Yamaha Grizzly 300 Owner'S Manual Download

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4-14

WARNING

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

1. Special wrench

Spring preload setting:

Minimum (soft):

Standard:

Maximum (hard):

Summary of Contents for Grizzly 300

Page 1: ...This ATV should not be ridden by anyone under 16 years of age WARNING OWNER S MANUAL 1SC F8199 11 LIT 11626 26 13 READ THIS MANUAL CAREFULLY It contains important safety information YFM30GD ...

Page 2: ...Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if it is sold ...

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Page 5: ...of this ATV This manual includes important safety information It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures 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...

Page 6: ...tice This is the safety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP p...

Page 7: ...and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV YFM30GD 2012 by Yamaha Motor Corporation U S A 1st edition May 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Taiwan P N LIT 11626 2...

Page 8: ...4 5 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Transfer gear oil 5 3 Final gear oil 5 3 Coolant 5 3 Front and rear brakes 5 3 Throttle lever 5 4 Tires 5 4 Chassis fasteners 5 6 Instruments lights and switches 5 6 WARNING Indicates a potential hazard that could result in serious injury or death Brake pedal and rear brake lever 4 5 Parking brake lever 4 6 Drive select lever 4 7 Fuel tank cap 4...

Page 9: ... TO DO IF 7 22 WHAT TO DO 7 22 PERIODIC MAINTENANCE AND ADJUSTMENT 8 1 Owner s manual and tool kit 8 2 Periodic maintenance chart for the emission control system 8 3 General maintenance and lubrication chart 8 5 Checking the spark plug 8 9 Engine oil 8 12 Final gear oil 8 17 Transfer gear oil 8 15 Coolant 8 18 Cleaning the air filter element 8 23 Cleaning the spark arrester 8 26 V belt cooling duc...

Page 10: ...cking the wheel hub bearings 8 40 Lubricating the swingarm pivots 8 40 Lubricating the steering shaft 8 40 Battery 8 41 Replacing a fuse 8 43 Replacing a headlight bulb 8 45 Adjusting a headlight beam 8 47 Replacing the tail brake light bulb 8 47 Removing a wheel 8 49 Installing a wheel 8 49 Troubleshooting 8 50 Troubleshooting charts 8 51 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFIC...

Page 11: ...erstand all of the labels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer 1 2 3 4 5 6 8 9 7 ...

Page 12: ...1 2 1 3 2 1 20 ll ll l l l l ll ll I I I I l I l l I l l I l l l I I ...

Page 13: ...1 3 1 6 7 5 4 8 9 l l I I l 2226 N 227 kgf 500 lbf 147 N 15 kgf 33 lbf ...

Page 14: ... of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and paved streets Never operate an ATV on any paved street paved road or motorway Never operate an ATV without wearing an ap proved motorcycle helmet that fits properly You should also w...

Page 15: ... proper procedures for climbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Ch...

Page 16: ... brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires specified in this manual Always maintain proper tire pressure as de scribe...

Page 17: ...contact your riding party or local authorities to let them know where you are and what has happened 2 3 1 If your vehicle will not restart or is not in safe operating condition turn off the main switch and engine stop switch If the breakdown occurs at twilight or night leave the main switch on so that your lights may warn other riders of your stopped vehicle 2 Get out of danger Check for oncoming ...

Page 18: ...ted to changes in the vehicle Keep the following guidelines in mind as well as those provided under Loading when mounting accessories Never install accessories that would impair the performance of your ATV Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance limit suspension travel steering travel or control operation Accessories fitted t...

Page 19: ...haust can be drawn into a building through openings such as windows and doors WARNING When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF position Otherwise fuel may leak out of the carburetor or fuel tank FOR MORE INFORMATION ABOUT ATV SAFE TY call the Consumer Products Safety Commis sion at 1 800 638 2772 or the ATV Distributor s Safety Ho...

Page 20: ...rester 3 Rear storage compartment and tool kit 5 Tail brake light 6 V belt cooling duct check hose 7 Spark plug 1 Battery and fuses 2 Throttle stop screw 3 Radiator cap 1 4 2 3 5 2 1 6 7 5 7 3 4 Coolant reservoir 5 Engine oil filler cap 6 Brake pedal 7 Rear brake light switch 6 4 ...

