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EBU24963

Checking the wheel hub bearings

The front and rear wheel hub bearings must be
checked at the intervals specified in the periodic
maintenance and lubrication chart. If there is play
in a wheel hub or if a wheel does not turn smoothly,
have a Yamaha dealer check the wheel hub bear-
ings.

EBU25022

Checking the stabilizer bushes

The stabilizer bushes must be checked for cracks
or damage at the intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer replace the stabilizer bush-
es if necessary.

EBU25052

Lubricating the rear knuckle pivots

The rear knuckle pivots must be lubricated at the
intervals specified in the periodic maintenance and
lubrication chart.

TIP

For parts equipped with a grease nipple, use a
grease gun.

Recommended lubricant:

Lithium-soap-based grease

1. Grease nipple

U1HP60E0.book Page 55 Monday, April 11, 2011 7:56 PM

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Summary of Contents for Grizzly 700 2011

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

Page 2: ...PRINTED IN USA 2011 05 0 8 1 CR E F S DIC183 ...

Page 3: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL YFM7FGPB YFM7FGPHB YFM7FGPSEB YFM700FADB 1HP F8199 60 E0 U1HP60E0 book Page 1 Monday April 11 2011 7 56 PM ...

Page 4: ...ate of issue of the other Directives of EEC If applicable YAMAHA MOTOR EUROPE N V Koolhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Shinya Shimada Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EE...

Page 5: ...understanding of the features and operation of this ATV This manual includes important safety information It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE Read this...

Page 6: ... safety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key info...

Page 7: ...y Please check your local riding laws and regulations before operating this ATV EBU17410 YFM7FGPB YFM7FGPHB YFM7FGPSEB YFM700FADB OWNER S MANUAL 2011 by Yamaha Motor Co Ltd 1st edition March 2011 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A U1HP60E0 book Page 1 Monday April 11 2011 7 56 PM ...

Page 8: ...e lever 4 14 Drive select lever 4 15 Fuel tank cap 4 15 Fuel 4 16 Seat 4 18 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 23 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Differential gear oil 5 3 Coolant 5 3 Front and rear brakes 5 3 Throttle lever 5 4 Tires 5 4 Chassis fasteners...

Page 9: ...moving the radiator grills 8 20 Checking the spark plug 8 20 Engine oil and oil filter cartridge 8 22 Final gear oil 8 27 Differential gear oil 8 29 Coolant 8 32 Cleaning the air filter element 8 39 Cleaning the spark arrester 8 42 V belt case drain plug 8 44 Adjusting the throttle lever free play 8 45 Valve clearance 8 46 Adjusting the drive select lever safety system cable 8 46 Brakes 8 46 Check...

Page 10: ...ry 8 56 Replacing a fuse 8 59 Replacing a headlight bulb 8 61 Adjusting a headlight beam 8 63 Replacing the tail brake light bulb 8 63 Removing a wheel 8 64 Installing a wheel 8 65 Troubleshooting 8 66 Troubleshooting charts 8 67 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 U1HP60E0 book Page 3 Monday April 11 2011 7 56...

Page 11: ...n your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace ment label from your Yamaha dealer For Europe 1 23 4 6 5 7 8 10 9 11 12 5 U1HP60E0 book Page 1 Monday April 11 2011 7 56 PM ...

Page 12: ...33 lbf 37S F817S 00 1HP F817R 10 85 kg 187 lbs 35 0 kPa 0 35 kgf cm 5 0 psi 30 0 kPa 0 30 kgf cm 4 4 psi 1HP F816M M0 YAMAHA 1HP F817R 00 45 kg 99 lbs 1P0 F816P 20 YAMAHA 1HP F2259 21 1 2 3 4 5 6 U1HP60E0 book Page 2 Monday April 11 2011 7 56 PM ...

Page 13: ...1 3 1 37S F816N 00 0 5 kg 1 lb YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM700FWAD 34 0 kW 294 kg 2011 1HP F155A 00 1P0 F816L 20 YAMAHA 7 8 9 U1HP60E0 book Page 3 Monday April 11 2011 7 56 PM ...

Page 14: ...1 4 1 37S F816S 00 1P0 F816R 00 YAMAHA 10 11 12 U1HP60E0 book Page 4 Monday April 11 2011 7 56 PM ...

