PERIODIC MAINTENANCE AND ADJUSTMENT. Yamaha KODIAK 700 YFM70KPXH, KODIAK 700 YFM70KPSH, KODIAK 700 YFM70KPAH, KODIAK 700 YFM70KPHH, KODIAK 700 YFM70KDXH

UB1661E0.book Page 1 Thursday, May 12, 2016 2:47 PM

EBU28788

EBU21675

PERIODIC MAINTENANCE AND ADJUSTMENT

Periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection, adjustment, and lubrication are explained on the following pages.

EWB01842

WARNING

Failure to properly maintain the vehicle or performing maintenance activities incorrectly may increase your risk of injury or death during service or while using the vehicle. If you are not familiar with vehicle service, have a Yamaha dealer perform the service.

EWB02563

WARNING

Turn off the engine when performing maintenance unless otherwise specified.



A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires.



Running the engine while servicing can lead to eye injury, burns, fire, or carbon monoxide poisoning - possibly leading to death. See

page 2-6 for more information about carbon

monoxide.

EWB02691

WARNING

Brake discs, calipers, drums, and linings can become very hot during use. To avoid possible burns, let brake components cool before touching them.

The intervals given in the periodic maintenance charts should be considered as a general guide under normal riding conditions. However, DE-

PENDING ON THE WEATHER, TERRAIN, GEO-

GRAPHICAL LOCATION, AND INDIVIDUAL USE,

THE MAINTENANCE INTERVALS MAY NEED TO

BE SHORTENED.

8

8-1


EBU29572

Owner’s manual and tool kit

Be sure to always keep the owner’s manual, the owner’s tool kit and the low-pressure tire gauge with the vehicle. Make sure to protect the owner’s manual by putting it in the plastic bag, then by placing the bag in the document pouch.

1

3

2

additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.

TIP

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

8

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,

8-2


EBU21745

Periodic maintenance chart for the emission control system

TIP



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 still be followed.



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

NO.

ITEM

CHECK OR MAINTENANCE

JOB

Whichever comes first month km (mi) hours

1

320

(200)

20

INITIAL

3

1300

(800)

80

EVERY

6

2500

(1600)

160

6

2500

(1600)

160

12

5000

(3200)

320

1

*

Fuel line

2 Spark plug

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

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

√ √

√

√

√

√

√

√

3

*

Valves

• Check valve clearance and adjust if necessary.

Every 2500 km (1600 mi) for the first

7500 km (4800 mi).

Every 5000 km (3200 mi) thereafter.

4

*

Crankcase breather system

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

√ √ √

8

8-3

8


5

NO.

*

ITEM

Exhaust system

6 Spark arrester

7

*

Air induction system


JOB


1

320

(200)

20

INITIAL

3

1300

(800)

80

EVERY

6

2500

(1600)

160

6

2500

(1600)

160

12

5000

(3200)

320

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

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

• Clean.

• Check the air cut-off valve, reed valve, and hose for damage.

• Replace any damaged parts if necessary.

√ √

√

√

√

√

√

√

√

√

√

8-4


EBU2186B

General maintenance and lubrication chart

TIP



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 still be followed.



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

NO.

ITEM


JOB


1

320

(200)

20

INITIAL

3

1300

(800)

80

EVERY

6

2500

(1600)

160

6

2500

(1600)

160

12

5000

(3200)

320

1 Air filter element

• Clean and replace if necessary.

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

2

*

Front brake

3

*

Rear brake

• Check operation and correct if necessary.

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

• Replace brake pads.


• Check brake lever and pedal free play, and adjust if necessary.

• Check brake friction plate wear and replace if necessary.

√

√

√

√ √

Whenever worn to the limit

√

√

√

√

√

√

√

√

√

8-5

8


8

NO.

ITEM


JOB


1

320

(200)

20

INITIAL

3

1300

(800)

80

EVERY

6

2500

(1600)

160

6

2500

(1600)

160

12

5000

(3200)

320

4

5

6

7

8

*

*

*

*

*

Brake hoses

Brake fluid

Wheels

Tires

Wheel hub bearings

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

• Replace.

• Change.

• 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.

9

10

*

*

V-belt

Chassis fasteners

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

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

11

*

Shock absorber assemblies


• Check for oil leakage and replace if necessary.

12

*

Stabilizer bushes


13

*

Rear knuckle pivots

• Lubricate with lithium-soap-based grease.

√

√

√

√

√

√

√

√

Every 4 years

Every 2 years

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

8-6


NO.