Page 21: ...r slightly from the figures shown in this manual 1 Rear brake lever 2 Handlebar switches 3 Indicator lights and warning light 4 Front brake lever 5 Throttle lever 6 Drive select lever 7 Parking brake lever 8 Fuel tank cap 9 Main switch 10 Starter choke 1 2 3 4 5 7 6 8 9 10 ...

Page 22: ...ical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed off All electrical systems are off The key can be re moved 1 Main switch WARNING Indicates a potential hazard that could result in serious injury or death 1 ...

Page 23: ...ud or dirt has accumulated on the radiator i e after riding in wet terrain 1 2 3 Neutral indicator light This indicator light comes on when the transmis sion is in the neutral position Coolant temperature warning light This warning light comes on when the engine over heats When this occurs during operation stop the engine as soon as it is safe to do so and allow it to cool down for about 10 minute...

Page 24: ... crank the engine with the start er See the starting instructions on page 6 1 prior to starting the engine Light switch OFF Set this switch to to turn on the low beams and the taillight Set the switch to to turn on the high beams and the taillight Set the switch to OFF to turn off all the lights NOTICE Do not use the headlights with the engine turned off for an extended period of time oth erwise t...

Page 25: ... released Speed limiter Your ATV is equipped with an adjustable speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum 1 Loosen the locknut 2 To increase the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction a To de 1 Throttle lever 1 crease the maximum engine power available a...

Page 26: ...ip 4 3 Tighten the locknut Front brake lever The front brake lever is located on the right handle bar To apply the front brake pull the brake lever toward the handlebar grip 1 Front brake lever 1 See page 8 29 WARNING Improper ad justment of the speed limiter and throttle could cause throttle cable damage or im proper throttle operation You could lose control resulting in an accident 1 Locknut 2 A...

Page 27: ...r locked position 1 Use the parking brake before starting the engine or parking the ATV especially on a slope To apply the parking brake move the parking brake lever in direction a To release the parking brake move the parking brake lever in direction b a 4 6 OVERRIDE 1 1 4 ...

Page 28: ...he parking brake before starting the engine The ATV could start moving unexpectedly if the parking brake is not applied This could cause loss of control or a collision Always be sure you have released the parking brake before you begin to ride 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 ...

Page 29: ...xplosions and to reduce the risk of injury when refueling fol low these instructions of sparks open flames or other sources of ig nition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reach es the bottom of the filler tube Because fuel expands whe...

Page 30: ...ne has been designed to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand Use of unleaded fuel will extend spark plug life and reduce maintenance costs Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 10 7 L 2 83 US gal 2 35 Imp gal Fuel reserve amount...

Page 31: ...g to ON 4 10 4 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations OFF With the fuel cock lever in this position fuel will not flow Always turn the fuel cock lever to this position when the engine is not running 1 Arrow mark pointing to OFF 1 1 ...

Page 32: ...e and be sure to turn the fuel cock lever back to ON 1 Arrow mark pointing to RES RES Move the starter choke in direction b to turn off the starter choke See the Starting a cold engine section on page 6 1 for proper operation 1 Starter choke Starter choke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn ...

Page 33: ... and pull up the seat at the rear To install the seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear Make sure that the seat is securely fitted 1 Seat 2 Seat lock lever 1 Projection 2 Seat holder 1 2 1 2 ...

Page 34: ... and the riding conditions WARNING Always adjust the shock absorber assemblies on the left and right side to the same setting Uneven adjustment can cause poor handling and loss of stability which could lead to an ac cident Adjust the spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in direction b to...

Page 35: ...4 14 WARNING Indicates a potential hazard that could result in serious injury or death 4 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 4 1 ...

Page 36: ...4 ...

Page 37: ...ted by a Yamaha dealer Before using this vehicle check the following points E G A P E N I T U O R M E T I Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary Engine oil Check oil level in engine and add recommended oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary Coolant Check coolant level in...

