Yamaha GRIZZLY 450, GRIZZLY YFM45FGW Owner's Manual

READ THIS MANUAL CAREFULLY!

It contains important safety information.

OWNER’S MANUAL

WARNING

LIT-11626-20-17

YFM45FGW

This ATV should not be ridden by anyone under 16 years of age.

1D9-F8199-13

U1D913E0.book Page 1 Thursday, April 20, 2006 2:47 PM

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EBU17170

INTRODUCTION

EBU17270

Congratulations on your purchase of the Yamaha YFM45FGW. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines.

With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

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 the 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 COMPLETE-

LY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.

NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS

AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMA-

●

TION.

THIS ATV, AND ANY OTHER ATV OVER 90 cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16

YEARS OF AGE.


EBU17330

IMPORTANT MANUAL INFORMATION

EBU17341

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN-

JURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

WARNING

CAUTION:

Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or repairing the ATV.

A CAUTION indicates special precautions that must be taken to avoid damage to the ATV.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

* Product and specifications are subject to change without notice.


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IMPORTANT NOTICE

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Welcome to the Yamaha world of motor sports!

This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway.

This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

Please check your local riding laws and regulations before operating this ATV.

EBU17401

AFFIX DEALER

LABEL HERE

YFM45FGW

OWNER’S MANUAL

©2006 by Yamaha Motor Corporation, U.S.A.

1st edition, April 2006

All rights reserved.

Any reprinting or unauthorized use without the written permission of

Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in U.S.A.

P/N LIT-11626-20-17


EWB00010

WARNING

Indicates a potential hazard that could result in serious injury or death.

EBU17420

TABLE OF CONTENTS

SAFETY INFORMATION .............................. 1-1

LOCATION OF THE WARNING AND

SPECIFICATION LABELS ............................ 2-1

DESCRIPTION .............................................. 3-1

Left view ...................................................... 3-1

Right view.................................................... 3-1

Controls and instruments ............................ 3-2

INSTRUMENT AND CONTROL

FUNCTIONS .................................................. 4-1

Main switch ................................................ 4-1

Indicator lights and warning light ................ 4-2

Multifunction display ................................... 4-4

Fuel gauge ................................................. 4-5

Handlebar switches .................................... 4-5

Throttle lever .............................................4-11

Speed limiter .............................................4-12

Front brake lever .......................................4-13

Brake pedal and rear brake lever .............4-14

Drive select lever ......................................4-14

Recoil starter .............................................4-15

Fuel tank cap ............................................4-16

Fuel ...........................................................4-16

Fuel cock ..................................................4-17

Starter (choke) ..........................................4-19

Seat ..........................................................4-19

Storage compartment ...............................4-20

Front carrier ..............................................4-21

Rear carrier ...............................................4-22

Adjusting the front and rear shock absorber assemblies ...............................4-22

Auxiliary DC jack .......................................4-23

PRE-OPERATION CHECKS ..........................5-1

Pre-operation check list ..............................5-1

Fuel .............................................................5-4

Engine oil ....................................................5-4

Final gear oil ...............................................5-4

Differential gear oil ......................................5-4

Coolant .......................................................5-4

Front and rear brakes .................................5-5

Throttle lever ...............................................5-6


Tires ........................................................... 5-7

Measuring the tire pressure ....................... 5-8

Tire wear limit ............................................. 5-9

Chassis fasteners ....................................... 5-9

Instruments, lights and switches ................ 5-9

OPERATION .................................................. 6-1

Starting a cold engine ................................ 6-1

Starting a warm engine .............................. 6-3

Operating the drive select lever and driving in reverse ...................................... 6-3

Engine break-in .......................................... 6-5

Parking ....................................................... 6-6

Parking on a slope ..................................... 6-6

Accessories and loading ............................ 6-6

RIDING YOUR ATV ...................................... 7-1

GETTING TO KNOW YOUR ATV............... 7-2

RIDE WITH CARE AND GOOD

JUDGEMENT............................................ 7-2

BE CAREFUL WHERE YOU RIDE........... 7-12

TURNING YOUR ATV .............................. 7-17

CLIMBING UPHILL ................................... 7-18

RIDING DOWNHILL.................................. 7-24

CROSSING A SLOPE............................... 7-26

CROSSING THROUGH SHALLOW

WATER ................................................... 7-28

RIDING OVER ROUGH TERRAIN............7-30

SLIDING AND SKIDDING .........................7-31

WHAT TO DO IF........................................7-32

WHAT TO DO............................................7-33

PERIODIC MAINTENANCE AND MINOR

REPAIR ..........................................................8-1

Owner’s manual and tool kit .......................8-1

Periodic maintenance chart for the emission control system ...........................8-3

General maintenance and lubrication chart ..........................................................8-5

Removing and installing panels ..................8-9

Checking the spark plug ...........................8-14

Engine oil and oil filter cartridge ................8-16

Final gear oil .............................................8-21

Differential gear oil ....................................8-23

Coolant .....................................................8-26

Cleaning the air filter element ...................8-30

Cleaning the spark arrester ......................8-33

V-belt cooling duct check hose .................8-34

V-belt case drain plug ...............................8-35

Adjusting the carburetor ............................8-35

Adjusting the engine idling speed .............8-36

Adjusting the throttle cable free play .........8-37

Valve clearance ........................................8-37


Adjusting the drive select lever safety system cable .......................................... 8-38

Checking the front and rear brake pads ....................................................... 8-38

Checking the brake fluid level .................. 8-39

Changing the brake fluid .......................... 8-40

Checking the front brake lever free play ......................................................... 8-41

Adjusting the rear brake lever free play and checking the brake pedal position ... 8-41

Axle boots ................................................ 8-43

Brake light switches ................................. 8-44

Checking and lubricating the cables ........ 8-45

Checking and lubricating the front and rear brake levers .................................... 8-45

Checking and lubricating the brake pedal ...................................................... 8-46

Checking the wheel bearings ................... 8-46

Lubricating the drive shaft universal joint ......................................................... 8-46

Checking the stabilizer bushes ................ 8-47

Lubricating the upper and lower arm pivots ...................................................... 8-47

Lubricating the knuckle pivots .................. 8-47

Lubricating the knuckle shafts .................. 8-47

Lubricating the steering shaft ................... 8-48

Battery ...................................................... 8-48

Replacing a fuse .......................................8-50

Replacing a headlight bulb .......................8-52

Adjusting a headlight beam ......................8-54

Replacing the tail/brake light bulb .............8-54

Removing a wheel ....................................8-56

Installing a wheel ......................................8-56

Troubleshooting ........................................8-58

Troubleshooting charts .............................8-59

CLEANING AND STORAGE ..........................9-1

Cleaning ......................................................9-1

Storage .......................................................9-2

SPECIFICATIONS .......................................10-1

CONSUMER INFORMATION.......................11-1

Identification numbers ...............................11-1

Noise regulation ........................................11-3

Maintenance record ..................................11-4

YAMAHA MOTOR CORPORATION,

U.S.A. ATV LIMITED WARRANTY .........11-5

YAMAHA EXTENDED SERVICE

(Y.E.S.) ...................................................11-7


EBU17430

SAFETY INFORMATION

EBU17482

AN ATV IS NOT A TOY AND CAN BE HAZARD-

OUS TO OPERATE.

An ATV handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.

SEVERE INJURY OR DEATH can result if you do not follow these instructions:

●

Read this manual and all labels carefully and 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 90 cc.

1-1

●

●

●

●

●

●

●

●

Never allow a child under age 16 to operate an

ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.

Never carry a passenger on an ATV.

Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.

Never operate an ATV on any public street, road or highway, even a dirt or gravel one.

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, a long-sleeved shirt or a jacket, and long pants.

Never consume alcohol or drugs before or while operating this ATV.

Never operate at speeds too fast for your skills or the riding conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience.

Never attempt wheelies, jumps, or other stunts.

1


1

●

●

●

●

●

●

Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation.

Always go slowly and be extra careful when operating on unfamiliar terrain. 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 and never turn at excessive speeds.

Never operate the ATV on hills too steep for the

ATV or for your abilities. Practice on smaller hills before attempting larger hills.

1-2

●

●

●

●

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 the 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.

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 of 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 SAFE-

TY,

call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s

Safety Hotline at 1-800-852-5344.

1

1-3


1

EWB00021

WARNING

POTENTIAL HAZARD

Improper handling of gasoline.

WHAT CAN HAPPEN

Gasoline can catch fire and you could be burned.

HOW TO AVOID THE HAZARD

Always turn off the engine when 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 in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers.

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.


If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, seek medical help immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

EWB00030

WARNING


Starting or running the engine in a closed area.

1-4


WHAT CAN HAPPEN

Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.


Always operate your ATV in an area with adequate ventilation.

1-5

1

2


EBU17660

LOCATION OF THE WARNING AND SPECIFICATION LABELS

2-1


EBU17670

Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation.

Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replacement label from your Yamaha dealer.

2

2-2

2


2-3


2

2-4

3


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EBU17690

Left view

DESCRIPTION

EBU17700

Right view

1. Radiator cap

2. Fuel cock

3. Recoil starter

4. Throttle stop screw

5. Air filter case

6. Battery

7. Fuses

8. Tail/brake light

9. Engine oil filler cap

10.Oil filter cartridge

11.Coolant reservoir

12.V-belt cooling duct check hose

3-1

1. Rear shock absorber assembly spring preload adjusting ring

2. Spark arrester

3. Storage compartment and tool kit

4. Spark plug

5. Rear brake fluid reservoir

6. Front shock absorber assembly spring preload adjusting ring

7. Brake light switch

8. Brake pedal

9. V-belt case drain plug


EBU17712

Controls and instruments

NOTE:

The ATV you have purchased may differ slightly from the figures shown in this manual.

3

1. Rear brake lever

2. Handlebar switches

3. Starter (choke)

4. Drive select lever

5. Multifunction meter unit

6. Main switch

7. Fuel tank cap

8. Auxiliary DC jack

9. On-Command four-wheel-drive/differential gear lock switch

10.Throttle lever

11.Front brake lever

3-2


EBU17720

INSTRUMENT AND CONTROL FUNCTIONS

EWB00010

WARNING


4

EBU17760

Main switch

The positions of the main switch are as follows:

ON

All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.

OFF

All electrical systems are off. The key can be removed.

1. Main switch

4-1


EBU17812

Indicator lights and warning light

1. On-Command differential gear lock indicator light “DIFF.

LOCK”

2. Low-range indicator light “L”

3. High-range indicator light “H”

4. Neutral indicator light “N”

5. Reverse indicator light “R”

6. Park indicator light “P”

7. On-Command four-wheel-drive/differential gear lock indicator “ ”/“ ”

8. Coolant temperature warning light “ ”

EBU17840

Reverse indicator light “ ”

This indicator light comes on when the transmission is in the reverse position.

4-2

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.

EBU17860

Neutral indicator light “ ”

This indicator light comes on when the transmission is in the neutral position.

4

EBU17920

Coolant temperature warning light “ ”

This warning light comes on when the engine overheats. When this occurs during operation, stop the engine as soon as it is safe to do so and allow it to cool down for about 10 minutes.

ECB00010

CAUTION:

●

●

The engine may overheat if the ATV is overloaded. In this case, reduce the load to specification.

Start the engine after making sure that the warning light is out. Continuous use while the warning light is on may cause damage to the engine.


4

EBU17961

On-Command four-wheel-drive/differential gear lock indicator “ ”/“

DIFF.

LOCK

”

The On-Command four-wheel-drive indicator “ ” comes on when the On-Command four-wheeldrive switch is set to the “4WD” position.

The On-Command differential gear lock indicator

“

DIFF.

LOCK

” in the On-Command four-wheel-drive indicator also comes on when the On-Command differential gear lock switch is set to the “LOCK” position.

NOTE:

●

Due to the synchronizing mechanism in the differential gear case, the four-wheel-drive indica-

● tor may not come on until the ATV starts moving.

When the On-Command differential gear lock switch is set to “LOCK”, the indicator “

DIFF.

LOCK

” will flash until the differential gear is locked.

EBU17970

Park indicator light “ ”

This indicator light comes on when the transmission is in the park position.

EBU17980

High-range indicator light “ ”

This indicator light comes on when the transmission is in the high-range position.

EBU17990

Low-range indicator light “ ”

This indicator light comes on when the transmission is in the low-range position.

