Yamaha Grizzly 550 YFM5FGA Owner'S Manual Download | Manualshive

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Front brake

• Check operation. If soft or spongy, have Yamaha dealer bleed hy-

draulic system.

• Check brake pads for wear, and replace if necessary.
• Check brake fluid level in reservoir, and add recommended brake

fluid to specified level if necessary.

• Check hydraulic system for leakage. Correct if necessary.

5-3, 8-44, 8-46, 8-47

Rear brake

• Check operation. If soft or spongy, have Yamaha dealer bleed hy-

draulic system.

• Check pedal free play, and adjust if necessary.
• Check brake pads for wear, and replace if necessary.
• Check brake fluid level in reservoir, and add recommended brake

fluid to specified level if necessary.

• Check hydraulic system for leakage. Correct if necessary.

5-3, 8-44, 8-46, 8-47,

Throttle lever

• Make sure that operation is smooth. Lubricate cable and lever hous-

ing if necessary.

• Check cable free play, and adjust if necessary.

Control cables

• Make sure that operation is smooth. Lubricate if necessary.

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.

Brake pedal

• Make sure that operation is smooth. Lubricate pedal pivoting point if

necessary.

Brake levers

• Make sure that operation is smooth. Lubricate lever pivoting points if

necessary.

Axle boots

• Check for cracks or damage, and replace if necessary.

Chassis fasteners

• Make sure that all nuts, bolts and screws are properly tightened.

Instruments, lights and
switches

• Check operation, and correct if necessary.

ITEM

ROUTINE

PAGE

U43P12E0.book Page 2 Monday, July 13, 2009 5:26 PM

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Summary of Contents for Grizzly 550 YFM5FGA

Page 1: ...This ATV should not be ridden by anyone under 16 years of age WARNING OWNER S MANUAL 43P 28199 12 LIT 11626 23 52 YFM7FGPSEZ READ THIS MANUAL CAREFULLY It contains important safety information DIC2342 ...

Page 2: ...EBU17092 Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if it is sold U43P12E0 book Page 1 Monday July 13 2009 5 26 PM ...

Page 3: ...nformation about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE Read this manual together with TIPS FOR THE ATV RIDER carefully and completely before operating your ATV Make sure you understan...

Page 4: ... safety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key info...

Page 5: ...ws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17382 YFM7FGPSEZ OWNER S MANUAL 2009 by Yamaha Motor Corporation U S A 1st edition July 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 1...

Page 6: ... 4 5 Handlebar switches 4 7 Throttle lever 4 13 Speed limiter 4 13 Front brake lever 4 14 Brake pedal and rear brake lever 4 14 Drive select lever 4 15 Fuel tank cap 4 15 Fuel 4 16 Seat 4 18 Storage compartments 4 19 Front carrier 4 22 Rear carrier 4 22 Adjusting the front and rear shock absorber assemblies 4 22 Auxiliary DC jack 4 23 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil...

Page 7: ...al and tool kit 8 1 Periodic maintenance chart for the emission control system 8 3 General maintenance and lubrication chart 8 4 Removing and installing panels 8 8 Removing the radiator grills 8 20 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 ...

Page 8: ...bricating the steering shaft 8 54 Battery 8 54 Replacing a fuse 8 57 Replacing a headlight bulb 8 59 Adjusting a headlight beam 8 61 Replacing the tail brake light bulb 8 61 Removing a wheel 8 62 Installing a wheel 8 63 Troubleshooting 8 64 Troubleshooting charts 8 65 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 Noise r...

Page 9: ...1 1 1 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 2 3 4 5 6 9 8 7 10 11 U43P12E0 book Page 1 Monday July 13 2009 5 26 PM ...

Page 10: ...nd 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 99 lbs 45 kg 3B4 24875 U0 187 lbs 85 kg 3B4 24875 S0 43P 2151K 00 5880 N 600 kgf 1322 lbf 147 N 15 kgf 33 lbf U43P12E0 book Page 2 Monday July 13 2009 5 26 PM ...

Page 11: ...ING TRAILER TOWING Cargo or a trailer can affect stability and handling Read owner s manual before loading or towing When loading with cargo or towing a trailer Reduce speed and allow more room to stop Avoid hills and rough terrain Maximum weight capacity 485 lbs 220 kg Includes weight of operator cargo and accessories and if applicable trailer tongue weight 28P 2816M U0 WARNING 4D3 2816L 00 NEVER...

