Yamaha GRIZZLY 450 Owner'S Manual Download Page 117

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8-24

To check the differential gear oil level

1. Place the ATV on a level surface.

NOTE:

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.

NOTE:

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 differential gear oil

1. Place the ATV on a level surface.
2. Place an oil pan under the differential gear

case to collect the used oil.

3. Remove the differential gear oil filler bolt and

the differential gear oil drain bolt to drain the
oil from the differential gear case.

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)

U1D913E0.book Page 24 Thursday, April 20, 2006 2:47 PM

Summary of Contents for GRIZZLY 450

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

Page 2: ...EBU17091 U1D913E0 book Page 1 Thursday April 20 2006 2 47 PM ...

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

Page 4: ...change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the ATV operator a bystander or a person inspecting or repairing the ATV A CAUTION indicates special precautions that must be taken to avoid damage to the ATV A NOTE provides key information to make procedures easier or ...

Page 5: ...d spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17401 AFFIX DEALER LABEL HERE YFM45FGW OWNER S MANUAL 2006 by Yamaha Motor Corporation U S A 1st edition April 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expre...

Page 6: ...Main switch 4 1 Throttle lever 4 11 Speed limiter 4 12 Front brake lever 4 13 Brake pedal and rear brake lever 4 14 Drive select lever 4 14 Recoil starter 4 15 Fuel tank cap 4 16 Fuel 4 16 Fuel cock 4 17 Starter choke 4 19 Seat 4 19 Storage compartment 4 20 Front carrier 4 21 Rear carrier 4 22 Adjusting the front and rear shock absorber assemblies 4 22 Auxiliary DC jack 4 23 PRE OPERATION CHECKS 5...

Page 7: ...2 TURNING YOUR ATV 7 17 RIDING OVER ROUGH TERRAIN 7 30 SLIDING AND SKIDDING 7 31 WHAT TO DO IF 7 32 WHAT TO DO 7 33 PERIODIC MAINTENANCE AND MINOR REPAIR 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...

Page 8: ... 8 46 Checking the wheel bearings 8 46 Lubricating the drive shaft universal joint 8 46 Checking the stabilizer bushes 8 47 Lubricating the upper and lower arm Replacing a fuse 8 50 Replacing a headlight bulb 8 52 Adjusting a headlight beam 8 54 Replacing the tail brake light bulb 8 54 Removing a wheel 8 56 Installing a wheel 8 56 Troubleshooting 8 58 Troubleshooting charts 8 59 CLEANING AND STORA...

Page 9: ...ruc tor Contact an authorized ATV dealer or call 1 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 Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and streets Never operate an ...

Page 10: ...steep for the 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 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 ...

Page 11: ...ce of skidding or sliding out of con trol Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have 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 12: ...open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the ATV in another vehi cle be sure it is kept upright and that the fuel cock is in the OFF position Other wise fuel may leak out of the carburetor or fuel tank HOW TO AVOID THE HAZARD If you should swallow some gasoline or in hale a lot of gasoline vapor or get some gas oline in...

Page 13: ...t fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad equate ventilation U1D913E0 book Page 5 Thursday April 20 2006 2 47 PM ...

Page 14: ...2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U1D913E0 book Page 1 Thursday April 20 2006 2 47 PM ...

Page 15: ...hese labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer U1D913E0 book Page 2 Thursday April 20 2006 2 47 PM ...

Page 16: ...2 U1D913E0 book Page 3 Thursday April 20 2006 2 47 PM ...

Page 17: ...2 U1D913E0 book Page 4 Thursday April 20 2006 2 47 PM ...

Page 18: ...e stop screw 5 Air filter case 6 Battery 7 Fuses 1 Rear shock absorber assembly spring preload adjusting ring 2 Spark arrester 3 Storage compartment and tool kit 4 Spark plug 5 Rear brake fluid reservoir 6 Front shock absorber assembly spring preload adjusting ring U1D913E0 book Page 1 Thursday April 20 2006 2 47 PM ...

Page 19: ...e figures shown in this manual 1 Rear brake lever 2 Handlebar switches 3 Starter choke 4 Drive select lever 5 Multifunction meter unit 6 Main switch 7 Fuel tank cap 8 Auxiliary DC jack 9 On Command four wheel drive differential gear lock switch U1D913E0 book Page 2 Thursday April 20 2006 2 47 PM ...

Page 20: ...switch The positions of the main switch are 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 U1D913E0 book Page 1 Thursday April 20 2006 2 47 PM ...

Page 21: ...operation stop the engine as soon as it is safe to do so and allow it to cool down for about 10 minutes CAUTION ECB00010 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 1 On Command differential gear lock indicator light DIFF LOCK 2 Low range indicator light L 3 High range indicator light H 4 Neutral indic...