Page 15: ... children under age 10 to operate this ATV Operation of this ATV by children under the age of 10 increases the risk of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 12 to operate this ATV Operation of this ATV by children under the age of 12 increases the risk of severe injury or death Adult supervision required for children under age 1...

Page 16: ...y or death Turning the ATV in 4WD LOCK DIFF LOCK takes more effort Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control This pictogram shows the loading limits and or maximum load capacity for this ATV Follow all load limits and other loading guidelines in this manual Load may include the driver passenger human protective gear accessories goods luggage a...

Page 17: ...loading can cause loss of control Loss of control can result in severe injury or death This pictogram shows trailer Hitch Tongue weight limit Weight on the trailer tongue Overloading can cause loss of control Loss of control can result in severe injury or death 1 2 3 4 Year of construction Model Name Max Power Mass In Running Order U1HP60E0 book Page 7 Monday April 11 2011 7 56 PM ...

Page 18: ...1 8 1 For Oceania 1 2 3 4 6 7 9 8 10 5 5 U1HP60E0 book Page 8 Monday April 11 2011 7 56 PM ...

Page 19: ... WEIGHT 147 N 15 kgf 33 lbf YAMAHA WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 1HP F2259 01 1 3 2 4 5 U1HP60E0 book Page 9 Monday April 11 2011 7 56 PM ...

Page 20: ...ills and rough terrain Maximum Vehicle Load 220 kg 485 lbs Includes weight of operator cargo and accessories and if applicable trailer tongue weight WARNING 1HP F816M 00 YAMAHA IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires cold LOADING TRAILER TOWING WARNING UNDER 16 Operating this ATV if ...

Page 21: ...ruction 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 use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNE...

Page 22: ...child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and paved streets Never operate an ATV on any paved street paved road or motorway Watch carefully for other vehicles when operat ing on unpaved public streets or roads Make sure you know your country s ...

Page 23: ...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 24: ...ed 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 pressure as de scribed in this manual Never...

Page 25: ... fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or par tially enclosed areas such as barns garages or carports Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as w...

Page 26: ...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 U1HP60E0 book Page 1 Monday April 11 2011 7 56 PM ...

Page 27: ... 2 Rear brake lever 3 Handlebar switches 4 Horn switch 5 Rear brake fluid reservoir 6 Multi function 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 U1HP60E0 book Page 2 Monday April 11 2011 7 56 PM ...

Page 28: ...e as follows on All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed off All electrical systems are off The key can be re moved 1 Main switch U1HP60E0 book Page 1 Monday April 11 2011 7 56 PM ...

Page 29: ...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 30: ...on 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 EBU30480 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 pag...

Page 31: ...ar 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 position TIP Due to the synchronizing...

Page 32: ...IP A and TRIP B in the follow ing order ODO 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 k...

Page 33: ...ELECT button and then release it to start the clock Fuel meter 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 ...

Page 34: ...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 35: ...e point that the starter motor will not operate properly If this should happen remove the battery and recharge it See page 8 56 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 36: ... 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 37: ...e 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 38: ...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 39: ...d push the switch to the 4WD position TIP When the switch is set to LOCK or 4WD the differential gear lock indicator and indicator light will flash until the differential gear is completely locked or unlocked When the indicator and indicator light are flash ing turning the handlebar back and forth will help the differential gear to lock or unlock 1 Differential gear lock lever 2 On Command four wh...

Page 40: ...throttle le ver will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decelerate and the engine will return to an idle any time the 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 r...

Page 41: ...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 handlebar...

Page 42: ...erating 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 U1HP60E0 book Page 15 Monday April 11 2011 7 56 PM ...

Page 43: ... 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 44: ...e 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 piston rings as well as to the exhaust system ...

Page 45: ...ce costs 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 of the seat into the seat holders and push down on the seat at the rear Make sure that the seat is securely fitted EBU27362 Storage compartments This ATV is equipped with two storage compart ments 1 Seat 2 Seat lock lever 1 Projection 2 ...

Page 46: ...ont 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 The rear storage compartment is located under the seat See page 4 18 To access the storage com partment remove the storage compartment cover 1 Front storage compartment cover 1 Front storage compartment U1HP60E0 book Page 19 Mon...

Page 47: ...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 the wa ter and then install the drain plug 1 Rear storage compartment cover 1 Rear storage compartment...

Page 48: ...485 lb for the ATV EBU30470 Adjusting the front and rear shock ab sorber assemblies The spring preload can be adjusted to suit the rid er s weight and the riding conditions WARNING 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 1 Storage compartment ...