14

15

16

17

18

19

20

21

22

*

*

*

*

ITEM

Steering shaft

Steering system

Engine mount

Axle boots

Engine oil

Engine oil filter cartridge

Differential gear oil

Final gear oil

Cooling system


JOB


1

320

(200)

20

INITIAL

3

1300

(800)

80

EVERY

6

2500

(1600)

160

√

6

2500

(1600)

160

√

12

5000

(3200)

320

√

• Lubricate with lithium-soap-based grease.

• 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.

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

• Replace.

√ √ √

• Change.


• Change.


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

• Replace coolant.

8-7

√

√

√ √

√

√

Every 2 years

√

√

√

√

√

8


8

NO.

ITEM


JOB


1

320

(200)

20

INITIAL

3

1300

(800)

80

EVERY

6

2500

(1600)

160

6

2500

(1600)

160

12

5000

(3200)

320

23

*

Moving parts and cables

• Lubricate.

24

*

Throttle lever

• Check operation.

• Check throttle lever free play, and adjust if necessary.

• Lubricate cable and lever housing.

25

*

Front and rear brake switches


26

*

Lights and switches


• Adjust headlight beams.

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

EBU28392

TIP



Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle.



Hydraulic brake service

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

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

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

8-8


EBU23091

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.

3

1

4

2

1. Panel A

2. Panel B

3. Panel C

4. Panel D

5. Panel F

5

1

2

1. Panel E

2. Panel G

EBU34180

Panel A

To remove the panel

Pull upward on the areas shown.

8-9

8


1

Panel B

To remove the panel

1. Remove panel A.

2. Remove the front carrier by removing the bolts.

1

8

1. Panel A

To install the panel

Place the panel in the original position.

2

1. Front carrier

2. Carrier bolt (upper)

2

8-10


1

1

2

1

2

2

2

1. Carrier bolt (under the fenders)

2. Carrier bolt (lower)

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

1. Panel B

2. Quick fastener


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

8

8-11


Panel C

To remove the panel

1. Remove the seat. (See page 4-21.)

2. Remove panel A.

3. Remove the hoses from panel C.

8

2. Install the front carrier by installing the bolts and tightening them to the specified torques.

Tightening torques:

Carrier bolt (upper):

34 N·m (3.4 kgf·m, 25 lb·ft)

Carrier bolt (lower):

34 N·m (3.4 kgf·m, 25 lb·ft)

Carrier bolt (under the fenders):

7 N·m (0.7 kgf·m, 5.1 lb·ft)

3. Install panel A.

1 1

1. Hose

4. Remove the quick fasteners and bolts.

8-12


1

1

1

2

1. Bolt

2. Quick fastener

5. Remove the screws under the storage compartment lid, and then pull the panel upward to remove it.

TIP

To ease removal of panel C, shift the drive select lever into the reverse position.

1. Screw


1. Place the panel in the original position.

1

8

8-13


8

2. Install the screws, quick fasteners, bolts, and hoses.

TIP

Make sure that the hoses are properly connected and routed, and are not pinched.

3. Install panel A.

4. Install the seat.

Panels D and E

To remove a panel

1. Remove panels A and C.

2. Remove the bolt, and then pull the panel upward to remove it.

1. Panel D

2. Bolt

2

2

1

8-14

1. Panel E

2. Bolt

1


To install a panel

1. Place the panel in the original position, and then install the bolt.

Panels F and G

To remove a panel

1. Remove the panel bolts, footboard bolt, and footboard nut.

2. Install panels A and C.

8-15

1. Panel F

2. Footboard nut

3. Footboard bolt

4. Panel bolt

5. Projection

8


8

1. Panel G

2. Footboard nut

3. Footboard bolt

4. Panel bolt

5. Projection

2. Pull the panel downward while pushing the projection.

To install a panel

1. Place the panel in the original position.

8-16

2. Install the bolts and nut, and then tighten them to the specified torques.


Tightening torques:

Panel bolt:

4.0 N·m (0.40 kgf·m, 2.9 lb·ft)

Footboard nut:

4.0 N·m (0.40 kgf·m, 2.9 lb·ft)

EBU34190

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 panels A and C. (See page 8-9.)

2. Remove the storage compartment by removing the bolt.

1. Storage compartment

2. Bolt

3. Remove the spark plug cap.

1

1

2

8

8-17

1. Spark plug cap


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

1

1. Spark plug wrench

8

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 vehicle is ridden normally).

TIP

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 vehicle.

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

Specified spark plug:

NGK/CPR7EA-9

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

8-18


1. Spark plug gap

Spark plug gap:

0.8–0.9 mm (0.031–0.035 in)

To install the spark plug

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

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

Tightening torque:

Spark plug:

11 N·m (1.1 kgf·m, 8.0 lb·ft)

TIP

If a torque wrench is not available when installing the 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.

