Yamaha GRIZZLY 550 FI YFM5FGY Owner'S Manual Download | Manualshive

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EBU28781

PERIODIC MAINTENANCE AND MINOR REPAIR

EBU21670

Safety is an obligation of the owner. Periodic in-
spection, adjustment and lubrication will keep your
ATV in the safest and best operating condition
possible. The most important points of inspection,
adjustment, and lubrication are explained on the
following pages.
The intervals given in the periodic maintenance
and lubrication chart should be considered as a
general guide under normal riding conditions.
However, DEPENDING ON THE WEATHER,
TERRAIN, GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORTENED.

WARNING

EWB01840

Never service an engine while it is running.
Moving parts can catch clothing or parts of the
body, causing injury. Electrical components
can cause shocks or start fires. Turn off the en-
gine when performing maintenance unless

otherwise specified. Have a Yamaha dealer
perform the service if you are not familiar with
maintenance work.

EBU27110

Owner’s manual and tool kit

Be sure to put this owner’s manual in the plastic
bag and to always carry it as well as the owner’s
tool kit and the low-pressure tire gauge in their re-
spective compartments under the seat.

1. Owner’s manual
2. Low-pressure tire gauge

3. Owner’s tool kit

U28P60E0.book Page 1 Thursday, April 17, 2008 8:51 AM

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Summary of Contents for GRIZZLY 550 FI YFM5FGY

Page 1: ...L PROPIETARIO 28P 28199 60 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad DIC183 ...

Page 2: ...PRINTED IN JAPAN 2008 04 1 1 1 CR E F S PRINTED ON RECYCLED PAPER IMPRIMÉ SUR PAPIER RECYCLÉ IMPRESO EN PAPEL RECICLADO YAMAHA MOTOR CO LTD DIC183 ...

Page 3: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL YFM5FGY YFM5FGPY 28P 28199 60 E0 U28P60E0 book Page 1 Thursday April 17 2008 8 51 AM ...

Page 4: ...able 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 EN292 ANSI SVIA 1 2007 Title and or number and date of issue of standards and or specifications General Manager RV Engineering Division RV Company Signature Date of Issue Shinya Shimada 2 March 2008 YAMAHA MOTOR EU...

Page 5: ... safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted EN292 ANSI SVIA 1 2007 Title and or number and date of issue of standards and or specifications General Manager RV Engineering Division RV Company Signature Date of Issue Shinya Shimada 2 March 2008 YAMAHA MOTOR EUROPE N V Koolhovenlaan 101 1119NC Schiphol Rijk The Netherland...

Page 6: ...s 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 MANUAL COMPLETELY BEFORE OP...

Page 7: ...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 infor...

Page 8: ...aved street paved road or motorway Please check your local riding laws and regulations before operating this ATV EBU17390 YFM5FGY YFM5FGPY OWNER S MANUAL 2008 by Yamaha Motor Co Ltd 1st edition April 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U28P60E0 book Page 1 Thursday April 17 2008 8...

Page 9: ...lever 4 14 Drive select lever 4 15 Fuel tank cap 4 15 Fuel 4 16 Seat 4 17 Storage compartments 4 18 Front carrier 4 21 Rear carrier 4 21 Adjusting the front and rear shock absorber assemblies 4 21 Auxiliary DC jack 4 22 PRE OPERATION CHECKS 5 1 Pre operation check list 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Differential gear oil 5 3 Coolant 5 3 Front and rear brakes 5 4 Throttle lever 5 4 ...

Page 10: ...ol system 8 3 General maintenance and lubrication chart 8 4 Removing and installing panels 8 8 Removing the radiator grills 8 19 Checking the spark plug 8 20 Engine oil and oil filter cartridge 8 22 Final gear oil 8 26 Differential gear oil 8 29 Coolant 8 31 Cleaning the air filter element 8 37 Cleaning the spark arrester 8 41 V belt case drain plug 8 43 Adjusting the throttle cable free play 8 43...

Page 11: ...ots 8 54 Lubricating the steering shaft 8 54 Battery 8 54 Replacing a fuse 8 57 Replacing a headlight bulb 8 59 Adjusting a headlight beam 8 62 Replacing the tail brake light bulb 8 62 Removing a wheel 8 63 Installing a wheel 8 64 Troubleshooting 8 65 Troubleshooting charts 8 66 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 1...

Page 12: ...hild if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and paved streets Never operate an ATV on any paved street paved road or motorway Watch carefully for other vehicles when operat ing on unpaved public streets or roads Make sure you know your country s l...

Page 13: ...mbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully ...

Page 14: ...ual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires specified in this manual Always maintain proper tire ...

Page 15: ...gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and wa ter If gasoline spills on your clothing change your clothes WARNING EWB00070 Always operate your ATV in an area with ade quate ventilation Never start or run the engine in a closed area Exhaust fumes are poisonous and may cause loss of con...

Page 16: ...2 1 2 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS U28P60E0 book Page 1 Thursday April 17 2008 8 51 AM ...

Page 17: ...s 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 For Europe and Oceania U28P60E0 book Page 2 Thursday April 17 2008 8 51 AM ...

