Yamaha GRIZZLY 450 YFM45FGY Owner'S Manual Download | Manualshive

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EBU23422

Differential gear oil

The differential gear case must be checked for oil
leakage before each ride. If any leakage is found,
have a Yamaha dealer check and repair the ATV.
In addition, the differential gear oil level must be
checked and the oil changed as follows at the in-
tervals specified in the periodic maintenance and
lubrication chart.

To check the differential gear oil level

1. Place the ATV on a level surface.

TIP

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

2. Remove the differential gear oil filler bolt, and

then check the oil level in the differential gear
case.

TIP

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

3. If the oil is below the brim of the filler hole, add

sufficient oil of the recommended type to raise
it to the correct level.

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

specified torque.

1. Differential gear oil
2. Differential gear oil filler bolt

3. Correct oil level

Tightening torque:

Differential gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

U37S60E0.book Page 25 Thursday, June 5, 2008 6:51 PM

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Summary of Contents for GRIZZLY 450 YFM45FGY

Page 1: ...OPIETARIO 37S F8199 60 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad DIC183 ...

Page 2: ...PRINTED IN USA 2008 06 0 9 1 CR E F S YAMAHA MOTOR CO LTD DIC183 ...

Page 3: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL YFM45FGY 37S F8199 60 E0 U37S60E0 book Page 1 Thursday June 5 2008 6 51 PM ...

Page 4: ...ealth and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted EN292 ANSI SVIA 1 2007 Title and or number and date of issue of standards and or specifications General Manager RV Engineering Division RV Company Signature Date of Issue Shinya Shimada 26 March 2008 YAMAHA MOTOR EUROPE N V Koolhovenlaan 101 1119NC Schiphol Rijk The ...

Page 5: ...d operation 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 COMPLETELY BEFORE OPERAT...

Page 6: ... 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 provides key info...

Page 7: ...face paved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17410 YFM45FGY OWNER S MANUAL 2008 by Yamaha Motor Co Ltd 1st edition May 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A U37S60E0 book Page 1 Thursday June 5 2008 6 51 PM...

Page 8: ...al and rear brake lever 4 13 Drive select lever 4 14 Recoil starter 4 14 Fuel tank cap 4 14 Fuel 4 15 Fuel cock 4 16 Starter choke 4 17 Seat 4 18 Storage compartments 4 19 Front carrier 4 21 Rear carrier 4 21 Adjusting the front and rear shock absorber assemblies 4 21 Auxiliary DC jack 4 23 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Differentia...

Page 9: ...8 1 Owner s manual and tool kit 8 1 Periodic maintenance chart for the emission control system 8 3 General maintenance and lubrication chart 8 5 Removing and installing panels 8 9 Checking the spark plug 8 14 Engine oil and oil filter cartridge 8 17 Final gear oil 8 22 Differential gear oil 8 25 Coolant 8 27 Cleaning the air filter element 8 31 Cleaning the spark arrester 8 34 V belt cooling duct ...

Page 10: ...49 Lubricating the drive shaft universal joint 8 49 Checking the stabilizer bushes 8 49 Lubricating the rear knuckle pivots 8 50 Lubricating the steering shaft 8 50 Battery 8 50 Replacing a fuse 8 52 Replacing a headlight bulb 8 54 Adjusting a headlight beam 8 56 Replacing the tail brake light bulb 8 56 Removing a wheel 8 58 Installing a wheel 8 58 Troubleshooting 8 60 Troubleshooting charts 8 61 ...

Page 11: ...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 Watch carefully for other vehicles when operat ing on unpaved public streets or roads Make sure you know your country s ...

Page 12: ...imbing 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 Check the terrain carefully...

Page 13: ...nual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires specified in this manual Always maintain proper tire...

Page 14: ...us If you should swal low some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and wa ter If gasoline spills on your clothing change your clothes WARNING EWB00070 Always operate your ATV in an area with ade quate ventilation Never start or run the engine in a closed area Exhaust fumes are pois...

Page 15: ...2 1 2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 6 7 8 10 9 11 12 U37S60E0 book Page 1 Thursday June 5 2008 6 51 PM ...

Page 16: ...t 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 For Europe and Oceania 5880 N 1322 600 kgf 37S F151K 00 1 5 4 U37S60E0 book Page 2 Thursday June 5 2008 6 51 PM ...

Page 17: ...2 3 2 For Europe 2 6 3 U37S60E0 book Page 3 Thursday June 5 2008 6 51 PM ...

Page 18: ...2 4 2 For Europe MODEL YFM450FWAN MAX POWER 19 4 kW MASS IN RUNNING ORDER 285 kg 37S F155A 00 10 8 7 9 U37S60E0 book Page 4 Thursday June 5 2008 6 51 PM ...

Page 19: ...2 5 2 For Oceania 5FU F816M 20 25 kPa 3 6 psi 25 kPa 3 6 psi 22 kPa 3 2 psi 22 kPa 3 2 psi 2 3 U37S60E0 book Page 5 Thursday June 5 2008 6 51 PM ...

Page 20: ...2 6 2 For Oceania 16 UNDER 1P0 F816L 00 7 6 U37S60E0 book Page 6 Thursday June 5 2008 6 51 PM ...

Page 21: ...ors can be a fire or explosion hazard To avoid injury or death never store fuel or flammable liquids in this storage compartment Storage should not exceed 0 5 kg 1 lb 37S F151F 00 11 12 U37S60E0 book Page 7 Thursday June 5 2008 6 51 PM ...

