Yamaha YFM660FAT Owner`s manual

EBU00438
READ THIS MANUAL CAREFULLY!
It contains important safety information.
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH.
BEER
BEER
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate:
ALWAYS:
without proper training or instruction.
use proper riding techniques to avoid
at speeds too fast for your skills or the
vehicle overturns on hills and rough
conditions.
terrain and in turns.
on public roads-a collision can occur with
avoid paved surfaces-pavement may
another vehicle.
seriously affect handling and control.
with a passenger-passengers affect
balance and steering and increase risk
of losing control.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
(For replacement manual, call 1-800-532-1558)
OWNER’S MANUAL
YFM660FAT
WARNING
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2004.03-5.0×1 CR
(E)
LIT-11626-18-03
This ATV should not be ridden by anyone under 16 years of age.
5KM-28199-13
EBU00776
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EBU00941
INTRODUCTION
1-
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 craftsmanship and reliability that have made Yamaha a leader in these fields.
This manual will provide you with a good basic understanding of the features and operation of this
ATV. This manual includes important safety information. It provides information about
special 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:
● READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND
COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL
INSTRUCTIONS.
● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.
● NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE
TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887
FOR MORE INFORMATION.
● THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE
UNDER 16 YEARS OF AGE.
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM
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IMPORTANT MANUAL INFORMATION
1-
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:
The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
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.
A CAUTION indicates special precautions that must be taken to
avoid damage to the machine.
A NOTE provides key information to make procedures easier or clearer.
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM
EBU15000
IMPORTANT NOTICE
2-
This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway.
This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.
Please check your local riding laws and regulations before operating this ATV.
EBU00981
AFFIX DEALER
LABEL HERE
YFM660FAT
OWNER’S MANUAL
©2004 by Yamaha Motor Corporation,
U.S.A.
1st edition, March 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission
of Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-18-03
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM
EBU00014
WARNING
Indicates a potential hazard that could
result in serious injury or death.
CONTENTS
1
LOCATION OF THE WARNING
AND SPECIFICATION LABELS....... 1-1
2
SAFETY INFORMATION.................. 2-1
3
DESCRIPTION AND MACHINE
IDENTIFICATION ............................. 3-1
Identification number records.......... 3-2
Key identification number................ 3-2
Vehicle identification number .......... 3-3
Model label ...................................... 3-3
4
CONTROL FUNCTIONS...................4-1
Main switch ......................................4-1
Indicator and warning lights .............4-2
Speedometer unit ............................4-4
Handlebar switches .........................4-6
Throttle lever ..................................4-13
Speed limiter ..................................4-14
Front brake lever............................4-15
Brake pedal and rear brake
lever .............................................4-15
Drive select lever ...........................4-16
Recoil starter..................................4-16
Fuel tank cap .................................4-17
Fuel cock........................................4-18
Starter (choke) ...............................4-19
Seat................................................4-20
Storage compartment ....................4-21
Front carrier ...................................4-21
Rear carrier ....................................4-21
Front and rear shock absorber
adjustment ...................................4-22
Auxiliary DC jack............................4-24
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5
6
PRE-OPERATION CHECKS ........... 5-1
Front and rear brakes ..................... 5-3
Fuel ................................................. 5-5
Engine oil ........................................ 5-7
Final gear oil.................................... 5-7
Differential gear oil .......................... 5-8
Coolant............................................ 5-9
Throttle lever ................................. 5-10
Fittings and fasteners.................... 5-10
Lights............................................. 5-10
Switches........................................ 5-10
Tires .............................................. 5-11
How to measure tire pressure....... 5-13
Tire wear limit................................ 5-14
OPERATION..................................... 6-1
Starting a cold engine ..................... 6-1
Starting a warm engine................... 6-3
Warming up..................................... 6-3
Drive select lever operation and
reverse driving............................... 6-4
Engine break-in............................... 6-7
Parking ............................................ 6-8
Parking on a slope........................... 6-9
Accessories and loading ............... 6-10
7
RIDING YOUR ATV .......................... 7-1
Getting to know your ATV ............... 7-3
Ride with care and good
judgement...................................... 7-4
Be careful where you ride.............. 7-16
Turning your ATV .......................... 7-22
Climbing uphill ............................... 7-24
Riding downhill .............................. 7-30
Crossing a slope............................ 7-32
Crossing through shallow water .... 7-34
Riding over rough terrain............... 7-37
Sliding and skidding....................... 7-38
What to do if .................................. 7-40
What to do .................................... 7-40
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM
8
PERIODIC MAINTENANCE AND
ADJUSTMENT.................................. 8-1
Owner’s manual and tool kit............ 8-1
Periodic maintenance/
lubrication ...................................... 8-3
Panel removal and installation ........ 8-6
Engine oil and oil filter cartridge .... 8-15
Final gear oil .................................. 8-21
Differential gear oil......................... 8-23
Cooling system.............................. 8-25
Axle boots...................................... 8-31
Spark plug inspection.................... 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.................... 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
adjustment................................... 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 ..................................8-48
Adjusting the rear brake light
switch ...........................................8-50
Cable inspection and lubrication....8-51
Brake lever and brake pedal
lubrication.....................................8-51
Rear knuckle upper and lower
pivot lubrication ............................8-52
Wheel removal...............................8-53
Wheel installation...........................8-53
Battery............................................8-55
Battery maintenance......................8-56
Fuse replacement ..........................8-56
Replacing a headlight bulb ............8-58
Headlight beam adjustment...........8-60
Tail/brake light bulb
replacement .................................8-61
Troubleshooting .............................8-62
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Troubleshooting charts ................. 8-63
9
CLEANING AND STORAGE............ 9-1
A. Cleaning...................................... 9-1
B. Storage ....................................... 9-3
10
SPECIFICATIONS.......................... 10-1
11
NOISE REGULATION.................... 11-1
12
MAINTENANCE RECORD ............ 12-1
13
ATV LIMITED WARRANTY ........... 13-1
14
YAMAHA EXTENDED SERVICE
(Y.E.S.) ........................................... 14-1
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LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1-1
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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. If a
label becomes difficult to read or comes off, a
replacement label is available from your
Yamaha dealer.
1
2
WARNING
1
NEVER sit here.
2
3MX-24875-A0
3
4
5
3
6
LOAD LIMIT
7
85 kg {187 lbs}
8
4WV-24877-A0
9
4
10
MAXIMUM LOADING LIMIT
11
PULLING LOAD:
12
TONGUE WEIGHT:
5390
1212
147
33
N (550 kgf)
lbf
N ( 15 kgf)
lbf
13
5KM-2151K-00
14
1-2
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5
6
7
1-3
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8
9
WARNING
UNDER
Operating this ATV if you are under
the age of 16 increases your chance
of severe injury or death.
NEVER operate this ATV if you are
under age 16.
5FE-21697-01
0
WARNING
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.
5KM-21558-00
1-4
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM
EBU01129
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:
● Read this manual and all labels carefully and follow the operating procedures described.
● Never operate an ATV without proper training or instruction. Take a Training Course. Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call
1-800-887-2887 to find out about the training courses nearest you.
● Always follow the age recommendation:
- A child under 16 years old should never 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.
● Never carry passenger on an ATV.
● Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.
● Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
2-1
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM
●
●
●
●
●
●
●
●
●
●
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.
Never consume alcohol or drugs before or while operating this ATV.
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.
Never attempt wheelies, jumps, or other stunts.
Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.
Always keep both hands on the handlebars and both feet on the footboards of the ATV during
operation.
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.
Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on
these kinds of terrain.
Always follow proper procedures for turning as described in this manual. Practice turning at low
speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM
●
●
●
●
Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose
surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of
a hill at high speed.
Always follow proper procedures for going down hills and for braking on hills as described in
this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause
the vehicle to lean sharply to one side. Go straight down the hill where possible.
Always follow proper procedures for crossing the side of a hill as described in this manual.
Avoid hills with excessively slippery or loose surfaces. 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 stalling, 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
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM
●
●
●
●
●
●
●
●
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 operating over obstacles as described in this manual.
Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice,
go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.
Never operate an ATV in fast flowing water or in water deeper than that recommended in this
manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several times to let friction dry out the linings.
Always 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 Commission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.
2-4
EE.book Page 5 Tuesday, March 9, 2004 10:33 AM
WARNING
When transporting the ATV in another
vehicle, be sure it is kept upright and
that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the
carburetor or fuel tank.
WHAT CAN HAPPEN
Gasoline is poisonous and can cause
injuries.
HOW TO AVOID THE HAZARD
If you should swallow some gasoline or
inhale a lot of gasoline vapor, or get
some gasoline in your eyes, see your
doctor immediately. If gasoline spills on
your skin, wash with soap and water. If
gasoline spills on your clothing, change
your clothes.
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 refueling. 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 pilot lights of water heaters and clothes
dryers.
2-5
EE.book Page 6 Tuesday, March 9, 2004 10:33 AM
WARNING
POTENTIAL HAZARD
Starting or running the engine in a
closed area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
HOW TO AVOID THE HAZARD
Always operate your ATV in an area with
adequate ventilation.
2-6
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DESCRIPTION AND MACHINE IDENTIFICATION
1. Rear shock absorber spring
preload adjusting ring
2. Storage compartment and tool kit
3. Air filter case
4. Front brake fluid reservoir
5. Front shock absorber spring
preload adjusting ring
6. Rear brake fluid reservoir
7. Brake pedal
8. V-belt case drain plug
9. Radiator cap
10. Drive select lever
11. Fuel tank cap
12. Fuel cock
13. Battery
14. Fuses
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Engine oil dipstick
Recoil starter
Coolant reservoir
Drive select lever box check hose
V-belt cooling duct check hose
Rear brake lever
Left handlebar switches
Starter (choke)
Speedometer unit
Main switch
Right handlebar switches
Throttle lever
Front brake lever
Auxiliary DC jack
NOTE:
The machine you have purchased may differ slightly
from those shown in the figures of this manual.
3-1
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM
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Identification number records
Record the key identification number, vehicle
identification number and model label information in the spaces provided for assistance
when ordering spare parts from a Yamaha
dealer or for reference in case the vehicle is
stolen.
Key identification number
The key identification number is stamped on
the key as shown in the following illustration.
This number can be used for ordering a new
key.
1
2
3
4
5
6
1. KEY IDENTIFICATION NUMBER:
7
8
9
2. VEHICLE IDENTIFICATION NUMBER:
10
1. Key identification number
11
12
3. MODEL LABEL INFORMATION:
13
14
3-2
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Vehicle identification number
The vehicle identification number is stamped
into the frame.
Model label
The model label is affixed to the location in the
illustration. Record the information on this label in the space provided. This information will
be needed to order spare parts from your
Yamaha dealer.
1. Vehicle identification number
NOTE:
The vehicle identification number is used to
identify your machine.
1. Model label
3-3
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM
EBU00039
CONTROL FUNCTIONS
1
WARNING
2
Indicates a potential hazard that could
result in serious injury or death.
3
4
EBU00942
5
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 when
the light switch is on.
OFF:
All electrical circuits are switched off. The key
can be removed in this position.
6
1. Main switch
7
8
9
10
11
12
13
14
4-1
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EBU10601
Indicator and warning lights
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 differential gear lock indicator light will flash until
the differential gear is locked.
_
_
1.
2.
3.
4.
5.
6.
7.
8.
Differential gear lock indicator light “DIFF. LOCK”
Low-range indicator light “L”
High-range indicator light “H”
Neutral indicator light “N”
Reverse indicator light “R”
Park indicator light “P”
Four-wheel-drive indicator “
”/“
”
Coolant temperature warning light “
”
EBU01122
Low-range indicator light “L”
This indicator light comes on when the drive
select lever is in the “L” position.
DIFF.
LOCK
EBU01064
High-range indicator light “H”
This indicator light comes on when the drive
select lever is in the “H” position.