Page 18: ...2 3 2 For Europe U28P60E0 book Page 3 Thursday April 17 2008 8 51 AM ...

Page 19: ...2 4 2 For Europe U28P60E0 book Page 4 Thursday April 17 2008 8 51 AM ...

Page 20: ...2 5 2 For Europe U28P60E0 book Page 5 Thursday April 17 2008 8 51 AM ...

Page 21: ...2 6 2 For Oceania U28P60E0 book Page 6 Thursday April 17 2008 8 51 AM ...

Page 22: ...2 7 2 For Oceania U28P60E0 book Page 7 Thursday April 17 2008 8 51 AM ...

Page 23: ...oil dipstick 7 Oil filter cartridge 8 Coolant reservoir 1 Rear shock absorber assembly spring preload adjusting ring 2 Rear storage compartment and tool kit 3 Fuel tank cap cover 4 Front shock absorber assembly spring preload adjusting ring 5 Spark plug 6 Brake pedal 7 V belt case drain plug U28P60E0 book Page 1 Thursday April 17 2008 8 51 AM ...

Page 24: ...2 Rear brake lever 3 Handlebar switches 4 Horn switch 5 Rear brake fluid reservoir 6 Multifunction display 7 Front brake fluid reservoir 8 On Command four wheel drive differential gear lock switch 9 Front brake lever 10 Throttle lever 11 Front storage compartment 12 Main switch 13 Auxiliary DC jack U28P60E0 book Page 2 Thursday April 17 2008 8 51 AM ...

Page 25: ... 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 U28P60E0 book Page 1 Thursday April 17 2008 8 51 AM ...

Page 26: ...al circuit of the warning light can be checked by turning the key to ON If the warning light does not come on have a Yamaha dealer check the electrical circuit NOTICE ECB00891 The engine may overheat if the ATV is over loaded In this case reduce the load to spec ification 1 On Command differential gear lock indicator light DIFF LOCK 2 Low range indicator light L 3 High range indicator light H 4 Ne...

Page 27: ... check the electrical circuit EBU29060 Electric Power Steering warning light EPS for EPS model This warning light comes on when the key is turned to ON and then goes off once the engine is start ed If the warning light remains on or comes on af ter the engine is started the EPS system may be defective When this occurs have a Yamaha deal er check the EPS system The electrical circuit of the warning...

Page 28: ...sh until the differential gear is locked EBU17970 Park indicator light This indicator light comes on when the transmis sion is in the park position EBU17980 High range indicator light This indicator light comes on when the transmis sion is in the high range position EBU17990 Low range indicator light This indicator light comes on when the transmis sion is in the low range position EBU18001 On Comm...

Page 29: ...O TRIP A TRIP B ODO To reset a tripmeter select it by pushing the SE LECT button and then push the RESET 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 information will enable you to plan future fuel stops TIP Pushing and holding in the SELECT button and turning the key to ON while the button is pushed switch...

Page 30: ...The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear from F full towards E empty as the fuel level decreases When the E segment disap pears and the fuel level warning indicator flashes refuel as soon as possible TIP This fuel meter is equipped with a self diagnosis system If the electrical circuit is defective all the display segments and fu...

Page 31: ...lay indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage EBU18061 Handlebar switches EBU18080 Engine stop switch Set this switch to before starting the engine The engine stop switch controls the ignition and stops the engine when it is running Use this switch to stop the engine in an emergency situation The engine will not start or run when this...

Page 32: ...ischarge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it EBU18170 Horn switch Press the switch to sound the horn EBU18190 Override switch OVERRIDE Top speed is normally limited when operating in differential gear lock If conditions require more en gine power when riding forward push and hold this switch to override the differen...

Page 33: ...n accident if you cannot make a sharp enough turn for the speed you are trav eling EBU26605 On Command four wheel drive switch 2WD 4WD This ATV is equipped with a switch to change from two wheel drive to four wheel drive and vice versa Select the appropriate drive according to the ter rain and the conditions 2WD two wheel drive Power is supplied to the rear wheels 4WD four wheel drive Power is sup...

Page 34: ...switch 4WD LOCK This ATV is equipped with a switch allowing you to lock the differential gear when in four wheel drive Select the appropriate switch position according to the terrain and the conditions 4WD four wheel drive Power is supplied to the rear and front wheels LOCK four wheel drive with the differential gear locked Power is supplied to the rear and front wheels and the differential gear i...

Page 35: ...he differential gear lock stop the ATV and push the switch to the 4WD position WARNING EWB00131 Always stop the ATV before changing from four wheel drive to four wheel drive differen tial gear lock or vice versa The ATV handles differently in four wheel drive than in differential gear lock in some circum stances Changing from four wheel drive to dif ferential gear lock or vice versa while moving m...

Page 36: ... and forth will help the differential gear lock to engage Riding before the differential gear lock is proper ly engaged e g when the indicator and indica tor light are flashing will cause the engine speed to be limited until engagement is complete 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...

