Yamaha BIG BEAR 4X4 YFM40FP Owner'S Manual Download Page 8 | Manualshive

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Crossing through shallow water.... 7-34
Riding over rough terrain............... 7-36
Sliding and skidding ...................... 7-38
What to do if ... .............................. 7-40
What to do ... ................................. 7-40

PERIODIC MAINTENANCE AND
ADJUSTMENT.................................. 8-1

Owner’s manual and tool kit............ 8-1
Periodic maintenance/

lubrication ...................................... 8-3

Engine oil......................................... 8-5
Final gear oil .................................... 8-9
Differential gear oil replacement ... 8-11
Front axle boots............................. 8-13
Spark plug inspection .................... 8-13
Air filter cleaning ............................ 8-14
Spark arrester cleaning ................. 8-17
Carburetor adjustment................... 8-18
Idle speed adjustment ................... 8-19
Valve clearance adjustment .......... 8-20
Throttle lever adjustment............... 8-20
Front brake pad inspection............ 8-21

Rear brake shoe inspection...........8-21
Brake fluid level inspection ............8-22
Brake fluid replacement .................8-23
Front brake adjustment..................8-24
Rear brake pedal and lever

adjustment ...................................8-25

Adjusting the rear brake light

switch ...........................................8-28

Clutch adjustment ..........................8-28
Cable inspection and lubrication....8-29
Brake and shift pedal/brake lever

lubrication.....................................8-30

Wheel removal ...............................8-30
Wheel installation...........................8-31
Battery............................................8-32
Battery maintenance......................8-33
Fuse replacement ..........................8-33
Replacing the headlight bulb .........8-35
Headlight beam adjustment...........8-37
Tail/brake light bulb replacement...8-37
Troubleshooting .............................8-39
Troubleshooting chart ....................8-40

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EE.book Page 3 Tuesday, April 24, 2001 9:31 AM

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Summary of Contents for BIG BEAR 4X4 YFM40FP

Page 1: ...READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 2: ...WARNING EBU00438 ...

Page 3: ...about special techniques and skills necessary to ride your ATV It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRU...

Page 4: ...Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures easier or cleare...

Page 5: ...l and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine EBU00531 AFFIX DEALER LABEL HERE YFM40FP C OWNER S MANUAL 2001 by Yamaha Motor Corporation U S A 1st Edition April 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation EE bo...

Page 6: ... Vehicle identification number 3 3 Model label 3 3 1 2 3 CONTROL FUNCTIONS 4 1 Main switch 4 1 Indicator lights 4 2 Oil temperature warning light checking method 4 3 Speedometer 4 4 Fuel gauge 4 4 Handlebar switches 4 5 Throttle lever 4 7 Speed limiter 4 8 Front brake lever 4 9 Rear brake pedal and lever 4 9 Parking brake 4 10 Shift pedal 4 11 Reverse knob 4 11 Recoil starter 4 12 Fuel tank cap 4 ...

Page 7: ...ow to measure tire pressure 5 11 Tire wear limit 5 12 OPERATION 6 1 Starting a cold engine 6 1 Starting a warm engine 6 3 Warming up 6 3 Reverse knob operation and reverse driving 6 4 Shifting 6 5 To start out and accelerate 6 5 To decelerate 6 6 Engine break in 6 7 Parking 6 8 Parking on a slope 6 9 Accessories and loading 6 10 RIDING YOUR ATV 7 1 Getting to know your ATV 7 3 Ride with care and g...

Page 8: ...rk arrester cleaning 8 17 Carburetor adjustment 8 18 Rear brake shoe inspection 8 21 Brake fluid level inspection 8 22 Brake fluid replacement 8 23 Front brake adjustment 8 24 Rear brake pedal and lever adjustment 8 25 Adjusting the rear brake light switch 8 28 Clutch adjustment 8 28 Cable inspection and lubrication 8 29 Brake and shift pedal brake lever lubrication 8 30 Wheel removal 8 30 Wheel i...

Page 9: ... 9 1 A Cleaning 9 1 B Storage 9 3 SPECIFICATIONS 10 1 NOISE REGULATION 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE Y E S 14 1 9 10 11 12 13 14 EE book Page 4 Tuesday April 24 2001 9 31 AM ...

Page 10: ...EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS EE book Page 1 Tuesday April 24 2001 9 31 AM ...

Page 11: ...machine They contain important information for safe and proper operation of your ATV Never remove any labels from your ATV If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 EE book Page 2 Tuesday April 24 2001 9 31 AM ...

Page 12: ...3 4 5 6 PULLING LOAD 4020 N 4 1 0 k g f 904 l b f TONGUE WEIGHT 147 N 1 5 k g f MAXIMUM LOADING LIMIT MAXIMUM LOADING LIMIT EE book Page 3 Tuesday April 24 2001 9 31 AM ...

Page 13: ...7 8 EE book Page 4 Tuesday April 24 2001 9 31 AM ...