Page 22: ...l filler cap 10 Oil filter cartridge 11 Coolant reservoir 12 V belt cooling duct check hose 1 Rear shock absorber assembly spring preload adjusting ring 2 Spark arrester 3 Rear storage compartment and tool kit 4 Spark plug 5 Front shock absorber assembly spring preload adjusting ring 6 Rear brake light switch 7 Brake pedal 8 V belt case drain plug U37S60E0 book Page 1 Thursday June 5 2008 6 51 PM ...

Page 23: ... Handlebar switches 3 Starter choke 4 Horn switch 5 Drive select lever 6 Multifunction display 7 Main switch 8 Auxiliary DC jack 9 Fuel tank cap 10 On Command four wheel drive differential gear lock switch 11 Throttle lever 12 Front brake lever 13 Front storage compartment 9 5 4 13 12 11 10 2 3 6 7 8 U37S60E0 book Page 2 Thursday June 5 2008 6 51 PM ...

Page 24: ...e as follows ON All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All electrical systems are off The key can be re moved 1 Main switch U37S60E0 book Page 1 Thursday June 5 2008 6 51 PM ...

Page 25: ... is in the neutral position EBU17920 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 minutes NOTICE ECB00010 The engine may overheat if the ATV is over loaded In this case reduce the load to spec ification 1 On Command differential gear lo...

Page 26: ...mand differential gear lock switch is set to LOCK the indicator will flash until the differential gear is locked EBU17970 Park indicator light This indicator light comes on when the transmis sion is in the park position EBU17980 High range indicator light This indicator light comes on when the transmis sion is in the high range position EBU17990 Low range indicator light This indicator light comes...

Page 27: ...set a tripmeter select it by pushing the TRIP ODO button and then push the TRIP ODO button for at least three seconds The tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel This in formation will enable you to plan future fuel stops TIP Pushing and holding in the TRIP ODO button and turning the key to ON while the button is pushed switches the display bet...

Page 28: ... indicates the amount of fuel in the fuel tank When the needle reaches the red line re fill the tank at the first opportunity TIP If the ATV runs out of fuel move the fuel cock lever to the RES position Approximately 4 5 L 1 19 US gal 0 99 Imp gal of fuel will be remaining in the tank EBU18061 Handlebar switches 1 Fuel gauge 2 Red line 1 Light switch OFF 2 Start switch 3 Engine stop switch 4 Overr...

Page 29: ...ing the engine EBU18151 Light switch OFF Set this switch to to turn on the low beams and the taillight Set the switch to to turn on the high beams and the taillight Set the switch to OFF to turn off all the lights NOTICE ECB00040 Do not use the headlights with the engine turned off for an extended period of time oth erwise the battery may discharge to the point that the starter motor will not oper...

Page 30: ...e take the ATV to a Yamaha dealer at the first opportunity WARNING EWB00150 Always ride at a slow speed when the ATV is in four wheel drive differential gear lock and al low extra time and distance for maneuvers All wheels turn at the same speed when the dif ferential is locked so it takes more effort to turn the ATV The effort needed to turn increas es with the riding speed You may lose control a...

Page 31: ...g from two wheel drive to four wheel drive or vice versa while moving may cause the ATV to unexpectedly handle differently This could distract the oper ator and increase the risk of losing control and of causing an accident EBU18254 On Command differential gear lock switch 4WD LOCK This ATV is equipped with a switch allowing you to lock the differential gear when in four wheel drive Select the app...

Page 32: ...ential gear lock switch in to the LOCK position When the dif ferential gear is locked the differential gear lock in dicator light DIFF LOCK will come on along with the indicator in the multifunction display 1 On Command four wheel drive switch 2WD 4WD 2 On Command differential gear lock switch 4WD LOCK 1 Differential gear lock lever 2 On Command four wheel drive switch 2WD 4WD U37S60E0 book Page 9...

Page 33: ...40 Always ride at a slow speed when the ATV is in differential gear lock and allow extra time and distance for maneuvers All wheels turn at the same speed when the dif ferential gear is locked so it takes more effort to turn the ATV The effort needed to turn in creases with the riding speed You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are trave...

Page 34: ...l increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decelerate and the engine will return to an idle any time the hand is removed from the throttle lever Before starting the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released...

Page 35: ...ten the locknut WARNING EWB00240 Improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation You could lose control have an accident or be injured Do not turn the adjusting screw out more than 12 mm 0 47 in or the throttle cable could be dam aged Always make sure the throttle lever free play is adjusted to 3 0 5 0 mm 0 12 0 20 in See page ...

Page 36: ...ight side of the ATV and the rear brake lever is located on the left handlebar To apply the rear brake push down on the brake pedal or pull the brake lever toward the handlebar grip 1 Front brake lever 1 Brake pedal 1 Rear brake lever U37S60E0 book Page 13 Thursday June 5 2008 6 51 PM ...

Page 37: ...r Firmly grasp the handle and pull slightly until en gagement can be felt Then pull forcefully being careful not to pull the rope all the way out WARNING EWB00330 Always shift the drive select lever to park posi tion before starting the engine otherwise the ATV could start to move unexpectedly which could cause an accident EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter clock...