EBU18001

On-Command differential gear lock indicator light “DIFF. LOCK”

This indicator light and the On-Command differential gear lock indicator in the display come on when the On-Command differential gear lock switch is set to the “LOCK” position.

NOTE:

When the switch is set to “LOCK”, the On-Command differential gear lock indicator light will flash until the differential gear is locked.

4-3


EBU18031

Multifunction display

1. Speedometer

2. “H” button

3. “M” button

4. Clock/Hour meter

5. Odometer/Tripmeter A/Tripmeter B

6. TRIP/ODO button

7. 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)

4-4

●

● a clock an hour meter (which shows the total time the key has been turned to “ON”)

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.

NOTE:

Holding in the “TRIP/ODO” button and then turning the key to “ON” switches the display between

“mph” and “km/h”.

4

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


4

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.

EBU18050

Fuel gauge

The fuel gauge indicates the amount of fuel in the fuel tank. When the needle reaches the red line, refill the tank at the first opportunity.

NOTE:

If the ATV runs out of fuel, move the fuel cock lever to the “RES” position. Approximately 4.5 L (1.19

US gal) (0.99 Imp.gal) of fuel will be remaining in the tank.

EBU18060

Handlebar switches

1. Fuel gauge

2. Red line

4-5

1. Light switch “

2. Start switch “ ”

/ /OFF”

3. Engine stop switch “ / ”

4. Override switch “OVERRIDE”


EBU18080

Engine stop switch “ / ”

Set this switch to “ ” before starting the engine.

The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation. The engine will not start or run when this switch is set to “ ”.

EBU18100

Start switch “ ”

Push this switch to crank the engine with the starter.

ECB00050

CAUTION:

See the starting instructions on page 6-1 prior to starting the engine.

ECB00040

CAUTION:

Do not use the headlights with the engine turned off for an extended period of time, otherwise 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.

EBU18180

Override switch “OVERRIDE”

EBU18151

Light switch “ / /OFF”

Set this switch to “ ” to turn on the low beams and the taillight. Set the switch to “ ” to turn on the high beams and the taillight. Set the switch to

“OFF” to turn off all the lights.

4-6

1. Override switch “OVERRIDE”

Top speed is normally limited when operating in differential gear lock. If conditions require more engine power when riding forward, push and hold this

4


4

switch to override the differential gear lock speed limiting function. (See page 4-9.) Releasing the switch restores the speed limiting function.

While the override switch is pushed, the segments of the speedometer digits will appear as shown in the figure.

EWB00110

WARNING


Riding too fast while the ATV is in fourwheel-drive differential gear 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 effort needed to turn increases with the riding speed. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling.


Always ride at a slow speed when the ATV is in four-wheel-drive differential gear lock, and allow extra time and distance for maneuvers.

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.

4-7

EBU26632

On-Command four-wheel-drive switch

“2WD”/“4WD”

This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice-versa.

Select the appropriate drive according to the terrain and the conditions.

●

“2WD” (two-wheel drive): Power is supplied to the rear wheels.


●

“4WD” (four-wheel drive): Power is supplied to the rear and front wheels.

To change from two-wheel drive to four-wheel drive, stop the ATV and push the switch in to the

“4WD” position. Then, the four-wheel-drive indicator “ ” comes on in the multifunction meter unit display.

To change from four-wheel drive to two-wheel drive, stop the ATV and push the switch in to the

“2WD” position.

EWB00120

WARNING


Changing from two-wheel drive to fourwheel drive or from four-wheel drive to twowheel drive while the ATV is moving.

WHAT CAN HAPPEN

The ATV handles differently in two-wheel drive than in four-wheel drive in some circumstances. Changing from two-wheel drive to four-wheel drive or from four-wheel drive to two-wheel drive while moving may cause the ATV to unexpectedly handle differently.

This could distract the operator and increase the risk of losing control and of causing an accident.


Always stop the ATV before changing from two-wheel drive to four-wheel drive or viceversa.

4

1. On-Command four-wheel-drive switch “2WD”/“4WD”

4-8


4

EBU18243

On-Command differential gear lock switch

“4WD”/“LOCK”

This ATV is equipped with a switch allowing you to lock the differential gear when in four-wheel drive.

Select the appropriate switch position according to the terrain and the conditions.

●

“4WD” (four-wheel drive): Power is supplied to the rear and front wheels.

●

“LOCK” (four-wheel drive with the differential gear locked): Power is supplied to the rear and front wheels and the differential gear is locked.

Unlike in four-wheel drive, all wheels turn at the same speed.

To lock the differential gear in four-wheel drive, make sure the On-Command four-wheel-drive switch is pushed in to the “4WD” position.

1. Differential gear lock lever


Stop the ATV, move the differential gear lock lever to position (a), and then push the differential gear lock switch in to the “LOCK” position. When the differential gear is locked, the differential gear lock indicator “DIFF. LOCK” will come on along with the indicator “

DIFF.

LOCK

” in the multifunction display.


2. On-Command differential gear lock switch “4WD”/“LOCK”

4-9


1. On-Command differential gear lock switch “4WD”/“LOCK”

To release the differential gear lock, stop the ATV and push the switch to the “4WD” position.

EWB00091

WARNING


Changing from four-wheel drive to fourwheel-drive differential gear lock or vice-versa while the ATV is moving.

WHAT CAN HAPPEN

The ATV handles differently in four-wheel drive than in differential gear lock in some circumstances. Changing from four-wheel drive to differential gear lock or vice-versa while moving may cause the ATV to handle differently unexpectedly. This could distract the operator and increase the risk of losing control and causing an accident.


Always stop the ATV before changing from four-wheel drive to four-wheel-drive differential gear lock or vice-versa.

4

4-10


4

EWB00101

WARNING


Riding too fast while the ATV is in fourwheel-drive differential gear lock.

WHAT CAN HAPPEN

All wheels turn at the same speed when the differential gear is locked, so it takes more effort to turn the ATV. The effort needed to turn increases with the riding speed. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling.


Always ride at a slow speed when the ATV is in differential gear lock, and allow extra time and distance for maneuvers.

NOTE:

● When the switch is set to “LOCK”, the differential gear lock indicator and indicator light will flash until the differential gear is locked.

●

When the indicator and indicator light are 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 and indicator light are flashing) will cause the engine speed to be limited until engagement is complete.

When the ATV is in four-wheel-drive differential gear lock, the maximum traveling speed is limited to 35 km/h (22 mi/h). However, if conditions require full engine power to be available, push and hold the override switch to disable the differential gear lock speed limiter. (See page 4-6 for a detailed explanation of this switch.)

EBU18270

Throttle lever

Once the engine is running, movement of the throttle lever will increase the engine speed.

Regulate the speed of the ATV by varying the throttle position. Because the throttle is springloaded, the ATV will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.

4-11


1. Throttle lever

Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released.

EWB00200

WARNING


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.


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.

EBU18311

Speed limiter

Your ATV was delivered with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum.

1. Loosen the locknut.

2. To increase the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (a). To decrease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b).

4

4-12


4


Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3.0–5.0

mm (0.12–0.20 in). (See page 8-37.)

EBU18391

Front brake lever

The front brake lever is located on the right handlebar. To apply the front brake, pull the brake lever toward the handlebar grip.

1. Locknut

2. Adjusting screw

3. No more than 12 mm (0.47 in)

3. Tighten the locknut.

EWB00190

WARNING


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.

1. Front brake lever

4-13


EBU18442

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. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip.

1. Brake pedal

1. Rear brake lever

EBU18611

Drive select lever

The drive select lever is used to shift your ATV into the low-range, high-range, neutral, reverse and park positions. See the “Operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation.

4

4-14


4


EBU18680

Recoil starter

Firmly grasp the handle and pull slightly until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out.

1. Recoil starter

EWB00290

WARNING


Starting the engine without setting the drive select lever to the park position.

WHAT CAN HAPPEN

The ATV could start to move unexpectedly, which could cause an accident.


Set the drive select lever to the park position before starting the engine.

4-15


EBU18720

Fuel tank cap

Remove the fuel tank cap by turning it counterclockwise.

1. Fuel tank cap

EBU18730

Fuel

Make sure that there is sufficient fuel in the tank.

Fill the fuel tank to the bottom of the filler tube as shown.

1. Fuel level

2. Fuel tank filler tube

Recommended fuel:

UNLEADED GASOLINE ONLY

Fuel tank capacity:

15.0 L (3.96 US gal) (3.30 Imp.gal)

Fuel reserve amount:

4.5 L (1.19 US gal) (0.99 Imp.gal)

4-16

4


4

ECB00070

CAUTION:

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.

Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost.

Gasohol

There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or

ATV performance problems.

EWB00270

WARNING


Improper care when refueling.

4-17

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.


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.


EBU18820

Fuel cock

The fuel cock supplies fuel from the tank to the carburetor while also filtering it.

The fuel cock lever positions are explained as follows and shown in the illustrations.


OFF ON

1. Arrow mark pointing to “OFF”

With the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running.

1. Arrow mark pointing to “ON”

With the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding.

4

4-18


RES

Move the starter (choke) in direction (b) to turn off the starter (choke).

See the “Starting a cold engine” section on page

6-1 for proper operation.

4

1. Arrow mark pointing to “RES”

This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available.

Turn the fuel cock lever to this position if you run out of fuel while riding. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to “ON”!

EBU18850

Starter (choke) “ ”

Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke).

Move the starter (choke) in direction (a) to turn on the starter (choke).

4-19

1. Starter (choke) “ ”

EBU18880

Seat

To remove the seat

Pull the seat lock lever upward and pull up the seat at the rear.


1. Seat

2. Seat lock lever

To install the seat

Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear.

NOTE:

Make sure that the seat is securely fitted.

1. Projection

2. Seat holder

EBU18941

Storage compartment

The storage compartment is located under the seat. (See page 4-19.)

When storing any 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.

4

4-20


4

ECB00130

CAUTION:

Do not store metal or sharply edged objects, like tools, in the storage compartment. If they must be stored, wrap them in appropriate cushion material to prevent damaging the storage compartment.

NOTE:

There is a check hose at the bottom of the storage compartment. If any water collects in this hose, remove the hose, empty it, and then install it.

1. Storage compartment

●

●

Do not exceed the load limit of 2.0 kg (4 lb) for the storage compartment.

Do not exceed the maximum load of 210.0 kg

(463 lb) for the ATV.

1. Storage compartment check hose

EBU18960

Front carrier

● Do not exceed the load limit of 40.0 kg (88 lb) for

● the front carrier.

Do not exceed the maximum load of 210.0 kg

(463 lb) for the ATV.

4-21


EBU18970

Rear carrier

● Do not exceed the load limit of 80.0 kg (176 lb)

● for the rear carrier.

Do not exceed the maximum load of 210.0 kg

(463 lb) for the ATV.

EBU19130

Adjusting the front and rear shock absorber assemblies

The spring preload can be adjusted to suit the rider’s weight and the riding conditions.

Adjust the spring preload as follows.

Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspension, and in direction (b) to decrease the spring preload and thereby soften the suspension.

1. Spring preload adjusting ring

2. Position indicator

NOTE:

A special wrench can be obtained at a Yamaha dealer to make this adjustment.

4

4-22


4

1. Special wrench

Spring preload setting:

Minimum (soft):

1

Standard:

2

Maximum (hard):

5

EWB00350

WARNING


Improper shock absorber assembly adjustment.

4-23

WHAT CAN HAPPEN

Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident.


Always adjust the shock absorber assemblies on the left and right side to the same setting.

EBU19180

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. Set the light switch to “OFF”.

2. Start the engine. (See page 6-1.)

3. Open the auxiliary DC jack cap, and then insert the accessory power plug into the jack.


1. Auxiliary DC jack cap

1. Auxiliary DC jack

4-24

Maximum rated capacity for the auxiliary DC jack:

DC 12 V, 120 W (10 A)

4. When the auxiliary DC jack is not being used, cover it with the cap.

ECB00120

CAUTION:

●

●

●

Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to blow.

If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine starting may become difficult.

Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged.

EWB00010

WARNING


4


5

EBU19200

PRE-OPERATION CHECKS

EBU19210

Pre-operation check list

Before operating this ATV, be sure to check the items listed in the following table.

NOTE:

The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a

Yamaha dealer.