Page 49: ...with the position indicator on the shock absorber TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment WARNING EWB02730 The rear shock absorber assembly contains highly pressurized nitrogen gas If the shock absorber assembly is damaged it could ex plode causing injury or property damage 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench Spring preload ...

Page 50: ...r assembly to a Yamaha deal er for any service EBU19183 Auxiliary DC jack The auxiliary DC jack is 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 and the light switch is set to OFF 1 Set the light switch to OFF 2 Turn the accessory off 3 Start the engine See page 6...

Page 51: ...cause the fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine start ing may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged Maximum rated capacity for the auxiliary DC jack DC 12 V 10 A 120 W U1HP60E0 book Page 24 Monday...

Page 52: ... 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 o...

Page 53: ...hrottle lever Make sure that operation is smooth Lubricate cable and lever hous ing if necessary Check lever free play and adjust if necessary 5 4 8 45 Control cables Make sure that operation is smooth Lubricate if necessary 8 53 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 Brake ...

Page 54: ...sary See page 8 32 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EBU29082 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 adjust...

Page 55: ...must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU19814 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 56: ...n 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 U1HP60E0 book Page...

Page 57: ...been approved for this model by Yamaha Motor Manufacturing Corporation of America 1 Tire wear limit Front Manufacturer model YFM700FADB CHENG SHIN C828 YFM7FGPB MAXXIS MU19 YFM7FGPHB MAXXIS MU19 YFM7FGPSEB MAXXIS MU19 Size AT25 x 8 12 Type Tubeless Rear Manufacturer model YFM700FADB CHENG SHIN C828 YFM7FGPB MAXXIS MU20 YFM7FGPHB MAXXIS MU20 YFM7FGPSEB MAXXIS MU20 Size AT25 x 10 12 Type Tubeless U1...

Page 58: ...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 EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary U1HP60E0 book Page 7 Monday April 11 2011 7 56 PM ...

Page 59: ... 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 check To avoid possible damage do not oper ate the ATV if a warning light stays on 2 Apply the brake pedal and then shift the drive select lever int...

Page 60: ... be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each attempt NOTICE ECB00163 For maximum engine life never accelerate hard when the engine is cold EBU20441 Operating the drive select lever and driving in reverse NOTICE ECB00170 Before shifting stop the ATV otherwise the transmission may be damaged Shifting Neutral to High range and High range to ...

Page 61: ...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 High...

Page 62: ...ven 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 63: ... 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 64: ... 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 grea...

Page 65: ...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 t...

Page 66: ...hifting load can cause an accident Make sure the load 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 heavie...

Page 67: ...7 1 7 EBU21141 RIDING YOUR ATV U1HP60E0 book Page 1 Monday April 11 2011 7 56 PM ...

Page 68: ...al 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 accident is greatly increased ...

Page 69: ...390 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 posi tion as needed during operation It is not for carry ing passengers WAR...

Page 70: ...G 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 wi...

Page 71: ...ach 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 r...

Page 72: ...entered 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 ta...

Page 73: ...ll 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 l...

Page 74: ...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 75: ...faces may seriously affect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets EWB01511 While riding on unpaved public streets or roads may be legal in your area such operation can in crease the risk of collision with other vehicles Watch carefully for other vehicles Make sure you U1HP60E0 boo...

Page 76: ...ch may cause the ATV to upset WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Al ways be alert to changing terrain conditions when operating the ATV EWB01531 Do not operate on rough slippery or loose terrain until you have learned and practiced the skills nec essary t...

Page 77: ...on flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if operating in areas where you cannot easily be seen Mount a caution flag on the ATV to make you more visible Watch carefully for other vehicles EWB01551 Do not ride in areas posted no trespassing Do not ride on private property without getting per mission U1HP60E0 book Page 11 Mo...

Page 78: ...release 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 p...

Page 79: ...f 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 while...

Page 80: ...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 81: ...are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to lose ...

Page 82: ...easily 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 ...

Page 83: ...ther 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 I...

Page 84: ...t 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 CR...

Page 85: ... 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 86: ...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 U1HP60E0 book Page 20 Monday April 11 2011 7 56 PM ...

Page 87: ... 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 88: ... 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 section...

Page 89: ...ed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE IF THE ATV IS IN 2WD the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 13 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned to wards the uphill side of the ATV to maintain proper ...

