots Lubricate with lithium soap based grease Drive shaft universal joint Engine mount Lubricate with lithium soap based grease Check for cracks or damage Front and rear axle boots Check operation Replace if damaged Stabilizer bushes Check for cracks or damage INITIAL Whichever month 3 ROUTINE comes first 1 200 gt 750 e Check all chassis fittings and fasteners e Correct if necessary e Check operation e Adjust headl
5. Compression normal No compression Ask a Yamaha dealer to inspect Use the electric starter to see if there is compression 3 Ignition Wet Wipe clean with dry cloth lanitich sysieni s Remove the Spark is good normal spark plug and check the electrodes Use the electric starter Attach spark plug cap and ground to chassis 4 Battery Engine turns over gt quickly Battery is good Use the electric starter gt Engine turns over Check the battery lead connections slowly and charge the battery if necessary 8 63 Spark is weak y Adjust the spark plug gap or replace the spark plug Ask a Yamaha dealer to inspect No spark Engine overheating A WARNING HOW TO AVOID THE HAZARD POTENTIAL HAZARD Wait for the engine to cool before re Removing the radiator cap when the en moving the radiator cap gine and radiator are still hot Always use a thick rag over the cap Al WHAT CAN HAPPEN low any remaining pressure to escape You could be burned by hot fluid and perore complete femoving thE cap steam blown out under pressure Ask a Yamaha dealer to inspect and repair the cooling system Leakage Level is low check the cooling system for leakage pa No Lf Add coolant See NOTE Wait until the Check the c
6. 8 58 Headlight beam adjustmenrt 8 60 Tail orake light bulb replacement ees ton teva 8 61 Troubleshooting eeeeeeeeeeees 8 62 gt wo N jo Troubleshooting charts 8 63 CLEANING AND STORAGE 9 1 A CIGANING iactcssiverassaceauseceteavenceezesce 9 1 DB SlOrdOO maian 9 3 SPECIFICATIONS 10 1 NOISE REGULATION 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE VE OY gael EA 14 1 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS Read and understand all of the labels on your machine They contain important information for safe and proper operation of your ATV Never remove any labels from your ATV Ifa label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer LOAD LIMIT A WARNING 45 kg 99 Ibs NEVER sit here 3MX 24875 A0 3GC 24877 A0 LOAD LIMIT 85 kg 187 Ibs 4WV 24877 A0 MAXIMUM LOADING LIMIT PULLING LOAD 5390 N 550 kgf 1212 TONGUE WEIGHT 147N 15 kgf 33 Ibf A WARNING Improper ATV use can result in SEVERE INJURY or DEATH 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
7. Checking the rear brake pads Check the brake pads for damage and wear If the thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the pads 1 Brake pad a Brake pad thickness 2 Brake pad plate EBU08751 Checking the brake fluid level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level and replenish when necessary A low brake fluid level may indi cate 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 The rear brake fluid master cylinder reservoir is located behind panel B See page 8 9 for panel removal and installation procedures 8 44 1 Minimum level mark Observe these precautions e When checking the fluid level make sure the top of the master cylinder reservoirs are level e Use only the designated quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor brake perfor mance Recommended brake fluid DOT 4 e Refill with the same type of brake fluid Mix ing fluids may result in a harmful chemical reaction and lead to poor brake perfor mance e Be careful that water does not enter the master cylinder reservoirs when refilling Water will significantly lower the boiling point of the fluid and may result in vapor loc
8. 08 in 1 Loosen the locknut 2 Adjusting bolt 1 Locknut c Rear brake lever free play 8 48 Turn the adjusting bolt in direction to increase free play and in direction to decrease free play 3 Tighten the locknut If correct free play cannot be obtained ask a Yamaha dealer to make that adjustment NOTE When adjusting the rear brake lever free play e Be sure not to step on the brake pedal e Make sure the brake pedal does not move Adjusting the brake pedal The top of the brake pedal should be posi tioned 72 mm 2 8 in above the top of the footrest If not ask a Yamaha dealer to adjust it a Distance between brake pedal and footrest 8 49 A WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag All air must be bled from the brake system Replacement of brake components re quires professional knowledge These procedures should be performed by a Yamaha dealer EBU12590 Adjusting the rear brake light switch The rear brake light switch which is activated by the brake pedal and rear brake lever is properly adjusted when the brake light comes on just before braking takes effect If neces sary adjust the brake light
9. DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the uphill side See pages 7 24 7 29 e f your ATV is traversing a sloping surface Be sure to ride with your weight positioned towards the uphill side of the ATV to main tain 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 dis cover that the ATV is going to tip over dis mount on the uphill side See pages 7 32 7 33 e f your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water 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 un til you have regained adequate braking ability See pages 7 34 7 36 A WARNING Indicates a potential hazard that could result in serious injury or death 7 41 EBU00515 PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection adjustment and lubrica tion will Keep your machine in the safest and most efficient condition possible Safety is an obligation of the machine owner The most important points of machine inspection ad justment and lubrication are explained on the following pages A WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical componen
10. L 0 77 Imp gal 0 92 US gal Carburetor Type quantity Manufacturer BSR42 1 MIKUNI Spark plug Type manufacturer Spark plug gap Clutch type Wet centrifugal automatic 10 3 DPR8EA 9 NGK 0 8 0 9 mm 0 031 0 035 in Model YFM660FA Transmission Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Reverse gear Sub transmission ratio Chassis Frame type Caster angle Trail V belt Shaft drive 41 21 x 24 18 x 33 9 9 544 V belt automatic Left hand operation 25 17 1 471 35 17 2 058 26 21 1 238 Steel tube frame 5 26 mm 1 02 in Tire Type Size 10 4 Tubeless AT25 x 8 12 AT25 x 10 12 YFM660FA Brake Front brake type operation type operation Rear brake Dual disc brake Right hand operation Single disc brake Left hand and right foot operation Suspension Front suspension Rear suspension Double wishbone Double wishbone Shock absorber Front shock absorber Rear shock absorber Coil spring oil damper Coil spring oil damper Wheel travel Front wheel travel Rear wheel travel 170 mm 6 69 in 225 mm 8 86 in Electrical Ignition system Generator system Battery type Battery capacity DC C D I A C magneto YTX20L BS 12 V 18 Ah Headlight type 10 5 Krypton bulb Model YFM660FA Bulb voltage wattage x quant
11. address by sending a postcard listing your ATV model name engine serial number dealer number or dealer s name as it is shown on your warranty identification your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A WARRANTY DEPARTMENT P O Box 6555 Cypress California 90630 This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law EBU00435 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 S 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 contract 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 rat
12. fails to start release the start switch then push the start switch again Pause a few seconds before the next attempt Each cranking should be as short as possible to preserve battery en ergy Do not crank the engine more than 10 seconds on each attempt e Ifthe battery is discharged pull the recoil starter to start the engine 7 If the engine is started with the starter choke in position the starter choke should be returned to position to warm up the engine If the engine is started with the starter choke in position keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter choke to position before riding 6 3 CAUTION See the Engine break in section prior to operating the engine for the first time EBU00180 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not be used The throttle should be opened slightly EBU00182 Warming up To get maximum engine life always warm up the engine before starting off Never acceler ate hard with a cold engine To see whether or not the engine is warm check if it responds to the throttle normally with the starter choke turned off EBU08461 Drive select lever operation and reverse driving CAUTION Before shifting you must stop the ATV and return the throttle lever to the clos
13. fluid leakage e Fill with DOT 4 brake fluid if necessary e Check fuel level e Fill with fuel if necessary e Check oil level e Fill with oil if necessary e Check coolant level in reservoir e Fill with coolant if necessary e Check for leakage e Check for proper throttle cable operation and free play 5 7 8 15 8 20 5 9 8 25 8 30 5 7 5 8 8 21 8 25 5 10 8 42 Wheels and tires e Check tire pressure wear and damage 5 11 5 14 8 53 8 54 Fittings and fasteners e Check all fittings and fasteners 5 10 Lights and switches e Check for proper operation 5 10 8 58 8 61 Axle boots e Check for damage 5 1 8 31 A WARNING POTENTIAL HAZARD Failure to inspect the ATV before oper ating 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 op erating condition Always follow the inspection and main tenance procedures and schedules de scribed in the Owner s Manual 5 2 EBU11011 Front and rear brakes Brake levers and brake pedal e Check that there is no free play in the front brake lever If there is free play have a Yamaha dealer adjust it e Check for correct free play in the rear brake lever If the free play is incorrect adjust it See page 8 48 e Check fo
14. kgf cm 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst 5 12 EBU00159 How to measure tire pressure Use the low pressure tire gauge NOTE The low pressure tire gauge is included as standard equipment Make two measure ments of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Set tire pressures to the following specifica tions Recommended pressure 35 kPa 32 kPa 38 kPa 0 35 kgf em 0 32 kgf cm 0 38 kgf cm Minimum Maximum 5 0 psi 4 6 psi 5 4 psi 30 kPa 27 kPa 33 kPa 0 30 kgf cm 0 27 kgf cm 0 33 kgf cm2 4 3 psi 3 9 psi 4 7 psi 5 13 EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit 5 14 EBU00161 OPERATION A WARNING Indicates a potential hazard that could result in serious injury or death A WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer 6 1 EBU15110 Starting a cold engine A WARNING POTENTIAL HAZARD Freezing control cables i
15. linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type tires specified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper installation 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 instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Products Safety Com mission at 1 800 638 2772 or the ATV Distributor s Safety Hotline at 1 800 852 5344 2 4 A WARNING 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 when refuel ing Do not refuel right after the engine has been running and is still very hot Do not spill gasoline on the engine or exhaust pipe muffler when refueling Never refuel while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pi lot lights of water heaters and clothes dryers 2 5 When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF posi tion Otherwise fuel may leak ou
16. or from 4WD to 4WD LOCK or vice versa while moving may cause the ATV to unexpectedly handle differently This could distract the operator and in crease the risk of losing control and an accident HOW TO AVOID THE HAZARD Always stop the ATV before changing from 2WD to 4WD or from 4WD to 4WD LOCK or vice versa 1 Lever 2 On Command four wheel drive switch 2WD 4WD On Command four wheel drive switch 2WD 4WD To change from 2WD to 4WD stop the ATV and then set the switch to 4WD When the ATV is in 4WD the 4WD indicator id will come on in the speedometer unit display To change from 4WD to 2WD stop the ATV be sure the lever is set to position and then set the switch to 2WD 4 11 1 Differential gear lock switch LOCK 4WD 2 Lever Differential lock switch LOCK AWD To lock the differential gear in 4WD make sure the On Command four wheel drive switch is set to AWD stop the ATV move the lever to position and then set the switch to LOCK When the differential gear is locked the differ ential gear lock indicator DIFF LOCK light will come on along with the indicator in the speedometer unit display To release the differential gear lock stop the ATV and set the switch to 4WD gear A WARNING POTENTIAL HAZARD Riding too fast while the ATV is in 4WD LOCK WHAT CAN HAPPEN All wheels tu