3. Install the spark plug cap.

4. Install the storage compartment as shown, and then install the bolt.

8

8-19

5. Install the panels.


EBU27469

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. Place the ATV on a level surface.

2. Check the engine oil level on a cold engine.

TIP

If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least 10 minutes until the oil settles for an accurate reading.

3. Remove the access cover by turning it counterclockwise.

1

1. Access cover

4. Remove the engine oil dipstick, and then wipe it off with a clean rag.

8-20

1. Engine oil dipstick


5. Insert the dipstick completely into the oil filler hole, and then remove it again to check the oil level.

TIP

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

7. Insert the dipstick completely into the oil filler hole.

8. Install the access cover by turning it clockwise.

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


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

3. Remove the access cover by turning it counterclockwise.

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

5. Remove the dipstick, and then remove the engine oil drain bolt and its gasket to drain the oil from the crankcase.

8

1. Maximum level mark

2. Minimum level mark

6. 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.

NOTICE:

Be sure the engine oil is at the correct level, otherwise engine damage may result.

[ECB00852]

8-21


2

1

2

1

1. Engine oil drain bolt

2. Gasket

8

TIP

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

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

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

1. Oil filter cartridge

2. Oil filter wrench

TIP

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.

8-22


1. O-ring

TIP

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.

1

1. Torque wrench

Tightening torque:

Oil filter cartridge:

15 N·m (1.5 kgf·m, 11 lb·ft)

10. Install panel F.

11. Install the engine oil drain bolt and its new gasket, and then tighten the bolt to the specified torque.

8

Tightening torque:

Engine oil drain bolt:

22 N·m (2.2 kgf·m, 16 lb·ft)

8-23


12. Refill with the specified amount of the recommended engine oil, and then insert the dipstick completely into the oil filler hole.

Recommended oil:

See page 10-1.

Oil quantity:

Without oil filter cartridge replacement:

2.00 L (2.11 US qt, 1.76 Imp.qt)

With oil filter cartridge replacement:

2.10 L (2.22 US qt, 1.85 Imp.qt)

8

TIP

Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down.

ECB00301

NOTICE



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.

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, wait at least ten minutes, and then check the oil level and correct it if necessary.

15. Install the access cover by turning it clockwise.

EBU27307

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


8-24


2. Remove the final gear oil level check bolt and its gasket, and then check the oil level in the final gear case. The oil level should be at the brim of the check hole.

1 2 3

2 1

4

1. Final gear oil

2. Gasket

3. Final gear oil level check bolt

4. Correct oil level

3. If the oil is below the brim of the check hole, remove the final gear oil filler bolt and its gasket, and then add sufficient oil of the recommended type to raise it to the correct level.

1. Final gear oil filler bolt

2. Gasket

4. Check the gaskets for damage, and replace them if necessary.

5. Install the oil level check bolt, the oil filler bolt and their gasket, and then tighten the bolts to the specified torques.

8

Tightening torques:

Final gear oil level check bolt:

10 N·m (1.0 kgf·m, 7.2 lb·ft)

Final gear oil filler bolt:

23 N·m (2.3 kgf·m, 17 lb·ft)

8-25


To change the final gear oil


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

3. Remove the final gear oil filler bolt, the final gear oil level check bolt, the final gear oil drain bolt and their gasket to drain the oil from the final gear case.

Tightening torque:

Final gear oil drain bolt:

23 N·m (2.3 kgf·m, 17 lb·ft)

5. Refill with the recommended final gear oil to the brim of the check hole as shown.

NOTICE:

Be sure no foreign material enters the final gear case.

[ECB00422]

1 2 3

4

8

2

1

1. Final gear oil drain bolt

2. Gasket

4. Install the drain bolt and its new gasket, and then tighten the bolt to the specified torque.

8-26

1. Final gear oil

2. Gasket

3. Final gear oil level check bolt


Recommended final gear oil:

See page 10-1.


6. Check the oil level check bolt gasket and the oil filler bolt gasket for damage, and replace them if necessary.

7. Install the oil level check bolt, the oil filler bolt and their gasket, and then tighten the bolts to the specified torques.

Tightening torques:

Final gear oil level check bolt:

10 N·m (1.0 kgf·m, 7.2 lb·ft)

Final gear oil filler bolt:

23 N·m (2.3 kgf·m, 17 lb·ft)

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

EBU23427

Differential gear oil

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.

To check the differential gear oil level


2. Remove the differential gear oil filler bolt and its gasket, and then check the oil level in the differential gear case. The oil level should be at the brim of the filler hole.

1 2

3

8-27

4

1. Differential gear oil filler bolt

2. Gasket

3. Differential 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. Check the gasket for damage, and replace it if necessary.

8

8


5. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.