Page 14: ...rocedures described Never operate an ATV without proper training or instruction Take a Training Course Be ginners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you Always follow the age recommendation A child under 16 years old should never operate an ATV with engine size greater than 90cc ...

Page 15: ...is proper for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footboards of the ATV du...

Page 16: ...p 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 back ward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follo...

Page 17: ... operating over obstacles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by prac ticing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate an ATV in fast flowing water or in water deepe...

Page 18: ...ated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Products Safety Com mission at 1 800 638 2772 or the ATV Distributor s Safety Hotline at 1 800 852 5344 EE book Page 5 Tuesday A...

Page 19: ...s of ignition such as the pi lot 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 posi tion Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoli...

Page 20: ... in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation EE book Page 7 Tuesday April 24 2001 9 31 AM ...

Page 21: ...light 7 Fuel cock 8 Recoil starter 9 Tail brake light 10 Rear wheel 11 Shift pedal 12 Front wheel 13 Rear brake lever 14 Parking brake lock plate 15 Starter choke 16 Speedometer 17 Reverse knob 18 Right handlebar switch 19 Front brake lever 20 Throttle lever 21 Fuel gauge 22 Main switch 23 Left handlebar switch NOTE EE book Page 1 Tuesday April 24 2001 9 31 AM ...

Page 22: ... from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION EBU00035 Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key 1 Key identification number EE book Page 2 Tuesday April 24 2001 9 31 AM...

Page 23: ...vehicle identification number is used to identify your machine EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label EE book Page 3 Tuesday April 24 2001 9 31 AM ...

Page 24: ...1 Main switch Functions of the respective switch positions are as follows ON Engine can be started only at this position and the headlight and taillight come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position EE book Page 1 Tuesday April 24 2001 9 31 AM ...

Page 25: ...ght comes on to warn that the en gine oil temperature is too hot If the warning light comes on during operation stop the en gine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes CAUTION The engine may overheat if the ATV is overloaded If this happens reduce the load to specification Restart after making sure that the warning light is out Continuous use while th...

Page 26: ...ck engine oil temperature Oil temperature warning light does not come on Engine oil temperature and electrical circuit are OK Go ahead with riding Push start switch with the transmission in neutral Ask a Yamaha dealer to inspect the electrical circuit Oil tempera ture is low Allow to cool Oil tempera ture is high Oil temperature warning light comes on momentarily EE book Page 3 Tuesday April 24 20...

Page 27: ...fore going to reserve This in formation will enable you to plan fuel stops in the future 1 Reset knob EBU00052 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 1 Fuel gauge NOTE If the machine runs out of fuel move the fuel cock lever to the RES position Approxi mately 4 0 L 0 9 Imp gal 1 1 US gal ...

Page 28: ...when this switch is pushed CAUTION _ See starting instructions prior to starting the engine See page 6 1 for details _ EBU00735 Light switch Turn the switch to the position to switch on the low beam and the taillight Turn the switch to the position to switch on the high beam and the taillight Turn the switch to the OFF position to switch off the headlight and the taillight CAUTION Do not use the h...

Page 29: ...4WD WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 2WD while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD in some circumstances Changing from 2WD to 4WD or from 4WD to 2WD while moving may cause the ATV to unexpectedly handle differ ently This could distract the operator and increase the risk of losing control and an accident HOW TO AVOID THE H...

Page 30: ...heck the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the le ver is released WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you...

Page 31: ... a 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an acci dent or be injured HOW TO AVOID THE HAZARD Do not turn the speed adjuster out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjusted to 3 5 mm 0 12...

Page 32: ...located on the right handlebar Pull it toward the handlebar to ap ply the front brake 1 Front brake lever EBU00073 Rear brake pedal and lever The brake pedal is located on the right side of 1 Rear brake pedal EE book Page 9 Tuesday April 24 2001 9 31 AM ...

Page 33: ...EN The ATV could start moving unexpect edly if the parking brake is not applied before starting the engine This could cause loss of control or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prema turely HOW TO AVOID THE HAZARD Always set the parking brak...

Page 34: ...ngine Reverse is at the bot tom position Neutral is one position above re verse 1 Shift pedal N Neutral R Reverse EBU00747 Reverse knob The reverse knob is used to shift into reverse gear Refer to the Reverse knob operation and re verse driving section page 6 4 before oper ating this machine in reverse gear 1 Reverse knob EE book Page 11 Tuesday April 24 2001 9 31 AM ...

Page 35: ...coil starter WARNING POTENTIAL HAZARD Starting the engine in gear and or start ing the engine without setting the park ing brake WHAT CAN HAPPEN The ATV could start to move unexpect edly which could cause an accident HOW TO AVOID THE HAZARD Put the transmission in neutral and set the parking brake before starting the en gine EE book Page 12 Tuesday April 24 2001 9 31 AM ...

Page 36: ...EBU00092 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap EE book Page 13 Tuesday April 24 2001 9 31 AM ...