Page 38: ... 1 Fuel tank cap 1 Fuel level 2 Fuel tank filler tube Recommended fuel UNLEADED GASOLINE ONLY For Europe Regular unleaded gasoline only with a research octane number of 91 or high er Fuel tank capacity 15 0 L 3 96 US gal 3 30 Imp gal Fuel reserve amount 4 5 L 1 19 US gal 0 99 Imp gal U37S60E0 book Page 15 Thursday June 5 2008 6 51 PM ...

Page 39: ...t to spill fuel especially on the engine or exhaust pipe which can cause a fire and severe injury Wipe up any spilled fuel immediately Do not refuel right after the engine has been running and is still very hot Be sure the fuel tank cap is closed securely EBU18820 Fuel cock The fuel cock supplies fuel from the tank to the car buretor while also filtering it The fuel cock lever positions are explai...

Page 40: ...rn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18850 Starter choke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke 1 Arrow mark pointing to ON 1 Arrow mark ...

Page 41: ... Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear To install the seat Insert the projections on the front of the seat into the seat holders and push down on the seat at the rear TIP Make sure that the seat is securely fitted 1 Starter choke 1 Seat 2 Seat lock lever U37S60E0 book Page 18 Thursday June 5 2008 6 51 PM ...

Page 42: ...rage compartment is located at the front right side of the ATV To access the storage compartment remove the storage compartment cover by turning it counterclockwise 1 Projection 2 Seat holder 1 Front storage compartment cover 1 Front storage compartment U37S60E0 book Page 19 Thursday June 5 2008 6 51 PM ...

Page 43: ... in appropriate cushion material to prevent damaging the stor age compartments Do not exceed the load limit of 0 5 kg 1 lb for the front storage compartment or 2 0 kg 4 lb for the rear storage compartment Do not exceed the maximum load of 210 0 kg 463 lb for the ATV TIP A drain plug is fitted at the bottom of the front stor age compartment and there is a check hose at the bottom of the rear storag...

Page 44: ... EBU19142 Adjusting the front and rear shock ab sorber assemblies The spring preload can be adjusted to suit the rid er s weight and the riding conditions 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 de crease the spring preload and thereby soften the suspension 1 St...

Page 45: ...obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 U37S60E0 book Page 22 Thursday June 5 2008 6 51 PM ...

Page 46: ...ary DC jack should only be used when the engine is running 1 Set the light switch to OFF 2 Start the engine See page 6 1 3 Open the auxiliary DC jack cap and then in sert the accessory power plug into the jack 4 When the auxiliary DC jack is not being used cover it with the cap NOTICE ECB00120 Do not use accessories requiring more than the above maximum capacity This may overload the circuit and c...

Page 47: ...e headlights turned on the battery will lose its charge and engine start ing 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 U37S60E0 book Page 24 Thursday June 5 2008 6 51 PM ...

Page 48: ...ntenance charts on page 8 3 to determine which service should be performed by a Yamaha dealer ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 15 5 3 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 5 3 8 17 Final ...

Page 49: ...free play and adjust if necessary 5 4 8 38 Control cables Make sure that operation is smooth Lubricate if necessary 8 48 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 5 5 6 5 7 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 8 48 Brake lever...

Page 50: ...essary See page 8 17 EBU19590 Final gear oil Make sure that the final gear oil is at the specified level Add oil as necessary See page 8 22 EBU19600 Differential gear oil Make sure that the differential gear oil is at the specified level Add oil as necessary See page 8 25 EBU19630 Coolant Make sure that the coolant is at the specified level Add coolant as necessary See page 8 27 TIP The coolant le...

Page 51: ... the lever moves slowly inward there may be a leak in the brake system If there is any leakage the brake system should be checked by a Yamaha dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance check the brake pads and friction plates for wear See page 8 39 WARNING EWB00580 Always che...

Page 52: ... SHIN C 828 AUS NZL MAXXIS M980 EUR Size AT25 x 10 12 Type Tubeless The tires should be set to the recommended pressure Recommended tire pressure Front 25 0 kPa 0 250 kgf cm 3 6 psi Rear 25 0 kPa 0 250 kgf cm 3 6 psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides Tire pressure below the minimum speci fied could cause the tire to dislodge from the...

Page 53: ... two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Set the tire pressure when the tires are cold Set the tire pressures to the following specifications 1 Low pressure tire gauge Recommended pressure Front 25 0 kPa 0 250 kgf cm 3 6 psi Rear 25 0 kPa 0 250 kgf cm 3 6 psi Minimum Front 22 0 kPa 0 220 kgf cm 3 2 psi...

Page 54: ... in EBU19840 Chassis fasteners Make sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary 1 Tire wear limit U37S60E0 book Page 7 Thursday June 5 2008 6 51 PM ...

Page 55: ...h could lead to an acci dent or collision NOTICE ECB00150 See the Engine break in section on page 6 5 prior to operating the engine for the first time 1 Turn the fuel cock to ON 2 Turn the main switch to ON and the engine stop switch to 3 Shift the drive select lever into the neutral or park position The corresponding indicator light should come on If the indicator light does not come on have a Ya...

Page 56: ...t attempt Each cranking should be as short as possible to preserve battery ener gy Do not crank the engine more than 10 sec onds on each attempt If the battery is discharged pull the recoil starter to start the engine 7 If the engine is started with the starter choke in position 1 the starter choke should be returned to position 2 to warm up the engine If the engine is started with the starter cho...