Tightening torque:

Differential gear oil filler bolt:

23 N·m (2.3 kgf·m, 17 lb·ft)

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, the differential gear oil drain bolt and their gasket to drain the oil from the differential gear case.

4. Install the drain bolt and its new gasket, and then tighten the bolt to the specified torque.

Tightening torque:

Differential gear oil drain bolt:

9.8 N·m (0.98 kgf·m, 7.1 lb·ft)

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

NOTICE:

Be sure no foreign material enters the differential gear case.

[ECB00412]

1 2

3

4

1. Differential gear oil drain bolt

2. Gasket

2

1

8-28

1. Differential gear oil filler bolt

2. Gasket

3. Differential gear oil



Recommended differential gear oil:

See page 10-1.

6. Check the oil filler bolt gasket for damage, and replace it if necessary.

7. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.

Tightening torque:

Differential gear oil filler bolt:

23 N·m (2.3 kgf·m, 17 lb·ft)

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

EBU23471

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.

EBU34201

To check the coolant level

1. Park the ATV on a level surface.

TIP

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.

TIP

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

1. Maximum level mark


1

2

8

8-29


8

3. If the coolant is at or below the minimum level mark, remove panels A and C to access the

coolant reservoir. (See page 8-9.)

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

NOTICE:

If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since they are 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.

[ECB01012]

1

1. Coolant reservoir cap

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

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

TIP



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



If the engine overheats, see page 8-67 for fur-

ther instructions.

8-30


EBU34211

To change the coolant

EWB01891

WARNING

Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by hot fluid and steam blown out under pressure. Always place a thick rag over the cap when opening. Allow any remaining pressure to escape before completely removing the cap.

1. Park the ATV on a level surface.

2. Remove panels A, B, C, and D. (See page

8-9.)

3. Remove the footboard by removing the bolts and nuts.

2

1

3

1. Footboard

2. Bolt and nut

3. Bolt

4. Remove the radiator cap.

3

2

8

8-31


1 2

8

1. Radiator cap

5. Place a container under the engine, and then remove the coolant drain bolt and its gasket.

(Use a trough or a similar object as shown to prevent coolant from spilling on the engine guard.)

1. Coolant drain bolt

2. Gasket

1

8-32

1. Trough


6. Place a container under the coolant reservoir to collect the used coolant.

7. Remove the coolant reservoir cap.

8. Disconnect the coolant reservoir hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir.

Tightening torque:

Coolant drain bolt:

8 N·m (0.8 kgf·m, 5.8 lb·ft)

11. Connect the coolant reservoir hose.

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

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

NOTICE:

Mix antifreeze with distilled water only. However, if distilled water is not available, soft water may be used for refilling. Do not use hard water or salt water since they are harmful to the engine.

[ECB00992]

8

1. Coolant reservoir hose

9. After draining the coolant, thoroughly flush the cooling system with clean tap water.

10. Install the coolant drain bolt and its new gasket, and then tighten the bolt to the specified torque.

8-33


8

Antifreeze/water mixture ratio:

1:1

Recommended antifreeze:

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

Coolant quantity:

Radiator (including all routes):

1.76 L (1.86 US qt, 1.55 Imp.qt)

Coolant reservoir (up to the maximum level mark):

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

14. Loosen the water pump air bleed bolt, without removing it, to allow all of the air to escape from the air bleed bolt hole.

1

1. Water pump air bleed bolt

15. When coolant begins to flow out of the bolt hole, tighten the water pump air bleed bolt to the specified torque.

Tightening torque:

Water pump air bleed bolt:

8 N·m (0.8 kgf·m, 5.8 lb·ft)

16. Remove panel E. (See page 8-9.)

17. Loosen the cylinder head air bleed bolt, without removing it, to allow all of the air to escape from the air bleed bolt hole.

8-34


1

1. Cylinder head air bleed bolt

18. When coolant begins to flow out of the bolt hole, tighten the cylinder head air bleed bolt to the specified torque.

Tightening torque:

Cylinder head air bleed bolt:

10 N·m (1.0 kgf·m, 7.2 lb·ft)

19. Start the engine and let it idle for ten minutes.

20. Rev the engine five times.

21. Pour additional coolant into the radiator until it is full.

22. Stop the engine and allow it to cool. If the coolant level has dropped after the engine has cooled, add sufficient coolant until it reaches the top of the radiator, and then install the radiator cap.

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

TIP

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

24. Install the footboard by installing the bolts and nuts, and then tighten them to the specified torques.

8

8-35


4

3

2

1

1. Footboard nut

2. Footboard bolt A

3. Footboard bolt B

8

TIP

Tighten footboard bolts B in the order shown.