Page 37: ...em be fore riding the ATV or consult a Yamaha dealer EBU18321 Speed limiter Your ATV was delivered with an adjustable speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum 1 Loosen the locknut 2 To increase the maximum engine power avail able and the maximum speed of the ATV turn the adjusting screw in direction a To de crease t...

Page 38: ...er free play is adjusted to 3 0 5 0 mm 0 12 0 20 in See page 8 43 EBU18391 Front brake lever The front brake lever is located on the right handle bar To apply the front brake pull the brake lever toward the handlebar grip EBU18442 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 brak...

Page 39: ...rating the drive select lever and driving in reverse section on page 6 2 for the drive select lever operation EBU27350 Fuel tank cap To remove the fuel tank cap Open the fuel tank cap cover and then remove the fuel tank cap by turning it counterclockwise 1 Brake pedal 1 Rear brake lever 1 Drive select lever U28P60E0 book Page 15 Thursday April 17 2008 8 51 AM ...

Page 40: ...is heard and then close the fuel tank cap cover EBU18752 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Fuel tank cap cover 1 Fuel tank cap 1 Fuel level 2 Fuel tank filler tube U28P60E0 book Page 16 Thursday April 17 2008 8 51 AM ...

Page 41: ...l not to spill fuel especially on the engine or exhaust pipe which can cause a fire and severe injury Wipe up any spilled fuel immediately Do not refuel right after the engine has been running and is still very hot Be sure the fuel tank cap is closed securely EBU18880 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear Recommended fuel UNLEADED GASOLINE ONLY Fo...

Page 42: ...tted EBU27361 Storage compartments This ATV is equipped with two storage compart ments 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 U28P60E0 book Page 18 Thursday April 17 2008 8 51 AM ...

Page 43: ...ted under the seat See page 4 17 To access the storage com partment remove the storage compartment cover 1 Front storage compartment 1 Rear storage compartment cover 1 Rear storage compartment U28P60E0 book Page 19 Thursday April 17 2008 8 51 AM ...

Page 44: ...ate cushion material to prevent damaging the stor age compartments Do not exceed the load limit of 0 5 kg 1 lb for the front storage compartment or 2 0 kg 4 lb for the rear storage compartment Do not exceed the maximum load of 220 0 kg 485 lb for the ATV TIP A drain plug is fitted at the bottom of each storage compartment If any water collects in a storage compartment remove the drain plug drain t...

Page 45: ...rear shock ab sorber assemblies The spring preload can be adjusted to suit the rid er s weight and the riding conditions Adjust the spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in direction b to de crease the spring preload and thereby soften the suspension TIP A special wrench can be obtained a...

Page 46: ...located at the front right side of the ATV The auxiliary DC jack can be used for suitable work lights radios etc The auxiliary DC jack should only be used when the engine is running 1 Set the light switch to OFF 2 Start the engine See page 6 1 3 Open the auxiliary DC jack cap and then in sert the accessory power plug into the jack 1 Special wrench Spring preload setting Minimum soft 1 Standard 3 M...

Page 47: ...es 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 1 Auxiliary DC jack cap 1 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12 V 10 A 120 W U28P60E0 book Page ...

Page 48: ...tenance charts on page 8 3 to determine which service should be performed by a Yamaha dealer ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 16 5 3 Engine oil Check oil level in engine and add recommended oil to specified lev el if necessary Check ATV for oil leakage Correct if necessary 5 3 8 22 Final g...

Page 49: ...ttle lever Make sure that operation is smooth Lubricate cable and lever hous ing if necessary Check cable free play and adjust if necessary 5 4 8 43 Control cables Make sure that operation is smooth Lubricate if necessary 8 52 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 5 5 6 5 7 B...

Page 50: ...ssary See page 8 22 EBU19590 Final gear oil Make sure that the final gear oil is at the specified level Add oil as necessary See page 8 26 EBU19600 Differential gear oil Make sure that the differential gear oil is at the specified level Add oil as necessary See page 8 29 EBU19630 Coolant Make sure that the coolant is at the specified level Add coolant as necessary See page 8 31 TIP The coolant lev...

Page 51: ...ever 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 Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance check the brake pads for wear See page 8 44 WARNING EWB00580 Always check the brakes at the star...

Page 52: ...4P AUS NZL YFM5FGY DUNLOP KT421 EUR Size AT25 x 8 12 Type Tubeless Rear Manufacturer model YFM5FGPY CHENG SHIN C828 4P AUS NZL YFM5FGPY DUNLOP KT425 EUR YFM5FGY CHENG SHIN C828 4P AUS NZL YFM5FGY DUNLOP KT425 EUR Size AT25 x 10 12 Type Tubeless The tires should be set to the recommended pressure Recommended tire pressure Front 35 0 kPa 0 350 kgf cm 5 0 psi Rear 30 0 kPa 0 300 kgf cm 4 4 psi Check ...

Page 53: ...ressure Use the low pressure tire gauge TIP The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Set the tire pressure when the tires are cold Set the tire pressures to the following specifications 1 Low pressure tire gauge Recommended pressure Fro...

Page 54: ...in EBU19840 Chassis fasteners Make sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary 1 Tire wear limit U28P60E0 book Page 7 Thursday April 17 2008 8 51 AM ...

