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Yamaha GRIZZLY 450 YFM45GDXG, Owner'S Manual

The Yamaha GRIZZLY 450 YFM45GDXG is a powerful all-terrain vehicle designed for adventure seekers. With its advanced features and reliable performance, this vehicle is perfect for outdoor enthusiasts. To ensure optimal usage, don't forget to download the comprehensive Owner's Manual for free from manualshive.com.

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8-43

8

the adjusting nut in direction (b). 

NOTICE:

Make sure that distance B measures 22
mm (0.87 in) or less. If distance B reaches
22 mm (0.87 in), adjust the brake lever free
play at the brake lever again. If distance A
exceeds 12.7 mm (0.50 in), have a Yamaha
dealer check the vehicle.

 [ECB01153]

7. Tighten the brake cable adjuster locknut.
8. Slide the rubber cover to its original position.
9. Tighten the locknut at the brake lever.

Adjusting the brake pedal height

The top of the brake pedal should be positioned
75.0–85.0 mm (2.95–3.35 in) above the footboard
bracket. If the brake pedal height is incorrect, ad-
just it as follows.

1. Remove the footboard by removing the bolts

and nuts.

1. Distance between brake pedal and footboard bracket

1

U2LC62E0.book  Page 43  Monday, May 11, 2015  2:28 PM

Summary of Contents for GRIZZLY 450 YFM45GDXG

Page 1: ...IRE MANUAL DEL PROPIETARIO 2LC F8199 6S 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 ...

Page 2: ...DIC183 Original instructions Notice originale Manual original PRINTED IN USA 2016 02 0 3 1 CR E F S ...

Page 3: ...Y It contains important safety information WARNING OWNER S MANUAL YFM45GDXG YFM45GPXG YFM45GPHG This ATV should not be ridden by anyone under 16 years of age 2LC F8199 6S E0 U2LC6SE0 book Page 1 Thursday January 21 2016 9 58 AM ...

Page 4: ...ives of EEC If applicable YAMAHA MOTOR EUROPE N V Koolhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Akihiro Tsuzuki Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and o...

Page 5: ... V Koolhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Akihiro Tsuzuki Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted Title...

Page 6: ...standing of the features and 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 manu...

Page 7: ...e 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 inf...

Page 8: ...rway Please check your local riding laws and regulations before operating this ATV EBU17411 YFM45GDXG YFM45GPXG YFM45GPHG OWNER S MANUAL 2016 by Yamaha Motor Co Ltd 1st edition January 2016 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 U2LC6SE0 book Page 1 Thursday January 21 2016 9 58 AM ...

Page 9: ...4 14 Brake pedal and rear brake lever 4 14 Drive select lever 4 15 Fuel tank cap 4 15 Fuel 4 15 Fuel cock 4 17 Starter choke 4 18 Seat 4 19 Storage compartments 4 20 Front carrier 4 22 Rear carrier 4 22 Adjusting the front and rear shock absorber assemblies 4 22 Auxiliary DC jack 4 24 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Differential gear oil 5 3 Coolant 5 3 Front an...

Page 10: ...he emission control system 8 3 General maintenance and lubrication chart 8 5 Removing and installing panels 8 10 Checking the spark plug 8 14 Engine oil and oil filter cartridge 8 16 Final gear oil 8 21 Differential gear oil 8 24 Coolant 8 26 Cleaning the air filter element 8 30 Cleaning the spark arrester 8 33 V belt cooling duct check hose 8 34 V belt case drain plug 8 35 Adjusting the carbureto...

Page 11: ...iversal joint 8 50 Checking the stabilizer bushes 8 51 Lubricating the rear knuckle pivots 8 51 Lubricating the steering shaft 8 52 Battery 8 52 Replacing a fuse 8 55 Replacing a headlight bulb 8 57 Adjusting a headlight beam 8 59 Replacing the tail brake light bulb 8 60 Removing a wheel 8 61 Installing a wheel 8 62 Troubleshooting 8 63 Troubleshooting charts 8 64 CLEANING AND STORAGE 9 1 Cleaning...

Page 12: ...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 re placement label from your Yamaha dealer For Europe 6 7 8 11 9 10 U2LC62E0 book Page 1 Monday May 11 2015 2 28 PM ...

Page 13: ...lbs 25 0 kPa 0 25 kgf cm 3 6 psi 25 0 kPa 0 25 kgf cm 3 6 psi 5FU F816M M0 1P0 F816P 20 37S F817R 10 80 kg 176 lbs 5880 N 600 kgf 1322 lbf 147 N 15 kgf 33 lbf 37S F817S 00 1 3 2 4 5 U2LC62E0 book Page 2 Monday May 11 2015 2 28 PM ...

Page 14: ...1 3 1 1P0 F816R 00 YAMAHA 1HP F811R 00 6 7 8 U2LC62E0 book Page 3 Monday May 11 2015 2 28 PM ...