Page 57: ...pen EBU20440 Operating the drive select lever and driving in reverse NOTICE ECB00170 Before shifting stop the ATV otherwise the transmission may be damaged Shifting Neutral to High range and High range to Low range 1 Bring the ATV to a complete stop 2 Apply the brake pedal and then shift by mov ing the drive select lever along the shift guide TIP Make sure that the drive select lever is completely...

Page 58: ...ce versa by moving the drive select lever along the shift guide TIP When in reverse the reverse indicator light should come on If the indicator light does not come on have a Yamaha dealer check the elec trical circuit Due to the synchronizing mechanism 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 Re...

Page 59: ...iding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the first 320 km 200 mi or 20 hours The various parts in the engine wear and polish themselves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in en gine overheating must be avoided ...

Page 60: ...jects Do not park the ATV at all on hills that are so steep you could not walk up them easily 1 Bring the ATV to a stop by applying the brakes 2 Stop the engine 3 With the brake pedal applied shift the drive select lever to the park position EBU20910 Accessories and loading EBU20920 Accessories Accessories can affect the handling and control of your ATV Keep the following in mind when consid ering...

Page 61: ... or a trailer can change the stability and han dling of an ATV You must use common sense and good judgment when carrying cargo or towing a trailer Keep the following points in mind Never exceed the weight limits shown An over loaded ATV can be unstable Do not exceed the maximum tongue weight You can measure tongue weight with a bath room scale Put the tongue of the loaded trailer on the scale with...

Page 62: ...arry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trail er Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV WARNIN...

Page 63: ...7 1 7 EBU21141 RIDING YOUR ATV U37S60E0 book Page 1 Thursday June 5 2008 6 51 PM ...

Page 64: ...y information on pages 1 1 1 4 Please also read all notice and warning labels on your ATV RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certified in structor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not at tempt to operate at maximum performance until you are totally familiar with th...

Page 65: ... child This ATV is designed to carry operator and car go only passengers prohibited WARNING EWB01400 Never carry a passenger The long seat is to al low the operator to shift position as needed during operation It is not for carrying passen gers Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV It could cause an accident resulting in harm to you and or yo...

Page 66: ...le helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants 1 Protective clothing 2 Goggles 3 Gloves 4 Boots 5 Helmet U37S60E0 book Page 4 Thursday June 5 2008 6 51 PM ...

Page 67: ...chances of severe injury in the event of an accident Do not operate after consuming alcohol or drugs The operator s performance capability is reduced by the influence of alcohol or drugs WARNING EWB01420 Never consume alcohol or drugs before or while driving this ATV Pre operation checks Always perform the pre operation checks listed on page 5 1 before riding for proper care of the ATV and to ensu...

Page 68: ...RNING EWB01450 Always go at a speed that is proper for the ter rain visibility and operating conditions and your experience Operating this ATV at speeds too fast for your skills or the conditions in creases your chances of losing control of the ATV which can result in an accident Speed limiter For riders less experienced with this model the throttle lever housing is equipped with a speed lim iter ...

Page 69: ... the instructions in your Own er s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the footboards during op eration otherwise they may contact the rear wheels MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and tongue 210 0 kg 463 lb Front carrier 40 0 kg 88 lb Rear carrier 80 0 kg 176 lb Front storage compartment 0 5 kg 1 lb...

Page 70: ...nto con tact with the rear wheels which could injure you or cause an accident Avoid wheelies and jumping You may lose control of the ATV or overturn WARNING EWB01480 Never attempt stunts such as wheelies or jumps Don t try to show off Modifications WARNING EWB01490 Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be gen u...

Page 71: ...stible materials to pre vent causing a fire hazard WARNING EWB01500 Do not touch the hot exhaust system Do not park the ATV during or after operation in a place where others might be likely to touch it Do not operate idle or park the ATV in dry grass dry ground cover or combustible ma terials BE CAREFUL WHERE YOU RIDE This ATV is designed for use on unpaved surfaces only Riding on paved surfaces c...

Page 72: ...oads Do not ride on any paved public street road or motorway WARNING EWB01520 Never operate this ATV on any paved street paved road or motorway You can collide with another vehicle In many areas it is illegal to operate ATVs on public streets roads and highways Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden ha...

Page 73: ... practiced the skills necessary to control the ATV on such terrain Failure to use extra care when operating on excessively rough slippery or loose terrain could cause loss of traction or ATV control which could result in an accident including an overturn When riding in an area where you might not easily be seen such as desert terrain mount a caution flag on the ATV DO NOT use the flag pole bracket...

Page 74: ...practice control of the throttle brakes shifting procedures and turning techniques in this area before trying more difficult terrain Always avoid riding on paved surfaces the ATV is designed for use on unpaved surfaces only and handling maneuvers are more difficult to perform on pavement Shift to the park position and follow the instruction on page 6 1 to start the engine Once it has warmed up you...

Page 75: ...re when riding in 4WD LOCK DIFF LOCK the front wheels also turn together at the same speed Therefore unless the wheel on the inside of the turn is allowed to slip or lose some traction the ATV will resist turning A special turning technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed WARNING EWB01770 Always follow pro...

Page 76: ...n may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the out side of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL Use proper riding techniques to avoid ATV over ...

Page 77: ... proper procedures for climb ing hills as described in this Owner s Manu al Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person cou...

Page 78: ...ed 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 side Physically turn the ATV around and then descend the hill If you start to roll backwards DO NOT apply either brake abruptly If you are in 2WD apply only the fron...