Page 22: ... until the differential gear is locked EBU17970 Park indicator light This indicator light comes on when the transmis 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 on when the transmis sion is in the low range position EBU18001 On Command differential gear lock indi...

Page 23: ...pmeter 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 NOTE Holding in the TRIP ODO button and then turning the key to ON switches the display between mph and km h Clock mode 1 Speedometer...

Page 24: ...050 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank When the needle reaches the red line re fill the tank at the first opportunity NOTE 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 EBU18060 Handlebar switches 1 Light switch OFF 2 Start switch 3 Engine stop switch U...

Page 25: ...e the starting instructions on page 6 1 prior to starting 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 CAUTION 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 sta...

Page 26: ...witch 2WD 4WD This ATV is equipped with a switch to change from POTENTIAL HAZARD Riding too fast while the ATV is in four wheel drive differential gear lock WHAT CAN HAPPEN All wheels turn at the same speed when the differential 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...

Page 27: ...nging from two wheel drive to four wheel drive or from four wheel drive to two wheel drive while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in two wheel drive than in four wheel drive in some cir cumstances Changing from two wheel drive to four wheel drive or from four wheel drive to two wheel drive while moving may cause the ATV to unexpectedly handle differently This could dis...

Page 28: ...al gear is locked Unlike in four wheel drive all wheels turn at the same speed To lock the differential gear in four wheel drive make sure the On Command four wheel drive switch is pushed in to the 4WD position Stop the ATV move the differential gear lock lever to position a and then push the differential gear lock switch in to the LOCK position When the dif ferential gear is locked the differenti...

Page 29: ...andles differently in four wheel drive than in differential gear lock in some circumstances Changing from four wheel drive to differential gear lock or vice versa while moving may cause the ATV to handle differently unexpectedly This could distract the operator and increase the risk of losing control and causing an accident HOW TO AVOID THE HAZARD Always stop the ATV before changing from four whee...

Page 30: ...ever Once the engine is running movement of the throt tle lever will 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 POTENTIAL HAZARD Riding too fast while the ATV is in four wheel drive differential gear l...

Page 31: ...ail able and the maximum speed of the ATV turn the adjusting screw in direction a To de crease the maximum engine power available and the maximum speed of the ATV turn the adjusting screw in direction b 1 Throttle lever POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate mak HOW TO AVOID THE HAZARD Check the operation of the throttle lever be fore you sta...

Page 32: ...g screw 3 No more than 12 mm 0 47 in POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Im HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in 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 1 Front brake lever U1D913E0 book Page 13 Thursday Apr...

Page 33: ... pedal or pull the brake lever toward the handlebar grip EBU18611 Drive select lever The drive select lever is used to shift your ATV into the low range high range neutral reverse and park positions See the Operating the drive select lever and driving in reverse section on page 6 3 for the drive select lever operation 1 Brake pedal 1 Rear brake lever U1D913E0 book Page 14 Thursday April 20 2006 2 ...

Page 34: ...ll the rope all the way out WARNING EWB00290 1 Drive select lever 1 Recoil starter POTENTIAL HAZARD Starting the engine without setting the drive select lever to the park position WHAT CAN HAPPEN The ATV could start to move unexpectedly which could cause an accident HOW TO AVOID THE HAZARD U1D913E0 book Page 15 Thursday April 20 2006 2 47 PM ...

Page 35: ...ent fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Fuel tank cap 1 Fuel level 2 Fuel tank filler tube Recommended fuel UNLEADED GASOLINE ONLY 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 U1D913E0 book Page 16 Thursday April 20 2006 2 47 PM ...

Page 36: ...n tent does not exceed 10 Gasohol containing methanol is not recommended by Yamaha be cause it can cause damage to the fuel system or ATV performance problems 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 explained as fol lows and shown in the illustrations WHAT CAN HAPPEN Fuel can spill which can cause a f...

Page 37: ...his position when the engine is not running ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding 1 Arrow mark pointing to OFF 1 Arrow mark pointing to ON U1D913E0 book Page 18 Thursday April 20 2006 2 47 PM ...

Page 38: ...oon as possible and be sure to turn the fuel cock lever back to ON EBU18850 Starter choke Move the starter choke in direction b to turn off the starter choke See the Starting a cold engine section on page 6 1 for proper operation EBU18880 Seat To remove the seat Pull the seat lock lever upward and pull up the seat 1 Arrow mark pointing to RES 1 Starter choke U1D913E0 book Page 19 Thursday April 20...