Page 15: ...OR CO LTD 2500 SHINGAI IWATA JAPAN YFM450FWAD 19 4 kW 282 kg 2015 2LC F155A 10 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM450FWA 19 4 kW 276 kg 2015 1CU F155A 70 9 10 11 YFM45GPXG YFM45GPHG 11 YFM45GDXG U2LC62E0 book Page 4 Monday May 11 2015 2 28 PM ...

Page 16: ...e from 12 years old Operation of this ATV by children under the age of 12 increases the risk of severe injury or death Adult supervision required for children under age 16 Use from 16 years old Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER use on paved roads NEVER carry passengers NEVER use with drugs or alcohol NEVER store fuel or flammabl...

Page 17: ... loss of control Adjust the tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death This pictogram shows the loading limits and or maximum load capacity for this ATV Follow all load limits and other loading guidelines in this manual Load may include the driver passenger human protective gear accessories goods luggage and all other load re...

Page 18: ...1 7 1 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN kW kg 1 2 3 4 1 2 3 4 Year of construction Model Name Max Power Mass In Running Order U2LC62E0 book Page 7 Monday May 11 2015 2 28 PM ...

Page 19: ...1 8 1 For Oceania 6 1 2 3 4 5 7 8 9 U2LC62E0 book Page 8 Monday May 11 2015 2 28 PM ...

Page 20: ...1 9 1 5880 N 1322 600 kgf 15 kgf 37S F151K 00 5FU F816M 20 25 kPa 3 6 psi 25 kPa 3 6 psi 22 kPa 3 2 psi 22 kPa 3 2 psi 1 3 4 5 2 U2LC62E0 book Page 9 Monday May 11 2015 2 28 PM ...

Page 21: ...1 10 1 16 UNDER 1P0 F816L 00 7 6 U2LC62E0 book Page 10 Monday May 11 2015 2 28 PM ...

Page 22: ...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 1 lb 0 5 kg 37S F151F 00 8 9 U2LC62E0 book Page 11 Monday May 11 2015 2 28 PM ...

Page 23: ...hild under 16 years old should never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV This vehicle is intended for off road use only Do not operate on any paved surfaces suc...

Page 24: ...pting to turn at faster speeds and never turn at excessive speeds Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow 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 surfaces Shi...

Page 25: ...ch as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there a...

Page 26: ...essary If you can physically operate your vehicle inspect your vehicle If the vehicle is in safe operating con dition and you can safely operate it restart it and ride gently back to camp or other known location where you can receive medical at tention If necessary contact your riding party or local authorities to let them know where you are and what has happened In the event of a breakdown 1 If y...

Page 27: ...f the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries re lated to changes in the vehicle Keep the following guidelines in mind as well as those provided un der Loading when mounting accessories Never install accessories that would impair the performance of your ATV Carefully inspect the accessory befor...

Page 28: ...d areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or par tially enclosed areas such as barns garages or carports Do n...

Page 29: ...10 Coolant reservoir 11 V belt cooling duct check hose 1 2 3 4 5 6 7 8 9 10 11 1 Rear shock absorber assembly spring preload adjusting ring 2 Spark arrester 3 Rear storage compartment and tool kit 4 Spark plug 5 Fuel tank cap 6 Front shock absorber assembly spring preload adjusting ring 7 Rear brake light switch 8 Brake pedal 9 V belt case drain plug 1 2 3 4 6 7 8 5 9 U2LC62E0 book Page 1 Monday M...

Page 30: ...e lever 2 Handlebar switches 3 Starter choke 4 Horn switch 5 Drive select lever 6 Multi function display 7 Main switch 8 Auxiliary DC jack 9 On Command four wheel drive differential gear lock switch 10 Throttle lever 11 Front brake lever 12 Front storage compartment 5 4 12 11 10 9 2 1 3 6 7 8 U2LC62E0 book Page 2 Monday May 11 2015 2 28 PM ...

Page 31: ...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 EPS 1 U2LC62E0 book Page 1 Monday May 11 2015 2 28 PM ...

Page 32: ...dicator light This indicator light comes on when the transmis sion is in the neutral position 1 On Command differential gear lock indicator light DIFF LOCK 2 Low range indicator light L 3 High range indicator light H 4 Neutral indicator light N 5 Reverse indicator light R 6 Park indicator light P 7 On Command four wheel drive differential gear lock indicator 8 Coolant temperature warning light 1 E...

Page 33: ...do so and allow it to cool down for about 10 minutes NOTICE ECB00011 The engine may overheat if the ATV is over loaded In this case reduce the load to spec ification Start the engine after making sure that the warning light is out Continuous use while the warning light is on may cause damage to the engine EBU29062 Electric Power Steering warning light EPS for EPS model This warning light comes on ...

Page 34: ... four wheel drive switch is set to the 4WD position The On Command differential gear lock indicator and the On Command differential gear lock indicator light DIFF LOCK come on when the On Command differential gear lock switch is set to the LOCK position TIP Due to the synchronizing mechanism in the dif ferential gear case the four wheel drive indica tor may not come on until the ATV starts moving ...

Page 35: ...ect 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 dis tance that can be traveled with a full tank of fuel This information 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 between mph and km h C...