Fuel

Engine oil

ITEM

Final gear oil

Differential gear oil

Coolant

Front brake

ROUTINE

• Check fuel level in fuel tank, and add recommended fuel if necessary.

• Check fuel line for leakage. Correct if necessary.

• Check oil level in engine, and add recommended oil to specified level if necessary.

• Check ATV for oil leakage. Correct if necessary.



• Check coolant level in reservoir, and add recommended coolant to specified level if necessary.

• Check cooling system for leakage. Correct if necessary.

• Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system.

• Check brake pads for wear, and replace if necessary.

• Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.

• Check hydraulic system for leakage. Correct if necessary.

PAGE

4-16, 5-4

5-4, 8-16

5-4, 8-21

5-4, 8-23

5-4, 8-26

5-5, 8-38, 8-39, 8-41

5-1


Rear brake

ITEM

Throttle lever

Control cables

Wheels and tires

Brake pedal

Brake levers

Axle boots

Chassis fasteners

Instruments, lights and switches

ROUTINE

• Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system.

• Check lever free play, and adjust if necessary.

• Check brake pads for wear, and replace if necessary.

• Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.

• Check hydraulic system for leakage. Correct if necessary.

• Make sure that operation is smooth. Lubricate cable and lever housing if necessary.

• Check cable free play, and adjust if necessary.

• Make sure that operation is smooth. Lubricate if necessary.

• Check wheel condition, and replace if damaged.

• Check tire condition and tread depth. Replace if necessary.

• Check air pressure. Correct if necessary.

• Make sure that operation is smooth. Lubricate pedal pivoting point if necessary.

• Make sure that operation is smooth. Lubricate lever pivoting points if necessary.

• Check for cracks or damage, and replace if necessary.

• Make sure that all nuts, bolts and screws are properly tightened.

• Check operation, and correct if necessary.

PAGE

5-5, 8-38, 8-39, 8-41

5-6, 8-37

8-45

5-7, 5-8, 5-9

8-46

8-45

8-43

5-9

5-9

5

5-2


5

EWB00470

WARNING


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.


Always inspect your ATV each time you use it to make sure it is in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.

5-3


EBU19530

Fuel

Make sure that there is sufficient fuel in the tank.

(See page 4-16.)

EWB00500

WARNING


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.


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.


EBU19560

Engine oil

Make sure that the engine oil is at the specified level. Add oil as necessary. (See page 8-16.)

5-4

EBU19590

Final gear oil

Make sure that the final gear oil is at the specified level. Add oil as necessary. (See page 8-21.)

EBU19600


Make sure that the differential gear oil is at the specified level. Add oil as necessary. (See page

8-23.)

EBU19620

Coolant

Make sure that the coolant is at the specified level.

Add coolant as necessary. (See page 8-26.)

NOTE:

The coolant level must be checked on a cold engine since the level varies with engine temperature.

5


5

EWB00490

WARNING


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.


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.

●

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 check the brake system.

Brake fluid level

Check the brake fluid level. Add fluid if necessary.

(See page 8-39.)

Recommended brake fluid:

DOT 4

EBU19721

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

● check the brake system.

Check for correct free play in the rear brake lever. If the free play is incorrect, adjust it. (See page 8-41.)

●

Check for correct brake pedal height. If the pedal height is incorrect, have a Yamaha dealer adjust it.

5-5

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 a lever moves slowly inward, there may be a leak in the brake system.

If there is any leakage, the brake system should be checked by a Yamaha dealer.

Brake operation

Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, check the brake pads for wear. (See page 8-38.)


EWB00540

WARNING


Riding with improperly operating brakes.

WHAT CAN HAPPEN

You could lose braking ability, which could lead to an accident.


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.

EBU19761

Throttle lever

Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary.

5-6

5


5

EBU19801

Tires

EWB00551

WARNING


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.


●

The tires listed below have been approved by Yamaha Motor Manufacturing Corporation of America for this model. Other tire combinations are not recommended.

Front:

Manufacturer/model:

MAXXIS/M979

Size:

AT25 x 8-12

Type:

Tubeless

Rear:

Manufacturer/model:

MAXXIS/M980

Size:

AT25 x 10-12

●

Type:

Tubeless

The tires should be set to the recommended pressure:

Recommended tire pressure:

Front:

25.0 kPa (3.6 psi) (0.250 kgf/cm²)

Rear:

25.0 kPa (3.6 psi) (0.250 kgf/cm²)

• Check and adjust tire pressures when the tires are cold.

• Tire pressures must be equal on both sides.

5-7


●

●

●

Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions.

Minimum tire pressure:

Front:

22.0 kPa (3.2 psi) (0.220 kgf/cm²)

Rear:

22.0 kPa (3.2 psi) (0.220 kgf/cm²)

Use no more than the following pressures when seating the tire beads.

Maximum tire seating pressure:

Front:

250 kPa (36 psi) (2.5 kgf/cm²)

Rear:

250 kPa (36 psi) (2.5 kgf/cm²)

Higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully.

EBU19820

Measuring the 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.

1. Low-pressure tire gauge

Set the tire pressure when the tires are cold. Set the tire pressures to the following specifications:

5

5-8


5

Recommended pressure:

Front

25.0 kPa (3.6 psi) (0.250 kgf/cm²)

Rear

25.0 kPa (3.6 psi) (0.250 kgf/cm²)

Minimum:

Front

22.0 kPa (3.2 psi) (0.220 kgf/cm²)

Rear

22.0 kPa (3.2 psi) (0.220 kgf/cm²)

Maximum:

Front

28.0 kPa (4.1 psi) (0.280 kgf/cm²)

Rear

28.0 kPa (4.1 psi) (0.280 kgf/cm²)

EBU19830

Tire wear limit

Replace the tire when the tire groove decreases to

3 mm (0.12 in).

1. Tire wear limit

EBU19840


Make sure that all nuts, bolts and screws are properly tightened.

EBU19850

Instruments, lights and switches

Check that all instruments, lights and switches are working properly. Correct if necessary.

5-9


EBU19870

EWB00010

WARNING


EBU19890

OPERATION

EWB00610

WARNING


Operating ATV without being familiar with all controls.

WHAT CAN HAPPEN

Loss of control, which could cause an accident or injury.


Read the Owner’s Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer.

EBU20042

Starting a cold engine

EWB00620

WARNING


Frozen control cables in cold weather.

WHAT CAN HAPPEN

You could be unable to control the ATV, which could lead to an accident or collision.


When riding in cold weather, always make sure all control cables work smoothly before you begin riding.

ECB00150

CAUTION:

See the “Engine break-in” section on page 6-5 prior to operating the engine for the first time.

1. Turn the fuel cock to “ON”.

2. Turn the main switch to “ON” and the engine stop switch to “ ”.

6

6-1


6

3. Shift the drive select lever into the neutral or park position. The corresponding indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit.

NOTE:

The engine can be started under the following conditions:

● The drive select lever is in the neutral or park position.

●

The rear brake lever is applied with the drive select lever in any position. However, it is recommended to shift into the neutral or park position before starting the engine.

4. Use the starter (choke) in reference to the figure:

Position (1):

Cold engine start with ambient temperature below 5 °C (40 °F).

Position (2):

Cold engine start with ambient temperature between 0 °C (30 °F) and 30 °C (90 °F).

Position (3):

Cold engine start with ambient temperature above 25 °C (80 °F).

Ambient temp./starter (choke) position

6-2

1. Fully open

2. Half open

3. Closed

4. Starter (choke)

5. Apply the rear brake lever.

6. Completely close the throttle lever and start the engine by pushing the start switch.

NOTE:

●

If the engine fails to start, release the start switch, then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt.


●

If the battery is discharged, pull the recoil starter to start the engine.

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.

ECB00160

CAUTION:

For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold!

8. Continue warming up the engine until it idles smoothly, then return the starter (choke) to position (3) before riding.

NOTE:

The engine is warm when it responds normally to the throttle with the starter (choke) turned off.

EBU20291

Starting a warm engine

Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open.

EBU20430

Operating the drive select lever and driving in reverse

ECB00170

CAUTION:

Before shifting, stop the ATV, otherwise the transmission may be damaged.

6

Shifting: Neutral to High-range and High-range to Low-range

1. Bring the ATV to a complete stop.

2. Apply the brake pedal, and then shift by moving the drive select lever along the shift guide.

NOTE:

Make sure that the drive select lever is completely shifted into position.

6-3


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.

6


2. L (Low-range)

3. H (High-range)

4. N (Neutral)

5. R (Reverse)

6. P (Park)

3. Release the brake pedal, and then open the throttle lever gradually.


2. L (Low-range)

3. H (High-range)

4. N (Neutral)

5. R (Reverse)

6. P (Park)

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 brake pedal.

1. Bring the ATV to a complete stop.

6-4

NOTE:

● When in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit.


●

Due to the synchronizing mechanism in the engine, the indicator light may not come on until the

ATV starts moving.

4. Check behind for people or obstacles, and then release the brake pedal.

5. Open the throttle lever gradually and continue to watch to the rear while backing.

EWB00660

WARNING


Improperly operating in reverse.

WHAT CAN HAPPEN

You could hit an obstacle or even a person behind you, resulting in serious injury.


When you shift into reverse, make sure there are no people or obstacles behind you.

When it is safe to proceed, go slowly.

EBU20681

Engine break-in

There is never a more important period in the life of your engine than the first 20 hours of riding. For this reason, you should read the following material carefully.

Since the engine is brand new, do not put an excessive load on it for the first 20 hours. The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided.

0–10 hours

Avoid prolonged operation above 1/2 throttle. Vary the speed of the ATV regularly. Do not operate it at one set throttle position.

6

10–20 hours

Avoid prolonged operation above 3/4 throttle. Rev the engine freely, but do not use full throttle at any time.

20 hours and beyond

The ATV can now be operated normally.

ECB00220

CAUTION:

If any engine trouble should occur during the engine break-in period, immediately have a

Yamaha dealer check the ATV.

6-5


EBU20690

Parking

When parking the ATV, stop the engine, shift the drive select lever into the park position, and then turn the fuel cock to the “OFF” position.

2. Stop the engine.

3. With the brake pedal applied, shift the drive select lever to the park position.

6

EBU20810

Parking on a slope

EWB00780

WARNING


Parking on a hill or other incline.

WHAT CAN HAPPEN

The ATV could roll out of control, increasing the chance of an accident.


Avoid parking on hills or other inclines. If you must park on an incline, place the ATV transversely across the incline, stop the engine, shift the drive select lever to the park position, and then block the front and rear wheels with rocks or other objects.

Do not park the ATV at all on hills that are so steep you could not walk up them easily.

1. Bring the ATV to a stop by applying the brakes.

EBU20910

Accessories and loading

6-6

EBU20920

Accessories

Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories.

●

Choose only accessories designed for your

ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market. However,


●

●

● it is not possible for Yamaha to test all non-

Yamaha accessories, nor control over their quality or suitability. Choose a genuine Yamaha accessory, or one that is equivalent in design and quality.

Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV.

Do not mount an accessory where it could 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.

EBU21030

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:

6-7

●

Never exceed the weight limits shown. An overloaded ATV can be unstable.

MAXIMUM LOADING LIMIT

ATV loading limit (total weight of rider, cargo, accessories, and tongue):

210.0 kg (463 lb)

Front carrier:

40.0 kg (88 lb)

Rear carrier:

80.0 kg (176 lb)

Storage compartment:

2.0 kg (4 lb)

Trailer hitch:

Pulling load (total weight of trailer and cargo):

4900 N (1102 lbf) (500 kgf)

Tongue weight (vertical weight on trailer hitch point):

147 N (33 lbf) (15 kgf)

● 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

6


6

●

●

●

●

●

●

● the weight on the hitch. If you are carrying cargo and towing a trailer, include the tongue weight in the maximum ATV load limit.

Load cargo on the carriers as close to the center of the ATV as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, and center it.

Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident.

Make sure the load does not interfere with controls or your ability to see where you are going.

Ride more slowly than you would without a load.

The more weight you carry, the 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 ATV takes longer to stop.

Avoid making sharp turns unless at very slow speeds.

Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV.

EWB00750

WARNING


Overloading this ATV or carrying or towing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in ATV handling which could lead to an accident.


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.

EWB00010

WARNING


6-8


EBU21131

RIDING YOUR ATV

7-1

7


EWB00010

WARNING


EBU21471

7

GETTING TO KNOW YOUR ATV

This ATV is for recreation and utility use. 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 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

1-1–1-5. Please also read all caution and warning labels on your ATV.