Page 37: ...ition when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling return the fuel cock lever to the ON position EE book Page 14 Tuesday April 24 2001 ...

Page 38: ...el mixture A separate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See page 6 1 EE book Page 15 Tuesday April 24 2001 9 31 AM ...

Page 39: ... pull up the seat at the rear 1 Seat lock lever To install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE Make sure that the seat is securely fitted EE book Page 16 Tuesday April 24 2001 9 31 AM ...

Page 40: ...ply edged prod ucts directly in the storage box If they must be stored wrap them in appropriate cushion material EBU00582 Front carrier EBU00583 Rear carrier Maximum load limit 2 kg 4 4 lb Maximum load limit 40 kg 88 lb Maximum load limit 80 kg 176 lb EE book Page 17 Tuesday April 24 2001 9 31 AM ...

Page 41: ...turn the ad juster in direction b a Increase spring preload b Decrease spring preload Standard position B A Minimum Soft E Maximum Hard WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the ...

Page 42: ...tions Adjust the spring preload as follows To increase the spring preload turn the ad juster in direction a To decrease the spring preload turn the ad juster in direction b a Increase spring preload b Decrease spring preload Standard position B A Minimum Soft E Maximum Hard EE book Page 19 Tuesday April 24 2001 9 31 AM ...

Page 43: ...e main switch is in the ON position 1 Turn the headlight switch to the OFF position 2 Start the engine See pages 6 1 6 3 3 Open the auxiliary DC jack cap and insert the accessory power plug into the jack 4 When the auxiliary DC jack is not being used cover it with the cap 1 Auxiliary DC jack 2 Cap Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A EE book Page 20 Tuesday April 24 ...

Page 44: ... If accessories are used without the en gine running or with the headlight turned on the battery will lose its charge and engine starting may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged _ EBU00112 EE book Page 21 Tuesday April 24 2001 9 31 AM ...

Page 45: ... Fuel Check fuel level Fill with fuel if necessary 5 5 5 6 Engine oil Check oil level Fill with oil if necessary 5 7 8 5 8 8 Final gear oil Differential gear oil Check for leakage 5 8 8 9 8 12 Throttle Check for proper throttle cable operation 5 8 8 20 Wheels and tires Check tire pressure wear and damage 5 9 5 12 8 30 8 31 Fittings and Fasteners Check all fittings and fasteners 5 8 Lights Check fo...

Page 46: ...reases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op erating condition Always follow the inspection and main tenance procedures and schedules de scribed in the Owner s Manual EE book Page 2 Tuesday April 24 2001 9 31 AM ...

Page 47: ...d if neces sary See pages 8 22 8 23 Brake fluid leakage Check to see if any brake fluid is leaking out of the hose joint or master cylinder of the front brake Apply the brake firmly for one minute If the lever moves slowly inward there may be a leak in the brake system If there is any leak age the brake system should be inspected by a Yamaha dealer Brake operation Test the brakes at slow speed aft...

Page 48: ...ead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any problem with the brakes If a problem cannot be corrected by the ad justment procedures provided in this manual have the ATV inspected by a Yamaha dealer EE book Page 4 Tuesday April 24 2001 9 31 AM ...

Page 49: ... or research octane number of 91 or higher If Gasohol There are two types of gasohol gasohol con taining ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 Gaso hol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems 1 Fuel level 2 Filler tube Recommended fuel UNLEADE...

Page 50: ... fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and is still very hot EE book Page 6 Tuesday April 24 2001 9 31 AM ...

Page 51: ...nd or starter clutch slippage resulting in re duced component life and poor engine performance Recommended oil Recommended engine oil classification API Service SE SF SG type or higher 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or SAE 20W40 Oil quantity Periodic oil change 2 9 L 2 6 Imp qt 3 1 US qt With oil filter replacement 3 0 L ...

Page 52: ...rential gear oil is at the specified level Add oil as necessary See pages 8 11 8 12 for details EBU00151 Throttle lever Check to see that the throttle lever operates correctly It must open smoothly and spring back to idle position when released Repair as necessary for proper operation EBU00152 Fittings and Fasteners Always check the tightness of chassis fittings and fasteners before a ride Take th...

Page 53: ...L HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of acci dent HOW TO AVOID THE HAZARD 1 The tires listed below have been ap proved by Yamaha Motor Co Ltd for this model Other tire combinations are ...

Page 54: ...d could cause the tire to dis lodge from the rim under severe riding conditions The following are minimums Front 22 kPa 0 22 kgf cm2 3 2 psi Rear 22 kPa 0 22 kgf cm2 3 2 psi 4 Use no more than the following pres sures when seating the tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully ...

Page 55: ... the gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifications 1 Low pressure tire gauge Recommended pressure Minimum Maximum Front 25 kPa 0 25 kgf cm2 3 6 psi 22 kPa 0 22 kgf cm2 3 2 psi 28 kPa 0 28 kgf cm2 4 0 psi Rear 25 kPa 0 25 kgf cm2 3 6 psi 22 kPa 0 22 kgf cm2 3 2 psi 28 kPa 0 28 kgf cm2 4 0 psi EE book Page 11 Tuesd...