17. rear brake be cause the wheels on the uphill side could come off the ground Apply both the front and rear brakes gradually Whenever possible ride your ATV straight downhill Avoid sharp angles which could al low the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear A WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn Always follow proper procedures for go ing down hills as described in this Own er s Manual Note a special technique is required when braking as you go down a hill HOW TO AVOID THE HAZARD Always check the terrain carefully be fore 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 vehicle to lean sharply to one side Go straight down the hill where possible 7 31 CROSSING A SLOPE Traversing a sloping surface on your ATV re quires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slippery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loose sur
18. rear while backing A WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person be hind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slow ly 6 6 EBU02101 Engine break in There is never a more important period in the life of your machine than the period between zero and 20 hours For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an excessive load on it for the first several hours of running During the first 20 hours the various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle oper ation or any condition which might result in ex cessive engine heating must be avoided However momentary 2 3 seconds maxi mum full throttle operation under load does not harm the engine 6 7 Each full throttle acceleration sequence should be followed with a substantial rest pe riod for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this period consult a Yamaha dealer 0 10 hours Avoid continuous operation above half throt tle Allow a cooling off period of five to ten min utes after every hou
19. sta bility and handling of the ATV 6 12 A WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking EBU15121 A WARNING Indicates a potential hazard that could result in serious injury or death 6 13 A WARNING Indicates a potential hazard that could result in serious injury or death GETTING TO KNOW YOUR ATV This ATV is mainly for utility use but may also be used for recreation This section Riding your ATV provides general ATV riding in structions for recreational riding The skills and techniques described in this section however are appropriate for all types of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic tech niques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill neces sary to enjoy riding safely Before you begin to 7 3 ride be sure you have read this Owner s
20. 2 0 20 in See page 8 42 EBU00070 Front brake lever The front brake lever is located on the right handlebar Pull it toward the handlebar to ap ply the front brake 1 Front brake lever EBU00732 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar Push down on the pedal or pull the lever toward the handlebar to apply the rear brake 1 Rear brake lever 4 15 EBU00608 Drive select lever The drive select lever is used to shift your ma chine into the low high neutral reverse and park positions Refer to page 6 4 for the drive select lever operation 1 Drive select lever 4 16 EBU00855 Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt Then pull forcefully being careful not to pull the rope all the way out 1 Recoil starter A WARNING POTENTIAL HAZARD Starting the engine without setting the drive select lever to the park position p7 WHAT CAN HAPPEN The ATV could start to move unexpect edly which could cause an accident HOW TO AVOID THE HAZARD Set the drive select lever to the park po sition before starting the engine EBU00092 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap 4 17 EBU00093 Fuel cock The fuel cock supplies fuel from the fu
21. 6 years of age A WARNING POTENTIAL HAZARD Failure to follow the age recommenda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc 7 5 This ATV is designed to carry operator and cargo only passengers prohibited 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 passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers 7 6 Apparel A WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet eye pro tection and protective clothing approved motor PES cycle helmet increas PH es your chances of a Hemet severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident 7 7 Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an appr
22. 7 Ib Storage box 2 0 kg 4 4 Ib Trailer hitch Pulling load total weight of trailer and cargo 550 kgf 1 212 Ibf Tongue weight vertical weight on trailer hitch point 15 kgf 33 Ibf 6 11 e Do not exceed the maximum tongue weight You can measure tongue weight with a bathroom scale Put the tongue of the loaded trailer on the scale with the tongue at hitch height Adjust the load in the trailer if necessary to reduce the weight on hitch If you are carrying cargo and towing a trail er include the tongue weight in the maxi mum vehicle load limit Load cargo on the carrier as close to the center of the vehicle as possible Put cargo at the rear of the front carrier and at the front of the rear carrier Center the load from side to side Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an acci dent Make sure the load does not interfere with controls or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slow er you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer Allow more braking distance A heavier ve hicle takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose ter rain carefully Added weight affects the
23. AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner s Manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions Operate at a slow speed and allow extra time and distance for maneuvers when in 4WD LOCK DIFF LOCK As you approach a curve slow down and be gin to turn the handlebars in the desired direc tion As you do so put your weight on the footboard to the outside 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 maneu ver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly Lean towards inside of turn ead ge weight on the outer footboard This procedure should be practiced at slow speed many times in a large off road area with no obstacles 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 procedure again If the riding sur face is slippery or loose it may help to posi tion more of your weight over the front wheels by moving forward on the seat 7 23 Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive br
24. D ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGA 13 1 TIONS 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 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 damage and oil oil filters air filters spark plugs and brake shoes or pads 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 out of oil sustained high rpm full throttle use 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
25. ED SERVICE 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 EBU00436 14 WARNING Indicates a potential hazard that could result in serious injury or death 14 2 EBU00437 PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual EBU00438 AWARNING ERES 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 e on 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 USE WITH DRUGS OR ALCOHOL NEVER CARRY PASSENGERS 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 gt YAMAHA YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004 03 5 0x1 CR E Dear Yamaha ATV Owner Please Revi
26. Man ual completely and understand the operation of the controls Pay particular attention to the safety information on pages 2 1 2 6 Please also read all caution and warning labels on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified instructor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not attempt to operate at maximum perfor mance until you are totally familiar with the machine s handling and performance charac teristics A WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in creased if the operator does not know how to operate the ATV properly in dif ferent situations and on different types of terrain 7 4 HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha They should then regularly practice the skills learned in the course and the operating tech niques described in this Owner s Manu al For more information about the training course contact an authorized ATV dealer or call 1 800 887 2887 Riding your ATV requires skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneu vers Not recommended for children under 1
27. NG POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Own er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly 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 7 26 A WARNING 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 technique 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 possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessiv
28. TATES
29. TION e THIS ATV AND ANY OTHER ATV OVER 90cc SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY 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 WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures easier or clearer EBU15000 IMPORTANT NOTICE This ATV is designed and manufactured for OFF ROAD use only It is illegal and unsafe to oper ate this ATV on any public street road or highway This ATV complies with all applicable OFF ROAD noise level and spark arrester laws and regu lations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU00981 YFM660FAT OWNER S MANUAL 2004 by Yamaha Motor Corporation U S A 1st edition March 2004 LABEL HERE All rights reserved AFFIX DEALER Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohib
30. YAMAHA Fa RIE CNFRNZAZILY e A WARNING EBU00776 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 EBU00941 INTRODUCTION Congratulations on your purchase of the Yamaha YFM660FA It represents the result of many years of Yamaha experience in the production of fine sporting touring and pace setting racing machines With the purchase of this Yamaha you can now appreciate the high degree of crafts manship 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 techniques and skills necessary to ride your ATV It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE e READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS e PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV e 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
31. ae a a 5 5 Engine Oil acesscterzssarcsereucacegazargeseeccness 5 7 RIDING YOUR ATV aeee 7 1 Final gear oll sistsscccareccepeeet atten 5 7 Getting to know your ATV 4 7 3 Differential gear Oil cee 5 8 Ride with care and good Coolant rran iiaea eens anecicmeaies 5 9 judgement sonseeoeeseeeeeeeeeeeeeseeeeee 7 4 Throttle lever s es 5 10 Be careful where you ride 7 16 Fittings and fastene s 00 5 10 Turning your ATV seses 7 22 IQINES sections siete tes tated sata Sis 5 10 Climbing uphill eee 7 24 SWIN OS arisan 5 10 Riding downhill eeeeeeeeee 7 30 LEE E ER E E ce tine 5 11 Crossing a SIOPGC cceceeeeeeees 7 32 How to measure tire pressure 5 13 Crossing through shallow water 7 34 Tire wear limit 5 14 Riding over rough terrain 7 37 Sliding and skidding 0 7 38 g OPERATION inipon nnsa 6 1 What to do if csccece cast eerier chee 7 40 Starting a cold engine 6 1 What df eRe ogame epeeeaer ern ener ae 7 40 Starting a warm engine 00 6 3 Warming UD cccscceeeeeeeeeeeeeeeeees 6 3 Drive select lever operation and reverse Criving ccceeseeeeeeeeees 6 4 Engine break in ccesseeeeeeees 6 7 Parking easa 6 8 8 PERIODIC MAINTENANCE AND ADJUSTMENT scctcissccaetisernsscleeciacteenas 8 1 Owners manual and tool kit 8 1 Periodic maintenance l prica