Page 90: ...rn off the engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 3 for more information about carbon monoxide WARNING EWB02690 B...

Page 91: ...l and the tools provided in the owner s tool kit are in tended to assist you in the performance of preven tive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Owner s manual 2 Low pressur...

Page 92: ...tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust if necessary...

Page 93: ...er Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 U1HP60E0 book Page 4 Monday April 11 2011 7 56 PM ...

Page 94: ...ith an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Front brake Check op...

Page 95: ...r damage and re place if necessary 6 Wheels Check runout and for damage and replace if nec essary 7 Tires Check tread depth and for damage and replace if necessary Check air pressure and balance and correct if necessary 8 Wheel hub bearings Check for looseness or damage and replace if necessary 9 V belt Check for wear cracks or other damage and re place if necessary NO ITEM CHECK OR MAINTENANCE JO...

Page 96: ...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 if neces sary 19 Engine oil filter car tridge Replace NO ITEM CHECK OR M...

Page 97: ...em cable Check operation and adjust or replace if neces sary 25 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 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 JOB INITIAL EVERY Whichev...

Page 98: ...t full throttle Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U1HP60E0 book Page 9 Monday April 11 2011 7 56 PM ...

Page 99: ...jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EBU27385 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 1 2 3 5 4 1 Panel E 2 Panel G 3 Panel H 1 3 2 U1HP60E0 book Page 10 Monday April 11 2011 7 56 PM ...

Page 100: ... 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 U1HP60E0 book Page 11 Monday April 11 2011 7 56 PM ...

Page 101: ... stays by removing the bolts 4 Remove the quick fasteners and then pull the panel upward to remove it 1 Front carrier 2 Carrier bolt top 1 Front carrier stay 1 Front carrier stay bolt U1HP60E0 book Page 12 Monday April 11 2011 7 56 PM ...

Page 102: ...nt 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 25 ft lbf U1HP60E0 book Page 13 Monday April 11 2011 7 56 PM ...

Page 103: ...ner screws 2 Install the seat Panels D and E To remove a panel 1 Remove panels A and 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 Tightening torques Carrier bolt top 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 Panel C 2 Quick fas...

Page 104: ...8 15 8 1 Panel D 2 Quick fastener screw 1 Bolt 1 Panel E 2 Quick fastener screw 1 Bolt U1HP60E0 book Page 15 Monday April 11 2011 7 56 PM ...

Page 105: ... fastener screw 2 Install panels A and C Panels F and G To remove a panel 1 Remove the panel bolts footboard bolt and footboard nut 2 Pull the panel downward while pushing the projection 1 Panel F 2 Footboard nut 3 Footboard bolt 4 Panel bolt 5 Projection U1HP60E0 book Page 16 Monday April 11 2011 7 56 PM ...

Page 106: ...ce the panel in the original position 2 Install the bolts and nut and then tighten them to the specified torques 1 Panel G 2 Footboard nut 3 Footboard bolt 4 Panel bolt 5 Projection U1HP60E0 book Page 17 Monday April 11 2011 7 56 PM ...

Page 107: ...e rear carrier by removing the bolts Tightening torques Panel bolt 4 0 Nm 0 40 m kgf 2 9 ft lbf Footboard nut 4 0 Nm 0 40 m kgf 2 9 ft lbf 1 Carrier bolt under the fenders 1 Rear carrier 2 Carrier bolt upper 1 Carrier bolt lower U1HP60E0 book Page 18 Monday April 11 2011 7 56 PM ...

Page 108: ...steners 2 Install the rear carrier by installing the bolts and tightening them to the specified torques 3 Install the seat 1 Panel H 2 Quick fastener 2 1 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 U1HP60E0 book Page 19 Monday April 11 2011 7 56 PM ...

Page 109: ...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 110: ... 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 111: ...should be tightened to the specified torque as soon as possible 3 Install the spark plug cap EBU27467 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 lev...

Page 112: ...Remove the access cover by turning it coun terclockwise 4 Remove the engine oil dipstick and then wipe it off with a clean rag 5 Insert the dipstick completely into the oil filler hole and then remove it again to check the oil level TIP The engine oil should be between the minimum and maximum level marks 1 Access cover 1 Engine oil dipstick U1HP60E0 book Page 23 Monday April 11 2011 7 56 PM ...