Page 56: ...EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a 3 mm 0 12 in EE book Page 12 Tuesday April 24 2001 9 31 AM ...

Page 57: ...iliar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or colli sion H...

Page 58: ... _ 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient tem perature below 5 C 40 F Position 2 Cold engine start ambient tem perature at 0 C 30 F 30 C 90 F and warming up position Position 3 Cold engine start ambient tem perature above 25 C 80 F and warm engine start position a Starter choke lever 1 Fully open 2 Half open 3 Closed 6 Completely close the throttle ...

Page 59: ...ter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter CAUTION _ See the Engine break in section prior to operating the engine for the first time _ EBU00180 Starting a warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not be used The t...

Page 60: ... down on the shift pedal NOTE When in reverse the reverse indicator light should be on If the light does not come on ask a Yamaha dealer to inspect the machine 4 Check behind you for people or obsta cles then release the rear brake lever 5 Open the throttle lever gradually and con tinue to watch to the rear while backing WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You ...

Page 61: ...e shift pedal until it stops CAUTION Do not coast for long periods with the en gine off and do not tow the machine a long distance Even with gears in neutral the transmission is only properly lubricat ed when the engine is running Inadequate lubrication may damage the transmission EBU00205 To start out and accelerate 1 Release the throttle lever CAUTION Always close the throttle while shifting gea...

Page 62: ... can cause the tires to lose traction reducing control and in creasing the possibility of an accident WARNING POTENTIAL HAZARD Opening the throttle before releasing the shift pedal WHAT CAN HAPPEN The machine could wheelie This would increase the chance of an accident in cluding overturn HOW TO AVOID THE HAZARD Release the shift pedal before opening the throttle Open the throttle gradually WARNING...

Page 63: ...ich might result in ex cessive engine heating must be avoided However momentary 2 3 seconds maxi mum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest pe riod for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this ...

Page 64: ...ut do not use full throttle at any time 3 After break in Avoid prolonged full throttle operation Vary speeds occasionally EBU00211 Parking When parking stop the engine and shift into neutral Turn the fuel cock to OFF and apply the parking brake 1 Lock plate EE book Page 8 Tuesday April 24 2001 9 31 AM ...

Page 65: ...n a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control in creasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline put the machine in low gear apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk u...

Page 66: ...e a genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object at...

Page 67: ...ng a trail er include the tongue weight in the maxi mum vehicle load limit Load cargo on the carrier as close to the center of the vehicle as possible Put cargo at the front of the rear carrier Center the load from side to side Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an acci dent Make sure the load does not interfere with ...

Page 68: ...oid hills and rough terrain Choose ter rain carefully Added weight affects the sta bility and handling of the ATV WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed...

Page 69: ...EE book Page 13 Tuesday April 24 2001 9 31 AM ...

Page 70: ...EBU00888 WARNING _ Indicates a potential hazard that could result in serious injury or death EE book Page 14 Tuesday April 24 2001 9 31 AM ...

Page 71: ...7 1 Riding Your ATV EE book Page 1 Tuesday April 24 2001 9 31 AM ...

Page 72: ...EE book Page 2 Tuesday April 24 2001 9 31 AM ...

Page 73: ...ypes of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic tech niques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure ride be sure you have read this Owner s Man ual completely and understand the operation of the controls Pay partic...

Page 74: ...arn the basic techniques well before attempting more difficult maneu vers WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in creased if the operator does not know how to operate the ATV properly in dif HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yama...

Page 75: ...commenda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc EE book Page 5 Tuesday April 24 2001 9 31 AM ...

Page 76: ...PPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers EE book Page 6 Tuesday April 24 2001 9 31 AM ...

Page 77: ...ent Operating without eye protection can re sult 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 HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots...

Page 78: ...AZARD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV EE book Page 8 Tuesday April 24 2001 9 31 AM ...

Page 79: ...n Always follow the in spection and maintenance procedures and schedules described in the Owner s WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pres sure WHAT CAN HAPPEN Use of improper tires on this ATV or op eration of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of an acci dent HOW TO AVOID THE H...

Page 80: ...o the maxi mum Screwing in the adjuster limits the max imum engine power available and decreases the maximum speed of the ATV Turning the screw in decreases top speed and turning it out increases top speed WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing con trol of the ATV which can result in an accid...

Page 81: ...t of trailer and cargo 410 kgf 904 lbf Tongue weight vertical weight on trailer hitch point 15 kgf 33 lbf WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and sec...

Page 82: ...g even one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operation...

Page 83: ...ING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off EE book Page 13 Tuesday April 24 2001 9 31 AM ...

Page 84: ...handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions If EE book Page 14 Tuesday April 24 2001 9 31 AM ...

Page 85: ...AZARD Hot exhaust system WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the en gine area could catch fire Someone touching the exhaust system during or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material EE bo...