RIDE WITH CARE AND GOOD JUDGEMENT

Get training if you are inexperienced.

Beginners should get training from a certified instructor.

Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum performance until you are totally familiar with the ATV’s handling and performance characteristics.

EWB01280

WARNING


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.

7-2



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.

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.

Not recommended for children under 16 years of age.

EWB00901

WARNING


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.


A child under 16 should never operate an

ATV with engine size greater than 90 cc.

7

7-3


7

This ATV is designed to carry operator and cargo only – passengers prohibited.

EWB00910

WARNING


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.


Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.

7-4


Apparel

EWB00920

WARNING


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.

Operating without protective clothing increases your chances of severe injury in the event of an accident.


Always wear an approved motorcycle helmet

●

●

●

●

●

that fits properly.

You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants

7

1. Protective clothing

2. Goggles

3. Gloves

4. Boots

5. Helmet

7-5


7

Do not operate after consuming alcohol or drugs.

The operator’s performance capability is reduced by the influence of alcohol or drugs.

EWB00930

WARNING


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.


Never consume alcohol or drugs before or while driving this ATV.

Pre-operation checks

Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety.

EWB00940

WARNING


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.


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.

7-6


EWB00950

WARNING


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.


Always use the size and type tires specified in the Owner’s Manual for this ATV on page

5-7.

Always maintain proper tire pressure as described in the Owner’s Manual on page 5-8.

EWB00010

WARNING


Do not operate at speeds too fast for your skills or the conditions.

EWB00960

WARNING


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.


Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience.

7

7-7


7

Speed limiter

For riders less experienced with this model, the throttle lever housing is equipped with a speed limiter. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (See page

4-12.)

1. Adjusting screw

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.

MAXIMUM LOADING LIMIT

ATV loading limit (total weight of cargo, rider, accessories, and tongue):

210.0 kg (463 lb)

Front carrier:

40.0 kg (88 lb)

Rear carrier:

80.0 kg (176 lb)

Storage compartment:

2.0 kg (4 lb)

Trailer hitch:

Pulling load (total weight of trailer and cargo):

4900 N (1102 lbf) (500 kgf)

Tongue weight (vertical weight on trailer hitch point):

147 N (33 lbf) (15 kgf)

7-8


EWB00970

WARNING


Overloading this ATV or carrying or towing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in ATV handling which could lead to an accident.


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.

7-9

7


7

During operation

Always keep your feet on the footboards during operation, otherwise they may contact the rear wheels.

EWB00980

WARNING


Removing hands from handlebars or feet from footboards during operation.

7-10

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.


Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation.

Avoid wheelies and jumping. You may lose control of the ATV or overturn.

EWB00990

WARNING


Attempting wheelies, jumps, and other stunts.

WHAT CAN HAPPEN

Increases the chance of an accident, including an overturn.


Never attempt stunts, such as wheelies or jumps. Don’t try to show off.


Modifications

EWB01000

WARNING


Operating this ATV with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of this ATV may cause changes in handling which in some situations could lead to an accident.

7-11


Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer.

7


7

Exhaust system

The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it.

EWB01010

WARNING


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.


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.

Do not touch the hot exhaust system.

Do not park the ATV in a place where others might be likely to touch it.

BE CAREFUL WHERE YOU RIDE

This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control.

EWB01020

WARNING


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 ATV to go out of control.

7-12



Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.

EWB01030

WARNING


Operating this ATV on public streets, roads or highways.

WHAT CAN HAPPEN

You can collide with another vehicle.


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

Do not ride on any public road, street, or highway.

Riding on public roads can result in collisions with other vehicles.

7-13


7

Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for

holes, rocks, or roots

in the terrain, and

other hidden hazards

which may cause the ATV to upset.

EWB01040

WARNING


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.


Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

EWB01050

WARNING


Failure to use extra care when operating on excessively rough, slippery or loose terrain.

WHAT CAN HAPPEN

Could cause loss of traction or ATV control, which could result in an accident, including an overturn.

7-14



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.

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.

EWB01060

WARNING


Operating in areas where you might not be seen by other off-road vehicles.

WHAT CAN HAPPEN

You could be in a collision. You could be injured.


Always mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles.

7

7-15


7

Do not ride in areas posted “no trespassing”.

Do not ride on private property without getting permission.

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.

Shift to the park position and follow the instruction on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your ATV.

Remember that the engine and exhaust pipe will

7-16 be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components.

With the engine idling, shift the drive select lever into the low-range position or the high-range position. 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.

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.

ECB00250

CAUTION:

Do not shift from drive position low-range to high-range or vice versa without coming to a complete stop. Damage to the engine or drive train may occur.


TURNING YOUR ATV

To achieve maximum traction while riding off-road in 2WD or 4WD, the two rear wheels 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.

EWB01310

WARNING


Turning improperly.

WHAT CAN HAPPEN

ATV could go out of control, causing a collision or overturn.


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”).

7

7-17


7

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.

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.

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.

1. Lean towards inside of turn.

2. Support your weight on the outer footboard.

This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV

7-18

CLIMBING UPHILL

Use proper riding techniques to avoid ATV overturns on hills. Be sure that you can maneuver your

ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes.

Try more difficult climbs only after you have devel-

U1D913E0.book Page 19 Thursday, April 20, 2006 2:47 PM oped your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.

EWB01090

WARNING


Operating on excessively steep hills.

WHAT CAN HAPPEN

The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills.


Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting large hills.

7-19

7

7


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.

EWB01180

WARNING


Climbing hills improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause the

ATV to overturn.


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. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

7-20


7-21

7


7

If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill.

EWB01190

WARNING


Improperly crossing hills or turning on hills.

WHAT CAN HAPPEN




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.

7-22

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.


If you start to roll backwards, DO NOT apply either brake abruptly. If you are in 2WD, apply only the front brake. If you are in 4WD or 4WD-LOCK, because all wheels are interconnected by the drive train, applying either brake will brake all wheels, therefore, avoid sudden application of either the front or rear brake as the wheels on the uphill side could come off the ground. The ATV could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the ATV immediately on the uphill side.

EWB01321

WARNING


Stalling, rolling backwards or improperly dismounting while climbing a hill.

WHAT CAN HAPPEN

Could result in ATV overturning.


Use the proper gear and maintain a steady

●

●

●

speed when climbing a hill.

If you lose all forward speed:

Keep weight uphill.

Apply the brakes.

Shift to the park position after you are stopped.

7-23

●

●

If you begin rolling backwards:

Keep weight uphill.

2WD: Never apply the rear brake while rolling backwards. Apply the front brake.

When fully stopped, shift to the park posi-

●

tion.

4WD or 4WD-LOCK: Apply both front and rear brakes gradually. When fully stopped, shift to the park position.

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


7

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 the low-range position 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.

7-24

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.

EWB01130

WARNING


Going down a hill improperly.

WHAT CAN HAPPEN




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.

Always check the terrain carefully before you start down any hill.

Shift your weight backward.

Never go down a hill at high speed.

Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side. Go straight down the hill where possible.


7-25

7


7

CROSSING A SLOPE

Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance.

As you travel across a slope, lean your body in the uphill direction. 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.

EWB01141

WARNING


Improperly crossing hills or turning on hills.

WHAT CAN HAPPEN




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.

7-26


7-27

7


7

CROSSING THROUGH SHALLOW WATER

The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and carefully.

EWB01150

WARNING


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.


Never operate this ATV in fast flowing water or in water deeper than that specified in your

Owner’s 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.

7-28

Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability.


1. Air filter case check hose

ECB00280

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, the drive select lever box check hose and the storage compartment 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.

1. V-belt cooling duct check hose (left front side of ATV)

7-29

7


7

1. Drive select lever box check hose

1. Storage compartment check hose

7-30


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.

EWB01160

WARNING


Improperly operating over obstacles.


WHAT CAN HAPPEN

Could cause loss of control or a collision.

Could cause the ATV to overturn.


Before operating in a new area, check for obstacles.

Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s

Manual.

SLIDING AND SKIDDING

Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident.

To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help.

7-31

7


7

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.

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.

EWB01170

WARNING


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.


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.

WHAT TO DO IF...

This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely.

7-32


WHAT TO DO...

● If your ATV doesn’t turn when you want it to:

Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the

● turn. Position your weight over the front wheels for better control. (See page 7-17.)

If your ATV begins to tip while turning:

Lean more into the turn to regain balance. If nec-

● essary, gradually let off the throttle and/or steer to the outside of the turn. (See page 7-17.)

If your ATV starts to slide sideways:

Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not

● recommended until you have corrected the slide. (See page 7-31.)

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 IF THE ATV IS IN 2WD – the ATV may tip over on top of you. Dismount the ATV on the uphill side. (See page 7-18.)

●

●

If your ATV is traversing a sloping surface:

Be sure to ride with your weight positioned 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 page 7-18.)

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 page 7-28.)

EWB00010

WARNING


7

7-33


8

EBU21641

EBU21660

PERIODIC MAINTENANCE AND MINOR REPAIR

Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your

ATV in the safest and best operating condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages.

The intervals given in the periodic maintenance and lubrication chart should be considered as a general guide under normal riding conditions.

However, DEPENDING ON THE WEATHER,

TERRAIN, GEOGRAPHICAL LOCATION, AND

INDIVIDUAL USE, THE MAINTENANCE INTER-

VALS MAY NEED TO BE SHORTENED.

EWB01820

WARNING


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 start fires.


Turn off the engine when performing maintenance unless otherwise specified. Have a

Yamaha dealer perform the service if you are not familiar with maintenance work.

EBU21720

Owner’s manual and tool kit

Be sure to put this owner’s manual in the plastic bag and always carry it on the bottom of the seat as shown. Put the owner’s tool kit and low-pressure tire gauge under the seat.

8-1


1. Owner’s manual

2. Owner’s tool kit

3. Low-pressure tire gauge

The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.

NOTE:

If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

8-2

EWB01830

WARNING


Operating this ATV with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of this ATV may cause changes in handling which in some situations could lead to an accident.


Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized Yamaha ATV dealer.

8


8

EBU21741

Periodic maintenance chart for the emission control system

NOTE:

●

●

For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.

For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance

● intervals should be followed.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

1

2

3

4

5

NO.

*

*

*

*

Spark plug

Valves

ITEM

Fuel line

Carburetor

Crankcase breather system

CHECK OR MAINTENANCE

JOB

Whichever comes first month km

(mi) hours

• Check fuel hoses for cracks or other damage, and replace if necessary.

• Check condition and clean, regap, or replace if necessary.

• Check valve clearance and adjust if necessary.

• Check starter (choke) operation and correct if necessary.

• Check engine idling speed and adjust if necessary.

• Check breather hose for cracks or other damage, and replace if necessary.

1

320

(200)

20

INITIAL

3

1300

(800)

6

2500

(1600)

80 160

EVERY

6

2500

(1600)

12

5000

(3200)

160 320

√ √ √

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

8-3


NO.

ITEM

6

*

Exhaust system

7 Spark arrester


JOB


(mi) hours

• Check for leakage and replace gasket(s) if necessary.

• Check for looseness and tighten all screw clamps and joints if necessary.

• Clean.

1

320

(200)

20

INITIAL

3

1300

(800)

80

6

2500

(1600)

160

6

EVERY

12

2500

(1600)

160

5000

(3200)

320

√

√

√

√

√

√

8

8-4


8

EBU21862

General maintenance and lubrication chart

1

NO.

Air filter element

2

*

Front brake

3

*

Rear brake

4

*

Brake hoses

5

*

Wheels

6

*

Tires

ITEM

7

*

Wheel bearings


JOB


(mi) hours

• Clean and replace if necessary.

1

320

(200)

INITIAL

3

1300

(800)

6

2500

(1600)

6

EVERY

12

2500

(1600)

5000

(3200)

20 80 160 160 320

Every 20–40 hours (more often in wet or dusty areas)

• Check operation and correct if necessary.

• Check fluid level and ATV for fluid leakage, and correct if necessary.

• Replace brake pads.


• Check brake lever free play and adjust if necessary.

• Check fluid level and ATV for fluid leakage, and correct if necessary.

• Replace brake pads.

• Check for cracks or other damage, and replace if necessary.

• Replace.

• Check runout and for damage, and replace if necessary.