Page 38: ...y Check lever free play and adjust if necessary 5 4 8 29 Control cables Make sure that operation is smooth Lubricate if necessary 8 38 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 8 49 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 8 39 ...

Page 39: ...ee page 8 18 Front and rear brakes Brake levers and brake pedal Check that there is no free play in the front brake lever If there is free play have a Yamaha dealer check the brake system Check for correct free play in the rear brake lever and brake pedal If the free play is incorrect ad just it See page 8 34 Check operation of the levers and pedal They should move smoothly and there should be a f...

Page 40: ...tle lever Check the operation of the throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary Tires Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage Tire pressure Use the low pressure tire gauge to check and ad just tire pressures when the tires are cold Tire pr...

Page 41: ...cause the first reading to be incorrect Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire Recommended tire pressure Front 30 0 kPa 0 300 kgf cm 4 4 psi Rear 25 0 kPa 0 250 kgf cm 3 6 psi Minimum tire pressure Front 27 0 kPa 0 270 kgf cm 4 0 psi Rear 22 0 kPa 0 220 kgf cm 3 2 psi 1 Low pressure tire gauge 1 Tire wear limit 1 1 5 ...

Page 42: ...me with your ATV were designed to match the performance capabilities and to provide the best combination of handling braking and comfort Other tires rims sizes and combinations may not be appropriate Rear Manufacturer model Size Type Tubeless Front Manufacturer model Size Type Tubeless Chassis fasteners Make sure that all nuts bolts and screws are prop erly tightened Instruments lights and switche...

Page 43: ...select lever into the neutral The corresponding indicator light should come on If the indicator light does not come on have a Yamaha dealer check the electrical circuit TIP The engine can be started under the following con ditions The drive select lever is in the neutral The rear brake lever is applied with the drive se lect lever in any position However it is recom mended to shift into the neutra...

Page 44: ...possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt 7 If the engine is started with the starter choke in position 1 the starter choke should be returned to position 2 to warm up the engine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it ...

Page 45: ...gh range and High range to Low range 1 Bring the ATV to a complete stop 2 Apply the brake pedal and then shift by mov ing the drive select lever along the shift guide TIP Make sure that the drive select lever is completely shifted into position 3 Release the brake pedal and then open the throttle lever gradually Shifting Neutral to Reverse WARNING Improper operation in reverse could make you hit a...

Page 46: ...echanism in the en gine the indicator light may not come on until the ATV starts moving 1 Drive select lever 2 L Low range 3 H High range 4 N Neutral 5 R Reverse 4 Check behind for people or obstacles and then release the brake pedal 5 Open the throttle lever gradually and continue to watch to the rear while backing Engine break in TIP For ATVs equipped with an odometer or an hour meter follow the...

Page 47: ...g brake and then turn the fuel cock to OFF 0 160 km 0 100 mi or 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set throttle position 160 320 km 100 200 mi or 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine freely but do not use full throttle at any time 320 km 200 mi or 20 hours and beyond The ATV can now...

Page 48: ...asily 1 Bring the ATV to a stop by applying the brakes 2 Stop the engine 3 Apply the parking brake Accessories and loading Genuine Yamaha Accessories Choosing accessories for your ATV is an important decision Genuine Yamaha Accessories which are available only from a Yamaha dealer have been designed tested and approved by Yamaha for use on your ATV Many companies with no con nection to Yamaha manu...

Page 49: ...n shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your...

Page 50: ...5 kgf 33 lbf Load cargo on the carriers as close to the center of the ATV as possible Put cargo at the rear of the front carrier at the front of the rear carrier and center it Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load does not interfere with con trols or your ability to see where you are going ...

Page 51: ...7 1 RIDING YOUR ATV 7 ...

Page 52: ...so read all warning and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain Do not operate this ...

Page 53: ...er 16 years of age WARNING A child under 16 should never operate an ATV with engine size greater than 90 cc Use by chil dren of ATVs that are not recommended for their age can lead to severe injury or death of the child This ATV is designed to carry the operator and cargo only passengers prohibited The long seat is to allow the operator to shift posi tion as needed during operation It is not for c...

Page 54: ...f injuries in an accident WARNING Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of visi...