Page 86: ...ng this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of con trol HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets EE book Page 16 Tuesday April 24 2001 9 31 AM ...

Page 87: ...Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways EE book Page 17 Tuesday April 24 2001 9 31 AM ...

Page 88: ...ilure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturn ing or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when op erating on unfamiliar terrain Always be alert to changing terrain conditions EE book Page 18 Tuesday April 24 2001 ...

Page 89: ... or vehicle control which could result in an acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills neces sary to control the ATV on such terrain Always be especially cautious on these kinds of terrain EE book Page 19 Tuesday April 24 2001 9 31 AM ...

Page 90: ...eas posted no trespassing Do not ride on private property without getting permission WARNING POTENTIAL HAZARD Operating in areas where you might not WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch care fully for other vehicles EE book Page 20 Tuesday April 24 2001 9 31 AM ...

Page 91: ... skin or clothing to come in contact with these With the engine idling lift the shift pedal to the 1st gear position and then release the parking brake Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate Once the ATV has at tained adequate speed release the throttle and lift the shift pedal to the 2nd gear position Release the shift pedal and ...

Page 92: ...mprop er use of the brakes or shifting can cause the tires to lose traction reducing control and in creasing the possibility of an accident WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating This could cause loss of control an accident and injury It could also cause engine or drive train damage HOW TO AVOID THE HAZARD Mak...

Page 93: ...s you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneu ver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of ...

Page 94: ...ds 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 in side It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoi...

Page 95: ...portant when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by lean ing forward and on steeper inclines standing on the footboards and leaning forward over the handlebars WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or smal...

Page 96: ... in this Own er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV could flip over backwards An obstacle a sharp drop or another vehicle or person could be on the other side of the hill EE book Page 26 Tuesday April 24 ...

Page 97: ...ills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose s...

Page 98: ... brake or the rear will brake all wheels When descending hills us ing 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 WARNING POTENTIAL HAZARD Stalling rolling backwards or improper ly dismounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW...

Page 99: ...Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the pro cedure described in the Owner s Manu al EE book Page 29 Tuesday April 24 2001 9 31 AM ...

Page 100: ...d by these surfaces Improper braking may also cause a loss of traction When this ATV is in 4WD 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 le ver or the brake pedal will brake the wheels on the downhill side Avoid sudden applica tion of either the fro...

Page 101: ...or go ing down hills as described in this Own er s Manual Note a special technique is required when braking as you go down a hill Always check the terrain carefully be fore you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply EE book Page 31 Tuesday April 24 2001 9 31 AM ...

Page 102: ...ing the front wheels slightly up hill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HA...

Page 103: ...f a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV EE book Page 33 Tuesday April 24 2001 9 31 AM ...

Page 104: ...ATV Drive slowly and carefully WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing Remember that wet brakes may have re duced stopping ability Test your brakes after leaving water If necessary apply th...

Page 105: ...ed proper braking ability CAUTION _ After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case Wash the ATV in fresh water if it has been operated in salt water or muddy con ditions _ 1 Check hose EE book Page 35 Tuesday April 24 2001 9 31 AM ...

Page 106: ...trol and damage to the ATV may result WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a colli sion Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always fol low proper proce...

Page 107: ...EE book Page 37 Tuesday April 24 2001 9 31 AM ...

Page 108: ... wheels to slide in loose or slippery conditions position ing your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways control can usually be regained if there is room to do so by steering in the direc tion of the slide Applying the brakes or accel erating is not recommended until you have corrected the slide EE book Page 38 Tuesday April 24 2001...

Page 109: ...control may be lost WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or slid ing by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautiou...

Page 110: ...c essary gradually let off the throttle and or steer to the outside of the turn See pages 7 23 7 24 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide See pages 7 38 7 39 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still hav...

Page 111: ... cover that the ATV is going to tip over dis mount on the uphill side See pages 7 32 7 33 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERA TION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability S...

Page 112: ...and tool kit You are recommended to put this owner s manual in the vinyl bag and always carry it un der the seat as shown Put the owner s tool kit and low pressure tire gauge in the storage box WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires...

Page 113: ...eration requiring one take your machine to a Yamaha dealer to check WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of access...

Page 114: ...djust if necessary Cylinderhead cover breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check leakage Retighten if necessary Replace gasket if necessary Spark arrester Clean Fuel line Check fuel hose for cracks or damage Replace if necessary Engine oil Replace Warm engine before draining Engine oil filter Replace Engine oil strainer Clean Final gear oil C...

Page 115: ...icates a potential hazard that could Clutch Check operation Adjust if necessary Reverse release cable Check operation Adjust if necessary Wheels Check balance damage run out Repair if necessary Wheel bearings Check bearing assembly for looseness damage Replace if damaged Steering system Check operation Replace if damaged Check toe in Adjust if necessary Drive shaft universal joint Lubricate Front ...