4-2
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EBU11312
Neutral indicator light “N”
This indicator light comes on when the drive
select lever is in the “N” position.
Four-wheel-drive indicator “ ”/“ ”
This indicator comes on when the “2WD”/
“4WD” switch is set to the “4WD” position. The
differential gear lock indicator “DIFF.LOCK” in
the four-wheel-drive indicator also comes on
when the “LOCK”-“4WD” switch is set to the
“4WD-LOCK” position.
DIFF.
LOCK
EBU00867
Reverse indicator light “R”
This indicator light comes on when the drive
select lever is in the “R” reverse position.
NOTE:
Due to the synchronizing mechanism in the
differential gear case, the four-wheel drive indicator may not come on until the ATV starts
moving.
_
NOTE:
If the indicator light flashes or the speedometer does not show the speed while riding,
have a Yamaha dealer check the speed sensor circuit.
_
_
EBU00609
Park indicator light “P”
This indicator light comes on when the drive
select lever is in the “P” (park) position.
4-3
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EBU00860
EBU15100
Coolant temperature warning light “ ”
When the coolant temperature reaches a
specified level, this light comes on to warn
that the coolant temperature is too hot. If the
light comes on during operation, stop the engine as soon as it is safe to do so and allow
the engine to cool down for about 10 minutes.
Speedometer unit
CAUTION:
_
●
●
The engine may overheat if the ATV is
overloaded. If this happens, reduce
the load to specification.
After restarting, make sure that the
light is out. Continuous use while the
light is on may cause damage to the
engine.
1.
3.
5.
7.
_
4-4
Speedometer
“H” button
Clock/Hour meter
TRIP/ODO button
2.
4.
6.
8.
Fuel meter
“M” button
Odometer/Tripmeter A/Tripmeter B
Clock/Hour “
”/“
” button
The speedometer unit is equipped with the
following:
● a speedometer (which shows the riding
speed)
● an odometer (which shows the total distance traveled)
● two tripmeters (which show the distance
traveled since they were last set to zero)
EE.book Page 5 Tuesday, March 9, 2004 10:33 AM
●
●
●
Clock mode
Pushing the “
”/“ ” button switches the
display between the clock mode “CLOCK”
and the hour meter mode “HOUR” in the following order:
CLOCK→HOUR→CLOCK
a clock
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 following order:
ODO→TRIP A→TRIP B→ODO
To reset a tripmeter, select it by pushing the
“TRIP/ODO” button, and then push the “TRIP/
ODO” button for at least three seconds. The
tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan
future fuel stops.
To set the clock
1. Set the display to the clock mode.
2. Push the “
”/“ ” button until the clock
starts flashing.
3. Set the hours by pushing the “H” button.
4. Set the minutes by pushing the “M” button.
5. Push the “
”/“ ” button, and then release it to start the clock.
NOTE:
Holding in the “TRIP/ODO” button and then
turning the key to “ON” switches the display
between “mph” and “km/h”.
_
_
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EBU00053
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 indicator flashes, set the fuel cock to reserve and refuel as soon as possible.
Handlebar switches
1.
2.
3.
4.
Light switch “
/
/OFF”
Start switch “ ”
Engine stop switch “ / ”
Override switch “OVERRIDE”
EBU12040
1. Fuel level warning indicator
3. “E” segment
Light switch “
/
/OFF”
Set the switch to “
” to turn on the low beam
and the taillight.
Set the switch to “
” to turn on the high
beam and the taillight.
Set the switch to “OFF” to turn off all the lights.
2. Fuel meter
4-6
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EBU12050
Engine stop switch “ / ”
Make sure that the engine stop switch is set to
“ ” 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 “ ”.
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 battery and recharge it.
_
EBU00607
Start switch “ ”
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
EE.book Page 8 Tuesday, March 9, 2004 10:33 AM
1. Override switch “OVERRIDE”
EBU13781
Override switch “OVERRIDE”
Top speed is normally limited when operating
in 4WD-LOCK. If conditions require more engine 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.
NOTE:
If the digits of the speedometer appear as
shown when the switch is NOT being pushed,
this could indicate a malfunction in the electrical system. In this case, take the ATV to a
Yamaha dealer at the first opportunity.
_
_
4-8
EE.book Page 9 Tuesday, March 9, 2004 10:33 AM
WARNING
POTENTIAL HAZARD
Riding too fast while the ATV is in
4WD-LOCK.
WHAT CAN HAPPEN
All wheels turn at the same speed when
the differential is locked, so it takes
more effort to turn the 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.
1. On-Command four-wheel drive switch “2WD”/“4WD”
2. Differential gear lock switch “LOCK”/“4WD”
EBU14091
On-Command four-wheel drive and differential 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 terrain and the conditions.
● Two-wheel drive (2WD): Power is supplied
to the rear wheels only.
4-9
EE.book Page 10 Tuesday, March 9, 2004 10:33 AM
●
●
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 differential gear is locked (“DIFF.LOCK”). Unlike
the 4WD mode, all wheels turn at the same
speed.
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 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 increase 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.
4-10
EE.book Page 11 Tuesday, March 9, 2004 10:33 AM
1. Lever
2. On-Command four-wheel drive switch “2WD”/“4WD”
1. Differential gear lock switch “LOCK”/“4WD”
2. Lever
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 “ ” 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 a, and then
set the switch to “2WD”.
Differential gear lock switch “LOCK”/
“4WD”
To lock the differential gear in 4WD, make sure
the On-Command four-wheel-drive switch is
set to “4WD”, stop the ATV, move the lever to
position b, and then set the switch to “LOCK”.
When the differential gear is locked, the differential 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”.
DIFF.
LOCK
4-11
EE.book Page 12 Tuesday, March 9, 2004 10:33 AM
NOTE:
● When the switch is set to “LOCK”, the differential gear lock indicator light will flash
until the differential gear is locked.
● When the indicator light is flashing, turning the handlebar back and forth will help
the differential gear lock to engage.
● Riding before the differential gear lock is
properly engaged (e.g., when the indicator light is flashing) will cause the engine
speed to be limited until engagement is
complete.
● 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 disable the 4WD-LOCK speed limiter. (See
page 4-8 for a detailed explanation of this
switch.)
WARNING
_
POTENTIAL HAZARD
Riding too fast while the ATV is in
4WD-LOCK.
WHAT CAN HAPPEN
All wheels turn at the same speed when
the differential is locked, so it takes
more effort to turn the 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
EE.book Page 13 Tuesday, March 9, 2004 10:33 AM
EBU00062
Throttle lever
Once the engine is running, movement of the
throttle lever will increase the engine speed.
Regulate the speed of the machine by varying
the throttle position. Because the throttle is
spring-loaded, the machine will decelerate,
and the engine will return to an idle any time
the hand is removed from the throttle lever.
Before starting the engine, check the throttle
to be sure it is operating smoothly. Make sure
it returns to the idle position as soon as the lever is released.
WARNING
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
ATV. Consult a Yamaha dealer if you
can’t find or solve the problem yourself.
1. Throttle lever
4-13
EE.book Page 14 Tuesday, March 9, 2004 10:33 AM
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 adjusting screw limits the maximum engine power available and decreases the maximum
speed of the ATV.
1. Locknut
a. 12 mm (0.47 in)
WARNING
POTENTIAL HAZARD
Improper adjustment of the speed limiter and throttle.
WHAT CAN HAPPEN
The throttle cable could be damaged.
Improper throttle operation could result.
You could lose control, have an accident or be injured.
HOW TO AVOID THE HAZARD
Do not turn the adjusting screw out
more than 12 mm (0.47 in). Always make
sure the throttle lever free play is adjusted to 3–5 mm (0.12–0.20 in). See
page 8-42.
2. Adjusting screw
4-14
EE.book Page 15 Tuesday, March 9, 2004 10:33 AM
EBU00070
Front brake lever
The front brake lever is located on the right
handlebar. Pull it toward the handlebar to apply the front brake.
1. Brake pedal
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
EE.book Page 16 Tuesday, March 9, 2004 10:33 AM
EBU00608
EBU00855
Drive select lever
The drive select lever is used to shift your machine into the low, high, neutral, reverse and
park positions. (Refer to page 6-4 for the drive
select lever operation.)
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. Drive select lever
1. Recoil starter
4-16
EE.book Page 17 Tuesday, March 9, 2004 10:33 AM
EBU00092
Fuel tank cap
Remove the fuel tank cap by turning it counterclockwise.
WARNING
POTENTIAL HAZARD
Starting the engine without setting the
drive select lever to the park position
“P”.
WHAT CAN HAPPEN
The ATV could start to move unexpectedly, which could cause an accident.
HOW TO AVOID THE HAZARD
Set the drive select lever to the park position before starting the engine.
1. Fuel tank cap
4-17
EE.book Page 18 Tuesday, March 9, 2004 10:33 AM
EBU00093
Fuel cock
The fuel cock supplies fuel from the fuel 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.
OFF Position
1. Arrow mark
ON Position
1. Arrow mark
4-18
EE.book Page 19 Tuesday, March 9, 2004 10:33 AM
EBU00095
Starter (choke) “
”
Starting a cold engine requires a richer air-fuel
mixture. A separate starter circuit supplies this
mixture.
Move in direction a to turn on the starter
(choke).
Move in direction b to turn off the starter
(choke).
Refer to “Starting a cold engine” for proper operation. (See page 6-1.)
RES Position
1. Arrow mark
1. Starter (choke) “
4-19
”
EE.book Page 20 Tuesday, March 9, 2004 10:33 AM
EBU00567
Seat
To remove the seat, pull the seat lock lever
upward and pull up the seat at the rear.
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. Seat
2. Seat lock lever
1. Projection (× 2)
4-20
2. Seat holder (× 2)
EE.book Page 21 Tuesday, March 9, 2004 10:33 AM
EBU00858
EBU00582
Storage compartment
The storage compartment is located under
the seat. (See page 4-20 for seat removal and
installation procedures.)
When storing the owner’s 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.
Front carrier
Maximum load limit: 45 kg (99 lb)
EBU00583
Rear carrier
Maximum load limit: 85 kg (187 lb)
1. Storage compartment
4-21
EE.book Page 22 Tuesday, March 9, 2004 10:33 AM
EBU01124
Front and rear shock absorber adjustment
The spring preload can be adjusted to suit the
rider’s 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 adjusting ring in direction a.
To decrease the spring preload, turn the adjusting ring in direction b.
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)
4-22
EE.book Page 23 Tuesday, March 9, 2004 10:33 AM
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 left and right side to the same setting.
1. Special wrench
4-23
EE.book Page 24 Tuesday, March 9, 2004 10:33 AM
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
Maximum rated capacity for the auxiliary
DC jack:
DC 12 V, 120 W (10 A)
1. Auxiliary DC jack cap
1. Set the light switch to “OFF”.
2. Start the engine. (See pages 6-1–6-3.)
3. Open the auxiliary DC jack cap, and then
insert the accessory power plug into the
jack.
4-24
EE.book Page 25 Tuesday, March 9, 2004 10:33 AM
4. When the auxiliary DC jack is not being
used, cover it with the cap.
CAUTION:
_
●
●
●
Do not use accessories requiring
more than the above maximum capacity. This may overload the circuit and
cause the fuse to blow.
If accessories are used without the
engine running or with the headlights
turned on, the battery will lose its
charge and engine starting may become difficult.
Do not use an automotive cigarette
lighter or other accessories with a
plug that gets hot because the jack
can be damaged.
_
EBU00112
WARNING
Indicates a potential hazard that could
result in serious injury or death.
4-25
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM
ROUTINE
PAGE
Brakes
• Check operation, free play, fluid level and fluid leakage.
• Fill with DOT 4 brake fluid if necessary.
5-3–5-4,
8-43–8-50
Fuel
• Check fuel level.
• Fill with fuel if necessary.