Page 12: ...subject to an approved ATV action plan submitted by YAMAHA and on file with the U S Consumer Product safety Commission Certification of Compliance YAMAHA MOTOR CORPORATION U S A 6555 Katella Avenue Cypress California 90630 5101 U S A 8 9 10 11 U43P12E0 book Page 4 Monday July 13 2009 5 26 PM ...

Page 13: ...hould never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and streets Neve...

Page 14: ...imbing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully...

Page 15: ...re duce the chance 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 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 opera...

Page 16: ...poorly ventilated areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or par tially enclosed areas such as barns garages ...

Page 17: ... oil dipstick 7 Oil filter cartridge 8 Coolant reservoir 5 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 U43P12E0 book Page 1 Monday July 13 2009 5 26 PM ...

Page 18: ...ct lever 2 Rear brake lever 3 Handlebar switches 4 Rear brake fluid reservoir 5 Multi function display 6 Front brake fluid reservoir 7 On Command four wheel drive differential gear lock switch 8 Front brake lever 9 Throttle lever 10 Front storage compartment 11 Main switch 12 Auxiliary DC jack U43P12E0 book Page 2 Monday July 13 2009 5 26 PM ...

Page 19: ...BU17760 Main 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 U43P12E0 book Page 1 Monday July 13 2009 5 26 PM ...

Page 20: ...tor light This indicator light comes on when the transmis sion is in the reverse position EBU17970 Park indicator light This indicator light comes on when the transmis sion is in the park position 1 On Command differential gear lock indicator light DIFF LOCK 2 Low range indicator light L 3 High range indicator light H 4 Neutral indicator light N 5 Reverse indicator light R 6 Park indicator light P...

Page 21: ...n how to access the radiator Start the engine after making sure that the warning light is out Continuous use while the warning light is on may cause damage to the engine EBU27284 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the engine is not work ing correctly When this occurs have a Yamaha dealer check the self diagnosis system See page...

Page 22: ...cator On Command differential gear lock indicator and indicator light DIFF LOCK The On Command four wheel drive indicator comes on when the On Command four wheel drive switch is set to the 4WD position The On Command differential gear lock indicator and the On Command differential gear lock indicator light DIFF LOCK come on when the On Command differential gear lock switch is set to the LOCK posit...

Page 23: ...t 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 switches the display between mph ...

Page 24: ...el 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 not working cor rectly all the display segments...

Page 25: ...ion display 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 w...

Page 26: ...charge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it See page 8 54 for battery charging information 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 differential gear l...

Page 27: ... enough turn for the speed you are trav eling EBU26606 On Command four wheel drive switch 2WD 4WD WARNING EWB00163 Always stop the ATV before changing from two wheel drive to four wheel drive and vice versa The ATV handles differently in two wheel drive than in four wheel drive in some circumstances Changing from two wheel drive to four wheel drive or vice versa while moving may cause the ATV to u...

Page 28: ...he 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 may cause the ATV to handle differently unex pectedly This could distract the operator and increase the risk of losing control and causing an accident WARNING EWB00140 Always ride at a slow speed when the ATV is in...

Page 29: ...pplied 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 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 1 On Command four wheel drive sw...

Page 30: ...lock stop the ATV and push the switch to the 4WD position TIP When the switch is set to LOCK the differential gear lock indicator and indicator light will flash until the differential gear is locked When the indicator and indicator light are flash ing turning the handlebar back and forth will help the differential gear lock to engage 1 Differential gear lock lever 2 On Command four wheel drive swi...

Page 31: ...ill 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 throttle lever is re leased Before starting the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released EBU18323 ...

Page 32: ... operation You could lose control resulting in an accident EWB00241 3 Tighten the locknut 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 handleba...

Page 33: ...perating 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 U43P12E0 book Page 15 Monday July 13 2009 5 26 PM ...

Page 34: ... fol low these instructions 1 Before refueling turn off the engine and be sure that no one is sitting on the vehicle Nev er refuel while smoking or while in the vicinity of sparks open flames or other sources of ig nition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop ...

Page 35: ...e by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes NOTICE ECB00070 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and p...

Page 36: ...at containing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 E10 Gasohol contain ing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems EBU18881 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear To install the seat Insert the projections on the front ...

Page 37: ...ey must be stored wrap them in appropriate cushion material to prevent damaging the stor age compartments The front storage compartment is located at the front right side of the ATV To access the storage compartment remove the storage compartment cover by turning it counterclockwise 1 Projection 2 Seat holder 1 Front storage compartment cover U43P12E0 book Page 19 Monday July 13 2009 5 26 PM ...