Page 79: ...o the park position Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and re mount following the procedure described in the Owner s Manual RIDING DOWNHILL When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as pos sible Move back on the seat and sit with your arms straight Engine compression will do most of the braking for...

Page 80: ...choose your path and ride no faster than you will be able to react to ob stacles which may appear WARNING EWB01620 Always follow proper procedures for going down hills as described in this Owner s Manu al Note a special technique is required when braking as you go down a hill Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high s...

Page 81: ...empt 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 crossing the side of a steep hill if possible 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 surfaces Shift your w...

Page 82: ...s of control which could lead to an accident Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability NOTICE ECB00920 After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case the V belt cooling duct check hose the drive select lever box check hos...

Page 83: ...h water if it has been operated in salt water or muddy con ditions 1 Air filter case check hose 1 V belt cooling duct check hose left front side of ATV 1 Drive select lever box check hose U37S60E0 book Page 21 Thursday June 5 2008 6 51 PM ...

Page 84: ...irmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult WARNING EWB01650 Before operating in a new area check for ob stacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When 1 Storage compartment check hose 1 V belt case drain plug 1 Storage compartment drain plug U37S60E0 book Page 22 Thursday June...

Page 85: ...he 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 be developed The terrain should be chosen carefully before attempting such maneuvers sinc...

Page 86: ...s Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide See page 7 23 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO ...

Page 87: ...7 BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability See page 7 19 U37S60E0 book Page 25 Thursday June 5 2008 6 51 PM ...

Page 88: ...VIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01840 Never service an engine while it is running Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or start fires Turn off the en gine when performing maintenance unless otherwise specified Have a Yamaha dealer perform the service if you are not familiar with maintena...

Page 89: ...nce required for a particular job have a Yamaha dealer perform it for you WARNING EWB01850 Never modify this ATV through improper in stallation or use of accessories as it may cause changes in handling which in some sit uations could lead to an accident All parts and accessories added to this ATV should be gen uine Yamaha or equivalent components de signed for use on this ATV and should be install...

Page 90: ...ire 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 clearance and adjust ...

Page 91: ...ess 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 U37S60E0 book Page 4 Thursday June 5 2008 6 51 PM ...

Page 92: ...ever worn to the limit 3 Rear brake Check operation and correct if necessary Check brake lever and pedal free play and adjust if necessary Replace brake friction plates Whenever worn to the limit 4 Brake hoses Check for cracks or other damage and replace if necessary Replace Every 4 years 5 Wheels Check runout and for damage and replace if nec essary 6 Tires Check tread depth and for damage and re...

Page 93: ...Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 16 Engine mount Check for cracks or other damage and replace if necessary 17 Axle boots Check for cracks or other damage and replace if necessary 18 Engine oil Change Check ATV for oil leakage and correct if neces sary 19 Engine oil filter car tridge Replace 20 Engine oil strainer Clean 21 Differe...

Page 94: ...operation and adjust or replace if neces sary 26 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing and cable 27 Front and rear brake switches Check operation and correct if necessary 28 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR...

Page 95: ... correct the brake fluid level Every two years replace the internal components of the brake master cylinder and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U37S60E0 book Page 8 Thursday June 5 2008 6 51 PM ...

Page 96: ... chapter Refer to this section each time a panel needs to be removed and installed EBU27600 Panels A and D To remove one of the panels 1 Remove the seat See page 4 18 2 Pull outward on the areas shown and then pull upward as shown 1 Panel A 2 Panel B 1 Panel C 2 Panel D 3 Panel E 4 Panel F U37S60E0 book Page 9 Thursday June 5 2008 6 51 PM ...

Page 97: ...8 10 8 To install one of the panels 1 Place the panel in its original position U37S60E0 book Page 10 Thursday June 5 2008 6 51 PM ...

Page 98: ...bolt and then take the panel off To install the panel Place the panel in the original position and install the bolt NOTICE ECB00380 When installing the panel be sure not to pinch the cables or wires 1 Panel B 2 Bolt U37S60E0 book Page 11 Thursday June 5 2008 6 51 PM ...

Page 99: ...ts 2 Remove the carrier bolts under the fenders and then take the carrier off 3 Remove the quick fastener screws and then pull the panel upward to remove it 1 Carrier bolt top 1 1 1 1 Carrier bolt under the fenders U37S60E0 book Page 12 Thursday June 5 2008 6 51 PM ...

Page 100: ... under the fenders 3 Install the carrier top bolts and then tighten all bolts to the specified torques Panel E To remove the panel Remove the bolts and then take the panel off 1 Quick fastener screw 2 Panel C 1 2 Tightening torques Carrier bolt top 34 Nm 3 4 m kgf 24 ft lbf Carrier bolt under fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 Panel E 2 Bolt U37S60E0 book Page 13 Thursday June 5 2008 6 51 PM ...

Page 101: ... is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accor dance 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 panel A See page 8 9 2 Remove the spark plug ca...

Page 102: ...electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally TIP If the spark plug shows a distinctly different color the engine could be operating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 1 Spark plug cap 1 Spark plug wrench U37S60E0 book Page 15 Thursday June 5 2008 6 51 PM ...

Page 103: ...to specification 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Specified spark plug NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in 1 Spark plug gap Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf U37S60E0 book ...

Page 104: ...intervals spec ified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the ATV on a level surface 2 Remove panel F See page 8 9 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 R...