Engine oil
• Check oil level.
• Fill with oil if necessary.
5-7, 8-15–8-20
Coolant reservoir tank
• Check coolant level in reservoir.
• Fill with coolant if necessary.
5-9, 8-25–8-30
Final gear oil/
Differential gear oil
• Check for leakage.
5-7–5-8,
8-21–8-25
Throttle
• Check for proper throttle cable operation and free play.
5-10, 8-42
Wheels and tires
• Check tire pressure, wear and damage.
5-11–5-14,
8-53–8-54
Fittings and fasteners
• Check all fittings and fasteners.
Lights and switches
• Check for proper operation.
Axle boots
• Check for damage.
5-5–5-6
5-10
5-10, 8-58–8-61
8-31
5-1
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM
WARNING
1
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident
or equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV each time you
use it to make sure the ATV is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
2
3
4
5
6
7
8
9
10
11
12
13
14
5-2
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM
EBU11011
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.
Front and rear brakes
Brake levers and brake pedal
● Check that there is no free play in the front
brake lever. If there is free play, have a
Yamaha dealer adjust it.
● Check for correct free play in the rear brake
lever. If the free play is incorrect, adjust it.
(See page 8-48.)
● Check for correct brake pedal height. If the
pedal height is incorrect, have a Yamaha
dealer adjust it.
● 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 operation
Test the brakes at slow speed after starting
out to make sure they are working properly. If
the brakes do not provide proper braking performance, inspect the brake pads for wear.
(See page 8-43.)
Brake fluid level
Check the brake fluid level. Add fluid if necessary. (See pages 8-44–8-46.)
Recommended brake fluid: DOT 4
5-3
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM
WARNING
POTENTIAL HAZARD
Riding with improperly operating
brakes.
WHAT CAN HAPPEN
You could lose braking ability, which
could lead to an accident.
HOW TO AVOID THE HAZARD
Always check the brakes at the start of
every ride. Do not ride the ATV if you
find any problem with the brakes. If a
problem cannot be corrected by the adjustment procedures provided in this
manual, have a Yamaha dealer check for
the cause.
5-4
EE.book Page 5 Tuesday, March 9, 2004 10:33 AM
EBU01085
Fuel
Make sure there is sufficient gasoline in the
tank.
Your Yamaha engine has been designed to
use regular unleaded gasoline with a pump
octane number ([R+M]/2) of 86 or higher, or
research octane number of 91 or higher. If
knocking or pinging occurs, use a different
brand of gasoline or premium unleaded fuel.
Unleaded fuel will give you longer spark plug
life and reduced maintenance cost.
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)
Gasohol
There are two types of gasohol; gasohol containing ethanol and that containing methanol.
Gasohol containing ethanol can be used if
ethanol content does not exceed 10%. Gasohol containing methanol is not recommended
by Yamaha because it may cause fuel system
damage or vehicle performance problems.
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
EE.book Page 6 Tuesday, March 9, 2004 10:33 AM
WARNING
1. Fuel level
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 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.
2. Fuel tank filler tube
5-6
EE.book Page 7 Tuesday, March 9, 2004 10:33 AM
EBU10842
EBU00493
Engine oil
Make sure the engine oil is at the specified
level. Add oil as necessary. (See pages 8-15–
8-20.)
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.)
CAUTION:
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
_
●
●
In order to prevent clutch slippage
(since the engine oil also lubricates
the clutch), do not mix any chemical
additives. Do not use oils with a diesel
specification of “CD” or oils of a higher quality than specified. In addition,
do not use oils labeled “ENERGY
CONSERVING II” or higher.
Make sure that no foreign material enters the crankcase.
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.
_
Recommended engine oil type and
quantity:
See page 10-2.
5-7
EE.book Page 8 Tuesday, March 9, 2004 10:33 AM
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
EE.book Page 9 Tuesday, March 9, 2004 10:33 AM
EBU12530
Coolant
Check the coolant level in the coolant reservoir when the engine is cold. (The coolant level will vary with engine temperature.) The
coolant level is satisfactory if it is between the
minimum and maximum level marks on the
coolant reservoir. If the coolant level is at or
below the minimum level mark, add 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.)
WARNING
POTENTIAL HAZARD
Removing the radiator cap when the engine and radiator are still hot.
WHAT CAN HAPPEN
You could be burned by hot fluid and
steam blown out under pressure.
HOW TO AVOID THE HAZARD
Wait for the engine to cool before removing the radiator cap. Always use a
thick rag over the cap. Allow any remaining pressure to escape before
completely removing the cap.
CAUTION:
_
Hard water or salt water is harmful to the
engine. You may use soft water if you cannot 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
EE.book Page 10 Tuesday, March 9, 2004 10:33 AM
EBU01083
EBU11700
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.
Switches
Check the operation of all switches. 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 headlights and tail/brake light to
make sure they are in working condition. Repair as necessary for proper operation.
5-10
EE.book Page 11 Tuesday, March 9, 2004 10:33 AM
EBU00157
Tires
2. The tires should be set to the recommended pressure:
● Recommended tire pressure
Front 35 kPa (0.35 kgf/cm2, 5.0 psi)
Rear 30 kPa (0.30 kgf/cm2, 4.3 psi)
● Check and adjust tire pressures when
the tires are cold.
● Tire pressures must be equal on both
sides.
3. Tire pressure below the minimum
specified could cause the tire to
dislodge from the rim under severe
riding conditions.
The following are minimums:
Front 32 kPa (0.32 kgf/cm2, 4.6 psi)
Rear 27 kPa (0.27 kgf/cm2, 3.9 psi)
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires,
or with improper or uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of
control, increasing your risk of accident.
HOW TO AVOID THE HAZARD
1. The tires listed below have been approved by Yamaha Motor Co., Ltd.
for this model. Other tire combinations are not recommended.
ACE-01E
ACE-01E
Manufacturer
Size
Type
Front
DUNLOP
AT25 × 8-12
KT131
Rear
DUNLOP
AT25 × 10-12
KT135
5-11
EE.book Page 12 Tuesday, March 9, 2004 10:33 AM
4. Use no more than the following
pressures when seating the tire
beads.
Front 250 kPa (2.5 kgf/cm2, 36 psi)
Rear 250 kPa (2.5 kgf/cm2, 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
EE.book Page 13 Tuesday, March 9, 2004 10:33 AM
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 measurements of the tire pressure and use the second
reading. Dust or dirt in the gauge could cause
the first reading to be incorrect.
Set pressure with tires cold.
Set tire pressures to the following specifications:
ACE-02EACE-02E
Recommended
pressure
Minimum
Maximum
Front
35 kPa
(0.35 kgf/cm2,
5.0 psi)
32 kPa
(0.32 kgf/cm2,
4.6 psi)
38 kPa
(0.38 kgf/cm2,
5.4 psi)
Rear
30 kPa
(0.30 kgf/cm2,
4.3 psi)
27 kPa
(0.27 kgf/cm2,
3.9 psi)
33 kPa
(0.33 kgf/cm2,
4.7 psi)
1. Low-pressure tire gauge
5-13
EE.book Page 14 Tuesday, March 9, 2004 10:33 AM
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
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM
EBU00161
EBU15110
OPERATION
Starting a cold engine
WARNING
WARNING
POTENTIAL HAZARD
Freezing control cables in cold weather.
WHAT CAN HAPPEN
You could be unable to control the ATV,
which could lead to an accident or collision.
HOW TO AVOID THE HAZARD
When riding in cold weather, always
make sure all control cables work
smoothly before you begin riding.
Indicates a potential hazard that could
result in serious injury or death.
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.
1. Apply the rear brake lever or brake pedal.
2. Turn the fuel cock to “ON”.
3. Turn the main switch to “ON” and the engine stop switch to “ ”.
4. Shift the drive select lever into the neutral
or park position.
6-1
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM
Position 3 : Cold engine startambient temperature above
25 °C (80 °F) and warm engine
start position.
NOTE:
● When the drive select lever is in the neutral or park position, if either indicator light
does not come on, ask a Yamaha dealer
to inspect the respective electric circuit.
● The engine can be started in any gear if
the rear brake lever or brake pedal is applied. However, it is recommended to
shift into neutral or park before starting
the engine.
_
1
2
3
4
5
6
7
_
5. Use the starter (choke) in reference to
the figure:
Position 1 : Cold engine startambient temperature below 5 °C
(40 °F).
Position 2 : Cold engine startambient temperature at 0 °C
(30 °F)–30 °C
(90 °F)
and
warming up position.
8
9
10
a. Starter (choke)
2. Half open
1. Fully open
3. Closed
6. Completely close the throttle lever and
start the engine by pushing the start
switch.
6-2
11
12
13
14
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM
NOTE:
● If the engine 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 energy. Do not crank the engine more than
10 seconds on each attempt.
● If the battery is discharged, pull the recoil
starter to start the engine.
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.
_
7. If the engine is started with the starter
(choke) in position 1, the starter (choke)
should be returned to position 2 to warm
up the engine. If the engine is started with
the starter (choke) in position 2, keep
the starter (choke) in this position to
warm up the engine.
8. Continue warming up the engine until it
idles smoothly and return the starter
(choke) to position 3 before riding.
EBU00182
Warming up
To get maximum engine life, always warm up
the engine before starting off. Never accelerate hard with a cold engine! To see whether or
not the engine is warm, check if it responds to
the throttle normally with the starter (choke)
turned off.
6-3
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM
EBU08461
Drive select lever operation and reverse
driving
CAUTION:
_
Before shifting, you must stop the ATV
and return the throttle lever to the closed
position, otherwise the transmission may
be damaged.
_
Shifting: Neutral to High and High to Low
1. Bring the ATV to a complete stop and return the throttle lever to the closed position.
2. Apply the brakes, then shift by moving
the drive select lever along the shift
guide.
1. Drive select lever
3. Open the throttle lever gradually.
NOTE:
Make sure that the drive select lever is completely shifted into position.
_
_
6-4
EE.book Page 5 Tuesday, March 9, 2004 10:33 AM
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. Bring the ATV to a complete stop and return the throttle lever to the closed position.
2. Apply the brake pedal.
3. Shift from neutral to reverse or from reverse to park and vice versa by moving
the drive select lever along the shift
guide.
1. Drive select lever
NOTE:
● When in reverse, the reverse indicator
light should be on. If the light does not
come on, ask a Yamaha dealer to inspect
the electrical circuit.
● Due to the synchronizing mechanism in
the engine, the light may not come on until the ATV starts moving.
_
_
4. Check behind for people or obstacles,
and then release the brake pedal.
6-5
EE.book Page 6 Tuesday, March 9, 2004 10:33 AM
5. Open the throttle lever gradually and continue to watch to the rear while backing.
WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or person behind 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 slowly.
6-6
EE.book Page 7 Tuesday, March 9, 2004 10:33 AM
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 operation or any condition which might result in excessive engine heating must be avoided.
However, momentary (2–3 seconds maximum) full throttle operation under load does
not harm the engine.
Each full throttle acceleration sequence
should be followed with a substantial rest period for the engine by cruising at lower r/min
so the engine can rid itself of the temporary
build up of heat. If any abnormality is noticed
during this period, consult a Yamaha dealer.
0–10 hours:
Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of operation. Vary the
speed of the machine from time to time. Do
not operate it at one set throttle position.
6-7
EE.book Page 8 Tuesday, March 9, 2004 10:33 AM
EBU00612
10–20 hours:
Avoid prolonged operation above 3/4 throttle.
Rev the machine freely but do not use full
throttle at any time.
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.
After break-in:
Avoid prolonged full throttle operation. Vary
speeds occasionally.
6-8
EE.book Page 9 Tuesday, March 9, 2004 10:33 AM
EBU06151
Parking on a slope
1. Bring the machine to a stop by applying
the brakes.