1

2 3

Tightening torques:

Footboard nut:

4.0 N·m (0.40 kgf·m, 2.9 lb·ft)

Footboard bolt A:

4.0 N·m (0.40 kgf·m, 2.9 lb·ft)

Footboard bolt B:

8 N·m (0.8 kgf·m, 5.8 lb·ft)

25. Install the panels.

1

8-36


EBU34230

Cleaning the air filter element

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

TIP

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.

2. Remove the seat. (See page 4-21.)

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

2

1

1

1

1. Air filter case cover holder

2. Air filter case cover

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

8

1. Air filter case check hose


8-37


1

1

3

2

8

1. Air filter element

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

1. Air filter element frame

2. Sponge material

3. Air filter element lock plate

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

WARNING! Always use parts cleaning solvent to clean the sponge material. Never use low-flash-point solvents or gasoline to clean the sponge material because the engine could catch fire or explode.

[EWB01942]

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

NOTICE:

Do not twist the sponge material when squeezing it.

[ECB00442]

8-38


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

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

TIP

The sponge material should be wet but not dripping.

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

11. 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.

NOTICE:

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

8-39

case. Never operate the engine with the air filter element removed. Doing so would allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage. Additionally, the fuel injection system would be affected resulting in poor engine performance and possible overheating.

[ECB00763]

12. Install the seat.

TIP

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 throttle body 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.

EBU28904

Cleaning the spark arrester

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

1. Remove the tailpipe bolts.

8


1

1

1

2

3

8

1. Tailpipe bolt

2. Remove the tailpipe by pulling it out of the muffler, and then remove the gasket.

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.

1. Gasket

2. Spark arrester

3. Tailpipe

4. Check the gasket for damage, and replace it if necessary.

5. Make sure the gasket is properly positioned, then insert the tailpipe into the muffler and align the bolt holes.

6. Install the bolts and tighten them to the specified torque.

Tightening torque:

Tailpipe bolt:

10 N·m (1.0 kgf·m, 7.2 lb·ft)

8-40


EWB02341

WARNING

Do not start the engine when cleaning the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poisoning, possibly leading to death, and start a fire.

Always let the exhaust system cool prior to touching exhaust components.

EBU23932

V-belt case drain plug

After riding in water deep enough to allow it to enter the V-belt case, remove the V-belt case drain plug to drain the water from the case.

TIP

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.

1

1. V-belt case drain plug

EBU29703

Adjusting the throttle lever free play

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

The throttle lever free play should measure 3.0–5.0

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

1. Slide the rubber cover back.

2. Loosen the locknut.

8

8-41


8

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

(b)

2 3

1

(a)

1. Rubber cover

2. Throttle lever free play adjusting bolt

3. Locknut

4. Throttle lever free play

2WD

4WD

4

4. Tighten the locknut.

5. Slide the rubber cover to its original position.

EBU24061

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

8-42 must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.

EBU29602

Brakes

Replacement of brake components requires professional knowledge. Brake service should be performed by a Yamaha dealer.

EWB02572

WARNING

Operating with improperly serviced or adjusted brakes could lead to a loss in braking ability and an accident.

EBU28414

Checking the front brake pads and rear brake friction plates

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


TIP

This ATV is equipped with a wet, multiple-disc type rear brake, which is located inside of the final gear case.

EBUM0191

Front brake pads

Each brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator groove. If a brake pad has worn to the point that the wear indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set.

1. Wear indicator groove

TIP

The wheels need to be removed to check the

brake pads. (See page 8-64.)

EBU30321

Rear brake friction plates

The rear brake friction plates must be checked and, if necessary, replaced by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.

8

8-43


8

EBU29843

Checking the brake fluid level

Before riding, check that the brake fluid is above the minimum level mark. Check the brake fluid level with the top of the reservoir level. Replenish the brake fluid if necessary.


1

Specified brake fluid:

DOT 4

2WD

4WD

EWB02721

WARNING

Improper maintenance can result in loss of braking ability. Observe these precautions:

8-44



Insufficient brake fluid may allow air to enter the brake system, reducing braking performance.



Clean the filler cap before removing. Use only DOT 4 brake fluid from a sealed container.



Use only the specified brake fluid; otherwise, the rubber seals may deteriorate, causing leakage.



Refill with the same type of brake fluid. Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction.



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.

ECB01161

NOTICE

Brake fluid may damage 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. A low brake fluid level may indicate worn brake pads and/or brake system leakage; therefore, be sure to check the

UB1661E0.book Page 45 Thursday, May 12, 2016 2:47 PM brake pads for wear and the brake system for leakage. If the brake fluid level goes down suddenly, have a Yamaha dealer check the cause before further riding.

EBU24283

Changing the brake fluid

Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrication chart. In addition, have the oil seals of the brake master cylinder 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.