Page 55: ...ways inspect your ATV each time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 1 Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual WARNING Failure to inspect the ATV before operating it and to maintain it prop erly increases the possibility of an accident or equipment damage Speed...

Page 56: ...n racks centered side to side and as low as possible Be sure cargo is se cured a loose load could change handling unexpectedly Make sure the load does not interfere with your control or ability to see where you are going Tie down cargo in the trailer securely Make sure cargo in the trailer cannot move around A shifting load can cause an accident Reduce speed and allow more room to stop A heavier v...

Page 57: ... 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 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including 7 MAXIMUM LOADING LIMIT ATV loading limit total ...

Page 58: ...ed around the engine area could catch fire Do not operate idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust system dur ing or after operation could be burned Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it The muffler and oth...

Page 59: ...OU RIDE This ATV is designed for off road use only WARNING Paved surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets Do not ride on any public road street or highway Riding on public roads can result in collisions with 7 ...

Page 60: ...zards which may cause the ATV to upset WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Al ways be alert to changing terrain conditions when operating the ATV Do not operate on rough slippery or loose terrain until you have learned and practiced the skills nec essary t...

Page 61: ...rrain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if operating in off road areas where you cannot easily be seen Mount a caution flag on the ATV to make you more visible Watch carefully for other vehicles Do not ride in areas posted no trespassing Do not ride on private property without getting per mission 7 ...

Page 62: ... When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly Im proper use of the brakes can cause the tires to lose traction reducing control and increasing the possi bility of an accident NOTICE Do not shift from low range to high range or vice versa without coming to a complete stop Damage to the engine or drive train may occur TURNING YOUR ATV WARNING Always fo...

Page 63: ... may help to position more of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body move ments or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to t...

Page 64: ...ever open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid...

Page 65: ...make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to lose control If you are unable to continue up the hill dismount the ATV on the up hill s...

Page 66: ... steep for the ATV or for your abilities The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills Shift your weight backward and to the up side of the hill Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where possi ble Improper braking can cause the wheels o...

Page 67: ...down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear CROSSING A SLOPE WARNING Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to overturn Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with exce...

Page 68: ...dy in the uphill direction It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the dir...

Page 69: ...s after leaving the water If neces sary apply them several times to let friction dry out the linings Do not continue to ride your ATV with out verifying that you have regained proper braking ability WARNING Wet brakes may have re duced stopping ability which could cause loss of control After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the...

Page 70: ...n trees When you go over obstacles always follow proper procedures as described in the Owner s Manual Riding over rough terrain should be done with cau tion Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sul...

Page 71: ...slippery conditions positioning your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide side ways control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide With practice over a period of time skill at con trolled sliding can...

Page 72: ...to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 13 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphil...

Page 73: ...Turn off the engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal 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 3 for more information about carbon monoxide 8 WARNING Brake ...

Page 74: ...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 1 Owner s manual 2 Owner s tool kit 3 Low pressure tire gauge 1 2 3 8 Owner s manual and tool kit Be sure to put this owner s manual in the plastic bag and always carry it on the bottom of the seat as shown Put the owner s tool...

Page 75: ...ealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve cle...

Page 76: ...s sary Check for looseness and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 8 ...

Page 77: ...HECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Front brake Check operation and correct if necessary Check fluid level and ATV for fluid leakage and correct if necessary Check fluid level ...

Page 78: ...lace if necessary 10 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 11 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 12 Stabilizer bushes Check for cracks or other damage and replace if necessary 13 Steering shaft Lubricate with lithium soap based grease 14 Steering system Check operation and re...

Page 79: ...r oil Change Check ATV for oil leakage and correct if neces sary 21 Cooling system Check coolant level and ATV for coolant leakage and correct if necessary s r a e y 2 y r e v E t n a l o o c e c a l p e R 22 Moving parts and cables Lubricate 23 Drive select lever safety system cable Check operation and adjust or replace if neces sary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes...

Page 80: ...brake hoses every four years and if cracked or damaged 24 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle lever free play and adjust if neces sary Lubricate throttle lever housing and cable 25 Front and rear brake switches Check operation and correct if necessary 26 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM...