• Check tread depth and for damage, and replace if necessary.

• Check air pressure and balance, and correct if necessary.

• Check for looseness or damage, and replace if necessary.

√

√

√

√

√

√ √ √

Whenever worn to the limit

√ √ √

Whenever worn to the limit

√ √

Every 4 years

√

√

√

√

√

√

√

√

√

√

√

√

√

8-5


NO.

ITEM

8

*

Upper and lower arm pivots

9

*

V-belt

10

*

Drive shaft universal joint

11

*


12

*

Shock absorber assemblies

13

*

Stabilizer bushes

14

*

Knuckle pivots

15

*

Knuckle shafts

16

*

Steering shaft

17

*

Steering system

18

19

20

*

*

Engine mount

Axle boots

Engine oil


JOB


(mi) hours

1

320

(200)

20

INITIAL

3

1300

(800)

80

6

2500

(1600)

160

6

EVERY

12

2500

(1600)

160

5000

(3200)

320

√ √ √

• Lubricate with lithium-soap-based grease.

• Check for wear, cracks or other damage, and replace if necessary.


• Make sure that all nuts, bolts, and screws are properly tightened.


• Check for oil leakage and replace if necessary.





• Check operation and repair or replace if damaged.

• Check toe-in and adjust if necessary.



• Change.

• Check ATV for oil leakage, and correct if necessary.

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

8-6

8


8

NO.

ITEM


JOB


(mi) hours

21

23

24

25

26

27

28

*

*

*

Engine oil filter cartridge

22

*

Engine oil strainer


Final gear oil

Cooling system

Moving parts and cables

Drive select lever safety system cable

Throttle lever housing and cable

29

*

Front and rear brake switches

30

*

Lights and switches

• Replace.

• Clean.

• Change.


• Change.


• Check coolant level and ATV for coolant leakage, and correct if necessary.

• Replace coolant.

• Lubricate.

• Check operation and adjust or replace if necessary.


• Check throttle cable free play and adjust if necessary.

• Lubricate throttle lever housing and cable.



• Adjust headlight beams.

1

320

(200)

20

INITIAL

3

1300

(800)

80

6

2500

(1600)

160

6

EVERY

12

2500

(1600)

160

5000

(3200)

320

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

Every 2 years

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

8-7


EBU23070

NOTE:

●

●

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake service

• Regularly check and, if necessary, correct the brake fluid level.

• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

• Replace the brake hoses every four years and if cracked or damaged.

8

8-8

8


EWB00010

WARNING


EBU23090

Removing and installing panels

The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed.

1. Panel A

2. Panel B

1. Panel C

2. Panel D

3. Panel E

4. Panel F

EBU27600

Panels A and D

To remove one of the panels

1. Remove the seat. (See page 4-19.)

2. Pull outward on the areas shown, and then pull upward as shown.

8-9


8-10

To install one of the panels

1. Place the panel in its original position.

8


Panel B

To remove the panel

Remove the bolt, and then take the panel off.

8

2. Install the seat.

8-11

1. Bolt

2. Panel B

To install the panel

Place the panel in the original position and install the bolt.

ECB00380

CAUTION:

When installing the panel, be sure not to pinch the cables or wires.


Panel C

To remove the panel

1. Remove the carrier top bolts.

1. Carrier bolt (top)

2. Remove the carrier bolts under the fenders, and then take the carrier off.

1. Carrier bolt (under the fenders)

3. Remove the quick fastener screws, and then pull the panel upward to remove it.

8

8-12


Panel E

To remove the panel

Remove the bolts, and then take the panel off.

1. Quick fastener screw

2. Panel C

8


1. Place the panel in the original position, and then install the quick fastener screws.

2. Place the carrier in the original position, and then install the carrier bolts under the fenders.

3. Install the carrier top bolts, and then tighten all bolts to the specified torques.

Tightening torques:

Carrier bolt (top):

34 Nm (3.4 m·kgf, 24 ft·lbf)

Carrier bolt (under fenders):

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

8-13

1. Panel E

2. Bolt


Place the panel in the original position and install the bolts.

Panel F

To remove the panel

Pull outward on the areas shown.


1. Panel F


Place the panel in its original position.

EBU23221

Checking the spark plug

The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plug can reveal the condition of the engine.

To remove the spark plug

1. Remove panel A. (See page 8-9.)

2. Remove the spark plug cap.

8

8-14

1. Spark plug cap


3. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit.

8

1. Spark plug wrench

To check the spark plug

1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan (the ideal color when the ATV is ridden normally).

NOTE:

If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the ATV.

2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

Specified spark plug:

NGK/DR8EA

To install the spark plug

1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification.

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

8-15


1. Spark plug gap

2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads.

3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque.

Tightening torque:

Spark plug:

17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)

8-16

NOTE:

If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.

4. Install the spark plug cap.

5. Install the panel.

EBU23322

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.

8

To check the engine oil level

1. Remove panel F. (See page 8-9.)

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 before checking.

5. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag.


8

1. Engine oil filler cap

6. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level.

1. Dipstick

2. Maximum level mark

3. Minimum level mark

NOTE:

The engine oil should be between the minimum and maximum level marks.

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 engine oil filler cap.


8-17


To change the engine oil (with or without oil filter cartridge replacement)

1. Remove panel F. (See page 8-9.)


3. Start the engine, warm it up for several minutes, and then turn it off.

4. Place an oil pan under the engine to collect the used oil.

5. Remove the engine oil filler cap, and then remove the engine oil drain bolt to drain the oil from the crankcase.

NOTE:

Skip steps 6–10 if the oil filter cartridge is not being replaced.

6. Remove panels D and E. (See page 8-9.)

7. Remove the oil filter cartridge with an oil filter wrench.

8

1. Oil filter cartridge

1. Engine oil drain bolt

8-18


1. Oil filter wrench

8

NOTE:

An oil filter wrench is available at a nearby Yamaha dealer.

8. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.

1. O-ring

NOTE:

Make sure that the O-ring is properly seated.

9. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench.

8-19


1. Torque wrench

Tightening torque:

Oil filter cartridge:

17 Nm (1.7 m·kgf, 12 ft·lbf)

10. Install panels E and D.

11. Install the engine oil drain bolt, and then tighten it to the specified torque.

Tightening torque:

Engine oil drain bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

12. Add the specified amount of the recommended engine oil, and then install and tighten the engine oil filler cap.

Recommended oil:

See page 10-1.

Oil quantity:

Without oil filter cartridge replacement:

2.30 L (2.43 US qt) (2.02 Imp.qt)

With oil filter cartridge replacement:

2.40 L (2.54 US qt) (2.11 Imp.qt)

ECB00300

CAUTION:

●

●

In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERV-

ING II” or higher.

Make sure that no foreign material enters the crankcase.

8

8-20


13. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause.

14. Turn the engine off, and then check the oil level and correct it if necessary.

15. Install panel F.

8

EBU23391

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. In addition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart.

To check the final gear oil level


NOTE:

The final gear oil level must be checked on a cold engine.

2. Remove the final gear oil filler bolt, and then check the oil level in the final gear case.

NOTE:

The oil level should be at the brim of the filler hole.

8-21

1. Final gear oil filler bolt

2. Correct oil level

3. Final gear oil

3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level.

4. Install the oil filler bolt, and then tighten it to the specified torque.

Tightening torque:

Final gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)


To change the final gear oil

1. Remove the engine guard and the final gear case guard by removing the bolts.

1. Engine guard

2. Final gear case guard

3. Bolt


3. Place an oil pan under the final gear case to collect the used oil.

4. Remove the final gear oil filler bolt and the final gear oil drain bolt to drain the oil from the final gear case.

1. Final gear oil drain bolt

5. Install the drain bolt, and then tighten it to the specified torque.

Tightening torque:

Final gear oil drain bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

6. Add the recommended final gear oil to the brim of the filler hole as shown.

8

8-22


1. Final gear oil filler bolt


3. Final gear oil

8

Recommended final gear oil:

See page 10-1.

ECB00420

CAUTION:

Be sure no foreign material enters the final gear case.


Tightening torque:

Final gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

8. Check the final gear case for oil leakage. If oil is leaking, check for the cause.

9. Install the engine guard and the final gear case guard by installing the bolts, and then tightening them to the specified torques.

Tightening torques:

Engine guard bolt:

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Final gear case guard bolt:

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

EBU23421


The differential 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.

In addition, the differential gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart.

8-23


To check the differential gear oil level


NOTE:

The differential gear oil level must be checked on a cold engine.

2. Remove the differential gear oil filler bolt, and then check the oil level in the differential gear case.

3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level.


Tightening torque:

Differential gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

To change the differential gear oil


2. Place an oil pan under the differential gear case to collect the used oil.

3. Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case.

8

1. Differential gear oil

2. Differential gear oil filler bolt


NOTE:

The oil level should be at the brim of the filler hole.

8-24


8

1. Differential gear oil drain bolt

4. Install the drain bolt, and then tighten it to the specified torque.

Tightening torque:

Differential gear oil drain bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

5. Add the recommended differential gear oil to the brim of the filler hole as shown.

1. Differential gear oil

2. Differential gear oil filler bolt


Recommended differential gear oil:

See page 10-1.

ECB00410

CAUTION:

Be sure no foreign material enters the differential gear case.


8-25


Tightening torque:

Differential gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

7. Check the differential gear case for oil leakage. If oil is leaking, check for the cause.

EBU23470

Coolant

The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart.

EBU27122

To check the coolant level


NOTE:

The coolant level must be checked on a cold engine since the level varies with engine temperature.

2. Check the coolant level in the coolant reservoir.

NOTE:

The coolant should be between the minimum and maximum level marks.

1. Coolant reservoir cap

2. Maximum level mark


3. If the coolant is at or below the minimum level mark, remove panel D. (See page 8-9.)

4. Remove the reservoir cap, add coolant or distilled water to the maximum level mark, install the reservoir cap, and then install the panel.

8

8-26


8

Coolant reservoir capacity (up to the maximum level mark):

0.25 L (0.26 US qt) (0.22 Imp.qt)

ECB00401

CAUTION:

●

●

●

If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine.

If water has been used instead of coolant, replace it with coolant as soon as possible, otherwise the cooling system will not be protected against frost and corrosion.

If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced.

NOTE:

●

The radiator fan is automatically switched on or off according to the coolant temperature in the radiator.

●

If the engine overheats, see page 8-59 for further instructions.

8-27

EBU23592

To change the coolant

EWB01880

WARNING



WHAT CAN HAPPEN



Wait for the engine to cool before removing the radiator cap. Always place a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap.


2. Remove panels E and F. (See page 8-9.)

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.)


4. Remove the front carrier and panel C. (See page 8-9.)

5. Remove the radiator cap.

1. Coolant drain bolt

1. Trough

8-28

1. Radiator cap

6. Remove panel D. (See page 8-9.)

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


8

1. Coolant reservoir 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, 7.2 ft·lbf)

11. Connect the coolant reservoir hose.

12. Pour the recommended coolant into the reservoir to the maximum level mark, and then install the reservoir cap.

8-29

13. Pour the recommended coolant into the radiator until it is full.

Antifreeze/water mixture ratio:

1:1

Recommended antifreeze:

High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines

Coolant quantity:

Radiator capacity (including all routes):

1.30 L (1.37 US qt) (1.14 Imp.qt)


0.25 L (0.26 US qt) (0.22 Imp.qt)

ECB00401

CAUTION:

●

●

If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine.

If water has been used instead of coolant, replace it with coolant as soon as possible, otherwise the cooling system will not be protected against frost and corrosion.


●

If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced.

14. Install the radiator cap, start the engine, let it idle for several minutes, and then turn it off.

15. Remove the radiator cap to check the coolant level in the radiator. If it is low, add sufficient coolant until it reaches the top of the radiator, and then install the radiator cap.

16. Start the engine, and then check for coolant leakage.

NOTE:

If any leakage is found, have a Yamaha dealer check the cooling system.

17. Install the panels and the front carrier.

EBU23630

Cleaning the air filter element

The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas.

8-30

NOTE:

There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case.

1. Air filter case check hose

1. Remove the seat. (See page 4-19.)

2. Remove the air filter case cover by unhooking the holders.

8


8

1. Air filter case holder

2. Air filter case cover

3. Pull the air filter element out of the air filter case.

1. Air filter element

4. Pull off the lock plate, and then remove the sponge material from the air filter element frame.

8-31


1. Air filter element frame

2. Sponge material

3. Air filter element lock plate

5. Wash the sponge material gently but thoroughly in solvent.

EWB01900

WARNING


Using low-flash-point solvents or gasoline to clean the sponge material.

