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Yamaha GRIZZLY 700 2012, Owner'S Manual, Page: 138 / 174

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Yamaha GRIZZLY 700 2012 Owner'S Manual Download Page 138

8-47

8

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-
tenance and lubrication chart. Each brake pad is
provided with a wear indicator groove, which al-
lows you to check the brake pad wear without hav-
ing to disassemble the brake. If a brake pad has
worn to the point that the wear indicator groove has
almost disappeared, have a Yamaha dealer re-
place the brake pads as a set.

TIP

The wheels need to be removed to check the
brake pads. (See page 8-64.)

Front brake

Rear brake

1. Wear indicator groove

1. Wear indicator groove

U1HP61E0.book  Page 47  Thursday, April 5, 2012  3:33 PM

Summary of Contents for GRIZZLY 700 2012

Page 1: ...MANUEL DU PROPRI TAIRE MANUAL DEL PROPIETARIO 1HP F8199 61 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de s...

Page 2: ...PRINTED IN USA 2012 04 0 6 1 CR E F S DIC183...

Page 3: ...fety information WARNING OWNER S MANUAL YFM7FGD YFM7FGPD YFM7FGPHD YFM7FGPAD YFM7FGPSED YFM7FGPLED YFM700FAPD YFM700FAPSED This ATV should not be ridden by anyone under 16 years of age 1HP F8199 61 E0...

Page 4: ...ure Eiji Kato 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...

Page 5: ...with a good basic 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 r...

Page 6: ...afety 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 sit...

Page 7: ...cal riding laws and regulations before operating this ATV EBU17410 YFM7FGD YFM7FGPD YFM7FGPHD YFM7FGPAD YFM7FGPSED YFM7FGPLED YFM700FAPD YFM700FAPSED OWNER S MANUAL 2012 by Yamaha Motor Co Ltd 1st edi...

Page 8: ...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 Au...

Page 9: ...ving 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 Cle...

Page 10: ...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...

Page 11: ...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...

Page 12: ...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 U1HP61...

Page 13: ...kg 2012 1ND F155A 00 37S F816N 00 0 5 kg 1 lb YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM700FWAD 34 0 kW 294 kg 2012 1HP F155A 10 YAMAHA 1HP F811R 00 8 9 7 YFM7FGD 7 YFM7FGPD YFM7FGPHD YFM7FGPAD...

Page 14: ...1 4 1 37S F816S 00 1P0 F816R 00 YAMAHA 10 11 12 U1HP61E0 book Page 4 Thursday April 5 2012 3 33 PM...

Page 15: ...rom 12 years old Operation of this ATV by children under the age of 12 increases the risk of severe injury or death Adult supervision required for children under age 16 Use from 16 years old Operating...

Page 16: ...oss of control Adjust the tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death This pictogram shows the loading limits and or maximum loa...

Page 17: ...1 7 1 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN kW kg 1 2 3 4 1 2 3 4 Year of construction Model Name Max Power Mass In Running Order U1HP61E0 book Page 7 Thursday April 5 2012 3 33 PM...

Page 18: ...1 8 1 For Oceania 1 2 3 4 6 7 9 8 10 5 5 U1HP61E0 book Page 8 Thursday April 5 2012 3 33 PM...

Page 19: ...MAXIMUM LOADING LIMIT 37S F151K 00 PULLING LOAD 5880 N 600 kgf 1322 lbf TONGUE WEIGHT 147 N 15 kgf 33 lbf YAMAHA WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in S...

Page 20: ...hills 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 PRESSUR...

Page 21: ...ction 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 losin...

Page 22: ...6 years old should never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a c...

Page 23: ...ve speeds Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as desc...

Page 24: ...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...

Page 25: ...d ride gently back to camp or other known location where you can receive medical atten tion If necessary contact your riding party or local authorities to let them know where you are and what has happ...

Page 26: ...others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following guide lines in mind as well as those provided under Loading whe...

Page 27: ...deadly levels of carbon monoxide can linger for hours or days in en closed or poorly ventilated areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh...

Page 28: ...il 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 absorb...

Page 29: ...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 F...

Page 30: ...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...

Page 31: ...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...

Page 32: ...o 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...

Page 33: ...r 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 gea...

Page 34: ...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...

Page 35: ...ECT 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 a...

Page 36: ...ay 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...

Page 37: ...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...

Page 38: ...nough 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 v...

Page 39: ...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 AT...

Page 40: ...lied 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...

Page 41: ...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 unlocke...

Page 42: ...he 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 retur...

Page 43: ...peration 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 pul...