32. aking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the in side It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills Be sure that you can ma neuver your ATV well on flat ground before at tempting any incline and then practice riding first on gentle slopes Try more difficult climbs only after you have developed your skill In all cases avoid inclines with slippery or loose sur faces or obstacles that might cause you to lose control A WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small hills 7 24 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 lean ing forward and on steeper inclines standing on the footboards and leaning forward over the handlebars A WARNI
33. an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch A WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch care fully for other vehicles Do not ride in areas posted no trespassing Do not ride on private property without getting permission 7 20 Select a large flat area off road to become fa miliar with your ATV Make sure that this area is free of obstacles and other riders You should practice control of the throttle brakes shifting procedures and turning techniques in this area before trying more difficult terrain Al ways avoid riding on paved surfaces the ATV is designed for off road use only and han dling maneuvers are more difficult to perform on pavement Shift to the parking position P and follow the instruction on page 6 1 to start the engine Once it has warmed up you are ready to begin riding your ATV Remember that the engine and exhaust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these components 7 21 With the engine idling shift the drive select le ver to the low position L or the high pos
34. and so on 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 No The warranty on a new ATV cannot be voided or cancelled However if a particular failure is caused by operation or maintenance other than as shown 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 satisfaction at the time of sale and upon your request at any later date In addition each Yamaha ATV dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The reminder of the existing warrant
35. bal When installing the panel be sure not to To install pinch the cables or wires Place the panel in the original position and in stall the bolts 1 Panel B 2 Bolt x 2 8 9 EBU01141 Panel C To remove 1 Remove the front carrier by removing the stay covers at the rear then by removing the bolts 1 Front carrier stay cover x 2 8 10 1 Bolt x 2 top To install 1 Place the panel in the original position and install the quick fasteners 2 Install the front carrier by installing the bolts and tightening them to the specified torques Tightening torques Carrier bolt top 26 Nm 2 6 m kgf 19 ft lbf 1 Bolt x 2 Under fenders Carrier bolt under fenders 2 Remove the quick fasteners and pull the 7 Nm 0 7 m kgf 5 1 ft Ibf panel upward 3 Install the stay covers 1 Quick fastener x 2 2 Panel C 8 11 EBU01013 Panel E To remove Remove the bolts and then take the panel off To install Place the panel in the original position and then install the bolts 1 Panel E 2 Bolt x 6 8 12 EBU00638 Panel F To install To remove Place the panel in its original position Pull outward on the areas shown 1 Panel F 8 13 EBU15041 Panel G To remove 1 Remove the seat See page 4 20 for seat removal and installation proce dures 2 Remove the rear carrier by removing the bolts 1 Bolt x 2 Under fenders 3 Remove the seat un
36. der bracket and the panel by pulling them off 3 14 1 Seat under bracket 2 Panel G To install 1 Place the panel and the seat under bracket in the original position 2 Install the rear carrier by installing the bolts and tightening them to the specified torques Tightening torques Carrier bolt top 26 Nm 2 6 m kgf 19 ft lbf Carrier bolt under fenders 7 Nm 0 7 m kgf 5 1 ft Ibf 3 Install the seat EBU10992 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter cartridge replaced at the inter vals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Remove panel F See page 8 13 for panel removal and installation proce dures 2 Place the ATV ona level surface 3 Start the engine warm it up for several minutes and then turn it off 4 Wait a few minutes until the oil settles 5 Remove the engine oil filler cap and wipe 6 Insert the dipstick in the oil filler hole off the dipstick with a clean rag without screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the mini mum and maximum level marks 1 Engine oil filler cap 2 Dipstick 1 Maximum level mark 2 Minimum level mark 8 16 7 9 If the engine oil is at or below the mini mum level mark add sufficient oil of the recom
37. dlights and tail brake light to make sure they are in working condition Re pair as necessary for proper operation 5 10 EBU11700 Switches Check the operation of all switches Have a Yamaha dealer repair as necessary for proper operation EBU00157 Tires A WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of accident HOW TO AVOID THE HAZARD 1 The tires listed below have been ap proved by Yamaha Motor Co Ltd for this model Other tire combina tions are not recommended C eree a T e Fon oumor mase Teo Rear DUNLOP AT25 x 10 12 KT135 5 11 2 The tires should be set to the rec ommended pressure e Recommended tire pressure Front 35 kPa 0 35 kgf cm2 5 0 psi Rear 30 kPa 0 30 kgf cm2 4 3 psi e Check and adjust tire pressures when the tires are cold e Tire pressures must be equal on both sides 3 Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions The following are minimums Front 32 kPa 0 32 kgf cm7 4 6 psi Rear 27 kPa 0 27 kgf cm 3 9 psi 4 Use no more than the following pressures when seating the tire beads Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5
38. e wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut x 4 8 53 EBU01121 Wheel installation 1 Install the wheel and the nuts NOTE e Tapered nuts are used for both the front and rear wheels Install the nut with its ta pered side towards the wheel e The arrow mark X on the tire must point toward the rotating direction of the wheel 1 Arrow mark 1 Tapered nut 2 Lower the ATV so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf 8 54 EBU00380 Battery This machine is equipped with a sealed type battery Therefore it is not necessary to check the electrolyte or add distilled water in the bat tery If the battery seems to have discharged HOW TO AVOID THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren consult a Yamaha dealer Antidote CAUTION EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magne sia beaten egg or vegetable oil Get prompt medical attention A WARNING EYES Flush with water for 15 minutes and get prompt medical attention Keep batteries away from sparks flames cig arettes or other sources of ignition Ven
39. ed You don t have any out of pocket expenses for covered repairs 14 1 e In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up ta 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 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 factory backed protection even after your Yamaha Limited Warranty expires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note YAMAHA EXTEND
40. ed position otherwise the transmission may be damaged Shifting Neutral to High and High to Low 1 Bring the ATV to a complete stop and re turn the throttle lever to the closed posi tion 2 Apply the brakes then shift by moving the drive select lever along the shift guide NOTE Make sure that the drive select lever is com pletely shifted into position Low L t H High t N Neutral R Reverse P Park 1 Drive select lever 3 Open the throttle lever gradually 6 4 Shifting Neutral to Reverse and Reverse to Park NOTE The drive select lever cannot be shifted into or from reverse or park without applying the rear brake 1 N Bring the ATV to a complete stop and re turn the throttle lever to the closed posi tion Apply the brake pedal Shift from neutral to reverse or from re verse to park and vice versa by moving the drive select lever along the shift guide 6 5 L Low H High N Neutral R Reverse P Park 1 Drive select lever NOTE e When in reverse the reverse indicator light should be on If the light does not come on ask a Yamaha dealer to inspect the electrical circuit e Due to the synchronizing mechanism in the engine the light may not come on un til the ATV starts moving 4 Check behind for people or obstacles and then release the brake pedal 5 Open the throttle lever gradually and con tinue to watch to the
41. edures remove the reser ant as soon as possible voir cap add coolant to the maximum e The radiator fan operation is completely level mark install the reservoir cap and automatic It is switched on or off accord then install the panel ing to the coolant temperature in the radi ator Coolant reservoir capacity up to the maximum level mark If your ATV overheats see page 8 64 for de 0 3 L 0 26 Imp qt 0 32 US at tails CAUTION Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water 8 26 EBU12572 Changing the coolant Place the ATV on a level surface A WARNING Remove panels E and F See pages 8 12 8 13 for panel removal and installation procedures Removing the radiator cap when the en 3 Place a container under the engine and gine and radiator are still hot then remove the coolant drain bolt Use WHAT CAN HAPPEN a trough or a similar object as shown to You could be burned by hot fluid and prevent coolant from spilling on the foot steam blown out under pressure rest HOW TO AVOID THE HAZARD Wait for the engine to cool before re moving the radiator cap Always use a thick rag over the cap Allow any re maining pressure to escape before completely removing the cap N POTENTIAL HAZARD Se Alsi a 1 Coolant drain bolt 8 27 1 Trough 1 Radiator cap 4 Remove the front carrie
42. eed when the differential is locked so it takes more effort to turn the ATV The amount of effort is more the faster you go You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling HOW TO AVOID THE HAZARD Always ride at a slow speed when the ATV is in 4WD LOCK and allow extra time and distance for maneuvers 4 9 1 On Command four wheel drive switch 2WD 4WD 2 Differential gear lock switch LOCK 4WD EBU14091 On Command four wheel drive and differ ential gear lock switches This ATV is equipped with an On Command four wheel drive switch 2WD 4WD and a differential gear lock switch LOCK 4WD Select the appropriate drive according to ter rain and the conditions Two wheel drive 2WD Power is supplied to the rear wheels only Four wheel drive 4WD Power is supplied to the rear and front wheels Four wheel drive with the differential gear locked 4WD LOCK Power is supplied to the rear and front wheels when the differen tial gear is locked DIFF LOCK Unlike the 4WD mode all wheels turn at the same speed 4 10 A WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 4WD LOCK DIFF LOCK or vice versa while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD and in 4WD LOCK in some circumstances Changing from 2WD to 4WD
43. el tank to the carburetor The fuel cock has three positions OFF With the lever in this position fuel will not flow Always turn the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling return the fuel cock lever to the ON position 4 18 OFF Position 1 Arrow mark RES Position 1 Arrow mark 4 19 EBU00095 Starter choke lt N Starting a cold engine requires a richer air fuel mixture A separate starter circuit supplies this mixture Move in direction to turn on the starter choke Move in direction to turn off the starter choke Refer to Starting a cold engine for proper op eration See page 6 1 1 Starter choke EBU00567 Seat To remove the seat pull the seat lock lever upward and pull up the seat at the rear 2 Seat lock lever 4 20 To install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE Make sure that the seat is securely fitted 1 Projection x 2 2 Seat holder x 2 EBU00858 Storage compartment The storage compartment is located u
44. ely slippery or loose surfaces Shift your weight to the uphill side of the 7 27 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 dis mount the ATV on the uphill side Physically turn the ATV around and then descend the hill If you start to roll backwards DO NOT apply either brake abruptly If you are in 2WD apply only the front brake When this ATV is in 4WD or 4WD LOCK all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake ped al will brake the wheels on the downhill side Avoid sudden application of either the front or rear brake because the wheels on the uphill side could come off the ground The ATV could easily tip over backwards Apply both 7 28 the front and rear brakes gradually or dis mount the ATV immediately on the uphill side WARNING POTENTIAL HAZARD Stalling rolling backwards or improper ly dismounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Shift to the parking posi