Page 116: ...pe it off with a clean rag Insert the dipstick in the filler hole without screwing it in 1 Dipstick 4 Remove the dipstick and then check the oil level 5 The oil level should be between the max imum and minimum marks If the level is low add oil to raise it to the proper level CAUTION _ Be sure no foreign material enters the crankcase _ EE book Page 5 Tuesday April 24 2001 9 31 AM ...

Page 117: ...e the dipstick and then remove the drain bolt to drain the oil CAUTION _ When removing the drain bolt the com pression spring oil strainer and O ring will fall out Take care not to lose these parts _ 1 Drain bolt 2 O ring 3 Compression spring 4 Oil strainer 5 Remove the oil filter cover by removing the bolts and then remove the oil filter element EE book Page 6 Tuesday April 24 2001 9 31 AM ...

Page 118: ... torque CAUTION _ Before installing the drain bolt be sure to install the O ring compression spring and oil strainer _ 11 Fill the engine with oil and then install the dipstick CAUTION _ Tightening torque Drain bolt engine 32 Nm 3 2 m kgf 23 ft lb Filter cover bolt 10 Nm 1 0 m kgf 7 2 ft lb Recommended oil See page 5 7 Oil quantity Periodic oil change 2 9 L 2 6 lmp qt 3 1 US qt With oil filter rep...

Page 119: ... head 3 Start the engine and keep it idling until oil begins to seep from the oil gallery If no oil comes out after one minute turn the engine off so it will not seize and find the cause 4 Start the engine and then check the oil pressure 5 After checking tighten the oil gallery bolt 1 Oil gallery bolt 2 Cloth CAUTION _ Be sure to check the oil pressure after re placing the engine oil _ Tightening ...

Page 120: ...ow add oil to raise it to the proper level CAUTION _ Be sure no foreign material enters the final gear case _ 3 Install the oil filler bolt and tighten it to the specified torque 1 Final gear oil 2 Correct oil level 3 Oil filler bolt Final gear oil replacement 1 Remove the final gear case cover Tightening torque Oil filler bolt 23 Nm 2 3 m kgf 17 ft lb EE book Page 9 Tuesday April 24 2001 9 31 AM ...

Page 121: ... torque 6 Fill the final gear case with oil CAUTION _ Be sure no foreign material enters the final gear case _ 7 Install the filler bolt and tighten to the specified torque Tightening torque Recommended oil See page 10 2 Oil quantity Periodic oil change 0 23 L 0 20 Imp qt 0 24 US qt Total amount 0 25 L 0 22 Imp qt 0 26 US qt Tightening torque Filler bolt final gear case 23 Nm 2 3 m kgf 17 ft lb EE...

Page 122: ...tial gear case 3 Remove the filler bolt and drain bolt to drain the oil 1 Filler bolt 1 Drain bolt 4 Install the drain bolt and tighten to speci fication 5 Fill the differential gear case with oil Tightening torque Drain bolt differential gear case 12 Nm 1 2 m kgf 8 7 ft lb EE book Page 11 Tuesday April 24 2001 9 31 AM ...

Page 123: ...tion 7 Check for oil leakage If oil leakage is Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity Periodic oil change 0 35 L 0 31 Imp qt 0 37 US qt Total amount 0 4 L 0 35 Imp qt 0 42 US qt Tightening torque Filler bolt differential gear case 12 Nm 1 2 m kgf 8 7 ft lb EE book Page 12 Tuesday April 24 2001 9 31 AM ...

Page 124: ... very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder Do not attempt to diagnose such problems yourself Instead take the machine to a Yamaha deal er You should periodically remove and in spect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive you ...

Page 125: ...m the threads and tight en to the specified torque EBU00851 Air filter cleaning NOTE _ There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case _ 1 Check hose 1 Remove the seat Refer to page 4 16 for seat removal and installation proce Spark plug gap 0 6 0 7 mm 0 024 0 028 in EE book Page 1...

Page 126: ...1 Air filter case cover 3 Pull out the air filter element 4 Separate the foam cover from the air filter element 1 Air filter element 2 Foam cover EE book Page 15 Tuesday April 24 2001 9 31 AM ...

Page 127: ...of the foam cover and let it dry CAUTION _ Do not twist the foam cover when squeezing it Do not add oil to the foam cover _ 8 Inspect the foam cover If damaged re place it WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the foam cover WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to cl...

Page 128: ...er operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally op eration without the filter element will affect carburetor jetting with subsequent poor EBU00754 Spark arrester cleaning Select a well ventilated area free of combusti ble materials and make sure the exhaust pipe and muffler are cool ...

Page 129: ...eone without sufficient technical knowledge poor engine perfor mance and damage may result WARNING POTENTIAL HAZARD Improperly purging the exhaust system Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poison ing possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system ...

Page 130: ...ly rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Connect the tachometer and set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in to increase engine speed and out to de crease engine speed 1 Throttle stop screw Specified idle speed 1 450 1 550 r min EE book Page 19 Tuesday April 24 2001 9 31 AM ...