Page 55: ...ead to an acci dent or collision NOTICE ECB00150 See the Engine break in section on page 6 4 prior to operating the engine for the first time 1 Turn the main switch to ON and the engine stop switch to NOTICE ECB00910 The coolant temperature warning light and en gine trouble warning light should come on then go off The EPS warning light should come on then go off when the engine is started for EPS ...

Page 56: ...e the next attempt Each cranking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt 5 Continue warming up the engine until it idles smoothly NOTICE ECB00160 For maximum engine life always warm the en gine up before starting off Never accelerate hard when the engine is cold EBU20440 Operating the drive select lever and driving in r...

Page 57: ...hift from neutral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide TIP When in reverse the reverse indicator light should come on If the indicator light does not come on have a Yamaha dealer check the elec trical circuit 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 H...

Page 58: ...n in hours There is never a more important period in the life of your engine than the first 320 km 200 mi or 20 hours of riding For this reason you should read the following material carefully Since the engine is brand new do not put an ex cessive load on it for the first 320 km 200 mi or 20 hours The various parts in the engine wear and polish themselves to the correct operating clear ances Durin...

Page 59: ...place the ATV transversely across the incline stop the engine shift the drive select lever to the park position and then block the front and rear wheels with rocks or other ob jects Do not park the ATV at all on hills that are so steep you could not walk up them easily 1 Bring the ATV to a stop by applying the brakes 2 Stop the engine 3 With the brake pedal applied shift the drive select lever to ...

Page 60: ...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 when riding an ATV with ac cessories The ATV may handle differently than it do...

Page 61: ... 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 trail er Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain C...

Page 62: ...rying or tow ing cargo improperly could cause changes in ATV handling which could lead to an accident Cargo should be properly distributed and se curely attached Reduce speed when carrying cargo or pulling a trailer Allow greater dis tance for braking U28P60E0 book Page 8 Thursday April 17 2008 8 51 AM ...

Page 63: ...7 1 7 EBU21141 RIDING YOUR ATV U28P60E0 book Page 1 Thursday April 17 2008 8 51 AM ...

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

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

Page 66: ...e helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants 1 Protective clothing 2 Goggles 3 Gloves 4 Boots 5 Helmet U28P60E0 book Page 4 Thursday April 17 2008 8 51 AM ...

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

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

Page 69: ...the instructions in your Own er s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the footboards during op eration otherwise they may contact the rear wheels MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and tongue 220 0 kg 485 lb Front carrier 45 0 kg 99 lb Rear carrier 85 0 kg 187 lb Front storage compartment 0 5 kg 1 lb ...

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

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

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

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

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

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

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

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

Page 78: ...d or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to lose control If you are unable to continue up the hill dismount the ATV on the up hill side Physically turn the ATV around and then descend the hill If you start to roll backwards DO NOT apply either brake abruptly If you are in 2WD apply only the front...

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

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

Page 81: ...mpt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your we...

Page 82: ...oss of control which could lead to an accident Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability NOTICE ECB00840 After riding your ATV in water be sure to drain the trapped water by removing the check hos es at the bottom of the air filter case Also re move the drain plugs from the front and rear storage compar...

Page 83: ...7 21 7 1 Air filter case check hose 1 Air filter case check hose 1 Storage compartment drain plug 1 Storage compartment drain plug U28P60E0 book Page 21 Thursday April 17 2008 8 51 AM ...

Page 84: ...or ob stacles Never attempt to ride over large obsta cles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manu al SLIDING AND SKIDDING Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front w...

Page 85: ...ding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to re duce the chance of skidding or sliding out of control 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 WHAT TO DO If your ATV doesn t turn when you want it to Bring the ...

Page 86: ... uphill side See page 7 14 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 If you discover that the ATV is going to tip over dismount on the uphill side See page 7 18 If your ATV encounters shallo...

Page 87: ...USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORTENED WARNING EWB01840 Never service an engine while it is running Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or start fires Turn off the en gine when performing maintenance unless otherwise specified Have a Yamaha dealer perform the service if you are not familiar with maintenance wor...

Page 88: ...ce required for a particular job have a Yamaha dealer perform it for you WARNING EWB01850 Never modify this ATV through improper in stallation or use of accessories as it may cause changes in handling which in some sit uations could lead to an accident All parts and accessories added to this ATV should be gen uine Yamaha or equivalent components de signed for use on this ATV and should be installe...

Page 89: ...nd technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust if necessary 4 Crankcase...

Page 90: ...enever worn to the limit 3 Rear brake Check operation and correct if necessary Check brake pedal 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 and replace if necessary Replace Every 4 years 5 Rear brake hose protectors Check for wear cracks or other...

Page 91: ... with lithium soap based grease 14 Steering shaft Lubricate with lithium soap based grease 15 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 16 Engine mount Check for cracks or other damage and replace if necessary 17 Axle boots Check for cracks or other damage and replace if necessary 18 Engine oil Change Check ATV for oil leakage and correct...