2. Stop the engine.
3. With the brake pedal applied, shift the
drive select lever to the park position “P”.
WARNING
POTENTIAL HAZARD
Parking on a hill or other incline.
WHAT CAN HAPPEN
The ATV could roll out of control, increasing 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 incline, 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.
6-9
EE.book Page 10 Tuesday, March 9, 2004 10:33 AM
EBU00221
Accessories and loading
●
EBU00222
Accessories
Accessories can affect the handling and control of your ATV. Keep the following in mind
when considering an accessory or operating
an ATV which has accessories.
● Choose only accessories designed for your
ATV. Your Yamaha dealer has a variety of
genuine Yamaha accessories. Other accessories may also be available on the
market. However, it is not possible for
Yamaha to test all non-Yamaha accessories, nor have any control over the quality or
suitability of them. Choose a genuine
Yamaha accessory, or one that is equivalent in design and quality.
●
●
6-10
Accessories should be rigidly and securely
mounted. An accessory which can shift position or come off while you are riding could
affect your ability to control the ATV.
Do not mount an accessory where it could
interfere with your ability to control the ATV.
Examples include (but are not limited to) a
heavy or bulky object attached to the handlebars which could make steering difficult,
an accessory that limits your ability to move
around on the seat, or one that limits your
view.
Use extra caution when riding an ATV with
accessories. The ATV may handle differently than it does without accessories.
EE.book Page 11 Tuesday, March 9, 2004 10:33 AM
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 cargo or towing a trailer. Keep the following
points in mind:
● Never exceed the weight limits shown. An
overloaded ATV can be unstable.
●
MAXIMUM LOADING LIMIT
● Vehicle loading limit (total weight of
cargo, rider and accessories, and
tongue weight): 220 kg (485 lb)
● Front carrier: 45 kg (99 lb)
● Rear carrier: 85 kg (187 lb)
● Storage box: 2.0 kg (4.4 lb)
● Trailer hitch:
Pulling load (total weight of trailer and
cargo): 550 kgf (1,212 lbf)
Tongue weight (vertical weight on
trailer hitch point): 15 kgf (33 lbf)
●
●
●
6-11
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 trailer, include the tongue weight in the maximum 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 accident.
Make sure the load does not interfere with
controls or your ability to see where you are
going.
EE.book Page 12 Tuesday, March 9, 2004 10:33 AM
●
●
●
●
Ride more slowly than you would without a
load. The more weight you carry, the slower 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 vehicle takes longer to stop.
Avoid making sharp turns unless at very
slow speeds.
Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV.
WARNING
POTENTIAL HAZARD
Overloading this ATV or carrying or towing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle handling which could lead to an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity
for this ATV.
Cargo should be properly distributed
and securely attached. Reduce speed
when carrying cargo or pulling a trailer.
Allow greater distance for braking.
6-12
EE.book Page 13 Tuesday, March 9, 2004 10:33 AM
EBU15121
WARNING
_
Indicates a potential hazard that could
result in serious injury or death.
6-13
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM
Riding
1-
Your
ATV
7-1
7
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM
WARNING
_
Indicates a potential hazard that could
result in serious injury or death.
ride, be sure you have read this Owner’s Manual 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.
GETTING TO KNOW YOUR ATV
This ATV is mainly for utility use, but may also
be used for recreation. This section, Riding
your ATV, provides general ATV riding instructions for recreational riding. 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 techniques 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 necessary to enjoy riding safely. Before you begin to
7-3
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM
RIDE WITH CARE AND GOOD
JUDGEMENT
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators
should complete the certified training
course offered by Yamaha. They should
then regularly practice the skills learned
in the course and the operating techniques described in this Owner’s Manual. For more information about the
training course, contact an authorized
ATV dealer or call 1-800-887-2887.
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 performance until you are totally familiar with the
machine’s handling and performance characteristics.
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 maneuvers.
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does not know
how to operate the ATV properly in different situations and on different types
of terrain.
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EE.book Page 5 Tuesday, March 9, 2004 10:33 AM
Not recommended for children under
16 years of age.
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations for this ATV.
WHAT CAN HAPPEN
Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child.
HOW TO AVOID THE HAZARD
A child under 16 should never operate
an ATV with engine size greater than
90cc.
7-5
EE.book Page 6 Tuesday, March 9, 2004 10:33 AM
This ATV is designed to carry operator and
cargo only - passengers prohibited.
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.
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EE.book Page 7 Tuesday, March 9, 2004 10:33 AM
Apparel
Operating without protective clothing
increases your chances of severe injury
in the event of an accident.
HOW TO AVOID THE HAZARD
Always wear an approved motorcycle
helmet that fits properly.
You should also wear:
eye protection
(goggles or face shield)
gloves
boots
long-sleeved shirt or jacket
long pants
WARNING
POTENTIAL HAZARD
Operating this ATV without wearing an
approved motorcycle helmet, eye protection and protective clothing.
WHAT CAN HAPPEN
Operating without an
approved
motorcycle helmet increases your chances of a
severe head injury or
death in the event of
an accident.
Operating
without
eye protection can
result in an accident and increases your
chances of a severe injury in the event
of an accident.
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EE.book Page 8 Tuesday, March 9, 2004 10:33 AM
Do not operate after consuming alcohol or
drugs.
Operator’s performance capability is reduced
by the influence of alcohol or drugs.
WARNING
POTENTIAL HAZARD
Operating this ATV after consuming alcohol or drugs.
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before
or while driving this ATV.
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EE.book Page 9 Tuesday, March 9, 2004 10:33 AM
Pre-operation checks
Always perform the pre-operation checks listed on page 5-1 before riding for safety and
proper care of the ATV.
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires,
or with improper or uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of
control, increasing your risk of an accident.
HOW TO AVOID THE HAZARD
Always use the size and type tires specified in the Owner’s Manual for this vehicle on pages. Always maintain proper
tire pressure as described in the Owner’s Manual on page 5-13.
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident
or equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV each time you
use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures
and schedules described in the Owner’s
Manual.
7-9
EE.book Page 10 Tuesday, March 9, 2004 10:33 AM
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 maximum. Screwing in the adjuster limits the maximum 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.
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.
WARNING
POTENTIAL HAZARD
Operating this ATV at speeds too fast
for your skills or the conditions.
WHAT CAN HAPPEN
Increases your chances of losing control of the ATV, which can result in an
accident.
HOW TO AVOID THE HAZARD
Always go at a speed that is proper for
the terrain, visibility and operating conditions, and your experience.
1. Locknut
7-10
2. Adjusting screw
EE.book Page 11 Tuesday, March 9, 2004 10:33 AM
Loading and accessories
Use extra caution when riding the ATV with
additional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Reduce your speed when adding
additional loads.
WARNING
POTENTIAL HAZARD
Overloading this ATV or carrying or towing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle handling which could lead to an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity
for this 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.
MAXIMUM LOADING LIMIT
● Vehicle loading limit: 220 kg (485 lb)
* Total weight of cargo, rider and
accessories, and trailer hitch
vertical load.
● Front carrier: 45 kg (99 lb)
● Rear carrier: 85 kg (187 lb)
● Storage box: 2.0 kg (4.4 lb)
● Trailer hitch:
Pulling load: 550 kgf (1,212 lbf)
Total weight of trailer and cargo.
Tongue weight: 15 kgf (33 lbf)
Vertical weight on trailer hitch point.
7-11
EE.book Page 12 Tuesday, March 9, 2004 10:33 AM
During operation
Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels.
WARNING
POTENTIAL HAZARD
Removing hands from handlebars or
feet from footboards during operation.
WHAT CAN HAPPEN
Removing even one hand or foot can reduce your ability to control the ATV or
could cause you to lose your balance
and fall off of the ATV. If you remove a
foot from a footboard, your foot or leg
may come into contact with the rear
wheels, which could injure you or cause
an accident.
HOW TO AVOID THE HAZARD
Always keep both hands on the handlebars and both feet on the footboards of
your ATV during operation.
7-12
EE.book Page 13 Tuesday, March 9, 2004 10:33 AM
Avoid wheelies and jumping. You may lose
control of the ATV or overturn.
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps, and other
stunts.
WHAT CAN HAPPEN
Increases the chance of an accident, including an overturn.
HOW TO AVOID THE HAZARD
Never attempt stunts, such as wheelies
or jumps. Don’t try to show off.
7-13
EE.book Page 14 Tuesday, March 9, 2004 10:33 AM
Modifications
WARNING
POTENTIAL HAZARD
Operating this ATV with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or
modification of this vehicle may cause
changes in handling which in some situations could lead to an accident.
HOW TO AVOID THE HAZARD
Never modify this ATV through improper installation or use of accessories. All
parts and accessories added to this vehicle should be genuine Yamaha or
equivalent components designed for
use on this ATV and should be installed
and used according to instructions. If
you have questions, consult an authorized ATV dealer.
7-14
EE.book Page 15 Tuesday, March 9, 2004 10:33 AM
Exhaust system
The exhaust system on the ATV is very hot
during and following operation. To prevent
burns, avoid touching the exhaust system.
Park the ATV in a place where pedestrians or
children are not likely to touch it.
Do not touch the hot exhaust system.
Do not park the ATV in a place where
others might be likely to touch it.
WARNING
POTENTIAL HAZARD
Hot exhaust system.
WHAT CAN HAPPEN
Dry grass or brush or other combustible
material accumulated around the engine 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
EE.book Page 16 Tuesday, March 9, 2004 10:33 AM
BE CAREFUL WHERE YOU RIDE
This ATV is designed for off-road use only.
Riding on paved surfaces can cause loss of
control.
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 control.
HOW TO AVOID THE HAZARD
Always avoid paved surfaces, including
sidewalks, driveways, parking lots and
streets.
7-16
EE.book Page 17 Tuesday, March 9, 2004 10:33 AM
Do not ride on any public road, street, or highway.
Riding on public roads can result in collisions
with other vehicles.
WARNING
POTENTIAL HAZARD
Operating this ATV on public streets,
roads or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate this ATV on any public
street, road or highway, even a dirt or
gravel one. In many states it is illegal to
operate ATVs on public streets, roads
and highways.
7-17
EE.book Page 18 Tuesday, March 9, 2004 10:33 AM
Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for
holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV
to upset.
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating
this ATV on unfamiliar terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks,
bumps, or holes, without enough time to
react. Could result in the ATV overturning or going out of control.
HOW TO AVOID THE HAZARD
Go slowly and be extra careful when operating on unfamiliar terrain. Always be
alert to changing terrain conditions
when operating the ATV.
7-18
EE.book Page 19 Tuesday, March 9, 2004 10:33 AM
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 accident, including an overturn.
HOW TO AVOID THE HAZARD
Do not operate on excessively rough,
slippery or loose terrain until you have
learned and practiced the skills necessary to control the ATV on such terrain.
Always be especially cautious on these
kinds of terrain.
7-19
EE.book Page 20 Tuesday, March 9, 2004 10:33 AM
When riding in an area where you might not
easily be seen, such as desert terrain, mount
a caution flag on the ATV. DO NOT use the
flag pole bracket as a trailer hitch.
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 carefully for other vehicles.
Do not ride in areas posted “no trespassing”.
Do not ride on private property without getting
permission.
WARNING
POTENTIAL HAZARD
Operating in areas where you might not
be seen by other off-road vehicles.
7-20
EE.book Page 21 Tuesday, March 9, 2004 10:33 AM
With the engine idling, shift the drive select lever to the low position “L” or the high position
“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 control. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV.
Select a large, flat area off-road to become familiar 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. Always avoid riding on paved surfaces: the ATV
is designed for off-road use only, and handling maneuvers are more difficult to perform
on pavement.
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.
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.
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.
_
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EE.book Page 22 Tuesday, March 9, 2004 10:33 AM
TURNING YOUR ATV
To achieve maximum traction while riding offroad 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 traction, the ATV will resist turning. A special turning technique must be used to allow the ATV
to make turns quickly and easily. It is essential
that this skill be learned first at low speed.