Page 81: ...e with the periodic maintenance and lubrica tion chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the seat See page 4 12 WARNING Indicates a potential hazard that could result in serious injury or death 1 Spark plug cap 1 3 Remove the spark plug cap 2 Remove the left side cover by pulling outward on the areas shown and then ...

Page 82: ...ttempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification Specified spark plug NGK CR8E 1 Spark plug gap Spark plug gap 0 7 0 8mm 0 028 0 031 in 1 TIP If...

Page 83: ...e specified torque 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 Tightening torque Spark plug 12 0 Nm 1 20 m kgf 8 9 ft lbf 4 Place the left side cover in its original position push forwa...

Page 84: ...ward as shown 3 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 ten minutes until the oil set tles for an accurate reading 4 Remove the engine oil filler cap and then wipe the engine oil dipstick off with a clean rag 1 Engine oil filler cap 1 Engine oil cap cover 1 1 2 Engine o...

Page 85: ...mum level mark 2 Minimum level mark 1 2 then tighten the engine oil filler cap 8 Install the engine oil cap cover 2 4 To change the engine oil 1 Place the ATV on a level surface 2 Start the engine warm it up for several min utes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the...

Page 86: ... parts after the engine and exhaust system have cooled down Recommended oil See page 10 1 Oil quantity 1 20 L 1 27 US qt 1 06 Imp qt 8 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 8 9 Turn the engine off wait at least ten minutes and then check the oil level and correct it if ne...

Page 87: ...ls specified in the periodic mainten ance and lubrication chart 1 Place the ATV on a level surface 2 Place an oil pan under the transfer gear case to collect the used oil 3 Remove the seat See page 4 12 4 Remove the right side cover by pulling outward on the areas shown and then pull rearward as shown To change the transfer gear oil 5 Remove the right footboard by removing the bolts washers and nu...

Page 88: ...ing bolt Transfer gear oil drain bolt 40 Nm 4 0 m kgf 28 9 ft lbf 8 Add the specified amount of the recommend ed transfer gear oil and then check the oil level NOTICE Be sure no foreign material enters the transfer gear case 9 Install and tighten the transfer gear oil filler bolt 10 Check the transfer gear case for oil leakage If oil is leaking check for the cause Recommended transfer gear oil See...

Page 89: ... 1 Place the ATV on a level surface 2 Place an oil pan under the final gear case to collect the used oil To change the final gear oil 11 Install the right footboard by installing the bolts 12 Place the right side cover in its original po sition push forward on the areas shown and then push inward as shown 3 Remove the final gear filling bolt and the drain bolt to drain the oil from the final gear ...

Page 90: ...al gear filling bolt 15 Nm 1 5 m kgf 10 8 ft lbf Recommended final gear oil See page 10 1 Oil quantity 0 15 L 0 16 US qt 0 13 Imp qt 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 To check the coolant level 1 Place the ATV on a level surface TIP The coolant level must ...

Page 91: ...se the cooling system will not be protected against frost and 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark 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 To change the coolant WARNING Wait for the engine and radiator to cool before r...

Page 92: ...pletely removing the cap 1 Place the ATV on a level surface 2 Place a container under the engine and then remove the coolant drain bolt 1 Coolant drain bolt 3 Remove the front carrier by removing the bolts 1 1 1 1 Carrier bolt top 1 Carrier bolt under the fenders 1 1 8 ...

Page 93: ...2 Quick fastener screw 1 Radiator cap 6 Remove the coolant reservoir cap 5 Remove the radiator cap 1 2 2 1 4 Remove the front panel by removing the quick fastener screws and then pull the front panel upward to remove it 8 ...

Page 94: ...ct the hose on the coolant reservoir side and then drain the coolant from the cool ant reservoir antifreeze with distilled water only Howev er 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 12 Pour the recommended coolant into the radia tor until it is full Antifreeze water mixture ratio 1 1 Recommen...

Page 95: ...have a Yamaha dealer check the cooling system 16 Install the front panel and the front carrier Cleaning the air filter element The air filter element should be cleaned at the in tervals 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 bo...