Page 39: ...41 Storage compartment The storage compartment is located under the seat See page 4 19 When storing any documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the ATV be careful not to let any water enter the storage 1 Seat 2 Seat lock lever 1 Projection 2 Seat holder U1D913E0 book Page 20 Thursday April 20 2006 2 47 PM ...

Page 40: ...mit of 2 0 kg 4 lb for the storage compartment NOTE There is a check hose at the bottom of the storage compartment If any water collects in this hose re move the hose empty it and then install it EBU18960 Front carrier Do not exceed the load limit of 40 0 kg 88 lb for the front carrier Do not exceed the maximum load of 210 0 kg 1 Storage compartment 1 Storage compartment check hose U1D913E0 book P...

Page 41: ...it the rid er s weight and the riding conditions Adjust the spring preload as follows Turn the adjusting ring in direction a to increase the spring preload and thereby harden the suspen sion and in direction b to decrease the spring preload and thereby soften the suspension NOTE A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Position i...

Page 42: ...tart the engine See page 6 1 3 Open the auxiliary DC jack cap and then in sert the accessory power plug into the jack 1 Special wrench Spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorber assem blies on the left and righ...

Page 43: ...s 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 automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged WARNING EWB00010 1 Auxiliary DC jack cap Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A U1D913E0 book Page 24 T...

Page 44: ...s sary Check fuel line for leakage Correct if necessary 4 16 5 4 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 4 8 16 Final gear oil Check ATV for oil leakage Correct if necessary 5 4 8 21 Differential gear oil Check ATV for oil leakage Correct if necessary 5 4 8 23 Coolant Check coolant level in reser...

Page 45: ...s Make sure that operation is smooth Lubricate if necessary 8 45 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 7 5 8 5 9 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 8 46 Brake levers Make sure that operation is smooth Lubricate lever piv...

Page 46: ...N Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual U1D913E0 book Page 3 Thursday April 20 2006 2 47 PM ...

Page 47: ...coolant level must be checked on a cold en gine since the level varies with engine tempera ture POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and se vere injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful...

Page 48: ...e Check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs Apply the brakes firmly for one minute If a lever moves slow ly 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 POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN...

Page 49: ...ith improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any prob lem with the brakes If a problem cannot be corrected by the adjustment procedures pro vided in this manual have a Yamaha dealer check for the cause U1D913E0 book Page 6 Thur...

Page 50: ...have been approved by Yamaha Motor Manufacturing Corpora tion of America for this model Other tire combinations are not recommended Front Manufacturer model MAXXIS M979 Size AT25 x 8 12 Rear Manufacturer model MAXXIS M980 Size AT25 x 10 12 Type Tubeless The tires should be set to the recommend ed pressure Recommended tire pressure Front 25 0 kPa 3 6 psi 0 250 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf...

Page 51: ...ecifications Tire pressure below the minimum speci fied could cause the tire to dislodge from the rim under severe riding conditions Minimum tire pressure Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Use no more than the following pressures when seating the tire beads Maximum tire seating pressure Front 250 kPa 36 psi 2 5 kgf cm Rear 250 kPa 36 psi 2 5 kgf cm Higher press...

Page 52: ...switches Check that all instruments lights and switches are working properly Correct if necessary Recommended pressure Front 25 0 kPa 3 6 psi 0 250 kgf cm Rear 25 0 kPa 3 6 psi 0 250 kgf cm Minimum Front 22 0 kPa 3 2 psi 0 220 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Maximum Front 28 0 kPa 4 1 psi 0 280 kgf cm Rear 28 0 kPa 4 1 psi 0 280 kgf cm 1 Tire wear limit U1D913E0 book Page 9 Thursday Apri...

Page 53: ... familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an acci dent or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer POTENTIAL HAZARD Frozen control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO ...

Page 54: ...it is recom mended to shift into the neutral or park position before starting the engine 4 Use the starter choke in reference to the fig ure Position 1 Cold engine start with ambient temperature below 5 C 40 F Position 2 Cold engine start with ambient temperature Ambient temp starter choke position 5 Apply the rear brake lever 6 Completely close the throttle lever and start the engine by pushing t...

Page 55: ...ding NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the starter choke is not required when the engine is warm Instead start the engine with the throttle slightly open EBU20430 Operating the drive select lever and driving in reverse CAU...

Page 56: ... 3 Shift from neutral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide 1 Drive select lever 2 L Low range 3 H High range 4 N Neutral 5 R Reverse 6 P Park 1 Drive select lever 2 L Low range 3 H High range 4 N Neutral 5 R Reverse 6 P Park U1D913E0 book Page 4 Thursday April 20 2006 2 47 PM ...