Page 105: ... panel To change the engine oil with or without oil fil ter cartridge replacement 1 Place the ATV on a level surface 2 Remove panel F See page 8 9 3 Start the engine warm it up for several min utes and then turn it off 4 Place an oil pan under the engine to collect the used oil 5 Remove the engine oil filler cap and then re move the engine oil drain bolt to drain the oil from the crankcase 1 Dipst...

Page 106: ...page 8 9 7 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a nearby Yamaha dealer 8 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge 1 Oil filter cartridge 1 Oil filter wrench U37S60E0 book Page 19 Thursday June 5 2008 6 51 PM ...

Page 107: ...pecified torque with a torque wrench 10 Install panels E and D 11 Install the engine oil drain bolt and then tight en it to the specified torque 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf U37S60E0 book Page 20 Thursday June 5 2008 6 51 PM ...

Page 108: ... use oils labeled ENERGY CONSERV ING II or higher Make sure that no foreign material enters the crankcase 13 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 14 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary 15 Install panel F ...

Page 109: ...ust be checked on a cold engine 2 Remove the final gear oil filler bolt and then check the oil level in the final gear case TIP The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level 4 Install the oil filler bolt and then tighten it to the specified torque To change the fin...

Page 110: ...gear oil drain bolt to drain the oil from the final gear case 5 Install the drain bolt and then tighten it to the specified torque 6 Refill with the recommended final gear oil to the brim of the filler hole as shown 1 Engine guard 2 Final gear case guard 3 Bolt 1 Final gear oil drain bolt Tightening torque Final gear oil drain bolt 24 Nm 2 4 m kgf 17 ft lbf U37S60E0 book Page 23 Thursday June 5 20...

Page 111: ...heck the final gear case for oil leakage If oil is leaking check for the cause 9 Install the engine guard and the final gear case guard by installing the bolts and then tightening them to the specified torques 1 Final gear oil filler bolt 2 Correct oil level 3 Final gear oil Recommended final gear oil See page 10 1 Tightening torque Final gear oil filler bolt 24 Nm 2 4 m kgf 17 ft lbf Tightening t...

Page 112: ...e differential gear oil level must be checked on a cold engine 2 Remove the differential gear oil filler bolt and then check the oil level in the differential gear case TIP The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level 4 Install the oil filler bolt and then tighten...

Page 113: ...ified torque 5 Refill with the recommended differential gear oil to the brim of the filler hole as shown NOTICE ECB00410 Be sure no foreign material enters the differen tial gear case 6 Install the oil filler bolt and then tighten it to the specified torque 1 Differential gear oil drain bolt Tightening torque Differential gear oil drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 Differential gear oil 2 Dif...

Page 114: ...d en gine since the level varies with engine tempera ture 2 Check the coolant level in the coolant reser voir TIP The coolant should be between the minimum and maximum level marks 3 If the coolant is at or below the minimum level mark remove panel D See page 8 9 4 Remove the coolant reservoir cap add cool ant or distilled water to the maximum level mark install the reservoir cap and then install t...

Page 115: ...he coolant temperature in the radiator If the engine overheats see page 8 61 for fur ther instructions EBU23602 To change the coolant WARNING EWB01890 Wait for the engine and radiator to cool before removing the radiator cap You could be burned by hot fluid and steam blown out under pressure Always place a thick rag over the cap when opening Allow any remaining pressure to escape before completely...

Page 116: ...iator cap 6 Remove panel D See page 8 9 7 Remove the coolant reservoir cap 8 Disconnect the hose on the coolant reservoir side and then drain the coolant from the cool ant reservoir 1 Coolant drain bolt 1 Trough 1 Radiator cap U37S60E0 book Page 29 Thursday June 5 2008 6 51 PM ...

Page 117: ...ap water instead Do not use hard wa ter or salt water since it is harmful to the en gine If water has been used instead of coolant re place it with coolant as soon as possible otherwise the cooling system will not be pro tected against frost and corrosion 1 Coolant reservoir hose Tightening torque Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf Antifreeze water mixture ratio 1 1 Recommended antifree...

Page 118: ... Yamaha dealer check the cooling system 17 Install the panels and the front carrier EBU23645 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 bott...

Page 119: ...filter case 5 Pull off the air filter element lock plate and then remove the sponge material from the air filter element frame 1 Air filter case cover holder 2 Air filter case cover 1 Air filter element U37S60E0 book Page 32 Thursday June 5 2008 6 51 PM ...

Page 120: ...out of the sponge material and let it dry NOTICE ECB00440 Do not twist the sponge material when squeez ing it 8 Check the sponge material and replace it if damaged 9 Apply a quality foam air filter oil to the sponge material TIP The sponge material should be wet but not drip ping 10 Pull the sponge material over the air filter ele ment frame and then install the lock plate 1 Air filter element fra...

Page 121: ... seal Tighten all fit tings securely to avoid the possibility of unfiltered air entering the engine NOTICE ECB00460 Make sure that the air filter element is prop erly seated in the air filter case Never operate the engine with the air filter el ement removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Addition ally operation without the a...

Page 122: ...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 EBU23920 V belt cooling duct check hose If dust or water collects in the V belt cooling duct check hose remove the hose and clean it 1 Tailpipe 2 Spark arrester Tightening torque T...

Page 123: ...cated adjustment Therefore most carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience The adjustment described in the following section however may be performed by the owner as part of routine main tenance NOTICE ECB00480 The carburetor has been set and extensively tested at the Yamaha factory Changing these settings without sufficien...