WHAT CAN HAPPEN

Low-flash-point solvents or gasoline can catch fire or explode.


Use parts cleaning solvent to clean the sponge material.

6. Squeeze the excess solvent out of the sponge material and let it dry.

ECB00440

CAUTION:

Do not twist the sponge material when squeezing it.

7. Check the sponge material and replace it if damaged.

8. Apply Yamaha foam air filter oil or other quality foam air filter oil to the sponge material.

NOTE:

The sponge material should be wet but not dripping.

9. Pull the sponge material over the air filter element frame, and then install the lock plate.

10. Insert the air filter element into the air filter case, and then install the air filter case cover by hooking the holders onto the air filter case.

11. Install the seat.

8

8-32


8

NOTE:

The air filter element should be cleaned every 20–

40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty areas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions. Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air-tight seal. Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine.

ECB00460

CAUTION:

●

●

Make sure that the air filter element is properly seated in the air filter case.

Never operate the engine with the air filter element removed. This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating.

EBU23881

Cleaning the spark arrester

Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester.

1. Remove the bolts.

1. Bolt

2. Tailpipe

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 and inside of the tailpipe housing.

8-33


1. Tailpipe

2. Spark arrester

4. Insert the tailpipe into the muffler and align the bolt holes.

5. Install and tighten the bolts.

EWB01910

WARNING


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.


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.

EBU23920

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.

8

8-34


1. V-belt cooling duct check hose (left front side of ATV)

8

EBU23930

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.

NOTE:

If water drains from the V-belt case after removing the plug, have a Yamaha dealer check the ATV as the water may affect other engine parts.


EBU23940

Adjusting the carburetor

The carburetor should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a

Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment described in the following section, however, may be performed by the owner as part of routine maintenance.

8-35


ECB00480

CAUTION:

The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine.

4. Check the engine idling speed and, if necessary, adjust it to specification by turning the throttle stop screw at the carburetor. To increase the engine idling speed, turn the throttle stop screw in direction (a), and to decrease it, turn the screw in direction (b).

EBU24010

Adjusting the engine idling speed

The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart.

NOTE:

A diagnostic tachometer is needed to make this adjustment.

1. Start the engine and warm it up.

NOTE:

The engine is warm when it quickly responds to the throttle.

2. Remove panel D. (See page 8-9.)

3. Attach the tachometer to the spark plug lead.

1. Throttle stop screw

Engine idling speed:

1450–1550 r/min

8-36

NOTE:

If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment.

8



8

EBU24043

Adjusting the throttle cable free play

The throttle cable free play should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.

The throttle cable free play should measure 3.0–

5.0 mm (0.12–0.20 in) at the throttle lever. Periodically check the throttle cable free play and, if necessary, adjust it as follows.

NOTE:

The engine idling speed must be checked, and adjusted if necessary, before adjusting the throttle cable free play.


2. To increase the throttle cable free play, turn the adjusting bolt in direction (a). To decrease the throttle cable free play, turn the adjusting bolt in direction (b).

1. Locknut

2. Throttle cable free play adjusting bolt

3. Throttle cable free play


EBU24060

Valve clearance

The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.

8-37


EBU24070

Adjusting the drive select lever safety system cable

The drive select lever safety system cable stretches with use, which can result in improper function.

Therefore, the safety system cable should be checked and adjusted at the intervals specified in the periodic maintenance and lubrication chart.

EBU24130

Checking the front and rear brake pads

The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.

EBU24171

Front brake pads

Check each front brake pad for damage and measure the lining thickness. If a brake pad is damaged or if the lining thickness is less than 1.0 mm

(0.04 in), have a Yamaha dealer replace the brake pads as a set.

1. Lining thickness

NOTE:

The wheels need to be removed to check the brake pads. (See page 8-56.)

8

EBU26460

Rear brake pads

Each rear brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake.

To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point

8-38

U1D913E0.book Page 39 Thursday, April 20, 2006 2:47 PM that the wear indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set.

Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.

Front brake

8

1. Wear indicator groove

NOTE:

The wheels need to be removed to check the brake pads. (See page 8-56.)

EBU24261

Checking the brake fluid level

Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective.


8-39


Rear brake


NOTE:

To check the rear brake fluid level, remove panel

C. (See page 8-9.)

Observe these precautions:

● When checking the fluid level, make sure that the top of the brake fluid reservoir is level.

●

Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance.

Recommended brake fluid:

DOT 4

8-40

●

●

●

●

Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance.

Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.

As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a

Yamaha dealer check the cause.

EBU24290

Changing the brake fluid

Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking.

●

●

Oil seals: Replace every two years.

Brake hoses: Replace every four years.

8


8

EBU24380

Checking the front brake lever free play

The brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart. The brake lever should have a free play of zero mm (zero in) as shown. If the free play is incorrect, have a Yamaha dealer check the brake system.

1. Brake lever free play

EWB02010

WARNING


Operating with improperly serviced or adjusted brakes.

WHAT CAN HAPPEN

You could lose braking ability, which could

●

●

lead to an accident.


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.

EBU27130

Adjusting the rear brake lever free play and checking the brake pedal position

The brake lever free play must be adjusted and brake pedal position must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.

NOTE:

●

Always perform this maintenance completely in the following order whenever adjusting the rear brake.

8-41


●

Before adjusting the brake lever free play and checking the brake pedal position, check the rear brake pads for wear.

Adjusting the brake lever free play

The brake lever free play should measure 0.5–2.0

mm (0.02–0.08 in) as shown. If the free play is incorrect, adjust it as follows.

1. Brake lever free play


2. Turn the brake lever free play adjusting bolt in direction (a) to increase the free play, and in direction (b) to decrease it.

1. Locknut

2. Brake lever free play adjusting bolt


If the correct free play cannot be obtained, have a

Yamaha dealer adjust it.

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.

8

8-42


Checking the brake pedal position

The top of the brake pedal should be positioned

72.0 mm (2.83 in) above the top of the footboard.

If the brake pedal position is incorrect, have a

Yamaha dealer adjust it.

●

●


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.

EBU24230

Axle boots

The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart. Check the axle boots for tears or damage. If any damage is found, have them replaced by a Yamaha dealer.

8

1. Distance between brake pedal and footboard

EWB02050

WARNING


Operating with improperly serviced or adjusted brakes.

WHAT CAN HAPPEN

You could lose braking ability, which could lead to an accident.

8-43


1. Front axle boot (each side)

1. Rear axle boot (each side)

8-44

EBU24751

Brake light switches

The operation of the brake light switches must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.

The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer.

1. Remove panel B. (See page 8-9.)

NOTE:

The brake light switch is properly adjusted when the brake light comes on just before braking takes effect.

2. Turn the adjusting nut while holding the 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).

8


1. Brake light switch

2. Brake light switch adjusting nut


8

EBU24890

Checking and lubricating the cables

The operation and the condition of all control cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.

Recommended lubricant:

Engine oil

8-45

EWB02120

WARNING


Damaged control cables.

WHAT CAN HAPPEN

Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could restrict the operation of controls and lead to an accident or injury.


Inspect cables frequently. Replace damaged cables.

EBU24911

Checking and lubricating the front and rear brake levers

The operation of the front and rear brake levers should be checked before each ride, and the lever pivots should be lubricated if necessary.


Lithium-soap-based grease (all-purpose grease)


EBU24950

Checking and lubricating the brake pedal

The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary.

NOTE:

To access the brake pedal pivot, remove panel B.

(See page 8-9.)


Lithium-soap-based grease (all-purpose grease)

8-46

EBU24961

Checking the wheel bearings

The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings.

EBU24970

Lubricating the drive shaft universal joint

The drive shaft universal joint must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.

Lubricate the universal joint using a grease gun.

8



Lithium-soap-based grease



8

EBU25021

Checking the stabilizer bushes

The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart.

Have a Yamaha dealer replace the stabilizer bushes if necessary.

EBU25040

Lubricating the upper and lower arm pivots

The upper and lower arm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.

1. Grease nipple



EBU25050

Lubricating the knuckle pivots

The knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.

Lubricate the pivoting points using a grease gun.

8-47

EBU25080

Lubricating the knuckle shafts

The knuckle shafts must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.




EBU25100

Lubricating the steering shaft

The steering shaft must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.



EBU25212

Battery

This model is equipped with a sealed-type (MF) battery, which does not require any maintenance.

There is no need to check the electrolyte or to add distilled water. Check and, if necessary, tighten the battery lead connections.

ECB00620

CAUTION:

Never attempt to remove the battery cell seals, as this would permanently damage the battery.

EWB02140

WARNING


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.


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.

8-48

To charge the battery

Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electrical accessories.

8


8

To store the battery

1. If the ATV will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place.

2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary.

To install the battery

NOTE:

Be sure the battery is fully charged.

1. Place the battery in its compartment.

2. Make sure to properly connect the battery leads to the battery terminals.

1. Positive battery terminal

2. Negative battery terminal

ECB00630

CAUTION:

●

●

Always keep the battery charged. Storing a discharged battery can cause permanent battery damage.

To charge a sealed-type (MF) battery, a special constant-voltage battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charger, have a Yamaha dealer charge your battery.

8-49


EBU25313

Replacing a fuse

1. Main fuse

2. Fuse box

1. Main fuse

2. Spare main fuse

8-50

8


8

1. Headlight fuse

2. Ignition fuse

3. Auxiliary DC jack fuse

4. Four-wheel-drive motor fuse

5. Signaling system fuse

6. Backup fuse (for odometer and clock)

7. Spare fuse

The main fuse and the fuse box are located under the seat. (See page 4-19.)

If a fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn off all electrical circuits.

ECB00640

CAUTION:

To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse.

2. Remove the blown fuse, and then install a new fuse of the specified amperage.

Specified fuses:

Main fuse:

30.0 A

Headlight fuse:

15.0 A

Ignition fuse:

10.0 A

Four-wheel-drive motor fuse:

3.0 A

Signaling system fuse:

10.0 A

Auxiliary DC jack fuse:

10.0 A

Backup fuse:

10.0 A

8-51


EWB02151

WARNING


Using an improper fuse.

WHAT CAN HAPPEN

An improper fuse can cause damage to the electrical system, which could lead to a fire.


Always use a fuse of the specified rating.

Never use a material in place of the proper fuse.

3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate.

4. If the fuse immediately blows again, have a

Yamaha dealer check the electrical system.

EBU26892

Replacing a headlight bulb

If a headlight bulb burns out, replace it as follows.

1. Remove the bulb holder cover at the rear of the headlight by pulling it off.

1. Cover at the rear of the headlight

2. Disconnect the headlight coupler by lifting the tab as shown and pulling out the coupler.

8

8-52

1. Headlight coupler


3. Remove the headlight bulb holder assembly by turning it counterclockwise.

WHAT CAN HAPPEN

You can be burned, or a fire could start if the bulb touches something flammable.


Wait for the bulb to cool before touching or removing it.

4. Install a new headlight bulb holder assembly by inserting it into the headlight unit and turning it clockwise.

1. Headlight bulb holder assembly

8

NOTE:

The headlight bulb cannot be removed from the headlight bulb holder. To replace the headlight bulb, replace the headlight bulb holder assembly.

EWB02180

WARNING


A headlight bulb is hot when it is on and immediately after it is turned off.

1. Do not touch the glass part of the bulb.

8-53


ECB00650

CAUTION:

Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner.

5. Connect the headlight coupler.

6. Install the headlight bulb holder cover at the rear of the headlight.

ECB00670

CAUTION:

Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly.

7. Adjust the headlight beam if necessary.

EBU25550

Adjusting a headlight beam

ECB00690

CAUTION:

It is advisable to have a Yamaha dealer make this adjustment.

To raise a headlight beam, turn the adjusting screw in direction (a).

To lower a headlight beam, turn the adjusting screw in direction (b).

1. Headlight beam adjusting screw

EBU25620

Replacing the tail/brake light bulb

If the tail/brake light bulb burns out, replace it as follows.