Page 57: ...ration or any condi tion that might result in engine overheating must be avoided 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the engine freely but do not use full throttle at any time 20 hours and beyond The ATV can now be operated normally CAU...

Page 58: ...r ATV Keep the following in mind when consid ering an accessory or operating an ATV which has POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The ATV could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the ATV transversely across the incline stop the en gine shift th...

Page 59: ...sory that limits your ability to move around on the seat or one that limits your view Use extra caution when riding an ATV with ac cessories The ATV may handle differently than it does without accessories EBU21030 Loading Cargo or a trailer can change the stability and han Never exceed the weight limits shown An over loaded ATV can be unstable Do not exceed the maximum tongue weight MAXIMUM LOADIN...

Page 60: ...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 WARNING EWB00750 WARNING EWB00010 Indicates a potential hazard that could result in serious injury or death POTENTIAL HAZARD Overloading thi...

Page 61: ...7 EBU21131 RIDING YOUR ATV U1D913E0 book Page 1 Thursday April 20 2006 2 47 PM ...

Page 62: ...o familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you ular attention to the safety information on pages 1 1 1 5 Please also read all caution 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 ...

Page 63: ...should then regularly practice the skills learned in the course and the operating techniques de scribed in this Owner s Manual For more in formation about the training course contact an authorized ATV dealer or call 1 800 887 2887 POTENTIAL HAZARD Failure to follow the age recommendations WHAT CAN HAPPEN Use by children of ATVs that are not recom mended for their age can lead to severe inju ry or ...

Page 64: ...APPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passen ger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as need ed during operation It is not for carrying passengers U1D913E0 book Page 4 Thursday April 20 2006 2 47 PM ...

Page 65: ...without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing in creases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved ...

Page 66: ... drugs WHAT CAN HAPPEN Could seriously affect your judgment HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make ...

Page 67: ... of control in creasing your risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual for this ATV on page 5 7 Always maintain proper tire pressure as de scribed in the Owner s Manual on page 5 8 POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of t...

Page 68: ...p speed See page 4 12 Loading and accessories Use extra caution when riding the ATV with addi tional loads such as accessories or cargo The ATV s handling may be adversely affected Re duce your speed when adding additional loads 1 Adjusting screw 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 ...

Page 69: ...dent HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pull ing a trailer Allow greater distance for brak ing Always follow the instructions in your Own er s Manual for carrying cargo or pulling a trailer U1D913E0 book Page 9 Thursday April 20 2006 2 47 PM ...

Page 70: ...e your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a foot board your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation POTENTIAL HAZARD Attempting whee...

Page 71: ...h in some situations could HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo nents designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV dealer U1D913E0 book Page 11 Thursday April...

Page 72: ...m WHAT CAN HAPPEN Dry grass or brush or other combustible ma terial accumulated around the engine area could catch fire Someone touching the exhaust system dur ing or after operation could be burned HOW TO AVOID THE HAZARD Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Do not touch the hot exhaus...

Page 73: ...ways parking lots and streets POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways U1D913E0 book Page 13 Thursday April 20 2006 2 47 PM ...

Page 74: ...terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operat ing on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV POTENTIAL HAZARD Failure to use extra care when operating on excessively rough...

Page 75: ... pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especial ly cautious on these kinds of terrain POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be in jured U1D913E0 book Page 15 Thursday April 20 2006 2 47 PM ...

Page 76: ...ng shift the drive select lever into the low range position or the high range posi tion Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds un til you are thoroughly familiar with the operation of your...

Page 77: ...make turns quickly and easily It is es sential that this skill be learned first at low speed WARNING EWB01310 POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causing a colli sion or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner s Manual Prac tice turning at low speeds before attempting to turn at faster speed...

Page 78: ...heels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body move ments or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more ...

Page 79: ...ARD Operating on excessively steep hills WHAT CAN HAPPEN The ATV can overturn more easily on ex tremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills U1D913E0 book Page 19 Thursday April 20 2006 2 47 PM ...

Page 80: ...use the ATV to overturn HOW TO AVOID THE HAZARD Always follow 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 sp...

Page 81: ...7 U1D913E0 book Page 21 Thursday April 20 2006 2 47 PM ...

Page 82: ...crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turn ing on any hill Avoid crossing the side of a steep hill if pos sible When crossing the side of ...

Page 83: ... HAZARD Stalling rolling backwards or improperly dis mounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Use the proper gear and maintain a steady speed when climbing a hill If you lose all forward speed If you begin rolling backwards Keep weight uphill 2WD Never apply the rear brake while roll ing backwards Apply the front brake When fully stoppe...