Page 92: ...d adjust or replace if neces sary 25 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 26 Front and rear brake switches Check operation and correct if necessary 27 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE...

Page 93: ...ulic 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 U28P60E0 book Page 7 Thursday April 17 2008 8 51 AM ...

Page 94: ...scribed in this chapter Refer to this section each time a panel needs to be removed and installed EBU27382 Panel A To remove the panel Pull upward on the areas shown 1 Panel A 2 Panel B 3 Panel C 4 Panel D 5 Panel F 6 Panel G 1 2 3 5 6 4 1 Panel E 2 Panel H 3 Panel I 1 3 2 U28P60E0 book Page 8 Thursday April 17 2008 8 51 AM ...

Page 95: ...Place the panel in the original position Panel B To remove the panel 1 Remove panel A 2 Remove the front carrier by removing the bolts 1 Panel A 1 Carrier bolt under the fenders U28P60E0 book Page 9 Thursday April 17 2008 8 51 AM ...

Page 96: ...carrier stays by removing the bolts 4 Remove the quick fasteners and then pull the panel upward to remove it 1 Carrier bolt top 1 Front carrier stay 1 Front carrier stay bolt U28P60E0 book Page 10 Thursday April 17 2008 8 51 AM ...

Page 97: ...t carrier stays by installing the bolts and tightening them to the specified torque 3 Install the front carrier by installing the bolts and tightening them to the specified torques 1 Panel B 2 Quick fastener Tightening torque Front carrier stay bolt 34 Nm 3 4 m kgf 24 ft lbf U28P60E0 book Page 11 Thursday April 17 2008 8 51 AM ...

Page 98: ... pull the panel upward to remove it To install the panel 1 Place the panel in the original position and then install the quick fastener screws Tightening torques Carrier bolt top 26 Nm 2 6 m kgf 19 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 Panel C 2 Quick fastener screw U28P60E0 book Page 12 Thursday April 17 2008 8 51 AM ...

Page 99: ...ls 1 Remove panel C 2 Remove the quick fastener screw and bolt and then pull the panel upward to remove it TIP To ease removal of panel D shift the drive select lever into the reverse position 1 Panel D 2 Quick fastener screw 1 Bolt U28P60E0 book Page 13 Thursday April 17 2008 8 51 AM ...

Page 100: ...ne of the panels 1 Place the panel in the original position and then install the bolt and quick fastener screw 2 Install panel C 1 Panel E 2 Quick fastener screw 1 Bolt U28P60E0 book Page 14 Thursday April 17 2008 8 51 AM ...

Page 101: ... shown To install the panel Place the panel in the original position Panels G and H To remove one of the panels Remove the nut and bolts and then pull the panel downward while pushing the projection 1 Panel F U28P60E0 book Page 15 Thursday April 17 2008 8 51 AM ...

Page 102: ...one of the panels Place the panel in the original position and then in stall the bolts and nut 1 Panel G 2 Nut 3 Bolt 4 Projection 1 Panel H 2 Nut 3 Bolt 4 Projection U28P60E0 book Page 16 Thursday April 17 2008 8 51 AM ...

Page 103: ...el I To remove the panel 1 Remove the seat See page 4 17 2 Remove the rear carrier by removing the bolts 1 Carrier bolt under the fenders 1 Carrier bolt upper U28P60E0 book Page 17 Thursday April 17 2008 8 51 AM ...

Page 104: ...d then push inward on the areas shown To install the panel 1 Place the panel in the original position and then install the quick fasteners 1 Carrier bolt lower 1 Panel I 2 Quick fastener U28P60E0 book Page 18 Thursday April 17 2008 8 51 AM ...

Page 105: ...move the quick fastener pull the radiator grill outward at the top and then pull it upward To install a radiator grill Place the radiator grill in its original position and then install the quick fastener Tightening torques Carrier bolt upper 53 Nm 5 3 m kgf 38 ft lbf Carrier bolt lower 53 Nm 5 3 m kgf 38 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 Radiator grill 2 Quick fast...

Page 106: ...k plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally TIP If the spark plug shows a distinctly different color the engine could be operating impr...

Page 107: ... specification 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Specified spark plug NGK LMAR6A 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in 1 Spark plug gap Tightening torque Spark plug 12 5 Nm 1 25 m kgf 9 0 ft lbf U28P60E0 book ...

Page 108: ...aced at the intervals spec ified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the ATV on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least 10 minutes until the oil settles for an accurate reading 3 Remove panel F See pa...

Page 109: ...0850 Be sure the engine oil is at the correct level otherwise engine damage may result To change the engine oil with or without oil fil ter cartridge replacement 1 Place the ATV on a level surface 2 Remove panel F See page 8 8 3 Place an oil pan under the engine to collect the used oil 4 Remove the dipstick and then remove the en gine oil drain bolt to drain the oil from the crankcase 1 Maximum le...

Page 110: ...ailable at a nearby Yamaha dealer 7 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge TIP Make sure that the O ring is properly seated 8 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 cartridge 2 Oil filter wrench 1 O ring U28P60E0 book Page 24 Thursday April 17 2008 8 51 AM ...