Page 131: ...his adjust ment however should be left to a professional Yamaha service technician EBU00307 Throttle lever adjustment NOTE Adjust the engine idling speed before adjust ing the throttle lever free play 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle le ver free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut 1 Locknut 2 Adjusting bolt EE book Page 20 Tuesday April 24 2001 9 31 A...

Page 132: ...limit 1mm 0 04 in EBU00313 Rear brake shoe inspection A wear indicator is provided on the rear brake This indicator allows checking of brake shoe wear without disassembling the brake Apply the rear brake and check the position of the indicator If the indicator reaches the wear limit line ask a Yamaha dealer to replace shoes as a set 1 Wear indicator 2 Wear limit EE book Page 21 Tuesday April 24 20...

Page 133: ...ning the handlebars 2 Use only the designated quality brake flu id Otherwise the rubber seals may dete riorate causing leakage and poor brake performance 1 Minimum level mark LOWER 3 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance 4 Be careful that water does not enter the master cylinder when refilling Water will ...

Page 134: ... goes down EBU00752 Brake fluid replacement 1 Complete fluid replacement should be done only by trained Yamaha service personnel 2 Have a Yamaha dealer replace the fol lowing components during periodic main tenance or when they are damaged or leaking Replace all rubber seals every two years Replace all hoses every four years EE book Page 23 Tuesday April 24 2001 9 31 AM ...

Page 135: ...usted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is cor rect Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re quires professional knowledge These EE book Page...

Page 136: ...justment a Fully loosen the adjusting nut on the brake cable 1 Adjusting nut brake cable 2 Adjusting nut brake rod b Turn the adjusting nut on the brake rod until free play is 20 30 mm 0 8 1 18 in a Free play 20 30 mm 0 8 1 18 in EE book Page 25 Tuesday April 24 2001 9 31 AM ...

Page 137: ... in the adjusting bolt at the brake lever 1 Locknut 2 Adjusting bolt b Screw in the adjusting nut on brake cable to provide a gap of 0 1 mm 0 0 04 in between the lever and the pin 1 Adjusting nut brake cable a 0 1 mm 0 0 04 in EE book Page 26 Tuesday April 24 2001 9 31 AM ...

Page 138: ...y serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is cor rect Make sure the brakes do not drag Replacement of brake components re quires professional knowledge These procedures should be performed by a Yamaha dealer EE book Page 27 Tuesday ...

Page 139: ...ollows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EBU00346 Clutch adjustment 1 Loosen the locknut 2 Slowly turn the adjusting bolt counter clockwise until resistance is felt Then turn it 1 8 turn clockwise 1 Locknut...

Page 140: ...ng torque 15 Nm 1 5 m kgf 11 ft lb WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables EE book Page 29 Tuesday Ap...

Page 141: ...cate the pivoting parts of each lever and pedal EBU00373 Wheel removal 1 Elevate the wheel by placing a suitable stand under the frame 2 Remove the nuts from the wheel 3 Remove the wheel assembly Recommended lubricant Yamaha chain and cable lube or SAE 10W30 motor oil Recommended lubricant Lithium soap based grease all purpose grease EE book Page 30 Tuesday April 24 2001 9 31 AM ...

Page 142: ...ing direction of the wheel _ 1 Arrow mark 1 Tapered wheel nuts are used for both front and rear wheels Install the nut with its tapered side towards the wheel 1 Tapered nut 2 Tighten the wheel nuts to the specified torque Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lb Rear 55 Nm 5 5 m kgf 40 ft lb EE book Page 31 Tuesday April 24 2001 9 31 AM ...

Page 143: ...uld be poisoned You could be severely burned by the sulfuric acid in HOW TO AVOID THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention EYES Flush with ...

Page 144: ...attery life 2 Always make sure the connections are correct when putting the battery back in the machine EBU00853 Fuse replacement 1 The main fuse case and the fuse box are located under the seat 2 If a fuse is blown turn off the main switch and install a new fuse of the specified amperage Then turn on the switches If the fuse immediately blows again con sult a Yamaha dealer Specified fuses Main fu...

Page 145: ...ng or replacing a fuse _ WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rat ing Never use a material in place of the proper fuse EE book Page 34 Tuesday April 24 2001 9 31 AM ...

Page 146: ...he headlight assembly by re moving the screws 2 Disconnect the coupler 3 Remove the light unit assembly from the headlight assembly by removing the screw 4 Remove the bulb holder cover 5 Turn the bulb holder counterclockwise and remove the defective bulb 1 Screw 3 EE book Page 35 Tuesday April 24 2001 9 31 AM ...

Page 147: ...e headlight assembly and con nect the coupler 9 Adjust the headlight beam See page 8 37 WARNING POTENTIAL HAZARD The headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flamma ble HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it EE book Page 36 Tuesday April ...