EBU24395

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 no free play as shown. If there is free play, have a

Yamaha dealer check the brake system.

8-45

1. No brake lever free play

EBU34242

Adjusting the rear brake lever and brake pedal free play

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

Adjusting the brake lever free play

The brake lever free play should measure 6.0–7.0

mm (0.24–0.28 in) (YFM70KDXH, YFM70KPAH,

YFM70KPHH, YFM70KPXH). If the free play is incorrect, adjust it as follows.

8


1. Locknut

2. Brake lever free play adjusting bolt

1

8

1. Brake lever free play

1. Loosen the locknut at the brake lever.

1 2

(a)

(b)

2. To increase the brake lever free play, turn the brake lever free play adjusting bolt in direction

(a). To decrease the brake lever free play, turn the adjusting bolt in direction (b).

TIP

If the specified brake lever free play could be obtained as described above, skip steps 3–8.

3. Fully turn the adjusting bolt in direction (a) to loosen the brake cable.

4. Slide the rubber cover back.

(a)

1

2

3

(b)

8-46

1. Brake cable adjuster locknut

2. Brake lever free play adjusting nut

3. Rubber cover

5. Loosen the brake cable adjuster locknut.


6. To increase the brake lever free play, turn the brake lever free play adjusting nut in direction

(a). To decrease the brake lever free play, turn the adjusting nut in direction (b).

7. Tighten the brake cable adjuster locknut.

8. Slide the rubber cover to its original position.

9. Tighten the locknut at the brake lever.

Adjusting the brake pedal free play

The brake pedal free play should measure 12.0–

17.0 mm (0.47–0.67 in). If the free play is incorrect, adjust it as follows.

1

(b)

2

1

(a)

1. Brake pedal free play adjusting nut

2. Locknut

3. To increase the brake pedal free play, turn the brake pedal free play adjusting nut in direction (a). To decrease the brake pedal free play, turn the adjusting nut in direction (b).

4. Tighten the locknut.

5. Install the panel.

8

1. Brake pedal free play

1. Remove panel G.

2. Loosen the locknut.

8-47


EBU24231

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

1. Front axle boot (each side)

1

8-48

1

1. Rear axle boot (each side)

1

EBU34270

Brake light switches

The brake light, which is activated by the brake pedal and brake levers, should come on just before braking takes effect.

The rear brake light switch can be adjusted as follows, but the front brake light switch should be adjusted by a Yamaha dealer.

Turn the rear brake light switch 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).


1

(b)

2

(a)

1. Rear brake light switch adjusting nut

2. Rear brake light switch

EBU24905

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:

Yamaha cable lubricant or other suitable cable lubricant

EWB02582

WARNING



Inspect cables frequently and replace if damaged. 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.



Always make sure all control cables work smoothly before you begin riding in cold weather. If the control cables are frozen or do not work smoothly, you could be unable to control the ATV, which could lead to an accident or collision.

EBU28712

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.

8

8-49

8


Recommended lubricants:

Front brake lever:

Silicone grease

Rear brake lever:

Lithium-soap-based grease

Front brake lever

Rear brake lever

8-50

EBU28833

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.

TIP

To access the brake pedal pivot, remove panel G.

(See page 8-9.)




EBU24964

Checking the wheel hub bearings

The front and rear wheel hub 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 hub bearings.

EBU25023

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.

8

8-51


1 1

8

EBU25053

Lubricating the rear knuckle pivots

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

TIP

For parts equipped with a grease nipple, use a grease gun.



1. Grease nipple

EBU25094

Lubricating the steering shaft

The steering shaft must be lubricated by a

Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.

TIP

For parts equipped with a grease nipple, use a grease gun.



8-52


YFM70KDXH

YFM70KPXH / YFM70KPHH / YFM70KPSH /

YFM70KPAH

8-53

EBU2904D

Battery

The battery is located under panel A. (See page

8-9.)

This model is equipped with a VRLA (Valve Regulated Lead Acid) battery. There is no need to check the electrolyte or to add distilled water.

However, the battery lead connections need to be checked and, if necessary, tightened.

EWB02161

WARNING

Battery electrolyte is poisonous and dangerous, as it contains sulfuric acid, which can cause severe burns. Avoid contact with skin, eyes or clothing. Always shield your eyes when working near batteries.

Antidote:

EXTERNAL: Flush with water.

INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call a physician immediately.

EYES: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes or other sources of ignition away. Ventilate when charging or using in an enclosed space.

8


8

KEEP OUT OF REACH OF CHILDREN.