Page 84: ... or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the down hill side Avoid sudden application of either the front or rear brake because the wheels on the up 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...

Page 85: ...7 U1D913E0 book Page 25 Thursday April 20 2006 2 47 PM ...

Page 86: ...ur ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING EWB01141 POTENTIAL HAZARD Improperly crossing hills or turning on hills HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as...

Page 87: ...7 U1D913E0 book Page 27 Thursday April 20 2006 2 47 PM ...

Page 88: ...50 Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an acci dent HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in wat...

Page 89: ...ir filter case the V belt cooling duct check hose the drive select lever box check hose and the storage compartment check hose Also remove the V belt case drain plug to drain any water that may have accumu lated Wash the ATV in fresh water if it has been 1 Air filter case check hose U1D913E0 book Page 29 Thursday April 20 2006 2 47 PM ...

Page 90: ...damage to the ATV or could lead to an upset or ac cident Be sure to keep your feet firmly mounted on the footboards at all times Avoid jumping the ATV as loss of control and damage to the ATV may re sult EWB01160 1 Drive select lever box check hose 1 V belt case drain plug U1D913E0 book Page 30 Thursday April 20 2006 2 47 PM ...

Page 91: ...s positioning your weight over the front wheels will sometimes help WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for ob stacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s...

Page 92: ...e WARNING EWB01170 WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each section on riding tech niques completely POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by pract...

Page 93: ...forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE 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 balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance I...

Page 94: ...DEPENDING ON THE WEATHER TERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01820 EBU21720 Owner s manual and tool kit Be sure to put this owner s manual in the plastic bag and always carry it on the bottom of the seat as shown Put the owner s tool kit and low pres sure tire gauge under the seat POTENTIAL HAZARD Servicing an engine while...

Page 95: ...ating this ATV with improper modifica tions WHAT CAN HAPPEN Improper installation of accessories or mod ification of this ATV may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper in stallation or use of accessories All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo nents...

Page 96: ...hould be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if ne...

Page 97: ... 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 U1D913E0 book Page 4 Thursday April 20 2006 2 47 PM ...

Page 98: ...ct if necessary Check fluid level and ATV for fluid leakage and correct if necessary Replace brake pads Whenever worn to the limit 3 Rear brake Check operation and correct if necessary Check brake lever free play and adjust if neces sary Check fluid level and ATV for fluid leakage and correct if necessary Replace brake pads Whenever worn to the limit 4 Brake hoses Check for cracks or other damage ...

Page 99: ...bushes Check for cracks or other damage and replace if necessary 14 Knuckle pivots Lubricate with lithium soap based grease 15 Knuckle shafts Lubricate with lithium soap based grease 16 Steering shaft Lubricate with lithium soap based grease 17 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 18 Engine mount Check for cracks or other damage and ...

Page 100: ...t Every 2 years 26 Moving parts and cables Lubricate 27 Drive select lever safety system cable Check operation and adjust or replace if neces sary 28 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 NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month ...

Page 101: ...lic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U1D913E0 book Page 8 Thursday April 20 2006 2 47 PM ...

Page 102: ...own need to be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EBU27600 Panels A and D To remove one of the panels 1 Remove the seat See page 4 19 1 Panel A 1 Panel C 2 Panel D 3 Panel E 4 Panel F U1D913E0 book Page 9 Thursday April 20 2006 2 47 PM ...

Page 103: ...8 To install one of the panels 1 Place the panel in its original position U1D913E0 book Page 10 Thursday April 20 2006 2 47 PM ...

Page 104: ...he panel Remove the bolt and then take the panel off To install the panel Place the panel in the original position and install the bolt CAUTION ECB00380 1 Bolt 2 Panel B U1D913E0 book Page 11 Thursday April 20 2006 2 47 PM ...

Page 105: ...s 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 Carrier bolt under the fenders U1D913E0 book Page 12 Thursday April 20 2006 2 47 PM ...

Page 106: ... carrier bolts 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 To install the panel Place the panel in the original position and install the bolts 1 Quick fastener screw 2 Panel C 1 Panel E 2 Bolt U1D913E0 book Page 13 Thursday April 20 2006 2 47 PM ...

Page 107: ...sits 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 cap 1 Panel F U1D913E0 book Page 14 Thursday April 20 2006 2 47 PM ...

Page 108: ...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 To install the spark plug 1 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification 1 Spark plug w...

Page 109: ...torque as soon as possible 4 Install the spark plug cap 5 Install the panel EBU23322 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 spec ified in the periodic maintenance and lubrication chart To check the engine oil level 1 Remove panel F See page 8 9 2 Place the...