Page 38: ...ated under the seat See page 4 18 To access the storage com partment remove the storage compartment cover 1 Front storage compartment 1 Rear storage compartment cover 1 Rear storage compartment U43P12E0 book Page 20 Monday July 13 2009 5 26 PM ...

Page 39: ...g 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 the wa ter and then install the drain plug 1 Storage compartment drain plug 1 Storage compartment drain p...

Page 40: ...e riding conditions WARNING EWB00400 Always adjust the shock absorber assemblies on the left and right side to the same setting Uneven adjustment can cause poor handling and loss of stability which could lead to an ac cident Adjust the spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring preload and thereby harden the suspension and in direction b ...

Page 41: ...ack should only be used when the engine is running and the light switch is set to OFF 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 Maximum hard 5 1 Auxiliary DC jack cap U43P12E0 book Page 23 Monday July 13 2009 5 26 PM ...

Page 42: ...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 EWB00011 Indicates a hazardous situation which if not avoided could result in death or serious injury 1 Auxiliary DC jack Maximum rated capacity for the auxiliary DC...

Page 43: ...y a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 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 gear oil Check ATV for ...

Page 44: ...8 Throttle 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 51 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 Bra...

Page 45: ...ssary See page 8 31 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EBU29081 Front and rear brakes Brake levers and brake pedal Check that there is no free play in the front and rear brake levers If there is free play have a Yamaha dealer check the brake system Check for correct free play in the brake pedal If the free play is incorrect adjus...

Page 46: ...must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU19794 Tires Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage Tire pressure Use the low pressure tire gauge to check and ad just tire pressures when the tires are cold Tire pressures must be equal on both sides WARNING Op...

Page 47: ...en the tire groove decreases to 3 mm 0 12 in due to wear replace the tire 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 Minimum tire pressure Front 32 0 kPa 0 320 kgf cm 4 6 psi Rear 27 0 kPa 0 270 kgf cm 4 0 psi Maximum tire seating pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi 1 Low pressure tire gauge U43P12E0 book Pag...

Page 48: ...s The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling braking and comfort Other tires rims sizes and combinations may not be appropriate EBU19840 Chassis fasteners Make sure that all nuts bolts and screws are prop erly tightened 1 Tire wear limit Front Manufacturer model DUNLOP KT421 Size AT25 x 8 12 Type Tu...

Page 49: ...5 7 5 EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary U43P12E0 book Page 7 Monday July 13 2009 5 26 PM ...

Page 50: ... engine for the first time 1 Turn the key to ON and the engine stop switch to The following warning lights should come on for a few seconds then go off Coolant temperature warning light Engine trouble warning light The EPS warning light should come on then go off when the engine is started NOTICE ECB00824 If a warning light does not go off see page 4 2 for the corresponding warning light circuit c...

Page 51: ...ard when the engine is cold ECB00162 TIP If the engine fails to start release the start switch then push it again Pause a few seconds before 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 EBU20441 Operating the drive select lever and driving in reverse NOTICE ECB00170 Before shifting stop the ATV...

Page 52: ... people or ob stacles behind you When it is safe to proceed go slowly 1 Bring the ATV to a complete stop 2 Apply the brake pedal The drive select lever cannot be shifted into or from reverse or park without applying the brake pedal 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 Hig...

Page 53: ...iven in hours For ATVs not equipped with an odometer or hour meter follow the figures given 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...

Page 54: ...e engine and shift the drive select lever into the park position EBU29900 Parking on a slope WARNING EWB00860 Avoid parking on hills or other inclines Park ing on a hill or other incline could cause the ATV to roll out of control increasing the chance of an accident If you must park on an incline place the ATV transversely across the incline stop the engine shift the drive select lever to the park...

Page 55: ...d aftermarket products similar in design and quality to genuine Yamaha Accesso ries recognize that some aftermarket accessories or modifications are not suitable because of poten tial safety hazards to you or others Installing after market products or having other modifications performed to your ATV that change any of the ve hicle s design or operation characteristics can put you and others at gre...

Page 56: ... trailer can change the stability and han dling of an ATV You must use common sense and good judgment when carrying cargo or towing a trailer Keep the following points in mind Never exceed the weight limits shown An over loaded ATV can be unstable Do not exceed the maximum tongue weight You can measure tongue weight with a bath room scale Put the tongue of the loaded trailer on the scale with the ...

Page 57: ...does not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trail er Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns un...