45. en the light switch is on OFF All electrical circuits are switched off The key can be removed in this position 4 1 1 Main switch EBU00802 Indicator and warning lights oe get oleae oss agaae B oS Soe SERR Reverse indicator light R Park indicator light P Four wheel drive indicator iQ ain Coolant temperature warning light Differential gear lock indicator light DIFF LOCK Low range indicator light L High range indicator light H Neutral indicator light N E 4 2 EBU10601 Differential gear lock indicator light DIFF LOCK This indicator light and the differential gear lock indicator in the display come on when the differential gear lock switch is set to the 4WD LOCK position NOTE When the switch is set to LOCK the differ ential gear lock indicator light will flash until the differential gear is locked EBU01122 Low range indicator light L This indicator light comes on when the drive select lever is in the L position EBU01064 High range indicator light H This indicator light comes on when the drive select lever is in the H position EBU00972 Neutral indicator light N This indicator light comes on when the drive select lever is in the N position EBU00867 Reverse indicator light R This indicator light comes on when the drive select l
46. er element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally op eration without the air filter element will af fect carburetor jetting with subsequent poor performance and possible engine overheating EBU01066 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester 1 Remove the bolts 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon depos its from the spark arrester portion of the tailpipe 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install and tighten the bolts 1 Bolt x 3 1 Tailpipe 2 Spark arrester 8 38 A WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poison ing possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool pri or to touching exhaust components Do not start the engine when cleaning the exhaust system EBU06411 V belt cooling duct check hose If dust or water collects in the V belt cooling duct check hose remove the hose and clean it 1 V belt cooling duct check hose Left side 8 39 EBU08741 V belt case drain pl
47. ever is in the R reverse position NOTE If the indicator light flashes or the spoeedome ter does not show the speed while riding have a Yamaha dealer check the speed sen sor circuit EBU00609 Park indicator light P This indicator light comes on when the drive select lever is in the P park position 4 3 EBU11312 Four wheel drive indicator j amp This indicator comes on when the 2WD AWD switch is set to the 4WD position The differential gear lock indicator DIFF LOCK in the four wheel drive indicator also comes on when the LOCK 4WD switch is set to the AWD LOCK position NOTE Due to the synchronizing mechanism in the differential gear case the four wheel drive in dicator may not come on until the ATV starts moving EBU00860 Coolant temperature warning light E When the coolant temperature reaches a specified level this light comes on to warn that the coolant temperature is too hot If the light comes on during operation stop the en gine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes CAUTION e The engine may overheat if the ATV is overloaded If this happens reduce the load to specification e After restarting make sure that the light is out Continuous use while the light is on may cause damage to the engine EBU15100 Speedometer unit
48. ew 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 sta pa p ATV Model Purchase Dote Address Primary I D gi Dealer Nome amp Address 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 POSTAGE NECESSARY IF MAILED IN THE UNITED S
49. 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 EBU10842 Engine oil Make sure the engine oil is at the specified level Add oil as necessary See pages 8 15 8 20 CAUTION e 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 high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher e Make sure that no foreign material en ters the crankcase Recommended engine oil type and quantity See page 10 2 5 7 EBU00493 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 21 8 22 for details Recommended oil SAE 80 API GL 4 Hypoid gear oil If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used EBU00678 Differential gear oil Make sure the differential gear oil is at the specified level Add oil as necessary See pages 8 23 8 25 for details Recommended oil SAE 80 API GL 4 Hypoid gear oil 5 8 EBU12530 Coolant Check the coolant level in the coolant reser voir when the engine is cold The coolant
50. 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 technique 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 proper gear range 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 side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual 2 3 Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when op erating over obstacles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by prac ticing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce 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
51. faces by pointing the front wheels slightly up hill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel 7 32 A WARNING 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 technique 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 possible 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 7 33 CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving shallow water of up to a maximum of 35 cm 14 inches in depth Before entering the wa ter choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or up set the ATV Drive slowly and carefully A WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN T
52. for your ATV Your Yamaha dealer has a variety of genuine Yamaha accessories Other ac cessories may also be available on the market However it is not possible for Yamaha to test all non Yamaha accesso ries nor have any control over the quality or Suitability of them Choose a genuine Yamaha accessory or one that is equiva lent in design and quality 6 10 e Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object attached to the han dlebars 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 accessories The ATV may handle differ ently than it does without accessories EBU09601 Loading Cargo or a trailer can change the stability and handling of an ATV You must use common sense and good judgment when carrying car go or towing a trailer Keep the following points in mind e Never exceed the weight limits shown An overloaded ATV can be unstable MAXIMUM LOADING LIMIT e Vehicle loading limit total weight of cargo rider and accessories and tongue weight 220 kg 485 Ib Front carrier 45 kg 99 Ib Rear carrier 85 kg 18
53. ft and right side to the same set ting EBU01002 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV The auxiliary DC jack can be used for suitable work lights radios etc The auxiliary DC jack should only be used when the engine is running 1 Auxiliary DC jack cap 1 Set the light switch to OFP 2 Start the engine See pages 6 1 6 3 3 Open the auxiliary DC jack cap and then insert the accessory power plug into the jack 4 24 1 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A 4 When the auxiliary DC jack is not being used cover it with the cap CAUTION e Do not use accessories requiring more than the above maximum capac ity This may overload the circuit and cause the fuse to blow e If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may be come difficult e Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged EBU00112 A WARNING Indicates a potential hazard that could result in serious injury or death 4 25 PRE OPERATION CHECKS Before using this machine check the following points Engine oil Coolant reservoir tank Final gear oil Differential gear oil Throttle ROUTINE e Check operation free play fluid level and
54. ghten it to the specified torque 2 Place a container under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and differential gear oil drain bolt to drain Tightening torque Differential gear oil drain bolt 10 Nm 1 0 m kgf 7 2 ftlbf the oil 5 Fill the differential gear case with the rec ommended oil Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 28 L 0 25 Imp qt 0 3 US qt CAUTION Be sure no foreign material enters the dif ferential gear case 1 Differential gear oil drain bolt 6 Install the differential gear oil filler bolt and then tighten it to the specified torque 8 24 Tightening torque 7 Differential gear oil filler bolt 23 Nm 2 3 m kgf 16 ft Ibf Check for oil leakage If oil leakage is found check for the cause 8 25 EBU12560 Cooling system 1 Place the ATV on a level surface 2 Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine tem perature NOTE The coolant should be between the minimum and maximum level marks 1 Coolant reservoir tank cap 2 Maximum level mark 3 Minimum level mark 3 If the coolant is at or below the minimum NOTE level mark remove panel D See e If water is added have a Yamaha dealer pages 8 7 8 8 for panel removal and in check the antifreeze content of the cool stallation proc
55. he training courses nearest you e Always follow the age recommendation Achild under 16 years old should never operate an ATV with engine size greater than 90cc 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 e Never carry passenger on an ATV e Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and streets e Never operate an ATV on any public street road or highway even a dirt or gravel one 2 1 e Never operate an ATV without wearing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants e Never consume alcohol or drugs before or while operating this ATV e Never operate at speeds too fast for your skills or the conditions Always go at a speed that is proper for the terrain visibility and operating conditions and your experience e Never attempt wheelies jumps or other stunts e 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 man ual e Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation e Always go slowly and be extra careful when
56. his 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 amoao ATV LIMITED WARRANTY 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 shall 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 dealer s 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 author ized 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 YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIE
57. ified rat 1 Main fuse 2 Spare main fuse Tacas 3 Headlight fuse a lonio tuse ing Never use a material in place of the 5 Auxiliary DC jack fuse 6 Four wheel drive fuse proper fuse 7 Signaling system fuse 8 Backup fuse for odometer and clock F 9 Spare fuse x 3 CAUTION To prevent accidental short circuiting Specified fuses turn off the main switch when checking or Main fuse replacing a fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four wheel drive fuse Signaling system fuse Backup fuse EBU11252 Replacing a headlight bulb If a headlight bulb burns out replace it as fol lows 1 Remove the cover at the rear of the headlight by pulling it off 1 Headlight bulb holder cover 3 Remove the headlight bulb holder by push ing it in and turning it counterclockwise 1 Cover 2 Remove the headlight bulb holder cover by pulling it off 1 Headlight bulb holder 8 58 4 Remove the defective bulb by pulling it out A WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flamma ble HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it 5 Insert a new headlight bulb into the bulb holder by pushing it in 8 59 CAUTION Do not touch the glass part of the head ligh