Page 124: ...eed and if neces sary adjust it to specification by turning the throttle stop screw at the carburetor To in crease the engine idling speed turn the throt tle stop screw in direction a and to decrease it turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment 5 Install the panel 1 Throttle stop screw Engine idlin...

Page 125: ...cover back 2 Loosen the locknut 3 To increase the throttle cable free play turn the throttle cable free play adjusting bolt in di rection a To decrease the throttle cable free play turn the adjusting bolt in direction b 4 Tighten the locknut 5 Slide the rubber cover to its original position EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or ...

Page 126: ...nd the rear brake friction plates must be checked for wear at the intervals specified in the periodic maintenance and lubrica tion chart TIP This ATV is equipped with a wet multiple disc type rear brake which is located inside of the final gear case EBU24171 Front brake pads Check each front brake pad for damage and mea sure the lining thickness If a brake pad is dam aged or if the lining thicknes...

Page 127: ...EBU24251 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly causing it to become inef fective Before riding check that the brake fluid is above the minimum level mark and replenish if neces sary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for we...

Page 128: ... goes down suddenly have a Yamaha dealer check the cause EBU24281 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart In addition have the oil seals of the brake master cylinder and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are dam aged or le...

Page 129: ...rake pedal and brake lever free play and the brake pedal position must be checked and if nec essary adjusted at the intervals specified in the periodic maintenance and lubrication chart TIP Always perform this maintenance completely in the following order whenever adjusting the rear brake When adjusting the rear brake be sure to adjust both the brake pedal and the brake lever Before adjusting the ...

Page 130: ...lever free play adjusting bolt 2 Fully loosen the brake lever free play adjust ing nut on the brake cable at the final gear case 1 Brake pedal free play 1 Brake lever free play 1 Locknut 2 Brake lever free play adjusting bolt U37S60E0 book Page 43 Thursday June 5 2008 6 51 PM ...

Page 131: ...s 2 5 3 0 mm 0 10 0 12 in 4 Push the brake camshaft lever in direction a until it stops apply approximately 50 N 5 0 kgf 11 0 lbf of force and then turn the brake lever free play adjusting nut on the brake ca ble at the final gear case so that gap B mea sures 4 0 6 0 mm 0 16 0 24 in 1 Brake lever free play adjusting nut 1 Brake pedal free play adjusting nut 2 Brake camshaft lever 3 Gap A U37S60E0 ...

Page 132: ...er TIP When adjusting the rear brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move Checking the brake pedal position The top of the brake pedal should be positioned 75 0 85 0 mm 2 95 3 35 in above the footboard If the brake pedal position is incorrect have a Yamaha dealer adjust it 1 Brake lever free play adjusting nut 2 Brake camshaft lever 3 Gap B...

Page 133: ...ent of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer EBU24230 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart Check the axle boots for tears or damage If any damage is found have them re placed by a Yamaha dealer 1 Distance between brake pedal and footboard 1...

Page 134: ...er 1 Remove panel B See page 8 9 TIP The brake light switch is properly adjusted when the brake light comes on just before braking takes effect 2 Turn the brake light switch adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b 3 Install th...

Page 135: ...ed or kinked which could re strict the operation of controls and lead to an accident or injury EBU28711 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if necessary EBU28832 Checking and lubricating the brake pedal The operation of the brake pedal should be checked...

Page 136: ...rive shaft universal joint The drive shaft universal joint must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricate the universal joint using a grease gun EBU25021 Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer...

Page 137: ... maintenance and lu brication chart EBU29182 Battery This model is equipped with a VRLA Valve Regu lated Lead Acid battery There is no need to check the electrolyte or to add distilled water However the battery lead connections need to be checked and if necessary tightened NOTICE ECB00620 Never attempt to remove the battery cell seals as this would permanently damage the battery Recommended lubric...

Page 138: ...ces of ig nition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN To remove the battery 1 Remove the seat See page 4 18 2 Remove the battery holding plate by removing the bolts 3 Disconnect the negative battery lead first then the positive battery lead by removing their bolt 4 Pull the battery out of its compartment To charge the battery Have a Yamaha dealer...

Page 139: ...nths check it at least once a month and fully charge it if necessary To install the battery TIP Be sure the battery is fully charged 1 Place the battery in its compartment 2 Connect the positive battery lead first then connect the negative battery lead by installing their bolt 3 Install the battery holding plate by installing the bolts 4 Install the seat See page 4 18 NOTICE ECB00940 Always keep t...

Page 140: ...al short circuiting turn off the main switch when checking or replacing a fuse 1 Main fuse 2 Fuse box 1 Main fuse 2 Spare main fuse 1 Headlight fuse 2 Ignition fuse 3 Auxiliary DC jack fuse 4 Four wheel drive motor fuse 5 Signaling system fuse 6 Backup fuse for odometer and clock 7 Spare fuse U37S60E0 book Page 53 Thursday June 5 2008 6 51 PM ...

Page 141: ...evices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU25480 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 Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Four whee...

Page 142: ...and imme diately after it is turned off Wait for the bulb to cool before touching or removing it You can be burned or a fire could start if the bulb touch es something flammable 5 Insert a new headlight bulb into the bulb hold er by pushing it in 1 Headlight bulb holder cover 1 Headlight bulb holder 1 Do not touch the glass part of the bulb U37S60E0 book Page 55 Thursday June 5 2008 6 51 PM ...