Page 58: ...7 1 7 EBU21132 RIDING YOUR ATV U43P12E0 book Page 1 Monday July 13 2009 5 26 PM ...

Page 59: ... have read this Owner s Manual completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 2 1 2 4 Also read all warning and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01381 Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an ac...

Page 60: ...perator Not recommended for children under 16 years of age WARNING EWB01390 A child under 16 should never operate an ATV with engine size greater than 90 cc Use by chil dren of ATVs that are not recommended for their age can lead to severe injury or death of the child This ATV is designed to carry the operator and cargo only passengers prohibited The long seat is to allow the operator to shift pos...

Page 61: ...NG Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01411 Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating w...

Page 62: ...each time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 1 Always follow the inspection and maintenance procedures and schedules described in the Own er s Manual WARNING Failure to inspect the ATV before operating it and to maintain it prop erly increases the possibility of an accident or equipment damage EWB01431 Speed limiter For ...

Page 63: ...side to side and as low as possible Be sure cargo is se cured a loose load could change handling unexpectedly Make sure the load does not interfere with your control or ability to see where you are going Tie down cargo in the trailer securely Make sure cargo in the trailer cannot move around A shifting load can cause an accident Reduce speed and allow more room to stop A heavier vehicle takes long...

Page 64: ...all off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident EWB01471 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rider accessories and tongue 220 0 kg 485 ...

Page 65: ... the engine area could catch fire Do not operate idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust system dur ing or after operation could be burned Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it The muffler and other engine...

Page 66: ...y seriously af fect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets EWB01511 Do not ride on any public road street or highway Riding on public roads can result in collisions with other vehicles In many states it is illegal to operate ATVs on public streets roads and highways U43P12E0 book ...

Page 67: ...ks bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Al ways be alert to changing terrain conditions when operating the ATV EWB01531 Do not operate on rough slippery or loose terrain until you have learned and practiced the skills nec essary to control the ATV on such terrain Always be especially cautious on these kinds of terrain WARNING Failure to use extra care...

Page 68: ...tch WARNING You could collide with another vehicle if operating in off road ar eas where you cannot easily be seen Mount a caution flag on the ATV to make you more vis ible Watch carefully for other vehicles EWB01061 Do not ride in areas posted no trespassing Do not ride on private property without getting per mission U43P12E0 book Page 11 Monday July 13 2009 5 26 PM ...

Page 69: ...lease the throt tle and apply the brakes smoothly and evenly Im proper use of the brakes can cause the tires to lose traction reducing control and increasing the possi bility of an accident NOTICE ECB00251 Do not shift from low range to high range or vice versa without coming to a complete stop Damage to the engine or drive train may occur TURNING YOUR ATV WARNING EWB01771 Always follow proper pro...

Page 70: ...of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body move ments or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside whil...

Page 71: ...suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a...

Page 72: ...e climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to lose co...

Page 73: ...y on extremely steep hills than on level surfaces or small hills Shift your weight backward and to the up side of the hill Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where possi ble Improper braking can cause the wheels on the uphill side to come off the ground or cause loss of traction Apply...

Page 74: ...ither the front or rear brake be cause the wheels on the uphill side could come off the ground Apply both the front and rear brakes gradually Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear CROSSING A SLOPE WARNING EWB01632 ...

Page 75: ...It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel C...

Page 76: ... ATV with out verifying that you have regained proper braking ability WARNING Wet brakes may have re duced stopping ability which could cause loss of control EWB02621 After riding your ATV in water be sure to drain the trapped water by removing the check hoses at the bottom of the air filter case Also remove the drain plugs from the front and rear storage compart ments and the V belt case to drain...

Page 77: ...7 20 7 1 Air filter case check hose 1 Air filter case check hose 1 Storage compartment drain plug 1 Storage compartment drain plug U43P12E0 book Page 20 Monday July 13 2009 5 26 PM ...

Page 78: ... the ATV may re sult SLIDING AND SKIDDING WARNING EWB01662 Skidding or sliding improperly may cause you to lose control of this ATV You may also re gain traction unexpectedly which may cause the ATV to overturn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to re ...

Page 79: ...f time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are re duced Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost WHAT TO DO IF This section is designed to be a reference guide only Be sure to read each sectio...

Page 80: ...nd physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE IF THE ATV IS IN 2WD the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 13 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if...

Page 81: ...nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 1 for more information about carbon monoxide The intervals given in the periodic maintenance and lubrica...

Page 82: ...intenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Owner s manual 2 Low pressure tire gauge 3 Owner s tool kit U43P12E0 book Page 2 Monday July 13 2009 5 26 PM ...