1. Remove the tail/brake light assembly by removing the nuts together with the washers.

8

8-54


8

1. Tail/brake light assembly

2. Nut

2. Remove the bulb holder (together with the bulb) by turning it counterclockwise.

1. Tail/brake light assembly

2. Tail/brake light bulb holder

3. Remove the defective bulb by pushing it in and turning it counterclockwise.

8-55


1. Tail/brake light bulb holder

2. Tail/brake light bulb

4. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops.

5. Install the bulb holder (together with the bulb) by turning it clockwise.

6. Install the tail/brake light assembly by installing the washers and the nuts.

EBU25650

Removing a wheel

1. Loosen the wheel nuts.

1. Wheel nut

2. Elevate the ATV and place a suitable stand under the frame.

3. Remove the nuts from the wheel.

4. Remove the wheel.

8

EBU25700

Installing a wheel

1. Install the wheel and the nuts.

NOTE:

●

The arrow mark on the tire must point toward the rotating direction of the wheel.

8-56

8


●

Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel.

1. Arrow mark

8-57

1. Tapered nut

2. Lower the ATV to the ground.

3. Tighten the wheel nuts to the specified torques.

Tightening torques:

Front wheel nut:

55 Nm (5.5 m·kgf, 40 ft·lbf)

Rear wheel nut:

55 Nm (5.5 m·kgf, 40 ft·lbf)


EBU25730

Troubleshooting

Although Yamaha ATVs receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.

The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself. However, should your ATV require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the ATV properly.

Use only genuine Yamaha replacement parts. Imitation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills.

EWB02260

WARNING


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.


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

8-58


8

EBU25771

Troubleshooting charts

Starting problems or poor engine performance

1. Fuel

Check the fuel level in the fuel tank.

There is enough fuel.

There is no fuel.

Check the compression.

Supply fuel.

The engine does not start.

Check the compression.

2. Compression

Operate the electric starter.

There is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealer check the ATV.

3. Ignition

Remove the spark plug and check the electrodes.

Wet

Dry

Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug.


Open the throttle halfway and operate the electric starter.


Check the battery.

4. Battery

Operate the electric starter.

The engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the battery lead connections, and charge the battery if necessary.



8-59


Engine overheating

EWB02270

WARNING



WHAT CAN HAPPEN



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.

Wait until the engine has cooled.

Check the coolant level in the reservoir and radiator.

The coolant level is low.

Check the cooling system for leakage.

The coolant level is OK.

There is leakage.

Have a Yamaha dealer check and repair the cooling system.

There is no leakage.

Add coolant. (See NOTE.)

Start the engine. If the engine overheats again, have a

Yamaha dealer check and repair the cooling system.

8

NOTE:

If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.

8-60


9

EBU25860

CLEANING AND STORAGE

EBU25870

Cleaning

Frequent, thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many components.

1. Before cleaning the ATV: a. Block off the end of the exhaust pipe to prevent water entry. 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.

ECB00710

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 coinoperated car washers.

4. Once most of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bottle brush is handy for hard-to-reach places.

5. Rinse the ATV off immediately with clean water and dry all surfaces with a chamois, clean towel or soft absorbing cloth.

6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.

7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished cleaning, start the engine and let it idle for several minutes.

EWB02300

WARNING


Operation with wet brakes after washing.

9-1


WHAT CAN HAPPEN

Wet brakes may have reduced stopping ability, increasing the chance of an accident.


Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings.

EBU25932

Storage

Short-term

Always store your ATV in a cool, dry place and, if necessary, protect it against dust with a porous cover.

ECB00720

CAUTION:

●

●

Storing the ATV in a poorly ventilated room or covering it with a tarp while it is still wet, will allow water and humidity to seep in and cause rust.

To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored.

Long-term

Before storing your ATV for several months:

1. Follow all the instructions in the “Cleaning” section of this chapter.

2. Turn the fuel cock lever to “OFF”.

3. Drain the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank.

4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel from deteriorating.

Specified amount:

7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel)

5. Perform the following steps to protect the cylinder, piston rings, etc. from corrosion.

a. Remove the spark plug cap and spark plug.

b. Pour a teaspoonful of engine oil into the spark plug bore.

9

9-2


9

c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder wall with oil.) e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap.

6. Lubricate all control cables and the pivoting points of all levers and pedals.

7. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that all of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.

8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it.

9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an excessively cold or warm place [less than 0 °C (30

°F) or more than 30 °C (90 °F)]. For more information on storing the battery, see page

8-48.

NOTE:

Make any necessary repairs before storing the

ATV.

9-3


EBU25960

Dimensions:

Overall length:

1993 mm (78.5 in)

Overall width:

1093 mm (43.0 in)

Overall height:

1120 mm (44.1 in)

Seat height:

830 mm (32.7 in)

Wheelbase:

1233 mm (48.5 in)

Ground clearance:

245 mm (9.6 in)

Minimum turning radius:

3000 mm (118 in)

Weight:

With oil and fuel:

285.0 kg (628 lb)

Engine:

Engine type:

Liquid cooled 4-stroke, SOHC

Cylinder arrangement:

Forward-inclined single cylinder

Displacement:

421.0 cm³ (25.69 cu.in)

Bore

×

stroke:

84.5

×

75.0 mm (3.33

×

2.95 in)

SPECIFICATIONS

Compression ratio:

10.00 :1

Starting system:

Electric and recoil starter

Lubrication system:

Wet sump

Engine oil:

Type:

YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40

0˚

10˚ 30˚ 50˚ 70˚

90˚

110˚

130˚F

YAMALUBE 4 (20W40) or SAE 20W40

YAMALUBE 4 (10W30) or SAE 10W30

SAE 5W30

-20˚

-10˚ 0˚ 10˚ 20˚

30˚ 40˚ 50˚C

10

10-1

Recommended engine oil grade:

API service SE, SF, SG type or higher

Engine oil quantity:

Without oil filter cartridge replacement:

2.30 L (2.43 US qt) (2.02 Imp.qt)


10

With oil filter cartridge replacement:

2.40 L (2.54 US qt) (2.11 Imp.qt)

Final gear oil:

Type:

SAE80 API GL-4 Hypoid gear oil

Quantity:

0.16 L (0.17 US qt) (0.14 Imp.qt)

Differential gear oil:

Type:

SAE80 API GL-4 Hypoid gear oil

Quantity:

0.23 L (0.24 US qt) (0.20 Imp.qt)

Cooling system:


0.25 L (0.26 US qt) (0.22 Imp.qt)

Radiator capacity (including all routes):

1.30 L (1.37 US qt) (1.14 Imp.qt)

Air filter:

Air filter element:

Fuel:

Wet element

Recommended fuel:

Unleaded gasoline only

Fuel tank capacity:

15.0 L (3.96 US gal) (3.30 Imp.gal)

Fuel reserve amount:

4.5 L (1.19 US gal) (0.99 Imp.gal)

Carburetor:

Manufacturer:

MIKUNI

Type x quantity:

BSR33 x 1

Spark plug (s):

Manufacturer/model:

NGK/DR8EA

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Clutch:

Clutch type:

Wet, centrifugal automatic

Transmission:

Primary reduction system:

V-belt

Secondary reduction system:

Shaft drive

Secondary reduction ratio:

39/24

×

24/18

×

33/9 (7.944)

Transmission type:

V-belt automatic

Operation:

Left hand operation

Reverse gear:

29/17 (1.706)

Low range:

45/16 (2.813)

High range:

38/23 (1.652)

Chassis:

Frame type:

Steel tube frame

10-2


Caster angle:

2.5 °

Trail:

8.5 mm (0.33 in)

Front tire:

Type:

Tubeless

Size:

AT25 x 8-12

Manufacturer/model:

MAXXIS/M979

Rear tire:

Type:

Tubeless

Size:

AT25 x 10-12

Manufacturer/model:

MAXXIS/M980

Loading:

Maximum loading limit:

210.0 kg (463 lb)

(Total weight of rider, cargo, accessories, and tongue)

Tire air pressure (measured on cold tires):

Recommended:

Front:

25.0 kPa (3.6 psi) (0.250 kgf/cm²)

Rear:

25.0 kPa (3.6 psi) (0.250 kgf/cm²)

Minimum:

Front:

22.0 kPa (3.2 psi) (0.220 kgf/cm²)

10-3

Rear:

22.0 kPa (3.2 psi) (0.220 kgf/cm²)

Maximum:

Front:

28.0 kPa (4.1 psi) (0.280 kgf/cm²)

Rear:

28.0 kPa (4.1 psi) (0.280 kgf/cm²)

Front wheel:

Wheel type:

Panel wheel

Rim size:

12 x 6.0AT

Rear wheel:

Wheel type:

Panel wheel

Rim size:

12 x 7.5AT

Front brake:

Type:

Dual disc brake

Operation:

Right hand operation

Recommended fluid:

DOT 4

Rear brake:

Type:

Single disc brake

Operation:

Left hand and right foot operation

Recommended fluid:

DOT 4

10


10

Front suspension:

Type:

Double wishbone

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

160 mm (6.3 in)

Rear suspension:

Type:

Double wishbone

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

180 mm (7.1 in)

Electrical system:

Ignition system:

DC. CDI

Charging system:

AC magneto

Battery:

Model:

YTX20L-BS

Voltage, capacity:

12 V, 18.0 Ah

Headlight:

Bulb type:

Halogen bulb

Bulb voltage, wattage x quantity:

Headlight:

12 V, 30.0/30.0 W

×

2

10-4

Tail/brake light:

12 V, 5.0/21.0 W

×

1

Neutral indicator light:

LED

Reverse indicator light:

LED

Coolant temperature warning light:

LED

Park indicator light:

LED

On-Command four-wheel-drive/differential gear lock indicator:

LCD

High-range indicator light:

LED

Low-range indicator light:

LED

Differential gear lock indicator light:

LED

Fuses:

Main fuse:

30.0 A

Headlight fuse:

15.0 A

Signaling system fuse:

10.0 A

Ignition fuse:

10.0 A

Auxiliary DC jack fuse:

10.0 A

Backup fuse:

10.0 A


Four-wheel-drive motor fuse:

3.0 A

10-5

10


EBU25981

CONSUMER INFORMATION

EBU26011

Identification numbers

Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen.

KEY IDENTIFICATION NUMBER:

EBU26020

Key identification number

The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key.

VEHICLE IDENTIFICATION NUMBER:

11

MODEL LABEL INFORMATION:

11-1

1. Key identification number

EBU26030

Vehicle identification number

The vehicle identification number is stamped into the frame.


1. Vehicle identification number (front left side)

NOTE:

The vehicle identification number is used to identify your ATV.

EBU26050

Model label

The model label is affixed at the location in the illustration. Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.

1. Model label

11-2

11

11


EBU26060

Noise regulation

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of 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

11-3


EBU26080

Maintenance record

Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

MAINTENANCE INTERVAL month

30

36

42

48

54

60

12

18

24

1

3

6

km (mi)

320 (200)

1300 (800)

2500 (1600)

5000 (3200)

7500 (4800)

10000 (6400)

12500 (8000)

15000 (9600)

17500 (11200)

20000 (12800)

22500 (14400)

25000 (16000)

hours

800

960

1120

1280

1440

1600

20

80

160

320

480

640

DATE OF

SERVICE

MILEAGE

SERVICING DEALER

NAME AND ADDRESS

REMARKS

11

11-4


11

EBU26501

YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY

Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha ATVs purchased from an authorized Yamaha ATV dealer in the continental

United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations.

THE PERIOD OF WARRANTY

for Yamaha ATVs shall be six (6) months from the date of purchase.

DURING THE PERIOD OF WARRANTY

include any failures caused by: a. Competition or racing use.

any authorized

Yamaha ATV dealer will, free of charge, repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory.

Parts used in warranty repairs will be warranted for the balance of the product’s warranty period. All parts replaced under warranty become property of Yamaha

Motor Corp. U.S.A.

GENERAL EXCLUSIONS

from this warranty shall b. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts.

c. Abnormal strain, neglect, or abuse.

d. Lack of proper maintenance.

e. Accident or collision damage.

f. Modification to original parts.

g. Damage due to improper transportation.

SPECIFIC EXCLUSIONS

from this warranty shall include parts replaced due to normal wear or routine maintenance, such as spark plugs, oil, oil filter, air filter, and brake shoes.