Page 113: ... access cover by turning it clock wise To change the engine oil with or without oil fil ter cartridge replacement 1 Place the ATV on a level surface 2 Remove the access cover by turning it coun terclockwise 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 and its gasket to drain the oil from the crankcase 1 Maximum level m...

Page 114: ...vailable 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 U1HP60E0 book Page 25 Monday April 11 2011 7 56 PM ...

Page 115: ...ince the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 30 Nm 3 0 m kgf 22 ft lbf Recommended...

Page 116: ... 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 2 Remove the final gear oil level check bolt and its gasket and then check the oil level in the final gear case The oil level should be at the brim of th...

Page 117: ...l 3 Remove the final gear oil filler bolt the final gear oil level check bolt the final gear oil drain bolt and their gasket to drain the oil from the final gear case 4 Install the drain bolt and its new gasket and then tighten the bolt to the specified torque 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 b...

Page 118: ...gear oil The differential gear case must be checked for oil leakage before each ride If any leakage is found have a Yamaha dealer check and repair the ATV In addition the differential gear oil level must be checked and the oil changed as follows at the in tervals specified in the periodic maintenance and lubrication chart Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf 1 Fina...

Page 119: ... if necessary 5 Install the oil filler bolt and its gasket and then tighten the bolt to the specified torque To change the differential gear oil 1 Place the ATV on a level surface 2 Place an oil pan under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt the differential gear oil drain bolt and their gasket to drain the oil from the differential gear...

Page 120: ...d replace it if necessary 7 Install the oil filler bolt and its gasket and then tighten the bolt to the specified torque 1 Differential gear oil drain bolt 2 Gasket Tightening torque Differential gear oil drain bolt 9 8 Nm 0 98 m kgf 7 1 ft lbf 1 2 1 Differential gear oil filler bolt 2 Gasket 3 Differential gear oil 4 Correct oil level Recommended differential gear oil See page 10 1 Tightening tor...

Page 121: ...r TIP The coolant should be between the minimum and maximum level marks 3 If the coolant is at or below the minimum level mark remove panel D to access the coolant reservoir See page 8 10 4 Remove the coolant reservoir cap add cool ant or distilled water to the maximum level mark install the reservoir cap and then install the panel NOTICE If coolant is not avail able use distilled water or soft ta...

Page 122: ...change the coolant WARNING EWB01890 Wait for the engine and radiator to cool before removing the radiator cap You could be burned by hot fluid and steam blown out under pressure Always place a thick rag over the cap when opening Allow any remaining pressure to escape before completely removing the cap 1 Place the ATV on a level surface 2 Remove panel D See page 8 10 3 Remove the footboard by remov...

Page 123: ...t and its gasket Use a trough or a similar object as shown to prevent coolant from spilling on the engine guard 5 Remove panel B See page 8 10 1 Footboard 2 Bolt and nut 3 Bolt 3 2 2 3 1 1 Coolant drain bolt 2 Gasket 1 Trough 1 2 1 U1HP60E0 book Page 34 Monday April 11 2011 7 56 PM ...

Page 124: ... thoroughly flush the cooling system with clean tap water 10 Install the coolant drain bolt and its new gas ket and then tighten the bolt to the specified torque 11 Connect the coolant reservoir hose 12 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 U1HP60E0 book Page 35 Monday...

Page 125: ...begins to flow out of the bolt hole tighten the water pump air bleed bolt to the specified torque 16 Remove panel E See page 8 10 17 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 ro...

Page 126: ...he cylinder head air bleed bolt to the specified torque 20 Start the engine and let it idle for ten minutes 21 Rev the engine five times 22 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 U1HP60E0 book Page 37 Monday April 11 2011 7 56 PM ...

Page 127: ... Yamaha dealer check the cooling system 25 Install the V belt cooling duct and then tighten the clamp screw 26 Install the footboard by installing the bolts and nuts and then tighten them to the specified torques 27 Install the panels 1 Footboard nut 2 Footboard bolt A 3 Footboard bolt B Tightening torques Footboard nut 4 0 Nm 0 40 m kgf 2 9 ft lbf Footboard bolt A 4 0 Nm 0 40 m kgf 2 9 ft lbf Foo...

Page 128: ...sty 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 10 for an explanation on removing the panels Check the hoses periodically and if dust or water collects in them empty them and clean the air filter element and air filter case 1 Place the ATV on a level surface 2 Remove panel C See page 8 10 1 Air filter case check hose 1...