Page 143: ...00670 Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly 8 Adjust the headlight beam if necessary EBU25551 Adjusting a headlight beam NOTICE ECB00690 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the headlight beam adjusting screw in direction a To lower a headlight beam turn the adjusting screw in dir...

Page 144: ...lb by turning it counterclockwise 3 Remove the defective bulb by pushing it in and turning it counterclockwise 1 Tail brake light assembly 2 Nut 1 Tail brake light assembly 2 Tail brake light bulb holder U37S60E0 book Page 57 Thursday June 5 2008 6 51 PM ...

Page 145: ...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 EBU25701 Installing a wheel 1 Place the ATV on a level surface 2 Install the wheel and the nuts TIP The arrow mark on the tire must point toward the rotating direction of the wheel 1 Tail brake light bulb holder 2 Tail bra...

Page 146: ... tapered side to wards the wheel 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torques 1 Arrow mark 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 40 ft lbf Rear wheel nut 55 Nm 5 5 m kgf 40 ft lbf U37S60E0 book Page 59 Thursday June 5 2008 6 51 PM ...

Page 147: ...ny repair take it to a Yamaha dealer whose skilled technicians have the necessary 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 EWB02280 Do not smoke when checking the fuel system Fuel can ignite or...

Page 148: ...TV 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 The battery is goo...

Page 149: ... 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 the engine overheats ...

Page 150: ...rioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed 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 warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach places ...

Page 151: ...d areas where strong chemicals are stored Long term Before storing your ATV for several months 1 Follow all the instructions in the Cleaning section of this chapter 2 Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosen ing the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabiliz...

Page 152: ... if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off the ground Alternative ly turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it o...

Page 153: ...637 lb AUS NZL Noise and vibration level Noise level 77 311 EEC 78 3 dB A EUR Vibration on seat EN1032 ISO5008 Will not exceed 0 5 m s EUR Vibration on handlebar EN1032 ISO5008 Will not exceed 2 5 m s EUR Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 421 0 cm Bore stroke 84 5 75 0 mm 3 33 2 95 in Compression ratio 10 00 1 Starting...

Page 154: ...aft Drive Gear Oil Part No ACC SHAFT LU 00 or SAE 80 API GL 4 Hypoid gear oil AUS NZL Yamaha Friction Modified Shaft Drive Gear Oil or SAE 80 API GL 4 Hypoid gear oil EUR Quantity 0 23 L 0 24 US qt 0 20 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 1 30 L 1 37 US qt 1 14 Imp qt Air filter Air filte...

Page 155: ...range 45 16 2 813 High range 38 23 1 652 Chassis Frame type Steel tube frame Caster angle 2 5 Trail 8 5 mm 0 33 in Front tire Type Tubeless Size AT25 x 8 12 Manufacturer model CHENG SHIN C 828 AUS NZL MAXXIS M979 EUR Rear tire Type Tubeless Size AT25 x 10 12 Manufacturer model CHENG SHIN C 828 AUS NZL MAXXIS M980 EUR Loading Maximum loading limit 210 0 kg 463 lb Total weight of rider cargo accesso...

Page 156: ...eration Front suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 160 mm 6 3 in Rear suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 180 mm 7 1 in Electrical system Ignition system DC CDI Charging system AC magneto Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah Headlight Bulb type Krypton bulb Bulb vol...

Page 157: ...ck indicator LCD High range indicator light LED Low range indicator light LED Differential gear lock indicator light LED Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Backup fuse 10 0 A Four wheel drive motor fuse 10 0 A U37S60E0 book Page 5 Thursday June 5 2008 6 51 PM ...

Page 158: ... erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26040 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key id...

Page 159: ...EBU26050 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha deal er 1 Vehicle identification number front left side 1 Vehicle identification number 2 Year of manufacture U37S60E0 book Page 2 Thursday June 5 2008 6 51 PM ...

Page 160: ...11 3 11 1 Model label U37S60E0 book Page 3 Thursday June 5 2008 6 51 PM ...

Page 161: ...1 Carrier rear 4 21 Chassis fasteners 5 7 Cleaning 9 1 Coolant 5 3 8 27 Coolant temperature warning light 4 2 D Differential gear lock indicator light 4 3 Differential gear oil 5 3 8 25 Drive select lever 4 14 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 39 Drive shaft universal joint lubricating 8 49 E Engine break in 6 5 Engine cold start 6 1 E...

Page 162: ...arking on a slope 6 6 Part locations 3 1 Pre operation check list 5 1 R Rear knuckle pivots lubricating 8 50 Recoil starter 4 14 Reverse indicator light 4 2 Riding your ATV 7 1 S Safety information 1 1 Seat 4 18 Shock absorber assemblies adjusting the front and rear 4 21 Spark arrester cleaning 8 34 Spark plug checking 8 14 Specifications 10 1 Speed limiter 4 12 Stabilizer bushes checking 8 49 Sta...

Page 163: ...V belt cooling duct check hose 8 35 Vehicle identification number 11 1 W Wheel hub bearings checking 8 49 Wheel installing 8 58 Wheel removing 8 58 U37S60E0 book Page 3 Thursday June 5 2008 6 51 PM ...

Page 164: ...YAMAHA MOTOR CO LTD PRINTED IN USA 2008 06 0 9 1 CR E U37S60E0 book Page 1 Thursday June 5 2008 6 51 PM ...

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