Page 96: ...age 4 12 3 Remove the air filter case cover by unhooking the air filter case cover holders 1 Air filter case cover holder 2 Air filter case cover 1 Bolts 2 Air filter element 1 1 2 4 Remove the bolts and pull the air filter element out of the air filter case 2 1 8 ...

Page 97: ...ter ele ment lock plate and then remove the sponge material from the air filter element frame 7 Squeeze the excess solvent out of the sponge material and let it dry NOTICE Do not twist the sponge material when squeezing it 8 6 Wash the sponge material gently but thor oughly in solvent WARNING Always use parts cleaning solvent to clean the sponge material Never use low flash point sol vents or gaso...

Page 98: ...amage Additionally operation without the air filter element will affect car buretor jetting with subsequent poor per formance and possible engine overheating 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 ar eas Each time the air filter element maintenance is performed check...

Page 99: ...muffler and align the bolt holes 1 Tailpipe 2 Spark arrester 3 Gasket Tightening torque Tailpipe bolt 12 Nm 1 2 m kgf 8 7 ft lbf WARNING Do not start the engine when cleaning the spark arrester otherwise it could cause injury to the eyes burns carbon monoxide poison ing possibly leading to death and start a fire Always let the exhaust system cool prior to touching exhaust components V belt cooling...

Page 100: ...t sufficient technical knowl edge may result in poor performance of or damage to the engine Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica tion chart TIP A diagnostic tachometer is needed to make this adjustment 3 Start the engine and warm it up TIP The engine is warm ...

Page 101: ...ngine idling speed must be checked and ad justed if necessary before adjusting the throttle leve free play 1 Slide the rubber cover back 2 Loosen the locknut 3 To increase the throttle leve free play turn the throttle leve free play adjusting bolt in di rection a To decrease the throttle leve free play turn the adjusting bolt in direction b 1 Throttle stop screw Engine idling speed 1600 1800 r min...

Page 102: ...e drive select lever safety system cable stretch es with use which can result in improper function Therefore the safety system cable should be checked and adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Brakes Replacement of brake components requires pro fessional knowledge Brake service should be per formed by a Yamaha dealer WARNING Operat...

Page 103: ...g thickness If a brake pad is dam aged or if the lining thickness is less than 1 5 mm 0 06 in have a Yamaha dealer replace the brake pads as a set 1 Lining thickness TIP The wheels need to be removed to check the brake pads See page 8 49 Rear brake pads Check each rear brake pad for damage and mea sure the lining thickness If a brake pad is dam aged or if the lining thickness is less than 1 5 mm 0...

Page 104: ...rk for the rear brake 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 MIN 1 8 Specified brake fluid DOT 4 ...

Page 105: ...tenance can result in loss of braking ability Observe these precautions insufficient brake fluid may allow air to enter the brake system reducing braking perfor mance Clean the filler cap before removing Use only DOT 4 brake fluid from a sealed container Use only the specified brake fluid other wise the rubber seals may deteriorate caus ing leakage Refill with the same type of brake fluid Add ing ...

Page 106: ...r free play The brake lever free play should measure 4 0 7 0 mm 0 16 0 28 in If the free play is incorrect adjust it as follows Checking the front brake lever free play 1 No brake lever free play 1 The brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart The brake lever should have a free play of zero mm zero in as shown If the free pla...

Page 107: ...ke pedal does not move Checking the brake pedal position The top of the brake pedal should be positioned 47 0 57 0 mm 1 85 2 24 in above the footboard If the brake pedal position is incorrect have a Yamaha dealer adjust it 1 Distance between brake pedal and footboard 1 Adjusting the parking brake free play The parking brake free play must be checked and if necessary adjusted at the intervals speci...

Page 108: ...n a to increase the cable length and in direction b to decrease it 1 Locknut 2 Adjusting nut If the cable length cannot be adjusted to specifica tion consult a Yamaha dealer 5 Tighten the locknut on the brake cable 6 Turn in the adjusting bolt at the rear brake cal iper until it feels tight then turn it out 1 8 turn and tighten its locknut to the specified torque TIP When tightening the locknut ho...