Page 36: ...nd then release it to start the clock EBU18051 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank When the needle reaches the red line refill the tank at the first opportunity 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 1 Fuel gauge 2 Red line U2LC62E0 book Page ...

Page 37: ...U18155 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 ECB00044 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 operate properly If t...

Page 38: ...ppear as shown in the figure TIP If the digits of the speedometer appear as shown when the switch is NOT being pushed this could indicate a malfunction in the electrical system In this case take the ATV to a Yamaha dealer at the first opportunity WARNING EWB00151 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 ...

Page 39: ...er ator and increase the risk of losing control and of causing an accident This ATV is equipped with a switch to change from two wheel drive to four wheel drive and vice ver sa Select the appropriate drive according to the terrain and the conditions 2WD two wheel drive Power is supplied to the rear wheels 4WD four wheel drive Power is supplied to the rear and front wheels To change from two wheel ...

Page 40: ...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 traveling This ATV is equipped with a switch allowing you to lock the differential...

Page 41: ...rential gear lock switch in to the LOCK position When the differential gear is locked the differential gear lock indicator light DIFF LOCK will come on along with the indicator in the multi function dis play 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 U2LC62E0 book Page ...

Page 42: ...nt is com plete When the ATV is in four wheel drive differential gear lock the maximum traveling speed is limit ed to 35 km h 22 mi h However if conditions require full engine power to be available push and hold the override switch to disable the dif ferential gear lock speed limiter See page 4 8 for a detailed explanation of this switch EBU18283 Throttle lever Once the engine is running pushing t...

Page 43: ...the adjusting screw in direction a To decrease the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction b Do not turn the adjusting screw out more than 12 mm 0 47 in or the throttle cable could be damaged Always make sure the throttle lever free play is adjusted to 3 0 5 0 mm 0 12 0 20 in See page 8 37 WARNING Im proper adjustment of the speed limi...

Page 44: ...andlebar grip EBU18443 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar To apply the rear brake push down on the brake pedal or pull the brake lever toward the handlebar grip 1 Front brake lever 1 Brake pedal 1 Rear brake lever U2LC62E0 book Page 14 Monday May 11 2015 2 28 PM ...

Page 45: ...tank cap by turning it counter clockwise EBU18757 Fuel Make sure there is sufficient gasoline in the tank WARNING EWB02522 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling fol low these instructions 1 Before refueling turn off the engine and be sure that no one is sitting on the vehicle Nev er refuel while smoking or...

Page 46: ...since fuel may deteriorate painted surfaces or plastic parts ECB00982 4 Turn the fuel tank cap fully clockwise to make sure it is securely closed WARNING EWB02532 Gasoline is poisonous and can cause injury or death Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor 1 Maximu...

Page 47: ...ctane number of 91 or higher 95 or higher for Europe 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 EBU18821 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while also filtering it The fuel cock lever positions are explained as fol lows and shown in the illustrations OFF With the ...

Page 48: ...Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EBU18851 Starter choke Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke 1 Arrow mark pointing to ON 1 Arrow mark...

Page 49: ...882 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 Make sure that the seat is securely fitted 1 Starter choke 1 Seat 2 Seat lock lever U2LC62E0 book Page 19 Monday May 11 2015 2 28 PM ...

Page 50: ...hey must be stored wrap them in appropriate cushion material to prevent damaging the stor age compartments The front storage 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 U2LC62E0 book Page 20 Monday May 11 2015 2 28 PM ...

Page 51: ...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 storage compartment If any water collects in a storage compartment re move the drain plug or the check hose drain the water ...

Page 52: ... 463 lb for the ATV EBU19148 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 WARNING EWB00401 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 1 Storage compartment...

Page 53: ...g preload and thereby soften the suspension Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber TIP A special wrench can be 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 U2LC62E0 book Page 23 Monday May 11 2015 2...

Page 54: ...essory on 6 When the auxiliary DC jack is not being used cover it with the cap NOTICE ECB00121 Do not use accessories requiring more than the above maximum capacity This may overload the circuit and cause the fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine start ing may become difficult Do not use an autom...

Page 55: ...by a Yamaha dealer Before using this vehicle check the following points 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 level if necessary Check ATV for oil leakage Correct if necessary 5 3 8 16 Final gear oil Check ATV for ...

Page 56: ...ver free play and adjust if necessary 5 4 8 37 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 4 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 8 49 Brake levers Ma...

Page 57: ... 8 26 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EBU28533 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 le ver and brake pedal If the free play is incorrect adjust ...

Page 58: ... 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 EBU19815 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 pressure...

Page 59: ...en the tire groove decreases to 3 mm 0 12 in due to wear replace the tire 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 Minimum tire pressure Front 22 0 kPa 0 220 kgf cm 3 2 psi Rear 22 0 kPa 0 220 kgf cm 3 2 psi Maximum tire seating pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi 1 Low pressure tire gauge U2LC62E0 book Pag...