THE CUSTOMER’S RESPONSIBILITY

ranty shall be to:

under this war-

1. Operate and maintain the ATV as specified in the appropriate owner’s manual;

2. Give notice to an authorized Yamaha ATV dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer’s place of business.

WARRANTY TRANSFER:

To transfer the warranty from the original purchaser to any subsequent purchaser(s), it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha ATV dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. An inspection and registration fee will be charged for this service.

EMISSION CONTROL SYSTEM WARRANTY

Yamaha Motor Corporation, USA also warrants to the ultimate purchaser and each subsequent purchaser of each 2006 and later model Yamaha

ATV covered by this warranty that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the period listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty.

All Models

Thirty (30) months from the original purchase date

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO

OTHER WARRANTY OF ANY KIND, EXPRESSED OR

IMPLIED. ALL IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE WHICH EXCEED THE

OBLIGATIONS AND TIME LIMITS STATED

IN THIS WARRANTY ARE HEREBY DISCLAIMED

BY YAMAHA MOTOR CORPORATION, U.S.A. AND

EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON

HOW LONG AN IMPLIED WARRANTY LASTS, SO THE

ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO

EXCLUDED FROM THIS WARRANTY ARE ANY

INCIDENTAL OR CONSEQUENTIAL DAMAGES

INCLUDING LOSS OF USE. SOME STATES DO NOT

ALLOW THE EXCLUSION OR LIMITATION OF

INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO

THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL

RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS

WHICH VARY FROM STATE TO STATE.

YAMAHA MOTOR CORPORATION, U.S.A.

P.O. Box 6555

Cypress, California 90630

11-5


WARRANTY QUESTIONS AND ANSWERS

Q. What costs are my responsibility during the warranty period?

A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes.

Q. What are some examples of “abnormal” strain, neglect, or abuse?

A. These terms are general and overlap each other in areas. Specific examples include:

Running the machine out of oil, sustained high rpm, full-throttle, operating the machine with a broken or damaged part which causes another part to fail, damage or failure due to improper or careless transportation and or tie-down. If you have any specific questions on operation or maintenance, please contact your dealer for advice.

Q. Does the warranty cover incidental costs such as towing or transportation due to a failure?

A. No. The warranty is limited to repair of the machine itself.

Q. May I perform any or all of the recommended maintenance shown in the Owner’s

Manual instead of having the dealer do them?

A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owner’s and Service Manual. We do recommend, however, that items requiring special tools or equipment be done by a Yamaha ATV dealer.

Q. Will the warranty be void or cancelled if I do not operate or maintain my new ATV exactly as specified in the Owner’s Manual?

A. No. The warranty on a new ATV cannot be “voided” or “cancelled.”

However, if a particular failure is caused by operation or maintenance other than as described in the Owner’s Manual, that failure may not be covered under warranty.

Q. What responsibility does my dealer have under this warranty?

A. Each Yamaha ATV dealer is expected to:

1. Completely set up every new machine before sale.

2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request at any later date.

3. Each Yamaha ATV dealer is held responsible for his setup, service and warranty repair work.

Q. Is the warranty transferable to second owners?

A. Yes. The remainder of the existing warranty can be transferred upon request. The unit has to be inspected and re-registered by an authorized Yamaha ATV dealer for the policy to remain effective.

CUSTOMER SERVICE

If your machine requires warranty service, you must take it to any authorized

Yamaha ATV dealer within the continental United States. Be sure to bring your warranty registration card or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write:

YAMAHA MOTOR CORPORATION U.S.A.

CUSTOMER RELATIONS DEPARTMENT

P.O. Box 6555

Cypress, California 90630

When contacting Yamaha Motor Corporation, U.S.A. don’t forget to include any important information such as names, addresses, model, V.I.N. (frame number), dates, and receipts.

CHANGE OF ADDRESS

The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related defect and recall. This list is compiled from the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase.

If you should move after you have purchased your new ATV, please advise us of your new address by sending a postcard listing your ATV model name, V.I.N. (frame number), dealer number (or dealer’s name) as it is shown on your warranty card, your name and new mailing address. Mail to:

YAMAHA MOTOR CORPORATION, U.S.A.

P.O. Box 6555

Cypress, California 90630

Attention: Warranty Department

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

11

11-6


EBU26122

YAMAHA EXTENDED SERVICE (Y.E.S.)

11

Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Ser vice (Y.E.S.).

Y.E.S. is designed and administered by Yamaha Motor

Corporation to provide maximum owner satisfaction. You get uninterr upted factor y-backed coverage for extra peace of mind.

Y. E. S. is flexible. You choose the plan that’s right for you: 12 months, 24 months, or 36 months beyond your warranty period.

Y.E.S. is designed and administered by the same

Yamaha people who handle your warranty – and it shows in the comprehensive coverage benefits. There are no mileage limitations. Coverage isn’t limited to

“moving par ts” or the “drive train” like many other plans.

And Y.E.S. covers manufacturing defects just like the wa r ra n t y. S e e t h e s a m p l e c o n t ra c t a t yo u r Ya m a h a dealer to see how comfor ting uninterr upted factor ybacked protection can be.

You don’t have to pay anything for covered repairs.

T h e r e ’s n o d e d u c t i b l e t o p a y, a n d r e p a i r s a r e n ’ t

“pro-rated.” You don’t have any “out-of-pocket” expenses for covered repairs.

In addition, Travel and Recreation Interruption Protection

(TRIP) is included at no extra cost. TRIP gives you up to

$150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered ser vice: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb coverage goes into effect when you purchase Y.E.S., so it applies to any warranty repairs as well as covered repairs during your entire

Y.E.S. plan period.

Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide.

Y.E.S. coverage is transferable to a new owner if you sell or trade in your ATV. That can make your Yamaha much more valuable!

This excellent Y.E.S. plan coverage is only available to

Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha

Extended Service.

11-7


We urge you to act now. You’ll get the excellent benefits of

TRIP coverage r ight away, and you’ll rest easy knowing you’ll have strong factor y-backed protection even after your

Ya m a h a L i m i t e d Wa r ra n t y ex p i r e s. Yo u c a n a l s o s ave money: Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today!

A special note:

If visiting your dealer isn’t convenient, contact Yamaha with your Pr imar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.

Yamaha Service Marketing

P.O. Box 6555

Cypress, CA 90630

11-8

WARNING


11

11


EBU26132

11-9


INDEX

A

Accessories and loading ................................................ 6-6

Accessories, auxiliary jack ........................................... 4-23

Air filter element, cleaning ............................................ 8-30

Axle boots .................................................................... 8-43

B

Battery .......................................................................... 8-48

Brake fluid, changing ................................................... 8-40

Brake fluid level, checking ........................................... 8-39

Brake lever free play and brake pedal position (rear), adjusting and checking .............................................. 8-41

Brake lever free play, checking the front ...................... 8-41

Brake lever, front .......................................................... 4-13

Brake levers, checking and lubricating ........................ 8-45

Brake light switches ..................................................... 8-44

Brake pads, checking the front and rear ...................... 8-38

Brake pedal and rear brake lever ................................. 4-14

Brake pedal, checking and lubricating ......................... 8-46

C

Brakes, front and rear .................................................... 5-5

Cables, checking and lubricating ................................. 8-45

Carburetor, adjusting ................................................... 8-35

Carrier, front ................................................................. 4-21

Carrier, rear .................................................................. 4-22

Chassis fasteners .......................................................... 5-9

Cleaning ......................................................................... 9-1

Coolant .................................................................. 5-4, 8-26

Coolant temperature warning light ................................. 4-2

D

Differential gear lock indicator light ................................ 4-3

Differential gear oil ................................................ 5-4, 8-23

Drive select lever ......................................................... 4-14

Drive select lever and driving in reverse ........................ 6-3

Drive select lever safety system cable, adjusting ........ 8-38

E

Drive shaft universal joint, lubricating .......................... 8-46

F

Engine break-in .............................................................. 6-5

Engine, cold start ........................................................... 6-1

Engine idling speed ..................................................... 8-36

Engine oil ....................................................................... 5-4

Engine oil and oil filter cartridge ................................... 8-16

Engine, starting a warm ................................................. 6-3

Engine stop switch ......................................................... 4-6

Final gear oil ......................................................... 5-4, 8-21

Four-wheel-drive/differential gear lock indicator ............ 4-3

Fuel ....................................................................... 4-16, 5-4

Fuel cock ..................................................................... 4-17

Fuel gauge ..................................................................... 4-5

Fuel tank cap ............................................................... 4-16

H

Fuses, replacing .......................................................... 8-50

Handlebar switches ....................................................... 4-5

Headlight beam, adjusting ........................................... 8-54

Headlight bulb, replacing ............................................. 8-52

High-range indicator light ............................................... 4-3


I

Identification numbers .................................................. 11-1

Indicator lights and warning light .................................... 4-2

Instruments, lights and switches .................................... 5-9

K

Key identification number ............................................. 11-1

Knuckle pivots, lubricating ............................................ 8-47

L

Knuckle shafts, lubricating ........................................... 8-47

Label locations ............................................................... 2-1

Light switch .................................................................... 4-6

M

Low-range indicator light ................................................ 4-3

Main switch .................................................................... 4-1

Maintenance and lubrication chart ................................. 8-5

Maintenance chart, emission control system ................. 8-3

Maintenance record ..................................................... 11-4

Model label ................................................................... 11-2

Multifunction display ....................................................... 4-4

N

Neutral indicator light ..................................................... 4-2

O

Noise regulation ........................................................... 11-3

On-Command differential gear lock switch .................... 4-9

On-Command four-wheel-drive switch ........................... 4-7

Override switch .............................................................. 4-6

Owner’s manual and tool kit ........................................... 8-1

P

Panels, removing and installing ..................................... 8-9

Park indicator light .......................................................... 4-3

Parking ........................................................................... 6-6

Parking on a slope ......................................................... 6-6

Part locations ................................................................. 3-1

R

Pre-operation check list .................................................. 5-1

S

Recoil starter ................................................................ 4-15

Reverse indicator light .................................................... 4-2

Riding your ATV ............................................................. 7-1

Safety information .......................................................... 1-1

Seat .............................................................................. 4-19

Shock absorber assemblies, adjusting the front and rear ............................................................................ 4-22

Spark arrester, cleaning ............................................... 8-33

Spark plug, checking .................................................... 8-14

Specifications ............................................................... 10-1

Speed limiter ................................................................ 4-12

Stabilizer bushes, checking .......................................... 8-47

Starter (choke) ............................................................. 4-19

Start switch ..................................................................... 4-6

Steering shaft, lubricating ............................................. 8-48

Storage ........................................................................... 9-2

Storage compartment ................................................... 4-20

Suspension, lubricating the upper and lower arm pivots ......................................................................... 8-47

T

Tail/brake light bulb, replacing ..................................... 8-54

Throttle cable free play, adjusting ................................ 8-37

Throttle lever ......................................................... 4-11, 5-6

Tire pressure, measuring ............................................... 5-8

Tires ............................................................................... 5-7

Tire wear limit ................................................................. 5-9

Troubleshooting ........................................................... 8-58

Troubleshooting charts ................................................. 8-59


V

W

Valve clearance ........................................................... 8-37

V-belt case drain plug .................................................. 8-35

V-belt cooling duct check hose .................................... 8-34

Vehicle identification number ....................................... 11-1

Warranty, extended ...................................................... 11-7

Warranty, limited .......................................................... 11-5

Wheel bearings, checking ............................................ 8-46

Wheel, installing ........................................................... 8-56

Wheel, removing .......................................................... 8-56

EBU26151

WARNING

Improper ATV use can result in SEVERE INJURY or DEATH.

B

E E R

B

E E R

ALWAYS USE

AN APPROVED

HELMET AND

PROTECTIVE GEAR

NEVER USE

ON PUBLIC

ROADS

NEVER CARRY

PASSENGERS

NEVER USE

WITH DRUGS

OR ALCOHOL

NEVER

operate:

without proper training or instruction.

at speeds too fast for your skills or the

conditions.

on public roads-a collision can occur with

another vehicle.

with a passenger-passengers affect

balance and steering and increase risk

of losing control.

ALWAYS

:

use proper riding techniques to avoid

vehicle overturns on hills and rough

terrain and in turns.

avoid paved surfaces-pavement may

seriously affect handling and control.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

(For replacement manual, call 1-800-532-1558)

YAMAHA MOTOR CO., LTD.

PRINTED IN USA

2006.04-1.4

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