Page 83: ...and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust if necessary 4 Crankcas...

Page 84: ... NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Front brake Check operation and correct if necessary Check fluid level and ATV for fluid leakage and correct if necessary Replace ...

Page 85: ...ry 10 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 11 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 12 Stabilizer bushes Check for cracks or other damage and replace if necessary 13 Rear knuckle pivots Lubricate with lithium soap based grease 14 Steering shaft Lubricate with lithium soap based...

Page 86: ...sary 21 Final gear oil Change Check ATV for oil leakage and correct if neces sary 22 Cooling system Check coolant level and ATV for coolant leakage and correct if necessary Replace coolant Every 2 years 23 Moving parts and cables Lubricate 24 Drive select lever safety system cable Check operation and adjust or replace if neces sary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes fi...

Page 87: ...four years and if cracked or damaged 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 MAINTENA...

Page 88: ...Removing and installing panels The panels shown 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 1 Panel A 2 Panel B 3 Panel C 4 Panel D 5 Panel F 6 Panel G 1 2 3 5 6 4 U43P12E0 book Page 8 Monday July 13 2009 5 26 PM ...

Page 89: ... Panel A To remove the panel Pull upward on the areas shown To install the panel Place the panel in the original position 1 Panel E 2 Panel H 3 Panel I 1 3 2 1 Panel A U43P12E0 book Page 9 Monday July 13 2009 5 26 PM ...

Page 90: ...emove panel A 2 Remove the front carrier by removing the bolts 3 Remove the front carrier stays by removing the bolts 1 Carrier bolt under the fenders 1 Carrier bolt top 1 Front carrier stay U43P12E0 book Page 10 Monday July 13 2009 5 26 PM ...

Page 91: ...hen pull the panel upward to remove it To install the panel 1 Place the panel in the original position and then install the quick fasteners 1 Front carrier stay bolt 1 Panel B 2 Quick fastener U43P12E0 book Page 11 Monday July 13 2009 5 26 PM ...

Page 92: ... Install panel A Panel C To remove the panel 1 Remove the seat See page 4 18 2 Remove panel A 3 Remove the quick fastener screws and then pull the panel upward to remove it Tightening torque Front carrier stay bolt 34 Nm 3 4 m kgf 24 ft lbf 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 U43P12E0 book Page 12 Monday July 13 200...

Page 93: ...3 Install the seat Panels D and E To remove one of the panels 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 C 2 Quick fastener screw U43P12E0 book Page 13 Monday July 13 2009 5 26 PM ...

Page 94: ...8 14 8 1 Panel D 2 Quick fastener screw 1 Bolt 1 Panel E 2 Quick fastener screw 1 Bolt U43P12E0 book Page 14 Monday July 13 2009 5 26 PM ...

Page 95: ...ginal position and then install the bolt and quick fastener screw 2 Install panel C Panel F To remove the panel Pull outward on the areas shown To install the panel Place the panel in the original position 1 Panel F U43P12E0 book Page 15 Monday July 13 2009 5 26 PM ...

Page 96: ...els 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 G 2 Nut 3 Bolt 4 Projection U43P12E0 book Page 16 Monday July 13 2009 5 26 PM ...

Page 97: ... panels Place the panel in the original position and then in stall the bolts and nut Panel I To remove the panel 1 Remove the seat See page 4 18 1 Panel H 2 Nut 3 Bolt 4 Projection U43P12E0 book Page 17 Monday July 13 2009 5 26 PM ...

Page 98: ...r carrier by removing the bolts 3 Remove the quick fasteners and then push inward on the areas shown 1 Carrier bolt under the fenders 1 Carrier bolt upper 1 Carrier bolt lower U43P12E0 book Page 18 Monday July 13 2009 5 26 PM ...

Page 99: ...er by installing the bolts and tightening them to the specified torques 3 Install the seat 1 Panel I 2 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 U43P12E0 book Page 19 Monday July 13 2009 5 26 PM ...

Page 100: ...ick fastener EBU23213 Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accor dance with the periodic maintenance and lubrica tion chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark p...

Page 101: ... plug shows a distinctly different color the engine could be operating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the ATV 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification 1 Spa...

Page 102: ...hould be tightened to the specified torque as soon as possible 3 Install the spark plug cap EBU27466 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 Place the ATV on a leve...

Page 103: ...le and then remove it again to check the oil level TIP The engine oil should be between the minimum and maximum level marks 6 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 NOTICE Be sure the engine oil is at the correct level otherwise engine damage may result ECB00851 7 Insert the dipstick completely into the o...