Page 111: ...ne 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 30 Nm 3 0 m kgf 22 ft lbf Recommended oil See page...

Page 112: ... before each ride If any leakage is found have a Yamaha dealer check and repair the ATV In ad dition the final 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 TIP The final gear oil level must be checked on a cold engine 2 Remove the final ...

Page 113: ...en them to the specified torques To change the final gear oil 1 Place the ATV on a level surface 2 Place an oil pan under the final gear case to collect the used oil 1 Final gear oil 2 Final gear oil level check bolt 3 Correct oil level 1 Final gear oil filler bolt Tightening torques Final gear oil level check bolt 10 Nm 1 0 m kgf 7 2 ft lbf Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf U28...

Page 114: ... the brim of the check hole as shown NOTICE ECB00420 Be sure no foreign material enters the final gear case 6 Install the oil level check bolt and oil filler bolt and then tighten them to the specified torques 1 Final gear oil drain bolt Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Final gear oil 2 Final gear oil level check bolt 3 Correct oil level Recommended final gea...

Page 115: ...surface TIP The differential gear oil level must be checked on a cold engine 2 Remove the differential gear oil filler bolt and then check the oil level in the differential gear case TIP The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level 4 Install the oil filler bolt an...

Page 116: ...bolt and then tighten it to the specified torque 5 Refill with the recommended differential gear oil to the brim of the filler hole as shown Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 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 Correc...

Page 117: ...periodic maintenance and lubrication chart EBU27123 To check the coolant level 1 Place the ATV on a level surface TIP The coolant level 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 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 remov...

Page 118: ...g system will not be pro tected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze con tent of the coolant as soon as possible oth erwise the effectiveness of the coolant will be reduced TIP The radiator fan is automatically switched on or off according to the coolant temperature in the radiator If the engine overheats see page 8 66 for fur...

Page 119: ...ow any remaining pressure to escape before completely removing the cap 1 Place the ATV on a level surface 2 Remove panels D and F See page 8 8 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 engine guard 4 Remove panel B See page 8 8 5 Remove the radiator cap 1 Coolant drain bolt 1 Trough ...

Page 120: ...with clean tap water 9 Replace the coolant drain bolt washer if it is damaged install the coolant drain bolt and then tighten it to the specified torque 10 Connect the coolant reservoir hose 11 Pour the recommended coolant into the radia tor until it is full 1 Radiator cap 1 Coolant reservoir hose Tightening torque Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf U28P60E0 book Page 34 Thursday April ...

Page 121: ...t of the coolant as soon as possible oth erwise the effectiveness of the coolant will be reduced 13 Loosen the water pump air bleed bolt without removing it to allow all of the air to escape from the air bleed bolt hole 14 When coolant begins to flow out of the bolt hole tighten the water pump air bleed bolt to the specified torque Antifreeze water mixture ratio 1 1 Recommended antifreeze High qua...

Page 122: ...le tighten the cylinder head air bleed bolt to the specified torque 19 Start the engine and let it idle for ten minutes 20 Rev the engine five times 21 Pour the recommended coolant into the radia tor until it is full Tightening torque Water pump air bleed bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 V belt cooling duct 2 Clamp screw 1 Cylinder head air bleed bolt Tightening torque Cylinder head air bleed bol...

Page 123: ...aning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean or if necessary replace the air filter element more frequently if you are riding in unusually wet or dusty areas TIP There are two check hoses at the bottom of the air filter case which are located behind panels D and E See page 8 8 for an explan...

Page 124: ... 8 8 3 Remove the air filter case cover by unhooking the holders 4 Remove the sponge material and the mesh from the air filter case 1 Air filter case check hose 1 Air filter case cover holder 2 Air filter case cover U28P60E0 book Page 38 Thursday April 17 2008 8 51 AM ...

Page 125: ...ire or ex plode 7 Squeeze the excess solvent out of the sponge material and let it dry NOTICE ECB00440 Do not twist the sponge material when squeez ing it 8 Check the sponge material and replace it if damaged 9 Apply 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 Install the mesh and the sponge mate...

Page 126: ...ould be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the throttle body and the rubber joint mani fold fittings for an air tight seal Tighten all fittings securely to avoid the possibility of unfiltered ...

Page 127: ...ection system with sub sequent poor performance and possible en gine overheating EBU27810 Cleaning the spark arrester Select a well ventilated area free of combustible materials and make sure the exhaust and muffler are cool 1 Remove the bolts 2 Remove the tailpipe by pulling it out of the muffler and then remove the gasket 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon ...

Page 128: ...while momentarily creating ex haust system back pressure by blocking the end of the muffler with a shop towel 8 Stop the engine and allow the exhaust pipe to cool 9 Install the purging bolt and tighten it to the specified torque 1 Tailpipe 2 Spark arrester 3 Gasket Tightening torque Tailpipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 Purging bolt Tightening torque Purging bolt 27 Nm 2 7 m kgf 19 ft lbf U28...

Page 129: ... allow it to en ter the V belt case remove this plug to drain the water from the case TIP If water drains from the V belt case after removing the plug have a Yamaha dealer check the ATV as the water may affect other engine parts EBU24044 Adjusting the throttle cable free play The throttle cable free play should be checked and if necessary adjusted at the intervals speci fied in the periodic mainte...