ECB00621

NOTICE

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

To remove the battery

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

2. Remove the front carrier by removing the bolts.

1

2

1. Front carrier

2. Carrier bolt (upper)

2

2

1

1

2

1. Carrier bolt (under the fenders)

2. Carrier bolt (lower)

3. Remove the battery holding plate by removing the nuts.

4. Disconnect the negative battery lead first, then the positive battery lead by removing their bolt.

NOTICE:

When removing the battery, the main switch must be off, and the negative lead must be disconnected before the positive lead.

[ECB01002]

8-54


1

4

2

3

1. Battery holding plate

2. Nut

3. Negative battery lead (black)

4. Positive battery lead (red)

5. Pull the battery out of its compartment.

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.

8-55

ECB00932

NOTICE

To charge a VRLA (Valve Regulated Lead Acid) battery, a special (constant-voltage) battery charger is required. Using a conventional battery charger will damage the battery.

To store the battery



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.



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

ECB00941

NOTICE

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

To install the battery

TIP

Be sure the battery is fully charged.

1. Place the battery in its compartment.

8


2. Connect the positive battery lead first, then connect the negative battery lead by installing their bolt.

NOTICE:

When installing the battery, the main switch must be off, and the positive lead must be connected before the negative lead.

[ECB01111]

1

Tightening torques:

Carrier bolt (upper):

34 N·m (3.4 kgf·m, 25 lb·ft)

Carrier bolt (lower):

34 N·m (3.4 kgf·m, 25 lb·ft)

Carrier bolt (under the fenders):

7 N·m (0.7 kgf·m, 5.1 lb·ft)

5. Install the panel.

8

2

1. Positive battery lead (red)

2. Negative battery lead (black)

3. Install the battery holding plate by installing the nuts.

4. Install the front carrier by installing the bolts and tightening them to the specified torques.

8-56


EBU30521

Replacing a fuse

1

2

3

4

5

1. Fuse box

2. Main fuse

3. EPS fuse (for EPS model)

4. Fuel injection system spare fuse

5. Fuel injection system fuse

3

4

1

2

5

6

8

7

8-57

1. Headlight fuse

2. Signaling system fuse

3. Radiator fan motor fuse

4. Ignition fuse

5. Four-wheel-drive motor fuse (YFM70KPSH)

6. Auxiliary DC jack fuse

7. Spare fuse

8. Spare fuse (YFM70KPXH / YFM70KPHH / YFM70KPSH /

YFM70KPAH)

The main fuse, the fuel injection system fuse, the

EPS fuse, and the fuse box are located under pan-

el A. (See page 8-9.)

If a fuse is blown, replace it as follows.

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

8

8


ECB00641

NOTICE

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.

WARNING! Always use a fuse of the specified rating, and never use a substitute object in place of the proper fuse. An improper fuse or a substitute object can cause damage to the electrical system, which could lead to a fire.

[EWB02173]

Specified fuses:

Main fuse:

40.0 A

Headlight fuse:

10.0 A (YFM70KDXH)

15.0 A (YFM70KPAH, YFM70KPHH,

YFM70KPSH, YFM70KPXH)

Ignition fuse:

10.0 A

Four-wheel-drive motor fuse:

10.0 A (YFM70KPSH)

Signaling system fuse:

10.0 A

Auxiliary DC jack fuse:

10.0 A

Radiator fan motor fuse:

20.0 A

Fuel injection system fuse:

15.0 A

EPS fuse:

40.0 A (YFM70KPAH, YFM70KPHH,

YFM70KPSH, YFM70KPXH)

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

8-58


4. If the fuse immediately blows again, have a

Yamaha dealer check the electrical system.

EBU34223

Replacing a headlight bulb

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

Left and right headlight bulbs

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

1

1

1. Bulb cover

3. Remove the socket by pushing it in and turning it counterclockwise.

8

1

1. Cover at the rear of the headlight

2. Remove the bulb cover by pulling it off.

8-59

1. Socket


4. Remove the burnt-out bulb.

5. Place a new bulb into position.

NOTICE:

Do not touch the glass part of the bulb. Oil from your fingers or other contamination will adversely affect the transparency of the glass, luminosity of the bulb, and bulb life. Thoroughly clean off any dirt and fingerprints using a cloth moistened with alcohol or thinner.

[ECB00653]

7. Install the bulb cover and the cover at the rear of the headlight.

NOTICE:

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

[ECB03320]

8. Adjust the headlight beam if necessary.

Handlebar-mounted light bulb (YFM70KPXH /

YFM70KPHH / YFM70KPSH / YFM70KPAH)

1. Remove the handlebar-mounted light cover by removing the quick fasteners.

1

8

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

6. Install the socket by pushing it in and turning it clockwise.

2

2

1. Handlebar-mounted light cover

2. Quick fastener

2. Remove the bulb cover by pulling it off.

8-60


1

1. Bulb cover

3. Remove the socket by pushing it in and turning it counterclockwise.

1

4. Remove the burnt-out bulb.

5. Place a new bulb into position.

NOTICE:

Do not touch the glass part of the bulb. Oil from your fingers or other contamination will adversely affect the transparency of the glass, luminosity of the bulb, and bulb life. Thoroughly clean off any dirt and fingerprints using a cloth moistened with alcohol or thinner.