HOW TO 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 begin to turn the handlebars in the desired direction. 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 maneuver will let the wheel on the inside of the turn
slip slightly, allowing the ATV to make the turn
properly.
WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
ATV could go out of control, causing a
collision or overturn.
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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 braking, incorrect
body movements, or too much speed for the
sharpness of the turn may cause the ATV to
tip. If the ATV begins to tip over to the outside
while negotiating a turn, lean more to the inside. It may also be necessary to gradually let
off on the throttle and steer to the outside of
the turn to avoid tipping over.
Remember: Avoid higher speeds until you are
thoroughly familiar with the operation of your
ATV.
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 surface is slippery or loose, it may help to position more of your weight over the front wheels
by moving forward on the seat.
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CLIMBING UPHILL
Use proper riding techniques to avoid vehicle
overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding
first on gentle slopes. Try more difficult climbs
only after you have developed your skill. In all
cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to
lose control.
HOW TO AVOID THE HAZARD
Never operate the ATV on hills too steep
for the ATV or for your abilities. Practice
on smaller hills before attempting large
hills.
It is important when climbing a hill to make
sure that your weight is transferred forward on
the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing
on the footboards and leaning forward over
the handlebars.
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle can overturn more easily on
extremely steep hills than on level surfaces or small hills.
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WARNING
An obstacle, a sharp drop, or another
vehicle or person could be on the other
side of the hill.
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 Owner’s Manual.
Always check the terrain carefully before you start up any hill.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly.
The ATV could flip over backwards.
Never go over the top of any hill at high
speed.
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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.
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.
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When crossing the side of a hill:
Always follow proper procedures as described in the Owner’s Manual.
Avoid hills with excessively slippery or
loose surfaces.
Shift your weight to the uphill side of the
ATV.
7-27
EE.book Page 28 Tuesday, March 9, 2004 10:33 AM
the front and rear brakes gradually, or dismount the ATV immediately on the uphill side.
If your ATV has stalled or stopped and you
believe you can continue up the hill, restart
carefully to make sure you do not lift the front
wheels which could cause you to lose control.
If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically
turn the ATV around and then descend the
hill.
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards or improperly 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 position “P” after
you are stopped.
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 pedal 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
EE.book Page 29 Tuesday, March 9, 2004 10:33 AM
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 parking position “P”.
Dismount on uphill side or to a side if
pointed straight uphill. Turn the ATV
around and remount, following the procedure described in the Owner’s Manual.
7-29
EE.book Page 30 Tuesday, March 9, 2004 10:33 AM
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 compression 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.
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 rear brake because 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 allow the ATV to tip or roll over. Carefully
choose your path and ride no faster than you
will be able to react to obstacles which may
appear.
7-30
EE.book Page 31 Tuesday, March 9, 2004 10:33 AM
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 going down hills as described in this Owner’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 before you start down any hill.
Shift your weight backward.
Never go down a hill at high speed.
Avoid going down a hill at an angle that
would cause the vehicle to lean sharply
to one side. Go straight down the hill
where possible.
7-31
EE.book Page 32 Tuesday, March 9, 2004 10:33 AM
CROSSING A SLOPE
Traversing a sloping surface on your ATV requires you to properly position your weight to
maintain proper balance. Be sure that you
have learned the basic riding skills on flat
ground before attempting to cross a sloping
surface. Avoid slopes with slippery surfaces
or rough terrain that may upset your balance.
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 described in the Owner’s Manual.
Avoid hills with excessively slippery or
loose surfaces. Shift your weight to the
uphill side of the ATV.
As you travel across a slope, lean your body
in the uphill direction. It may be necessary to
correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill. 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
EE.book Page 33 Tuesday, March 9, 2004 10:33 AM
7-33
EE.book Page 34 Tuesday, March 9, 2004 10:33 AM
CROSSING THROUGH SHALLOW WATER
The ATV can be used to cross slow moving,
shallow water of up to a maximum of 35 cm
(14 inches) in depth. Before entering the water, choose your path carefully. Enter where
there is no sharp drop off, and avoid rocks or
other obstacles which may be slippery or upset the ATV. Drive slowly and carefully.
Remember that wet brakes may have reduced stopping ability. Test your brakes
after leaving water. If necessary, apply
them several times to let friction dry out
the linings.
WARNING
POTENTIAL HAZARD
Operating this ATV through deep or fast
flowing water.
WHAT CAN HAPPEN
Tires 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 specified in your Owner’s Manual.
7-34
EE.book Page 35 Tuesday, March 9, 2004 10:33 AM
Test your brakes after leaving the water. Do
not continue to ride your ATV without verifying
that you have regained proper braking ability.
CAUTION:
_
After riding your ATV in water, be sure to
drain the trapped water by removing the
check hose at the bottom of the air filter
case, the V-belt cooling duct check hose
and the drive select lever box check hose.
Also, remove the V-belt case drain plug to
drain any water that may have accumulated. Wash the ATV in fresh water if it has
been operated in salt water or muddy conditions.
_
7-35
1. Air filter case check hose
EE.book Page 36 Tuesday, March 9, 2004 10:33 AM
1. V-belt cooling duct check hose (Left side)
1. Drive select lever box check hose
1. V-belt case drain plug
7-36
EE.book Page 37 Tuesday, March 9, 2004 10:33 AM
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.
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Could cause loss of control or a collision. Could cause the ATV to overturn.
HOW TO AVOID THE HAZARD
Before operating in a new area, check
for obstacles.
Never attempt to ride over large obstacles, such as large rocks or fallen trees.
When you go over obstacles, always follow proper procedures as described in
the Owner’s Manual.
7-37
EE.book Page 38 Tuesday, March 9, 2004 10:33 AM
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.
If the rear wheels of your ATV start to slide
sideways, control can usually be regained (if
there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have
corrected the slide.
To reduce the tendency for the front wheels to
slide in loose or slippery conditions, positioning your weight over the front wheels will
sometimes help.
7-38
EE.book Page 39 Tuesday, March 9, 2004 10:33 AM
With practice, over a period of time, skill at
controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability
and control are reduced. Bear in mind that
sliding maneuvers should always be avoided
on extremely slippery surfaces such as ice,
since all control may be lost.
WARNING
POTENTIAL HAZARD
Skidding or sliding improperly.
WHAT CAN HAPPEN
You may lose control of this ATV. You
may also regain traction unexpectedly,
which may cause the ATV to overturn.
HOW TO AVOID THE HAZARD
Learn to safely control skidding or sliding by practicing at low speeds and on
level, smooth terrain.
On extremely slippery surfaces, such as
ice, go slowly and be very cautious in
order to reduce the chance of skidding
or sliding out of control.
7-39
EE.book Page 40 Tuesday, March 9, 2004 10:33 AM
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.)
● If 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
If your ATV starts to slide sideways:
Steer in the direction of the slide if you have
the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See 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 forward speed. If not, stop, dismount on the
uphill side of the ATV and physically turn
the ATV around. If the ATV starts to slip
backwards DO NOT USE THE REAR
BRAKE - the ATV may tip over on top of
you. Dismount the ATV on the uphill side.
(See pages 7-24–7-29.)
EE.book Page 41 Tuesday, March 9, 2004 10:33 AM
●
●
If your ATV is traversing a sloping surface:
Be sure to ride with your weight positioned
towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip,
steer down the hill (if there are no obstacles
in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 7-32–
7-33.)
If 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 until you have regained adequate braking
ability. (See pages 7-34–7-36.)
WARNING
_
Indicates a potential hazard that could
result in serious injury or death.
7-41
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM
EBU00515
PERIODIC MAINTENANCE AND
ADJUSTMENT
Have a Yamaha dealer perform service if
you are not familiar with machine service.
Periodic inspection, adjustment and lubrication 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, adjustment and lubrication are explained on the
following pages.
EBU00562
Owner’s manual and tool kit
You are recommended to put this owner’s
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.
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 components can cause
shocks or can start fires.
HOW TO AVOID THE HAZARD
Turn off the engine when performing
maintenance unless otherwise specified.
8-1
1. Owner’s manual
2. Owner’s tool kit
3. Low-pressure tire gauge
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM
The service information included in this manual is intended to provide you, the owner, with
the necessary information for completing your
own preventive maintenance and minor repairs. The tools provided in the Owner’s tool
kit are sufficient for this purpose, except that a
torque wrench is also necessary to properly
tighten nuts and bolts.
WARNING
POTENTIAL HAZARD
Operating this ATV with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or
modification of this vehicle may cause
changes in handling which in some situations could lead to an accident.
HOW TO AVOID THE HAZARD
Never modify this ATV through improper installation or use of accessories. All
parts and accessories added to this vehicle should be genuine Yamaha or
equivalent components designed for
use on this ATV and should be installed
and used according to instructions. If
you have questions, consult an authorized Yamaha ATV dealer.
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 necessary.
_
_
8-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM
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.
_
ITEM
Valves*
Cooling system
Spark plug
Air filter element
Carburetor*
Crankcase breather
system*
Exhaust system*
Sparks arrester
Whichever month
comes first
km
(mi)
hours
ROUTINE
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check valve clearance.
Adjust if necessary.
Check coolant leakage.
Repair if necessary.
Replace coolant every 24 months.
Check condition.
Adjust gap and clean.
Replace if necessary.
Clean.
Replace if necessary.
Check starter (choke).
Adjust engine idling speed.
Check breather hose for cracks or damage.
Replace engine idling speed.
Check for leakage.
Tighten if necessary.
Replace gasket(s) if necessary.
Clean.
8-3
1
320
(200)
20
INITIAL
3
1,200
(750)
75
6
2,400
(1,500)
150
EVERY
6
12
2,400
4,800
(1,500) (3,000)
150
300
Every 20–40 hours
(More often in wet or dusty areas.)
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM
ITEM
Fuel line*
Engine oil
Engine oil filter cartridge
Final gear oil
Differential gear oil
ROUTINE
•
•
•
•
Check fuel hose for cracks or damage.
Replace if necessary.
Replace (Warm engine before draining).
Replace.
• Check oil level/oil leakage.
• Replace.
•
•
•
Rear brake*
•
Select lever safety system
•
cable*
•
•
V-belt*
•
•
Wheels*
•
•
Wheel bearing*
•
•
Front and rear suspension*
•
•
Steering system*
•
Rear upper and lower
•
knuckle pivots*
Drive shaft universal joint* •
Engine mount*
•
•
Front and rear axle boots*
•
Stabilizer bushes*
•
Front brake*
Whichever month
comes first
km
(mi)
hours
Check operation/fluid leakage/see NOTE page 8-5.
Correct if necessary.
Check operation/fluid leakage/see NOTE page 8-5.
Correct if necessary.
Check operation.
Adjust if necessary.
Check operation.
Check for cracks or damage.
Check balance/damage/runout.
Repair if necessary.
Check bearing assemblies for looseness/damage.
Replace if damaged.
Check operation.
Correct if necessary.
Check operation/Replace if damaged.
Check toe-in/Adjust if necessary.
Lubricate with lithium-soap-based grease.
Lubricate with lithium-soap-based grease.
Check for cracks or damage.
Check operation.
Replace if damaged.
Check for cracks or damage.
8-4
1
320
(200)
20
INITIAL
3
1,200
(750)
75
6
2,400
(1,500)
150
EVERY
6
12
2,400
4,800
(1,500) (3,000)
150
300
EE.book Page 5 Tuesday, March 9, 2004 10:33 AM
ITEM
Fittings and fasteners*
Lights and switches*
Whichever month
comes first
km
(mi)
hours
ROUTINE
•
•
•
•
1
320
(200)
20
INITIAL
3
1,200
(750)
75
6
2,400
(1,500)
150
EVERY
6
12
2,400
4,800
(1,500) (3,000)
150
300
Check all chassis fittings and fasteners.