Page 109: ... malfunction resulting in reduced braking performance This could increase the chance of a collision or accident After adjusting the parking brake free play block the rear of the ATV off the ground and spin the rear wheels Check to make sure there is no brake drag If brake drag is noticed perform the adjustment again 1 Rear axle boot 1 Brake light switches The rear brake light which is activated by...

Page 110: ...NG Inspect cables frequently and replace if dam aged 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 una...

Page 111: ...d grease 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 the right footboard See page 8 15 Recommended lubricant Lithium soap based grease Rear brake lever 8 ...

Page 112: ...check the wheel hub bear ings 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 Recommended lubricant Lithium soap based grease Lubricating the swingarm pivots The swingarm pivots must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubricat...

Page 113: ...TERNAL 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 8 Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ig nition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH...

Page 114: ...ltage battery charger is required Using a conventional bat tery 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 NOTICE Always keep the battery charged ...

Page 115: ... must be off and the positive lead must be connected before the negative lead 3 Install the battery holding plate by installing the bolts 4 Install the seat See page 4 12 Replacing a fuse The fuse boxes are located under the seat See page 4 12 1 Positive battery lead red 2 Negative battery lead black 1 1 Fuse box 2 2 Main fuse 3 Spare fuse Main fuse 4 Fan fuse 5 Spare fuse 6 Ignition fuse 7 Headli...

Page 116: ...e and then install a new fuse of the specified amperage WARNING Always use a fuse of the spec ified rating and never use a substitute ob ject 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 NOTICE To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse If a fuse is blo...

Page 117: ...r 1 Headlight coupler 1 1 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the cover at the rear of the headlight by pulling it off 2 Remove the headlight bulb holder cover by pulling it off 1 Cover at the rear of the headlight 1 8 ...

Page 118: ...ight bulb holder 2 Headlight bulb hold cables 6 Place a new headlight bulb into position and then secure it with the bulb holder 5 Remove the burnt out bulb by pulling it out NOTICE Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt a...

Page 119: ...s 1 2 1 Headlight beam adjusting screw Adjusting a headlight beam NOTICE It is advisable to have a Yamaha dealer make this adjustment 1 a 8 To raise a headlight beam loosen the headlight beam adjusting screw slide the adjusting screw in direction a and tighten the adjusting screw To lower a headlight beam loosen the headlight beam adjusting screw slide the adjusting screw in direction b and tighte...

Page 120: ... pushing it in and turning it clockwise 6 Install the tail brake light assembly by install ing the washers and the nuts 1 Tail brake light bulb holder 2 Tail brake light bulb 1 2 3 Remove the burnt out bulb by pushing it in and turning it counterclockwise 1 Tail brake light cover 2 Bolts 2 Remove the tail brake light cover by removing the bolts 1 2 8 ...

Page 121: ...n the tire must point toward the rotating direction of the wheel Installing a wheel 1 Place the ATV on a level surface 2 Install the wheel and the nuts Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 3 Elevate the ATV and place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel 1 Wheel nut 1 1 8 ...

Page 122: ...essary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING Do not smoke when checking the fuel system Fuel can ignite or explode causing severe inju ry or property damage Make sure there are no open flame...

Page 123: ... dealer check the ATV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly...

Page 124: ...available tap water can be temporarily used instead provided that it is changed to the rec ommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See TIP Start the engine If th...

Page 125: ...slow speeds to let friction dry out the linings NOTICE Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with...

Page 126: ...l stabilizer if available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This wil...

Page 127: ...g to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation on storing the battery see page 8 41 TIP Make any necessary repairs before storing the ATV 9 ...

Page 128: ...b Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Vertical single cylinder Displacement 287 cm Bore stroke 75 0 65 0 mm 29 5 2 56 in Compression ratio 8 6 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type YAMALUBE SAE10W 30 SAE10W 40 SAE20W 40 SAE20W 50 or SAE5W 30 Recommended engine oil grade API service SG type or higher JASO standard MA 10 SAE 20...