Page 110: ...n the minimum and maximum level marks 7 If the engine oil is at or below the minimum level mark add sufficient oil of the recom mended type to raise it to the correct level 8 Insert the dipstick into the oil filler hole and 1 Engine oil filler cap 1 Dipstick 2 Maximum level mark 3 Minimum level mark U1D913E0 book Page 17 Thursday April 20 2006 2 47 PM ...

Page 111: ... 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 NOTE Skip steps 6 10 if the oil filter cartridge is not being replaced 6 Remove panels D and E See page 8 9 7 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter cartridge U1D913E0 book Page 18 Thursday April...

Page 112: ...the O ring of the new oil filter cartridge NOTE 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 U1D913E0 book Page 19 Thursday April 20 2006 2 47 PM ...

Page 113: ...additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher Make sure that no foreign material enters the 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Recommended oil See page 10 1 Oil quantity Without oil filter cartridge replacement ...

Page 114: ...inal gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface NOTE The final gear oil level must be checked on a cold engine NOTE 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...

Page 115: ...inal gear oil filler bolt and the fi nal gear oil drain bolt to drain the oil from the 5 Install the drain bolt and then tighten it to the specified torque 6 Add 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 23 Nm 2 3 m kgf 17 ft lbf U1D913E0 book Page 22 T...

Page 116: ...tial 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 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 23 Nm 2 3 m kgf 17 ft lbf Tightening torques Engine guard bolt...

Page 117: ...he correct level 4 Install the oil filler bolt and then tighten it to the specified torque To change the differential gear oil 1 Place the ATV on a level surface 2 Place an oil pan under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case 1 Differential gear oil 2...

Page 118: ...ECB00410 Be sure no foreign material enters the differen tial gear case 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 Differential gear oil filler bolt 3 Correct oil level Recommended differential gear oil See page 10 1 U1D913E0 book Page 25 Thursday April 20 2006 2 47 PM ...

Page 119: ... must be checked on a cold en gine since the level varies with engine tempera ture 2 Check the coolant level in the coolant reser NOTE 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 reservoir cap add coolant or dis tilled water to the maximum level mark install Tightening torque Diffe...

Page 120: ...o change the coolant WARNING EWB01880 1 Place the ATV on a level surface 2 Remove panels E and F See page 8 9 3 Place a container under the engine and then remove the coolant drain bolt Use a trough or a similar object as shown to prevent coolant from spilling on the footrest Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt POTENTIAL HAZARD Removing the radiato...

Page 121: ...diator 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 Radiator cap U1D913E0 book Page 28 Thursday April 20 2006 2 47 PM ...

Page 122: ...ft tap water instead Do not use hard wa ter or salt water since it is harmful to the en gine 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 antifreeze High quality ethylene glycol antifreeze con taining corrosion inhibitors for aluminum en gines Coolant quantity Radiator capacity including all routes 1 30 L 1 ...

Page 123: ...en install the radiator cap 16 Start the engine and then check for coolant leakage NOTE If any leakage is found have a Yamaha dealer check the cooling system 17 Install the panels and the front carrier EBU23630 Cleaning the air filter element The air filter element should be cleaned at the in NOTE There is a check hose at the bottom of the air filter case If dust or water collects in this hose emp...

Page 124: ... the air filter case 4 Pull off the lock plate and then remove the sponge material from the air filter element frame 1 Air filter case holder 2 Air filter case cover 1 Air filter element U1D913E0 book Page 31 Thursday April 20 2006 2 47 PM ...

Page 125: ...al NOTE The sponge material should be wet but not drip ping 9 Pull the sponge material over the air filter ele ment frame and then install the lock plate 10 Insert the air filter element into the air filter case and then install the air filter case cover 1 Air filter element frame 2 Sponge material 3 Air filter element lock plate POTENTIAL HAZARD Using low flash point solvents or gasoline to clean...

Page 126: ...CB00460 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 air filter element will affect carburetor jetting with subsequent EBU23881 Cleaning the spark arrester Be sur...

Page 127: ...rk arrester POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the ex...

Page 128: ... carburetor The carburetor should be checked and if neces sary adjusted at the intervals specified in the peri odic maintenance and lubrication chart The carburetor is an important part of the engine and requires very sophisticated adjustment Therefore most carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience The adjustment 1 V belt ...

Page 129: ...odic maintenance and lubrica tion chart NOTE A diagnostic tachometer is needed to make this adjustment 1 Start the engine and warm it up NOTE The engine is warm when it quickly responds to the throttle 4 Check the engine idling speed 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 i...