Correct if necessary.
Check operation.
Adjust headlight beam.
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
● Recommended brake fluid: DOT 4
● Brake fluid replacement:
• When disassembling the master cylinders or calipers, replace the brake fluid. Normally check the brake fluid level
and add fluid as required.
• On the inner parts of the master cylinders and calipers, replace the oil seals
every two years.
• Replace the brake hoses every four
years, or if cracked or damaged.
WARNING
_
Indicates a potential hazard that could
result in serious injury or death.
8-5
EE.book Page 6 Tuesday, March 9, 2004 10:33 AM
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 D
3. Panel F
1. Panel A
3. Panel B
2. Panel C
8-6
2. Panel E
4. Panel G
EE.book Page 7 Tuesday, March 9, 2004 10:33 AM
EBU00879
Panels A and D
To remove
1. Remove the seat. (See page 4-20 for
seat removal and installation procedures.)
2. Pull outward on the area shown, and
then pull upward as shown.
1. Panel D
1. Panel A
8-7
EE.book Page 8 Tuesday, March 9, 2004 10:33 AM
To install
1. Insert the panel projections in the numerical 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
EE.book Page 9 Tuesday, March 9, 2004 10:33 AM
EBU00962
Panel B
To remove
Remove the bolts.
To install
Place the panel in the original position and install the bolts.
1. Panel B
CAUTION:
_
When installing the panel, be sure not to
pinch the cables or wires.
_
2. Bolt (× 2)
8-9
EE.book Page 10 Tuesday, March 9, 2004 10:33 AM
EBU01141
Panel C
To remove
1. Remove the front carrier by removing the
stay covers at the rear, then by removing
the bolts.
1. Bolt (× 2) (top)
1. Front carrier stay cover (× 2)
1. Bolt (× 2) (top)
8-10
EE.book Page 11 Tuesday, March 9, 2004 10:33 AM
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)
Carrier bolt (under fenders):
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
1. Bolt (× 2) (Under fenders)
2. Remove the quick fasteners and pull the
panel upward.
3. Install the stay covers.
1. Quick fastener (× 2)
2. Panel C
8-11
EE.book Page 12 Tuesday, March 9, 2004 10:33 AM
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 (× 6)
8-12
EE.book Page 13 Tuesday, March 9, 2004 10:33 AM
EBU00638
Panel F
To remove
Pull outward on the areas shown.
To install
Place the panel in its original position.
1. Panel F
8-13
EE.book Page 14 Tuesday, March 9, 2004 10:33 AM
EBU15041
Panel G
To remove
1. Remove the seat. (See page 4-20 for
seat removal and installation procedures.)
2. Remove the rear carrier by removing the
bolts.
1. Bolt (× 2) (Under fenders)
3. Remove the seat under bracket and the
panel by pulling them off.
1. Bolt (× 4)
8-14 1. Seat under bracket
2. Panel G
EE.book Page 15 Tuesday, March 9, 2004 10:33 AM
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 intervals specified in the periodic maintenance
and lubrication chart.
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·lbf)
To check the engine oil level
1. Remove panel F. (See page 8-13 for
panel removal and installation procedures.)
2. Place the ATV on a 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.
3. Install the seat.
8-15
EE.book Page 16 Tuesday, March 9, 2004 10:33 AM
5. Remove the engine oil filler cap and wipe
off the dipstick with a clean rag.
6. Insert the dipstick in the oil filler hole
(without screwing it in), and then remove
it again to check the oil level.
NOTE:
The engine oil should be between the minimum and maximum level marks.
_
_
1. Engine oil filler cap
2. Dipstick
1. Maximum level mark
8-16
2. Minimum level mark
EE.book Page 17 Tuesday, March 9, 2004 10:33 AM
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 procedures.)
2. Start the engine, warm it up for several
minutes, and then turn it off.
3. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap.
4. Remove the engine oil drain bolt to drain
the oil from the crankcase.
7. If the engine oil is at or below the minimum level mark, add sufficient oil of the
recommended type to raise it to the correct level.
8. Insert the dipstick into the oil filler hole,
and then tighten the oil filler cap.
9. Install the panel.
1. Engine oil drain bolt
8-17
EE.book Page 18 Tuesday, March 9, 2004 10:33 AM
NOTE:
Skip steps 5–9 if the oil filter cartridge is not
being replaced.
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.
_
_
5. Remove panels D and E. (See
pages 8-7–8-8 and 8-12 for panel removal and installation procedures.)
6. Remove the oil filter cartridge with an oil
filter wrench.
_
1. O-ring
1. Engine oil filter cartridge
2. Oil filter wrench
NOTE:
An oil filter wrench is available at a nearby
Yamaha dealer.
_
_
8-18
EE.book Page 19 Tuesday, March 9, 2004 10:33 AM
8. Install the new oil filter cartridge with an
oil filter wrench, and then tighten it to the
specified torque with a torque wrench.
9. Install panels D and E.
10. Install the engine oil drain bolt, and then
tighten it to the specified torque.
Tightening torque:
Engine oil drain bolt:
30 Nm (3.0 m·kgf, 22 ft·lbf)
11. Add the specified amount of recommended 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 qt, 2.11 US qt)
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
8-19
EE.book Page 20 Tuesday, March 9, 2004 10:33 AM
CAUTION:
_
●
●
In order to prevent clutch slippage
(since the engine oil also lubricates
the clutch), do not mix any chemical
additives. Do not use oils with a diesel
specification of “CD” or oils of a higher quality than specified. In addition,
do not use oils labeled “ENERGY
CONSERVING II” or higher.
Make sure that no foreign material enters the crankcase.
_
12. Start the engine and warm it up for several minutes. While warming up, check for
oil leakage. If oil leakage is found, turn
the engine off immediately and check for
the cause.
13. Turn the engine off, and then check the
oil level and correct it if necessary.
14. Install panel F.
8-20
EE.book Page 21 Tuesday, March 9, 2004 10:33 AM
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 repair 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.
3. Remove the oil filler bolt and the drain
bolt to drain the oil.
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.
1. Final gear oil filler bolt
8-21
EE.book Page 22 Tuesday, March 9, 2004 10:33 AM
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
EE.book Page 23 Tuesday, March 9, 2004 10:33 AM
EBU07062
Differential gear oil
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
the brim of the filler hole. If the level is
low, add sufficient oil of the recommended type to raise it to the specified level.
CAUTION:
Be sure no foreign material enters the differential gear case.
_
3. Install the differential gear oil filler bolt.
1. Differential gear oil
2. Differential gear oil filler bolt
3. Specified level
8-23
EE.book Page 24 Tuesday, March 9, 2004 10:33 AM
Differential gear oil replacement
1. Place the ATV on a level surface.
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
the oil.
4. Install the differential gear oil drain bolt
and tighten it to the specified torque.
Tightening torque:
Differential gear oil drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
5. Fill the differential gear case with the recommended 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 differential 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
EE.book Page 25 Tuesday, March 9, 2004 10:33 AM
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 temperature.
Tightening torque:
Differential 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.
NOTE:
The coolant should be between the minimum
and maximum level marks.
_
_
1. Coolant reservoir tank cap
3. Minimum level mark
8-25
2. Maximum level mark
EE.book Page 26 Tuesday, March 9, 2004 10:33 AM
NOTE:
● If water is added, have a Yamaha dealer
check the antifreeze content of the coolant as soon as possible.
● The radiator fan operation is completely
automatic. It is switched on or off according to the coolant temperature in the radiator.
3. If the coolant is at or below the minimum
level mark, remove panel D (See
pages 8-7–8-8 for panel removal and installation procedures.), remove the reservoir cap, add coolant to the maximum
level mark, install the reservoir cap, and
then install the panel.
_
Coolant reservoir capacity
(up to the maximum level mark):
0.3 L (0.26 Imp qt, 0.32 US qt)
_
If your ATV overheats, see page 8-64 for details.
CAUTION:
_
Hard water or salt water is harmful to the
engine. You may use soft water if you cannot get distilled water.
_
8-26
EE.book Page 27 Tuesday, March 9, 2004 10:33 AM
EBU12572
Changing the coolant
1. Place the ATV on a level surface.
2. Remove panels E and F. (See
pages 8-12–8-13 for panel removal and
installation procedures.)
3. Place a container under the engine, and
then remove the coolant drain bolt. (Use
a trough or a similar object as shown to
prevent coolant from spilling on the footrest.)
WARNING
POTENTIAL HAZARD
Removing the radiator cap when the engine and radiator are still hot.
WHAT CAN HAPPEN
You could be burned by hot fluid and
steam blown out under pressure.
HOW TO AVOID THE HAZARD
Wait for the engine to cool before removing the radiator cap. Always use a
thick rag over the cap. Allow any remaining pressure to escape before
completely removing the cap.
1. Coolant drain bolt
8-27
EE.book Page 28 Tuesday, March 9, 2004 10:33 AM
1. Radiator cap
1. Trough
4. Remove the front carrier and panel C.
(See pages 8-10 and 8-11 for removal
and installation procedures.)
5. Remove the radiator cap.
6. Remove panel D. (See pages 8-7–8-8 for
panel removal and installation procedures.)
7. Remove the coolant reservoir cap.
8. Disconnect the hose on the coolant reservoir side, and then drain the coolant
from the coolant reservoir.
8-28
EE.book Page 29 Tuesday, March 9, 2004 10:33 AM
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
aluminum engines.
Antifreeze and water mixing ratio:
1:1
Total amount:
1.8 L (1.58 Imp qt, 1.90 US qt)
Coolant reservoir capacity
(up to the maximum level mark):
0.3 L (0.26 Imp qt, 0.32 US qt)
1. Coolant reservoir drain hose
9. After draining the coolant, thoroughly
flush the cooling system with clean tap
water.
10. Replace the coolant drain bolt washer if it
is damaged, install the coolant drain bolt,
and then tighten it to the specified torque.
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf, 7 ft·lbf)
8-29
EE.book Page 30 Tuesday, March 9, 2004 10:33 AM
CAUTION:
_
Hard water or salt water is harmful to the
engine. You may use soft water if you cannot get distilled water.
_
14. Start the engine and let it idle for several
minutes. Stop 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 dealer check the cooling system.
_
_
16. Install the panels and the front carrier.
8-30
EE.book Page 31 Tuesday, March 9, 2004 10:33 AM
EBU00862
Axle boots
Check the protective boots for holes or tears.
If any damage is found, have them replaced
by a Yamaha dealer.
1. Rear axle boot (× 2 each side)
1. Front axle boot (× 2 each side)
8-31
EE.book Page 32 Tuesday, March 9, 2004 10:33 AM
EBU00864
Spark plug inspection
Removal
1. Remove panel A. (See pages 8-7–8-8 for
panel removal and installation procedures.)
2. Remove the spark plug cap.
1. Spark plug wrench
1. Spark plug cap
3. Use the spark plug wrench in the tool kit
to remove the spark plug as shown.
8-32
EE.book Page 33 Tuesday, March 9, 2004 10:33 AM
Installation
1. Measure the electrode gap with a wire
thickness gauge and, if necessary, adjust
the gap to specification.
Inspection
The spark plug is an important engine component and is easy to inspect. The condition of
the spark plug can indicate the condition of
the engine. The ideal color on the white insulator around the center electrode is a mediumto-light tan color for a ATV that is being ridden
normally. Do not attempt to diagnose such
problems yourself. Instead, take the ATV to a
Yamaha dealer. You should periodically remove 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 replace the spark plug with the specified plug.
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
Specified spark plug:
DPR8EA-9 (NGK)
a. Spark plug gap
2. Clean the gasket surface. Wipe off any
grime from the threads.
3. Install the spark plug and tighten it to the
specified torque.