58. ight beam Fittings and fasteners Lights and switches Since these items require special tools data and technical skills have a Yamaha dealer perform the service NOTE e Recommended brake fluid DOT 4 e Brake fluid replacement e When disassembling the master cylin ders or calipers replace the brake flu id Normally check the brake fluid level and add fluid as required e On the inner parts of the master cylin ders and calipers replace the oil seals every two years A WARNING Replace i AA E tee four Indicates a potential hazard that could pele S APAA eee result in serious injury or death EBU00614 Panel removal and installation The panels illustrated need to be removed to perform some of the maintenance described in this chapter Refer to this section each time a panel has to be removed or reinstalled 1 Panel A 2 Panel C 3 Panel B 8 6 1 Panel D 3 Panel F 2 Panel E 4 Panel G EBU00879 Panels A and D To remove 1 Remove the seat See page 4 20 for seat removal and installation proce dures 2 Pull outward on the area shown and then pull upward as shown 1 PanelA 8 7 Panel D To install 1 Insert the panel projections in the numer ical order shown in the illustration and then push inward on the area shown 2 Install the seat 1 Panel D 1 Panel A 8 8 EBU00962 Panel B CAUTION To remove Bsmove the
59. in traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or slid ing 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 reduce 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 techniques completely WHAT TO DO If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight over the front wheels for better control See pages 7 22 7 23 e f your ATV begins to tip while turning Lean more into the turn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See pages 7 22 7 23 7 40 e If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerat ing is not recommended until you have cor rected the slide See pages 7 38 7 39 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have for ward 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
60. ires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that spec ified in your Owner s Manual Remember that wet brakes may have re duced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings 7 34 Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability 7 35 CAUTION After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case the V belt cooling duct check hose and the drive select lever box check hose Also remove the V belt case drain plug to drain any water that may have accumulat ed Wash the ATV in fresh water if it has been operated in salt water or muddy con ditions 1 Air filter case check hose 1 V belt case drain plug RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may result 7 37 A WARNING POTENTIAL HAZARD Improperly operating over obstacle
61. ited Printed in Japan P N LIT 11626 18 03 EBU00014 A WARNING Indicates a potential hazard that could result in serious injury or death CONTENTS LOCATION OF THE WARNING AND SPECIFICATION LABELG 1 1 SAFETY INFORMATION 2 1 DESCRIPTION AND MACHINE o D IDENTIFICATION oseese 3 1 Identification number records 3 2 Key identification number 3 2 Vehicle identification number 3 3 Model label s ssseseseeeeeeeenees 3 3 CONTROL FUNCTIONG Main switch onli cccsediclsntaavaceaniadestiesce Indicator and warning lights Speedometer unit c cceccceee Handlebar switches 000 Throttle lever cceceeesseeeeeeeeeseees Speed limiter ccccccesssseeeeeeees Front brake l VEr ccsceeeeeeeeees Brake pedal and rear brake Recoil starter ccceceeeeeeeeeeeeeee Fuel tank CAD aisiasccctice aici catacte Fuel COCK 2 ccccccceeeecneeeceeeeceees Storage compartment 000 Front carrier ccehs since cuvsenanocentastucneneee Rear carrier faitiiaud vessonstavnivents citineds Front and rear shock absorber adjustment 2vvctwndeesuehentaces Meola ses Auxiliary DC jack aacc5 cen uses PRE OPERATION CHECKS 5 1 Parking on a SlIOPGC ceeeeeeee 6 9 Front and rear brakes 006 5 3 Accessories and loading 6 10 F el i era ee IS t
62. ith the specified plug Specified spark plug DPR8EA 9 NGK 8 33 Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification Spark plug gap 0 8 0 9 mm 0 031 0 035 in a Spark plug gap 2 Clean the gasket surface Wipe off any grime from the threads Install the spark plug and tighten it to the specified torque 3 Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 5 ft lbf NOTE If a torque wrench is not available when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possible 4 Install the spark plug cap 5 Install the panel 8 34 EBU12111 Air filter element cleaning NOTE _ There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case 1 Air filter case check hose 1 Remove the seat See page 4 20 for seat removal and installation proce dures 2 Remove the air filter case cover by un hooking the holders dp UNLOCK g 1 Holder x 5 2 Air filter case cover 3 Remove the air filter element 1 Frame 2 Air filter element 1 Air filter element 4 Remove the air filter element from its frame 5 Wash the air filter element gently but th
63. ition H Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional con trol Avoid higher speeds until you are thor oughly familiar with the operation of your ATV When slowing down or stopping release the throttle and apply the brakes smoothly and evenly Improper use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident CAUTION Do not shift from drive position low L to high H or vice versa without coming to a complete stop Damage to the engine or drive train may occur TURNING YOUR ATV To achieve maximum traction while riding off road in 2WD or 4WD the two rear wheels are mounted solidly on one axle and turn together at the same speed Furthermore when riding in 4WD LOCK DIFF LOCK the front wheels also turn together at the same speed Therefore unless the wheel on the inside of the turn is allowed to slip or lose some trac tion the ATV will resist turning A special turn ing 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 WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causing a collision or overturn 7 22 HOW TO
64. ity Headlight Tail brake light Indicator light Neutral indicator light Reverse indicator light Coolant temperature warning light Park indicator light High range indicator light Low range indicator light Differential gear lock indicator light 12 V 30W 30Wx2 12V 5W 21Wx1 LED LED LED LED LED LED LED Fuses Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four wheel drive fuse Signaling system fuse Backup fuse 10 6 30A 15A 10A 10A 3A 10A 10A EBU00430 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inop erative by any person other than for purposes of maintenance repair or replacement of any de vice or element of design 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 Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Intake system Air cleaner element Intake duct 11 1 EBU13653 MAINTENANCE RECORD Copies of work orders and or receipts for parts you pu
65. k 8 45 e Brake fluid may deteriorate painted surfac es or plastic parts Always clean up spilled fluid immediately e Have a Yamaha dealer check the cause if the brake fluid level goes down EBU11860 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking e Replace the oil seals every two years e Replace the brake hoses every four years 8 46 EBU11870 Front brake lever free play The front brake lever should have a free play of zero mm zero in at the lever end If not have a Yamaha dealer check the brake sys tem a Front brake lever free play 8 47 A WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing e Make sure the brakes operate smoothly and that the free play is correct e Make sure the brakes do not drag e Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re quires professional knowledge These procedures should be performed by a Yamaha dealer EBU09631 Adjusting the rear brake lever and brake pedal Adjusting the rear brake lever The rear brake lever free play should be 0 5 2 mm 0 02 0
66. lev el will vary with engine temperature The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir If the coolant level is at or below the minimum level mark add distilled water to bring the level up to maximum level mark Change the coolant every two years See pages 8 25 8 30 for details CAUTION Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water Coolant reservoir capacity up to the maximum level mark 0 3 L 0 26 Imp qt 0 32 US qt 5 9 A WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine 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 re moving the radiator cap Always use a thick rag over the cap Allow any re maining pressure to escape before completely removing the cap EBU01083 Throttle lever Check to see that the throttle lever operates correctly It must open smoothly and spring back to the idle position when released Have a Yamaha dealer repair as necessary for proper operation EBU11620 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque EBU10030 Lights Check the hea
67. mended type to raise it to the cor rect level Insert the dipstick into the oil filler hole and then tighten the oil filler cap Install the panel 8 17 To change the engine oil with or without oil filter cartridge replacement 1 Remove panel F See page 8 13 for panel removal and installation proce dures Start the engine warm it up for several minutes and then turn it off Place an oil pan under the engine to col lect the used oil and then remove the en gine oil filler cap Remove the engine oil drain bolt to drain the oil from the crankcase 1 Engine oil drain bolt NOTE Skip steps 5 9 if the oil filter cartridge is not being replaced 5 Remove panels D and E See pages 8 7 8 8 and 8 12 for panel remov al and installation procedures 6 Remove the oil filter cartridge with an oil filter wrench al Y N X 1 Engine oil filter cartridge 2 Oil filter wrench NOTE An oil filter wrench is available at a nearby Yamaha dealer 7 Apply a light coat of engine oil to the O ring of the new oil filter cartridge NOTE Make sure the O ring is seated properly 1 O ring 8 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft Ibf 9 Install panels D and E 10 Install the engi
68. n cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or colli sion HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding Apply the rear brake lever or brake pedal 2 Turn the fuel cock to ON 3 Turn the main switch to ON and the en gine stop switch to O 4 Shift the drive select lever into the neutral or park position NOTE Position Cold engine start e When the drive select lever is in the neu ambient temperature above tral or park position if either indicator light 25 C 80 F and warm engine does not come on ask a Yamaha dealer start position to inspect the respective electric circuit e The engine can be started in any gear if AMBIENT TEMP STARTER CHOKE POSITION 30 c 0 O the rear brake lever or brake pedal is ap plied However it is recommended to shift into neutral or park before starting the engine 5 Use the starter choke in reference to the figure Position Q Cold engine start ambient temperature below 5 C 40 F a Starter choke 1 Fully open Position Cold engine start 2 Half open 3 Closed ambient temperature at 0 C 6 Completely close the throttle lever and 30 F 30 C 90 F and start the engine by pushing the start warming up position switch 6 2 NOTE e f the engine
69. nder the seat See page 4 20 for seat removal and installation procedures When storing the owners manual or other documents in the storage compartment be sure to wrap them in a plastic bag so that they will not get wet When washing the ATV be careful not to let any water enter the storage compartment 1 Storage compartment 4 21 EBU00582 Front carrier Maximum load limit 45 kg 99 Ib EBU00583 Rear carrier Maximum load limit 85 kg 187 Ib EBU01124 Front and rear shock absorber adjustment The spring preload can be adjusted to suit the riders weight and riding conditions NOTE When adjusting the rear shock absorbers the rear wheels need to be removed See pages 8 53 8 54 for removal and installation procedures Adjust the spring preload as follows To increase the spring preload turn the ad justing ring in direction To decrease the spring preload turn the ad justing ring in direction 1 Spring preload adjusting ring 2 Position indicator NOTE A special wrench can be obtained at a Yamaha dealer to make this adjustment Standard position B A Minimum soft E Maximum hard 1 Special wrench 4 23 WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the le