Page 60: ...del by Yamaha Motor Manufacturing Corporation of America 1 Tire wear limit Front Manufacturer model CHENG SHIN C 828 YFM45GDXG_AUS NZL YFM45GPXG_AUS NZL MAXXIS MU13 YFM45GDXG_EUR FRA GBR YFM45GPHG YFM45GPXG_EUR FRA GBR Size AT25 x 8 12 Type Tubeless Rear Manufacturer model CHENG SHIN C 828 YFM45GDXG_AUS NZL YFM45GPXG_AUS NZL MAXXIS MU14 YFM45GDXG_EUR FRA GBR YFM45GPHG YFM45GPXG_EUR FRA GBR Size AT...

Page 61: ... of handling braking and comfort Other tires rims sizes and combinations may not be appropriate EBU19841 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened EBU19851 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary U2LC62E0 book Page 7 Monday May 11 2015 2 28 PM ...

Page 62: ...stop switch to 3 Shift the drive select lever into the neutral or park position The corresponding indicator light should come on if it does not come on have a Yamaha dealer check the electrical circuit TIP The engine can be started under the following conditions The drive select lever is in the neutral or park po sition The rear brake lever is applied with the drive se lect lever in any position H...

Page 63: ...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 en gine 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 idles smoothly then return the starter choke to position 3 before riding TIP The en...

Page 64: ... 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 and Reverse to Park WARNING EWB00721 Improper operation in reverse could make you hit an...

Page 65: ... reverse to park and vice versa by moving the drive se lect 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 ...

Page 66: ...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 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 oper ate it at one set throttle position 160 320 km 100 200 mi or 10 20 hours Avoid prolonged ...

Page 67: ... brakes 2 Stop the engine 3 With the brake pedal applied shift the drive select lever to the park position 4 Turn the fuel cock to OFF EBU20911 Accessories and loading EBU20922 Genuine Yamaha Accessories Choosing accessories for your ATV is an impor tant decision Genuine Yamaha Accessories which are available only from a Yamaha dealer have been designed tested and approved by Yamaha for use on you...

Page 68: ...f 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 view Use extra caution whe...

Page 69: ... with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow s...

Page 70: ...7 1 7 EBU21142 RIDING YOUR ATV U2LC62E0 book Page 1 Monday May 11 2015 2 28 PM ...

Page 71: ...1 2 6 Also read all warn ing and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01382 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...

Page 72: ...hat 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 carry ing passengers WARNING Never carry a passenger Carrying a passenger on this ATV greatly reduces your ability to balance and contr...

Page 73: ...NG Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01412 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 vision WARNING Operating w...

Page 74: ... 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 mainte nance procedures and schedules described in the Owner s Manual WARNING Failure to inspect the ATV before riding it or failure to maintain it properly increases the possibility of an acci dent and equipment damage EWB01433 Speed limite...

Page 75: ...ks 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 vehicl...

Page 76: ...ll off of the ATV If you remove a foot from a footboard your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident EWB01472 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rid er accessories and tongue 210 0 kg 463...

Page 77: ... 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 other engine...

Page 78: ...rfaces 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 EWB01512 While riding on unpaved public streets or roads may be legal in your area such operation can in crease the risk of collision with other vehicles Watch carefully for other vehicles Make sure you U2LC62E0 bo...

Page 79: ...h 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 EWB01532 Do not operate on rough slippery or loose terrain until you have learned and practiced the skills nec essary to...

Page 80: ...n 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 areas where you cannot easily be seen Mount a cau tion flag on the ATV to make you more visible Watch carefully for other vehicles EWB01552 Do not ride in areas posted no trespassing Do not ride on private property without getting permission U2LC62E0 book Page 11 Mon...

Page 81: ...g release the throttle and apply the brakes smoothly and evenly Improper use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident NOTICE ECB00252 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 EWB01772 Always follow proper pr...

Page 82: ...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 throt tle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV be gins to tip over to the outside whi...

Page 83: ... 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 crossing the side of ...

Page 84: ...d If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill 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...

Page 85: ... 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 on the uphill side to come off the ground or cause loss of traction Apply bra...

Page 86: ...ither the front or rear brake because the wheels on the uphill side could come off the ground Apply both the front and rear brakes gradually Whenever possible ride your ATV straight 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 EWB01633 I...

Page 87: ...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 grad ually steer again in the direction you wish to travel ...

Page 88: ...u have regained proper braking ability WARNING Wet brakes may have reduced stopping ability which could cause loss of control EWB02622 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 and the rear storage compartment check hose Also remove the V belt case drain plug and front storage...

Page 89: ...7 20 7 1 Air filter case check hose 1 V belt cooling duct check hose left front side of ATV 1 Storage compartment check hose 1 V belt case drain plug U2LC62E0 book Page 20 Monday May 11 2015 2 28 PM ...

Page 90: ...ards at all times Avoid jumping the ATV as loss of control and damage to the ATV may result SLIDING AND SKIDDING WARNING EWB01663 Skidding or sliding improperly may cause you to lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippe...

Page 91: ...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 since both stability and control are reduced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost WHAT TO DO IF This s...