Page 104: ...s gasket to drain the oil from the crankcase TIP Skip steps 5 9 if the oil filter cartridge is not being replaced 5 Remove panel G See page 8 8 6 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a nearby Yamaha dealer 7 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge 1 Engine oil drain bolt 2 Gasket 1 1 2 1 Oil filter ...

Page 105: ... torque with a torque wrench 9 Install panel G 10 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the speci fied torque 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 30 Nm 3 0 m kgf 22 ft lbf U43P12E0 book Page 25 Monday July 13 2009 5 26 PM ...

Page 106: ...nd check for the cause 13 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary 14 Install panel F EBU27306 Final gear oil The final gear case must be checked for oil leak age 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 ...

Page 107: ...f necessary 5 Install the oil level check bolt the oil filler bolt and their gasket and then tighten the bolts to the specified torques 1 Final gear oil 2 Gasket 3 Final gear oil level check bolt 4 Correct oil level 1 2 4 3 1 Final gear oil filler bolt 2 Gasket 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 1 2 U43...

Page 108: ...in bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill with the recommended final gear oil to the brim of the check hole as shown NOTICE Be sure no foreign material enters the final gear case ECB00421 1 Final gear oil drain bolt 2 Gasket 1 1 2 Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Final gear oil 2 Gasket 3 Final gear oil level check ...

Page 109: ...s at the in tervals specified in the periodic maintenance and lubrication chart To check the differential gear oil level 1 Place the ATV on a level surface 2 Remove the differential gear oil filler bolt and its gasket and then check the oil level in the differential gear case The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil...

Page 110: ...the oil from the differential gear case 4 Install the drain bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill with the recommended differential gear oil to the brim of the filler hole as shown NOTICE Be sure no foreign material en ters the differential gear case ECB00411 Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Differential ge...

Page 111: ...periodic maintenance and lubrication chart EBU27124 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 1 Differential gear oil filler bolt 2 Gasket 3 Differential ...

Page 112: ...ater has been used instead of coolant re place it with coolant as soon as possible otherwise the cooling system will not be protected 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 otherwise the effectiveness of the coolant will be reduced ECB01011 1 Maximum level mark 2 Minimum level mark 1 C...

Page 113: ...d steam blown out under pressure Always place a thick rag over the cap when opening Allow 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 and its gasket Use a trough or a similar object as shown to prevent coolant from spilling on t...

Page 114: ...hly flush the cooling system with clean tap water 9 Install the coolant drain bolt and its new gas ket and then tighten the bolt 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 U43P12E0 book Page 34 Monday July 13 ...

Page 115: ...t begins to flow out of the bolt hole tighten the water pump air bleed bolt to the specified torque 15 Remove panel E See page 8 8 16 Loosen the clamp screw and then remove the V belt cooling duct 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 r...

Page 116: ...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 1 V belt cooling duct 2 Clamp screw 1 Cylinder head air bleed bolt Tightening torque Cylinder head air bleed bolt 10 Nm 1 0 m kgf 7 2 ft lbf U43P12E0 book Page 36 Monday July 13 2009 5 26 PM ...

Page 117: ...eaning 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 expla...

Page 118: ...ge 8 9 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 U43P12E0 book Page 38 Monday July 13 2009 5 26 PM ...

Page 119: ... material when squeezing it ECB00441 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 material into the air filter case NOTICE Make sure that the air filter element is properly seated in the air filter case N...

Page 120: ...ginal position as shown 13 Install the panel TIP The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the throttle body and the rubber joi...

Page 121: ...ove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 4 Check the gasket for damage and replace it if necessary 5 Install the gasket and then insert the tailpipe into the muffler and align the bolt holes 6 Install the bolts and tighten them to the speci fied torque 7 Remove the purging bolt and its gasket 1 Bolt 1 Tailpipe 2 Spark arrester 3 Gas...

Page 122: ...rea when purging the spark arrester otherwise it could cause injury to the eyes burns carbon monox ide poisoning possibly leading to death and start a fire Always let the exhaust system cool prior to touching exhaust components Always wear eye protection and make sure no one is behind the ATV Make sure there are no combustible materi als in the area EBU23930 V belt case drain plug After riding in ...