70. ne oil drain bolt and then tighten it to the specified torque Tightening torque Engine oil drain bolt 30 Nm 3 0 m kgf 22 ft lbf 11 Add the specified amount of recommend ed engine oil and then install the engine oil filler cap and tighten it Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacement 1 9 L 1 67 Imp qt 2 01 US qt With oil filter cartridge replacement 2 0 L 1 76 Imp gt 2 11 US qt CAUTION e In order to prevent clutch slippage 12 13 14 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 high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase Start the engine and warm it up for seve ral minutes While warming up check for oil leakage If oil leakage is found turn the engine off immediately and check for the cause Turn the engine off and then check the oil level and correct it if necessary Install panel F 8 20 EBU08801 Final gear oil The final gear case must be checked for oil leakage before each ride If any leakage is found have a Yamaha dealer check and re pair the ATV Replacing the final gear oil 1 Place the ATV on a level surface 2 Place a container under the final gear case to collect the used oil
71. ne speed and in direc tion to decrease the engine speed Specified idle speed 1 450 1 550 r min 8 41 1 Throttle stop screw 4 Install the panel EBU00303 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clear ance must be adjusted regularly This adjust ment however should be left to a professional Yamaha service technician EBU00307 Throttle lever adjustment NOTE Adjust the engine idling speed before adjust ing the throttle lever free play 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle le ver free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut 1 Locknut a Throttle lever free play 2 Adjusting bolt 8 42 EBU03050 Select lever safety system cable adjustment The select lever safety system cable stretch es with use resulting in improper function To prevent this the cable must be adjusted regu larly This adjustment however should be left to a Yamaha dealer EBU13090 Front brake pad check Check the brake pads for damage and wear If a brake pad thickness is less than 1mm 0 04 in have a Yamaha dealer replace the pads as a set 1 Brake pad a Brake pad thickness NOTE The wheels need to be removed to check the brake pads See pages 8 53 8 54 for remov al and installation procedures 8 43 EBU08781
72. need to drain the fuel system Con sult a Yamaha dealer if the fuel system needs to be drained instead 9 3 Remove the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine over seve ral times to coat the cylinder wall with oil Lubricate all control cables Block up the frame to raise all wheels off the ground Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering If storing in a humid or salt air atmo sphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat cover 7 Remove the battery and charge it Store it in a dry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 80 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the machine 9 4 EBU00428 SPECIFICATIONS YFM660FA Dimensions Overall length 2 085 mm 82 1 in Overall width 1 150 mm 45 3 in Overall height 1 210 mm 47 6 in Seat height 880 mm 34 6 in Wheelbase 1 275 mm 50 2 in Ground clearance 275 mm 10 8 in Minimum turning radius 3 200 mm 126 0 in Basic weight With oil and full fuel tank 290 kg 639 Ib Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Dis
73. 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 handle bars and both feet on the footboards of your ATV during operation Avoid wheelies and jumping You may lose control of the ATV or overturn A WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off 7 13 Modifications A WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle 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 autho rized ATV dealer 7 14 Exhaust system The exhaust system on the ATV is very hot during and following operation To prevent burns avoid touching the exhaust system Park the ATV in a
74. on sys tems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your machine requires any repair take it to a Yamaha dealer The skilled technicians at a Yamaha dealer ship have the tools experience and know how to properly service your machine Use only genuine Yamaha parts on your machine Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to ex pensive repair bills 8 62 7 WARNING POTENTIAL HAZARD Checking the fuel system while smok ing or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing se vere injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnac es EBU08061 Troubleshooting charts Starting problems or poor engine performance lever to ON Creactne Lom note fo Fuel cocks Clean the fuel cock Turn the fuel cock lever to OFF Remove the fuel hose from the fuel cock gt Turn the fuel cock R Some fuel lever to RES Restart the engine No fuel Supply fuel There is compression There is fuel 1 Fuel Check if there is fuel in the fuel tank 2 Compression
75. oolant level in the leakage coolant S s engine has cooled reservoir tank and or radiator 3 Restart the engine If the engine overheats again ask a Level is OK i Yamaha dealer to inspect and or repair the cooling system If it is difficult to get the recommended coolant tap water can be temporarily used provided that it is changed to the recommended coolant as soon as possible EBU00419 CLEANING AND STORAGE A CLEANING Frequent thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components 1 Before cleaning the machine 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 2 If the engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job 9 1 CAUTION Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car wash ers 4 Once the majority of the dirt has been hosed off wash all surfaces with warm wate
76. operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV e 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 e Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed e Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills 2 2 e 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 surfaces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed e 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 back ward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible e Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose sur
77. oroughly in solvent WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element 6 Squeeze the excess solvent out of the air filter element and let it dry CAUTION Do not twist the air filter element when squeezing it 8 36 7 Inspect the air filter element and replace it if damaged 8 Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter el ement NOTE The air filter element should be wet but not dripping 9 Pull the air filter element over its frame 10 Install the air filter element 1 Breather hose 11 Install the air filter case cover and be sure to connect the hose 12 Install the seat NOTE The air filter element should be cleaned every 20 40 hours It should be cleaned and lubri cated more often if the machine is operated in extremely dusty areas Each time air filter ele ment maintenance is performed check the air inlet to the air filter case for obstructions Check the air filter element rubber joint to the carburetor and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine 8 37 CAUTION Never operate the engine with the air filt
78. oved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants Do not operate after consuming alcohol or A WARNING drugs Operator s performance capability is reduced by the influence of alcohol or drugs POTENTIAL HAZARD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV 7 8 Pre operation checks Always perform the pre operation checks list ed on page 5 1 before riding for safety and A WARNING POTENTIAL HAZARD proper care of the ATV A WARNING POTENTIAL HAZARD Failure to inspect the ATV before oper ating 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 op erating condition Always follow the in spection and maintenance procedures and schedules described in the Owner s Manual 7 9 Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of
79. p the engine and then check the coolant level in the radiator If it is low add more coolant until it reaches the top of the radiator 15 Check for coolant leakage NOTE If any leakage is found have a Yamaha deal er check the cooling system 16 Install the panels and the front carrier 8 30 EBU00862 Axle boots Check the protective boots for holes or tears If any damage is found have them replaced by a Yamaha dealer 1 Front axle boot x 2 each side 8 31 EBU00864 Spark plug inspection Removal 1 Remove panel A See pages 8 7 8 8 for panel removal and installation proce dures 2 Remove the spark plug cap 1 Spark plug cap 3 Use the spark plug wrench in the tool kit to remove the spark plug as shown 8 32 1 Spark plug wrench Inspection The spark plug is an important engine compo nent and is easy to inspect The condition of the spark plug can indicate the condition of the engine The ideal color on the white insu lator around the center electrode is a medium to light tan color for a ATV that is being ridden normally Do not attempt to diagnose such problems yourself Instead take the ATV toa Yamaha dealer You should periodically re move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should re place the spark plug w
80. place where pedestrians or children are not likely to touch it A WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en gine area could catch fire Someone touching the exhaust system during or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material 7 15 Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it BE CAREFUL WHERE YOU RIDE This ATV is designed for off road use only Riding on paved surfaces can cause loss of control A WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of con trol HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets 7 16 Do not ride on any public road street or high way Riding on public roads can result in collisions with other vehicles A WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Neve
81. placement 660 cm Bore x stroke 100 x 84 mm 3 94 x 3 31 in Compression ratio 9 1 1 Starting system Electric and recoil starter Lubrication system Wet sump 10 1 Model YFM660FA Engine oil Type Recommended engine oil classification Quantity Without oil filter cartridge replacement With oil filter cartridge replacement z YAMAL UBE 4 20W40 or SAE 20W40 0 ie 30 50 70 ne au S Ls a E E al YAMALUBE 4 10W30 or SAE 10W30 i i SAE 5W30 i i 20 10 o 10 20 30 40 50 C API Service SE SF SG type or higher CAUTION _ _ O OSS O In order to prevent clutch slippage since the en gine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher 1 9 L 1 67 Imp qt 2 01 US qt 2 0 L 1 76 Imp qt 2 11 US qt YFM660FA Final gear case oil Type Quantity SAE80 API GL 4 Hypoid gear oil 0 25 L 0 22 Imp qt 0 26 US qt Differential gear case oil Type Quantity SAE80 API GL 4 Hypoid gear oil 0 28 L 0 25 Imp qt 0 30 US qt Radiator capacity including all routes 1 80 L 1 58 Imp qt 1 90 US qt Air filter Wet type element Fuel Type Fuel tank capacity Fuel reserve amount UNLEADED GASOLINE ONLY 20 L 4 40 Imp gal 5 28 US gal 3 5
82. r and mild detergent type soap An old toothbrush or bottle brush is handy for hard to get at places 5 Rinse the machine off immediately with clean water and dry all surfaces with a chamois clean towel or soft absorbent cloth 6 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 7 Automotive type wax may be applied to all painted and chrome plated surfaces Avoid combination cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it idle for several minutes 9 2 amp WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent 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 EBU00530 B STORAGE Long term storage 60 days or more of your machine will require some preventive proce dures to guard against deterioration After thoroughly cleaning the machine prepare for storage as follows 1 Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equiva lent product Specified amount 1 oz of stabilizer to each gallon of fuel or 7 5 cc of stabilizer to each liter of fuel NOTE Use of fuel stabilizer and conditioner elimi nates the