Page 92: ...ed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE IF THE ATV IS IN 2WD the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 13 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to maintain proper ...

Page 93: ...urn 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 6 for more information about carbon monoxide WARNING EWB02691 ...

Page 94: ... the tools provided in the owner s tool kit are intended to assist you in the performance of pre ventive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Owner s manual 2 Owner s tool kit ...

Page 95: ...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 clearance and adj...

Page 96: ...ness 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 U2LC62E0 book Page 4 Monday May 11 2015 2 28 PM ...

Page 97: ...ls 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 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 c...

Page 98: ...place if necessary 9 V belt Check for wear cracks or other damage and re place if necessary 10 Drive shaft univer sal joint Lubricate with lithium soap based grease 11 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 12 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary NO ITEM CHECK OR MAINTENANCE JOB...

Page 99: ...r other damage and replace if necessary 18 Axle boots Check for cracks or other damage and replace if necessary 19 Engine oil Change Check ATV for oil leakage and correct if neces sary 20 Engine oil filter car tridge Replace 21 Engine oil strainer Clean 22 Differential gear oil Change Check ATV for oil leakage and correct if neces sary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er come...

Page 100: ...place if neces sary 27 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 28 Front and rear brake switches Check operation and correct if necessary 29 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 32...

Page 101: ...at full throttle Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinder and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U2LC62E0 book Page 9 Monday May 11 2015 2 28 PM ...

Page 102: ...bed in this chapter Refer to this section each time a panel needs to be removed and installed EBU30262 Panels A and C To remove a panel 1 Remove the seat See page 4 19 2 Pull outward on the areas shown and then pull upward as shown 1 Panel A 1 Panel B 2 Panel C 3 Panel D 4 Panel E U2LC62E0 book Page 10 Monday May 11 2015 2 28 PM ...

Page 103: ...8 11 8 To install a panel 1 Place the panel in its original position 2 Install the seat U2LC62E0 book Page 11 Monday May 11 2015 2 28 PM ...

Page 104: ...lts 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 U2LC62E0 book Page 12 Monday May 11 2015 2 28 PM ...

Page 105: ...olts to the specified torques Panel D To remove the panel Remove the bolts and then take the panel off To install the panel Place the panel in the original position and install the bolts Panel E To remove the panel Pull outward on the areas shown 1 Quick fastener screw 2 Panel B Tightening torques Carrier bolt top 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt under fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 2 1...

Page 106: ...will cause any spark plug to slowly erode the spark plug should be removed and checked in ac cordance with the periodic maintenance and lubri cation 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 10 2 Remove the spark plug cap 1 Panel E 1 1 Spark plug cap U2LC62E0 book Page 14 Monday May 11 2015 2 28 PM ...

Page 107: ...rk 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 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 1 S...

Page 108: ...e speci fied torque as soon as possible 3 Install the spark plug cap 4 Install the panel EBU30241 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrica tion chart To check the engine oil level 1 Place the ATV on a level s...

Page 109: ... level TIP The engine oil should be between the tip of the dipstick and the maximum level mark 6 If the engine oil is not between the tip of the dipstick and the maximum level mark add sufficient oil of the recommended type to raise it to the correct level NOTICE Be sure the engine oil is at the correct level other wise engine damage may result ECB00852 7 Insert the dipstick into the oil filler ho...

Page 110: ...il 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 and its gasket to drain the oil from the crankcase TIP Skip steps 6 10 if the oil filter cartridge is not be ing replaced 6 Remove panels C and D See page 8 10 7 Remove the oil filter cartridge with an oil filter wrench 1 Engine oil drain bolt 2 Gasket 1 2 1 Oil filter cart...

Page 111: ...l to the O ring of the new oil filter cartridge TIP Make sure that the O ring is properly seated 9 Install the new oil filter cartridge with an oil fil ter wrench and then tighten it to the specified torque with a torque wrench 1 Oil filter wrench 1 O ring U2LC62E0 book Page 19 Monday May 11 2015 2 28 PM ...

Page 112: ...ince the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher 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 Recommended...

Page 113: ...cked and the oil changed as follows at the intervals speci fied in the periodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface 2 Remove the final gear oil filler bolt and its gas ket and then check the oil level in the final gear case 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 ...

Page 114: ... final gear oil drain bolt and their gasket to drain the oil from the final gear case 5 Install the drain bolt and its new gasket and then tighten the bolt to the specified torque Tightening torque Final gear oil filler bolt 22 Nm 2 2 m kgf 16 ft lbf 1 Engine guard 2 Final gear case guard 3 Bolt 2 3 3 1 Final gear oil drain bolt 2 Gasket Tightening torque Final gear oil drain bolt 22 Nm 2 2 m kgf ...

Page 115: ...l filler bolt and its gasket and then tighten the bolt to the specified torque 9 Check the final gear case for oil leakage If oil is leaking check for the cause 10 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 Gasket 3 Final gear oil 4 Correct oil level Recommended final gear oil See p...

Page 116: ...l gear oil filler bolt and its gasket and then check the oil level in the differential gear case The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level 4 Check the gasket for damage and replace it if necessary 5 Install the oil filler bolt and its gasket and then tighten th...