8-33
EE.book Page 34 Tuesday, March 9, 2004 10:33 AM
EBU12111
Air filter element cleaning
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.5 ft·lbf)
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.
_
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.
1. Air filter case check hose
1. Remove the seat. (See page 4-20 for
seat removal and installation procedures.)
2. Remove the air filter case cover by unhooking the holders.
8-34
EE.book Page 35 Tuesday, March 9, 2004 10:33 AM
1. Holder (× 5)
2. Air filter case cover
3. Remove the air filter element.
1. Frame
1. Air filter element
8-35
2. Air filter element
EE.book Page 36 Tuesday, March 9, 2004 10:33 AM
4. Remove the air filter element from its
frame.
5. Wash the air filter element gently but
thoroughly in solvent.
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 element.
WARNING
NOTE:
The air filter element should be wet but not
dripping.
POTENTIAL HAZARD
Using low flash point solvents or gasoline to clean the air filter element.
WHAT CAN HAPPEN
Low flash point solvents or gasoline can
catch fire or explode.
HOW TO AVOID THE HAZARD
Use parts cleaning solvent to clean the
air filter element.
_
_
9. Pull the air filter element over its frame.
10. Install 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.
1. Breather hose
_
8-36
EE.book Page 37 Tuesday, March 9, 2004 10:33 AM
11. Install the air filter case cover and be sure
to connect the hose.
12. Install the seat.
CAUTION:
_
Never operate the engine with the air filter
element removed. This will allow unfiltered
air to enter, causing rapid engine wear and
possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent
poor performance and possible engine
overheating.
NOTE:
The air filter element should be cleaned every
20–40 hours. It should be cleaned and lubricated more often if the machine is operated in
extremely dusty areas. Each time air filter element 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
EE.book Page 38 Tuesday, March 9, 2004 10:33 AM
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 deposits 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 (× 3)
1. Tailpipe
8-38
2. Spark arrester
EE.book Page 39 Tuesday, March 9, 2004 10:33 AM
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.
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 poisoning, possibly leading to death.
Could start a fire.
HOW TO AVOID THE HAZARD
When cleaning the spark arrester:
Always let the exhaust system cool prior to touching exhaust components.
Do not start the engine when cleaning
the exhaust system.
1. V-belt cooling duct check hose (Left side)
8-39
EE.book Page 40 Tuesday, March 9, 2004 10:33 AM
EBU08741
EBU00296
V-belt case drain plug
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.
Carburetor adjustment
The carburetor is a vital part of the engine and
requires very sophisticated adjustment. Most
adjusting should be left to a Yamaha dealer
who has the professional knowledge and experience to do so. However, the idling speed
may be performed by the owner as a part of
the usual maintenance routine.
NOTE:
If water drains from the V-belt case after removing the plug, have a Yamaha dealer inspect the ATV as the water may affect other
engine parts.
_
CAUTION:
_
The carburetor was set at the Yamaha factory after many tests. If the settings are
disturbed by someone without sufficient
technical knowledge, poor engine performance and damage may result.
1. V-belt case drain plug
8-40
EE.book Page 41 Tuesday, March 9, 2004 10:33 AM
EBU12580
Idle speed adjustment
NOTE:
A diagnostic tachometer must be used for this
procedure.
_
_
1. Start the engine and warm it up for a few
minutes at approximately 1,000 to
2,000 r/min. Occasionally rev the engine
to 4,000 to 5,000 r/min. The engine is
warm when it quickly responds to the
throttle.
2. Remove panel D. (See pages 8-7 and 8-8
for removal and installation procedures.)
3. 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 a to
increase the engine speed, and in direction b to decrease the engine speed.
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 clearance must be adjusted regularly. This adjustment however, should be left to a professional
Yamaha service technician.
Specified idle speed:
1,450–1,550 r/min
8-41
EE.book Page 42 Tuesday, March 9, 2004 10:33 AM
EBU00307
EBU03050
Throttle lever adjustment
Select lever safety system cable
adjustment
The select lever safety system cable stretches with use, resulting in improper function. To
prevent this, the cable must be adjusted regularly. This adjustment, however, should be left
to a Yamaha dealer.
NOTE:
Adjust the engine idling speed before adjusting the throttle lever free play.
1. Loosen the locknut.
2. Turn the adjusting bolt until the throttle lever 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
EE.book Page 43 Tuesday, March 9, 2004 10:33 AM
EBU13090
EBU08781
Front brake pad check
Check the brake pads for damage and wear.
If a brake pad thickness is less than 1 mm
(0.04 in), have a Yamaha dealer replace the
pads as a set.
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
1. Brake pad
a. Brake pad thickness
a. Brake pad thickness
NOTE:
The wheels need to be removed to check the
brake pads. (See pages 8-53–8-54 for removal and installation procedures.)
_
_
8-43
2. Brake pad plate
EE.book Page 44 Tuesday, March 9, 2004 10:33 AM
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 indicate worn brake pads and/or brake system
leakage. If the brake fluid level is low, be sure
to check the brake pads for wear and the
brake system for leakage. The rear brake fluid
master cylinder reservoir is located behind
panel B. (See page 8-9 for panel removal and
installation procedures.)
FRONT
1. Minimum level mark
REAR
1. Minimum level mark
8-44
EE.book Page 45 Tuesday, March 9, 2004 10:33 AM
Observe these precautions:
● When checking the fluid level, make sure
the top of the master cylinder reservoirs are
level.
● Use only the designated quality brake fluid,
otherwise the rubber seals may deteriorate,
causing leakage and poor brake performance.
●
●
Recommended brake fluid: DOT 4
●
●
Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical
reaction and lead to poor brake performance.
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
lock.
8-45
Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled
fluid immediately.
Have a Yamaha dealer check the cause if
the brake fluid level goes down.
EE.book Page 46 Tuesday, March 9, 2004 10:33 AM
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.
● Replace the oil seals every two years.
● Replace the brake hoses every four years.
8-46
EE.book Page 47 Tuesday, March 9, 2004 10:33 AM
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 system.
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.
● Make sure the brakes are not
spongy. All air must be bled from
the brake system.
Replacement of brake components requires professional knowledge. These
procedures should be performed by a
Yamaha dealer.
a. Front brake lever free play
8-47
EE.book Page 48 Tuesday, March 9, 2004 10:33 AM
EBU09631
2. Turn the adjusting bolt in direction a to
increase free play, and in direction b to
decrease free play.
3. Tighten the locknut.
If correct free play cannot be obtained, ask a
Yamaha dealer to make that adjustment.
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 (0.02–0.08 in).
1. Loosen the locknut.
NOTE:
When adjusting the rear brake lever free play:
● Be sure not to step on the brake pedal.
● Make sure the brake pedal does not
move.
_
_
1. Locknut
2. Adjusting bolt
c. Rear brake lever free play
8-48
EE.book Page 49 Tuesday, March 9, 2004 10:33 AM
Adjusting the brake pedal
The top of the brake pedal should be positioned 72 mm (2.8 in) above the top of the
footrest. If not, ask a Yamaha dealer to adjust
it.
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 requires professional knowledge. These
procedures should be performed by a
Yamaha dealer.
a. Distance between brake pedal and footrest
8-49
EE.book Page 50 Tuesday, March 9, 2004 10:33 AM
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 necessary, adjust the brake light switch as follows.
1. Remove panel B. (See page 8-9 for panel 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 a. To make the
brake light come on later, turn the adjusting nut in direction b.
1. Rear brake light switch
3. Install the panel.
8-50
2. Adjusting nut
EE.book Page 51 Tuesday, March 9, 2004 10:33 AM
EBU00356
EBU00717
Cable inspection and lubrication
Brake lever and brake pedal lubrication
Lubricate the pivoting parts.
WARNING
POTENTIAL HAZARD
Damaged control cables.
WHAT CAN HAPPEN
Corrosion can result when the outer
covering of control cables becomes
damaged. Cables can also become
frayed or kinked. Operation of controls
could be restricted, which could cause
an accident or injury.
HOW TO AVOID THE HAZARD
Inspect cables frequently. Replace damaged cables.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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
8-51
EE.book Page 52 Tuesday, March 9, 2004 10:33 AM
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
EE.book Page 53 Tuesday, March 9, 2004 10:33 AM
EBU01112
EBU01121
Wheel removal
1. Loosen the 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.
Wheel installation
1. Install the wheel and the nuts.
NOTE:
● Tapered nuts are used for both the front
and rear wheels. Install the nut with its tapered side towards the wheel.
● The arrow mark
on the tire must point
toward the rotating direction of the wheel.
_
_
1. Nut (× 4)
1. Arrow mark
8-53
EE.book Page 54 Tuesday, March 9, 2004 10:33 AM
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
EE.book Page 55 Tuesday, March 9, 2004 10:33 AM
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 battery. If the battery seems to have discharged,
consult a Yamaha dealer.
HOW TO AVOID THE HAZARD
Avoid contact with skin, eyes or clothing. Always shield eyes when working
near batteries. Keep out of reach of children.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Get
prompt medical attention.
EYES: Flush with water for 15 minutes
and get prompt medical attention. Keep
batteries away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed
space.
CAUTION:
Do not try to remove the sealing caps of
the battery cells. You may damage the battery.
WARNING
POTENTIAL HAZARD
Failure to handle batteries or battery
electrolyte carefully.
WHAT CAN HAPPEN
You could be poisoned. You could be
severely burned by the sulfuric acid in
battery electrolyte. Batteries produce
explosive gases.
8-55
EE.book Page 56 Tuesday, March 9, 2004 10:33 AM
EBU00385
EBU08762*
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.
Fuse replacement
1. The main fuse and the fuse box are located under the seat.
2. 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, consult a Yamaha dealer.
CAUTION:
A special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed-type
battery. Using a conventional battery
charger may shorten the battery life.
2. Always make sure the connections are
correct when putting the battery back in
the machine.
8-56
EE.book Page 57 Tuesday, March 9, 2004 10:33 AM
WARNING
1.
3.
5.
7.
8.
9.
POTENTIAL HAZARD
Using an improper fuse.
WHAT CAN HAPPEN
An improper fuse can cause damage to
the electrical system which could lead
to a fire.
HOW TO AVOID THE HAZARD
Always use a fuse of the specified rating. Never use a material in place of the
proper fuse.
Main fuse
2. Spare main fuse
Headlight fuse
4. Ignition fuse
Auxiliary DC jack fuse 6. Four-wheel drive fuse
Signaling system fuse
Backup fuse (for odometer and clock)
Spare fuse (× 3)
Specified fuses:
Main fuse:
Headlight fuse:
Ignition fuse:
Auxiliary DC jack fuse:
Four-wheel drive fuse:
Signaling system fuse:
Backup fuse:
CAUTION:
_
To prevent accidental short-circuiting,
turn off the main switch when checking or
replacing a fuse.
30 A
15 A
10 A
10 A
3A
10 A
10 A
_
8-57
EE.book Page 58 Tuesday, March 9, 2004 10:33 AM
EBU11252
Replacing a headlight bulb
If a headlight bulb burns out, replace it as follows.
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 pushing it in and turning it counterclockwise.
1. Cover
2. Remove the headlight bulb holder cover
by pulling it off.
8-58
1. Headlight bulb holder
EE.book Page 59 Tuesday, March 9, 2004 10:33 AM
4. Remove the defective bulb by pulling it
out.
CAUTION:
_
Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any
dirt and fingerprints on the headlight bulb
using a cloth moistened with alcohol or
thinner.
WARNING
POTENTIAL HAZARD
A headlight bulb is hot when it is on and
immediately after it is turned off.
WHAT CAN HAPPEN
You can be burned, or a fire could start
if the bulb touches something flammable.
HOW TO AVOID THE HAZARD
Wait for the bulb to cool before touching
or removing it.
_
5. Insert a new headlight bulb into the bulb
holder by pushing it in.