Page 44: ...rating the drive select lever and driving in reverse section on page 6 2 for the drive select lever operation EBU27350 Fuel tank cap To remove the fuel tank cap Open the fuel tank cap cover and then r...

Page 45: ...ol 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 s...

Page 46: ...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 you...

Page 47: ...maintenance 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 ho...

Page 48: ...t 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 i...

Page 49: ...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...

Page 50: ...85 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 adju...

Page 51: ...ith 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 press...

Page 52: ...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...

Page 53: ...use 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 automo...

Page 54: ...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...

Page 55: ...rottle 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...

Page 56: ...ary 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 i...

Page 57: ...ust 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 specif...

Page 58: ...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...

Page 59: ...e tires listed below have been approved for this model by Yamaha Motor Manufacturing Corporation of America 1 Tire wear limit Front Manufacturer model YFM700FAPD CHENG SHIN C828 YFM700FAPSED CHENG SHI...

Page 60: ...ake 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 Rear M...

Page 61: ...lant temperature warning light Engine trouble warning light The EPS warning light should come on then go off when the engine is started for EPS model NOTICE ECB00824 If a warning light does not go off...

Page 62: ...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 EB...

Page 63: ...eople 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 wit...

Page 64: ...en 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...

Page 65: ...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...

Page 66: ...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...

Page 67: ...railer 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 li...

Page 68: ...ifting 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 car...

Page 69: ...7 1 7 EBU21141 RIDING YOUR ATV U1HP61E0 book Page 1 Thursday April 5 2012 3 33 PM...

Page 70: ...l completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 2 1 2 6 Also read all warning and notice labels on your ATV RIDE WITH CARE AND G...

Page 71: ...0 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...

Page 72: ...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...

Page 73: ...ch 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 describ...

Page 74: ...tered 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...

Page 75: ...l 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 WARNI...

Page 76: ...he 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...

Page 77: ...aces 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 r...

Page 78: ...h may cause the ATV to upset WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks bumps or holes Go slowly and be extra care ful when operating on unfamiliar...

Page 79: ...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 AT...

Page 80: ...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 ECB...

Page 81: ...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...

Page 82: ...ddenly 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 t...

Page 83: ...re 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...

Page 84: ...asily 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 th...

Page 85: ...her 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 sha...

Page 86: ...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 you...

Page 87: ...TV 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 s...

Page 88: ...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 U1HP61E0 book Page 20 Thursday April 5 2012 3 33 PM...

Page 89: ...he 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...

Page 90: ...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 maneu...

Page 91: ...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...

Page 92: ...n 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...

Page 93: ...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 neces...

Page 94: ...ools 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 Fue...

Page 95: ...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 U1HP61E0 book Page 4 Thursday...

Page 96: ...th 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...

Page 97: ...essary 6 Tires Check tread depth and for damage and replace if necessary Check air pressure and balance and correct if necessary 7 Wheel hub bearings Check for looseness or damage and replace if nece...

Page 98: ...Check toe in and adjust if necessary 15 Engine mount Check for cracks or other damage and replace if necessary 16 Axle boots Check for cracks or other damage and replace if necessary 17 Engine oil Cha...

Page 99: ...ace if neces sary 24 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 25 Front and rear brake switches Check operation and corre...

Page 100: ...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 chan...

Page 101: ...obs 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...

Page 102: ...lace 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 U1HP61E0 book Page 11 T...

Page 103: ...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 U1HP61E0 book Pag...

Page 104: ...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 fa...

Page 105: ...r 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...

Page 106: ...8 15 8 1 Panel D 2 Quick fastener screw 1 Bolt 1 Panel E 2 Quick fastener screw 1 Bolt U1HP61E0 book Page 15 Thursday April 5 2012 3 33 PM...

Page 107: ...astener 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 Foo...

Page 108: ...e 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 U1HP61E0 book Page...

Page 109: ...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...

Page 110: ...teners 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...

Page 111: ...k 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 shou...

Page 112: ...lug 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...

Page 113: ...ould 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 addit...

Page 114: ...emove 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...

Page 115: ...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 tercloc...

Page 116: ...ailable at a nearby Yamaha dealer 7 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge TIP Make sure that the O ring is properly seated 8 Install the new oil filter cartridg...

Page 117: ...nce 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...

Page 118: ...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...

Page 119: ...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 ne...

Page 120: ...ar 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 mus...

Page 121: ...f 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 und...

Page 122: ...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 o...

Page 123: ...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...

Page 124: ...ange 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...

Page 125: ...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 drai...