Page 117: ...ifferential gear oil to the brim of the filler hole as shown NOTICE Be sure no foreign material en ters the differential gear case ECB00412 6 Check the oil filler bolt gasket for damage and replace it if necessary 7 Install the oil filler bolt and its gasket and then tighten the bolt to the specified torque 1 Differential gear oil drain bolt 2 Gasket Tightening torque Differential gear oil drain b...

Page 118: ...ck 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 C to access the coolant reservoir See page 8 10 4 Remove the coolant reservoir cap add cool ant or distilled water to the maximum level mark install the reservoir cap and then install the panel NOTICE If coolant is ...

Page 119: ...lant temperature in the radiator If the engine overheats see page 8 65 for fur ther instructions EBU23608 To change the coolant WARNING EWB01891 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 remov...

Page 120: ...nder the engine and then remove the coolant drain bolt and its gasket Use a trough or a similar object as shown to prevent coolant from spilling on the footrest 1 Radiator cap 1 Coolant drain bolt 2 Gasket 1 Trough 2 1 U2LC62E0 book Page 28 Monday May 11 2015 2 28 PM ...

Page 121: ...r only However if distilled water is not available soft water may be used for refilling Do not use hard water or salt water since they are harmful to the engine ECB00992 13 Pour the recommended coolant into the radi ator until it is full 14 Install the radiator cap start the engine let it idle for several minutes and then turn it off 1 Coolant reservoir hose Tightening torque Coolant drain bolt 10...

Page 122: ...lement 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 rid ing in unusually wet or dusty areas TIP There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air fil ter case 1 Plac...

Page 123: ... 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 U2LC62E0 book Page 31 Monday May 11 2015 2 28 PM ...

Page 124: ...rial and replace it if damaged 9 Apply Yamaha foam air filter oil or other qual ity 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 11 Insert the air filter element into the air filter case and then install the air filter case cover by hooking the holder...

Page 125: ...main tenance is performed check the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the carburetor fittings and the rubber joint manifold fittings for an air tight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine EBU27083 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cle...

Page 126: ...carbon monoxide poison ing possibly leading to death and start a fire Always let the exhaust system cool prior to touching exhaust components EBU23921 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 Tailpipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 V belt cooling duct check hose left ...

Page 127: ... sophisticated adjustment There fore most carburetor adjustments should be left to a Yamaha dealer who has the necessary pro fessional knowledge and experience The adjust ment described in the following section however may be performed by the owner as part of routine maintenance NOTICE ECB00481 The carburetor has been set and extensively tested at the Yamaha factory Changing these settings without...

Page 128: ...peed 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 idli...

Page 129: ...ck 2 Loosen the locknut 3 To increase the throttle lever free play turn the throttle lever free play adjusting bolt in di rection a To decrease the throttle lever free play turn the adjusting bolt in direction b 4 Tighten the locknut 5 Slide the rubber cover to its original position EBU24061 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine n...

Page 130: ... serviced or adjust ed brakes could lead to a loss in braking ability and an accident EBU28414 Checking the front brake pads and rear brake friction plates The front brake pads and the rear brake friction plates must be checked for wear at the intervals specified in the periodic maintenance and lubrica tion chart TIP This ATV is equipped with a wet multiple disc type rear brake which is located in...

Page 131: ...e and lubrication chart EBU29843 Checking the brake fluid level Before riding check that the brake fluid is above the minimum level mark Check the brake fluid lev el with the top of the reservoir level Replenish the brake fluid if necessary WARNING EWB02721 Improper maintenance can result in loss of braking ability Observe these precautions 1 Lining thickness 1 Minimum level mark Specified brake f...

Page 132: ...id level may indicate worn brake pads and or brake system leakage therefore be sure to check the brake pads for wear and the brake system for leakage If the brake fluid level goes down sud denly have a Yamaha dealer check the cause be fore further riding EBU24283 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubricat...

Page 133: ...d and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart Adjusting the brake lever free play The brake lever free play should measure 10 0 mm 0 39 in If the free play is incorrect adjust it as fol lows 1 Loosen the locknut at the brake lever 1 No brake lever free play 1 Brake lever free play U2LC62E0 book Page 41 Monday May 11 2015 2 28 PM ...

Page 134: ... specified brake lever free play could be ob tained as described above skip steps 3 8 3 Fully turn the adjusting bolt in direction a to loosen the brake cable 4 Slide the rubber cover back 5 Loosen the brake cable adjuster locknut 6 To increase the brake lever free play turn the brake lever free play adjusting nut in direction a To decrease the brake lever free play turn 1 Locknut 2 Distance A 3 B...

Page 135: ... Tighten the brake cable adjuster locknut 8 Slide the rubber cover to its original position 9 Tighten the locknut at the brake lever Adjusting the brake pedal height The top of the brake pedal should be positioned 75 0 85 0 mm 2 95 3 35 in above the footboard bracket If the brake pedal height is incorrect ad just it as follows 1 Remove the footboard by removing the bolts and nuts 1 Distance betwee...