83. r and panel C 5 See pages 8 10 and 8 11 for removal 6 and installation procedures 8 28 Remove the radiator cap Remove panel D See pages 8 7 8 8 for panel removal and installation proce dures Remove the coolant reservoir cap Disconnect the hose on the coolant res ervoir side and then drain the coolant from the coolant reservoir 11 Install the coolant reservoir hose 12 Pour the recommended coolant into the reservoir to the maximum level mark and then install the reservoir cap and panel D 13 Pour the recommended coolant into the radiator until it is full and then install the radiator cap Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for 1 Coolant reservoir drain hose 9 After draining the coolant thoroughly aluminum engines flush the cooling system with clean tap Antifreeze and water mixing ratio water 1 1 10 Replace the coolant drain bolt washer if it Total amount is damaged install the coolant drain bolt 1 8 L 1 58 Imp qt 1 90 US qt and then tighten it to the specified torque Coolant reservoir capacity up to the maximum level mark Tightening torque 0 3 L 0 26 Imp qt 0 32 US qt Coolant drain bolt 10 Nm 1 0 m kgf 7 ft Ibf 8 29 CAUTION Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water 14 Start the engine and let it idle for several minutes Sto
84. r correct brake pedal height If the pedal height is incorrect have a Yamaha dealer adjust it e Check the operation of the brake levers and pedal They should move smoothly and there should be a firm feeling when the brakes are applied If not have a Yamaha dealer inspect the brake system Brake fluid level Check the brake fluid level Add fluid if neces sary See pages 8 44 8 46 Recommended brake fluid DOT 4 5 3 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs Apply the brakes firmly for one minute If the lever moves slowly inward there may be a leak in the brake system If there is any leakage the brake system should be inspected by a Yamaha dealer 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 per formance inspect the brake pads for wear See page 8 43 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 problem with the brakes If a problem cannot be corrected by the ad justment procedures provided in this manual have a Yamaha dealer check for the cause 5 4 EBU01085 Fuel Make sure there is sufficient ga
85. r of operation Vary the speed of the machine from time to time Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the machine freely but do not use full throttle at any time After break in Avoid prolonged full throttle operation Vary speeds occasionally EBU00612 Parking When parking stop the engine and shift the drive select lever into the park position then turn the fuel cock to the OFF position EBU06151 Parking on a slope A WARNING POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control in creasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the machine transversely across the in cline apply the parking brake and 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 Bring the machine to a stop by applying the brakes Stop the engine With the brake pedal applied shift the drive select lever to the park position P 6 9 EBU00221 Accessories and loading EBU00222 Accessories Accessories can affect the handling and con trol of your ATV Keep the following in mind when considering an accessory or operating an ATV which has accessories e Choose only accessories designed
86. r 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 7 17 a er G cas i JE A ang S gt a ro J Know the terrain where you ride Ride cau tiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and oth 7 er hidden hazards which may cause the ATV to upset Al 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 overturn ing or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when op erating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV 7 18 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 vehicle control which could result in an acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain 7 19 When riding in
87. rchase and install will be required to docu ment maintenance done in accordance with the warranty The chart below is printed only as a re minder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF MILEAGE SERVICING DEALER SERVICE NAME AND ADDRESS neva km mi 320 200 1 200 750 2 400 1 500 4 800 3 000 7 200 4 500 9 600 6 000 12 000 7 500 14 400 9 000 16 800 10 500 19 200 12 000 21 600 13 500 24 000 15 000 12 1 EBU00432 YAMAHA MOTOR CORPORATION U S A Yamaha Motor Corporation U S A hereby warrants that each new Yamaha ATV purchased from an autho rized Yamaha ATV dealer in the continental United States will be free from defects in material and work manship for the period of time stated herein subject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha ATVs _ shall be six 6 months from the date of purchase DURING THE PERIOD OF WARRANTY any authorized Yamaha ATV dealer will free of charge repair or replace at Yamaha s option any part adjudged defec tive 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 warran ty period All parts replaced under warranty become property of Yamaha Motor Corporation U S A GENERAL EXCLUSIONS from t
88. ries or car go The ATV s handling may be adversely af fected Reduce your speed when adding additional loads MAXIMUM LOADING LIMIT Vehicle loading limit 220 kg 485 Ib Total weight of cargo rider and accessories and trailer hitch vertical load Front carrier 45 kg 99 Ib Rear carrier 85 kg 187 lb e Storage box 2 0 kg 4 4 Ib Trailer hitch Pulling load 550 kgf 1 212 Ibf Total weight of trailer and cargo Tongue weight 15 kgf 33 Ibf Vertical weight on trailer hitch point 7 11 A WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in your Owner s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the footboards dur ing operation Otherwise your feet may con tact the rear wheels 7 12 A WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation WHAT CAN HAPPEN Removing even one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall
89. rn at the same speed when the differential is locked so it takes more effort to turn the ATV The amount of effort is more the faster you go You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling HOW TO AVOID THE HAZARD Always ride at a slow speed when the ATV is in 4WD LOCK and allow extra time and distance for maneuvers 4 12 NOTE e When the switch is set to LOCK the dif ferential gear lock indicator light will flash until the differential gear is locked e When the indicator light is flashing turn ing the handlebar back and forth will help the differential gear lock to engage e Riding before the differential gear lock is properly engaged e g when the indica tor light is flashing will cause the engine speed to be limited until engagement is complete e When the ATV is in 4WD LOCK the maximum traveling speed is limited to 35 km h 22 mph However if conditions require full engine power to be available push and hold the override switch to dis able the 4WD LOCK speed limiter See page 4 8 for a detailed explanation of this switch EBU00062 Throttle lever Before starting the engine check the throttle Once the engine is running movement of the to be sure it is operating smoothly Make sure throttle lever will increase the engine speed it returns to the idle position as soon as the le Regulate the speed of the machine by
90. ry and recharge it EBU00607 Start switch S The starter motor cranks the engine when this switch is pushed CAUTION See starting instructions prior to starting the engine See page 6 1 for details 4 7 EBU12050 Engine stop switch KO Make sure that the engine stop switch is set to C before starting the engine The engine stop switch controls ignition and can be used at all times to stop the engine especially in an emergency The engine will not start or run when the engine stop switch is set to 1 Override switch OVERRIDE EBU13781 Override switch OVERRIDE Top speed is normally limited when operating in 4WD LOCK If conditions require more en gine power when riding forward push and hold this switch to override the 4WD LOCK speed limiting function See page 4 11 for a detailed explanation about the differential gear lock switch and its function Releasing the switch restores the speed limiting function While this switch is pushed the segments of the speedometer digits will appear as shown in the figure 4 8 NOTE If the digits of the speedometer appear as shown when the switch is NOT being pushed this could indicate a malfunction in the electri cal system In this case take the ATV toa Yamaha dealer at the first opportunity A WARNING POTENTIAL HAZARD Riding too fast while the ATV is in 4WD LOCK WHAT CAN HAPPEN All wheels turn at the same sp
91. s WHAT CAN HAPPEN Could cause loss of control or a colli sion Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always fol low proper procedures as described in the Owner s Manual SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide If unexpected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions position ing your weight over the front wheels will sometimes help 7 38 If the rear wheels of your ATV start to slide sideways control can usually be regained if there is room to do so by steering in the direc tion of the slide Applying the brakes or accel erating is not recommended until you have corrected the slide With practice over a period of time skill at controlled sliding can be developed The ter rain should be chosen carefully before at tempting such maneuvers since both stability and control are reduced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost 7 39 A WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also rega
92. soline in the tank Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity Total 20 L 4 40 Imp gal 5 28 US gal Reserve 3 5 L 0 77 Imp gal 0 92 US gal CAUTION Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system 5 5 Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Gasohol There are two types of gasohol gasohol con taining ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 Gaso hol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems 1 Fuel level 2 Fuel tank filler tube 5 6 A WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or
93. sories All parts and accessories added to this ve hicle 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 autho rized Yamaha ATV dealer EBU02611 PERIODIC MAINTENANCE LUBRICATION NOTE For ATVs not equipped with an odometer or an hour meter follow the month maintenance intervals For ATVs equipped with an odometer or an hour meter follow the km mi or hours maintenance intervals How ever keep in mind that if the ATV isn t used for a long period of time the month maintenance intervals should be followed INITIAL Whichever 3 ROUTINE comes first 1 200 750 e Check valve clearance e Adjust if necessary Check coolant leakage Cooling system Repair if necessary Replace coolant every 24 months Check condition Spark plug Adjust gap and clean O O Replace if necessary Clean Every 20 40 hours Replace if necessary More often in wet or dusty areas Check starter choke Adjust engine idling speed Crankcase breather Check breather hose for cracks or damage system Replace engine idling speed Check for leakage Exhaust system Tighten if necessary Replace gasket s if necessary Sparks arrester e Clean Valves Air filter element Carburetor 8 3 INITIAL Whichever 3 ROUTINE comes first 1 200 gt gt
94. switch as follows 1 Remove panel B See page 8 9 for pan el removal and installation procedures 2 Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction To make the brake light come on later turn the adjust ing nut in direction 1 Rear brake light switch 2 Adjusting nut 3 Install the panel 8 50 EBU00356 EBU00717 Cable inspection and lubrication Brake lever and brake pedal lubrication A WARNING Lubricate the pivoting parts POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer Recommended lubricant Lithium soap based grease all purpose grease covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a Yamaha dealer to replace them Recommended lubricant Yamaha chain and cable lube or SAE 10W30 motor oil EBU13110 Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun 1 Upper knuckle 2 Lower knuckle Recommended lubricant Lithium soap based grease 8 52 EBU01112 Wheel removal 1 Loosen th