Page 123: ...asure 3 0 5 0 mm 0 12 0 20 in at the throttle lever Period ically check the throttle cable free play and if nec essary adjust it as follows 1 Slide the rubber cover back 2 Loosen the locknut 3 To increase the throttle cable free play turn the throttle cable free play adjusting bolt in di rection a To decrease the throttle cable free play turn the adjusting bolt in direction b 4 Tighten the locknut...

Page 124: ...n chart EBU29601 Brakes Replacement of brake components requires pro fessional knowledge Brake service should be per formed by a Yamaha dealer WARNING EWB02571 Operating with improperly serviced or adjust ed brakes could lead to a loss in braking ability and an accident EBU27470 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified...

Page 125: ...ntenance 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 TIP The wheels need to be removed to check the brake hose protectors See page 8 62 1 Wear indicator groove 1 Wear indicator groove U43P12E0 book Page 45 Monday July 13 2009 5 26 PM ...

Page 126: ...k 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 Rear brake 1 Rear brake hose protector 2 Wear indicator 3 Protector is normal 4 Protector is worn 1 Minimum level mark 1 Minimum level mark 2WD 4WD 1 U43P12E0 book Page 46...

Page 127: ... 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 maintenance and lubrication chart In addition have the oil seals of the master cylinders and cali pers as well as the brake hoses replaced at the in...

Page 128: ...ays perform this maintenance 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 No brake lever free play 1 No brake lever free play U43P12E0 book Page 48 Monday July 13 2009 5 2...

Page 129: ...ncrease the free play and in direction b to decrease it 4 Tighten the locknut 5 After adjusting there should be slight play at the brake pedal cable joint as shown If there is no play repeat steps 2 to 4 1 Brake pedal free play 1 Locknut 2 Brake pedal free play adjusting nut U43P12E0 book Page 49 Monday July 13 2009 5 26 PM ...

Page 130: ...r brake lever and brake pedal do not move 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 Brake pedal cable joint 2 Slight play 1 2 1 Front axle boot each side 1 1 U43P12E0 book Page 50 Monday July 13 200...

Page 131: ...hich could restrict the operation of controls and lead to an accident or injury Always make sure all control cables work smoothly before you begin riding in cold weather If the control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead to an acci dent or collision EBU24912 Checking and lubricating the front and rear brake levers The operation of the f...

Page 132: ...edal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricated if necessary TIP To access the brake pedal pivot remove panel H See page 8 8 Recommended lubricant Lithium soap based grease U43P12E0 book Page 52 Monday July 13 2009 5 26 PM ...

Page 133: ...ushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer replace the stabilizer bush es if necessary EBU25051 Lubricating the rear knuckle pivots The rear knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricate the pivoting point...

Page 134: ...danger ous as it contains sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately EYES Flush with water for 15 minutes and get prompt medical attentio...

Page 135: ...hen removing the bat tery the main switch must be off and the negative lead must be disconnected be fore the positive lead ECB01001 5 Pull the battery out of its compartment 1 Carrier bolt under the fenders 1 Carrier bolt top 1 Battery holding plate 2 Nut 3 Negative battery lead black 4 Positive battery lead red 1 2 4 3 U43P12E0 book Page 55 Monday July 13 2009 5 26 PM ...

Page 136: ...charger have a Yamaha dealer charge your battery To store the battery If the ATV will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary NOTICE ECB00940 Always keep the battery charged Storing a dis charged battery can caus...

Page 137: ...nel EBU27751 Replacing a fuse 1 Positive battery lead red 2 Negative battery lead black 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 2 1 Fuse box 2 Main EPS spare fuse 3 Main fuse 4 EPS fuse 5 Fuel injection system spare fuse 6 Fuel injection system fuse U43P12E0 book Page 57 Monday July 13 2009 5 26 PM ...

Page 138: ...replacing a fuse 2 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Always use a fuse of the spec ified rating and never use a substitute ob ject in place of the proper fuse An improper fuse or a substitute object can cause damage to the electrical system which could lead to a fire EWB02172 1 Ignition fuse 2 Headlight fuse 3 Four wheel drive motor fuse 4 Radiator...

Page 139: ...eplace it as follows 1 Remove the cover at the rear of the headlight by pulling it off 2 Remove the headlight bulb cover 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 Radiator fan fuse 20 0 A Fuel injection system fuse 15 0 A EPS fuse 40 0 A 1 Cover at the rear of the headligh...

Page 140: ...part of the head light bulb to keep it free from oil otherwise the transparency of the glass the luminos ity of the bulb and the bulb life will be ad versely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner ECB00651 1 Headlight bulb cover 1 Headlight coupler 1 Headlight bulb holder 2 Headlight bulb U43P12E0 book Page 60 M...