Page 136: ...ified limits 4 Tighten the locknut 5 Install the footboard by installing the bolts and nuts and then tighten them to the speci fied torques 1 Footboard 2 Bolt and nut 3 Bolt 2 2 3 1 1 Locknut 2 Adjusting bolt Tightening torque Locknut 7 Nm 0 7 m kgf 5 1 ft lbf 2 1 U2LC62E0 book Page 44 Monday May 11 2015 2 28 PM ...

Page 137: ...free play should measure 20 0 mm 0 79 in If the free play is incorrect adjust it as follows 1 Footboard bolt A 2 Footboard bolt B 1 1 2 Tightening torques Footboard bolt A 4 0 Nm 0 40 m kgf 2 9 ft lbf Footboard bolt B 7 Nm 0 7 m kgf 5 1 ft lbf 6 5 6 6 5 6 2 4 3 1 U2LC62E0 book Page 45 Monday May 11 2015 2 28 PM ...

Page 138: ...the brake pedal free play turn the adjusting nut in direction b 3 Tighten the locknut EBU24231 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart Check the axle boots for tears or damage If any damage is found have them replaced by a Yamaha dealer 1 Brake pedal free play 1 Locknut 2 Brake pedal free play adjusting nut 2...

Page 139: ... should be adjusted by a Yamaha dealer Turn the rear brake light switch adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b 1 Front axle boot each side 1 Rear axle boot each side 1 1 1 Rear brake light switch 2 Rear brake light switch adj...

Page 140: ...controls and lead to an accident or injury Always make sure all control cables work smoothly before you begin riding in cold weather If the control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead to an accident or collision EBU28712 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be c...

Page 141: ... each ride and the pedal pivot should be lubricated if necessary EBU24964 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play Recommended lubricant Lithium soap based grease U2LC62E0 book Page 49 Monday May 11 2015 2 28 PM ...

Page 142: ...rive shaft universal joint The drive shaft universal joint must be lubricated at the intervals specified in the periodic mainte nance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun Front Recommended lubricant Lithium soap based grease 1 Grease nipple 1 U2LC62E0 book Page 50 Monday May 11 2015 2 28 PM ...

Page 143: ...amaha dealer replace the stabilizer bush es if necessary EBU25053 Lubricating the rear knuckle pivots The rear knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun 1 Grease nipple 1 Recommended lubricant Lithium soap based grease U2LC62E0 book Page 51 Monday May 11 2015 2 28 PM ...

Page 144: ...ghtened WARNING EWB02161 Battery electrolyte is poisonous and danger ous as it contains sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately EYES F...

Page 145: ...ICE When removing the bat tery the main switch must be off and the negative lead must be disconnected be fore the positive lead ECB01002 4 Pull the battery out of its compartment To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional elec tric...

Page 146: ...ICE ECB00941 Always keep the battery charged Storing a discharged battery can cause permanent bat tery damage 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 NOTICE When installing the bat tery the main switch must be off and the positive ...

Page 147: ...e seat See page 4 19 For non EPS models 1 Main fuse 2 Fuse box 3 Spare main fuse 1 2 3 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 clock 7 Spare fuse 1 2 3 4 5 6 7 U2LC62E0 book Page 55 Monday May 11 2015 2 28 PM ...

Page 148: ...dental short circuiting turn off the main switch when checking or replacing a fuse 1 Main fuse 2 Fuse box 3 EPS fuse 4 Spare main fuse 1 2 3 4 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Four wheel drive motor fuse 5 Backup fuse for clock 6 Auxiliary DC jack fuse 7 Spare fuse 1 2 3 4 5 6 7 U2LC62E0 book Page 56 Monday May 11 2015 2 28 PM ...

Page 149: ...rn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU25482 Replacing a headlight bulb If a headlight bulb burns out replace it as follows Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Four wheel drive motor fuse 10 0 A Signaling system fuse 10 0 A Auxiliary DC jack fuse ...

Page 150: ...ove the headlight bulb holder cover by pulling it off 3 Remove the headlight bulb holder by pushing it in and turning it counterclockwise 1 Cover at the rear of the headlight 1 Headlight bulb holder cover 1 Headlight bulb holder 1 U2LC62E0 book Page 58 Monday May 11 2015 2 28 PM ...

Page 151: ...tall the bulb holder by pushing it in and turning it clockwise 7 Install the bulb holder cover and the cover at the rear of the headlight NOTICE Make sure the headlight bulb holder cover is se curely fitted over the bulb holder and seat ed properly ECB00672 8 Adjust the headlight beam if necessary EBU25553 Adjusting a headlight beam NOTICE ECB00691 It is advisable to have a Yamaha dealer make this...

Page 152: ...ollows 1 Remove the tail brake light assembly by re moving the nuts together with the washers 2 Remove the tail brake light bulb holder to gether with the bulb by turning it counter clockwise 1 Headlight beam adjusting screw 1 Tail brake light assembly 2 Nut U2LC62E0 book Page 60 Monday May 11 2015 2 28 PM ...