[ECB00653]

1

8

1. Socket

8-61

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

6. Install the socket by pushing it in and turning it clockwise.

7. Install the bulb cover.

NOTICE:

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

[ECB03320]


8. Install the handlebar-mounted light cover as shown, and then install the quick fasteners.

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

1

8

1. Handlebar-mounted light cover

9. Adjust the handlebar-mounted light beam if necessary.

EBU25553

Adjusting a headlight beam

ECB00691

NOTICE

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

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

8-62

(b)

1. Headlight beam adjusting screw

1

(a)


YFM70KPXH / YFM70KPHH / YFM70KPSH /

YFM70KPAH

1

(b)

1

(a)

1. Handlebar-mounted light beam adjusting screw

EBU25614

Replacing the tail/brake light bulb

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

1. Remove the tail/brake light bulb holder (together with the bulb) by turning it counterclockwise.

1. Tail/brake light bulb holder

2. Remove the burnt-out bulb by pushing it in and turning it counterclockwise.

8

1

8-63

1. Tail/brake light bulb


8

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

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

EBU25652

Removing a wheel


2. Loosen the wheel nuts.

1

EBU36241

Installing a wheel

1. Install the wheel and the nuts.

TIP



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



For YFM70KDXH / YFM70KPXH /

YFM70KPHH / YFM70KPAH: tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel.

1

1

1. Wheel nut

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

4. Remove the nuts from the wheel.

5. Remove the wheel.

1. Arrow mark

8-64


1

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 N·m (5.5 kgf·m, 40 lb·ft)

Rear wheel nut:

55 N·m (5.5 kgf·m, 40 lb·ft)

8-65

EBU25741

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.

EWB02281

WARNING

Do not smoke when checking the fuel system.

Fuel can ignite or explode, causing severe injury or property damage. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces.

8


8

EBU27695

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 battery.

Supply fuel.

The engine does not start.

Check the battery.

2. Battery

Operate the electric starter.

3. Ignition

Remove the spark plug and check the electrodes.

The engine turns over quickly.

The engine turns over slowly.

Wet

The battery is good.

Check the battery lead connections, and have a Yamaha dealer charge the battery if necessary.

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


Check the ignition.


Dry

Have a Yamaha dealer check the ATV.


Check the compression.

4. Compression


There is compression.

There is no compression.




8-66


Engine overheating

EWB02291

WARNING

Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by hot fluid and steam blown out under pressure. Always put a thick rag over the cap when opening.

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.

There is leakage.

Have a Yamaha dealer check and repair the cooling system.

The coolant level is low.

Check the cooling system for leakage.

The coolant level is OK.

There is no leakage.

Add coolant. (See TIP.)

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

Yamaha dealer check and repair the cooling system.

8

TIP

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.

8-67

PERIODIC MAINTENANCE AND ADJUSTMENT. Yamaha KODIAK 700 YFM70KPXH, KODIAK 700 YFM70KPSH, KODIAK 700 YFM70KPAH, KODIAK 700 YFM70KPHH, KODIAK 700 YFM70KDXH

PERIODIC MAINTENANCE AND ADJUSTMENT

Owner’s manual and tool kit

Periodic maintenance chart for the emission control system

General maintenance and lubrication chart

Removing and installing panels

Checking the spark plug

Engine oil and oil filter cartridge

Final gear oil

Differential gear oil

Coolant

Cleaning the air filter element

Cleaning the spark arrester

V-belt case drain plug

Adjusting the throttle lever free play

Valve clearance

Brakes

Checking the front brake pads and rear brake friction plates

Checking the brake fluid level

Changing the brake fluid

Checking the front brake lever free play

Adjusting the rear brake lever and brake pedal free play

Axle boots

Brake light switches

Checking and lubricating the cables

Checking and lubricating the front and rear brake levers

Checking and lubricating the brake pedal

Checking the wheel hub bearings

Checking the stabilizer bushes

Lubricating the rear knuckle pivots

Lubricating the steering shaft

Battery

Replacing a fuse

Replacing a headlight bulb

Adjusting a headlight beam

Replacing the tail/brake light bulb

Removing a wheel

Installing a wheel

Troubleshooting

Troubleshooting charts

1. Fuel

2. Battery

3. Ignition

4. Compression

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