Page 141: ...have a Yamaha dealer make this adjustment To raise a headlight beam turn the headlight beam adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b EBU25641 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 counterclockw...

Page 142: ...lb 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 1 1 U43P12E0 book Page 62 Monday July 13 2009 5 26 PM ...

Page 143: ...heel 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 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 1 U43P12E0 book Page 63 Monday July 13 2009 5 26 PM ...

Page 144: ...any 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 o...

Page 145: ...ler 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 146: ...r can be temporarily used instead provided that it is changed to the rec ommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See TIP Start the engine If the engine overheats...

Page 147: ...on dry out the linings EWB02311 NOTICE Excessive water pressure may cause water seepage and deteriora tion of wheel bearings brakes transmis sion seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applica tions such as those available in coin oper ated car washers ECB00711 4 Once most of the dirt has been hosed off wash all surfaces with wa...

Page 148: ... the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparking during the next step d Turn the engine over several times with the starter This will coat the cylinder wall with oil e Remove the spark plug cap...

Page 149: ...e it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation on storing the battery see page 8 54 TIP Make any necessary repairs before storing the ATV U43P12E0 book Page 3 Monday July 13 2009 5 26 PM ...

Page 150: ...ke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 686 cm Bore stroke 102 0 84 0 mm 4 02 3 31 in Compression ratio 9 20 1 Starting system Electric starter Lubrication system Wet sump Engine oil Recommended brand YAMALUBE Type SAE 5W 30 10W 30 10W 40 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA 0 10 30 50 70 90 110 130 F...

Page 151: ...0 US qt 1 75 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 20 0 L 5 28 US gal 4 40 Imp gal Fuel reserve amount 4 5 L 1 19 US gal 0 99 Imp gal Fuel injection Throttle body ID mark 43PG 10 Spark plug s Manufacturer model NGK LMAR6A 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Clutch Clutch type Wet centrifugal automatic Transmission Pr...

Page 152: ...ressure measured on cold tires Recommended Front 35 0 kPa 0 350 kgf cm 5 0 psi Rear 30 0 kPa 0 300 kgf cm 4 4 psi Minimum Front 32 0 kPa 0 320 kgf cm 4 6 psi Rear 27 0 kPa 0 270 kgf cm 4 0 psi 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 fluid DOT 4 Rear brake...

Page 153: ...Halogen bulb Bulb voltage wattage quantity Headlight 12 V 35 35 W 2 Tail brake light 12 V 5 0 21 0 W 1 Meter lighting EL Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Engine trouble warning light LED EPS warning light LED Park indicator light LED On Command four wheel drive differential gear lock indicator LCD High range indicator light LED Low range...

Page 154: ...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 A U43P12E0 book Page 5 Monday July 13 2009 5 26 PM ...

Page 155: ...f 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 the frame 1 Key i...

Page 156: ...ll be need ed when ordering spare parts from a Yamaha deal er EBU29662 Vehicle Emission Control Information label The Vehicle Emission Control Information label is affixed at the location in the illustration This label shows specifications related to exhaust emissions as required by federal law state law and Environ ment Canada 1 Vehicle identification number front left side 1 Model label U43P12E0...

Page 157: ...11 3 11 1 Vehicle Emission Control Information label 1 U43P12E0 book Page 3 Monday July 13 2009 5 26 PM ...

Page 158: ...rpose 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 ...

Page 159: ...t the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 22500 14400 1440 60 25000 16000 1600 U4...

Page 160: ...ubsequent 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 w...

Page 161: ...nd upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Q Is the warranty transferable to second owners A Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain effective CUSTOMER SERVICE If your m...

Page 162: ...e to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 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 lodg...

Page 163: ...s 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 Indicates a hazardous situation which if not avoided could result in death or serious injury W...

Page 164: ...11 10 11 EBU26132 U43P12E0 book Page 10 Monday July 13 2009 5 26 PM ...

Page 165: ...nt temperature warning light 4 3 D 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 4 3 F Final gear oil 5 3 8 26 Four wheel drive differentia...

Page 166: ...tor light 4 2 Riding your ATV 7 1 S Safety information 2 1 Seat 4 18 Shock absorber assemblies adjusting the front and rear 4 22 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 19 T Tail brake light bulb replacing 8...

Page 167: ...U43P12E0 book Page 3 Monday July 13 2009 5 26 PM ...

Page 168: ... surfaces pavement may seriously affect 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 HELME...

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