Page 153: ...the bulb holder together with the bulb by turning it clockwise 6 Install the tail brake light assembly by install ing the washers and the nuts EBU25652 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 1 Tail brake light assembly 2 Tail brake light bulb holder 1 Tail brake light bulb holder 2 Tail brake light bulb U2LC62E0 book Page 61 Monday May 11 2015 2 28 PM ...

Page 154: ...l 1 Place the ATV on a level surface 2 Install the wheel and the nuts TIP The arrow mark on the tire must point to ward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nuts with their tapered side towards the wheel 1 Wheel nut 1 Arrow mark 1 U2LC62E0 book Page 62 Monday May 11 2015 2 28 PM ...

Page 155: ...t to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the ATV properly Use only genuine Yamaha replacement parts 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 EWB02281 Do not smoke when checking the fuel system Fuel can ignite or explode causing ...

Page 156: ...maha dealer check the ATV Have a Yamaha 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 Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The battery is go...

Page 157: ...er can be temporarily used instead provided that it is changed to the recommended 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 158: ...tion dry out the linings EWB02312 NOTICE Excessive wa ter 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 de tergent applications such as those avail able in coin operated car washers ECB00712 4 Once most of the dirt has been hosed off wash all surfaces with w...

Page 159: ...r 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 will limit spa...

Page 160: ...e 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 infor mation on storing the battery see page 8 52 TIP Make any necessary repairs before storing the ATV U2LC62E0 book Page 3 Monday May 11 2015 2 28 PM ...

Page 161: ...45GPHG YFM45GPXG_EUR FRA GBR Vibration on seat EN1032 ISO5008 0 6 m s YFM45GDXG_EUR FRA GBR 1 0 m s YFM45GPHG YFM45GPXG_EUR FRA GBR Uncertainty of measurement 0 3 m s YFM45GDXG_EUR FRA GBR YFM45GPHG YFM45GPXG_EUR FRA GBR Vibration on handle EN1032 ISO5008 2 9 m s YFM45GDXG_EUR FRA GBR Will not exceed 2 5 m s YFM45GPHG YFM45GPXG_EUR FRA GBR Uncertainty of measurement 0 5 m s YFM45GDXG_EUR FRA GBR 0...

Page 162: ...Oil or SAE 80 API GL 4 Hypoid gear oil Quantity 0 23 L 0 24 US qt 0 20 Imp qt Coolant quantity Coolant reservoir up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator including all routes 1 32 L 1 40 US qt 1 16 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 15 0 L 4 0 US gal 3 30 Imp gal Fuel reserve amount 4 5...

Page 163: ... C 828 YFM45GDXG_AUS NZL YFM45GPXG_AUS NZL MAXXIS MU13 YFM45GDXG_EUR FRA GBR YFM45GPHG YFM45GPXG_EUR FRA GBR Rear tire Type Tubeless Size AT25 x 10 12 Manufacturer model CHENG SHIN C 828 YFM45GDXG_AUS NZL YFM45GPXG_AUS NZL MAXXIS MU14 YFM45GDXG_EUR FRA GBR YFM45GPHG YFM45GPXG_EUR FRA GBR Loading Maximum loading limit 210 0 kg 463 lb Total weight of rider cargo accessories and tongue Tire air press...

Page 164: ... 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 voltage wattage quantity Headlight 12 V 30 0 30 0 W 2 Tail brake light 12 V...

Page 165: ...2 For Europe only The figures quoted are emission levels and are not necessarily safe working levels Whilst there is a correlation between the emission and exposure levels this cannot be used reliably to determine whether or not further precautions are required Factors that influence the actual level of exposure of work force include the characteristics of the work room the other sources of noise ...

Page 166: ...EL LABEL INFORMATION EBU26031 Vehicle identification number The vehicle identification number is stamped into the frame TIP The vehicle identification number is used to iden tify your ATV EBU26051 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 Ya...

Page 167: ...11 2 11 1 Model label U2LC62E0 book Page 2 Monday May 11 2015 2 28 PM ...

Page 168: ...olant 5 3 8 26 Coolant temperature warning light 4 3 D Differential gear oil 5 3 8 24 Drive select lever 4 15 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 38 Drive shaft universal joint lubricating 8 50 E Engine break in 6 5 Engine cold start 6 1 Engine idling speed 8 35 Engine oil 5 3 Engine oil and oil filter cartridge 8 16 Engine starting a wa...

Page 169: ... pedal height 8 41 Rear knuckle pivots lubricating 8 51 Reverse indicator light 4 3 Riding your ATV 7 1 S Safety information 2 1 Seat 4 19 Shock absorber assemblies adjusting the front and rear 4 22 Spark arrester cleaning 8 33 Spark plug checking 8 14 Specifications 10 1 Speed limiter 4 13 Stabilizer bushes checking 8 51 Starter choke 4 18 Start switch 4 7 Steering shaft lubricating 8 52 Storage ...

Page 170: ...PPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PAVED ROADS NEVER CARRY PASSENGERS NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND W...

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