Page 130: ... and lu brication chart EBU24070 Adjusting the drive select lever safety system cable The drive select lever safety system cable stretch es with use which can result in improper function Therefore the safety system cable should be checked and adjusted at the intervals specified in the periodic maintenance and lubrication chart EBU27470 Checking the front and rear brake pads The front and rear brak...

Page 131: ...ing the rear brake hose protec tors The rear brake hoses protectors must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart Each brake hose protector is provided with a wear indicator If a protector wears to the point that its indicator be comes visible have a Yamaha dealer replace the protector 1 Wear indicator groove 1 Wear indicator groove U28P60E0 ...

Page 132: ...heck 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 Rear brake hose protector 2 Wear indicator 3 Protector is normal 4 Protector is worn 1 Minimum level mark 2WD 4WD...

Page 133: ... 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 EBU24291 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic...

Page 134: ...dealer check the brake system Front brake Rear brake WARNING EWB02471 Operating with improperly serviced or adjust ed brakes could cause loss of braking ability which could lead to an accident After servicing Make sure the brakes operate smoothly and that there is no free play Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system 1 Brake le...

Page 135: ...nce completely in the following order whenever adjusting the rear brake Before adjusting the brake pedal free play check the rear brake pads for wear The brake pedal free play should measure 0 0 5 0 mm 0 00 0 20 in as shown If the free play is in correct adjust it as follows 1 Remove panel H See page 8 8 2 Loosen the locknut 3 Turn the brake pedal free play adjusting nut in direction a to increase...

Page 136: ...anel If the correct free play cannot be obtained have a Yamaha dealer adjust it TIP When adjusting the rear brake pedal free play Be sure not to step on the brake pedal Make sure the rear brake lever and brake pedal do not move 1 Locknut 2 Brake pedal free play adjusting nut 1 Brake pedal cable joint 2 Slight play 1 2 U28P60E0 book Page 50 Thursday April 17 2008 8 51 AM ...

Page 137: ... must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by a Yamaha dealer EBU24230 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart Check the axle boots for tears or damage If any damage is found have them re placed by a Yamaha dealer 1 ...

Page 138: ...lace if dam aged Corrosion can result when the cable sheaths become damaged and cables can also become frayed or kinked which could re strict the operation of controls and lead to an accident or injury EBU24912 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if nec...

Page 139: ...d rear wheel hub 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 hub bear ings EBU25021 Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lub...

Page 140: ... vals specified in the periodic maintenance and lu brication chart EBU29042 Battery This model is equipped with a VRLA Valve Regu lated Lead Acid battery There is no need to check the electrolyte or to add distilled water However the battery lead connections need to be checked and if necessary tightened NOTICE ECB00620 Never attempt to remove the battery cell seals as this would permanently damage...

Page 141: ...ately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ig nition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN To remove the battery 1 Remove panel A See page 8 8 2 Remove the front carrier by removing the bolts 3 Remove the battery holding plate by rem...

Page 142: ...onth remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 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...

Page 143: ...ery a special constant voltage bat tery charger is required Using a conventional battery charger will damage the battery If you do not have access to a constant voltage battery charger have a Yamaha dealer charge your battery EBU27750 Replacing a fuse 1 Positive battery lead red 2 Negative battery lead black 1 2 1 Fuse box 2 Main EPS spare fuse 3 Main fuse 4 EPS fuse for EPS model 5 Fuel injection...

Page 144: ...ctrical circuits NOTICE ECB00640 To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Ignition fuse 2 Headlight fuse 3 Four wheel drive motor fuse 4 Radiator fan fuse 5 Signaling system fuse 6 Auxiliary DC jack fuse 7 Spare fuse U28P60E0 book Page 58 Thursday April 17 2008 8...

Page 145: ...fuse immediately blows again have a Yamaha dealer check the electrical system EBU27440 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the cover at the rear of the headlight by pulling it off Specified fuses Main fuse 40 0 A Headlight fuse 15 0 A Ignition fuse 15 0 A Four wheel drive motor fuse 15 0 A Signaling system fuse 5 0 A Auxiliary DC jack fuse 15 0 A...

Page 146: ...er 3 Disconnect the headlight coupler 4 Unhook the headlight bulb holder and then remove the defective bulb 1 Cover at the rear of the headlight 1 Headlight bulb cover 1 Headlight coupler U28P60E0 book Page 60 Thursday April 17 2008 8 51 AM ...

Page 147: ...ouch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affect ed Thoroughly clean off any dirt and finger prints on the headlight bulb using a cloth moistened with alcohol or thinner 6 Connect the headlight coupler 7 Install the headlight bulb cover 8 Install the cover at the rear of ...

Page 148: ... this adjustment To raise a headlight beam turn the headlight beam adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b EBU25640 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove panel I See page 8 8 2 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Headlight beam adju...