Page 130: ...hecked and ad justed if necessary before adjusting the throttle ca ble free play 1 Loosen the locknut 2 To increase the throttle cable free play turn the adjusting bolt in direction a To decrease the throttle cable free play turn the adjusting bolt in direction b 3 Tighten the locknut EBU24060 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine...

Page 131: ...intervals specified in the periodic main tenance and lubrication chart 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 thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the brake pads as a set NOTE The wheels need to be removed to check the brake pads See page 8 56 EBU26460 Rear brake pad...

Page 132: ...ke fluid level 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 wear and the brake system for leakage Front brake 1 Wear indicator groove 1 Minimum level mark U1D913E0 book Page 39 Thursday April 20 ...

Page 133: ...boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid imme diately As the brake pads wear it is normal for the brake fluid level to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause EBU24290 Changing the brake fluid Have a Yamaha dealer change the b...

Page 134: ...justed and brake pedal position must be checked and if nec essary adjusted at the intervals specified in the periodic maintenance and lubrication chart NOTE 1 Brake lever free play WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not ...

Page 135: ...n If the free play is in correct adjust it as follows 1 Loosen the locknut 3 Tighten the locknut If the correct free play cannot be obtained have a Yamaha dealer adjust it NOTE 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 1 Brake lever free play 1 Locknut 2 Brake lever free play adjusting bolt U1D913E0 book Page 42 Thu...

Page 136: ...for tears or damage If any damage is found have them re placed by a Yamaha dealer 1 Distance between brake pedal and footboard POTENTIAL HAZARD Operating with improperly serviced or ad HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brak...

Page 137: ...itches should be adjusted by a Yamaha dealer 1 Remove panel B See page 8 9 NOTE The brake light switch is properly adjusted when the brake light comes on just before braking takes effect 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direc tion a To make the brake light come on lat er turn the adjusting nut i...

Page 138: ...ers The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if necessary 1 Brake light switch 2 Brake light switch adjusting nut POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged and cables can also be come frayed or kinked which could restrict the operation of con...

Page 139: ...remove panel B See page 8 9 EBU24961 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EBU24970 Lubricating the drive shaft universal joint U1D913E0 book Page 46 Thursday April 20 ...

Page 140: ...pper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte nance and lubrication chart EBU25050 EBU25080 Lubricating the knuckle shafts The knuckle shafts must be lubricated at the inter vals specified in the periodic maintenance and lu brication chart Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease Recommended lub...

Page 141: ...ed lubricant Lithium soap based grease WHAT CAN HAPPEN You could be poisoned You could be se verely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gas es HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Al ways shield eyes when working near batter ies Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of ...

Page 142: ...s fully charged 1 Place the battery in its compartment 2 Make sure to properly connect the battery leads to the battery terminals CAUTION ECB00630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a spe cial constant voltage battery charger is re quired Using a conventional battery charger will damage the battery If y...

Page 143: ...8 EBU25313 Replacing a fuse 1 Main fuse 2 Fuse box 1 Main fuse 2 Spare main fuse U1D913E0 book Page 50 Thursday April 20 2006 2 47 PM ...

Page 144: ...use 2 Remove the blown fuse and then install a new fuse of the specified amperage 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 Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Four wheel drive motor fuse 3 0 A Signaling system fuse 10 0 A Auxiliary DC jack...

Page 145: ...lb holder cover at the rear of the headlight by pulling it off 2 Disconnect the headlight coupler by lifting the tab as shown and pulling out the coupler POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rating Never use a material in place of the p...

Page 146: ...180 4 Install a new headlight bulb holder assembly by inserting it into the headlight unit and turn ing it clockwise 1 Headlight bulb holder assembly POTENTIAL HAZARD WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flammable HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it 1 Do not touch the glass part of the bulb U1D913E0 book ...

Page 147: ...dlight CAUTION ECB00670 Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly 7 Adjust the headlight beam if necessary EBU25550 Adjusting a headlight beam ECB00690 To raise a headlight beam turn the adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b EBU25620 Replacing the tail brake light bulb If the tail...

Page 148: ...y 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 U1D913E0 book Page 55 Thursday April 20 2006 2 47 PM ...

Page 149: ...l brake light assembly by install ing the washers and the nuts EBU25650 Removing a wheel 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel EBU25700 Installing a wheel 1 Install the wheel and the nuts NOTE 1 Tail brake light bulb holder 2 Tail brake light bulb 1 Wheel nut U1D913E0 book Page 56 Thursday April 20 2006 2 47 PM ...

Page 150: ...pered side to wards the wheel 2 Lower the ATV to the ground 3 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 U1D913E0 book Page 57 Thursday April 20 2006 2 47 PM ...