Page 129: ...4 Remove the sponge material and the mesh from the air filter case 5 Clean the mesh with solvent and then wipe the solvent off 1 Air filter case cover holder 2 Air filter case cover 1 Sponge material 2 Air filter mesh U1HP60E0 book Page 40 Monday April 11 2011 7 56 PM ...

Page 130: ...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 Never operate the engine with the air filter element removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Additionally operation with...

Page 131: ...nlet 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 air en tering the engine EBU27813 Cleaning the spark arrester Select a well ventilated area free of combustible materials and make sure the exhaust and muffler are ...

Page 132: ...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 Tailpipe bolt 1 Tailpipe 2 Spark arrester 3 Gasket Tightening torque Tailpipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf U1HP60E0 book ...

Page 133: ...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 EBU23931 V belt case drain plug After riding in water dee...

Page 134: ...12 0 20 in as shown Periodically check the throttle lever free play and if necessary adjust it as follows 1 Slide the rubber cover back 2 Loosen the locknut 3 To increase the throttle lever free play turn the throttle lever free play adjusting bolt in di rection a To decrease the throttle lever free play turn the adjusting bolt in direction b 4 Tighten the locknut 5 Slide the rubber cover to its o...

Page 135: ...eplacement 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 in the periodic main ten...

Page 136: ...tenance 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 64 1 Wear indicator groove 1 Wear indicator groove U1HP60E0 book Page 47 Monday April 11 2011 7 56 PM ...

Page 137: ...rk Check the brake fluid lev el with the top of the reservoir level Replenish the brake fluid if necessary 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 U1HP60E0 book Page 48 Monday April 11 2011 7 56 PM ...

Page 138: ...nted surfaces or plastic parts Always clean up spilled fluid im mediately As the brake pads wear it is normal for the brake fluid level to gradually go down A low brake fluid level may indicate worn brake pads and or brake system leakage therefore be sure to check the brake pads for wear and the brake system for leak age If the brake fluid level goes down suddenly have a Yamaha dealer check the ca...

Page 139: ...check the brake system Front brake Rear brake EBU29072 Adjusting the brake pedal free play The brake pedal free play must be adjusted at the intervals specified in the periodic maintenance and lubrication chart TIP Always perform this maintenance completely in the following order whenever adjusting the rear brake Before adjusting the brake pedal free play check the rear brake pads for wear 1 No br...

Page 140: ...urn the brake pedal free play adjusting nut in direction a to increase 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 U1HP60E0 book Page 51 Monday April 11 2011 7 56 PM ...

Page 141: ... 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 0 1 0 5 mm 0 004 0 02 in 1 2 1 Front axle boot each side 1 1 U1HP60E0 book Page 52 Monday...

Page 142: ...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 143: ...dal 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 G See page 8 10 Recommended lubricant Lithium soap based grease U1HP60E0 book Page 54 Monday April 11 2011 7 56 PM ...

Page 144: ...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 EBU25052 Lubricating the rear knuckle pivots The rear knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart TIP For parts equipped with a grea...

Page 145: ...nger 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 attention ...

Page 146: ...nuts 4 Disconnect the negative battery lead first then the positive battery lead by removing their bolt NOTICE When removing the bat tery the main switch must be off and the negative lead must be disconnected be fore the positive lead ECB01001 1 Carrier bolt under the fenders 1 Front carrier 2 Carrier bolt top U1HP60E0 book Page 57 Monday April 11 2011 7 56 PM ...

Page 147: ...ll damage the 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 cause permanent battery damage ...

Page 148: ...installing the nuts 4 Install the front carrier by installing the bolts and tightening them to the specified torques 5 Install the panel EBU30520 Replacing a fuse 1 Positive battery lead red 2 Negative battery lead black 1 2 Tightening torques Carrier bolt top 34 Nm 3 4 m kgf 25 ft lbf Carrier bolt under the fenders 7 Nm 0 7 m kgf 5 1 ft lbf 1 Fuse box 2 Main fuse 3 EPS fuse 4 Fuel injection syste...

Page 149: ...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 Auxiliary DC jack fuse 2 Four wheel drive motor fuse 3 Ignition fuse 4 ...

Page 150: ...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 10 0 A Ignition fuse 10 0 A Four wheel drive motor fuse 10 0 A Signaling system fuse 5 0 A Auxiliary DC jack fuse 10 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 151: ...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 U1HP60E0 book Page 62 M...