95. t bulb to keep it free from oil otherwise the transparency of the glass the luminos ity of the bulb and the bulb life will be ad versely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner EBU01089 Headlight beam adjustment CAUTION It is advisable to have a Yamaha dealer make this adjustment To raise the beam turn the adjusting screw in direction To lower the beam turn the adjusting screw in direction 1 Do not touch the glass part of the bulb 6 Install the bulb holder by pushing it in and turning it clockwise 7 Install the bulb holder cover and the cov er at the rear of the headlight 1 Headlight beam adjusting screw 8 60 EBU15050 Tail brake light bulb replacement 5 Install the bulb holder together with the 1 Remove panel G See pages 8 14 8 15 bulb for removal and installation procedures 6 Install the panel 2 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Bulb holder 3 Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise 4 Install a new bulb in the bulb holder by pushing it inward and turning it clockwise 8 61 EBU00412 Troubleshooting Although Yamaha machines receive a rigid in spection before shipment from the factory trouble may occur during operation Any prob lem in the fuel compression or igniti
96. t of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes 2 6 A WARNING POTENTIAL HAZARD Starting or running the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 3 1 ere PRON Rear shock absorber spring preload adjusting ring Storage compartment and tool kit Air filter case Front brake fluid reservoir Engine oil dipstick Recoil starter Coolant reservoir Drive select lever box check hose V belt cooling duct check hose Front shock absorber spring 20 Rear brake lever preload adjusting ring 21 Left handlebar switches 6 Rear brake fluid reservoir 22 Starter choke 7 Brake pedal 23 Speedometer unit 8 V belt case drain plug 24 Main switch 9 Radiator cap 25 Right handlebar switches 10 Drive select lever 26 Throttle lever 11 Fuel tank cap 27 Front brake lever 12 Fuel cock 28 Auxiliary DC jack 13 Battery 14 Fuses NOTE
97. the clock 1 Set the display to the clock mode 2 Push the button until the clock starts flashing 3 Set the hours by pushing the H button 4 Set the minutes by pushing the M but ton 5 Push the f button and then re lease it to start the clock Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear towards E Empty as the fuel level decreases When the E segment disappears and the fuel level warning indica tor flashes set the fuel cock to reserve and re fuel as soon as possible HE pm Paf zE fafafa ta gopgam B ODOTRIP AB CLOCKHOUR 1 By 1 Fuel level warning indicator 2 Fuel meter 3 E segment 4 6 EBU00053 Handlebar switches Light switch 20 Z0 0FF Start switch S _ Engine stop switch K O Override switch OVERRIDE RON EBU12040 Light switch 0 ZO OFF Set the switch to ZO to turn on the low beam and the taillight Set the switch to O to turn on the high beam and the taillight Set the switch to OFF to turn off all the lights CAUTION Do not use the headlights with the engine turned off for more than thirty minutes The battery may discharge to the point that the starter motor will not operate properly If this should happen remove the batte
98. 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 i 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 1 3 DRIVE SELECT LEVER e Read owner s manual carefully before operating e ATV MUST be stopped before shifting select lever Shifting info or from reverse or park is impossible without applying rear brake 5GH 2151E 00 A WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires cold e Recommended FRONT 35kPa 0 35kgf cm 5 0psi REAR _ 30kPa 0 30kgf cm 4 3psi Minimum FRONT 32kPa 0 32kgf cm 4 6psi REAR 27kPa 0 27kgf cm 3 9psi Never set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING TRAILER TOWING Cargo or a trailer can affect stability and handling Read owner s manual before loading or towing When loading with cargo or towing a trailer Reduce speed and allow more room to stop Avoid hills and rough terrain e Ma
99. this ATV with improper or un even tire pressure may cause loss of control increasing your risk of an acci dent HOW TO AVOID THE HAZARD Always use the size and type tires spec ified in the Owner s Manual for this vehi cle on pages Always maintain proper tire pressure as described in the Own er s Manual on page 5 13 A WARNING Indicates a potential hazard that could result in serious injury or death Do not operate at speeds too fast for your skills or the conditions 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 con trol 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 con ditions and your experience 7 10 Speed limiter For riders less experienced with this model this model is equipped with a speed limiter in the throttle lever housing The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maxi mum Screwing in the adjuster limits the max imum engine power available and decreases the maximum speed of the ATV Turning the screw in decreases top speed and turning it out increases top speed 1 Locknut 2 Adjusting screw Loading and accessories Use extra caution when riding the ATV with additional loads such as accesso
100. tilate when charging or using in a closed Do not try to remove the sealing caps of the battery cells You may damage the bat tery POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully WHAT CAN HAPPEN space You could be poisoned You could be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases 8 55 EBU00385 Battery maintenance 1 When the machine is not used for a month or longer remove the battery and store it in a cool dark place Completely recharge the battery before reinstallation CAUTION A special battery charger constant volt age ampere or constant voltage is re quired for recharging a sealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine 8 56 EBU08762 Fuse replacement 1 2 The main fuse and the fuse box are locat ed under the seat If a fuse is blown turn off the main switch and the switch of the circuit in question Then install a new fuse of the specified amperage Turn on the main switch If the fuse immediately blows again con sult a Yamaha dealer 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 spec
101. tion P after you are stopped If you begin rolling backwards Keep weight uphill 2WD Never apply the rear brake while rolling backwards Apply the front brake 4WD or 4WD LOCK Apply both front and rear brakes gradually When fully stopped shift to the park ing position P Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the pro cedure described in the Owner s Manu al 7 29 RIDING DOWNHILL When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as possible Move back on the seat and sit with your arms straight Engine compres sion will do most of the braking for you For maximum engine compression braking effect select low range L and change to 4WD or 4WD LOCK before beginning to descend the hill Improper braking may cause a loss of traction Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of traction 7 30 When this ATV is in 4WD or 4WD LOCK all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the downhill side Avoid sudden application of either the front or
102. tloNisi ia renina 8 3 Panel removal and installation 8 6 Engine oil and oil filter cartridge 8 15 Final gear oil 8 21 Differential gear Oil eee 8 23 Cooling SySteM ccceeeeeeees 8 25 PIG DOOIS ncnian 8 31 Spark plug inspection 05 8 32 Air filter element cleaning 8 34 Spark arrester cleaning 8 38 V belt cooling duct check hose 8 39 V belt case drain plug 0 8 40 Carburetor adjustment 8 40 Idle speed adjustment 8 41 Valve clearance adjustment 8 41 Throttle lever adjustment 8 42 Select lever safety system cable AQIUSIMENL iii 8 42 Front brake pad check 8 43 Checking the rear brake pads 8 43 Checking the brake fluid level 8 44 Brake fluid replacement 8 46 Front brake lever free play 8 47 Adjusting the rear brake lever and brake pedal cceeseceeeeeeeees 8 48 Adjusting the rear brake light SWINGIN deae ote eet es ce 8 50 Cable inspection and lubrication 8 51 Brake lever and brake pedal IWDKICAN ON ceeecncererer erences 8 51 Rear knuckle upper and lower pivot lubrication cceeeee 8 52 Wheel removal cceeeeeeeeeeeee 8 53 Wheel installation 8 53 Batte Nannanaa 8 55 Battery maintenance 8 56 Fuse replacement eceeeee 8 56 Replacing a headlight bulb
103. ts shocks or can start fires HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified can cause 8 1 Have a Yamaha dealer perform service if you are not familiar with machine service EBU00562 Owner s manual and tool kit You are recommended to put this owners manual in the vinyl bag and always carry it in the storage box Put the owner s tool kit and low pressure tire gauge in the space beside the battery 1 Owner s manual 2 Owner s tool kit 3 Low pressure tire gauge The service information included in this man ual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor re pairs The tools provided in the Owner s tool kit are sufficient for this purpose except that a torque wrench is also necessary to properly tighten nuts and bolts NOTE If you do not have a torque wrench available during a service operation requiring one take your machine to a Yamaha dealer to check the torque settings and adjust them as neces sary 8 2 A WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of acces
104. ug After riding in water deep enough to allow it to enter the V belt case remove this plug to drain the water from the case NOTE If water drains from the V belt case after re moving the plug have a Yamaha dealer in spect the ATV as the water may affect other engine parts 1 V belt case drain plug 8 40 EBU00296 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment Most adjusting should be left to a Yamaha dealer who has the professional knowledge and ex perience to do so However the idling speed may be performed by the owner as a part of the usual maintenance routine CAUTION The carburetor was set at the Yamaha fac tory after many tests If the settings are disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result EBU12580 Idle speed adjustment NOTE gt A diagnostic tachometer must be used for this procedure 1 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle Remove panel D See pages 8 7 and 8 8 for removal and installation procedures Connect the tachometer to the spark plug lead and then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in direction to increase the engi
105. varying ver is released the throttle position Because the throttle is A WARNING spring loaded the machine will decelerate and the engine will return to an idle any time the hand is removed from the throttle lever POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine If it does not work smoothly check for the cause Correct the problem before riding the 1 Throttle lever ATV Consult a Yamaha dealer if you can t find or solve the problem yourself 4 13 EBU11590 Speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum Turning in the ad justing screw limits the maximum engine pow er available and decreases the maximum speed of the ATV 1 Locknut 2 Adjusting screw a 12 mm 0 47 in 4 14 A WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an acci dent or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjust ed to 3 5 mm 0 1
106. ximum Vehicle Load 220kg 485 Ibs Includes weight of operator cargo and accessories and if applicable trailer tongue weight ke 5KM 21696 00 NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 5SFE 2151H 01 AWARNING _ 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 C 5FE 21697 01 J Turning the ATV in 4WD LOCK DIFF LOCK takes more effort Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control S 5KM 21558 00 J EBU01129 AX SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE An ATV handles differently from other vehicles including motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers such as turning and riding on hills or over obstacles if you fail to take proper precautions SEVERE INJURY OR DEATH can result if you do not follow these instructions e Read this manual and all labels carefully and follow the operating procedures described e Never operate an ATV without proper training or instruction Take a Training Course Begin ners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about t
107. y can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the warranty coverage to remain effective 13 2 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 identification 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 engine serial number 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 the purchases registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase lf you should move after you have purchased your new ATV please advise us of your new

Yamaha YFM660FAT Owner`s manual

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