Page 129: ...sfer gear oil Type SAE 90 API GL 5 Hypoid gear oil SAE 80 API GL 4 Hypoid gear oil Quantity 1 20 L 1 27 US qt 1 06 Imp qt Final gear oil Type Quantity 0 15 L 0 16 US qt 0 13 Imp qt Carburetor Type quantity CVK 32 x 1 Spark plug s Manufacturer model NGK CR8E Spark plug gap 0 7 0 8 mm 0 028 0 031 in Clutch Clutch type Dry centrifugal automatic Fuel reserve amount 3 0 L 0 79 US gal 0 66 Imp gal Fuel ...

Page 130: ...rimary reduction system V belt Secondary reduction system Shaft drive Transmission type V belt automatic Operation Right hand operation Reverse gear 47 17 31 26 32 18 19 17 6 54 Front tire Type Tubeless Size AT22 x 7 10 Manufacturer model MAXXIS M919 Rear tire Type Tubeless Size AT22 x 10 9 Manufacturer model MAXXIS M920 Loading Maximum loading limit 155 0 kg 342 lb Total weight of rider cargo acc...

Page 131: ... in Rear suspension Type Swingarm Spring shock absorber type Coil spring oil damper Wheel travel 141 mm 5 6 in Rear brake Type Single disc brake Operation Specified fluid DOT 4 Left hand and right foot operation Front brake Type Dual disc brake Operation Right hand operation Specified fluid DOT 4 Front wheel Wheel type Panel wheel Rim size 10 x 5 5AT Rear wheel Wheel type Panel wheel Rim size 9 x ...

Page 132: ...ail brake light 12 V 5 0 21 0 W 1 12 V 1 7 W 1 Neutral indicator light 12 V 1 7 W 1 Reverse indicator light 12 V 1 7 W 1 Coolant temperature warning light Fuses Main fuse 30 0 A Fan fuse 10 0 A Ignition fuse 10 0 A Headlight fuse 10 0 A Signaling system fuse 10 0 A ...

Page 133: ...aha dealer or for ref erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key Vehicle identification number The vehicle identification number is stamped into the frame 1 Key...

Page 134: ...ssions as required by federal law state law and Environ ment Canada 1 2 3 11 2 The year of manufacture is listed in the vehicle identification number as shown in the illustration 1 Vehicle identification number front side 1 TIP The vehicle identification number is used to identify your ATV Model label The model label is affixed at the location in the il lustration Record the information on this la...

Page 135: ...e for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exha...

Page 136: ...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 month km mi hours 1 320 200 20 3 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 22500 14400 1440 60 25...

Page 137: ...rchaser to any subsequent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corpor...

Page 138: ...on at the time of sale and upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Q Is the warranty transferable to second owners A Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain effective CU...

Page 139: ...re s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 250 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls e...

Page 140: ... money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 WARNING Indicates a hazardous situation which if not avoided could resul...

Page 141: ...ce knowing your Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory manual for your vehicle t...

Page 142: ... Brakes Brakes front and rear 8 41 8 32 8 33 8 34 8 34 4 5 8 38 8 37 8 31 4 5 8 39 8 30 5 3 Cables checking and lubricating Carburetor adjusting Carrier front Carrier rear 8 38 8 28 4 13 4 13 Chassis fasteners 5 6 Cleaning Coolant Coolant temperature warning light 9 1 5 3 8 18 4 2 Drive select lever Drive select lever and driving in reverse Drive select lever safety system cable adjusting 4 7 6 3 ...

Page 143: ...n control system Model label 4 1 8 5 8 3 11 2 Neutral indicator light 4 2 8 2 Parking Parking brake free play adjusting Parking brake lever Parking on a slope Part locations Pre operation checks 6 5 8 35 4 6 6 6 3 1 5 1 O Owner s manual and tool kit Reverse indicator light Riding your atv 4 2 7 1 Safety information Seat Sliding and skidding Spark arrester cleaning Spark plug checking Specification...

Page 144: ...tle lever Tires Troubleshooting Troubleshooting charts 8 29 4 4 5 4 5 4 8 50 8 51 8 30 8 27 11 1 8 40 8 49 8 49 Wheel hub bearings checking Wheel installing Wheel removing 8 47 Valve clearance V belt cooling duct check hose Vehicle identification number Transfer gear oil 5 3 8 15 ...

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