Page 149: ...ulb holder together with the bulb by turning it clockwise 6 Install the panel EBU25651 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 3 Elevate the ATV and place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel 1 Tail brake light bulb holder 1 Tail brake light bulb 1 Wheel nut U28P60E0 book Page 63 Thursday April 17 2008 8 51 AM ...

Page 150: ...wheel Tapered nuts are used for both the front and rear wheels Install the nuts with their tapered side to wards the wheel 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torques 1 Arrow mark 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 40 ft lbf Rear wheel nut 55 Nm 5 5 m kgf 40 ft lbf U28P60E0 book Page 64 Thursday April 17 2008 8 51 AM ...

Page 151: ...y repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02280 Do not smoke when checking the fuel system Fuel can ignite or ...

Page 152: ...er check the ATV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Have a Yamaha dealer check the ATV The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The ...

Page 153: ...can be temporarily used instead provided that it is changed to the rec ommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See TIP Start the engine If the engine overheats a...

Page 154: ...ioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bot tle brush is handy for hard to reach places 5...

Page 155: ...g term Before storing your ATV for several months 1 Follow all the instructions in the Cleaning section of this chapter 2 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorat ing 3 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...

Page 156: ...heels a little every month in order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 7 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation o...

Page 157: ...GPY 79 0 dB A EUR YFM5FGY 79 0 dB A EUR Vibration on seat EN1032 ISO5008 YFM5FGPY Will not exceed 0 5 m s EUR YFM5FGY Will not exceed 0 5 m s EUR Vibration on handlebar EN1032 ISO5008 YFM5FGPY Will not exceed 2 5 m s EUR YFM5FGY Will not exceed 2 5 m s EUR Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 558 0 cm Bore stroke 92 0 84 ...

Page 158: ... Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 24 L 0 25 US qt 0 21 Imp qt Radiator capacity including all routes 1 99 L 2 10 US qt 1 75 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel YFM5FGPY Regular unleaded gasoline only EUR YFM5FGPY Unleaded gasoline only AUS NZL YFM5FGY Regular unleaded gasoline only EUR YFM5FGY Unleaded gasoline only ...

Page 159: ...ame Caster angle 5 0 Trail 26 0 mm 1 02 in Front tire Type Tubeless Size AT25 x 8 12 Manufacturer model YFM5FGPY CHENG SHIN C828 4P AUS NZL YFM5FGPY DUNLOP KT421 EUR YFM5FGY CHENG SHIN C828 4P AUS NZL YFM5FGY DUNLOP KT421 EUR Rear tire Type Tubeless Size AT25 x 10 12 Manufacturer model YFM5FGPY CHENG SHIN C828 4P AUS NZL YFM5FGPY DUNLOP KT425 EUR YFM5FGY CHENG SHIN C828 4P AUS NZL YFM5FGY DUNLOP K...

Page 160: ...n Left hand and right foot operation Recommended fluid DOT 4 Front suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 180 mm 7 1 in Rear suspension Type Double wishbone Spring shock absorber type Coil spring oil damper Wheel travel 230 mm 9 1 in Electrical system Ignition system TCI digital Charging system AC magneto Battery Model YTX20L BS Voltage capac...

Page 161: ... 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 fuse 40 0 A Fuel injection system fuse 15 0 A EPS fuse YFM5FGPY 40 0 A Headlight fuse 15 0 A Signaling system fuse 5 0 A Ignition fuse 15 0 A Auxiliary DC jack fuse 15 0 A Four wheel drive motor fuse 15 0 A Radiator fan fuse 20 0 ...

Page 162: ...erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26040 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key ide...

Page 163: ...BU26050 Model label The model label is affixed at the location in the il lustration Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha deal er 1 Vehicle identification number front left side 1 Vehicle identification number 2 Year of manufacture U28P60E0 book Page 2 Thursday April 17 2008 8 51 AM ...

Page 164: ...11 3 11 1 Model label U28P60E0 book Page 3 Thursday April 17 2008 8 51 AM ...

Page 165: ...t 4 2 D Differential gear lock indicator light 4 4 Differential gear oil 5 3 8 29 Drive select lever 4 15 Drive select lever and driving in reverse 6 2 Drive select lever safety system cable adjusting 8 44 E Engine break in 6 4 Engine oil 5 3 Engine oil and oil filter cartridge 8 22 Engine stop switch 4 7 Engine trouble warning light 4 3 EPS warning light for EPS model 4 3 F Final gear oil 5 3 8 2...

Page 166: ...ricating 8 54 Reverse indicator light 4 2 Riding your ATV 7 1 S Safety information 1 1 Seat 4 17 Shock absorber assemblies adjusting the front and rear 4 21 Spark arrester cleaning 8 41 Spark plug checking 8 20 Specifications 10 1 Speed limiter 4 13 Stabilizer bushes checking 8 53 Starting the engine 6 1 Start switch 4 8 Steering shaft lubricating 8 54 Storage 9 2 Storage compartments 4 18 T Tail ...

Page 167: ...U28P60E0 book Page 3 Thursday April 17 2008 8 51 AM ...

Page 168: ...YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2008 04 1 1 1 CR E U28P60E0 book Page 1 Thursday April 17 2008 8 51 AM ...

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