Page 126: ...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 1...

Page 127: ...egins 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 Antif...

Page 128: ...e 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 f...

Page 129: ...check for coolant leakage TIP If any leakage is found have a Yamaha dealer check the cooling system 25 Install the V belt cooling duct and then tighten the clamp screw 26 Install the footboard by ins...

Page 130: ...s 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...

Page 131: ...r filter case cover by unhooking the holders 4 Remove the sponge material and the air filter mesh from the air filter case 1 Air filter case check hose 1 Air filter case check hose 1 Air filter case c...

Page 132: ...n the sponge ma terial because the engine could catch fire or explode EWB01941 7 Squeeze the excess solvent out of the sponge material and let it dry NOTICE Do not twist the sponge material when squee...

Page 133: ...using rapid engine wear and possible engine damage Additionally operation without the air filter element will affect the fuel injection system with subsequent poor performance and possible engine over...

Page 134: ...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 combusti...

Page 135: ...ly twenty times while momentarily creating ex haust system back pressure by blocking the end of the muffler with a shop towel 9 Stop the engine and allow the exhaust pipe to cool 10 Check the gasket f...

Page 136: ...case remove the V belt case drain plug to drain the water from the case TIP If water drains from the V belt case after removing the plug have a Yamaha dealer check the ATV as the water may affect oth...

Page 137: ...aha dealer at the inter vals specified in the periodic maintenance and lu brication chart EBU24071 Adjusting the drive select lever safety system cable The drive select lever safety system cable stret...

Page 138: ...ubrication chart Each brake pad is provided with a wear indicator groove which al lows you to check the brake pad wear without hav ing to disassemble the brake If a brake pad has worn to the point tha...

Page 139: ...ake Rear brake WARNING EWB02720 Improper maintenance can result in loss of braking ability Observe these precautions Insufficient brake fluid may allow air to enter the brake system reducing braking p...

Page 140: ...ar and the brake system for leak age If the brake fluid level goes down suddenly have a Yamaha dealer check the cause before fur ther riding EBU24291 Changing the brake fluid Have a Yamaha dealer chan...

Page 141: ...s 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 s...

Page 142: ...crease 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...

Page 143: ...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...

Page 144: ...ct 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...

Page 145: ...al 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 Recommende...

Page 146: ...e 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 E...

Page 147: ...ger 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 INTERN...

Page 148: ...ts 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 discon...

Page 149: ...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...

Page 150: ...g 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...

Page 151: ...eplacing 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 prop...

Page 152: ...eadlight 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...

Page 153: ...rt 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 f...

Page 154: ...a 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...

Page 155: ...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...

Page 156: ...eel 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...

Page 157: ...y repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts m...

Page 158: ...e 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 no...

Page 159: ...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 c...

Page 160: ...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...

Page 161: ...he 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...

Page 162: ...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...

Page 163: ...seat EN1032 ISO5008 YFM7FGD Will not exceed 0 5 m s YFM7FGPAD Will not exceed 0 5 m s YFM7FGPD Will not exceed 0 5 m s YFM7FGPHD Will not exceed 0 5 m s YFM7FGPLED Will not exceed 0 5 m s YFM7FGPSED...

Page 164: ...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 YFM700FAPD Unl...

Page 165: ...belt automatic Operation Left hand operation Reverse gear 23 14 28 23 2 000 Low range 31 16 1 938 High range 31 27 1 148 Chassis Frame type Steel tube frame Caster angle 5 0 Trail 26 0 mm 1 02 in Fron...

Page 166: ...i 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 brak...

Page 167: ...g light LED Engine trouble warning light LED EPS warning light YFM700FAPD LED YFM700FAPSED LED YFM7FGPAD LED YFM7FGPD LED YFM7FGPHD LED YFM7FGPLED LED YFM7FGPSED LED Park indicator light LED On Comman...

Page 168: ...sed reliably to determine whether or not further precautions are required Factors that influence the actual level of exposure of work force include the characteristics of the work room the other sourc...

Page 169: ...LABEL INFORMATION EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame TIP The vehicle identification number is used to identify your ATV EBU26050 Model...

Page 170: ...11 2 11 1 Model label U1HP61E0 book Page 2 Thursday April 5 2012 3 33 PM...

Page 171: ...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...

Page 172: ...erse 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 43 Spark plug checking 8 20 Specif...

Page 173: ...U1HP61E0 book Page 3 Thursday April 5 2012 3 33 PM...

Page 174: ...PPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PAVED ROADS NEVER CARRY PASSENGERS NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public r...

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