Page 148: ...n the adjusting screw clockwise To lower the beam turn the screw coun terclockwise EBU00945 Tail brake light bulb replacement 1 Open the storage box See page 4 17 2 Remove the nuts together with washers 1 Storage box 2 Nut 2 3 Remove the bulb holder together with the bulb by turning it counterclockwise EE book Page 37 Tuesday April 24 2001 9 31 AM ...

Page 149: ...d and turning it counterclockwise 1 Bulb holder 2 Bulb 5 Install a new bulb in the bulb holder by pushing it inward and turning it clockwise 6 Install the bulb holder together with the bulb 7 Install the washers and then install the nuts EE book Page 38 Tuesday April 24 2001 9 31 AM ...

Page 150: ...erience and know how to properly service your machine Use only genuine Yamaha parts on your machine Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to ex pensive repair bills WARNING POTENTIAL HAZARD Checking the fuel system while smok ing or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing se ve...

Page 151: ...e if there is compression There is compression No compression 3 Ignition Remove the plug and check the electrodes Wet Wipe clean with dry cloth Dry Attach plug cap and ground to chassis Use the electric starter Spark good Ignition system normal Spark weak Adjust plug gap or replace plug No spark 4 Battery Engine turns over quickly Battery good Check fuel flow Turn the fuel cock to ON Compression n...

Page 152: ...les 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car wash ers 4 Once the ma...

Page 153: ...ch may mar the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out th...

Page 154: ...ark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine over sever al times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 6 If sto...

Page 155: ...a dry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the machine EE book Page 4 Tuesday April 24 2001 9 31 AM ...

Page 156: ...m 33 7 in 1 230 mm 48 4 in 245 mm 9 65 in 3 150 mm 124 0 in Basic weight With oil and full fuel tank 266 kg 586 lb Engine Engine type Cylinder arrangement Displacement Bore Stroke Compression ratio Starting system Lubrication system Air cooled 4 stroke SOHC Single cylinder Forward inclined 386 cm3 83 0 71 5 mm 3 27 2 82 in 8 6 1 Electric starter and recoil starter Wet sump EE book Page 1 Tuesday A...

Page 157: ...tal amount SAE 80 API GL 4 Hypoid gear oil 0 23 L 0 20 lmp qt 0 24 US qt 0 25 L 0 22 lmp qt 0 26 US qt Differential gear oil Type Quantity Periodic oil change Total amount SAE 80 API GL 4 Hypoid gear oil 0 35 L 0 31 Imp qt 0 37 US qt 0 40 L 0 35 Imp qt 0 42 US qt Air filter Dry type element Fuel Type Tank capacity Reserve amount UNLEADED GASOLINE 15 L 3 3 Imp gal 4 0 US gal 4 0 L 0 9 Imp gal 1 1 U...

Page 158: ...tio Transmission type Operation Gear raito 1st 2nd 3rd 4th 5th Reverse gear Spur gear 76 24 3 166 Shaft drive 28 24 24 18 33 09 5 703 Constant mesh 5 speed forward 1 speed reverse Left foot operation 40 12 3 333 34 18 1 888 30 22 1 363 25 26 0 961 19 27 0 703 22 17 35 15 3 019 Chassis Frame type Caster angle Trail Steel tube 4 21 mm 0 83 in Tire Type Tubeless MODEL YFM40F EE book Page 3 Tuesday Ap...

Page 159: ...ont Rear Coil spring oil damper Coil spring oil damper Wheel travel Front wheel travel Rear wheel travel 150 mm 5 91 in 150 mm 5 91 in Electrical Ignition system Generator system Battery type voltage capacity C D I DC A C magneto YTX20L BS 12V 18AH Headlight type Krypton bulb Bulb voltage wattage quantity Headlight Tail brake light 12V 30W 30W 2 12V 5W 21W 1 MODEL YFM40F EE book Page 4 Tuesday Apr...

Page 160: ...pose 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 Mu...

Page 161: ... with the warranty The chart below is printed only as a re minder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS 1 Month 3 Months 6 Months 12 Months 18 Months 24 Months 30 Months 36 Months 42 Months 48 Months 54 Months EE book Page 1 Tuesday April 24 2001 9 31 AM ...

Page 162: ...EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY EE book Page 1 Tuesday April 24 2001 9 31 AM ...

Page 163: ...1 2 3 4 5 6 7 8 9 10 9 9 13 14 EE book Page 2 Tuesday April 24 2001 9 31 AM ...

Page 164: ...EBU00435 YAMAHA EXTENDED SERVICE Y E S EE book Page 1 Tuesday April 24 2001 9 31 AM ...

Page 165: ...1 2 3 4 5 6 7 8 9 10 9 9 9 14 EE book Page 2 Tuesday April 24 2001 9 31 AM ...

Page 166: ...EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death EE book Page 3 Tuesday April 24 2001 9 31 AM ...

Page 167: ...EE book Page 4 Tuesday April 24 2001 9 31 AM ...

Page 168: ...EBU00437 EE book Page 5 Tuesday April 24 2001 9 31 AM ...

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