Page 151: ... 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 EWB02260 POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame HOW...

Page 152: ...arter 2 Compression There is compression There is no compression Check the ignition 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 battery 4 Battery Dry Wet Open the throttle halfway and operate the e...

Page 153: ...e cap Allow any remaining pressure to escape before completely removing the cap Wait until the engine has cooled Check the coolant level in the reservoir and radiator 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 NOTE Start the engine If the engine overheats again have a Yamaha dealer c...

Page 154: ...10 Excessive water pressure may cause water 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 5 Rinse the ATV off immediately with clean wa ter and dry all surfaces wit...

Page 155: ...osen 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 stabilizer if available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the WHAT CAN HA...

Page 156: ...s and the pivoting points of all levers and pedals 7 Check and 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 an...

Page 157: ...th oil and fuel 285 0 kg 628 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Compression ratio 10 00 1 Starting system Electric and recoil starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 SAE5W30 or SAE10W30 or SAE20W40 0 10 30 50 70 90 110 130 F YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 20 30 40 50 C YAMALUBE 4 20W40 or...

Page 158: ...p qt Air filter Air filter element Wet element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 15 0 L 3 96 US gal 3 30 Imp gal Fuel reserve amount Type x quantity BSR33 x 1 Spark plug s Manufacturer model NGK DR8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet centrifugal automatic Transmission Primary reduction system V belt Secondary reduction system Shaft drive...

Page 159: ...d tongue Tire air pressure measured on cold tires Recommended Front 25 0 kPa 3 6 psi 0 250 kgf cm Rear 22 0 kPa 3 2 psi 0 220 kgf cm Maximum Front 28 0 kPa 4 1 psi 0 280 kgf cm Rear 28 0 kPa 4 1 psi 0 280 kgf cm Front wheel Wheel type Panel wheel Rim size 12 x 6 0AT Rear wheel Wheel type Panel wheel Rim size 12 x 7 5AT Front brake Type Dual disc brake Operation Right hand operation Recommended flu...

Page 160: ...del YTX20L BS Voltage capacity 12 V 18 0 Ah Headlight Bulb type Tail brake light 12 V 5 0 21 0 W 1 Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Park indicator light LED On Command four wheel drive differential gear lock indicator LCD High range indicator light LED Low range indicator light LED Differential gear lock indicator light LED Fuses Main fu...

Page 161: ...10 Four wheel drive motor fuse 3 0 A U1D913E0 book Page 5 Thursday April 20 2006 2 47 PM ...

Page 162: ...ef 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 EBU26030 Vehicle identification number The vehicle identification number is stamped into 1 Key identifica...

Page 163: ...0 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 1 Vehicle identification number front left side 1 Model label U1D913E0 book Page 2 Thursday April 20 2006 2 47 PM ...

Page 164: ...e of noise control prior to its sale or delivery to the ul timate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Muff...

Page 165: ...e maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 22500 14400 1440 60 25000 16000 1600 U1D913...

Page 166: ...quent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation USA also warra...

Page 167: ...set up every new machine before sale 2 Explain the operation maintenance and warranty requirements to your satis faction at the time of sale and upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha ATV dealer within the con...

Page 168: ... pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodging ...

Page 169: ...expires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 U1D913E0 book Page 8 Thursday April 20 2006 2 4...

Page 170: ...11 EBU26132 U1D913E0 book Page 9 Thursday April 20 2006 2 47 PM ...

Page 171: ... front and rear 5 5 C Cables checking and lubricating 8 45 Carburetor adjusting 8 35 Carrier front 4 21 D Differential gear lock indicator light 4 3 Differential gear oil 5 4 8 23 Drive select lever 4 14 Drive select lever and driving in reverse 6 3 Drive select lever safety system cable adjusting 8 38 Drive shaft universal joint lubricating 8 46 E Engine break in 6 5 Engine cold start 6 1 Engine ...

Page 172: ...ial gear lock switch 4 9 On Command four wheel drive switch 4 7 Override switch 4 6 Part locations 3 1 Pre operation check list 5 1 R Recoil starter 4 15 Reverse indicator light 4 2 Riding your ATV 7 1 S Safety information 1 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 12 Stabilizer...

Page 173: ... 8 35 V belt cooling duct check hose 8 34 Vehicle identification number 11 1 W Warranty extended 11 7 Warranty limited 11 5 Wheel bearings checking 8 46 Wheel installing 8 56 Wheel removing 8 56 U1D913E0 book Page 3 Thursday April 20 2006 2 47 PM ...

Page 174: ...ct handling and control Improper ATV use can result in SEVERE INJURY or DEATH 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 ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PU...

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