8-59
EE.book Page 60 Tuesday, March 9, 2004 10:33 AM
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 a.
To lower the beam, turn the adjusting screw in
direction b.
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 cover at the rear of the headlight.
1. Headlight beam adjusting screw
8-60
EE.book Page 61 Tuesday, March 9, 2004 10:33 AM
EBU15050
Tail/brake light bulb replacement
1. Remove panel G. (See pages 8-14–8-15
for removal and installation procedures.)
2. Remove the bulb holder (together with
the bulb) by turning it counterclockwise.
5. Install the bulb holder (together with the
bulb).
6. Install the panel.
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
EE.book Page 62 Tuesday, March 9, 2004 10:33 AM
EBU00412
Troubleshooting
Although Yamaha machines receive a rigid inspection before shipment from the factory,
trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of
power. The troubleshooting chart describes a
quick, easy procedure for making checks. If
your machine requires any repair, take it to a
Yamaha dealer.
The skilled technicians at a Yamaha dealership have the tools, experience, and knowhow 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 expensive repair bills.
WARNING
POTENTIAL HAZARD
Checking the fuel system while smoking or near an open flame.
WHAT CAN HAPPEN
Fuel can ignite or explode, causing severe 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 furnaces.
8-62
EE.book Page 63 Tuesday, March 9, 2004 10:33 AM
EBU08061
Troubleshooting charts
Starting problems or poor engine performance
Turn the fuel cock
lever to “ON”.
There is fuel.
Turn the fuel cock
lever to “OFF”.
Remove the fuel hose
from the fuel cock.
Some fuel.
Turn the fuel cock
lever to “RES”.
Restart the engine.
No fuel.
Supply fuel.
1. Fuel
Check if there is fuel
in the fuel tank.
2. Compression
Use the electric
starter to see if
there is compression.
3. Ignition
There is compression.
Compression normal.
No compression.
Ask a Yamaha dealer to
inspect.
Wet
Dry
Wipe clean with dry cloth.
Attach spark plug cap and
ground to chassis.
Use the
electric starter.
Battery is good.
Engine turns over
slowly.
Check the battery lead connections,
and charge the battery if necessary.
Ignition system is
normal.
Adjust the spark plug gap
or replace the spark plug.
Use the electric starter.
8-63
Fuel cock is
clogged.
Spark is weak.
No spark.
Engine turns over
quickly.
No fuel.
Clean the
fuel cock.
Spark is good.
Remove the
spark plug and
check the electrodes.
4. Battery
Check the
fuel flow.
Ask a Yamaha dealer to
inspect.
EE.book Page 64 Tuesday, March 9, 2004 10:33 AM
Engine overheating
WARNING
HOW TO AVOID THE HAZARD
Wait for the engine to cool before removing the radiator cap.
Always use a thick rag over the cap. Allow any remaining pressure to escape
before completely removing the cap.
POTENTIAL HAZARD
Removing the radiator cap when the engine and radiator are still hot.
WHAT CAN HAPPEN
You could be burned by hot fluid and
steam blown out under pressure.
Leakage.
Ask a Yamaha dealer to inspect
and repair the cooling system.
No
leakage.
Add coolant. (See NOTE.)
Level is low, check the
cooling system for leakage.
Wait until the
engine has cooled.
Check the coolant level in the
reservoir tank and/or radiator.
Level is OK.
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and/or repair the cooling system.
NOTE:
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.
_
_
8-64
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM
EBU00419
CLEANING AND STORAGE
CAUTION:
¯
Excessive water pressure may cause water seepage and deterioration of wheel
bearings, brakes, transmission seals and
electrical devices. Many expensive repair
bills have resulted from improper high
pressure detergent applications such as
those available in coin-operated car washers.
A. 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.
4. Once the majority of the dirt has been
hosed off, wash all surfaces with warm
water 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.
9-1
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM
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.
WARNING
POTENTIAL HAZARD
Operation with wet brakes after washing.
WHAT CAN HAPPEN
Wet brakes may have reduced stopping
ability, increasing the chance of an accident.
HOW TO AVOID THE HAZARD
Test the brakes after washing. Apply the
brakes several times at slow speeds to
let friction dry out the linings.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
9-2
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM
EBU00530
B. STORAGE
Long term storage (60 days or more) of your
machine will require some preventive procedures 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 equivalent product.
2. Remove the spark plug, pour about one
tablespoon of SAE 10W30 or 20W40
motor oil in the spark plug hole and reinstall the spark plug. Ground the spark
plug wire and turn the engine over several times to coat the cylinder wall with oil.
3. Lubricate all control cables.
4. Block up the frame to raise all wheels off
the ground.
5. Tie a plastic bag over the exhaust pipe
outlet to prevent moisture from entering.
6. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces
with a light film of oil. Do not apply oil to
any rubber parts or the seat cover.
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 eliminates the need to drain the fuel system. Consult a Yamaha dealer if the fuel system needs
to be drained instead.
9-3
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM
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 excessively warm or cold place (less than
0 °C (30 °F) or more than 30 °C (90 °F)).
NOTE:
Make any necessary repairs before storing
the machine.
9-4
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM
EBU00428
SPECIFICATIONS
Model
YFM660FA
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Ground clearance
Minimum turning radius
Basic weight:
With oil and full fuel tank
Engine:
Engine type
Cylinder arrangement
Displacement
Bore × stroke
Compression ratio
Starting system
Lubrication system
2,085 mm (82.1 in)
1,150 mm (45.3 in)
1,210 mm (47.6 in)
880 mm (34.6 in)
1,275 mm (50.2 in)
275 mm (10.8 in)
3,200 mm (126.0 in)
290 kg (639 lb)
Liquid-cooled 4-stroke, SOHC
Forward-inclined single cylinder
660 cm3
100 × 84 mm (3.94 × 3.31 in)
9.1 :1
Electric and recoil starter
Wet sump
10-1
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM
Model
YFM660FA
1
Engine oil:
Type
0°
10°
30°
50°
70°
90°
110° 130°F
2
YAMALUBE 4 (20W40) or SAE 20W40
3
YAMALUBE 4 (10W30) or SAE 10W30
4
SAE 5W30
-20°
Recommended engine oil classification
-10°
5
0°
10°
20°
30°
40°
50°C
API Service SE, SF, SG type or higher
CAUTION:
In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any
chemical additives. 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.
6
7
8
9
10
11
12
Quantity:
Without oil filter cartridge replacement
With oil filter cartridge replacement
1.9 L (1.67 Imp qt, 2.01 US qt)
2.0 L (1.76 Imp qt, 2.11 US qt)
13
14
10-2
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM
Model
YFM660FA
Final gear case oil:
Type
Quantity
Differential gear case oil:
Type
Quantity
Radiator capacity (including all routes):
Air filter:
Fuel:
Type
Fuel tank capacity
Fuel reserve amount
Carburetor:
Type / quantity
Manufacturer
Spark plug:
Type/manufacturer
Spark plug gap
Clutch type:
SAE80 API GL-4 Hypoid gear oil
0.25 L (0.22 Imp qt, 0.26 US qt)
SAE80 API GL-4 Hypoid gear oil
0.28 L (0.25 Imp qt, 0.30 US qt)
1.80 L (1.58 Imp qt, 1.90 US qt)
Wet type element
UNLEADED GASOLINE ONLY
20 L (4.40 lmp gal, 5.28 US gal)
3.5 L (0.77 lmp gal, 0.92 US gal)
BSR42 / 1
MIKUNI
DPR8EA-9 / NGK
0.8–0.9 mm (0.031–0.035 in)
Wet, centrifugal automatic
10-3
EE.book Page 4 Tuesday, March 9, 2004 10:33 AM
Model
Transmission:
Primary reduction system
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Reverse gear
Sub transmission ratio
Chassis:
Frame type
Caster angle
Trail
Tire:
Type
Size
YFM660FA
V-belt
Shaft drive
41/21 × 24/18 × 33/9 (9.544)
V-belt automatic
Left hand operation
25/17 (1.471)
35/17 (2.058)
26/21 (1.238)
low
high
Steel tube frame
5°
26 mm (1.02 in)
Tubeless
AT25 × 8 - 12
AT25 × 10 - 12
front
rear
10-4
EE.book Page 5 Tuesday, March 9, 2004 10:33 AM
Model
Brake:
Front brake
Rear brake
YFM660FA
type
operation
type
operation
Dual disc brake
Right hand operation
Single disc brake
Left hand and right foot operation
Suspension:
Front suspension
Rear suspension
Shock absorber:
Front shock absorber
Rear shock absorber
Wheel travel:
Front wheel travel
Rear wheel travel
Electrical:
Ignition system
Generator system
Battery type
Battery capacity
Headlight type:
Double wishbone
Double wishbone
Coil spring / oil damper
Coil spring / oil damper
170 mm (6.69 in)
225 mm (8.86 in)
DC. C.D.I.
A.C. magneto
YTX20L-BS
12 V, 18 Ah
Krypton bulb
10-5
EE.book Page 6 Tuesday, March 9, 2004 10:33 AM
Model
YFM660FA
Bulb voltage, wattage × quantity:
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
Fuses:
Main fuse
Headlight fuse
Ignition fuse
Auxiliary DC jack fuse
Four-wheel-drive fuse
Signaling system fuse
Backup fuse
12 V, 30 W / 30 W × 2
12 V, 5 W / 21 W × 1
LED
LED
LED
LED
LED
LED
LED
30A
15A
10A
10A
3A
10A
10A
10-6
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM
EBU00430
1-
NOISE REGULATION
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of 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.
Exhaust system
Muffler
Exhaust pipe
Silencer
Intake system
Air cleaner case
Air cleaner element
Intake duct
11-1
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM
EBU13653
1-
MAINTENANCE RECORD
Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance
work.
ACL-06E
MAINTENANCE
INTERVAL
month
DATE OF
SERVICE
MILEAGE
SERVICING DEALER
NAME AND ADDRESS
1
2
3
4
5
REMARKS
6
km (mi)
hours
1
320 (200)
20
7
3
1,200 (750)
75
8
6
2,400 (1,500)
150
12
4,800 (3,000)
300
9
18
7,200 (4,500)
450
10
24
9,600 (6,000)
600
30
12,000 (7,500)
750
11
36
14,400 (9,000)
900
12
42
16,800 (10,500) 1,050
48
19,200 (12,000) 1,200
54
21,600 (13,500) 1,350
60
24,000 (15,000) 1,500
13
14
12-1
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM
EBU00432
YAMAHA MOTOR CORPORATION, U.S.A.
ATV LIMITED WARRANTY
13-1
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
13-2
EE.book Page 1 Tuesday, March 9, 2004 10:33 AM
EBU00435
YAMAHA EXTENDED SERVICE (Y.E.S.)
14-1
EE.book Page 2 Tuesday, March 9, 2004 10:33 AM
1
2
3
4
5
6
7
8
9
10
11
12
13
EBU00436
14
WARNING
_
Indicates a potential hazard that could
result in serious injury or death.
14-2
EE.book Page 3 Tuesday, March 9, 2004 10:33 AM
EBU00437
EBU00438
READ THIS MANUAL CAREFULLY!
It contains important safety information.
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH.
BEER
BEER
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate:
ALWAYS:
without proper training or instruction.
use proper riding techniques to avoid
at speeds too fast for your skills or the
vehicle overturns on hills and rough
conditions.
terrain and in turns.
on public roads-a collision can occur with
avoid paved surfaces-pavement may
another vehicle.
seriously affect handling and control.
with a passenger-passengers affect
balance and steering and increase risk
of losing control.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
(For replacement manual, call 1-800-532-1558)
OWNER’S MANUAL
YFM660FAT
WARNING
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2004.03-5.0×1 CR
(E)
LIT-11626-18-03
This ATV should not be ridden by anyone under 16 years of age.
5KM-28199-13