Page 152: ...ha 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 EBU25642 Replacing the tail brake light bulb If the tail brake light bulb burns out replace it as follows 1 Remove panel H See page 8 10 2 Remove the tail brake light bulb holder to gether with the bulb by turning it count...

Page 153: ...bulb 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 U1HP60E0 book Page 64 Monday April 11 2011 7 56 PM ...

Page 154: ...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 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 U1HP60E0 book Page 65 Monday April 11 2011 7 56 PM ...

Page 155: ...ny repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02280 Do not smoke when checking the fuel system Fuel can ignite or...

Page 156: ...he ATV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Check the battery Dry Wet Operate the electric starter The engine does not start Have a Yamaha dealer check the ATV Operate the electric starter 4 Battery The engine turns over quickly The en...

Page 157: ... 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 158: ...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 159: ...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 160: ... 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 56 TIP Make any necessary repairs before storing the ATV U1HP60E0 book Page 3 Monday April 11 2011 7 56 PM ...

Page 161: ... dB A 3125 r min Vibration on seat EN1032 ISO5008 YFM7FGPB Will not exceed 0 5 m s YFM7FGPHB Will not exceed 0 5 m s YFM7FGPSEB Will not exceed 0 5 m s Vibration on handlebar EN1032 ISO5008 YFM7FGPB Will not exceed 2 5 m s YFM7FGPHB Will not exceed 2 5 m s YFM7FGPSEB Will not exceed 2 5 m s Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displac...

Page 162: ...r 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 YFM700FADB Unleaded gasoline only YFM7FGPB Regular unleaded gasoline only YFM7FGPHB Regular unleaded gasoline only YFM7FGPSEB Regular unleaded gasoline only Fuel tank capacity 20 0 L 5 28 US gal 4 ...

Page 163: ... angle 5 0 Trail 26 0 mm 1 02 in Front tire Type Tubeless Size AT25 x 8 12 Manufacturer model YFM700FADB CHENG SHIN C828 YFM7FGPB MAXXIS MU19 YFM7FGPHB MAXXIS MU19 YFM7FGPSEB MAXXIS MU19 Rear tire Type Tubeless Size AT25 x 10 12 Manufacturer model YFM700FADB CHENG SHIN C828 YFM7FGPB MAXXIS MU20 YFM7FGPHB MAXXIS MU20 YFM7FGPSEB MAXXIS MU20 Loading Maximum loading limit 220 0 kg 485 lb Total weight ...

Page 164: ...ht foot operation Specified brake 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 gas oil damper Wheel travel 230 mm 9 1 in Electrical system Ignition system TCI Charging system AC magneto Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah He...

Page 165: ...em fuse 5 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Four wheel drive motor fuse 10 0 A Radiator fan fuse 20 0 A EBU30400 For EUR only The figures quoted are emission levels and are not necessarily safe working levels Whilst there is a correlation between the emission and exposure levels this cannot be used reliably to determine whether or not further precautions are required Factors t...

Page 166: ...10 6 10 sure level can vary from country This information however will enable the user of the machine to make a better evaluation of the hazard and risk U1HP60E0 book Page 6 Monday April 11 2011 7 56 PM ...

Page 167: ...rom a Yamaha dealer or for reference in case the ATV is stolen VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26041 Vehicle identification number The vehicle identification number is stamped into the frame The year of manufacture is listed in the vehicle identification number as shown in the illustration 1 Vehicle identification number front left side U1HP60E0 book Page 1 Monday April 11...

Page 168: ...ion 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 2 Year of manufacture 0 0 8 2008 9 2009 A 2010 B 2011 I O Q U Z not used 1 2 1 Model label U1HP60E0 book Page 2 Monday April 11 2011 7 56 PM ...

Page 169: ...32 Coolant 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 46 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 27 Four wheel drive dif...

Page 170: ...ing 8 55 Reverse indicator 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 21 Spark arrester cleaning 8 42 Spark plug checking 8 20 Specifications 10 1 Speed limiter 4 13 Stabilizer bushes checking 8 55 Starting the engine 6 1 Start switch 4 8 Steering shaft lubricating 8 56 Storage 9 2 Storage compartments 4 18 T Tail brake...

Page 171: ...U1HP60E0 book Page 3 Monday April 11 2011 7 56 PM ...

Page 172: ...PRINTED IN USA 2011 05 0 8 1 CR E U1HP60E0 book Page 1 Monday April 11 2011 7 56 PM ...

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